Res i dent i al Pr oduc t s SnowMas t er ® / SnowMax® I s s ued: May2016
ABOUT THIS MANUAL This service manual was written expressly for TORO® and LAWN-BOY® service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. The SnowMaster® and SnowMax® Snowthrower is covered in this manual. The manual may also be specified for use on later model products.
TABLE OF CONTENTS Chapter 1 - Safety Information General Information.................................................................................................................................. 1-1 Chapter 2 - Specifications & Maintenance Torque Specifications............................................................................................................................... 2-1 U.S. to Metric Conversions.........................................................................................
This symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction because if has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. ! This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro SnowMaster® and SnowMax® snowthrowers.
SPECIFICATIONS AND MAINTENANCE Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
SPECIFICATIONS AND MAINTENANCE Standard Torque Values (Inch) Grade 1, 5, & 8 with Thin Height Nuts Thread Size SAE Grade 1 Bolts In-lb In-lb SAE Grade 5 Bolts N-cm In-lb SAE Grade 8 Bolts N-cm In-lb N-cm 1/4-20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170 1/4-28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170 5/16-18 UNC 115 ± 15 105 ± 15 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340 5/16-24 UNF 138 ± 17 128 ± 17 1446 ± 1
SPECIFICATIONS AND MAINTENANCE Thread Size Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23, or Type F Thread Size Baseline Torque* No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
SPECIFICATIONS AND MAINTENANCE Equivalents & Conversions Decimal & Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.
SPECIFICATIONS AND MAINTENANCE Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) After the first hour • Check for loose fasteners and tighten them if necessary. After the first 2 hours • Change the engine oil. • Inspect the auger cable and adjust it if necessary. • Inspect the transmission cable and adjust it if necessary.
SPECIFICATIONS AND MAINTENANCE Checking and Adjusting the Skids Inspecting the Throwing Edges Service Interval: Yearly Service Interval: Yearly—Inspect the throwing edges and have an Authorized Service Dealer replace the throwing edges and scraper if necessary. Check the skids to ensure that the auger does not contact the paved surface. Adjust the skids as needed to compensate for wear (Figure 2). 1. 2. Before each session, inspect the throwing edges for wear.
Specifications & Maintenance SPECIFICATIONS AND MAINTENANCE Figure 4 Oil-drain plug 3. After draining the used oil, return the machine to the operating position. 4. Install the oil drain plug and tighten it securely. 5. Clean around the oil fill cap. 6. Use Figure 5 below to select the best oil viscosity for the outdoor temperature range expected: Model Max fill 36001, 36002, 38710, 38711 0.5 L (16.9 oz) 36003, 38712 0.7 L (23.7 oz) 2 1.
SPECIFICATIONS AND MAINTENANCE Replacing the Spark Plug Adjusting the Auger Cable Service Interval: Every 100 hours—Replace the spark Service Interval: After the first 2 hours plug. Yearly WARNING If the drive belt slips or squeals under heavy load, adjust the auger cable. Replacing the spark plug while the engine is hot can result in burns. 1. Wait until the engine is cool to replace the spark plug. Loosen the nut on the lower cable clamp, but do not remove it (Figure 9).
SPECIFICATIONS AND MAINTENANCE Adjusting the Transmission Cable Service Interval: After the first 2 hours Yearly 2 Specifications & Maintenance If the wheels easily stall out, or if the wheels drive without engaging the self-propel handle, adjust the transmission cable. 1. Loosen the nut on the upper cable clamp, but do not remove it (Figure 10). Figure 10 1. Nut 2. Cable 2. Pull the cable down to remove most of the slack in the cable (Figure 10). Important: Do not remove all the slack from the cable.
SPECIFICATIONS AND MAINTENANCE Storage 16. Storing the Snowthrower 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. WARNING • Gasoline fumes are highly flammable, explosive, and dangerous if inhaled. If you store the machine in an area with an open flame, the gasoline fumes may ignite and cause an explosion.
CHASSIS Handles and Controls 3 1 4 1 5 2 3 Chassis 2 6 Figure 11 1. Upper Handle 2. Lower Handle 3. Personal Pace® Handle 4. Transmission Cable 5. Upper Rotor Cable 6. Lower Rotor Cable 1 All slack must be removed from the traction cable before cable is secured. Transmission cable to be adjusted so 2.50 ± .05 in. of conduit sticks out past cable anchor. Rear wheels should spin freely in both forward and reverse without Personal Pace® engagement and should lock with Personal Pace® engagement.
CHASSIS Engine 1 1 1 2 3 2 4 Figure 12 1. Engine 2. Engine Pulley 1 Apply a light coat of anti-seize to engine crankshaft, before installing engine pulley. 2 Apply Loctite® 243 to the threads of the engine 3 Pulley groves, item 2, need to be dry and free of oil, anti-seize or other lubricants. 4 Torque engine pulley bolt to 170 ± 15 in-lbs. (19.5 ± 1.7 Nm) When inspecting the proper torque, torque must be checked immediately before Loctite® 243 sets up. mounting studs.
CHASSIS Chute Asm. 7 8 5 9 6 3 11 13 10 4 2 3 Chassis 1 12 Figure 13 1. Lower Chute 2. Chute Guide 3. Chute Support Tube Bracket 4. Chute Post 5. Chute Gear 6. Chute Toro® - SnowMaster® Service Manual 7. Chute Handle 8. Spring Cover 9. Extension Spring 10. LH Upper Shroud 11. RH Lower Shroud 12. Housing Kicker 13.
CHASSIS Chute Asm. 7 9 8 4 5 3 6 11 2 10 1 12 Figure 14 1. Lower Chute 2. Chute Guide 3. Chute Post 4. Chute Gear 5. Chute 6. Chute Ring 3-4 Table of Contents 7. Gear Chute Mount 8. Face Gear 9. Gear Chute Cover 10. LH Upper Shroud 11. RH Lower Shroud 12.
CHASSIS Chute and Shroud Removal & Replacement (Figure 13 and 14) Replacement 1. Install the lower chute (item 1). Install the lower chute bottom screws and the screws that hold the lower chute to the housing kicker (item 12). Torque screws to 25-35 in-lbs. (2.8-4 Nm) (Figure 16). Removal 1. Remove RH (item 11) and LH (item 10) upper shrouds.. 2. Remove the bolt and nut attaching the chute post (Figure 13) (item 4). Remove the post and chute assembly. 3.
CHASSIS Belt Removal & Replacement Removal Replacement 1. Remove the bolts securing the belt cover and remove the cover (Figure 18). 1. Start the belt over the jackshaft pulley. Route the belt under the idler pulley and between the tabs on the rotor clutch arm. Route the belt over the rotor pulley (Figure 20). Figure 18 2. Unhook the brake spring clip and remove the clip and spring. 3. Remove the Rotor Pulley bolt and pull the Rotor Pulley out (Figure 19). Figure 19 4.
CHASSIS Rotor and Rotor Drive 2 A B 3 1 4 3 4 4 Chassis 5 3 4 4 3 Figure 22 A. Rotor Center Support B. Paddle 1 Torque to 60-80 in-lbs. (7-9 Nm) 2 Torque to 40-60 in-lbs. (4-7 Nm) 4 Tighten center screw first when assembling rotor paddles. Torque to 45-55 in-lbs. 5 Insure rotor assembly, rotates freely after completely installed in frame. Rotor cannot make contact with frame or ground surface.
CHASSIS Rotor Removal & Replacement (Figure 22) Removal Replacement 1. Remove the belt cover and remove belt and rotor pulley as outlined in “Belt Removal & Replacement.” 1. Make sure the thrust washer, bearing, and bearing retainer are on the rotor shaft on the drive belt side. Insert into the rotor hole. Insert the rotor through the other side of the rotor hole. 2. Remove the three bolts from behind the rotor pulley. Figure 25 Figure 23 3.
CHASSIS Rotor Removal & Replacement (Figure 22)(Cont.) Replacement (Cont.) 3. Install the rubber washer and bearing cap. Ensure the rubber washer is properly positioned before installing the bearing cap. Torque bolts to 40-60 inlbs. (4.6-7 Nm). 4. Install the bolts that go behind the rotor pulley. Torque to 60-80 in-lbs. (7-9 Nm). 3 Chassis 5. Install the rotor belt and belt cover as outlined in “Belt Removal & Replacement.
CHASSIS Transmission, Drive and Tire 3 2 3 6 3 8 7 2 1 4 4 5 1 Figure 27 1. Transmission 2. Jackshaft Support Plate 3. Traction Idler 4. Jackshaft Pulley 5. Idler Pulley 6. Belt 7. Jackshaft 8. Transmission Bearing Support 1 Spring must be assembled into the slot of the traction idler arm and hole in jackshaft support plate. 3-10 Table of Contents 2 Ensure idler arm, pivots freely after assembly.
CHASSIS Transmission Cable Removal and Replacement Figure 27) 4. Remove the two bolts holding the cable to the chassis (Figure 30). Removal 1. Remove the LH upper shroud. Remove the belt cover. 2. Remove the cable end from its retainer (Figure 28). Figure 30 Chassis 5. Remove cable from the spring. Figure 28 3 3. Remove the bolt from inside the belt cover (Figure 29).
CHASSIS Transmission Cable Replacement (Cont.) 3. Insert the bolt through the bolt holes from inside the belt cover into the bracket. Tighten bolts to 60-80 in-lbs. (7-9 Nm) (Figure 33). Replacement 1. Place the looped end of the cable on the spring (Figure 31).. Figure 33 4.Insert the cable end into its retainer (Figure 34). Figure 31 2. Install the two bolts holding the cable to the chassis. Torque bolts to 60-80 in-lbs. (7-9 Nm) (Figure 32). Figure 34 5. Install the LH upper shroud and belt cover.
CHASSIS Transmission Removal 3. Remove the tensioner spring. 4. Remove the wheels from the axles. Removal 1. Remove the upper shroud. Remove the bolt holding the upper belt cover (Figure 35). 5. Slide the transmission to the right. Work the belt over the pulley (Figure 37). Figure 37 Figure 35 Chassis 6. Remove the belt from the crankshaft pulley (Figure 38). 3 2. Tip blower forward resting the auger housing on a protective mat. Remove the fasteners holding the lower belt cover in place.
CHASSIS Transmission Removal (Cont.) Removal (Cont.) 8. Remove the bolts that secure the drive shaft bearings and retainers to the housing (Figure 39). Figure 39 9. Slide the transmission to the right until the left hand axle clears the housing. Lift the transmission up and out. Disconnect the traction cable (Figure 40).
CHASSIS 3. Slide the pulley back on the shaft. Pulley Removal Removal 1. Remove the transmission from the unit. Remove the two pulley screws. Figure 43 4. Using a puller, pull the bearing off the shaft. Remove the pulley. Figure 41 3 Chassis 2. Using a punch, tap the pin out of the pulley.
CHASSIS Pulley Removal (Cont.) 3. Align the pulley holes with the hole in the shaft. Replacement 1. Clean the shaft of any debris or rust. Slide the new pulley into the shaft. Figure 47 4. Insert a pin punch into the pulley. Figure 45 2. Tap the pulley into position Figure 48 5. Insert the transmission into a vice or clamp to create a solid surface for the pulley to rest on.
CHASSIS Pulley Removal (Cont.) 8. Install screws into the pulley to secure the pin into position. Replacement (Cont.) 6. Place bearing on shaft. Using a spacer, tap the bearing in place until the inner race of the bearing is flush with the shaft. Figure 52 9. Pulley and bearing installation is complete. 3 Chassis Figure 50 7. Remove the pinch punch. Insert the new pin.
CHASSIS Rotor and Rotor Drive 4 3 1 4 2 3 1 6 2 5 Figure 54 1. Rotor-Pulley Asm. 2. Rotor Clutch Asm. 3. Flat Idler-Pulley 4. Rotor Jack shaft-Pulley 5. V Poly-Belt 6. Extension Spring 3 Extended pulley hub must be assembled towards the rotor. 4 Ensure idler arm, pivots freely after assembly. 1 Lubricate idler arm, on both sides around pivot hole with grease. 2 Spring must be assembled as shown, it must pass through both the slot and hole in spring clip.
CHASSIS Jackshaft Removal and Replacement (Figure 54) 4. Inside the housing, remove the bolts securing the other jackshaft pulley (item 4). Remove the pulley (Figure 57). Removal 1. Remove the belt covers, belt, and transmission from the unit. 2. Place a screw driver or similar tool through the hole in the jackshaft (Figure 55). Figure 57 Chassis 5. Remove the three bearing retainer bolts from inside the belt housing (Figure 58). 3. Remove the bolt securing the jackshaft/rotor pulley (item 4).
CHASSIS Jackshaft Replacement (Cont.) Replacement Removal (Cont.) 7. Loosen the tensioner arm bolt. Move the tensioner out of the way (Figure 60). 1. Slide the jackshaft, thrust washer, bearing, and bearing retainer into the chassis, through the hole in the belt cover (Figure 62). Figure 60 Figure 62 8. Slide the jackshaft support plate to the right and remove (Figure 61). 2.
CHASSIS Jackshaft Replacement (Cont.) 4. Slide the tensioner arm back into position. Torque to 30 ft-lbs. (40 Nm) (Figure 66). Replacement (Cont.) 5. Insert a screw drive or similar tool into the hole in the jackshaft. Install the jackshaft/rotor pulley. Apply Loctite® 243 to bolt. Torque to 96 in-lbs. (11 Nm) (Figure 64). Figure 66 Chassis Figure 64 3 6. Install the other jackshaft pulley. Torque to 96 in-lbs. (11 Nm). Install the lower bearing retainer. Torque to 96 in-lbs. (11 Nm) (Figure 65).
CHASSIS Transmission Replacement (Cont.) 3. Slide the bearing carriers to the housing and install the mounting bolts. Torque bolt to 96 in-lbs. (11 Nm) (Figure 69). Replacement 1. Install the traction cable (Figure 67). Figure 69 Figure 67 4. Slide the drive belt up through the housing and around the lower pulley (Figure 70). 2. Slide the bearings and bearing retainers on the drive shafts.
CHASSIS Transmission Replacement (Cont.) Replacement (Cont.) 6. Install the tensioner spring. Check for proper belt routing and tension (Figure 72). Figure 72 Chassis 7. Install the belt covers and install all mounting bolts. 3 8. Install the wheels. Add anti-seize to lock wheels. 9. Replace all shrouds, the drive belt and cover.
CHASSIS Main Frame 8 2 1 7 2 2 3 4 4 1 4 6 2 5 3 Figure 73 1. Frame 2. Belt Cover 3. Scraper Asm. 4. Skid Asm. 5. Lower Belt Cover 6. Upper Belt Cover 7. Bottom Ferrule (2x) 8. Top Ferrule (2x) 1 To assemble skids, item D, to correct height with tires 2 Bottom ferrule must be assembled such that body extends through frame. Top ferrule must be assembled around bottom ferrule. Neither ferrule can be pinched during assembly. 3 Torque to 25-35 in-lbs. (2.9-4 Nm) 4 Torque to 60-80 in. lbs.
CHASSIS Scraper Removal and Replacement (Figure 73) Paddle Removal and Replacement Removal Removal 1.Remove the six bolts that attach the scraper (Figure 73, item 3) to the housing (Figure 74). 1. Remove the three bolts that attach the paddle to the rotor (Figure 75). Figure 75 Figure 74 1. Install the new scraper and torque bolts to 96 in-lbs. (11 Nm) 1. Insert he new paddle behind the center support. Install the new paddles, tighten the center bolt first. Torque bolts to 45-55 in-lbs. (5.2-6.
CHASSIS Quickstick 1 4 7 5 1 6 2 3 8 Figure 77 1. Latch Trigger 2. LH Chute Lever Cover 3. Chute Control Rod 4. Lever Cap 5. RH Chute Control Lever 6. LH Chute Control Lever 7. RH Chute Lever Cover 8. Chute Rod 3-26 Table of Contents 1 Torque to 5-10 in-lbs. (0.5-1.
CHASSIS Clocking the Quick Stick 4. Disengage the pawl and pull back on the face gear/ chute gear mount. Rotate the chute until it faces straight ahead. (Figure 80). 1. Make sure the Quick Stick handle is in the center position. 2. Remove the two screws holding the front cover on (Figure 78). Figure 80 5. Once clocking is set, tighten the two screws holding the gear chute mount to the quick stick chute mount to 50-60 in-lbs. (5.7-6.9 Nm). Figure 78 7. Install the top cover.
Res i dent i al Pr oduc t s 2016T heT or oCompa ny . Al l r i ght sr es er v ed.
