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Toro 38080 - page 1
TORO /LAWN-BOY TWO ST A G E SNOWTHROWER DRIVE SYST E M S M A N U A L Table of C ontents – Page 1 of 2 AUGER G EARBOX SERVICE GENERAL INFORMAT ION AUGER G EARBOX LUBRICAN T GEARBO X REMO VAL PRIMAR Y MET HOD — MINI MUM DI SASSEM BLY SECONDAR Y METHOD — T RACTION AND AUGER HOUSI NGS SEP ARATED: TORO MODELS 3806 5 AND 3 8080 ALL OTHER MODELS INS ...
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Toro 38080 - page 2
TORO /LAWN-BOY TWO ST A G E SNOWTHROWER DRIVE SYST E M S M A N U A L Table of C ontents – Page 2 of 2 TRACT ION DRIVE SYST EMS - CONT INUED DISA SSEMBLY LAW N-BOY MODEL S 28230 , 23231 TORO MODELS 3805 1, 3805 2, 380 54, 38056, 3 8062, 3 8063, 38064, 380 72, 38 073 ASSEMB LY LAW N-BOY MODEL S 28230 , 23231 TORO MODELS 3805 1, 3805 2, 380 54, 3805 ...
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Toro 38080 - page 3
2-S t age Snowthrower Service Manual Drive Systems ...
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Toro 38080 - page 4
About Th is Manu al This manu al was writte n expre ssly for the T oro and Lawn-Boy ser vicing dea ler . The T oro Compan y has made ev ery ef fort to ma ke the in formation in this manu al complete an d correct. This ma nual was writte n with assu mption th at the reader h as basic me chanical knowledg e and ski lls. This boo k con tains mat erial ...
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Toro 38080 - page 5
Two St age Sno wthro wer Drive Syst ems Man ual Conte nts AUGER GEARBOX S ERVICE . . . . . . . . . . . . . 1-1 GENERAL INF ORMATIO N . . . . . . . . . . . . . . . . 1 -1 AUGER GEA RBOX L UBRICANT . . . . . . . . . . . 1- 1 GEARBOX REMOVA L . . . . . . . . . . . . . . . . . . . 1- 1 Primary Method — M inimum Disassemb ly . . . . . . . . . . . . . ...
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Toro 38080 - page 6
Two Stag e Snow throwe r Drive Sys tems M anual THIS P AGE INTENTIONALL Y LEFT BLANK ...
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Toro 38080 - page 7
Two Stage Snowt hrower Driv e Systems Manual Introducti on - 1 Introduc tion This m anual will cover servic e to the auger and tractio n drive systems on smal l and intermed iate fr ame 2 stage snowthro wers. Se rvice inf ormat ion for P ower Shi ft snowthrowers is contain ed in manu al 492- 0354. The mode ls cov ered ar e as foll ows*: Model num b ...
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Toro 38080 - page 8
Introducti on - 2 Two Stage Snowthro wer Drive Sy stems Manual THIS P AGE INTENTIONALL Y LEFT BLANK ...
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Toro 38080 - page 9
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 1 Chapter 1 — Auger Gearb ox Serv ice GENERAL INFORMA TION The manu al takes a sy stems app roach. Th ere are two versions of the auger gea rbox an d three v ersions o f the tractio n drive sy stem used amon g the v arious 2- stage models. For in formatio n on the auger drive o r link age adjust ...
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Toro 38080 - page 10
Auger G earbox Ser vice 1 - 2 Two S tage S nowthr ower Dr ive Sys tems M anual Primary Method — Mini mum Disassembly The foll owing ste ps apply to all models. 1. Remove the belt c over . Loosen th e belt g uide o n the engine crank shaft and rem ove the auger be lt. DO NOT ben d the be lt guide o ut of the way (Fig ure 3 ). Figure 3 MVC-526 2. O ...
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Toro 38080 - page 11
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 3 Auger Ge arbox Servic e 5. Loosen th e rear a nd rem ove the fr ont capscrew secu ring the idler arm to the c hassis . Figure 7 M-3331 6. Begin to pull th e auger a ssem bly out to the front. Note: The auger pu lley and k ey have not yet be en removed . Howev er , i f you pull the a uger sl ight ...
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Toro 38080 - page 12
Auger G earbox Ser vice 1 - 4 Two S tage S nowthr ower Dr ive Sys tems M anual 9. The auge r flighti ng is attach ed to th e auger s haft with one bo lt and locknut. Reach through th e holes in the drum auger s to acc ess. On model s without drum aug ers, the bolts are ea sily access ible (Figur e 1 1). Figure 1 1 MVC-533 The auge r assem bly can b ...
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Toro 38080 - page 13
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 5 Auger Ge arbox Servic e 5. There ar e 4 lock nuts in the for ward part o f the housing. These a re on stu ds from the auge r . Remove the lock nuts. The trac tion assembl y will now lift str aight u p off the auger assem bly (Fig ure 1 5). Figure 15 2768-025 6. Now perform steps 1 - 9 u nder “ ...
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Toro 38080 - page 14
Auger G earbox Ser vice 1 - 6 Two S tage S nowthr ower Dr ive Sys tems M anual INST ALLA TION Installation of the auge r assem bly into the aug er housing can be done wh ether the auger hou sing and tractio n assemb lies are c onnec ted or no t. There is no signifi cant time savi ngs to ei ther seq uence. 1. All sel f-align ing bear ings (sometim e ...
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Toro 38080 - page 15
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 7 Auger Ge arbox Servic e AUGER GEARBOX DISASSEMBL Y / SERVICE Once the a uger gear box asse mbly is rem oved from the housing the repair p rocess i s the sam e for all model s. The only v ariables are what ty pe of lub ricant i s used (see the c hart on Int roducti on page 1), whe ther the impell ...
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Toro 38080 - page 16
Auger G earbox Ser vice 1 - 8 Two S tage S nowthr ower Dr ive Sys tems M anual 6. Clean t he outpu t shaft and sl ide th e case ha lves off. Remove the s eals fr om the case halves and discard t he sea ls. 7. Clean a nd inspe ct the bushings in the c ase halves. If they ar e dama ged or worn, press them out of th e case h alves at this tim e. 8. Sl ...
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Toro 38080 - page 17
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 9 Auger Ge arbox Servic e Failure Analysis There a re some miscon ceptio ns rega rding the se gearbox es that result in incor rectly iden tifying t he causes of fail ure. The squ are cut rin g on the imp eller s haft is not re ally a seal. It i s a wiper r ing that h as a te ndency to pull down to ...
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Toro 38080 - page 18
Auger G earbox Ser vice 1 - 10 Two Stag e Snow throwe r Drive Sys tems M anual 3. Insert th e keys into the shaft and sl ide the large worm gear i nto pla ce. Note: There is a lar ge lett er “R” and an arrow on one side of the gear . This gear MUS T be installe d such th at the R a nd the arrow are on the right hand s ide and the arrow is point ...
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Toro 38080 - page 19
Two St age Sno wthro wer Drive Syst ems Man ual 1 - 11 Auger Ge arbox Servic e 7. Apply a VERY ligh t coat o f Loctit e™ Blue # 242 or quivale nt to the out er diame ter of the beari ng. Loctite™ should n ot squeez e out wh en everyth ing is tighte ned (F igure 33) . Figure 33 2773-059 8. Some m odels us e a ga sket and some d o not. For those ...
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Toro 38080 - page 20
1 - 12 Two Stag e Snow throwe r Drive Sys tems M anual THIS P AGE INTENTIONALL Y LEFT BLANK ...
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Toro 38080 - page 21
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 1 Chapter 2 — Belts, Controls an d Linkages INTRODUCTION All mode ls us e two b elts. One to d riv e the auger and a seco nd to dri ve the tr action s ystem. T he aug er drive uses a com binati on idler and brak e to engag e the be lt for driving and to d isengage the bel t and appl y the brake ...
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Toro 38080 - page 22
Belts, Contro ls and Linkage s 2 - 2 Two S tage S nowthr ower Dr ive Sys tems M anual 7. The belt guide mus t be chec ked and adjusted. With the e ngine off, en gage both th e auger a nd tractio n contro ls. Adju st the b elt gu ide so that there is appr oximatel y 1/8 inch (.3 cm) cleara nce between the belt gu ide an d the be lt. Check au ger bel ...
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Toro 38080 - page 23
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 3 Belts, Controls and Li nkages Replacing the T raction Belt — Lawn-Boy Models 2823 0, 28 231 and T oro Models 38051, 3805 2, 38054 , 3805 6, 38062 , 38063, 38064, 3807 2, 38073 When t he traction drive b elt bec omes wor n, stret ched, oil-so aked, or otherwis e dama ged, repl ace the be lt. 1. ...
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Toro 38080 - page 24
Belts, Contro ls and Linkage s 2 - 4 Two S tage S nowthr ower Dr ive Sys tems M anual 1 1. Install a new belt arou nd the lar ge trac tion pull ey . 12. Loop the belt over the eng ine pull ey , ens uring tha t the belt i s on the i nside of t he belt guide (Fig ure 4 0). 13. Ti p the snowth rower forw ard and block it so that it canno t fall. 14. H ...
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Toro 38080 - page 25
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 5 Belts, Controls and Li nkages 3. Loose n auger b rake ar m assem bly b y loosening rear screw and remov ing fro nt screw (Figu re 45). Figure 45 M-2678 4. Remove i dler pul ley spr ing (Fig ure 45 ). Let br ake arm assem bly h ang free b ut out of the way . 5. Remove (2 ) screws, (2) was hers, a ...
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Toro 38080 - page 26
Belts, Contro ls and Linkage s 2 - 6 Two S tage S nowthr ower Dr ive Sys tems M anual 15. Reinstall ( 2) screw s that secur e auge r brake arm assembl y . Mak e sure tabs fit int o holes in left side of machi ne (Fig ure 48) . Figure 48 M-2678 16. Whil e some one squee zes the auge r/impel ler control leve r (Figur e 49) ag ainst the han dgrip, rei ...
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Toro 38080 - page 27
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 7 Belts, Controls and Li nkages CONTROL AND LINKAGE ADJUSTMENT Note: Before ma king any cont rol adj ustmen ts, verify that the han dles are secur ed to th e traction f rame. If the handle s mov e at all, the linka ges will not ma intain adjustme nt. Auger Control Adjustment — T oro Mod els 3806 ...
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Toro 38080 - page 28
Belts, Contro ls and Linkage s 2 - 8 Two S tage S nowthr ower Dr ive Sys tems M anual Auger/Impeller Drive Control Linka ge — All Other Models There ar e two adjus tment m echanis ms used. One has a clevis with a jam nut. The o ther h as a rod goi ng through a loop w ith a flang e nut on either sid e. 1. Thread a h ex fla nge nut (flange s ide do ...
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Toro 38080 - page 29
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 9 Belts, Controls and Li nkages ADJUSTING TRACTION CONTROL Adjusting the T raction Control — T oro Models 38065 , 38080, 38085 1. Move whee l drive control i nto No. 1 , 1st gear . Positio n cont rol lev er so i ts front s urface i s 1/4 of an inch ( 6mm) from bottom of slot ( Figure 56 ); then ...
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Toro 38080 - page 30
Belts, Contro ls and Linkage s 2 - 10 Two Stag e Snow throwe r Drive Sys tems M anual Adjust ing the T raction Co ntrol — 824X L (T oro Models 380 66, 3807 8, 38083 , 38084, 38086 and Lawn-Boy Model 2 8232) 1. Slide s pring on to botto m of trac tion contr ol rod (Fig ure 5 9). Figure 59 M-2665 2. Thread a fl ange loc k nut (fl ange sid e up) ont ...
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Toro 38080 - page 31
Two St age Sno wthro wer Drive Syst ems Man ual 2 - 11 Belts, Controls and Li nkages ADJUSTING THE TRACTION ROD — LA WN-BOY MODELS 28230, 28231 AND T ORO MODE LS 38051, 38052 , 38054, 38056, 3806 2, 38063 , 3806 4 1. Thread the locking flan ge nut (flange si de up) onto the bottom o f the tr action c ontrol rod , below the loop in th e lower t ra ...
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Toro 38080 - page 32
Belts, Contro ls and Linkage s 2 - 12 Two Stag e Snow throwe r Drive Sys tems M anual ADJUSTING THE SPEED SELECT OR If the snow throwe r is slow, the No.1 speed s elect ion has no s peed, or t he speed s elector do es not move into the No . 3 spe ed selec tion, adjust the speed sele ctor lin kage. 1. Disconn ect the wire fr om the spark pl ug and m ...
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Toro 38080 - page 33
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 1 Chapter 3 — Tra ction Drive Systems INTRODUCTION All mode ls us e some v ariatio n of a fr iction drive. The engin e drives a belt, whic h cau ses a dr ive pla te(s) to rotate. As th is be lt is c onstantly ten sione d, the be lt and drive p late turn whenever the engin e is run ning (Fig ure ...
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Toro 38080 - page 34
Tractio n Drive Systems 3 - 2 Two S tage S nowthr ower Dr ive Sys tems M anual TROUBLESHOOTING THE TRACTION DRIVE — ALL MODELS Drive slipping: 1. V erify adjustm ent of t raction drive lin kage. 2. Make sure th e engage ment sp ring and i dler spr ing are in p lace and undamaged. 3. V erify that the dri ve plate and frictio n wheel are clean and ...
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Toro 38080 - page 35
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 3 Traction Dri ve Systems 6. The axle c an now be remov ed from t he chassis . Inspect the gear , the r oll pin, and the areas where the beari ngs con tact the axle for da mage or severe wear . Remove the th rust washers fr om either e nd of the ax le. The purpo se of the r oll pin and thrus t was ...
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Toro 38080 - page 36
Tractio n Drive Systems 3 - 4 Two S tage S nowthr ower Dr ive Sys tems M anual E. If th e eyeb olt, or trac tion dr ive hub i s to be replaced, remove t he snap r ing on the hub (Fig ure 7 8). Figure 78 2768-040 F . The sma ll sproc ket is retaine d to the hex shaft with a key and se t screw . G . The lar ge sp rocket just rotates o n the be arings ...
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Toro 38080 - page 37
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 5 Traction Dri ve Systems Assembly 1. Slide th e pillow b lock be aring , reverse plate (with the hub sid e away from the pulley ), thrust was her , bearing (hub si de fac ing the re verse plate), th rust washer , and spacer on to the dri ve shaft. Dri ve the roll pin th rough the space r and sh a ...
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Toro 38080 - page 38
Tractio n Drive Systems 3 - 6 Two S tage S nowthr ower Dr ive Sys tems M anual 4. If the piv ot as sembly was re paired, now i s the ti me to assem ble it. A. Sec ure the f riction wheel to th e hub wi th four cap scre ws and locknuts. If the loc knuts are worn, app ly a dro p of Locti te™ Red #271 or equival ent to th e threads. B. Sl ip a sli d ...
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Toro 38080 - page 39
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 7 Traction Dri ve Systems 6. Next, tens ion the pivot as sembly . With the uni t upright, use a sc rewdrive r to str etch the tr action spring and hoo k it into the hol e provided (Fig ure 8 6). Figure 86 MVC- 714 7. Slip one thrust wa sher on each e nd of th e axle and in sert it i nto the chassi ...
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Toro 38080 - page 40
Tractio n Drive Systems 3 - 8 Two S tage S nowthr ower Dr ive Sys tems M anual 6. Remove 4 s elf-tappin g screws th at secure t he axle bea rings to the trac tion fram e. Lift the a xle and bea rings o ut (Fig ure 89) . Slid e the b earings and thrus t wash ers off the ax le. Figure 89 2773-074 7. Disconn ect the sh ift rod an d traction d rive rod ...
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Toro 38080 - page 41
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 9 Traction Dri ve Systems 1 1. If it is nec essary to remov e the g ear quad rant, it i s best to ju st re move the two self- tapping sc rews that secu re the ge ar qua drant mou nt to the tractio n frame. The gear qua drant and gear quadrant frame ca n then b e separa ted easil y (Fig ure 9 3). F ...
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Toro 38080 - page 42
Tractio n Drive Systems 3 - 10 Two Stag e Snow throwe r Drive Sys tems M anual ASSEMB L Y — LA WN-BOY MODELS 2823 0, 232 31 AND T OR O MO DELS 3805 1, 38 052, 38054, 3805 6, 38062 , 3806 3, 38064 , 38072, 38073 Assem bly T ip s 1. Before as sembli ng somethi ng with a new bu shing , wipe th e bushing with a clean s hop towe l. This should r emove ...
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Toro 38080 - page 43
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 11 Traction Dri ve Systems 5. Install the fri ction pl ate spring i nto the fr ont frame assembl y . Note some models just ha ve a ho le in the frame . Other s have a tab bent outwa rd to ho ok the spring in to (Figure 100). Hook the lower end of the sp ring int o the no tch in the tractio n fram ...
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Toro 38080 - page 44
Tractio n Drive Systems 3 - 12 Two Stag e Snow throwe r Drive Sys tems M anual 1 1. Slide the whe el and hub on the hex shaft with the frictio n wheel c losest to the sl iding br acket. I nstall the lock nut, holdi ng the h ex shaft with an open- end wrench ( Figure 1 04). Figure 104 MVC-720 12. If the r eceive r cam ha s been remo ved, ins tall it ...
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Toro 38080 - page 45
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 13 Traction Dri ve Systems 17. Install th e friction wheel a nd slidi ng brac ket. The frictio n wheel s hould be o n your l eft (Figure 1 09). Figure 109 2773-081 The gear q uadra nt must be free to pivot. The first tooth on the quadr ant sh ould go i nto the hol e in the righ t side as s hown in ...
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Toro 38080 - page 46
Tractio n Drive Systems 3 - 14 Two Stag e Snow throwe r Drive Sys tems M anual 21. If the l ower tra ction rod wa s rem oved, re install it now . Slide the end through th e tracti on bracket then in stall the sp ring and lo cknut. Turn the locknut on unti l the spr ing is compres sed to approxi mately 2 ¼” (5.7 cm) long (F igure 1 13). Figure 1 ...
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Toro 38080 - page 47
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 15 Traction Dri ve Systems 6. T o remove the int ermediat e shaft, lo osen th e retaining b olts and rem ove the chai n. Loctite ™ Red # 271 is used to s ecur e thes e bo lt s. Re move the sh aft (Figure 1 16). Figure 1 16 0054-009 7. T o remove the ax le and frictio n plate as sembly , disconn ...
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Toro 38080 - page 48
Tractio n Drive Systems 3 - 16 Two Stag e Snow throwe r Drive Sys tems M anual ASSEMBL Y — TORO MODELS 38 066, 38078, 3808 3, 38084 , 3808 6 Reverse the proces s for ass embly . See the foll owing tips for sp ecial informa tio n. 1. Lightly gr ease the a xle gear . S pread abou t ½ teaspoon of #2 ge neral-p urpose grea se around the cir cumferen ...
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Toro 38080 - page 49
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 17 Traction Dri ve Systems SUB ASSEMBL Y R EP AIR — T ORO MODE LS 38066, 38078 , 38083, 38084, 3808 6 This s ection wi ll cov er the di sass embly an d repair of the tractio n shaft/friction wheel a nd the ax le and fr iction p late assembl y after they have bee n remo ved from the chas sis. T r ...
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Toro 38080 - page 50
Tractio n Drive Systems 3 - 18 Two Stag e Snow throwe r Drive Sys tems M anual 6. There ar e 2 vers ions of th e hub a nd slide r . The early mod els u se a nor mal thrust wa sher on eithe r side of th e slider. Later models use a t hrust washer with a n interna l key that fi ts into a keyway cut into t he sha ft portion of th e hub. This key ed ve ...
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Toro 38080 - page 51
Two St age Sno wthro wer Drive Syst ems Man ual 3 - 19 Traction Dri ve Systems Axle and Friction Plate Assembly Assemb le in reverse o rder . The fo llowing a re notes to assis t you: 1. Install the s nap r ing into t he gro ve in the pulle y and shaft. The sh arp edge of the s nap ring sh ould face the p ulley . Install the thrus t bearing next t ...
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Toro 38080 - page 52
3 - 20 Two Stag e Snow throwe r Drive Sys tems M anual THIS P AGE INTENTIONALL Y LEFT BLANK ...
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Toro 38080 - page 53
THIS P AGE INTENTIONALL Y LEFT BLANK . ...
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Toro 38080 - page 54
492-4738 ...
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