Toro Power Clear 621 QZR/QZE Snowthrower

Operator's Manual

Model No. 38458 - Serial No. 312000001 and Up

Model No. 38459 - Serial No. 312000001 and Up

Introduction

This machine is intended for use by residential homeowners. It is designed for removing snow from paved surfaces, such as driveways and sidewalks, and other surfaces for traffic on residential or commercial properties. It is not designed for removing materials other than snow, nor is it designed for clearing off gravel surfaces.

Read this information carefully to learn how to operate and maintain your machine properly and to avoid injury and machine damage. You are responsible for operating the machine properly and safely.

You may contact Toro directly at www.Toro.com for machine and accessory information, help finding a dealer, or to register your machine.

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 machine ready. Figure 1 identifies the location of the model and serial numbers on the machine. Write the numbers in the space provided.

Figure 1 shows the location of the model and serial numbers on the machine.

This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Figure 2 shows the safety alert symbol.

This manual uses two words to highlight information: Important calls attention to special mechanical information, and Note emphasizes general information worthy of special attention.

Safety

Read and understand the contents of this manual before you start the engine. The safety alert symbol shown in Figure 2 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 machine could result in injury or death. To reduce this potential, comply with the following safety instructions.

This machine is capable of amputating hands and feet and of throwing objects. Failure to observe the following safety instructions could result in serious injury.

Training

Preparation

Operation

Clearing a Clogged Discharge Chute

Hand contact with the rotating rotor blades inside the discharge chute is the most common cause of injury associated with snowthrowers. Never use your hand to clean out the discharge chute.

To clear the chute:

Maintenance and Storage

Toro Snowthrower Safety

The following list contains safety information specific to Toro products or other safety information that you must know:

Safety and Instructional Decals

Important: Safety and instruction decals are located near areas of potential danger. Replace damaged decals.

Decal 94-2577: 1. To engage the rotor blades, hold the control bar against the handle. 2. To disengage the rotor blades, release the control bar.

Decal 115-5698 (Order part no. 117-9121): 1. Cutting dismemberment hazards, impeller and auger—do not place your hand in the chute; remove the ignition key and read the instructions before servicing or performing maintenance.

Decal 117-9102 (Model 38458 only, Order part no. 117-6036):

Decal 117-9103 (Model 38459 only, Order part no. 117-6046):

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Procedure Description Qty. Use
1 No parts required Unfold the handle.
2 Screws
Chute assembly
3
1
Install the discharge chute.

Unfolding the Handle

No Parts Required

Procedure:

  1. Loosen the handle knobs, pull out the “U”-shaped handle locks until you can move the handle freely, and rotate the handle to the operating position (Figure 4). Figure 4 shows the "U"-shaped handle lock and handle knobs.
  2. Insert the end of the “U”-shaped handle lock into the open hole in the handle and tighten the handle knobs until they are snug (Figure 5). Figure 5 illustrates this step.

Important: Ensure that you do not pinch or kink the control cable or the Quick Shoot™ cables (Figure 6). Figure 6 shows the control cable and Quick Shoot™ cables.

Installing the Discharge Chute

Parts needed for this procedure:

Description Qty.
3 Screws 1
1 Chute assembly 1

Procedure:

Install the discharge chute as shown (Figure 7). Figure 7 shows the discharge chute and screws.

Note: The bottle of oil may contain an ounce or two more than the engine requires. Do not overfill or underfill the engine. Max fill: 20 oz. (0.6 L), type: automotive detergent oil with an API service classification of SJ, SL, or higher.

Use Figure 8 to select the best oil viscosity for the outdoor temperature range expected. Figure 8 is a chart showing oil viscosity recommendations based on temperature.

1. Move the machine to a level surface.

2. Clean around the oil fill cap (Figure 9). Figure 9 shows the oil fill cap.

Note: For easier installation, use a small ratchet wrench to tighten the screws.

Important: Do not overtighten the screws; otherwise you may damage the discharge chute and prevent it from turning freely.

Filling the Engine with Oil

No Parts Required

Procedure:

Your machine does not come with oil in the engine, but it does come with a bottle of oil.

Important: Before starting the engine, fill the engine with oil.

  1. Unscrew the oil fill cap and remove it.
  2. With the machine in the operating position, carefully pour oil into the crankcase. Wait 3 minutes for the oil to settle and add enough to bring it to the point of overflow. There should be very little, if any, oil left in the bottle.
  3. Screw the oil fill cap into the oil fill hole and tighten it securely.

Adjusting the Control Cable

No Parts Required

Procedure:

Refer to Adjusting the Control Cable in Maintenance.

Product Overview

Figure 10 provides a labeled diagram of the snowthrower components:

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

DANGER

Gasoline is extremely flammable and explosive. A fire or explosion from gasoline can burn you and others.

Filling the Fuel Tank

Fill the fuel tank with fresh unleaded gasoline having an octane rating at or near 87 from a major name-brand service station (Figure 11). Figure 11 shows the fuel tank filler neck.

Important: Do not add oil to the gasoline.

Important: Do not use E85 or E20 fuel. Alternative fuels with high alcohol content can cause hard starting, poor engine performance, and may cause internal engine damage.

Note: For best results, purchase only the quantity of gasoline that you expect to use in 30 days. Otherwise, you may add fuel stabilizer to newly purchased gasoline to keep it fresh for up to 6 months.

Checking the Engine Oil Level

Service Interval: Before each use or daily—Check the engine oil level and add oil if necessary.

  1. Move the machine to a level surface.
  2. Clean around the oil fill cap (Figure 12). Figure 12 shows the oil fill cap.
  3. Unscrew the oil fill cap and remove it.
  4. If the oil level is low, keep the machine in the operating position and carefully pour oil into the crankcase until the point of overflow. (Max. fill: 20 oz. (0.6 L), type: automotive detergent oil with an API service classification of SJ, SL, or higher.)
  5. Wait 3 minutes for the oil to settle and add enough oil to bring it to the point of overflow.
  6. Screw the oil fill cap into the oil fill hole and hand tighten it securely.

Starting the Engine

  1. Turn the ignition key clockwise to the On position (Figure 13). Figure 13 shows turning the ignition key.
  2. Pull out the choke lever (Figure 14 and Figure 15). Figure 14 shows the choke lever. Figure 15 shows symbols on the choke lever indicating to move the choke lever to the right to activate the choke.
  3. Firmly push in the primer 3 times with your thumb, holding the primer in for a second before releasing it each time (Figure 16). Figure 16 illustrates priming the engine.

Note: Remove your glove when you push in the primer so that air cannot escape from the primer hole.

Important: Do not use the primer or the choke if the engine has been running and is hot. Excessive priming may flood the engine and prevent it from starting.

  1. Connect an extension cord to a power source and the machine, and push the electric-start button (model 38459 only) (Figure 17), or pull the recoil start handle (Figure 18). Figure 17 shows connecting the electric start. Figure 18 shows pulling the recoil start handle.

Note: Use only a UL-listed, 16-gauge extension cord recommended for outdoor use that is not longer than 50 feet (15 m).

WARNING

The electrical cord can become damaged, causing a shock or fire. Thoroughly inspect the electrical cord before plugging it into a power source. If the cord is damaged, do not use it to start the machine. Replace or repair the damaged cord immediately. Contact an Authorized Service Dealer for assistance.

Important: Run the electric starter no more than 10 times at intervals of 5 seconds on, then 5 seconds off. Running the electric starter extensively can overheat and damage it. If the engine does not start after this series of attempts, wait at least 40 minutes to allow the starter to cool before attempting to start it again. If the engine does not start after the second series of attempts, take the machine to an Authorized Service Dealer for service (model 38459 only).

Note: If you pull the recoil handle and feel no resistance, the starter may be frozen. Thaw out the starter before attempting to start the machine.

  1. While the engine is running, push in the choke lever slowly.
  2. Unplug the extension cord from the power source and the machine (model 38459 only).

CAUTION

If you leave the machine plugged into a power source, someone can inadvertently start the machine and injure people or damage property (model 38459 only). Unplug the power cord whenever you are not starting the machine.

Engaging the Rotor Blades

To engage the rotor blades, hold the control bar against the handle (Figure 19). Figure 19 shows the control bar.

Disengaging the Rotor Blades

To disengage the rotor blades, release the control bar (Figure 20). Figure 20 shows releasing the control bar.

Stopping the Engine

To stop the engine, turn the ignition key counterclockwise to the Off position (Figure 21). Figure 21 shows turning the ignition key to the Off position.

Adjusting the Discharge Chute and Chute Deflector

To adjust the discharge chute, press the trigger of the Quick Shoot™ control on the right hand side of the handle and move it up or down along the handle. Moving the control down the handle rotates the discharge chute to the left; moving the control up the handle rotates the discharge chute to the right (Figure 22). Figure 22 illustrates adjusting the discharge chute direction.

To raise or lower the angle of the chute deflector, press the trigger on the chute deflector and move the chute deflector up or down (Figure 23). Figure 23 shows the chute deflector trigger and deflector.

Clearing a Clogged Discharge Chute

Important: Hand contact with the rotating rotor blades inside the discharge chute is the most common cause of injury associated with snowthrowers. Never use your hand to clean out the discharge chute.

To clear the chute:

Preventing Freeze-up after Use

Operating Tips

WARNING

The rotor blades can throw stones, toys, and other foreign objects and cause serious personal injury to the operator or to bystanders.

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service Interval Maintenance Procedure
After the first hour
  • Check the control cable and adjust it if necessary.
  • Check for loose fasteners and tighten them if necessary.
After the first 2 hours
  • Change the engine oil.
Before each use or daily
  • Check the engine oil level and add oil if necessary.
Yearly
  • Check the control cable and adjust it if necessary.
  • Inspect the rotor blades and have an Authorized Service Dealer replace the rotor blades and scraper if necessary.
  • Change the engine oil.
  • Check the spark plug and replace it if necessary.
  • Check for loose fasteners and tighten them if necessary.
  • Have an Authorized Service Dealer inspect the drive belt and replace it if necessary.
Yearly or before storage
  • Prepare the machine for storage.

Adjusting the Control Cable

Checking the Control Cable

Service Interval: After the first hour—Check the control cable and adjust it if necessary. Yearly—Check the control cable and adjust it if necessary.

Move the control bar back toward the handle to remove the slack in the control cable (Figure 25). Figure 25 shows the control bar and the gap measurement.

Important: The control cable must contain some slack when you disengage the control bar for the rotor blades to stop properly.

Adjusting the Control Cable

  1. Slide up the spring cover and unhook the spring from the adjuster link (Figure 26). Figure 26 shows the adjuster link, Z-fitting, and spring cover.
  2. Move the Z-fitting to a higher or lower hole on the adjuster link as needed to obtain the 1/16-inch to 1/8-inch (2 mm to 3 mm) gap between the control bar and the handle (Figure 25).

Note: Moving the Z-fitting higher decreases the gap between the control bar and the handle; moving it lower increases the gap.

  1. Hook the spring to the adjuster link and slide the spring cover over the adjuster link.
  2. Check the adjustment; refer to Checking the Control Cable.

Note: After extended use, the drive belt may wear and lose its proper belt tension. If the drive belt slips (continuously squeals) under a heavy load, disconnect the spring from the adjustor link and move the upper end of the spring to the hole that is further from the pivot point in the control bar (Figure 27). Then connect the spring to the adjustor link and adjust the control cable. Figure 27 illustrates adjusting the drive belt tension.

Note: The belt may slip (squeal) in wet conditions; to dry out the drive system, start the rotor and run it without a load for 30 seconds.

Inspecting the Rotor Blades

Service Interval: Yearly—Inspect the rotor blades and have an Authorized Service Dealer replace the rotor blades and scraper if necessary.

Before each session, inspect the rotor blades for wear. When a rotor blade edge has worn down to the wear indicator hole, have an Authorized Service Dealer replace the rotor blades and the scraper (Figure 28). Figure 28 shows the wear indicator holes on the rotor blades.

Changing the Engine Oil

Service Interval: After the first 2 hours, Yearly

Run the engine a few minutes before changing the oil to warm it. Warm oil flows better and carries more contaminants.

  1. Siphon the fuel from the fuel tank into an approved fuel container, or run the engine until it stops.
  2. Move the machine to a level surface.
  3. Place an oil drain pan under the oil drain plug, remove the oil drain plug, and tip the machine backward and drain the used oil in the oil drain pan (Figure 29). Figure 29 shows draining the oil.
  4. After draining the used oil, return the machine to the operating position.
  5. Install the oil drain plug and tighten it securely.
  6. Clean around the oil fill cap (Figure 30). Figure 30 shows the oil fill cap.
  7. Unscrew the oil fill cap and remove it (Figure 30).
  8. With the machine in the operating position, carefully pour oil into the oil fill hole. Wait 3 minutes for the oil to settle and add enough to bring it to the point of overflow. There should be very little, if any, oil left in the bottle (Figure 32). Figure 32 shows adding oil.

Max fill: 20 oz. (0.6 L), type: automotive detergent oil with an API service classification of SJ, SL, or higher.

Use Figure 31 below to select the best oil viscosity for the outdoor temperature range expected. Figure 31 is a chart showing oil viscosity recommendations based on temperature.

Servicing the Spark Plug

Service Interval: Yearly—Check the spark plug and replace it if necessary.

Use a NGK BPR6ES or Champion RN9YC spark plug or equivalent.

  1. Stop the engine and wait for all moving parts to stop.
  2. Rotate the discharge chute so that it faces forward.
  3. Remove the discharge chute, the discharge chute handle, and the chute seal by removing the 3 large screws and one small screw (Figure 33). Figure 33 shows removing the chute components.
  4. Remove the 4 screws that secure the shroud (Figure 34). Figure 34 shows removing the shroud screws.
  5. Remove the fuel tank cap.
  6. Remove the shroud (Figure 34).
  7. Install the fuel tank cap.
  8. Disconnect the wire from the spark plug.
  9. Clean around the spark plug.
  10. Remove the spark plug from the cylinder head.

Important: Replace a cracked, fouled, or dirty spark plug. Do not clean the electrodes because grit entering the cylinder can damage the engine.

  1. Set the gap on the plug to 0.030 inch (0.76 mm) (Figure 35). Figure 35 shows the spark plug gap measurement.
  2. Install the spark plug and torque it to 20–22 ft-lb (27–30 N-m).
  3. Connect the wire to the spark plug.

Note: Ensure that the breather tube is routed above the spark plug wire as shown in Figure 36. Figure 36 shows the correct routing of the breather tube and spark plug wire.

  1. Remove the fuel tank cap.
  2. Install the shroud with the screws you removed in step 4.

Note: Ensure that the upper and lower shrouds fit together in the side grooves.

  1. Install the fuel tank cap.
  2. Install the chute seal, the discharge chute, and the discharge chute handle onto the machine using the hardware you removed in step 3.

Note: The small screw goes through the small hole in the chute seal at the front of the discharge chute opening.

Replacing the Drive Belt

If drive belt becomes worn, oil-soaked, excessively cracked, frayed, or otherwise damaged, replace the belt.

  1. Remove the drive belt cover by removing the 3 bolts as shown in Figure 37. Figure 37 shows the drive belt components.
  2. Unhook the brake spring from the idler arm to release the belt tension (Figure 37).
  3. Remove the screw and curved washer that holds the rotor pulley (Figure 37).
  4. Remove the rotor pulley and the drive belt (Figure 37).
  5. Install the new drive belt, routing it as shown in (Figure 38). Figure 38 illustrates routing the new drive belt.

Note: Route the new drive belt first around the engine pulley, then the idler pulley, and finally around the loose rotor pulley positioned just above the rotor shaft (Figure 37).

  1. Install the rotor pulley onto the rotor shaft (Figure 37).
  2. Install the curved washer and the rotor pulley bolt and tighten them securely (Figure 37).

Note: The concave side of the curved washer goes against the outside of the pulley.

  1. Install the brake spring onto the idler arm (Figure 38).
  2. Install the drive belt cover with the bolts you removed in step 1.

Note: Ensure that the drive belt is properly adjusted and operating; refer to Checking the Control Cable and Adjusting the Control Cable.

Adjusting the Quick Shoot™ Control

If there is more than 1/2 inch (13 mm) of slack in the Quick Shoot cable (Figure 39) or the discharge chute does not rotate left and right in equal angles, adjust the Quick Shoot control cables.

1. Loosen the two Quick Shoot control cable clamps (Figure 40). Figure 40 shows the cable clamps.

2. Position the Quick Shoot control between the two arrows located on the right hand side of the upper handle (Figure 41). Figure 41 shows the positioning arrows.

3. Rotate the discharge chute so that it faces straight ahead and the arrow on the back of the discharge chute aligns with the arrow on the shroud (Figure 42). Figure 42 shows aligning the chute with the shroud arrow.

4. Hold the discharge chute in the straight-ahead position, pull the lower cable casing downward until you remove the slack in the cable, and tighten the screw on the lower cable clamp securely (Figure 43). Figure 43 shows adjusting the lower cable casing.

5. Pull the upper cable casing forward until you remove the slack in the cable, and tighten the screw on the upper cable clamp securely (Figure 44). Figure 44 shows adjusting the upper cable casing.

Note: Do not over-tension the cables. If the cables are over-tensioned, the Quick Shoot will be hard to operate.

Storage

Storing the Snowthrower

WARNING

  1. On the last refueling of the season, add fuel stabilizer to fresh fuel as directed by the engine manufacturer.
  2. Run the engine for 10 minutes to distribute the conditioned fuel through the fuel system.
  3. Stop the engine, allow it to cool, and siphon the fuel tank or run the engine until it stops.
  4. Start the engine and run it until it stops.
  5. Choke or prime the engine, start it a third time, and run the engine until it will not start.
  6. Drain the fuel in the carburetor through the carburetor drain bolt (Figure 36) into an approved gasoline container.
  7. Dispose of unused fuel properly. Recycle it according to local codes, or use it in your automobile.
  8. While the engine is still warm, change the engine oil. Refer to Changing the Engine Oil.
  9. Remove the spark plug.
  10. Squirt 2 teaspoons of oil into the spark plug hole.
  11. Install the spark plug by hand and then torque it to 20–22 ft-lb (27–30 N-m).
  12. With the ignition key in the Off position, pull the recoil starter slowly to distribute the oil on the inside of the cylinder.
  13. Clean the machine.
  14. Touch up chipped surfaces with paint available from an Authorized Service Dealer. Sand affected areas before painting, and use a rust preventative to prevent the metal parts from rusting.
  15. Tighten any loose fasteners. Repair or replace any damaged parts.
  16. Cover the machine and store it in a clean, dry place out of the reach of children. Allow the engine to cool before storing it in any enclosure.
Models: 38458 Serial, 312000001, 38459 Serial, 312000001, Power Clear 621 QZR QZE Snowthrower, Power Clear 621, Clear 621 Snowthrower, Power Clear Snowthrower, Snowthrower, QZR Snowthrower, QZE Snowthrower

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