Form No. 3355-498 Rev B Power Max® 828LXE Snowthrower Model No. 38631—Serial No. 270000001 and Up Operator's Manual Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Safety Bef or e Ope r a t ing Re a d a nd unders t a n d t he cont e n t s o f t hi s manual b e fo r e oper atin g t h e sn o w t hr o w e r . Becom e fa m iliar wi t h a ll co n t r o ls a n d kno w ho w t o st o p t h e e ng ine q ui ck ly. Ca u ti o n : Im p r o p er u se ma y r e su lt in lo ss o f fin g e r , h a n d s, o r fe e t. Th e r e is a h ig h -sp e e d im p e lle r clo se t o t h e o p e n in g .
• Never operate the snow thrower without good visibility safety glasses or eye shields during operation or while performing an adjustment or repair. or light. • Take all possible precautions when leaving the machine Operation unattended. Shift into neutral, set the parking brake, stop the engine and remove the key. • Do not put hands or feet near or under rotating parts. • • • • • • • • • • • • • • • Keep clear of the discharge opening at all times.
Sound Pressure • 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. If major repairs are ever needed, contact an Authorized Service Dealer. This unit has a maximum sound pressure level at the operator’s ear of 92 dBA, based on measurements of identical machines per EN 11201. Sound Power • Do not change the governor settings on the engine.
112-6627 1. Left turn control 3. 5. Cutting/dismemberment 7. hazard, impeller—keep away from moving parts; remove the ignition key and read the instructions before servicing or performing maintenance. Cutting/dismemberment 6. Thrown object hazard—keep 8. hazard, impeller—do not place bystanders a safe distance from your hand in the chute; stop the snowthrower. the engine before leaving the operator’s position, use the tool to clear the chute. 2.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1. 2. 3. 4. 5. 6. 7. 8. Qty. Description Use Handle bolts Curved washers Locknuts 4 4 4 Install the upper handle. No parts required – Install the wheel clutch cable ends No parts required – Install the traction control linkage. Carriage bolts Locknuts 2 2 Install the chute control rod. Cable ties 2 Connect the wire to the headlight. No parts required – Fill the engine with oil.
Figure 7 1. Cable clamp Important: Ensure that the curved side of the cable clamp is against the handle and that the cable is routed below the clamp bolt. The cable must be in a straight line from the cable clamp to the point where it attaches to the wheel clutch lever. Figure 4 2. Installing the Wheel Clutch Cable Ends 4. Pull the cable jacket down gently until the wheel clutch lever is down and the slack is out of the cable, then tighten the cable clamp nut securely (Figure 8). 1.
3. Installing the Traction Control Linkage 1. Remove the hairpin cotter and washer from the lower end of the speed control rod and insert the lower end of the rod into the lower link arm so that the bent end of the speed control rod faces rearward (Figure 10). Figure 12 6. Lift up on the speed control rod and insert the trunnion into the hole in the speed selector lever (Figure 11).
5. Connecting the Wire to the Headlight 1. Insert the wire connector on the loose end of the wire straight into the back of the headlight until it is securely in place (Figure 17). Figure 14 1. Short rod 2. Long chute control rod 4. Insert the front end of the rod into the opening in the back of the chute gear cover until it slides into the chute gear (Figure 15). Figure 17 1. 2. Plastic clip on wire connector U-bolt 3.
Product Overview Figure 18 2. Install the dipstick securely. Note: Do not spill oil around the oil fill tube; oil could leak onto traction parts and cause the traction to slip. 7. Checking the Tire Pressure Figure 19 1. Auger/impeller lever 2. Speed selector lever 3. Quick Stick™ discharge chute control 4. Traction lever 5. Wheel clutch lever (2) 6. Headlight 7. Fuel tank The tires are overinflated at the factory for shipping.
Operation Starting the Engine 1. Connect the spark plug wire (Figure 23). Note: Determine the left and right sides of the machine from the normal operating position. Filling the Fuel Tank Gasoline is extremely flammable and explosive. A fire or explosion from gasoline can burn you and others. • To prevent a static charge from igniting the Figure 23 gasoline, place the container and/or snowthrower on the ground before filling, not in a vehicle or on an object. 2.
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 are not starting the snowthrower. Figure 27 Stopping the Engine 6. Firmly push in the primer 3 times with your thumb, holding the primer in for a second before releasing it each time (Figure 28). 1. Move the throttle to the Stop position (Figure 29).
Note: This disengages the drive to the right wheel while the left wheel continues driving, and the snowthrower turns to the right. Note: Similarly, squeezing the left wheel clutch lever turns the snowthrower to the left. When you complete the turn, release the wheel clutch lever, and the drive re-engages both wheels (Figure 33). Figure 31 2. To stop the traction drive, release the traction lever. 3.
Operating the Speed Selector Operating the Quick Stick™ The speed selector has 6 forward and 2 reverse gears. To change speeds, release the traction lever and shift the speed selector lever to the desired position (Figure 34). The lever locks in a notch at each speed selection. Hold the blue trigger cap down to use the Quick Stick to move the discharge chute and the chute deflector. Release the trigger cap to lock the discharge chute and chute deflector into position (Figure 36).
Moving the Chute Deector moving parts to stop, and remove all ice and snow from the snowthrower. Hold the blue trigger cap down and move the Quick Stick forward to lower the chute deflector; move it rearward to raise the chute deflector (Figure 38). • With the engine off, pull the recoil starter handle several times to prevent the recoil starter from freezing up. Operating Tips When the snowthrower is in operation, the impeller and auger can rotate and cut off or injure hands and feet.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the rst 2 operating hours Before each use or daily Yearly Yearly or before storage Maintenance Procedure • Inspect the traction cable and adjust it if necessary. • Inspect the auger/impeller cable and adjust it if necessary. • Change the engine oil. • Check the engine oil level and add oil if necessary.
Note: To quickly adjust the skids if they loosen, support the scraper 1/8 inch (3 mm) off the pavement, then adjust the skids down to the pavement. Note: If the skids become excessively worn, you can turn them over and set the unused side toward the pavement. Checking and Adjusting the Traction Cable Check and adjust the traction cable after the first 2 operating hours, then yearly thereafter.
4. If the auger/impeller cable is not properly adjusted, do the following steps: 5. Loosen the jam nut (Figure 46). Figure 43 1. Jam nut 2. Turnbuckle Checking and Adjusting the Auger/Impeller Cable Check and adjust the auger/impeller cable after the first 2 operating hours, then yearly thereafter. Figure 46 1. 1. Remove the 2 screws from the right side of the belt cover as shown. Jam nut 2. Turnbuckle 6. Loosen or tighten the turnbuckle that adjusts the tension on the cable (Figure 46). 2.
Lubricating the Hex Shaft 5. 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. Lightly lubricate the hex shaft yearly with automotive engine oil (Figure 49). Note: Do not use synthetic oil. 6. Install the pipe plug in the gearbox. Changing the Engine Oil Change the engine oil after the first 2 operating hours, then yearly thereafter.
Inspecting and Replacing the Spark Plug Use a Champion RJ-19LM or equivalent spark plug. Check and gap the spark yearly, and replace the plug if necessary. 1. Clean around the base of the spark plug. 2. Remove the spark plug. 3. Examine the spark plug and replace it if it is cracked, fouled, dirty, or if the electrodes are worn. Figure 53 Important: Do not clean the electrodes because grit could enter the cylinder and damage the engine. 1. Cable conduit 2. Cable clamp 3.
Replacing the Headlight Bulb Use a GE 892 16W halogen light bulb. Do not touch the bulb with your hands or allow dirt or moisture to come into contact with the bulb. 1. Remove the wire connector from the back of the headlight (Figure 55). Figure 59 6. Insert the wire connector straight into the back of the headlight until it is securely in place (Figure 60). Figure 55 2. Turn the base of the bulb counterclockwise until it stops (Figure 56). Figure 60 Figure 56 3.
Storage Removing the Snowthrower from Storage 1. Remove the spark plug and spin the engine rapidly using the starter to blow the excess oil from the cylinder. • Gasoline vapors can explode. • Do not store gasoline more than 30 days. 2. Install the spark plug by hand and then torque it to 15 ft-lb (20.4 N·m). • Do not store the snowthrower in an enclosure 3. Connect the spark plug wire. near an open flame. 4. Perform the annual maintenance procedures as given in the Recommended Maintenance Schedule.
Troubleshooting Problem Electric starter does not turn (electric-start models only) Engine does not start or starts hard Possible Cause Corrective Action 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. 2. Replace the power cord. 1. The key is not in the ignition or is in the Stop position. 1.
Problem Engine runs rough Possible Cause 1. The choke is in the On position. 1. Move the choke to the Off position. 2. The fuel shutoff valve is not completely open. 3. The fuel tank is nearly empty or contains stale fuel. 2. Open the fuel shutoff valve. 4. The spark plug wire is loose. 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.
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The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.