TORO SNOW COMMANDER SERVICE MANUAL
Contents
1. A Drive Belt Cover B Left Rotor Guard C Washer diamond shaped on some models D Snowthrower Frame E Self Tapping Screws A Brake Arm Assembly Belt Guides B Idler Pulley F Rotor Pulley C Roller G Left Rotor Guard D Engine Pulley 5 Remove the left rotor guard Figure 91 and save it for installation in step 10 The left rotor guard acts as a water seal for the drive Do not assemble the drive cover without installing this part or the drive belt will slip and fail 7 Push down on the idler pulley and remove the drive belt from the rotor pulley Figure 92 8 Push down on the idler pulley and route the new drive belt around the rotor pulley Figure 92 9 Release the idler pulley and route the drive belt over the two belt guides around the engine pulley and between the idler pulley and the roller Figure 92 The drive belt must be on top of the roller and the two belt guides as shown in Figure 92 10 Install the left rotor guard 11 Install the drive belt cover Tighten the fasteners securely but do not overtighten NOTE Install the diamond shaped washer as shown in Figure 91 and Figure 93 Snow Commander Service Manual 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 Inflate both tires to2. FER RUE RW RIP PPA ee ES 7 6 Replacing ihe Drive Belt desing ert eh TEQUE odie Sees 7 7 Checking the Tire Pressure 7 9 TrOUDIeSIDOLIDO sinss ES ee 7 9 Specifications General 7 11 Torque Specifications 12 5 33 9 ador rah ck ele ir d sata bade RR B edn 7 11 PUDFICAUOM ea toco ets Os ed Maden he eee ees qe 7 11 Snow Commander Service Manual iii THIS PAGE INTENTIONALLY LEFT BLANK Snow Commander Service Manual 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 The main Figure 2 DSC 0037 difference between the standard R tek and the version used on the Snow Commander is in the piston and cylinder A Ports The piston has two additional square ports Figure 2 which line up with two grooves machined in the cylinder wall Figure 3 As the piston goes down and compresses the fuel air charge in the crankcase the ports in the piston uncover t
3. tie S dius tes 1 8 Preparing the Snowthrower 1 8 CONTROLS LOCATION amp OPERATION Operating Control S nernet a teas fl e eR MER e 2 1 Starting the ENgINe 2 46 3 9 duris be sd Decr en al epe eut eu Ares 2 1 Stoppin the 555558 58 88 Gore qois ott ee ede et ATE oO Pe eae BARE SS 2 1 starmng the Rotor Blad8s 2m het exec pa beso oce cett RE e DUE 2 2 stopping the Rotor Blades 55 aem eu v ad o mo me do 2 2 Starting the Traction Drive ov v MER 2 2 stopping the Traction Drive si e Ue e Ho ooa e tabe PE 2 2 Snow Commander Service Manual i TABLE OF CONTENTS CONTROLS LOCATION amp OPERATION cont d Adjusting the Discharge Chute d eee hese eee SECRET EHE ES 2 2 Chute s 1 4 aos Sek Re en et A doge 2 2 Chute Grarike ok arta eco o de auo dete s Abad raul ode Cant dud e 2 3 Upper Shroud Removal 5 2s eet aa anche deed BeOS a Enc RR UR 2 3 Snow Commander Chute Handle System 2 3 Chute Crank Syslerm s re acce reti eee eee tte 2 4 Gear Lash Adjustment 2 5 Gear Assembly Repair tats dy dade eis ets tate de de p E E tate haa 2 5 ENGINE REMO
4. Shaft and Push Nut 2 4 Snow Commander Service Manual CONTROLS LOCATION amp 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 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 Adjust the clearance so that a 1 16 1 6mm drill bit will fit between the top of the tooth on the worm gear and the valley between two teeth on the chute ring gear Figure 14 Grasp the chute rod and push it to the front Hold the rod and tighten the capscrews Remove the drill bit Figure 13 0621 0077 A Capscrews Snow Commander Service Manual Figure 14 0621 0076 A A 1 1 1 6mm Drill Bit Chute Ring Gear Assembly Repair Should you need to replace 1 or more of the chute gears proceed as follows Remove the chute rod from the face gear Remove the 4 capscrews referred to in Figure 13 The gear assembly can be lifted out and the gears replaced 2 6 THIS PAGE INTENTIONALLY LEFT BLANK Snow Commander Service Manual ENGINE REMOVAL INSTALLATION The Snow Commander engine sits in a cradle which is 3 Remove th
5. as shown in Figure 83 Figure 83 m 5056 A Pivot Plate D 0 to 1 8 in 0 to 3mm B Pivot Cable Adjuster gap C Z fitting E Wheel Frame MAINTENANCE TTE 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 12 and position the Z fitting in a different hole on the pivot cable adjuster to obtain the proper gap between the pivot plate and the wheel frame Note Moving the Z fitting to a hole closer to the ground decreases the gap between the pivot plate and the wheel frame moving it to a hole farther from the ground increases the gap Note The traction is most aggressive the traction speed is fastest when the rotor blades are new If you want to reduce the aggressiveness of the traction move the Z fitting one hole farther from the ground The gap between the pivot plate and the wheel frame will be about 1 4 in 6mm After the rotor blades have worn slightly the traction won t feel as aggressive To increase the traction adjust the pivot cable to attain the original gap between the pivot plate and the wheel frame of 0 to 1 8 in 0 t
6. it will be necessary to The belt system is now fully exposed Figure 40 hold the rotor steady A block of wood can be used to stop the rotor from turning Figure 42 allowing the capscrew to be removed from the rotor pulley Figure 43 The rotor pulley is removed by pulling straight off 4 2 Snow Commander Service Manual DRIVE SYSTEM Figure 44 3428 0244 Figure 42 3428 0250 7 Toremove the engine pulley loosen the setscrews and pull the pulley straight off Figure 45 Figure 43 3428 0272 Figure 45 3428 0237 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 Snow Commander Service Manual 4 3 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 Figure 48 3428 0236 A Cap Nut Drive System Assembly Assemble in reverse order The following are tips to assist you 1 Many of the capscrews and nuts are the locking type However the material in the threads that provides the locking feature wears out If the parts assemble easily we suggest either replacing the locknut or capscrew or cleaning the scre
7. store Replacing only one half of the connection will likely result in a repeat failure 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 3428 0262 Switch The switch is a simple push button on off switch It is intended to make continuity only when the button is depressed To test the switch use a continuity light or ohmmeter Remove the wires and insert the probes from the tester Use two holes that are directly across from each other Figure 66 With the button depressed there should be continuity when it is released there should be no continuity At no time should there be continuity between the diagonal terminals Figure 66 3428 0270 Motor Testing To properly test the motor it must be removed from the chassis Refer to System Disassembly on page 5 1 Remove the two motor wires from the switch Figure 67 Attach one ohmmeter test lead to each wire SLOWLY rotate the motor shaft and watch the ohmmeter At no time should continuity be lost although it will fluctuate The motor comes with the wires permanently attached If the wires are damaged or there is internal damage to the motor it must be repl
8. then stop 2 Release the starter tension gradually by allowing the rope to go back slowly to prevent the engine from reversing due to compression pressure Preparing the Snowthrower 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 Snow Commander Service Manual CONTROLS LOCATION 8 OPERATION NOTE Determine the left and right sides of the machine from normal operating position Operating Controls The snowthrower control panel contains a key switch a primer a recoil starter and an electric start button electric start model only The choke lever and the cord connection for the electric start model are located below the control panel as show in Figure 5 Note Do not use the choke or the primer when starting a warm engine 4 Start the engine by doing the following For arecoil starter Hold the snowthrower handle with one hand and pull the recoil starter vigorously with the other hand For an electric starter A Connect the power cord to the snowthrower and to a standard household power outlet If you leave the snowthrower plugged into power outlet someone can inadvertently start the snowthrower and injure people or damage property CAUTION Unplug th
9. 3 Ensure that a 1 8 to 1 4 inch 3 to 6mm gap exists Adjusting the Rotor Control Cable between the control bar bracket and the handle as shown in Figure 80 1 Unhook the spring end from the hole in the center of the control bar bracket G as shown in Figure 81 Figure 80 m 5069 A Control Bar Bracket C Handle sd 1 8 to 1 4 in 3 to 6mm A Cable E Spring Cover B Z fitting F Control Bar Bracket The rotor control cable must have slack C Cable Adjuster G Hole in the center of in it when you disengage the control bar in order for the D Spring the control bar bracket rotor brake to operate properly 2 Slide the spring cover off the cable adjuster 3 Unhook the Z fitting from the cable adjuster Figure 81 and position it in a different hole on the adjuster to obtain specified gap of 1 8 to 1 4 inch 3 to 6mm between the control bar bracket and the handle Figure 80 NOTE Moving the Z fitting to a hole closer to the spring decreases the gap between the control bar bracket and the handle moving it to a hole farther from the spring increases the gap 4 Install the spring cover over the cable adjuster 5 Hook the spring into the hole in the center of the control bar bracket as shown in Figure 81 6 Checkthe adjustment Checking the Rotor Control Cable on page 7 1 7 2 Snow Commander Service Manual NOTE After extended use the drive
10. Mfg The Toro Company 141cc E series R tek Fuel Mix Ratio 50 1 Spark Plug NGK BPMRAA or equivalent Fuel Capacity 1 2 US quart 1 11 Weight 113 Ibs 51 4 kg recoil start 115 Ibs 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 95 1 TORQUE SPECIFICATIONS Torque Value Description Where Used In Lbs N cm Engine Pulley Square Head Set Screw 120 150 1355 1694 Allen Head Set Screw 60 80 678 904 Nut On Recoil Support 90 120 1016 1355 Engine Mounting Screws 170 220 1920 2483 Rotor Pulley Capscrew 100 1125 Brake Arm Shoulder Bolt 170 250 1920 2824 Must pivot freely Plastite Screws Tighten securely but do not deform the plastic Belt Cover Top Screw has an O ring on it Tighten to compress O ring to 08 11 2 03 2 79mm thick LUBRICATION Engine Fuel and Requirements on page 1 6 Engine crankshaft pulley Apply anti seize compound to shaft before installation of pulley Apply a light coat of 2 general purpose grease to the brake arm shoulder bolt and washers Snow Commander Service Manual THIS PAGE INTENTIONALLY LEFT BLANK Snow Commander Service Manual 492 4
11. a burn Perform only those maintenance instructions described in this manual Before performing any maintenance service or adjustment stop the engine remove the key If major repairs are ever needed contact your Authorized Service Dealer Do change the governor settings on the engine When storing the snowthrower for more than 30 days drain the fuel from the fuel tank to prevent a potential hazard Store fuel in an approved fuel container Remove the key from the ignition switch before storing the snowthrower To ensure the best performance and safety purchase only genuine Toro replacement parts and accessories Snow Commander Service Manual 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 104 4106 Recoil start model only 61 4790 Electric start model only AWARNING C DONOTUSENRAN ATTENTION NE PAS UTILISER SOUS LAPLUIE J 104 0863 Electric start model only 104 0874 FUEL MIX 5 1 RATIO UNLEADED TRANGLEUR M LANGE DE CARBURANT Proportion p D MARRAGE A Fi D PLACER pia d DROITE LAU ARE ye DEUX REPRISES AFTER LE VOLET DE DEPART VERS LA GAUCHE 104 2775 ENGAGE ROTOR DRIVE DISENGAGE 5 ENTRAINEMEN
12. 3 Lift up the shroud and disconnect the wire from the spark plug Figure 89 m 5062 Figure 89 A Shroud B Spark Plug Wire 4 Clean any debris from around the base of the spark plug 5 Remove the spark plug Figure 89 Snow Commander Service Manual MAINTENANCE 6 Examine the spark plug and replace it if it is cracked fouled or dirty Do not sandblast scrape or clean the spark plug Dirt may fall into the cylinder and cause engine damage 7 Set the spark plug gap Figure 90 between the electrodes to 0 030 in 0 76mm Figure 90 m 3215 8 Install the spark plug and torque it to 15 ft lb 20 4 N m If you do not have a torque wrench tighten the plug firmly 9 Connect the wire to the spark plug 10 Install the control panel Replacing the Drive Belt Inspect the drive belt before each season and replace it if it is worn or damaged 1 Stop the engine and wait for all moving parts to stop 2 Remove the key from the switch 3 Disconnect the wire from the spark plug Refer to steps 1 through 3 of Replacing the Spark Plug on page 7 6 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 Figure 91 m 5064 6 Remove the old drive belt from the engine pulley and the idler pulley Figure 92 Figure 92
13. 3428 0228 Snow Commander Service Manual 5 1 ELECTRIC START SYSTEM 3 Remove the left rear fuel tank mounting bolt securing the wire harness clamp Figure 59 Figure 59 3428 0223 4 Remove one screw A Figure 60 which holds the wire harness to the blower housing 5 Remove one starter motor mounting screw B Figure 60 from the front 3428 0249 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 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 Figure 61 3428 0253 8 The motor wire harness and switch box can now be removed from the chassis Assembly Assemble in reverse order When mounting the starter motor itself we suggest that you loosely install the front or top mounting screw first This will make it easier to line up the motor and start the rear mounting screw Snow Commander Service Manual 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 ot
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15. ABLE REPLACEMENT MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE ROTOR CONTROL CABLE CHECKING THE ROTOR CONTROL CABLE ADJUSTING THE ROTOR CONTROL CABLE ADJUSTING THE PIVOT CABLE CHECKING THE PIVOT CABLE ADJUSTING THE PIVOT CABLE REPLACING THE ROTOR BLADES REMOVING THE OLD ROTOR BLADES INSTALLING THE NEW ROTOR BLADES REPLACING THE SCRAPER REPLACING THE SPARK PLUG REPLACING THE DRIVE BELT CHECKING THE TIRE PRESSURE TROUBLESHOOTING SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS LUBRICATION 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 We hope you find this manual a valuable addition to your service shop If you have questions or comments regarding this manual please contact us at the following address The Toro Company Consumer Service Department 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this manual without notice Copyright All Rights Reserved 2001 The Toro Company TABLE OF CO
16. NTENTS GENERAL INFORMATION n bacca o drm aatem p iit ede meal b are WE AoE We 1 1 ENGINE OPTED wie wale ihe Doles Ocala a hele 1 1 Identification and Ordering coe Settee ee ED RET SERRE e RAE 1 2 General Safety Instructions Reproduced from Operator s Manual 1 2 to ded Lade erga ete petas fua f 1 3 Safe Operating Practices ded ew be pue EE RE EA 1 3 RI APP 1 3 toe debris amd eigens uu did tates 1 3 Operation bones EC E Eo ap iioi aon 1 3 Maintenance and Storage 1 4 Toro Snowthrower Safety 1 4 Safety and Instruction Decals E Re 30e xx 1 5 Fuel and Oil Requirements 2 34443 54550446 donee Xx Ge woe bese Redes ta 1 6 Mixing Gasoline and Oil o e ents estea aie perso PAGS evene Eus 1 6 Pilling the Fuel Take yea ER ea Se ae a eo Ree A EE 1 7 Off Season Stora e 1 7 Emplyingsthe Fuel O 1 7 Stora gE Loue m nC de ore gg eee Gag a tt wl hes 1 7 Preparing the Fuel System 2 0 00 cece eee eee eee 1 8 Preparing the Engine
17. T q 2 ROTOR EMBRAYER uncus D BRAYER Snow Commander Service Manual 1 5 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 EPA emission regulations for ULGE engines are certified to operate on a mixture of regular unleaded gasoline and oil include the following emission control system s EM and TWC if equipped and do not include any user adjustable features Do not use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas Using these fuels can damage the fuel system Do not use an automotive oil such as SAE 30 or 10W30 a two cycle oil that is not NUMA TCW certified or a fuel mixed at the wrong gasoline to oil ratio This can cause engine damage not covered under the Toro warranty In certain conditions gasoline is extremely flammable and highly explosive A fire or explosion from gasoline an burn you and others and cause property damage DANGER Fill the fuel tank outdoors in an open area and when the engine is cold Wipe up any gasoline that spills e Do not fill the fu
18. 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 PREPARING THE SNOWTHROWER CONTROLS LOCATION amp OPERATION OPERATING CONTROLS STARTING THE ENGINE STOPPING THE ENGINE STARTING THE ROTOR BLADES STOPPING THE ROTOR BLADES STARTING THE TRACTION DRIVE STOPPING THE TRACTION DRIVE ADJUSTING THE DISCHARGE CHUTE CHUTE HANDLE CHUTE CRANK UPPER SHROUD REMOVAL SNOW COMMANDER CHUTE HANDLE SYSTEM CHUTE CRANK SYSTEM GEAR LASH ADJUSTMENT GEAR ASSEMBLY REPAIR ENGINE REMOVAL INSTALLATION ASSEMBLY RECOIL STARTER ACCESS ASSEMBLY 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 C
19. VAL INSTALLATION aa SE Sse Ase od Ea Lab 3 4 RECO Starter ACCESS oa ove Wack eee teat Ca Oe toe ie desde 3 5 Assembly fe wb bai On edt edes Lak ee nt SSA WER MR Ae 3 6 DRIVE SYSTEM Op ration aers pee oa T TI LI 4 1 Drive System Disassembly on dye gare an Pe a URE Gee eae ERE 4 2 Drive System Assembly 22240242542 e 00 4 4 Rotor Bearing Replacement 4 5 rate adi qa dee div eda toe are 4 6 Rotor Cable 0 0 0 4 6 ELECTRIC START SYSTEM Operation Soaks d elis Salads 2 9 a ale ads 5 1 Troubleshooting c 5e b uibus du ed I eoa BO og ced 5 1 System Disassembly o ooa Sea usu aos Ro Que Su OVE e 5 1 Assembly o nid abd I REL a hath ies fade faded f 5 2 oWilCIBox i odisse e tet vox oo Ee beads CC ESI 5 3 POWE Plug ieu dud si b e DE ie dedo sie 5 3 Pug Terminal a vta dub hoe V Xd RE Eo ote Dome SURE RE oe eee 5 3 SWILCIY 22 E REA S Ee E od de m oa dedo 5 4 Motor Testing ubi esq Jt peeves LES pour wee 5 4 ASSSITDIV 22 05 49 hs de ee ewe
20. a diamond shaped washer A Support Pin 6 Disconnect the primer line from the primer bulb and the wires from the ignition switch Figure 20 Figure 22 3428 0229 2 9 Remove the belt Push the idler arm down as far as it will go Measure the distance between the A Primer and Ignition Switch idler pulley and engine pulley at its closest point Figure 23 Make a note of this distance as it will be needed during assembly Figure 20 DSC 0138 7 On electric start models remove three screws connecting the switch box to the control panel support Figure 21 3 2 Snow Commander Service Manual ENGINE REMOVAL INSTALLATION Figure 23 3428 0232 Figure 25 3428 0237 10 On the left side of the engine is an engine brace 12 Tip the machine forward and remove the 3 which is bolted to the side plate in 3 places Figure locknuts securing the center pivot bracket Figure 24 Remove all three bolts 26 They are on studs so it will not be necessary to try to hold the bolt head Figure 26 3428 0251 Figure 24 3428 0246 11 Remove the engine pulley Loosen 2 set screws and pull the pulley straight off Figure 25 Snow Commander Service Manual 3 3 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 Figure 27 3428 0242 A Engine B Starter Motor 14 T
21. aced Figure 67 0621 0086 Assembly Assemble in reverse order To install the wires in the switch merely push them into the holes The jaws will grab them Snow Commander Service Manual ELECTRIC START SYSTEM NOTE When installing the wires install the black With the motor mounting screws removed the motor wires directly across from each other and the light can be accessed from the top To remove the pinion wires across from each other Figure 68 push the pinion stop down to uncover the wire lock ring around the end of the armature Figure 69 The lock ring can be grasped with a pliers or side cutters and pulled off Replace the ring do not re use With the ring off the pinion and spring can be removed Figure 70 Figure 68 3428 0261 Starter Pinion Replacement In order to replace the pinion the upper shroud must Figure 69 3428 0264 be removed and at least the two motor mounting screws removed If you know the wire switch and A Ring B Pinion Stop motor are all ok they can be left in place Refer to System Disassembly on page 5 1 Figure 70 3428 0266 A amp B Pinion Assembly D Spring C Pinion Stop E Lock Ring Snow Commander Service Manual 5 5 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 f
22. acing 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 Figure 72 3428 0265 Slip the starter motor back into place Loosely install the front top mounting screw then tip the machine forward to install the bottom screw Tighten both mounting screws Snow Commander Service Manual CHASSIS Wheels and Tires 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 Figure 73 3428 0203 The rear tires are pneumatic The normal pressure is 15 20 psi 103 137kPa In this case pressure is not critical to function The rear wheels are retained by a push nut Use a new push nut to secure the wheel Snow Commander Service Manual Tilt Mechanism Frame The basic function of this machine requires the engine and rotor to tilt forward until the rotor blades engage the ground Figure 74 This provides the self propelling action and the ability to clean down to the surface Figure 74 3428 0207 2 The wheel frame stays level with the ground at all times There is a hinge point at the front that the engin
23. assist you in obtaining replacement manuals General Safety Instructions Reproduced from Operator s Manual This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death Danger Warning and Caution are signal words used to identify the level of hazard However regardless of the hazard be extremely careful Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions This manual uses two other words to highlight information calls attention to special mechanical information and Note emphasizes general information worthy of special attention Snow Commander Service Manual GENERAL INFORMATION Safety 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 N This is the safety alert symbol It 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 s
24. 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 Adjust the gap between the control bar bracket and the handle to 1 8 to 1 4 in 3 to 6mm NOTE Using the incorrect adjusting hole in the control bar bracket can reduce the drive belt life Occasional belt slippage squealing may occur in extremely wet conditions due to moisture in the drive system To remove moisture start the rotor and operate it without a load for 30 seconds Once you remove the moisture the drive belt should not slip Adjusting the Pivot Cable Check the pivot cable for proper adjustment initially after the first operating hour and then annually thereafter Checking the Pivot Cable 1 Stop the engine and wait for all moving parts to stop 2 Squeeze the control bar toward the handle Snow Commander Service Manual MAINTENANCE 3 Hold the control bar against the right side of the handle as shown in Figure 11 Figure 82 m 5066 A Right side of the control bar B Handle 4 Ensure that the distance between the pivot plate and the wheel frame is 0 to 1 8 in 0 to 3mm
25. between 15 and 20 psi 103 and A Locknut Housing 197 KPA B Washer diamond shaped on some models Troubleshooting Problem Possible Causes Corrective Action Electric starter does not 1 The power cord is disconnected atthe 1 Connect the power cord to the outlet turn electric start outlet or the snowthrower and or the snowthrower models only 2 The power cord is worn corroded 2 Replace the power cord damaged 3 The power outlet is not energized 3 Have a qualified electrician energize the power outlet Engine does not start or 1 The key is not in the ignition or is in the 1 Insert the key into the ignition and turn it starts hard Off position to the On position 2 The choke is in the Off position and the 2 Move the choke to the On position and primer has not been pressed press the primer two times 3 The fuel tank is empty or the fuel 3 Drain and fill the fuel tank with a fresh system contains stale fuel gasoline and oil mixture not more than 30 days old If the problem persists contact an Authorized Service Dealer 4 The engine is flooded 4 Move the choke to the Off position and pull the rope several times to clear out the rich fuel and air mixture from the engine 5 The spark plug wire is loose or 5 Connect the wire to the spark plug disconnected 6 The spark plug is pitted fouled or the 6 Check the spark plug and adjust the gap gap is incorrect if necessary Replace t
26. cknut 18 F Spacer 6 E Torx Screw 12 G Hex head Cap Screw 6 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 Installing the New Rotor Blades 1 Examine a new rotor blade edge for the difference in the thickness of the rubber layers Figure 86 Snow Commander Service Manual Figure 86 m 5059 A Thick Rubber Side C Thin Rubber Side B Wear Indicator Hole Install the rotor blades with the thick rubber layer on the inside of the curve Figure 86 If you do not install the rotor blades properly they will wear more quickly and may vibrate excessively 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 Replace the scraper Refer to Replacing the Scraper below 7 Connect the wire to the spark
27. ctions When cleaning repairing or inspecting make certain that the rotor blades and all moving parts have stopped 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 Never operate the snowthrower near glass enclosures automobiles window wells and drop offs without properly adjusting the snow discharge angle Keep children and pets away Do not overload the machine capacity by attempting to clear snow at too fast a rate Look behind and use care when backing up with the snowthrower Never direct the discharge at bystanders or allow anyone in front of the unit Never operate the snowthrower without good visibility or light Always be sure of your footing and keep a firm hold on the handle Walk never run Maintenance and Storage Check all fasteners at frequent intervals for proper tightness to be sure that the equipment is in safe working condition Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters and clothes dryers Allow the engine to co
28. e and rotor assembly pivots on Figure 75 3428 0208 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 um 4 A Figure 76 3428 0211 When the operator engages the bail the cable that runs down the right hand handle causes the pivot assembly to rotate and move the engine and rotor frame Figure 77 3428 0199 A Pivot Cable 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 If the cable is not connected this way it will have a tendency to come unhooked from the handle See Adjusting the Pivot Cable on page 7 3 mvc 492 Snow Commander Service Manual MAINTENANCE NOTE Determine the left and right side of the machine from the normal operating position Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Initial 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 Annually Check the rotor control cable and the pivot cable Adjust if necessary I
29. e Fuel Tank uii Do not overfill the fuel tank The gasoline and oil mixture must have room to expand 1 Clean around the fuel tank cap do not allow snow or water to enter the fuel tank 2 Remove the fuel tank cap and fill the fuel tank with the gasoline and oil mixture until the level is 1 4 to 1 2 in 6 to 13mm below the bottom of the filler neck Do not fill into the filler neck 3 Install the fuel tank cap securely and wipe up any spilled fuel Off Season Storage Emptying the Fuel Tank 1 Stop the engine and wait for all moving parts to stop Snow Commander Service Manual 2 Remove the key from the switch A DANGER A Gasoline is highly flammable it can ignite and cause serious personal injury Drain gasoline outdoors Drain gasoline from a cold engine only Wipe up any gasoline that may have spilled e Do not drain gasoline near any open flame or where gasoline fumes may be ignited by a spark Do not smoke a cigar a cigarette or a pipe when handling gasoline 3 Remove the fuel tank cap and use a hand pump to pump the fuel into an approved fuel container 4 Start the engine and allow it to run until it stops Repeat this step two more times to ensure that the fuel tank and the carburetor are empty Storage HINC Store the snowthrower in its operating position and on its wheels Storing the snowthrower on its front housing may cause hard starting WARNING A Gasolin
30. e 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 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 Figure 11 3428 0082 A Control Handle Support Rotating the handle turns a set of gears that engage a ring gear that the chute is mounted to The gears are contained in a bracket located under the upper shroud The chute ring gear rests on a support and is held in place by two retainers Figure 10 1854 40 To access the chute ring and gears A Spring C Retainer Mounting Bolts 1 Remove the upper shroud B Detent Arm 2 The gears are held in the bracket by a shaft with a NOTE The rear bolt in the left hand chute ring retainer push nut on either end Figure 12 To remove the is also the pivot for the detent arm This arm engages shaft remove one of the push nuts and pull the the notches in the chute ring to prevent unwanted shaft out movement With the 4 bolts removed the retainers and chute ring will lift off Reassembly is the reverse of disassembly Chute Crank System The chute crank handle goes through hole in the control panel support Figure 11 Figure 12 1854 19 A
31. e fumes are highly flammable explosive and dangerous if inhaled If you store the product in an area with an open flame the gasoline fumes may ignite and cause an explosion Do not store the snowthrower in a house living area basement or any other area where ignition sources may be present such as hot water and space heaters clothes dryers furnaces and other like appliances GENERAL INFORMATION Preparing the Fuel System 1 fuel stabilizer conditioner to the fuel in the fuel tank as directed NOTE If you use Toro 50 1 2 Cycle Fuel Stabilizer Added you do not need to add a fuel stabilizer conditioner 2 Runthe engine for five minutes to distribute the conditioned fuel through the fuel system 3 Stop the engine allow it to cool 4 Use a hand pump to pump the fuel from the fuel tank into an approved fuel container or run the engine until it stops 5 Start the engine and run it until it stops 6 Choke or prime the engine start it a third time and run the engine until it will not start 7 Dispose of unused fuel properly Recycle it according to local codes or use it in your automobile Note Do not store stabilized fuel for more than 90 days Preparing the Engine Follow this procedure to prevent cylinder bore corrosion by closing both the intake and exhaust ports of the engine 1 Slowly pull the recoil starter until you feel resistance due to compression pressure
32. e power cord whenever you are not starting the snowthrower Figure 5 m 5067 A Key switch B Primer C Electric start button electric start model only D Recoil start E Cord connection electric start model only underneath the control panel F Choke lever Starting the Engine 1 the key to the On position 2 Move the choke lever to the right 3 Cover the hole in the center of the primer with your thumb and push the primer in twice pausing a moment between pushes In extremely cold temperatures repeat this step if necessary Note Take off your glove when you push in the primer so that air cannot escape from the primer hole Snow Commander Service Manual B Push the starter button Note Run the electric starter no more than ten times at intervals of five seconds on then five seconds off TW Running the electric starter extensively can overheat and damage the starter Note 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 5 With the engine running move the choke lever to the left slowly Stopping the Engine Turn the key to the Off position and wait for all moving parts to stop before leaving the operating position CONTROLS LOCATION 8 OPERATION Starting the Rotor Blades To start the rotor blades squeeze the control bar toward the handle until the snowthrow
33. e powered products during operation and storage A fuel stabilizer conditioner cleans the engine during operation and prevents gum like varnish deposits from forming in the engine during storage A fuel stabilizer conditioner works best when you mix it with fresh gasoline If you use Toro 50 1 2 Cycle Oil Fuel Stabilizer Added you do not need to add a fuel stabilizer conditioner Do not use fuel additives except a fuel stabilizer during storage Do not use fuel stabilizers with an alcohol base such as ethanol methanol or isopropanol 1 Pour a half gallon 1 9 liters of fresh unleaded gasoline into an approved fuel container Note Do not mix gasoline and oil in the fuel tank Oil at room temperature mixes easier and more thoroughly than cold oil Oil below 32 F 0 C requires additional mixing Snow Commander Service Manual 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 Slowly remove the cap and add the remaining amount of gasoline Filling th
34. e 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 When the engine starts release the starter button and unplug the extension cord Figure 57 3428 0259 A Starter Button System Disassembly 1 Remove the upper shroud Refer to Upper Shroud Removal on page 2 3 Figure 56 3428 0257 2 Remove three screws holding the switch box to Troubleshooting the control panel support Figure 58 NOTE At this point the switch box can be opened and the parts tested It may not be necessary to remove the starter motor Proceed to Switch Box Repair on page 5 3 1 First check the electric outlet An easy way to do that is plug a light into that outlet 2 Substitute a different extension cord or plug the same light into the cord 3 Ifthe cord and outlet are supplying power the problem must be in the motor wires or switch 4 A continuity tester or ohmmeter can be connected to the terminals where you would normally plug in the extension cord Figure 57 NOTE For clarity the switch box has been removed and opened Normally this test would be done with the machine fully assembled Figure 58
35. e the fuel tank cap securely and wipe up any spilled fuel Useonly the power cord supplied with the snowthrower and a receptacle appropriate for use with the power cord for electric start motors Never attempt to make any adjustments while the engine is running except where specifically recommended by Toro Letthe engine and the snowthrower adjust to the outdoor temperature before starting to clear snow Operating any powered machine can result in foreign objects being thrown into the eyes Always wear safety glasses or eye shields while operating adjusting or repairing the snowthrower Operation Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times Exercise extreme caution when crossing gravel drives walks or roads Stay alert for hidden hazards or traffic Donotattemptto clear snow from a crushed rock or gravel surface This product is intended for use only on paved surfaces After striking a foreign object stop the engine remove the ignition key thoroughly inspect the snowthrower for any damage and repair the damage before operating the snowthrower Ifthe unit should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble Stop the engine whenever you leave the operating position before unclogging the discharge chute and when making any repairs adjustments or inspe
36. e two screws in the carburetor cover bolted to the frame It is best to remove the cradle and slide the cover to the left to disengage the tabs on separate it from the engine after removing them as an the right side Figure 17 Remove the cover assembly from the chassis Figure 15 The steps are as follows DSC 0181 Figure 17 Figure 15 DSc 0138 4 Temporarily clamp the fuel line and slip it off the carburetor fitting Be prepared with something to 1 Remove fuel from the tank Remove the chute and catch any fuel remaining in the line or filter Figure upper shroud refer to Upper Shroud Removal 16 on page 2 3 Tie a slip knot in the starter rope where it comes out of the recoil Figure 16 5 remove the fuel tank remove the two bolts and locknuts on the left side of the tank Figure 18 Then slide the tank to the left to disengage it from the support pin on the right side Figure 19 Lift the tank out of the machine Pay F Figure 16 3428 0222 A Starter Rope B Carburetor Fitting Figure 18 3428 0223 2 Untie the knot in the starter handle and the rope through the control panel and support Roll up the rope and secure with tape to keep it out of your way Snow Commander Service Manual 3 1 ENGINE REMOVAL INSTALLATION Figure 19 3428 0227 Figure 21 3428 0228 8 Remove the belt cover 3 bolts and 2 screws Figure 22 Some models were built with
37. el tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 in 6 to 13mm below the bottom of the filler neck This empty space in the tank allows the gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where a spark may ignite gasoline fumes Store gasoline in an approved fuel container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline When fueling under certain circumstances static charge can develop igniting the gasoline A fire or explosion from gasoline can burn you and other and damage property DANGER Always place gasoline containers on the ground and away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container not from a gasoline dispenser nozzle f you must use a gasoline dispenser nozzle keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Note Use a fuel stabilizer conditioner for all Toro gasolin
38. embly Reverse the above steps Note wiring routing on electric start units 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 3 6 Snow Commander Service Manual 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 Figure 36 0621 0083 A Belt Brake B Pivot C Idler Snow Commander Service Manual DRIVE SYSTEM The same control bail on the handle has a second cable attached to it This cable controls tilting of the powerhead Figure 37 Figure 37 3428 0206 3428 0207 A At Rest B Engaged tilted C Cable When the bail is squeezed the powerhead containing the engine and rotor is tilted forward until the rotor blades contact the surface This action provides a self pro
39. er begins to pivot Stopping the Rotor Blades To stop the rotor blades release the control bar Note When you release the control bar the rotor blades stop but the engine continues to run Starting the Traction Drive To start the traction drive slowly squeeze the control bar toward the handle The front of the snowthrower pivots downward When the rotor blades touch the ground the snowthrower begins to move forward Squeezing the control bar completely to the handle provides maximum traction Note The traction is most aggressive the traction speed is fastest when the rotor blades are new If you want to reduce the aggressiveness of the traction refer to Adjusting the Pivot Cable on page 7 3 Stopping the Traction Drive To stop the traction drive partially release the control bar until the rotor blades lift off the ground disengaging the traction drive Releasing the control bar completely stops both the traction drive and the rotor blades Adjusting the Discharge Chute Chute Handle On models equipped with a manual chute move the chute handle left and right to adjust the direction of the snow stream Figure 6 The chute deflector handle on top of the discharge chute controls the height of the snow stream Do not overtighten the chute deflector mounting locknuts A Chute deflector mounting locknut 2 B Chute deflector handle C Chute handle Do not use the chute handle to l
40. he engine and engine cradle will now lift out of the chassis 15 Remove the 3 locknuts shown in Figure 28 to access the recoil starter Also the engine cradle and engine can be separated if necessary Figure 28 3428 0247 Assembly Reverse the order If the engine was removed from the cradle torque the 4 bolts around the crankshaft to 170 220 in Ibs 1355 2483 However leave the bolts securing the engine cradle slightly loose until the engine location can be checked and adjusted Adjust the engine to achieve the same gap between the idler pulley and engine pulley as measured previously Figure 29 Then snug the mounting screws to hold the engine in place Figure 29 3428 0232 To assure the engine is properly located in the housing measure the distance between the carburetor and the left side of the opening When the engine is correct the gap should be 030 762mm Figure 30 NOTE If this check is not done the choke lever may hang up on the shroud Snow Commander Service Manual ENGINE REMOVAL INSTALLATION Secure the engine and cradle 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 r
41. he grooves in the cylinder wall This provides extra area for the fuel charge to move to the firing chamber The result is a larger fuel charge which makes more power Figure 3 DSC 0032 A Grooves All service procedures and techniques are the same as those on the other R tek engines See E Engine Service Manual Form 492 0647 Figure 1 DSC 0138 Snow Commander Service Manual 1 1 GENERAL INFORMATION Identification and Ordering 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 Figure 4 m 5045 A Location of the model and serial numbers Provide the full model and serial number to any Authorized Toro Service Dealer They will be able to look up the part number and provide you with price quotes and availability The factory does not sell parts or products direct Should you wish to obtain your own parts catalog or a replacement owners manual they can be obtained from the factory Be prepared to supply the complete model and serial number and contact us at the following address The Toro Company 8111 Lyndale Ave S Bloomington MN 55420 Phone 1 800 348 2424 Follow the instructions to contact the parts dept The parts department staff will be happy to
42. he spark plug if it is pitted fouled or cracked 7 The fuel cap vent is restricted 7 Remove the vent restriction or replace the fuel cap Engine runs rough 1 The choke is in the On position 1 Move the choke to the Off position N Drain and fill the fuel tank with a fresh gasoline and oil mixture not more than 30 days old If the problem persists contact an Authorized Service Dealer 3 The spark plug wire is loose 3 Connect the wire to the spark plug 4 The spark plug is pitted fouled or the Check the spark plug and adjust the gap gap is incorrect if necessary Replace the spark plug if it is pitted fouled or cracked 2 The fuel system contains stale fuel gt Snow Commander Service Manual 7 9 MAINTENANCE Troubleshooting Problem Possible Causes Corrective Action Engine runs but the snowthrower discharges snow poorly or not at all N You are walking too fast or too slow You are trying to remove too much snow per swath You are trying to remove extremely heavy or wet snow The discharge chute is plugged The rotor control cable is improperly adjusted or broken The drive belt is loose or is off the pulley The drive belt is worn or broken The rotor blades are worn Change your walking speed Reduce the amount of snow removed Don t overload the snowthrower with Stop the engine wait for all moving Ad
43. her moving objects mvc 497 Switch Box Repair Power Plug By opening the switch box you can access all 3 major components of the electric start system The plug terminal switch and the wire harness starter motor Snow Commander Service Manual NOTE There are two versions of the electric start system A 120 VAC sold in North America and a 220 VAC system sold in Europe The plug terminal and motor will be different because of the different electrical systems However the troubleshooting and repair procedures are the same The 120VAC system is shown After removing and opening the switch box note the location of all wires Figure 64 before removing any parts from the box Figure 64 3428 0258 0260 To Motor Plug Terminal The possible failure modes of the plug are simple It can be broken physical damage or burnt signs of arcing Physical damage is apparent However a burnt terminal requires an understanding of the process The terminal becomes burnt when it is loosely plugged into the extension cord or the terminal inside the female end of the cord is worn or damaged The loose fit results in electrical arcing between the terminals on the snowthrower and the extension cord This arcing causes the burnt terminals Replace BOTH the plug terminal AND the terminal on the end of the extension cord as both are damaged by the arcing Extension cord terminals are available at your local hardware
44. ift the snowthrower This can damage both the chute handle and the snowthrower Snow Commander Service Manual CONTROLS LOCATION amp 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 Figure 7 0621 0073 Upper Shroud Removal The first step in many service procedures will be removing the upper shroud for access to the engine Remove the three Phillips head screws washer and locknuts that hold the chute and chute handle to the chassis Figure 8 Remove two Phillips head screws 4 washers and 2 locknuts that secure the front corners of the upper shroud Figure 8 Snow Commander Service Manual Figure 8 3428 0216 A 2 Phillips Head Screws Washers and Locknuts B 3 Phillips Head Screws Washers and Locknuts Remove two 5 16 screws that hold the control panel to the chassis Figure 9 Figure 9 3428 0217 Remove the fuel cap lift the upper shroud off and replace the fuel cap Snow Commander Chute Handle System Some Snow Commander models were equipped with a manual chute system As with the others the component parts are all plastic to eliminate the need for lubrication and reduce icing CONTROLS LOCATION amp OPERATION On this version the discharge chut
45. just or replace the rotor control cable Inspect the drive belt and install or Replace the drive belt Replace the rotor blades and the per swath extremely heavy or wet snow reduce the amount of snow removed per swath parts to stop and use a stick to remove the snow from the discharge chute replace it scraper Snowthrower does not properly clear snow off the surface The snow the surface to be cleared is compacted down The front of the snowthrower is not down The scraper is excessively worn The rotor blades are excessively worn Check the pivot cable and adjust or Replace the scraper and the rotor Replace the rotor blades and the Throw the snow off the surface before it becomes compacted replace it blades scraper Snowthrower does not self propel The front of the snowthrower is not down The rotor blades are excessively worn The snow is too deep or the surface is too slippery Check the pivot cable and adjust or Replace the rotor blades and the Push forward on the handle but allow replace it scraper the snowthrower to work at its own pace Rotor blades do not stop properly The rotor control cable is improperly adjusted Adjust the rotor control cable Snow Commander Service Manual SPECIFICATIONS General MAINTENANCE Item Description Engine
46. nowthrower could result in injury or death To reduce this potential comply with the following safety instructions Safe Operating Practices The following instructions have been adapted from the ANSI OPEI 71 3 1995 standard and the ISO 8437 1989 standard Information or terminology specific to Toro snowthrowers is enclosed in parenthesis Training Read the operator s manual carefully Be thoroughly familiar with the controls and the proper use of the equipment Know how to stop the unit and disengage the controls quickly Never allow children to operate the snowthrower Never allow adults to operate the snowthrower without proper instruction Keep the area of operation clear of all persons particularly small children and pets Exercise caution to avoid slipping or falling Preparation e Thoroughly inspect the area where you will use the snowthrower Remove all doormats sleds boards wires and other foreign objects Release the control bar to disengage the rotor blades before starting the engine Do not operate the snowthrower without wearing adequate winter garments Wear footwear that will improve your footing on slippery surfaces Snow Commander Service Manual Handle fuel with care it is highly flammable Use an approved fuel container Never add fuel to a running or hot engine Fill the fuel tank outdoors with extreme care Never fill the fuel tank indoors Replac
47. nspect the rotor blades and replace if necessary Replace the scraper when you replace the rotor blades Inspect the scraper and replace if necessary If the rotor blades are partially or completely worn replace the rotor blades when you replace the scraper Inspect and gap the spark plug replace if necessary Inspect the drive belt and replace if necessary For storage add stabilizer drain the fuel and run the engine until the fuel tank and the carburetor are empty Check the pressure in the tires and inflate them to between 15 and 20 psi 103 and 137 kPa Check for loose fasteners and tighten them if necessary CAUTION If you leave the wire on the spark plug someone could start the engine accidentally and seriously injure you or other bystanders Disconnect the wire from the spark plug before you do any maintenance Set the wire aside so that it does not accidentally contact the spark plug Rotor Control Cable Check the rotor control cable for proper adjustment initially after the first operating hour and then annually thereafter Checking the Rotor Control Cable 1 Stop the engine and wait for all moving parts to stop Figure 79 m 5065 Move the left side of the control bar back toward the handle until you remove the slack in the cable A Rotor Control Cable Handle Figure 79 and m 5065 on page 7 1 B Control Bar Snow Commander Service Manual 7 1 MAINTENANCE
48. o 3mm Replacing the Rotor Blades Before each season inspect the rotor blades for wear When a rotor blade edge has worn to the wear indicator hole Figure 84 replace all three rotor blades to ensure proper performance and to prevent damage to the underside of the snowthrower Figure 84 m 5058 A Rotor blade wear indicator hole Replace the scraper whenever you replace the rotor blades This ensures proper snowthrower operation and performance NOTE The running time and the roughness of the driveway or the sidewalk determines the wear rate of the rotor blades NOTE You need a T27 Torx driver to complete this procedure 1 Stop the engine and wait for all moving parts to stop 2 Remove the key from the switch 3 Disconnect the wire from the spark plug Refer to steps 1 through 3 of Replacing the Spark Plug on page 7 6 Removing the Old Rotor Blades NOTE To make replacing the rotor blades easier do not remove all the old rotor blades at once this disassembles the rotor drum making installing the new rotor blades more difficult Replace the rotor blades one at a time to keep the rotor drum intact 1 Remove the four Torx screws and the four locknuts that secure the outer edges of the rotor blade to the rotor assembly Figure 85 Snow Commander Service Manual MAINTENANCE A Thick rubber side of the Rotor Assembly rotor blade 3 C Rotor Drum D Lo
49. ol before storing in any enclosure Always refer to this operator s manual for important details if the snowthrower is to be stored for an extended period Maintain or replace safety and instruction labels when necessary Toro Snowthrower Safety The following list contains safety information specific to Toro products or other safety information that you must know Rotating rotor blades can injure fingers or hands Stay behind the handles and away from the discharge opening while operating the snowthrower Keep your face hands feet and any other part of your body or clothing away from moving or rotating parts Before adjusting cleaning repairing and inspecting the snowthrower and before unclogging the discharge chute stop the engine remove the key and wait for all moving parts to stop Use a stick not your hands to remove obstructions from the discharge chute Before leaving the operating position stop the engine remove the key and wait for all moving parts to stop Do not wear loose fitting clothing that could get caught in moving parts e Ifa shield safety device or decal is damaged illegible or lost repair or replace it before beginning operation Also tighten any loose fasteners Do not smoke while handling gasoline Do not use the snowthrower on a roof Do not touch the engine while it is running or soon after it has stopped because the engine may be hot enough to cause
50. ope or other moving objects CCE Figure 30 3428 0211 Before tightening the setscrews on the engine pulley the alignment of the pulleys needs to be checked Figure 31 Measure from the side plate to the outer pulley flange Adjust the pulley until the gap is 1 25 4mm Figure 32 mvc 496 Figure 31 mvc 504 Figure 33 mvc 497 NOTE Use Loctite on setscrews Recoil Starter Access Torque the square head setscrew to 120 150 in Ibs 1355 1694 Torque the Allen head setscrewto Beginning with 2002 production models the blower 60 80 in Ibs 678 904 Torque the nutonthe housing and recoil starter is accessible without recoil side support to 90 120 in Ibs 1016 1355 removing the engine from the chassis N cm Process 1 Remove the chute and upper shroud refer to Upper Shroud Removal on page 2 3 Snow Commander Service Manual 3 5 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 Ass
51. pelling action by the rotor blades as well as cleaning down to the surface Figure 38 Figure 38 3428 0229 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 Any attempt to adjust it up to pass over the gravel will result in not cleaning to the surface and a complete loss of self propelling Drive System Disassembly 1 The belt cover is on the left hand side of the machine The belt cover is held on with two screws and three bolts Figure 40 0621 0083 3 Before you remove the belt note the routing and if diamond shape washer used in the front top hole the belt is damaged There is a belt routing decal Sub t tandard on the inside of the belt cover and a copy of that 30 decal in the owners manual Figure 41 If the belt was misrouted or has jumped the pulleys it will likely be damaged A damaged belt should be replaced NOTE The first year only there was a special Figure 39 3428 0230 A Diamond Shaped Washer B Belt Cover Figure 41 3428 0231 2 2 Remove the belt cover and the left rotor guard 4 To remove the rotor pulley
52. plug 8 Install the control panel 9 Insert the key in the switch Replacing the Scraper NOTE If the rotor blades are partially or completely worn replace the rotor blades when you replace the scraper This ensures proper snowthrower operation and performance 1 Stop the engine and wait for all moving parts to stop 2 Remove the key from the switch 3 Disconnect the wire from the spark plug Refer to steps 1 through 3 of Replacing the Spark Plug below 4 Tip the snowthrower backward onto its handle 5 Remove the six bolts and locknuts that hold the scraper in place Fig 17 m 5060 A Carriage Bolt 6 B Locknut 6 C Scrapper 6 Remove the scraper 7 Install the new scraper to the housing using the bolts and the locknuts you previously removed 8 Connect the wire to the spark plug 9 Install the control panel 10 Insert the key in the switch Replacing the Spark Plug Before each season check the spark plug Replace the plug if fouled with deposits or if the electrodes in the center of the plug are dark or have deteriorated spark plug NGK BPMRAA or equivalent Snow Commander Service Manual 1 Remove the two mounting screws that secure the control panel to the housing Fig 18 Figure 88 m 5061 A Control Panel B Mounting Screws 2 2 Remove the ignition key and lift off the panel allowing it to hang on the recoil rope
53. s eee eee oe eed 5 4 Starter Pinion Replacement 5 ccce ee Sa DARE CEPR dew eee 5 5 PASS SM Yes addo tlt de wing indu aes ndo al a rte Y da dando B Der dba an rio ek 5 6 CHASSIS Whesls and Tires requi X a 844 wale d ck 6 1 Tite Mecharism F nacio ote ro hao et RES us 6 1 Pivot Cable Replacement 6 2 ii Snow Commander Service Manual TABLE OF CONTENTS MAINTENANCE Recommended Maintenance 5 7 1 Rotor Control Cable cei uk CER lente a Ra ee a ea We ara 7 1 Checking the Rotor Control Cable 7 1 Adjusting the Rotor Control Cable 7 2 Adjusting the Pivot Cable 7 3 Checking the Pivot 7 3 Adj sting the PIVOV Cable ed ek et eed eee eee 7 4 Replacing the Rotor Blades van Oe eee 7 4 Removing the Old Rotor 7 4 Installing the New Rotor Blades 7 5 Replacing the Scraper 28 Dn AL a ge Dead e dau eed Mea 7 6 Replacing the Spark PIUG s euni
54. tainers to each side plate Figure 51 Figure 51 3428 0273 DRIVE SYSTEM 3 On the right side opposite the belt there is one Rotor Cable Replacement bolt that goes through the bearing and into the rotor shaft Remove this bolt Figure 52 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 The ends of the cable are interchangeable there is no top or bottom end Replace the belt cover and adjust per the Adjusting the Rotor Control Cable on page 7 2 Figure 52 3428 0275 4 You might now be able to work the rotor assembly out of the chassis It may be necessary to loosen the bolts securing the right hand side plate to obtain more clearance 5 The bearings will now slide off the rotor shaft X449 N Figure 54 mvc 502 Assembly A Cable Z Bend B Opening Assemble in reverse order Note the locations of the special thrust washers Figure 53 Figure 53 Figure 55 3428 0198 A Bearing Retainer D Ball Bearing B Flat Washer E Thrust Washer C Rubber Washer F Bearing Flange 4 6 Snow Commander Service Manual ELECTRIC START SYSTEM Operation If there is no continuity with the starter button depressed th
55. w threads and applying a chemical thread locker such as Loctite brand Figure 47 3428 0243 9 Replace nylon rollers if worn or damaged One is retained by a cap nut Figure 48 Use side cutters to remove it and replace with a new cap nut 4 4 Snow Commander Service Manual 2 Before tightening the setscrews 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 mvc 504 Torque the square head setscrew to 120 150 in Ibs 1355 1694 N cm Torque the Allen head setscrew to 60 80 in Ibs 678 904 N cm Torque the capscrew securing the rotor pulley to 100 in Ibs 1125 N cm 3 idler pulley must be installed with the longer hub towards the brake arm Figure 50 If it is installed backwards it will not rotate when tightened down Torque the shoulder bolt to 170 250 in Ibs 1920 2824 N cm Figure 50 3428 0245 Snow Commander Service Manual DRIVE SYSTEM 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 1 Toreplace the rotor bearings remove the belt cover belt and rotor pulley as shown in the preceding steps 2 Remove the three nuts and bolts attaching the bearing and bearing re
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