Toro 624 Power Shift Snowthrower, 828 Power Shift Snowthrower, 724 Power Shift Snowthrower User manual

Toro 624 Power Shift Snowthrower, 828 Power Shift Snowthrower, 724 Power Shift Snowthrower User manual
ENGLISH FORM NO. 3320-488
MODEL: 38505 — 8000001 & UP
MODEL: 38525 — 8000001 & UP
MODEL: 38545 — 8000001 & UP
OPERATOR'S
MANUAL
624, 824 and 828 POWER SHIFT SNOWTHROWERS E
A SAFETY INSTRUCTIONS
The 624, 824 and 828 POWER SHIFT SNOWTHROWERS meet or exceed the Outdoor Power
Equipment Institute's safety standards for snowthrowers; thus, Toro proudly displays the
OPEIl safety seal. To assure maximum safety, optimum performance, and to gain knowledge
of the product, it is essential that you or any other operator of the snowthrower read
The followirig instructions are comparable to the
Instructions For Safety Snowthrowing adopted
by ANSI — American National Standards Insti-
tute. The snowthrower is designed and tested
to offer reasonably safe service; however,
failure to operate it in accordance with the fol-
lowing Safety Instructions MAY RESULT IN
PERSONAL INJURY.
BEFORE OPERATING
1. Read and understand the contents of this
manual before starting and operating the
machine. Become familiar with all controls and
know how to stop the engine quickly.
2. Keep everyone, especially children and pets,
away from the area of operation. Never allow
children to operate the snowthrower.
3. Inspect area thoroughly where snowthrow-
er will be used. Remove door mats, sleds,
boards, sticks, wire and any other foreign ob-
jects which might be picked up and thrown by
the snowthrower.
4. Keep all shields and safety devices in place.
If a shield, safety device or decal is defective
or damaged, repair or replace it before opera-
tion is commenced. Also, tighten any loose nuts,
bolts and screws.
5. Wear adequate winter clothing and footwear
that will improve footing on slippery surfaces.
Do not wear loose fitting clothing that could pos-
sibly get caught in moving parts.
6. Adjust both skids so auger housing clears
gravel or crushed rock surfaces.
/. Before starting the engine, move speed con-
trol to N (neutral).
©The Toro Company — 1987
and understand the contents of this manual before the engine is ever started. Pay particular
attention to the safety symbol which means CAUTION, WARNING or DANGER — “personal
safety instruction”. Read and understand the instruction because it has to do with safety.
Failure to comply with the instruction may result in personal injury.
8. Always use a grounded three wire plug and
cord to start snowthrower equipped with an
electric starter,
9. Fill fuel tank with gasoline before starting the
engine. Avoid spilling any gasoline. Since gaso-
line is highly flammable, handle it carefully. DO
NOT SMOKE WHILE HANDLING GASOLINE.
A. Use an approved gasoline container.
B. Fill fuel tank outdoors and only when engine
is not running. Engine must be cool to pre-
vent a potential fire hazard.
C. Open doors if engine will be run in the garage
because exhaust fumes are dangerous and
could possibly be deadly. Do not run engine
indoors.
D. Wipe up any gasoline that spilled, and install
gasoline container cap and snowthrower fuel
tank cap securely before starting the engine.
WHILE OPERATING
10. STAY BEHIND THE HANDLES AND AWAY
FROM DISCHARGE OPENING WHILE OPERAT-
ING THE SNOWTHROWER. Keep face, hands,
feet and any other part of your body or clothing
away from concealed, moving or rotating parts.
11. BEFORE ADJUSTING, CLEANING, REPAIR-
ING AND INSPECTING THE SNOWTHROWER,
AND BEFORE UNCLOGGING THE DISCHARGE
CHUTE, SHUT ENGINE OFF AND WAIT FOR
ALL MOVING PARTS TO STOP. ALSO, PULL
WIRE OFF SPARK PLUG AND KEEP WIRE
AWAY FROM THE PLUG TO PREVENT ACCI-
DENTAL STARTING. USE A STICK TO REMOVE
OBSTRUCTIONS.
PRICE $1.00
SAFETY INSTRUCTIONS
12. Keep people and pets a safe distance away
from the snowthrower and area of operation.
13. Allow engine to warm up for about 2
minutes and machine to adjust to outdoor tem-
perature before clearing snow.
14. Do not run engine indoors, except when
starting engine. When starting engine indoors,
open outside doors because exhaust gasses are
dangerous.
15. Operate the snowthrower only when there
is good visibility or light. Always maintain se-
cure footing and keep a firm grip on the handles,
especially when operating in reverse.
16. Be attentive when using the snowthrower,
and stay alert for holes in the terrain and other
hidden hazards. Be careful when clearing snow
fromm a gravel drive because stones could be
picked up and thrown if the skids are not adjust-
ed so auger housing clears all rocks.
17. Do not make any adjustments while the en-
gine is running.
18. Never direct discharge of snow or operate
snowthrower near bystanders, glass enclosures,
automobiles and trucks, window wells or a drop-
off without proper adjustment of the snow dis-
charge angle.
19. Clear snow from slopes by going up and
down; never across the face, and use caution
when changing directions. Use lower gear and
rear wheel position when operating on slopes.
Never clear snow from steep slopes.
20. Do not overload the snowthrower by clear-
ing snow at too fast a rate.
21. If a solid object is hit or snowthrower
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all movement to stop. Pull high tension wire off
spark plug and check snowthrower immediate-
ly for possible damage, an obstruction or loose
parts. Vibration is generally a warning of trou-
ble. Repair any damage before restarting engine
and operating snowthrower again.
22. 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 oll
or check oil level in crankcase when engine is
running because this could be a potential hazard.
23. Before leaving the operator's position — be-
hind handles — rotate ignition key to OFF. Re-
move key from switch if snowthrower will be left
unattended.
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EN-2
24. Never operate snowthrower at high trans-
port speeds on slippery surfaces. Use care when
backing.
25. Let engine run for a few minutes after clear-
ing snow so moving parts do not freeze.
MAINTAINING SNOWTHROWER
26. Perform only those maintenance instruc
tions described in this manual. Shut engine off
before performing any maintenance service or
adjustment. Additionally, pull high tension wire
off spark plug and keep wire away from plug to
prevent possibility of accidental starting. If major
repairs are ever needed, contact the local Autho-
rized TORO Service Dealer for assistance.
27. Keep snowthrower in safe operating con-
dition by keeping nuts, bolts and screws tight.
Check engine mounting bolts frequently to as-
sure they are tight.
28. Do not overspeed the engine by changing
governor settings. Recommended maximum en-
gine speed is 4000 rpm. To assure safety and
accuracy, check maximum engine speed (4000
rpm) with a tachometer.
29. Allow engine to cool before storing snow-
thrower in an enclosure such as a garage or
storage shed, and make sure the snowthrower
fuel tank is empty. Do not store snowthrower
near any open flame or where gasoline fumes
may be ignited by a spark.
30. When storing the snowthrower for an ex-
tended time — off season storage or 30 days
— drain gasoline from fuel tank to prevent a
potential hazard. Store gasoline in a safety-
approved red metal container. Remove key from
ignition switch and keep it in a memorable place.
31. At the time of manufacture, the snowthrow-
er conformed with and exceeded safety stan-
dards in effect for snowthrowers. Therefore, to
assure optimum performance and safety, pur-
chase genuine TORO replacement parts and ac-
cessories to keep the TORO all TORO. NEVER
USE “WILL-FIT” REPLACEMENT PARTS AND
ACCESSORIES. The TORO logo assures
genuineness.
32. For safety reasons, use only those acces-
sories and attachments recommended by The
TORO Company to assure continued safety cer-
tification of the product. Using unapproved ac-
cessories and attachments could contribute to
a potential hazard.
SYMBOL GLOSSARY
Slow Fast Ignition Ignition
on off
Keep hands away
Pie a
J %
Y ’
NN”
Neutral Engine speed
Read and understand (Throttle)
operators manual
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Hot surface
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Go) pm unclogging discharge chute auger, keep hands, feet and
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clothing away.
Stop engine before
leaving operator
position
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Choke Choke Auger/impeller
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Traction drive
Forward Reverse
engaged
Chute Direction
EN-3
LOOSE PARTS
Part | Oty Use
Flange head capscrew- 6 Mount Auger Housing, page 5
5/16-18 x 5/8” Ig.
Lower belt cover 1
Flange head capscrew- 5 Mount Belt Covers, page
1/4-20x1/2" lg.
Cable cover 1
Shift rod 1
Locknut-3/8-24 2 Install Shift Rod, page 5
Discharge chute 1 Install Discharge Chute, page 6
Worm gear 1
Gear Bracket 1
Carriage bolt-5/16-18 x1" Ig. 1 Install Chute Control Gear, page 6
Flat washer 1
Locknut-5/16 1
Key 1 Use in Ignition Switch
Registration card 2 Use to Register Product with Factory
Specifications and design subject to change without notice.
TABLE OF CONTENTS
Safety INStrictionNs carey on es 8 muaa E
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loose Parts: oo oo cv anni EX EX EZ SUENOS $ 4
Setting Up Instructions. ou su ax en ewes 5-7
Preparation Before Starting . ........... 8
Fill Crankcase With Qi - +1 55 из сноса я 8
Fill Fuel Tank With Gasoline. ........, 8
Controls: ... à ©: 47 17 0705 Ll YN EX 58 9-10
Starting and Stopping Instructions ...... 11
Operating Instructions ............. 12-13
Power Shift Operation... ........... 12
Free Wheeling or Self Propelled Drive 12
Snowthrowing Tins... ............. 12
Adjusting: SKIde + ¡ura 10 47 an cua 12
EN-4
Page
Maintenance i. vs ww wn 2% ve Ea Жо 13
Draining Gasoline .......... eee... 13
Lubricating Snowthrower . . . ......... 14
Changing Crankcase Oil ............ 14
Auger Gear Box: - .. .. 44 6 a DE 14
Adjusting Auger Drive Belt .......... 14
Adjusting Traction Drive Belt ......... 15
Replacing Drive Belts :..: 1024202400 15
Adjusting Drive Chain . ............. 16
Replacing Spark Plug . ............. 17
Preparing Snowthrower For Storage . . . .18
Identification and Ordering . ........... 19
Maintenance Chart... 19
SETTING UP INSTRUCTIONS
Note: Determine left and right sides of snow-
thrower by standing in the normal operating
position.
MOUNT AUGER HOUSING (Fig. 1-3)
1. Remove (2) flange head capscrews securing
idler pulley assembly to engine frame. Remove
idler pulley assembly.
2. Align auger housing and engine frame
mounting holes (Fig. 1).
Figure 1
4. Idler pulley assembly
5. Mounting screws (2)
1. Auger housing
Z. Engine frame
3. Impeller pulley
3. Route impeller belt around impeller pulley.
4. Secure auger housing to engine frame with
(6) 5/16-18 x 5/8" |g. flange head capscrews.
Figure 2
1. Lower belt cover
(shown from bottom)
2. Mounting tabs
5. Reinstall idler pulley assembly. Make sure
idler pulleys are aligned with belts when reinstall-
ing idler pulley assembly.
6. Tip snowthrower up on auger housing.
7. Mount lower belt cover to underside of auger
housing and engine frame with (2) 1/4-20x1/2"
lg. flange head capscrews (Fig. 2). Make sure
belt cover mounting tabs are positioned to rear
of engine frame member.
8. Mount upper belt cover to engine frame
with (3) 1/4-20x 1/2" Ig. flange head capscrews
(Fig. 3).
9. Slide cable cover onto cables and into hole
in belt cover.
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Figure 3
1. Upper belt cover
2. Cable cover
INSTALL-SHIFT ROD (Fig. 4)
1. Insert upper shift rod ball joint stud thru front
of shift bracket and secure with 3/8-24 locknut.
2. Insert bottom ball joint stud thru right side
of transmission lever and secure with 3/8-24
locknut.
Note: |f gear shift lever is not aligned with Pow-
er Shift slot in control panel (Fig. 4, Inset), shift
rod length must be adjusted as follows:
A. Disconnect ball joint from transmission lever
and loosen jam nut.
B. Rotate ball joint up or down, until gear shift
lever is aligned with power shift slot.
EN-5
SETTING UP INSTRUCTIONS
C. Reinstall ball joint to transmission lever and
tighten jam nut.
Figure 4
Shift rod 5. Locknut
Ball joint 6. Jam nut
Shift bracket 7. Gear shift lever
Transmission lever 8. Shift slot
E 6) К —
INSTALL DISCHARGE CHUTE (Fig. 5)
1. Set discharge chute — open side forward —
onto auger discharge opening, so plastic chute
retainers are positioned on chute ring. Make sure
LC wr mm wr = ==
chute retainer guide pins are inserted into holes
in chute gear.
2. Tighten left hand machine screw and locknut
until chute retainer plate is positioned against
plastic chute retainers and discharge chute
is secured to chute ring.
3. Push right hand chute retainers toward
discharge chute (slotted) and tighten machine
screw.
4. Make sure chute rotates freely on ring. Move
right hand retainer outward to ease operation.
EN-6
Figure 5
1. Discharge chute 3. Chute retainer plate
2. Plastic chute retainer
INSTALL CHUTE CONTROL GEAR (Fig. 6)
1. Insert the 5/16-18 x1" lg. carriage bolt into
gear bracket mounting hole.
2. Position worm gear into bracket, align holes
and insert chute gear rod through bracket and
gear.
Figure 6
Gear bracket
Carriage bolt, flat-washer & locknut
Worm gear
Chute gear rod
lo ho
SETTING UP INSTRUCTIONS
3. Loosely mount worm gear and bracket to
mounting flange with flat washer and locknut.
4. Slide worm gear into teeth of chute gear and
tighten locknut.
5. Check operation, move gear slightly outward
If binding is evident.
CHECK TIRE PRESSURE
IMPORTANT: Check pressure of tires because
they are over inflated at the factory for shipping.
Therefore, before the snowthrower is operated,
reduce pressure in both tires to 7-15 psi on models
624 and 824 and 10-15 psi on model 828, equally.
TIRE CHAINS
If snowthrower is to be equipped with optional
tire chains, wheels must be pinned to outer axle
holes.
CHECK AUGER GEAR BOX OIL (Fig. 7)
1. Move snowthrower to a level surface.
2. Remove pipe plug from gear box.
3. Check level of oil in gear box. Oil must be at
point of overflowing in filler opening.
Figure 7
1. Pipe plug
4. If level of oil is low, add GL-5 or GL-6 SAE
85-95 EP transmission oil to the gear box until
point of overflow.
5. Install pipe plug in gear box.
EN-7
PREPARATION BEFORE STARTING
FILL CRANKCASE WITH OIL (Fig. 8)
The engine is shipped from the factory without
oil in the crankcase. Therefore, before trying to
start engine, oil must be added to the crankcase.
IMPORTANT: Check level of oil every 5 operat-
ing hours or each time unit is used. Initially,
change oil after the first 2 hours of operation;
thereafter, under normal conditions, change oil
after every 25 hours of operation or annually.
1. Move unit to a level surface to assure an ac-
curate oil level reading.
2. Clean area around dipstick to prevent foreign
matter from entering filler hole when dipstick is
removed.
3. Remove dipstick from crankcase.
Figure 8
1. Dipstick
4. Slowly, pour SAE 5W-30 or SAE 10 oil into
the filler hole, using oil filler chart below. The en-
gine uses any high-quality detergent oil having
the American Petroleum Institute — API —
“Service classification” SE or SF.
Oil Fill Chart
19 ounces of oil
624 Snowthrowers
824 & 828 Snowthrowers 27 ounces of oil
Note: Dipstick must be fully installed to assure
accurate gauging of oil level. DO NOT OVERFILL.
EN-8
Because gasoline is flammabie, caution
must be used when storing or handling it.
Do not fill fuel tank while engine is running,
hot or when unit is in an enclosed area. Keep
away from open flame and electrical spark,
and DO NOT SMOKE while filling the fuel
tank to prevent the possibility of an explo-
sion. Always fill fuel tank outside and wipe
up any spilled gasoline before starting en-
gine. Use a funnel or spout to prevent spill-
ing gasoline, and fill fuel tank to about 1/2
inch (13 mm) from the top of the tank, not
the filler neck.
Store gasoline in a clean, approved contain-
er and keep the cap in place on the contain-
er. Keep gasoline in a cool, well-ventilated
place; never in the house. To assure volatil-
ity, do not buy more than a 30 day supply
of gasoline. Gasoline is a fuel for internal
combustion engines; therefore, do not use
it for any other purpose. Since many chil-
dren like the smell of gasoline, keep it out
of their reach because the fumes are explo-
sive and dangerous to inhale.
FILL FUEL TANK WITH GASOLINE.
THE TORO COMPANY STRONGLY RECOM-
MENDS THE USE OF CLEAN, FRESH UNLEAD-
ED REGULAR GASOLINE IN TORO GASOLINE
POWERED PRODUCTS. UNLEADED GASOLINE
BURNS CLEANER, EXTENDS ENGINE LIFE, AND
PROMOTES GOOD STARTING BY REDUCING
THE BUILDUP OF COMBUSTION CHAMBER
DEPOSITS. LEADED GASOLINE CAN BE USED
IF UNLEADED 15 NOT AVAILABLE.
NOTE: NEVER USE METHANOL, GASOLINE
CONTAINING METHANOL, GASOHOL CON-
TAINING MORE THAN 10% ETHANOL, GASO-
LINE ADDITIVES, PREMIUM GASOLINE, OR
WHITE GAS BECAUSE ENGINE FUEL SYSTEM
DAMAGE COULD RESULT.
1. Clean area around the fuel tank cap. Remove
cap from fuel tank and fill tank to within 1/2”
(13 mm) from the top with unleaded regular
gasoline. Reinstall fuel tank cap.
Fuel tank capacity is 4 quarts on 624 and 5
quarts on 824 and 828.
CONTROLS
Auger/Impeller Control (Fig. 9) — Control has
two positions: ENGAGE and DISENGAGE. To en-
gage auger and impeller, compress lever against
right handle grip. To disengage, release lever.
Traction Drive Control (Fig. 9) — To engage trac-
tion or activate power shift system, lever must
be compressed against left handle grip. To stop
traction, release lever.
Speed Shift Control (Fig. 9) — The control has
four speeds forward and two reverse and also
controls power shifting of wheels. To select
speeds, move shift control to desired position.
Note: Release traction drive control when shift-
ing to change speeds or to Power Shift.
Auger Lock-Up: (Fig. 9) — When auger/impeller
control and traction drive control are both com-
pressed, the traction control locks the au-
ger/impeller control down. Releasing the traction
control releases the auger/impeller.
Figure 9.
Auger/impeller control
Traction drive control
Speed shift control
Ignition switch
Discharge chute control
Roky <a
Discharge Chute Control (Fig. 9) — Rotate dis-
charge chute control clockwise to move dis-
charge chute to the right and counterclockwise
to move chute to the left.
Ignition Switch (Fig. 9) — Switch has two posi-
tions: ON and OFF. Rotate key to ON position
before starting engine. To stop engine, rotate key
to OFF.
Throttle (Fig. 10) — Moving the throttle upward
increases the engine speed.
Choke (Fig. 10) — Choke is located on back of
engine cover, Pull choke out to FULL choke
position to start a cold engine. As engine warms
up, push choke in gradually to OFF.
= 6 77
Figure 10
1. Throttle 4. Fuel shut off valve
2. Choke 5. Recoil starter
3. Primer
Primer (Fig. 10) — Pull primer up to pump small
amount of gasoline into engine for improved
cold weather starting.
EN-9
CONTROLS
Fuel Shut-Off Valve (Fig. 10) — Valve is located
under fuel tank. Close valve to stop fuel flow
from fuel tank and open valve to allow fuel to
flow to the carburetor. Close valve when snow-
thrower is not used.
EN-10
Deflector Handle — Deflector handle on top of
discharge chute is used to control the height of
the snow stream.
Recoil Starter (Fig. 10) — Recoil starter is on
back side of engine. Pull recoil starter to start
engine.
STARTING AND STOPPING INSTRUCTIONS
IMPORTANT: Check auger and impeller to assure
that both parts are not frozen solid, but free to
rotate. Also, make sure discharge chute is not
obstructed.
1. Move speed selector to N — neutral — and
throttle to FAST (Fig. 9).
2. Open fuel shut-off valve below fuel tank.
3. Pull choke out to full choke position (Fig. 10).
4. Rotate ignition key to ON (Fig. 9).
5. Pull primer (Fig. 10) once if temperature is
between 0°and 10°F and twice if temperature is
below O*F.
Note: Priming is not required ¡f temperature
is above 10°F.
6. Grasp recoil starter handle (Fig. 10) and pull
it out slowly until positive engagement results;
then pull vigorously to start the engine. Keep firm
grip on starter handle and return the rope slowly.
7. After engine starts, push choke in (Fig. 10)
to 1/2 position for 10-30 seconds, then com-
pletely in.
BEFORE STOPPING ENGINE
1. Run engine for a few minutes to help dry off
any moisture which may have accumulated on
engine.
2. With engine running, pull recoil starter with
a rapid continuous full arm stroke (3) three or
(4) four times. This will help prevent possible
freeze-up of recoil starter due to extreme snow
blowing conditions.
Note: Pulling of recoil starter rope will produce
a loud clattering sound. This is not harmful to
the engine or the starter.
TO STOP ENGINE:
1. Release traction and auger/impeller drive con-
trols (Fig. 9).
2. Move speed selector to N — neutral.
3. Move throttle to slow and rotate ignition key
to OFF.
EN-11
OPERATING INSTRUCTIONS
POWER SHIFT OPERATION
Move wheels rearward to the Power Shift posi-
tion in heavy and/or drifted snow.
Leave wheels in the front position for light snow
or for transporting snowthrower,
1. Release traction drive lever.
2. To move wheels to front or rear position,
move shift control fully forward to Power Shift
position and hold (Fig. 11).
Figure 11
3. Fully engage traction drive lever to move
wheels into Power Shift position (Figs. 11 & 12).
Note: When power shifting it may be necessary
to slightly raise handles to assist wheel move-
ment.
Figure 12
Note: If wheels do not move in desired direction
when power shifting, repeat procedure. Wheels
must rotate in forward direction to move wheels
ahead and rotate rearward to move wheels back.
FREE WHEELING OR SELF PROPELLED DRIVE
The snowthrower can be free wheeled or en-
gaged for self propelled operation. When axle
pins are through outer axle holes (Fig. 13), snow-
thrower will free wheel. By contrast, when both
pins are installed through holes in wheel hub
EN-12
and inner hole of axle (Fig. 13), snowthrower
will self propel itself,
Figure 13
1. Axle pin
SNOWTHROWING TIPS
1. When snowthrower is not being used, close
fuel shut-off valve, have speed control in N —
neutral position, and key removed from the
switch.
2. Remove snow as soon as possible after it
falls. This will produce best snow removal
results.
3. When in the Power Shift position, push down
on handles to increase traction,
4. If snow will be removed from crushed rock
or gravel areas, adjust skids so bottom of auger
housing clears the rocks: refer to Adjusting
Skids, page 12.
5. For concrete or asphalt surfaces, adjust skids
so there is 1/8 inch (3 mm) between bottom of
auger and concrete or asphalt surface.
6. Discharge snow downwind whenever possi-
ble, and overlap each swath to assure complete
snow removal. If wheels slip, shift into a lower
gear which reduces forward speed.
7. In some snow and cold weather conditions,
some controls and moving parts may freeze
solid. Therefore, when any control becomes hard
to operate, stop the engine; then check all parts
for freeze up. DO NOT USE EXCESSIVE FORCE
AND TRY TO OPERATE THE CONTROLS WHEN
FROZEN. Free all controls and moving parts be-
fore operating.
ADJUSTING SKIDS (Fig. 14)
When snowthrower will be used on concrete or
asphalt surfaces, adjust skids using steps 1 - 2.
However, use only step 3 when snowthrower
will be used on gravel or crushed rock surfaces.
OPERATING INSTRUCTIONS
1. Move snowthrower to a level surface. Next,
loosen four flange screws securing both skids
to auger side plates. Skids must slide up and
down.
2. Adjust both skids so there is 1/8 of an inch
between bottom of auger and level surface.
When skids are adjusted correctly, tighten flange
nuts. Next, check scraper blade that is mounted
at bottom of auger housing. Scraper must be
parallel with level surface. If scraper is not
parallel, adjust skids again. Do not use step 3
after adjusting skids for hard surfaces.
3. Loosen four flange screws securing both
skids to auger side plates. Next, slide skids down
as far as possible so auger is as far from the level
surface as skid adjustment allows; then tighten
flange screws.
Figure 14
1. Flange screws
MAINTENANCE
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To prevent accidental starting of the engine
while performing maintenance, rotate igni-
tion key to off and remove it from the
switch. Next, pull wire off spark plug and
make sure wire does not accidentally touch
the plug.
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DRAINING GASOLINE
1. Stop engine and pull wire off spark plug.
2. Remove cap from fuel tank and use pump-
type syphon to drain fuel into clean gas can.
Note: This is the only procedure recommended
for draining fuel,
Since gasoline is highly flammable, drain it
outdoors and make sure engine is cool to
prevent a potential fire hazard. 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, cigarette, or a pipe
when handling gasoline.
EN-13
MAINTENANCE
LUBRICATING SNOWTHROWER
1. Annually, lubricate drive chain with chain
lubricant (Fig. 15). Wipe up any excess oil.
Figure 15
1. Drive chain
CHANGING CRANKCASE OIL (Fig. 16)
Initially, change oil after the first 2 hours of en-
gine operation; thereafter, change oil after ev-
ery 25 hours of engine operation or annually. If
possible, run engine just before changing oil be-
cause warm oil flows better and carries more
contaminants than cold oil.
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.
7 \
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E
77
Figure 16
1. Drain cap
3. After all oil is drained, install oil drain cap.
4. Position snowthrower on a level surface.
Next, fill crankcase with oil: see Fill Crankcase
With Oil, page 8. Wipe up any oil that may have
spilled.
EN-14
AUGER GEAR BOX OIL (Fig. 17)
The auger gear box is filled with oil at the facto-
ry so regular maintenance is not required.
However, if oil must be replaced in gear box:
1. Drain gasoline from fuel tank. Wipe up any
spilled gas.
2. Position snowthrower on a level surface.
3. Clean area around pipe plug so dirt is
removed.
4. Put a drain pan below front of auger gear box
and remove pipe plug: refer to Check Auger Gear
Box Oil, page 7.
5. Tip snowthrower forward and hold it up un-
til all oil drains from the gear box.
Figure 17
1. Pipe plug
6. Carefully let snowthrower down to its nor-
mal position. Make sure it is on a level surface.
Next, fill auger gear box with GL-5 or GL-6 SAE
85-95 EF transmission oii to the point of
overflow.
7. Install pipe plug in gear box.
ADJUSTING AUGER/IMPELLER DRIVE BELT
(Figs. 18-19)
If auger/impeller belt slips, resulting in decreased
snowthrowing performance, an adjustment is re-
quired. WHENEVER A NEW BELT IS INSTALLED,
AN ADJUSTMENT IS REQUIRED.
1. Remove (3) flange head capscrews securing
belt cover to engine frame and slide belt cover
up cables.
2. Check idler and brake adjustment. There
should be a minumum clearance of 1/8" between
tab on impeller idler arm and brake arm (Fig. 19).
If there is less than 1/8” clearance, belt must be
replaced.
3. Loosen upper jam nut securing auger/impeller
cable to mounting bracket (Fig. 18).
MAINTENANCE
Figure 18
1. Auger/impeller cable
2. Traction cable
4. Rotate bottom jam nut upward to increase
belt tension.
3. Mounting bracket
Note: When adjusting cable, always rotate nut
one turn at a time.
5. Tighten upper jam nut against bracket.
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A WARNING
Improper adjustment may cause injury if
auger/impeller turns when disengaged. Use
only genuine Toro replacement parts.
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ADJUSTING TRACTION DRIVEBELT (Fig. 18)
If traction belt slips during operation, an adjust-
ment is required. Whenever the belt is replaced
an adjustment is required.
1. Loosen upper jam nut securing traction cable
to mounting bracket.
2. Rotate bottom jam nut upward to increase
belt tension.
Note: When adjusting cable, always rotate nut
one turn at a time.
3. Tighten upper jam nut against bracket.
4. Check tension of belt by operating machine.
If belt still slips, repeat procedure.
IMPORTANT: Do not adjust the belt too tight be-
cause it may cause snowthrower to creep when
traction lever is in disengaged position. If this
occurs, readjust, loosening belt tension.
REPLACING DRIVE BELTS (Fig. 20)
If auger/impeller belt or traction belt become
worn, glazed, stretched, oil-soaked, or otherwise
defective, belt replacement is required.
1. Pull wire off spark plug and make sure it does
not contact the plug accidentally.
2. Remove (3) thread forming screws holding
belt cover in place, and slide belt cover up cables.
3. Move speed shift control to N, neutral.
4. Remove (2) flange head capscrews securing
idler pulley assembly to engine frame. Remove
idler pulley assembly.
#
Figure 19
1. Idler arm
2. Brake arm
6. Reinstall belt cover.
7. Check tension of belt by operating the au-
ger. If belt still slips, repeat procedure.
Figure 20
1. Idler pulley assembly 4. Half sheave
2. Mounting screws (2) 5. Auger/impeller belt
3. Capscrew & lockwasher 6. Traction belt
5. Remove capscrew and lockwasher securing
half sheave to front of pulley assembly.
6. Slide auger/impeller pulley and belt off crank-
shaft and remove belt from impeller pulley.
EN-15
MAINTENANCE
7. If replacing traction belt, slide traction pul-
ley and belt off crankshaft and remove belt from
transmission pulley.
8, On control cable which corresponds to belt
being replaced, loosen jam nuts securing cable
to bracket (Fig. 18). Cable must be free to slide
in bracket when changing belt(s).
9. Reinstall belts by reversing procedure. Make
sure tabs in half sheave are inserted into mount-
ing grooves in auger/impeller pulley when re-
installing.
Note: Make sure idler pulleys are aligned with
belts when reinstalling idler pulley assembly.
10. Readjust belts, refer to Adjusting Auger/
Impeller Drive Belt or Adjusting Traction Drive
Belt.
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7 QUO
improper adjustment may cause injury if
auger/impeller turns when disengaged. Use
only genuine Toro replacement parts.
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ADJUSTING DRIVE CHAIN (Figs. 21-24)
The drive chain must be adjusted to maintain
1/8-3/8 of an inch deflection at mid span be-
tween transmission and axle sprocket. Check
chain deflection after every 25 hours of
operation.
1. Check deflection of chain by lifting up on
chain with moderate pressure at mid span. There
should be 1/8-3/8" deflection. If deflection is not
as specified an adjustment is required.
1/8" - 3/8"
DEFLECTION
Figure 21
IMPORTANT: To adjust drive chain, the snow-
thrower must be tipped up on auger housing.
However, before the snowthrower is tipped,
drain all gasoline from fuel tank.
2. Make sure wheels are positioned in rear po-
sition, move shift control into 2nd gear and tip
snowthrower up onto auger housing.
EN-16
Figure 22
1. Transmission
2. Transmission frame
3. Loosen (4) flange head capscrews (2 each
side) securing transmission frame to engine
frame (Fig, 23).
4. Lightly lift up on transmission frame until
1/8-3/8" chain deflection is attained, then,
retighten flangehead capscrews.
Figure 23
1. Flange head cap screws
IMPORTANT: Do not pry or use excessive force
when lifting transmission frame, as transmission
damage may occur.
Note: If gear shift lever is not aligned with Power
Shift slot in control panel (Figure 24 inset),
shift rod length must be adjusted as follows:
MAINTENANCE
Figure 24
1. Shift rod 5. Locknut
2. Ball joint 6. Jam nut
3. Shift bracket 7. Gear shift lever
4. Transmission lever
A. Disconnect ball joint from transmission lever
and loosen jam nut.
B. Rotate ball joint up or down, until gear shift
lever is aligned with Power Shift slot.
C. Reinstall ball joint to transmission lever and
tighten jam nut.
5. Recheck chain deflection and lower snow-
thrower to normal position.
REPLACING SPARK PLUG (Fig. 25)
Correct spark plug to use is a NGK BP-4HS or
equivalent, and correct air gap is .025-.030 of
an inch. Since air gap between center and side
electrodes of the spark plug increases gradually
during normal engine operation, install a new
plug after every 25 hours of engine operation.
1. Clean area around spark plug so foreign mat-
ter cannot fall into cylinder when plug is
removed.
2. Pull wire off spark plug and remove plug from
cylinder head.
IMPORTANT: A cracked, fouled, or dirty spark
plug must be replaced. Do not sand blast,
scrape, or clean electrodes because grit may
eventually release from the plug and fall into the
cylinder. The result will likely be engine damage.
3. Set air gap between electrodes of new spark
plug at .,025-.030 of an inch (Fig. 25). Next, in-
stall spark plug in cylinder head. Tighten plug to
15 ft-lb. If torque wrench is not used, tighten
plug firmly,
4, Push the wire onto spark plug.
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Figure 25
EN-17
MAINTENANCE
PREPARING SNOWTHROWER FOR STORAGE
1. Drain gasoline from fuel tank: refer to Drain-
ing Gasoline. Wipe up any gasoline that may
have spilled.
2. Start the engine and let it run until it stops
because there is no gasoline in the fuel system.
3. Remove spark plug from cylinder head. Next,
pour two teaspoons of engine oil into spark plug
hole in cylinder head. Install spark plug in
cylinder head, but do not install wire on the plug.
Then pull recoil starter slowly to distribute oil on
inside of cylinder.
4. Lubricate the snowthrower: refer to Lubricat-
EN-18
ing Snowthrower. Change crankcase oil: see
Changing Crankcase Oil.
5. Clean the snowthrower. Touch up chipped
surfaces with paint. Sand affected areas before
painting, and use a rust preventative to prevent
metal parts from rusting.
6. Tighten all screws and nuts. If any part is
damaged, repair or replace it.
7. Store snowthrower in a clean, dry place, and
cover it to give protection.
8. The snowthrower may be stored in upright
position. Make sure to drain gas before tipping
snowthrower upright on auger housing.
IDENTIFICATION AND ORDERING
MODEL AND SERIAL NUMBERS
The snowthrower has two identification num-
bers: a model number and a serial number. The
two numbers are stamped on a decal which is
located on back of engine mounting plate. In any
correspondence concerning the snowthrower,
supply model and serial numbers to assure that
correct information and replacement parts are
obtained.
To order replacement parts from an Authorized
TORO Service Dealer, supply the following in-
formation:
1. Model and serial numbers of the snow-
thrower.
2. Part number, description, and quantity of
part(s) desired.
Note: Do not order by reference number if a parts
catalog is being used; use the PART NUMBER.
MAINTENANCE RECORD
. Spark
Date Hours Oil Lubrication Summer Fall Plug
Used Change Storage Service Gap
UPL-44201
EN-19
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