Toro 38560, 1028 power shift, 38592, 1332 power shift, 924 power shift Operator's Manual
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)
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.
1
Figure 1
1. Location of the model and serial numbers
181
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
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.
3
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
4
• 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 highspeed
impeller within two inches
of the opening.
1508
The lowspeed auger
has a moving pinch
point close to the
opening.
5
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
6
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
7
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
2
1. Latch arm 2. Latch rod
Figure 3
1
m5009
2
3
4
5
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).
1
2
3
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.
8
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).
1
2
3
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).
2
1
3
4
5
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
5
2
6
4
1. Discharge chute
2. Chute retainer (3)
3. Chute retainer plate (3)
Figure 7
4. Chute ring
5. Screw (3)
6. Locknut (3)
3
m-168
7
6
8
9
3
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).
9
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