FORM NO. 3321–378 824 and 1028 Power Shift Snowthrowers Model No. 38542–9900001 & Up Model No.
WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Figures 1 3 2 1 181 1. Model and serial number decal 3 4 2 1 1. Lower belt cover (shown from bottom) 5 164 2. Mounting tabs 3. Flange head capscrew 2 4 3 1 5 2 1 163 1. Auger housing 2. Engine frame 3. Impeller pulley 4. Idler pulley assembly 5. Mounting screws (2) 3 1. Upper belt cover 2. Cable cover EThe Toro Company – 1998 Printed in USA All Rights Reserved 166 3.
5 6 8 1 5 7 3 2 6 2 1 3 6 4 4 168 1. Discharge chute 2. Plastic chute retainer 5 1. 2. 3. 4. Shift rod Ball joint Shift bracket Transmission lever 3. Chute retainer plate 4. Chute ring 2 167 5. 6. 7. 8. Locknut Jam nut Gear shift lever Power Shift slot 7 3 4 1 2 5 170 1. Gear bracket 2. Carriage bolt, flat washer & locknut ii 3. Worm gear 4. Chute gear rod 5.
8 11 1 1. Scraper 2. Carriage bolt 3 2 171 1 3. Auger blades 171 1. Pipe plug 2 12 9 1 5 4 3 m–4063 3 2 1 1. Flange bolts 2. Skid 3. Flat washers 1. Dipstick and filler hole 2. Fuel tank cap 474 13 4. Locknut 5. Sideplate 1 3 2 4 10 173 m–4064 1. Auger/impeller control 2. Traction drive control 3. Speed shift control 4.
14 17 6 1 3 5 934 1 4 2 m-4067 4. Ignition switch 5. Heater box 6. Mounting screw 1. Throttle 2. Choke 3. Primer 1. Recoil starter 18 1 15 2 1 2 m–4066 m–4065 3 1. Fuel shut-off valve 2. Hose clamp 3. Fuel line 1. Mounting screw 16 1 2. Heater box 19 2 176 1. Deflector handle 2.
20 22 1 179 181 21 1. Drive chain 23 m-4036 1. Axle pin 2. Inner axle hole 3. Outer axle hole and wheel hub 1.
24 26 1/8” min. (3 mm) 1 907 2 184 1. Feeler gauge 1. Impeller idler arm 2. Center of spring 27 25 2. Brake arm 7 6 5 4 3 1 4 2 3 2 1 8 185 183 1. Auger/impeller cable (outer cable) 2. Traction cable (inner cable) vi 3. Mounting bracket 4. Jam nut 1. Idler pulley assembly 2. Flange head capscrews (2) 3. Capscrew & lockwasher 4. Half sheave 5. 6. 7. 8.
28 31 1/8” – 3/8” DEFLECTION 186 29 m-4068 1. Spark plug wire 32 1 0.30” (0.76 mm) 2 187 1. Transmission 2. Transmission frame 110 30 1 189 1.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . Maintaining Snowthrower . . . . . . . . . . . . . Safety Decals and Instructions . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. reasonably safe service; however, failure to comply with the following instructions MAY RESULT IN PERSONAL INJURY.
10. Always use a grounded, three wire plug and cord to start snowthrower equipped with an electric starter. Extension cord must be connected to a properly grounded outlet. 11. Fill fuel tank with gasoline before starting the engine. Avoid spilling any gasoline. Because gasoline is highly flammable, handle it carefully. DO NOT SMOKE WHILE HANDLING GASOLINE. AND KEEP WIRE AWAY FROM THE PLUG TO PREVENT ACCIDENTAL STARTING. USE A STICK, NOT YOUR HAND, TO REMOVE OBSTRUCTIONS FROM DISCHARGE CHUTE. 14.
immediately for possible damage, an obstruction or loose parts. Vibration is generally a sign of trouble. Repair any damage before starting engine and operating snowthrower again. 24. Do not touch 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 oil level in crankcase when engine is running. 25. Never operate snowthrower at high transport speeds on slippery surfaces. Use care when backing. Maintaining Snowthrower 26.
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. CAUTION: IMPROPER USE MAY RESULT IN LOSS OF FINGERS, HANDS OR FEET. HIGH SPEED IMPELLER WITHIN 2 INCHES OF OPENING OPERATOR’S POSITION 1508 472 LOW SPEED AUGER HAS MOVING PINCH POINT, CLOSE TO OPENING.
Safety Decals and Instructions Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Decals with Tecumseh part numbers must be obtained from Tecumseh Product Company. Decals with Toro part numbers must be obtained from The Toro Company. ON ENGINE (Tecumseh Part No. 37119) ON ENGINE BASE AND RIGHT HANDLE (Toro Part No. 66Ć6860) ON AUGER HOUSING (Toro Part No. 53Ć7670) NEXT TO PRIMER (Tecumseh Part No.
Loose Parts Part Qty Use Flange head capscrew — 5/16–18 x 3/4” lg. 6 Lower belt cover 1 Flange head capscrew — 1/4–20 x 1/2” lg. 5 Cable cover 1 Shift rod 1 Locknut—3/8-24 2 Discharge chute 1 Worm gear 1 Gear bracket 1 Carriage bolt—5/16-18 x 1” lg. 1 Flat washer 1 Locknut—5/16 1 Skid 2 Flange head capscrew—5/16-18 x 3/4” lg.
Assembly Note: Determine left and right sides of snowthrower by standing in the normal operating position. Install Shift Rod (Fig. 5) 1. Insert upper shift rod ball joint stud through front of shift bracket and secure with 3/8–24 locknut. Note: Mount Auger/impeller Housing 1. Remove (2) flange head capscrews securing idler pulley assembly to engine frame. Remove idler pulley assembly. 2. Align auger/impeller housing and engine frame mounting holes (Fig. 2). 3.
3. Push chute retainers on right side toward discharge chute (slotted) and tighten machine screw. 4. Make sure chute rotates freely on ring. If chute binds, move right hand retainer outward to ease operation. 3. Remove (2) flange bolts and washers securing ends of scraper to side plates (Fig. 9). Reinstall bolts through rear slots in skids. Assemble both skids so that washers are between skids and sideplates (Fig. 9). Do not tighten bolts. 4.
Before Starting ENGINES WHICH ARE CERTIFIED TO COMPLY WITH CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR ULGE ENGINES: Are certified to operate on regular unleaded gasoline. Include the following emission control system(s): EM, TWC (if so equipped); Do not include any user adjustable features – therefore no other adjustments are needed. Fill Crankcase With Oil The engine is shipped from the factory without oil in the crankcase. Therefore, before starting the engine, oil must be added to the crankcase.
storage seasons. Toro Stabilizer/Conditioner cleans the engine during operation and prevents gum–like varnish deposits from forming in the engine during periods of storage. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. DO NOT USE FUEL ADDITIVES OTHER THAN THOSE MANUFACTURED FOR FUEL STABILIZATION DURING STORAGE SUCH AS TORO’S STABILIZER/CONDITIONER OR A SIMILAR PRODUCT. TORO’S STABILIZER/CONDITIONER IS A PETROLEUM DISTILLATE BASED CONDITIONER/STABILIZER.
Starting/Stopping Engine 7. Starting Note: If engine is operated when temperature is +40_ F (4_ C) or higher, remove carburetor heater box. However, the heater box must be reinstalled when temperature falls below +40_ F (4_ C). To remove heater box: A. Remove (4) mounting screws securing heater box in place (Fig. 14 and 18). B. Grasp choke knob and pull it off mounting pin. C. Lift heater box up and away from the engine, and reinstall choke knob on mounting pin.
4. Wait for all moving parts to stop before leaving the operator’s position (behind the handles). 5. Store key in a memorable place. Power Shift Operation free wheels. By contrast, when both pins are installed thru holes in wheel hub and inner hole of axle (Fig. 21), snowthrower propels itself. Snowthrowing Tips 1. When snowthrower is not being used, close fuel shut–off valve and remove key from the switch. 2. Remove snow as soon as possible after it falls. This produces best snow removal results.
10. Always use full throttle (maximum engine speed) when throwing snow. 4. Loosen the (4) flange bolts securing both skids to the auger side plates. 11. In wet or slushy conditions, clogging of the discharge chute will be reduced by maintaining maximum engine speed and by not overloading the engine. 5. Next, loosen the carriage bolts securing the scraper to the auger/impeller housing. 6. Support the auger blades so that the auger is 1/8 – 1/4 inch off the ground. 7.
Note: 6. The scraper should be higher than 3/16 inch above the pavement if the pavement surfaces are cracked, rough or uneven. Draining Gasoline 1. Close fuel shut–off valve located under fuel tank (Fig. 15). Move the skids down to sit flat on the ground and tighten the (4) flange bolts securing both skids to the auger side plates. POTENTIAL HAZARD • Gasoline is highly flammable. For Gravel Surfaces WHAT CAN HAPPEN • Gasoline can be ignited and cause serious personal injury.
annually. If possible, run engine just before changing oil because warm oil flows better and carries more contaminants than cold oil. Adjusting Auger/Impeller Drive Belt 1. Pull wire off spark plug and make sure wire does not contact plug accidentally. 2. Clean area around oil drain cap. Next, slide oil drain pan below drain extension; then remove oil drain cap (Fig. 23). If auger/impeller belt slips, resulting in decreased snowthrowing performance, an adjustment is required.
4. POTENTIAL HAZARD • Improper adjustment may cause injury if auger/impeller turns when disengaged. WHAT CAN HAPPEN • Rotating impeller or auger can cut off or injure fingers or hands. HOW TO AVOID THE HAZARD • Keep face, hands, feet and any other part of your body or clothing away from concealed, moving or rotating parts. • Make certain that impeller brake arm clearance is maintained.
9. Reinstall belts by reversing procedure. Make sure tabs in half sheave are inserted into mounting grooves in middle pulley section when reinstalling. Note: 2. IMPORTANT: To adjust drive chain, the snowthrower must be tipped up on front edge of auger/impeller housing. However, before the snowthrower is tipped, drain all gasoline from fuel tank. Refer to Draining Gasoline, page 15. Make sure idler pulleys are aligned with belts when reinstalling idler pulley assembly. 10.
Replacing Spark Plug Use a Champion RJ–19LM spark plug or equivalent. Set air gap at 0.030” (0.76 mm). Check spark plug yearly or every 100 operating hours. If electrodes in center of plug are dark or have deteriorated, install a new plug. 1. Clean area around spark plug so foreign matter cannot fall into cylinder when plug is removed. 2. Pull wire off spark plug (Fig. 31) and remove plug from cylinder head. IMPORTANT: A cracked, fouled or dirty spark plug must be replaced.
If you have a general understanding of internal combustion engines and wish to repair and service your engine yourself, refer to the Warranty and Repair section in your engine owner’s manual for information on how to obtain a “MECHANICS HANDBOOK” from Tecumseh Products Company.
Gas Powered Snow Products THE TORO TOTAL COVERAGE GUARANTEE A Full TwoĆYear Warranty (Limited Warranty for Commercial Use) What Is Covered By This Express Warranty? The Toro Company promises 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. For single stage snowthrowers, the cost of parts and labor is included, but the customer pays the transportaĆ tion costs.
