Toro 38051, 38052, 38053, 38054, 38056C Service Manual
...
TORO/LAWN-BOY TWO STAGE SNOWTHROWER DRIVE SYSTEMS MANUAL
Table of Contents – Page 1 of 2
AUGER GEARBOX SERVICE
GENERAL INFORMATION
AUGER GEARBOX LUBRICANT
GEARBOX REMOVAL
PRIMARY METHOD — MINIMUM DISASSEMBLY
SECONDARY METHOD — TRACTION AND AUGER HOUSINGS SEPARATED:
TORO MODELS 38065 AND 38080
ALL OTHER MODELS
INSTALLATION
AUGER GEARBOX DISASSEMBLY / SERVICE
FAILURE ANALYSIS
GEARBOX ASSEMBLY
BELTS, CONTROLS AND LINKAGES
INTRODUCTION
REPLACING THE AUGER/IMPELLER DRIVE BELT
REPLACING THE TRACTION BELT
REPLACING THE TRACTION BELT
TORO MODELS 38065, 38080, 38085
LAWN-BOY MODELS 28230, 28231
TORO MODELS 38051, 38052, 38054, 38056, 38062, 38063, 38064, 38072, 38073
LAWN-BOY MODEL 28232
TORO MODELS 38053, 38066, 38078, 38083, 38084, 38086
CONTROL AND LINKAGE ADJUSTMENT
AUGER CONTROL ADJUSTMENT — TORO MODELS 38065, 38080, 38085
INSTALL AUGER DRIVE CONTROL ROD
ADJUSTING AUGER/IMPELLER DRIVE BELT
AUGER/IMPELLER DRIVE CONTROL LINKAGE — ALL OTHER MODELS
ADJUSTING TRACTION CONTROL
ADJUSTING THE TRACTION CONTROL
TORO MODELS 38065, 38080, 38085
824XL (TORO MODELS 38066, 38078, 38083, 38084, 38086
LAWN-BOY MODEL 28232
ADJUSTING THE TRACTION ROD
LAWN-BOY MODELS 28230, 28231
TORO MODELS 38051, 38052, 38054, 38056, 38062, 38063, 38064
ADJUSTING THE SPEED SELECTOR
TRACTION DRIVE SYSTEMS
INTRODUCTION
TROUBLESHOOTING THE TRACTION DRIVE — ALL MODELS
DISASSEMBLY
TORO MODELS 38065, 38080, 38085
ASSEMBLY
TORO MODELS 38065, 38080, 38085
PREPARATION
ASSEMBLY
TORO/LAWN-BOY TWO STAGE SNOWTHROWER DRIVE SYSTEMS MANUAL
Table of Contents – Page 2 of 2
TRACTION DRIVE SYSTEMS - CONTINUED
DISASSEMBLY
LAWN-BOY MODELS 28230, 23231
TORO MODELS 38051, 38052, 38054, 38056, 38062, 38063, 38064, 38072, 38073
ASSEMBLY
LAWN-BOY MODELS 28230, 23231
TORO MODELS 38051, 38052, 38054, 38056, 38062, 38063, 38064, 38072, 38073
ASSEMBLY TIPS
ASSEMBLY STEPS
DISASSEMBLY
TORO MODELS 38066, 38078, 38083, 38084, 38086
ASSEMBLY
TORO MODELS 38066, 38078, 38083, 38084, 38086
SUB ASSEMBLY REPAIR
TORO MODELS 38066, 38078, 38083, 38084, 38086
TRACTION SHAFT/FRICTION WHEEL DISASSEMBLY
ASSEMBLY
AXLE AND FRICTION PLATE DISASSEMBLY
AXLE AND FRICTION PLATE ASSEMBLY
2-Stage Snowthrower
Drive Systems
Service Manual
About This Manual
This manual was written expressly for the Toro and Lawn-Boy servicing dealer. The Toro
Company has made every effort to make the information in this manual complete and
correct.
This manual was written with assumption that the reader has basic mechanical knowledge
and skills. This book contains material covering the Toro and Lawn-Boy brand 2-Stage
Snowthrowers produced from 1990 to 2002, and may be specified for use on products built
before 1990 or after 2002 that are similar in design.
We hope that 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
The Toro Company - 2001
Bloomington, MN 55420 - U.S.A.
Contents
AUGER GEARBOX SERVICE . . . . . . . . . . . . . 1-1
GENERAL INFORMATION . . . . . . . . . . . . . . . . 1-1
AUGER GEARBOX LUBRICANT . . . . . . . . . . . 1-1
GEARBOX REMOVAL . . . . . . . . . . . . . . . . . . . 1-1
Primary Method — Minimum
Disassembly . . . . . . . . . . . . . . . . . . . . . . 1-2
Secondary Method — Traction and Auger
Housings Separated: Toro Models
38065 and 38080 . . . . . . . . . . . . . . . . . . 1-4
Secondary Method — Traction and
Auger Housings Separated:
All Other Models . . . . . . . . . . . . . . . . . . . 1-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
AUGER GEARBOX
DISASSEMBLY / SERVICE . . . . . . . . . . . . . . 1-7
Failure Analysis . . . . . . . . . . . . . . . . . . . . . 1-9
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . 1-9
BELTS, CONTROLS AND LINKAGES . . . . . . 2-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 2-1
REPLACING THE AUGER/IMPELLER
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
REPLACING THE TRACTION BELT . . . . . . . . 2-2
Replacing the Traction Belt — Toro Models
38065, 38080, 38085 . . . . . . . . . . . . . . . 2-2
Replacing the Traction Belt —
Lawn-Boy Models 28230, 28231 and
Toro Models 38051, 38052, 38054, 38056,
38062, 38063, 38064, 38072, 38073 . . . 2-3
Replacing the Traction Belt —
Lawn-Boy Model 28232 and
Toro Models 38053, 38066,
38078, 38083, 38084, 38086 . . . . . . . . . 2-4
CONTROL AND LINKAGE ADJUSTMENT. . . . 2-7
Auger Control Adjustment —
Toro Models 38065, 38080, 38085 . . . . . 2-7
Install Auger Drive Control Rod . . . . . 2-7
Adjusting Auger/Impeller Drive Belt . . 2-7
Auger/Impeller Drive Control Linkage —
All Other Models . . . . . . . . . . . . . . . . . . . 2-8
ADJUSTING TRACTION CONTROL . . . . . . . . 2-9
Adjusting the Traction Control —
Toro Models 38065, 38080, 38085 . . . . . 2-9
Adjusting the Traction Control —
824XL (Toro Models 38066, 38078,
38083, 38084, 38086 and
Lawn-Boy Model 28232) . . . . . . . . . . . . . 2-10
ADJUSTING THE TRACTION ROD —
LAWN-BOY MODELS 28230, 28231 AND
TORO MODELS 38051, 38052, 38054,
38056, 38062, 38063, 38064 . . . . . . . . . . . . 2-11
ADJUSTING THE SPEED SELECTOR . . . . . 2-12
TRACTION DRIVE SYSTEMS . . . . . . . . . . . . 3-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 3-1
TROUBLESHOOTING THE TRACTION
DRIVE — ALL MODELS . . . . . . . . . . . . . . . . 3-2
DISASSEMBLY — TORO MODELS 38065,
38080, 38085 . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ASSEMBLY — TORO MODELS 38065,
38080, 38085 . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Preparation . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DISASSEMBLY — LAWN-BOY MODELS 28230,
23231 AND TORO MODELS 38051, 38052,
38054, 38056, 38062, 38063, 38064, 38072,
38073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
ASSEMBLY — LAWN-BOY MODELS 28230,
23231 AND TORO MODELS 38051, 38052,
38054, 38056, 38062, 38063, 38064, 38072,
38073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Assembly Tips . . . . . . . . . . . . . . . . . . . . . 3-10
Assembly Steps . . . . . . . . . . . . . . . . . . . . 3-10
DISASSEMBLY — TORO MODELS 38066,
38078, 38083, 38084, 38086 . . . . . . . . . . . . 3-14
ASSEMBLY — TORO MODELS 38066, 38078,
38083, 38084, 38086 . . . . . . . . . . . . . . . . . . 3-16
SUB ASSEMBLY REPAIR —
TORO MODELS 38066, 38078, 38083, 38084,
38086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Traction Shaft/Friction
Wheel Disassembly . . . . . . . . . . . . . . . . 3-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Axle and Friction Plate Disassembly . . . . 3-18
Axle and Friction Plate Assembly . . . . . . 3-19
Two Stage Snowthrower Drive Systems Manual
THIS PAGE INTENTIONALLY LEFT BLANK
Two Stage Snowthrower Drive Systems Manual
Introduction
This manual will cover service to the auger and traction drive systems on small and intermediate frame 2 stage
snowthrowers. Service information for Power Shift snowthrowers is contained in manual 492-0354.
The models covered are as follows*:
Model Model Name Year Auger Gearbox Lubricant
28230 522R 1997-2000 MAG 1
28231 522R 1997 MAG 1
28232 824E 1999-2000 MAG 1
38051 522 2000-2001 MAG 1
38052 521 1990-1996 MAG 1
38053 824 2000-2002 MAG 1
38054 521 1990-1996 MAG 1
38056 521 1990-1991 MAG 1
38056C 521 1990 MAG 1
38062 622 1997-1999 MAG 1
38063 622 1997-2002 MAG 1
38064 622 2000-2002 MAG 1
38065 624 1990 90 wt.
38066 824XL 2000-2002 90 wt.
38072 724 1993-2000 MAG 1
38073 724 1993-2000 MAG 1
38078 824 2000-2002 MAG 1
38080 824 1990-1993 90 wt.
38083 824XL 1997-1999 90 wt.
38084 824XL 1997-1999 90 wt.
38085 824 1990 90 wt.
38086 824XL 2000-2002 90 wt.
Model numbers 28XXX are Lawn-Boy.
Model numbers 38XXX are Toro.
Engines: All of the models in the table were
manufactured with engines from the Tecumseh
Products Company. Refer to their service manual for
engine information.
Note:
Maximum RPM for all models is 3300 ± 150 RPM.
* This manual may be specified for products produced
before 1990 or after 2002 in addition to the models
above.
Two Stage Snowthrower Drive Systems Manual Introduction - 1
THIS PAGE INTENTIONALLY LEFT BLANK
Introduction - 2 Two Stage Snowthrower Drive Systems Manual
Chapter 1 — Auger Gearbox Service
1.Check/fill pl
GENERAL INFORMATION
The manual takes a systems approach. There are two
versions of the auger gearbox and three versions of the
traction drive system used among the various 2-stage
models.
For information on the auger drive or linkage
adjustments see the section titled Belts, Controls and
Linkages.
The lubricant level in a gearbox should be checked
prior to each season.
AUGER GEARBOX LUBRICANT
Two different lubricants are used in the various models.
They are NOT interchangeable. Use the lubricant
specified in the model chart.
90 wt. indicates a 90-weight gear oil. A multi weight
such as 85-120 is acceptable as long as it
encompasses the 90 weight. The oil used must also
have an extreme pressure (EP) rating of GL5 or higher.
Fill until it runs out of the fill check plug (Figure 1).
Figure 2
Should you see an oil leak, disassembly is required.
Lubriplate MAG 1 is thick so it will normally not leak out
even with a failed seal. The bearings used in all
applications are oil impregnated, so they do not require
regular maintenance. Internal gearbox repair will
require removal from the chassis.
MVC-458
GEARBOX REMOVAL
There are two methods commonly used to remove the
auger gearbox:
• The primary method is to remove the auger
assembly without separating the traction assembly
from the auger housing.
• The secondary method is to separate the auger
and traction assemblies. Separating the auger and
traction assemblies improves access if the auger is
difficult to remove.
1
Figure 1
ug
MAG 1 is a special low temperature grease made by
Lubriplate™. Use 1/3 tube of MAG 1 per gearbox.
Obtain from your area Lubriplate Distributor or from
your Toro parts supplier (Toro Part Number 505-101)
(Figure 2).
Two Stage Snowthrower Drive Systems Manual 1 - 1
DSC-0168
Auger Gearbox Service
Primary Method — Minimum Disassembly
The following steps apply to all models.
1. Remove the belt cover. Loosen the belt guide on
the engine crankshaft and remove the auger belt.
DO NOT bend the belt guide out of the way
(Figure 3).
Figure 3
MVC-526
3. In the center of each side plate are either two or
four cap screws (depending on the model). These
go into the bearing that supports each side of the
auger. Remove the cap screws (Figure 5).
Figure 5
4. Many models have side plates that are attached
by cap screws and lock nuts. Removing or at least
loosening one side plate will ease removal of the
auger assembly (Figure 6).
MVC-529/MVC-531
2. On the forward side of the auger pulley is 1 or 2
set screws, depending on the model, which must
be loosened. Use the square end of a 3/8” socket
extention. Note: The pulley is keyed to the shaft
and will be removed later (Figure 4).
Figure 4
MVC-527/MVC-536
Figure 6
MVC-530
1 - 2 Two Stage Snowthrower Drive Systems Manual
5. Loosen the rear and remove the front capscrew
1.L
2.R
1.Pull
2.A
1.Sid
3.S
securing the idler arm to the chassis.
1
Auger Gearbox Service
1
2
2
M-3331
oosen
Figure 7
emove
6. Begin to pull the auger assembly out to the front.
Note: The auger pulley and key have not yet been
removed. However, if you pull the auger slightly
forward, it will make it easier to slide the pulley off
the end of the impeller shaft. Once the pulley is
out of the way, remove the key (Figure 8 and
Figure 9).
ey
Figure 9
uger housing
2768-023
7. Model 38065 and 38080 only — Disconnect the
(2) scraper springs from either the slot in the side
plates or from the scraper. Also there are two
bolts, sleeves, and bumpers that limit the scraper
travel, one through the side plate on each side,
into the scraper. Both must be removed
(Figure 10).
4
1
3
2
e plate
2. Bumper
Figure 10
craper
4. Spring mount
2768-029
Figure 8
2768-022
8. The auger assembly can now be pulled
completely from the auger housing.
Two Stage Snowthrower Drive Systems Manual 1 - 3
Auger Gearbox Service
1.A
9. The auger flighting is attached to the auger shaft
with one bolt and locknut. Reach through the
holes in the drum augers to access. On models
without drum augers, the bolts are easily
accessible (Figure 11).
1
Figure 11
ccess hole
The auger assembly can be separated from the
traction assembly. However, it is generally not
necessary to work on the auger. Should the auger
pulley be rusted on the shaft, it might be easier to
remove the pulley with the traction assembly out of the
way.
MVC-533
2. Drain the fuel and oil and stand the machine up on
its auger. Support or brace to prevent tipping
(Figure 13).
Figure 13
3. Disconnect the chute crank rod at the auger
(Figure 14).
2768-027
Secondary Method — Traction and Auger
Housings Separated: Toro Models 38065
and 38080
1. Remove the belt cover. Loosen the belt guide and
remove the auger belt (Figure 12).
Figure 12
2768-021
Figure 14
4. Remove the lower cover from the traction
assembly.
MVC-534
1 - 4 Two Stage Snowthrower Drive Systems Manual
5. There are 4 locknuts in the forward part of the
1.Locknut
housing. These are on studs from the auger.
Remove the locknuts. The traction assembly will
now lift straight up off the auger assembly
(Figure 15).
Auger Gearbox Service
1
Figure 15
6. Now perform steps 1 - 9 under “GEARBOX
REMOVAL” on page 1 - 1.
2768-025
Secondary Method — Traction and Auger
Housings Separated: All Other Models
1. Remove the belt cover, loosen the belt guide, and
remove the traction belt (Figure 16).
Figure 17
3. Place a block of wood under BOTH the auger and
traction assembly to support them when the
connecting cap screws are removed. Remove the
6 cap screws, 3 on each side, that connect the
auger to the traction assembly and separate the
two (Figure 18).
Figure 18
MVC-534
MVC-535
4. Now perform steps 1 - 8 under “GEARBOX
REMOVAL” on page 1 - 1.
Figure 16
2. Disconnect the chute crank rod at the auger
(Figure 17).
Two Stage Snowthrower Drive Systems Manual 1 - 5
MVC-526
Auger Gearbox Service
1.B
1.U
INSTALLATION
Installation of the auger assembly into the auger
housing can be done whether the auger housing and
traction assemblies are connected or not. There is no
significant time savings to either sequence.
1. All self-aligning bearings (sometimes called the
flange bearings) MUST be installed loosely. All
models have one next to the auger drive pulley
and some use 2 more supporting the auger output
shafts. In all cases, these bearings must be a little
loose to assure the bearing can align itself with the
shaft before it is secured (Figure 19).
1
Figure 19
earing and flange
MVC-540
2. Make sure all the parts are installed on the auger
assembly. All spacers, thrust washers, and auger
bearings need to be hanging on the shafts.
(Including the scraper for models 38065 and
38080.)
3. Slide the assembly into the housing, directing the
input shaft into the rear bearing.
Figure 20
MVC-542
6. All models — Rotate the impeller back and forth.
One direction will push the impeller shaft to the
rear. Rotate it in that direction to force the shaft as
far to the rear as possible (Figure 21).
1
Figure 21
se pulley to remove gap
2773-012
7. Secure the 4 cap screws on the self-aligning
bearing. Install the thrust washer and key.
4. Start the cap screws from the side plates into the
bearings that support the auger output shafts.
Some models have 2 cap screws into a fixed
bearing; others have 4 cap screws into a selfaligning bearing.
8. Holding the shaft to the rear, install the pulley on
the shaft. Push the pulley forward, hold and
secure. The pulley is used to limit the front to back
movement of the impeller (Figure 21).
5. Models using four bolt bearings ONLY - Strike the
side plate and bearing area with a rubber mallet
three or four times, then secure the bearings. The
jolt aligns the bearings (Figure 20).
1 - 6 Two Stage Snowthrower Drive Systems Manual
AUGER GEARBOX DISASSEMBLY /
SERVICE
Once the auger gearbox assembly is removed from the
housing the repair process is the same for all models.
The only variables are what type of lubricant is used
(see the chart on Introduction page 1), whether the
impeller is removable from the shaft (on some models
the impeller is welded to the shaft) and how the
gearbox case halves are sealed.
Auger gearbox disassembly:
1. With the gearbox assembly removed from the
housing the first step is to slide the bearings off
the output shafts. (Model 38080 & 38065, also
slide the scraper off).
2. All models use a cap screw, lock nut, and spacer
to connect the auger to the shaft (Figure 22).
Remove the cap screw, nut and spacer and slide
both augers from the shaft.
Auger Gearbox Service
Figure 23
4. Remove the 8 or 9 self-tapping screws that hold
the gearbox halves together. Note: On a model
that uses 90 weight gear oil, you may want to
place the gearbox over a pan when the screws are
removed. Then separate the gearbox halves
(Figure 24).
2773-055/2773-066
Figure 22
3. Some models have the impeller welded to the
impeller shaft. Others use a combination of bolts,
set screws, and a key. If you see bolt(s) through
the impeller hub, remove them. Some may have
set screws, which only require being loosened.
The models with the setscrews also have a key
between the hub and shaft. Once the visible
retainers are removed, slide the impeller away
from the gearbox, the key will be uncovered.
Remove the key (Figure 23).
MVC-533
Figure 24
5. The impeller shaft can now be removed
(Figure 25).
Figure 25
2773-060
2773-061
Two Stage Snowthrower Drive Systems Manual 1 - 7
Auger Gearbox Service
1
LH
ASM
5:1.A
ASM, RH
12.Bushi
t
6. Clean the output shaft and slide the case halves
off. Remove the seals from the case halves and
discard the seals.
7. Clean and inspect the bushings in the case
halves. If they are damaged or worn, press them
out of the case halves at this time.
8. Slide the worm gear off the shaft. Depending on
the model, there will be one or two woodruff keys
between the gear and the shaft. Refer to the parts
manual for your specific machine.
9. Returning to the impeller shaft, the 824XL models
have a worm that is actually rolled into the impeller
shaft. All other models use an individually
replaceable gear. Remove all the bushings,
bearings and spacers from the impeller shaft
(Figure 26).
10. Now inspect the worm and worm gear. If either
gear is damaged, replace them both. When gears
run together, they develop wear patterns unique to
the two of them. Replacing only one gear will
result in early failure.
Figure 26
.
1:1. Auger gearcase ASM, LH
1:1:1. Bushing
1:1:2. Seal-oil
2. Bearing-thrust
4. Gear-helical
5. RH auger gearcase ASM
auger gearcase
uger gearcase
5:1:1. Bushing
5:1:2. Seal-oil
6. Shaft-auger, 24”
9. Key-woodruff
10. Impeller shaft
11. Seal-oil
13. Bushing-worm
14. Washer-thrust
15. Bearing-thrust
16. Ring-retaining, Ext.
17. Screw-HWH
18. Plug-SQH pipe
ng-inpu
1577-028
1 - 8 Two Stage Snowthrower Drive Systems Manual
Auger Gearbox Service
1.Wi
1.Flush
Failure Analysis
There are some misconceptions regarding these
gearboxes that result in incorrectly identifying the
causes of failure.
The square cut ring on the impeller shaft is not really a
seal. It is a wiper ring that has a tendency to pull down
to the shaft when the shaft begins to turn. The bushing
next to the ring really deflects most of the oil that is
thrown towards that area. The loose fit provides a vent
for the case (Figure 27). Occasionally a drop or two of
oil will get between the bushing and ring. When the
auger drive is disengaged, the ring will relax and that
oil might drip into the auger housing. At this rate, the
machine can be used for several years without any
significant oil loss. The yearly oil level check is more
than adequate to compensate for this.
1
Figure 27
per ring
If there is a significant amount of oil coming out of this
area, it would indicate that the gearbox has been at a
severe operating angle or the bushing is badly worn.
2773-061
GEARBOX ASSEMBLY
1. Use a wire brush or sandpaper to clean the auger
shaft. A clean, smooth shaft will help avoid
damage when installing new bushings and seals.
Clean the old gasket material from the case
mating surfaces (Figure 28).
Figure 28
2. If new bushings are to be installed in the gear
case halves, now is the time. Apply a thin coat of
Loctite™ Blue #242 or equivalent to the OUTSIDE
of the bushing and press in flush with the INSIDE
of the case (Figure 29). This will allow space for
the seal on the outside. Wipe up any Loctite™ that
is visible. The Loctite™ must not get into the gear
or seal area.
2773-067
Oil on the bottom of the gearbox can result from a leak
at any part of the case. As there is no internal pressure,
any leaking oil runs down the side of the case and
collects on the bottom until there is enough to drip off.
1
The source of the oil leak oil can be difficult to see.
Sprinkling some powder on the outside of the gearbox
will usually show the oil trail. The type of powder used
is not important. Just something that will stick to the oil.
When you open a gearbox that has had the gears fail,
the remaining oil will likely appear as a small puddle of
very thick grease in the bottom. Worm gears normally
create a large amount of friction due to the sliding
Figure 29
MVC-710
action. When something goes wrong, not enough oil,
poor quality oil, a problem with the gears, or just a gear
or bearing wearing out, the friction becomes
abnormally high. The remaining oil is cooked down to a
very thick residue. This can be the result of failures, not
the cause.
Two Stage Snowthrower Drive Systems Manual 1 - 9
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