Toro 38413, 38419, 38439, 38440, 38445 Operator's Manual

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Page 1

Form No. 3322-820 Rev A

CCR CCR CCR

2450 GTS 3600 GTS 3650 GTS

  

Snowthrower

Model No. 38413—000000001 and Up Model No. 38413—200000001 and Up Model No. 38419—000000001 and Up Model No. 38419—200000001 and Up Model No. 38439—200000001 and Up Model No. 38440—200000001 and Up Model No. 38445—200000001 and Up

Operator’s Manual

Pour

obtenir gratuitement une version en français de ce manuel, écrivez à l’adresse

ci-dessous. N’oubliez pas d’indiquer les numéros de modèle et de série de votre produit.

The T

oro Company

, Attn: Parts Dept., 8111 L

yndale A

ve S, Bloomington, MN 55420–1

196

Domestic English (EN)

Page 2

Contents

Introduction

Page

Introduction 2. Safety 3

General Snowthrower Safety3. . . . . . . . . . . . . . . . .

oro Snowthrower Safety4. . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals5. . . . . . . . . . . . . . . . .

Assembly 6

Loose Parts6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Dischar

Installing the Chute Crank7. . . . . . . . . . . . . . . . . . .

Unfolding the Handle7. . . . . . . . . . . . . . . . . . . . . . .

Before Starting8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mixing Gasoline and Oil8. . . . . . . . . . . . . . . . . . . .

Operation 10

Operating Controls10. . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine10. . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Engine10. . . . . . . . . . . . . . . . . . . . . . . .

Starting the Rotor Blades10. . . . . . . . . . . . . . . . . . . .

Stopping the Rotor Blades10. . . . . . . . . . . . . . . . . . .

Adjusting the Dischar

Throwing Snow11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 12

Recommended Maintenance Schedule12. . . . . . . . .

Adjusting the Control Cable12. . . . . . . . . . . . . . . . . .

Emptying the Fuel T

Replacing the Scraper13. . . . . . . . . . . . . . . . . . . . . .

Replacing the Drive Belt14. . . . . . . . . . . . . . . . . . . .

Replacing the Spark Plug14. . . . . . . . . . . . . . . . . . . .

Replacing the Rotor Blades15. . . . . . . . . . . . . . . . . .

Storage 16

Preparing the Fuel System16. . . . . . . . . . . . . . . . . . .

Preparing the Engine17. . . . . . . . . . . . . . . . . . . . . . .

ightening the Fasteners and Cleaning the

Snowthrower 17

Covering and Storing the Snowthrower17. . . . . . . . .

Federal and California Emission Control W

Statement 18

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ge Chute6. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ge Chute10. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ank 13

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

arranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back cover

Thank you for choosing a T be completely satisfied with your new purchase.

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 T products, you are responsible for operating the product properly and safely

Whenever you contact your Authorized Service Dealer or the factory for help with service, genuine T additional information, have the model number and the serial number of your product handy model number and serial number decal on the product as illustrated in Figure 1.

1. Model

Write space below:

This safety messages that help you and others avoid personal injury and even death. DANGER, W CAUTION are words used to identify the level of hazard.

number and serial number decal

the product model number and serial number in the

Model

No.

Serial No.

manual identifies potential hazards and has special

oro product. W

oro designs and produces safe

Figure

e want you to

oro parts, or

. Y

ou will find the



637

ARNING, and

WARNING

The engine exhaust fr chemicals known to the State of California to cause cancer harm.

The T

, birth defects, or other r

oro Company

om this pr

– 1999

oduct contains

eproductive

DANGER

serious injury or death if you do not follow the recommended precautions.

WARNING

or death if you do not follow the recommended precautions.

CAUTION

moderate injury if you do not follow the recommended precautions.

signals an extreme hazard that will cause

signals a hazard that may cause serious injury

signals a hazard that may cause minor or

Printed in USA

Page 3

This manual uses two other words to highlight information. mechanical information and information worthy of special attention.

Important

calls attention to special

Note

emphasizes general

Safety

o ensur gain knowledge of the pr and any other operator of the snowthr understand the contents of this manual befor motor is ever started. Pay particular attention to the safety alert symbol

W instruction.” Read and understand the instruction because it has to do with safety instruction may r

The snowthrower is designed and tested to of reasonably safe service; however, failur

the following instructions may r injury.

General

The ANSI/OPEI standard B71.3—1995 and ISO standard 8437:1989. Information or terminology specific to T snowthrowers is enclosed in parenthesis.

e maximum safety

ARNING, OR DANGER — “personal safety

esult in personal injury

, best performance, and to

oduct, it is essential that you

ower r

ead and e the

which means CAUTION,

. Failur

e to comply with

fer

e to comply with

esult in personal

Snowthrower Safety

following instructions have been adapted from the

oro

•

Do not operate the equipment without wearing adequate winter garments. W improve 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 fuel tank outdoors with extreme care. Never fill fuel tank indoors.

•

Replace gasoline caps securely and wipe up spilled fuel.

Use only the power cord supplied with the

•

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

•

Adjust the collector (auger) housing height to clear gravel or crushed rock surface (this is not necessary on single-stage snowthrowers).

•

Never attempt to make any adjustments while the engine is running, except where specifically recommended by manufacturer (T

Let engine and machine adjust to outdoor temperatures

•

before starting to clear snow The operation of any powered machine can result in

•

foreign objects being thrown into the eyes. Always wear safety glasses or eye shields during operation or while performing an adjustment or repair

ear footwear which will

oro).

Training

•

Read the operator’s manual carefully familiar with the controls and the proper use of the equipment. Know how to stop the unit and disengage the controls quickly

Never allow children to operate the equipment. Never

•

allow adults to operate the equipment 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 in reverse.

. Be thoroughly

Preparation

•

Thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards, wires, and other foreign objects.

•

Disengage all clutches and shift into neutral before starting the engine.

Operation

•

Do not put hands or feet near or under rotating parts. Keep clear of the dischar

•

Exercise extreme caution when operating on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traf

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 restarting and operating the snowthrower

If the unit should start to vibrate abnormally

•

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

•

Stop the engine whenever you leave the operating position, before unclogging the collector (auger)/impeller housing or dischar and when making any repairs, adjustments, or inspections.

When cleaning, repairing, or inspecting, make certain

•

the collector/impeller (auger/impeller or rotor blades) and all moving parts have stopped. Disconnect the

ge opening at all times.

fic.

, stop the

ge guide (chute),

ibration

Page 4

spark-plug wire, and keep the wire away from the plug to prevent someone from accidentally starting the engine. Disconnect the cable on electric motors.

•

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. plates or other safety protective devices in place.

•

Never operate the snowthrower near glass enclosures, automobiles, window wells, drop-of proper adjustment of the snow dischar 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 dischar in front of the unit.

•

Disengage power to the collector/impeller (auger/impeller or rotor blades) when snowthrower is transported or not in use.

•

Use only attachments and accessories approved by the manufacturer of snowthrower (T weights, counterweights, cabs, etc. (Refer to your Authorized Service Dealer for accessories available for your snowthrower

Never operate the snowthrower without good visibility

•

or light. Always be sure of your footing, and keep a firm hold on the handles. W

ge at bystanders or allow anyone

alk; never run.

fs, etc. without

ge angle. Keep

oro), such as wheel

Maintenance and storage

• Check

•

all fasteners at frequent intervals for proper tightness to be sure 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, clothes dryers, etc. 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, as necessary.

Run the machine a few minutes after throwing snow to

•

prevent freeze-up of the collector (auger)/impeller

ith the engine running, pull the recoil starter handle

(W several times.)

Toro

The T know that is not included in the ANSI or ISO standards.

•

• Before

•

Snowthrower Safety

following list contains safety information specific to

oro products or other safety information that you must

The r

otating impeller/auger or r

off or injur

handles and away from the dischar operating the snowthrower

feet, and any other part of your body or clothing away fr

Before adjusting, cleaning, repairing, and inspecting the snowthrower, and before unclogging the dischar chute,

all moving parts to stop

the spark plug and keep it away from the plug to prevent someone from accidentally starting the engine.

Use a stick, from the dischar

handles, stop the engine, remove the key all moving parts to stop.

Do not wear loose fitting clothing that could possibly get caught in moving parts.

If a shield, safely device, or decal is damaged, illegible, or lost, repair or replace it before beginning operation. Also, tighten any loose fasteners.

Do not

For two-stage snowthrowers, use the lower gear and, if applicable, the rear wheel position when operating on slopes.

Do not

Do not touch the engine while it is running or soon after it is stopped because the engine will be hot enough to cause a burn. Do not add oil or check the oil level in the crankcase when 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 pull the wire from the spark plug, keeping it away from the plug to prevent someone from accidentally starting the engine. If major repairs are ever needed, contact your Authorized Toro Service Dealer

Do not over speed the engine by changing the governor settings.

e fingers or hands.

. Keep your face hands,

om concealed, moving, or r

stop the engine, r

not your hands

ge chute.

leaving the operator’s position behind the

smoke while handling gasoline.

use the snowthrower on a roof.

emove the key

. Also, pull the wire of

otor blades can cut

Stay behind the

ge opening while

otating parts.

, and wait for

to remove obstructions

, and wait for

f of

Page 5

•

When storing the snowthrower for more than 30 days, drain the gasoline from the fuel tank to prevent a potential hazard. Store gasoline in a safety approved, red metal container switch before storing the snowthrower

. Remove the key from the ignition

o ensure the best performance and safety

• T

only genuine T to keep the T

eplacement parts and accessories as they could

r cause a safety hazard.

oro replacement parts and accessories

oro all T

oro.

Do not use “W

, purchase

ill Fit”

Safety

(Part No. 60-9480)

and Instruction Decals

Safety

decals and instructions are easily visible to the operator and are located near any

area of potential danger

Inside of Belt Cover

. Replace any decal that is damaged or lost.

On Handle

(Part No. 66-6870)

On Chute

(Part No. 94-2900)

By Muffler

(Part No. 95-1904)

Replace Control Panel for Models 38413 and 38440

(Part No. 55-9350)

Replace Control Panel for Models 38419, 38439, and 38445

(Part No. 61-4410)

Page 6

Assembly

Note:

Determine the left and right sides of the snowthrower by standing in the normal operating position.

Loose

DESCRIPTION QTY. USE

Carriage Locknuts Discharge chute

Plastic bushing Capscrews Locknuts Chute crank and mounting bracket

Installing

Models 38413 and 38419 only

1. Place

Parts

bolts

the Discharge Chute

the chute handle over the chute ring (Fig. 2).

3 3 1

1 2 2 1

Installing the discharge chute

Installing the chute crank (Models 38439, 38440, and 38445 only)

Install the carriage bolts and the locknuts through the remaining holes, with the locknuts on the outside.

6. T

ighten all locknuts

securely.

Models 38439, 38440, and 38445 only

1. Set

the dischar

ge chute over the chute ring (Fig. 3).

Figure

1. Chute

2. Insert

Note: You can rotate the chute ring for easier assembly

ring Discharge chute Chute handle

the dischar

the chute handle. (Fig. 2). Align the hole in the back of the chute with the center

hole in the ring.

Install a carriage bolt and a locknut through the center holes, with the locknut on the outside.

ge chute between the chute ring and

5. Locknut

m-3277

Carriage bolt

Figure

1. Chute

2. Align

Note: You can rotate the chute ring for easier assembly

5. T

ring

the hole in the back of the chute with the center

hole in the ring (Fig. 3) Install a carriage bolt and a locknut through the center

holes, with the locknut on the outside (Fig. 3)

Install carriage bolts and locknuts through the remaining holes, with the locknuts on the outside.

ighten all locknuts

securely.

Discharge chute

636

Page 7

Installing

the Chute Crank

Models 38439, 38440, and 38445 only

1. Insert

1. Chute

3. Gear

2. Slowly

the flattened end of the chute crank through the hole in the shroud while aligning the mounting bracket with the holes in the lower handle (Fig. 4).

893

635

Figure

crank

Mounting bracket

Plastic bushing

Hidden gear opening

rotate the crank until the flattened end fits into the hidden gear opening and the chute ring turns with the crank (Fig. 4).

Fully insert the plastic bushing into the hole in the mounting bracket (Fig. 4).

Secure the mounting bracket to the handle with two capscrews and locknuts (Fig. 4).

Figure

1. Upper

Note:

handle

Ensure that the cable guide is in the position as

shown in Figure 6.





Unfolding

1. Cut

the tie that secures the control cable to the handle.

Loosen the knobs and pull out the handle locks until

the Handle

the upper handle rotates freely (Fig. 6).

Position the upper handle as shown in Figure 5.

1. Knob

2. Handle

4. Insert

Figure

lock

the loose end of the control cable into the top

Cable guide

hole of the control bar as illustrated in Figure 7 (models 38413 and 38419) or into the bottom hole as illustrated in Figure 8 (models 38439, 38440, and

38445).

Page 8

1. Control

4. T

cable Spring cover Control bar bracket

op hole

m-2708

Figure

Bottom hole

1/16 to 1/8 in. (0.16 to

0.32 cm) gap

Before

Mixing

Use

only clean, fresh, lead-free gasoline (including oxygenated or reformulated gasoline) with an octane rating of 87 or higher the amount of gasoline you expect to use in 30 days. Using unleaded gasoline results in fewer combustion chamber deposits and longer spark plug life.

IMPORTANT containing methanol, gasohol containing mor 10% ethanol, pr these fuels can damage the engine’

Starting

Gasoline and Oil

. T

o ensure freshness, purchase only

: Do not use methanol, gasoline

emium gasoline, or white gas. Using

s fuel system.

e than

m–4017/4012

Figure

1. Cable

2. Control

3. T

5. Fully

6. T

bar bracket

op hole

insert the handle locks.

ighten the knobs until they are snug.

Ensure that a 1/16 to 1/8 in. (0.16 to 0.32 cm) gap

Bottom hole

1/16 to 1/8 in. (0.16 to

0.32 cm) gap

exists between the control bar and the handle (Refer to

Adjusting the Contr

ol Cable

on page 12).

IMPORTANT

: Do not use automotive oil (i.e., SAE 30, 10W30, etc.), a two-cycle oil that is not NMMA- or TCW

-certified, or a fuel mixed at the wr

ong gasoline/oil ratio. This can cause engine damage not cover

ed under the Toro warranty

Page 9

DANGER

POTENTIAL HAZARD

•

In certain conditions gasoline is extr flammable and highly explosive.

WHA

T CAN HAPPEN

•

A fir

e or explosion fr

others, and cause pr

HOW T

•

• Stor

•

O AVOID THE HAZARD Use a funnel and fill the fuel tank outdoors, in an open ar 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” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand. Never smoke when handling gasoline, and stay away fr fumes may be ignited by a spark.

keep it out of the r Never buy mor gasoline.

ea, when the engine is cold. W

om an open flame or wher

e gasoline in an appr

om gasoline can burn you,

operty damage.

oved container and

each of childr

e than a 30-day supply of

emely

e gasoline

en.

ipe up

POTENTIAL HAZARD

•

When fueling, under certain cir static charge can develop, igniting the gasoline.

WHA

T CAN HAPPEN

•

A fir

e or explosion fr

and others and cause pr

HOW T

•

O AVOID THE HAZARD Always place gasoline containers on the gr away from your vehicle befor 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, r equipment fr the equipment with its wheels on the gr If this is not possible, then refuel such equipment on a truck or trailer fr container dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

om the truck or trailer and r

, rather than fr

om gasoline can burn you

operty damage.

emove gas-power

om a gasoline

cumstances, a

e filling.

ound.

om a portable

ound

efuel

Pour a half gallon (1.9 liters) of gasoline into an approved gasoline container

Do not mix gasoline and oil in the fuel tank. Oil at

Note:

room temperature mixes easier and more thoroughly than cold oil. Oil below 32°F (0°C) requires additional mixing.

Add the proper amount of high grade, NMMA- or TCW

-certified two-cycle oil as directed on the

container label. For best results, use Install the cap on the gasoline container and shake the

container to mix the gasoline and oil thoroughly Remove the cap and add the remaining gasoline.

Tor

o 50:1 T

wo-Cycle Oil

Page 10

1. Add

oil to small amount of

gasoline

Install cap and shake can to mix

recommend using a stabilizer/conditioner for all T gasoline-powered products during operation and storage. A fuel stabilizer/conditioner cleans the engine during operation and prevents gum-like varnish deposits from forming in the engine during storage. A fuel stabilizer/conditioner works best when you mix it with fresh gasoline.

Note:

If you use

Engine Oil with Fuel Stabilizer

fuel stabilizer/conditioner

IMPORTANT stabilizer during storage. Do not use fuel stabilizers with an alcohol base such as ethanol, methanol, or isopropanol.

Tor

o Heavy Duty 50:1 All Season 2-Cycle

: Do not use fuel additives except a fuel

Figure

, you do not need to add a

Add remaining amount of gasoline

111

oro

Cover the hole in the center of the primer with your thumb and push the primer in twice. In extremely cold temperatures, repeat this step as necessary

Do not use the choke and the primer when starting a

Note:

warm engine.

For a r

ecoil starter:

hand and pull the recoil starter vigorously with the other hand.

For an electric starter:

Connect the power cord to the snowthrower and to a standard household power outlet.

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

intervals of five seconds on, then five seconds of If the engine does not start after this attempt, wait at least 40 minutes to allow the starter to cool before attempting to start it again.

IMPORTANT can overheat and damage the starter

If the engine does not start after the second attempt, bring the snowthrower to an Authorized Service Dealer for service.

When the engine starts, disconnect the power cord from the snowthrower and the outlet.

: Running the electric starter extensively

Hold the snowthrower with one

Operation

Operating

The

snowthrower control panel contains a key switch, a

primer

, a recoil starter

choke is just below the control panel (Fig. 10).

1. Key

switch

2. Primer

Recoil start

4. Choke

Starting

1. Turn

the key to the On position and pull the choke out.

Controls

, and an electric start button. The

Figure

Elec. start button (electric

5. start models only)

Cord connection (electric start models only)

the Engine

4. W

ith the engine running, push in the choke slowly

Stopping

Turn

the key to the Of

parts to stop before leaving the operating position.

Starting

start the rotor blades, squeeze the control bar and

handle together

Stopping

642

Release

Note:

stop, but the engine continues to run.

the control bar to stop the rotor blades.

When you release the control bar

Adjusting

the Engine

f position, and wait for all moving

the Rotor Blades

, the rotor blades

the Discharge Chute

Models 38413 and 38419 only

Move

the chute handle left and right to adjust the direction of the snow stream (Fig. 1 handle on top of the discharge chute controls the height of the snow stream.

mounting locknuts.

Do not overtighten the chute deflector

1). The chute deflector

Page 11

Throwing

Snow

m-3278

Figure 11

1. Chute

IMPORTANT: snowthrower

handle

Chute deflector handle

Do not use the chute handle to lift the

. This can damage the chute handle.

Deflector mounting locknuts

Models 38439, 38440, and 38445 only

Rotate

the chute crank clockwise to move the dischar chute to the right or counterclockwise to move the chute to the left (Fig. 12). The chute deflector handle on top of the dischar

ge chute controls the height of the snow stream.

Do not overtighten the chute deflector mounting locknuts.

WARNING

POTENTIAL

•

Stones, toys and other foreign objects may be picked up and thr

WHA

T CAN HAPPEN

• Thr

own objects can cause serious personal

injury to operator or bystanders.

HOW T

•

Keep the ar that could be picked up and thr blades. Keep all childr

•

operation.

•

The snowthrower clears down to the ground and propels itself forward when you raise the handle. The snowthrower tilts strike the ground. The wheels do not need to touch the ground to self-propel. The more you tilt the handle forward, the faster the snowthrower self-propels.

•

Always overlap each swath and dischar downwind whenever possible.

• T

o clear snow from crushed rock or gravel, push down on the handle to raise the rotor blades clear of the loose material and push the snowthrower forward.

•

In snowy and cold conditions, some controls and moving parts may freeze solid.

for

ce when trying to operate fr

have dif engine and let it run for a few minutes.

HAZARD

own by the r

otor blades.

O AVOID THE HAZARD

ea to be clear

en and pets away fr

slightly

ed fr

ee of all objects

own by r

om ar

otor ea of

forward so that rotor blades

ge the snow

Do not use excessive

ozen contr

ols.

ficulty operating any control or part, start the

If you

1. Chute

crank

Chute deflector handle

Figure

Deflector mounting locknuts

629

•

After clearing the snow

, let the engine run for a few minutes to prevent moving parts from freezing. Shut of

f the engine and remove all ice and snow from the snowthrower. On models 38439, 38440, and 38445: Operate the chute crank several times to remove any ice and snow

Page 12

Maintenance

Recommended

Service

Control cable

Fuel tank Scraper

Drive belt Spark plug Rotor blades Tighten

fasteners

Item

Check the control cable. Adjust if necessary Drain the fuel and run the engine until the fuel tank

and the carburetor are dry Check the scraper Inspect the drive belt. Replace if necessary Clean, inspect, and gap. Replace if necessary Inspect the rotor blades. Replace if necessary Check and for loose fasteners and tighten them if

necessary.

POTENTIAL

•

If you leave the wir

WHA

T CAN HAPPEN

•

Someone accidentally starting the engine could seriously injur

HOW T

•

Pull the wir does not accidentally contact the spark plug.

HAZARD

O AVOID THE HAZARD

e off of the spark plug befor

Maintenance Schedule

Service Operation

. X X

. Replace if necessary

CAUTION

e on the spark plug, someone could start the engine.

e you do any maintenance. Also, push it aside so it

. X

. X . X

Initial Annually Comments

Check and adjust

as needed.

X X

e you or other bystanders.

ighten fasteners

as needed.

Adjusting

Periodically adjustment.

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

Move the control bar back toward the handle to remove the slack in the cable (Fig. 7 or Fig. 8).

Ensure that a 1/16 to 1/8 in. (0.16 to 0.32 cm) gap exists between the control bar and the handle (Refer to the inset in Fig. 7). T

Note: The control cable must have slack in the disengaged position.

Adjust the cable as follows:

Models 38413 and 38419 only:

Unhook the spring end from the top hole in the control bar bracket (Fig. 7).

Slide the spring cover of adjuster.

the Control Cable

check the control cable for proper

o adjust the cable, go to step 4.

f the spring and the cable

Unhook the Z fitting from the cable adjuster and

reposition the Z fitting in the top or bottom hole on the adjuster to obtain a proper gap of 1/16 to 1/8 in. (0.16 to 0.32 cm) between the control bar bracket and the handle (Fig. 13).

4321

Figure

1. Spring

2. Cable

adjuster

D. Install

Models 38439, 38440, and 38445 only:

the spring cover over the cable adjuster and

the spring. Hook the spring into the top hole of the control bar

bracket (Fig. 7).

Z fitting

4. Cable

897

Page 13

Unhook the upper cable end from the hole in the control bar bracket (Fig. 7).

Slide the spring cover up the cable to expose the cable adjuster (Fig. 7).

Unhook the Z fitting from the cable adjuster and position it in the top or bottom hole on the adjuster to obtain a gap of 1/16 to 1/8 in. (0.16 to 0.32 cm) between the control bar bracket and the handle (Fig. 13).

Install the spring cover over the cable adjuster Install the upper cable end into the bottom hole in

the control bar bracket (Fig. 8).

1. Spring

Z fitting

Figure

cover

Cable adjuster

630

Remove the fuel tank cap and use a pump-type syphon to drain the fuel into a clean gasoline container

Start the engine and allow it to run until it consumes

all the fuel in the fuel tank and stops running. Repeat this step two more times to ensure that the fuel tank is empty.

Replacing

Before

each season, inspect the scraper for wear

thickness of the scraper’s bottom is less than 1/16 in.

the Scraper

. If the

(1.6 mm), replace the scraper (Fig. 15).

Figure

1. Scraper 2. 1/16

Note:

The running time and the roughness of the driveway

in.

634

or sidewalk determines the scraper wear rate.

5. Check

the adjustment (refer to steps 2 and 3 above).

After extended use, the drive belt may wear and lose its proper belt tension. Improper belt tension causes belt slippage and decreases the performance under a heavy load. Belt slippage may occur after two or three seasons of normal usage (10 to 15 hours). If the drive belt slips (continuously squeals) under a heavy load, increase the belt tension by doing one of the following steps:

•

For Models 38413 and 38419:

Reposition the spring end in the bottom hole of the control bar bracket (Fig. 7).

•

For Models 38439, 38440, and 38445:

Reposition the upper cable end into the upper hole of the control bar bracket (Fig. 8).

Using the incorrect adjusting hole in the control bar bracket can reduce the drive belt life. Occasional belt slippage (squealing) may occur in extremely wet conditions due to moisture in the drive system. T

o remove moisture, start the rotor and operate it without a load for 30 seconds. Once you remove the moisture, the drive belt should not slip.

Emptying

the Fuel T

ank

Stop the engine.

Drain the fuel from the fuel tank. Refer to

the Fuel T

3. T

ip the snowthrower forward onto its front housing.

Remove three carriage bolts and the locknuts holding

ank

on page 13.

Emptying

scraper in place (Fig. 16).

Remove the scraper by sliding it to the right and down.

Figure

1. Scraper 2. Carriage

locknuts

644

bolts and

1. Stop

the engine and remove the key from the switch.

Page 14

6. Install

the new scraper to the housing using the

carriage bolts and locknuts.

4. Loop

the new drive belt around the engine pulley under the idler pulley brake assembly

, over the roller

, through the

, and around the rotor pulley (Fig. 18).

Replacing

Inspect

the drive belt before each season, and replace it if

the Drive Belt

it is worn or damaged.

Stop the engine.

Remove three self tapping screws, two capscrews, one washer

, and two locknuts that secure the belt cover to the snowthrower frame (Fig. 17). Set the drive belt cover aside.

631

1. Cap screw

2. Capscrew washer

3. Push

, locknut

, locknut,

down on the idler pulley and remove the drive

belt from the rotor pulley

Figure

Long self tapping screw

Short self tapping screws

, the brake arm assembly, and

the engine pulley (Fig. 18).

IMPORTANT:

The drive belt must be on top of the roller

as shown in Figure 18.

Install the drive belt cover securely

Replacing

Before

, but

do not overtighten

the Spark Plug

each season, check the spark plug. If the electrodes

. T

ighten the fasteners

in the center of the plug are dark or have deteriorated, install a new NGK BPMR4A spark plug.

Remove the three mounting screws that secure the control panel to the housing (Fig. 19).

643

1. Control

Figure

panel

Mounting screws

1. Engine

Idler pulley

3. Roller

pulley

Figure

Brake arm assembly

Rotor pulley

Belt guide

626

2. Remove

the ignition key and lift of

f the panel,

allowing it to hang on the recoil rope.

Pull the wire of

f the spark plug and remove the spark

plug (Fig. 20).

628

1. Spark

4. Examine

plug wire

the spark plug and replace it if it is cracked,

fouled, or dirty

IMPORTANT

Figure

: Do not sandblast, scrape, or clean the

spark plug. Dirt may fall into the cylinder and cause engine damage.

Page 15

Set the spark plug gap (Fig. 21) between the electrodes to .032 in. (.81 mm).

.032 in.

(.81 mm)



Figure

6. Install

Replacing

Before When a rotor blade edge has worn to the wear indicator hole (Fig. 22), replace performance and to prevent damage to the underside of the snowthrower

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

Push the wire onto the spark plug. Install the control panel with the capscrews.

the Rotor Blades

each season, inspect the rotor blades for wear

both

rotor blades to ensure proper

Note:

Replace the scraper whenever you replace the rotor blades. This ensures proper snowthrower operation and performance.

The running time and the roughness of the driveway

Note:

or the sidewalk determines the wear rate of the rotor blades.

Removing the Old Blade

Note: You will need a No. T27 torx driver to complete

this procedure.

Remove four torx screws and four locknuts that secure the outer edges of the rotor blade to the rotor shaft assembly (Fig. 23).

Remove two hex-head capscrews, spacers, and locknuts that secure the center of the blade to the rotor halves (Fig. 23).

Loosen the hex-head screw securing the rotor halves to the auger shaft assembly (Fig. 23).

Slide the blade out from between the rotor halves (Fig. 23).

1. Wear

indicator hole

Figure

Page 16

1. Rotor

Rotor half

blade

3. Torx screw

4. Locknut

Installing a New Blade

1. Examine

layer thickness (Fig. 24). Some rotor blades have a part number on the thick side of the blade.

1. Thin

Thick layer

a new rotor blade edge for the dif

Figure

layer

3. W

681

ear indicator hole

ference in

Figure

Hex-head capscrew

6. Spacer

Insert the new rotor blade between the rotor halves.

Secure the rotor blade to the rotor halves with two

Auger shaft assembly

Hex-head screw

hex-head capscrews, two spacers, and two locknuts, positioning the bolt heads on the thick side of the blade (Fig. 23).

Curve the rotor blade and secure it with the remaining torx screws and locknuts, positioning the screw heads on the thick side of the blade (Fig. 23).

5. T

ighten all screws and locknuts securely

Storage

Preparing

1. Add

Note:

mix it with fresh gasoline.

a fuel stabilizer/conditioner to the gasoline in the

fuel tank as directed.

A fuel stabilizer/conditioner works best when you

the Fuel System

680

Install

the rotor blades with the thick layer on the

inside

of the curve. (Fig. 24). If you do not install the

blades properly

, the blades may be out of balance and

cause the snowthrower to “hop” or “bounce.”

Note:

If you use

Tor

Engine Oil with Fuel Stabilizer

fuel stabilizer/conditioner

o Heavy Duty 50:1 All Season 2-Cycle

, you do not need to add a

Page 17

Run the engine for five minutes to distribute the conditioned fuel through the fuel system.

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

Start the engine again and run it until it stops.

Prime the engine, start it a third time, and run it until it will not restart.

Recycle the fuel according to local codes.

Preparing

This

procedure allows you to close both the intake and the exhaust ports of the engine, preventing cylinder bore corrosion.

Slowly pull the recoil starter until you feel resistance

due to compression pressure, then stop.

Release the starter tension slowly to prevent the engine from reversing due to compression pressure.

Tightening

the Engine

the Fasteners and

Cleaning the Snowthrower

1. Tighten

replace damaged parts.

Clean the snowthrower thoroughly

Covering

all loose screws, bolts, and locknuts. Repair or

and Storing the

Snowthrower

Cover

the snowthrower and store it in a clean, dry place

out of the reach of children.

IMPORTANT position and on its wheels. Storing the snowthr its fr

ont housing may cause hard starting.

: Stor

e the snowthrower in its operating

WARNING

POTENTIAL HAZARD

•

Gasoline is highly flammable, explosive, and danger

WHA

•

If gasoline contacts a flame or is inhaled, serious personal injury can occur

HOW T

•

Never stor ar be pr clothes dryers.

•

Allow the engine to cool befor snowthr

ous if inhaled.

T CAN HAPPEN

O AVOID THE HAZARD

e the snowthrower in a house (living

ea) or a basement wher

esent, such as hot water and space heaters,

ower in an enclosur

e ignition sour

e storing the

ces may

ower on

Page 18

Federal

The U.S. Environmental Protection Agency (EP explain the emission control system warranty on your 1995 and later utility/lawn/garden equipment engine. In California, new utility/lawn/garden equipment engines must be designed, built and equipped to meet the State’ standards. In other states, new 1997 and later model year utility/lawn/garden equipment engines must be designed, built and equipped, at the time of sale, to meet the U.S. EPA regulations for small nonroad engines. The equipment engine must be free from defects in materials and workmanship which cause it to fail to conform with U.S. EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser your utility/lawn/garden equipment engine for the period of time listed above provided there has been no abuse, neglect or improper maintenance of your utility/lawn/garden equipment engine.

our emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and

catalytic converter Where a warrantable condition exists, T

and California Emission Control W

A T

wo Y

ear Limited W

our W

. Also included may be hoses, belts, and connectors and other emission related assemblies.

oro will repair your engine at no cost to you including diagnosis, parts and labor

arranty Rights and Obligations

A), the California Air Resources Board (CARB) and Toro are pleased to

arranty

. T

oro must warrant the emission control system on

arranty Statement

s stringent anti–smog

Manufacturer’s

Utility/Lawn/Garden part on your engine is defective in materials or workmanship, the part will be repaired or replaced by T charge.

Owner’s

• As

the engine owner manual. T deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

Any replacement part or service that is equivalent in performance and durability may be used in non–warranty

•

maintenance or repairs, and shall not reduce the warranty obligations of the engine manufacturer As the engine owner

•

part has failed due to abuse, neglect, improper maintenance or unapproved modifications or parts.

• Y

ou are responsible for presenting your equipment engine to a T

The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

•

If you have any questions regarding your warranty rights and responsibilities or if you need a referral to a T Service Dealer

arranty Coverage:

equipment engines are warranted for two years from the date of delivery

arranty Responsibilities:

, you are responsible for the performance of the required maintenance listed in your owner

oro recommends that you retain all receipts covering maintenance on your equipment, but T

, you should, however

, please feel free to contact us at the following address:

, be aware that T

oro Customer Service Department

811

1 L

yndale A Bloomington, MN 55420–1 612–888–8801 800–348–2424

oro may deny you warranty coverage if your engine or a

ORO Service Dealer as soon as a problem exists.

venue South

196

. If any emission–related

oro free of

’s

oro cannot

ORO

Warranted

The warrants to the initial owner and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years.

Failures caused by abuse, neglect, or improper maintenance are not covered. The use of add–on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to cover failures of warranted parts caused by the use of add–on or modified parts. T a warranted part still under warranty defined by the manufacturer in the written instructions.

Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of ”repair or replace as necessary” shall be warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. Coverage under this warranty extends only to the parts listed below (the emissions system parts) to the extent that these parts were present on the engine when purchased.

Parts:

warranty period begins on the date the engine or equipment is delivered to a retail purchaser

oro is liable for damages to other engine components caused by the failure of

. The owner is responsible for the performance of the required maintenance, as

. The manufacturer

Rev

. 10/26/1998

Page 19

–

Fuel Metering System

•

Cold start enrichment system including the choke mechanism or priming system

•

Fuel pump

•

Air fuel ratio feed back system

•

Carburetor and internal parts

•

Fuel injection system

–

Air Induction System

•

Air cleaner

•

Reed intake system

•

Intake manifold

•

Controlled hot air intake system

–

Ignition System

•

Spark plug(s)

•

Ignition coils and electronics

•

Advance/retard mechanisms

–

Catalytic Converter/Thermal Reactor System

•

Catalytic converter

•

Thermal reactor

•

Exhaust manifold

–

Air Injection System

•

Air injection system or pulse valve

• V

alves af

fecting distribution of air

–

Exhaust Gas Recirculation (EGR) System

•

EGR valve body and piping system connecting to the intake side of the engine

•

EGR control system

–

Particulate Controls

• T

raps filters, precipators and any other device used to capture particulate emissions

–

Miscellaneous Items Used in the Above Systems

• V

acuum, temperature, and time sensitive valves and switches

•

Electronic controls

•

Hoses, connectors, and assemblies of same

How

to Get W

Should Authorized T good reference source. The dealer will either arrange service at his/her dealership or recommend another Authorized Service Dealer who may be more convenient. Y etc.) for warranty validation. The owner shall not be char a warranted part is defective, if the diagnostic work is performed at a warranty station.

The Toro Company is not liable for indir T

ORO Pr warranted part still under warranty the above exclusion may not apply to you.

arranty Service:

you feel your T

ORO Service Dealer or T

oducts cover

ORO Product requires warranty service, contact the dealer who sold you the product or any

ed by this warranty

ORO Master Service Dealer

ou may need proof of purchase (copy of registration card, sales receipt,

ged for diagnostic labor which leads to the determination that

ect, incidental or consequential damages in connection with the use of the

, except for damages to other engine components caused by the failur

. Some states do not allow exclusions of incidental or consequential damages, so

. The Y

ellow Pages of your telephone directory is a

e of a

This warranty gives you specific legal rights, and you may also have other rights which vary fr

om state to state.

Page 20

The Toro Total Coverage

Gas

Powered

Snow

Products

A Full Two-Year Warranty

(Limited Warranty for Commercial Use)

What

Is Covered By This Express W

The Toro Company promises to repair any T for normal residential purposes* if defective in materials or workmanship for a period of two years from the date of pur chase. For single stage snowthrowers, the cost of parts and labor is included, but the customer pays the transportation costs.

ransportation within a 15 mile radius of the servicing dealer

is covered under this warranty for two-stage snowthrowers.

What

Products Are Covered By This W

This

warranty applies to all gasoline powered snow products.

How

About Commercial Use?

Toro

Consumer Products used for commercial, institutional or

rental use are covered by a limited warranty for 45 days from the date of purchase.

How

Do Y

ou Get W

Should

you feel your T rial or workmanship, contact the dealer who sold you the product or any Authorized T ter Service Dealer rectory is a good reference source. The dealer will either arrange service at his/her dealership or recommend another Authorized Service Dealer who may be more convenient. Y

ou may need proof of purchase (copy of registration card,

sales receipt, etc.) for warranty validation. If for any reason you are dissatisfied with the Service Deal

s analysis of the defect in materials or workmanship or if

er’ you need a referral to a T to contact us at the following address:

oro Customer Service Department

811

1 L Bloomington, MN 55420–1 612–888–8801 800–348–2424

What

Must Y

oro Product contains a defect in mate

. The Y

yndale A

ou Do T

arranty Service?

oro Service Dealer or T

ellow Pages of your telephone di

oro Service Dealer

venue South

196

o Keep The W

In Effect?

You

must maintain your T

nance

procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

oro Product by following the mainte

arranty?

oro Product used

, please feel free

arranty

Guarantee

arranty?

oro Mas

What

Does This W

arranty Not Cover?

and

How Does Y

There

is no other express warranty except for special emis sion system coverage on some products and the T Guarantee on GTS Engines. This express warranty does not cover:



Cost of regular maintenance service or parts, such as fil ters, 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 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.



Pickup and delivery charges for distances beyond a 15 mile radius from an Authorized T

ucts only). All repairs covered by this warranty must be performed by an

Authorized T ment parts.

Repair by an Authorized T edy under this warranty

The T

oro Company is not liable for indirect, incidental or consequential damages in connection with the use of the T

oro Products covered by this warranty cost or expense of providing substitute equipment or ser vice

during reasonable periods of pending states do not allow exclusions of incidental or conse quential damages, so the above exclusion 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.

Normal residential purposes means removing snow on the same lot as your home. Use at more than one location is considered commercial use and the commercial use war ranty would apply

our State Law Relate T

oro Service Dealer (covered prod

oro Service Dealer using T

oro Service Dealer is your sole rem

completion of repairs under this warranty

o This Warranty?

oro approved replace

, including any

malfunction or non–use

oro Starting

, accidents,

. Some

Countries

Customers who have purchased T tributor (Dealer) to obtain guarantee policies for your country your Distributor fail, you may contact us at The Toro Company

’s service or have dif

oro Products exported from the United States or Canada should contact their T

Other than the United States or Canada

ficulty obtaining guarantee information, contact the T

, province, or state. If for any reason you are dissatisfied with

oro importer

. If all other remedies

oro Dis-

