TORO SNOW COMMANDER SERVICE MANUAL Table of Contents – Page 1 of 2 GENERAL INFORMATION INTRODUCTION ENGINE IDENTIFICATION AND ORDERING GENERAL SAFETY INSTRUCTIONS (REPRODUCED FROM OPERATOR'S MANUAL SAFETY SAFE OPERATING PRACTICES TRAINING PREPARATION OPERATION MAINTENANCE AND STORAGE TORO SNOWTHROWER SAFETY SAFETY AND INSTRUCTION DECALS FUEL AND OIL REQUIREMENTS MIXING GASOLINE AND OIL FILLING THE FUEL TANK OFF-SEASON STORAGE EMPTYING THE FUEL TANK STORAGE PREPARING THE FUEL SYSTEM PREPARING THE ENGINE PREP
TORO SNOW COMMANDER SERVICE MANUAL Table of Contents – Page 2 of 2 DRIVE SYSTEM OPERATION DRIVE SYSTEM DISASSEMBLY DRIVE SYSTEM ASSEMBLY ROTOR BEARING REPLACEMENT ASSEMBLY ROTOR CABLE REPLACEMENT ELECTRIC START SYSTEM OPERATION TROUBLESHOOTING SYSTEM DISASSEMBLY ASSEMBLY SWITCH BOX REPAIR POWER PLUG PLUG TERMINAL SWITCH MOTOR TESTING ASSEMBLY STARTER PINION REPLACEMENT ASSEMBLY CHASSIS WHEELS AND TIRES TILT MECHANISM/FRAME PIVOT CABLE REPLACEMENT MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE ROTOR CONTROL CA
TORO ® Snow Commander Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro servicing dealers. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the assumption that the reader has basic mechanical knowledge and skills. This book contains material covering the Toro Snow Commander models produced in 2001 and 2002, and may be specified for use on products built after 2002 that are similar in design.
TABLE OF CONTENTS GENERAL INFORMATION Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Identification and Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2 General Safety Instructions (Reproduced from Operator’s Manual) . . . . .
TABLE OF CONTENTS CONTROLS LOCATION & OPERATION (cont’d) Adjusting the Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chute Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chute Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS MAINTENANCE Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Checking the Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Adjusting the Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Engine The Toro Snow Commanders are powered by a high output version of the R tek engine (Figure 1).
GENERAL INFORMATION Identification and Ordering Be prepared to supply the complete model and serial number and contact us at the following address: 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 product ready. Figure 1 illustrates the location of the model and serial numbers on the product. The Toro Company 8111 Lyndale Ave. S.
GENERAL INFORMATION Safety • Handle fuel with care; it is highly flammable. – Use an approved fuel container. – Never add fuel to a running or hot engine. To ensure maximum safety and best performance, and to gain knowledge of the product, it is essential that you and any other operator of the snowthrower read and understand the contents of this manual before the engine is ever started. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
GENERAL INFORMATION • Do not run the engine indoors, except when starting it and for moving the snowthrower in or out of the building. Open the outside doors; exhaust fumes are dangerous. • Do not clear snow across the face of slopes. Exercise extreme caution when changing direction on slopes. Do not attempt to clear steep slopes. • Never operate the snowthrower without proper guards, plates, or other safety protective devices in place.
GENERAL INFORMATION Safety and Instruction Decals 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.
GENERAL INFORMATION Fuel and Oil Requirements Mixing Gasoline and Oil This Toro snowthrower is powered by a two-cycle engine that requires a 50:1 gasoline-to-oil mixture. Use only clean, unleaded gasoline no more than 30 days old and with an octane rating of 87 or higher. Using unleaded gasoline reduces combustion chamber deposits and promotes longer spark plug life. Engines certified to comply with U.S.
GENERAL INFORMATION 2. Add the full amount of Toro 50:1 2-Cycle Oil (Fuel Stabilizer Added) or an equivalent high grade, NMMA TCW-certified two-cycle oil to the gasoline according to the chart below: 50:1 Gasoline-to Oil Ration Mixing Chart Gasoline Oil 1 gallon (4 liters) 2.6 ounces (80 ml) 2 gallons (8 liters) 5.2 ounces (160 ml) 5 gallons (20 liters) 13 ounces (400 ml) 3. Install the cap on the fuel container. 4. Shake the container to mix the gasoline and oil thoroughly. 5.
GENERAL INFORMATION Preparing the Fuel System Preparing the Snowthrower 1. 1. Tighten all loose screws, bolts, and locknuts. Repair or replace any damaged parts. 2. Clean the snowthrower thoroughly. 3. Cover the snowthrower 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. Add a fuel stabilizer/conditioner to the fuel in the fuel tank as directed.
CONTROLS LOCATION & OPERATION Note: Do not use the choke or the primer when starting a warm engine. NOTE: Determine the left and right sides of the machine from normal operating position. 4. Operating Controls Start the engine by doing the following: For a recoil starter: Hold the snowthrower handle with one hand and pull the recoil starter vigorously with the other hand.
CONTROLS LOCATION & OPERATION Starting the Rotor Blades Adjusting the Discharge Chute To start the rotor blades, squeeze the control bar toward the handle until the snowthrower begins to pivot. Chute Handle Stopping the Rotor Blades To stop the rotor blades, release the control bar. On models equipped with a manual chute, move the chute handle left and right to adjust the direction of the snow stream (Figure 6).
CONTROLS LOCATION & OPERATION Chute Crank On models equipped with a chute crank, crank clockwise to rotate the chute to the right, counterclockwise to rotate the chute to the left (Figure 7). The chute deflector on these models is the same as on models with a chute handle. B A A Figure 8 (A) 2 Phillips Head Screws, Washers, and Locknuts Figure 7 0621-0073 3428-0216 (B) 3 Phillips Head Screws, Washers, and Locknuts Remove two 5/16” screws that hold the control panel to the chassis (Figure 9).
CONTROLS LOCATION & OPERATION On this version, the discharge chute attaches to the handle and chute ring. Three Phillips head bolts, nuts, and washers connect the parts. Below the upper shroud is the balance of the chute components. A Remove the upper shroud to access the chute ring, the 2 chute ring retainers, and the detent spring and arm (Figure 10). To remove the chute ring, remove the four bolts and nuts that retain the left and right chute ring retainers.
CONTROLS LOCATION & OPERATION 3. To reassemble, reverse the process. NOTE: When installing the chute, the rounded heads of the Phillips head screws must be on the inside of the chute. The smooth head prevents snow from building up on the bolt head. A Gear Lash Adjustment There are 4 capscrews that hold the chute gear assembly to the housing. Two are visible in Figure 13. There will be 2 identical capscrews on the other side. Loosen all 4 capscrews. Rotate the chute to find the tightest point.
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ENGINE REMOVAL / INSTALLATION The Snow Commander engine sits in a cradle which is bolted to the frame. It is best to remove the cradle and separate it from the engine after removing them as an assembly from the chassis (Figure 15). The steps are as follows: 3. Remove the two screws in the carburetor cover, slide the cover to the left to disengage the tabs on the right side (Figure 17). Remove the cover. Figure 17 DSC-0138 4. Remove fuel from the tank.
ENGINE REMOVAL / INSTALLATION A Figure 19 8. (A) Support Pin 6. Figure 21 3428-0227 Disconnect the primer line from the primer bulb and the wires from the ignition switch (Figure 20). 3428-0228 Remove the belt cover (3 bolts and 2 screws) (Figure 22). Some models were built with a diamond shaped washer. A Figure 22 Figure 20 DSC-0138 (A) Primer and Ignition Switch 7. 3-2 On electric start models, remove three screws connecting the switch box to the control panel support (Figure 21). 9.
ENGINE REMOVAL / INSTALLATION Figure 23 3428-0232 10. On the left side of the engine, is an engine brace which is bolted to the side plate in 3 places (Figure 24). Remove all three bolts. Figure 25 12. Tip the machine forward and remove the 3 locknuts securing the center pivot bracket (Figure 26). They are on studs, so it will not be necessary to try to hold the bolt head. Figure 26 Figure 24 3428-0237 3428-0251 3428-0246 11. Remove the engine pulley.
ENGINE REMOVAL / INSTALLATION 13. Remove 2 bolts right in front of the engine. It will be necessary to reach under the unit to access the locknuts (Figure 27). Assembly Reverse the order. If the engine was removed from the cradle, torque the 4 bolts around the crankshaft to 170 - 220 in. lbs (1355 2483 N·cm). B A However, leave the bolts securing the engine cradle slightly loose until the engine location can be checked and adjusted.
ENGINE REMOVAL / INSTALLATION When reinstalling the wire harness on electric start models, route the wire as follows: The wire must come out of the starter motor to one of the blower housing screws (Figure 32). It then must run under the fuel tank up to the left rear mount for the fuel tank (Figure 33), then up to the switch box. Assure that the wires will not rub on the starter rope or other moving objects. Secure the engine and cradle.
ENGINE REMOVAL / INSTALLATION 2. Remove fuel tank. 3. Remove the recoil support. You can remove the 2 bottom nuts and bolts and leave the support attached to the recoil or remove all 3 and separate the support (Figure 28). 4. Remove the self-tapping screws that secure the blower housing to the engine (Figure 34). Figure 34 3428-0249 NOTE: One screw must be accessed by tipping the machine. Drain fuel from the tank if necessary (Figure 35). Figure 35 5. The recoil and blower housing can be removed.
DRIVE SYSTEM Operation A multigrooved V belt transfers power from the engine pulley to the rotor drive pulley. Belt clutching is controlled by a cable connected to a bail on the upper handle. When engaged, the combination idler/brake arm rotates to disengage the brake and move the idler to tighten the belt (Figure 36). When the bail is released, a spring pulls the idler away from the belt and engages the rotor brake. See Figure 46 for location of spring.
DRIVE SYSTEM This machine is specifically designed to clean to the surface and propel itself in this manner. For this reason it is not recommended for use on unpaved surfaces. If the machine is adjusted correctly and used on a gravel surface, it will pick up and throw gravel along with the snow. This is undesirable due to possible injury to passers by and potential damage to property.
DRIVE SYSTEM Figure 42 Figure 44 7. Figure 43 To remove the engine pulley, loosen the setscrews and pull the pulley straight off (Figure 45). 3428-0272 5. Remove upper shroud, refer to “Upper Shroud Removal” on page 2 - 3. 6. The idler pulley is secured to the idler/brake arm with a capscrew and locknut (Figure 44).
DRIVE SYSTEM 8. To remove the brake arm, first unhook the brake spring (Figure 46). The brake arm is attached by a single shoulder bolt through the side plate (Figure 47). Remove the locknut and large washer. Pull the brake arm off carefully as there is a pivot washer between the brake arm and side plate. A Figure 48 3428-0236 (A) Cap Nut Drive System Assembly Figure 46 3428-0240 Assemble in reverse order. The following are tips to assist you. 1. Figure 47 9.
DRIVE SYSTEM 2. Before tightening the setscrews on the engine pulley, the alignment of the pulleys needs to be checked (Figure 49). Measure from the side plate to the outer pulley flange. Adjust the pulley until the gap is 1” (25.4mm). 4. Check the belt adjustment even if the belt was not replaced. Most belt failures are due to not maintaining proper adjustment. Refer to "Rotor Control Cable" on page 5 - 1. Rotor Bearing Replacement Figure 49 1.
DRIVE SYSTEM 3. On the right side (opposite the belt) there is one bolt that goes through the bearing and into the rotor shaft. Remove this bolt (Figure 52). Rotor Cable Replacement The first step is to remove the belt cover and upper shroud. Unhook the end of the cable from the idler/ brake arm (Figure 54). Pull the cable down through the opening in the side plate. Unhook the upper end from the clutch cable adjuster (Figure 55). Reverse the process to replace the cable.
ELECTRIC START SYSTEM Operation If there is no continuity with the starter button depressed, the switch box will need to be removed and opened. Proceed to Disassembly. The electric start system consists of a 120 (USA) or 220 (Europe) VAC motor, a momentary switch, a plug terminal, and a connecting wire (Figure 56). A cord from a household power supply is plugged into the machine. When the starter button is depressed, current is directed to the motor.
ELECTRIC START SYSTEM 3. Remove the left rear fuel tank mounting bolt securing the wire harness clamp (Figure 59). Figure 59 6. To access the other motor mounting screw, the machine must be tipped forward. Depending on how much fuel is in the tank it may be necessary to drain the tank. 7. Tip the machine forward and reach in with a ratchet and extension to remove the last motor mounting screw through the access hole provided (Figure 61). 3428-0223 4.
ELECTRIC START SYSTEM When reinstalling the wire harness on electric start models, route the wire as follows: The wire must come out of the starter motor to one of the blower housing screws (Figure 62). It then must run under the fuel tank up to the left rear mount for the fuel tank (Figure 63) then up to the switch box. Assure that the wires will not rub on the starter rope or other moving objects. NOTE: There are two versions of the electric start system.
ELECTRIC START SYSTEM To remove the wires from the switch, slip the smooth end of a small drill bit in next to the wire (Figure 65). The inside of the switch has spring loaded jaws that grip the wire. The jaws will not grab the hardened drill bit. This allows the drill to be easily removed after it opens the jaws to allow the wire to be removed. Figure 65 Motor Testing To properly test the motor it must be removed from the chassis. Refer to "System Disassembly" on page 5 - 1.
ELECTRIC START SYSTEM NOTE: When installing the wires, install the black wires directly across from each other and the light wires across from each other (Figure 68). Figure 68 3428-0261 Starter Pinion Replacement In order to replace the pinion, the upper shroud must be removed and at least the two motor mounting screws removed. If you know the wire, switch, and motor are all ok, they can be left in place. Refer to "System Disassembly" on page 5 - 1.
ELECTRIC START SYSTEM Assembly Apply a thin coat of light weight oil to the motor shaft. Just enough to prevent rust. Slip the pinion and spring on the shaft. Slide the pinion stop on with the recessed side facing outward. Press the lock ring on over the end of the motor shaft. Sometimes a small socket helps when used like a seal installer (Figure 71). Figure 71 3428-0269 The pinion stop should come outward and keep the lock ring from coming out of the groove (Figure 72).
CHASSIS Wheels and Tires Tilt Mechanism/Frame The machine is setting on two solid rubber front tires and two pneumatic rear tires (Figure 73). Should one of the front tires become damaged, remove one push nut and the axle can be pulled out to replace a wheel. Use a new push nut to secure the wheel. The basic function of this machine requires the engine and rotor to tilt forward until the rotor blades engage the ground (Figure 74).
CHASSIS The normal resting position is with the engine and rotor to the rear. A spring connected between the engine and wheel frame assures that the engine and rotor return to the resting position when the controls are released (Figure 76). Figure 76 Pivot Cable Replacement Replacement of the tilt cable requires no tools. Both ends are made with a Z bend and can be removed by hand only. Insert the Z bend into the handle as shown in Figure 78.
MAINTENANCE NOTE: Determine the left and right side of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure • Check the rotor control cable and the pivot cable initially, and after the first hour of operation. Adjust if necessary. • Check for loose fasteners and tighten if necessary. • Check the rotor control cable and the pivot cable. Adjust if necessary. • Inspect the rotor blades and replace if necessary.
MAINTENANCE 3. Ensure that a 1/8 to 1/4 inch (3 to 6mm) gap exists between the control bar bracket and the handle as shown in Figure 80. Figure 80 (A) Control Bar Bracket (B) 1/8 to 1/4 in. (3 to 6mm) gap Adjusting the Rotor Control Cable 1. Unhook the spring end from the hole in the center of the control bar bracket (G) as shown in Figure 81.
MAINTENANCE NOTE: After extended use, the drive belt may wear and result in a loss of belt tension. Improper belt tension allows the belt to slip and decreases the performance under a heavy load. Belt slippage may occur after two or three seasons of normal usage (10 to 15 hours). If the drive belt slips (continuously squeals) under a heavy load, increase the belt tension by positioning the spring end in the other hole in the control bar bracket as shown in Figure 81.
MAINTENANCE Important If the pivot plate touches the wheel frame before the control bar touches the handle, the cable is too tight. Adjust the cable to increase the gap between the pivot plate and the wheel frame, but ensure that the gap is not more than 1/8 in. (3mm). Adjusting the cable correctly minimizes the effort needed to operate the control bar. Adjusting the Pivot Cable Unhook the Z-fitting from the pivot cable adjuster (Fig.
MAINTENANCE Figure 85 (A) Thick rubber side of the rotor blade (3) (B) Rotor Assembly (C) Rotor Drum 2. Remove the two hex-head cap screws and two locknuts that secure the center of the rotor blade to the rotor drum (Figure 85). 3. Slide the rotor blade out from between the rotor drum parts (Figure 85). 4. Remove the two spacers from the old rotor blade and install them in the new blade.
MAINTENANCE 2. Insert the new rotor blade between the rotor drum parts. 3. Secure the rotor blade to the rotor drum parts with the two hex-head cap screws and two locknuts that you previously removed. Position the bolt heads on the thick rubber side of the rotor blade (Figure 85). 4. Curve the rotor blade and secure it with the remaining Torx screws and locknuts, positioning the screw heads on the thick rubber side of the rotor blade (Figure 85). 5. Tighten all screws and locknuts securely. 6.
MAINTENANCE 1. Remove the two mounting screws that secure the control panel to the housing (Fig. 18). 6. Examine the spark plug and replace it if it is cracked, fouled, or dirty. Important Do not sandblast, scrape, or clean the spark plug. Dirt may fall into the cylinder and cause engine damage. 7. Figure 88 (A) Control Panel Set the spark plug gap (Figure 90) between the electrodes to 0.030 in. (0.76mm). m-5061 Figure 90 (B) Mounting Screws (2) 2.
MAINTENANCE 4. Remove the two self-tapping screws, three cap screws, one washer, and three locknuts that secure the drive belt cover to the snowthrower frame (Figure 91). Set the drive belt cover aside. 6. Remove the old drive belt from the engine pulley and the idler pulley (Figure 92).
MAINTENANCE 12. Connect the wire to the spark plug. 13. Install the control panel. 14. Insert the key in the switch. Checking the Tire Pressure Figure 93 m-5076 (A) Locknut (C) Housing (B) Washer (diamond-shaped on some models) Inflate both tires to between 15 and 20 psi (103 and 137 kPA). Troubleshooting Problem Possible Causes Electric starter does not 1. The power cord is disconnected at the turn (electric-start outlet or the snowthrower. models only) 2.
MAINTENANCE Troubleshooting Problem Possible Causes Engine runs, but the 1. You are walking too fast or too slow. snowthrower discharges 2. You are trying to remove too much snow poorly or not at all snow per swath. Snowthrower does not properly clear snow off the surface Corrective Action 1. Change your walking speed. 2. Reduce the amount of snow removed per swath. 3. You are trying to remove extremely heavy or wet snow. 3.
MAINTENANCE SPECIFICATIONS (General) Item Description Engine Mfg. The Toro Company 141cc E series (R tek) Fuel Mix Ratio 50:1 Spark Plug NGK BPMR4A or equivalent Fuel Capacity 1.2 US quart (1.1 l) Weight 113 lbs. (51.4 kg) (recoil start) 115 lbs. (52.3 kg) (electric start) Width 24.3” (61.7 cm) Height 40.4” (102.6 cm) (highest point) Length 51.3” (130.3 cm) Chute Rotation 210 degrees Chute Throat Diameter 6.2” (15.7 cm) Impeller Diameter 10” (25.4 cm) Rotor Drive Reduction 3.
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