Toro 38600, 38601, 38602, 38603 Service Manual

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 & 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 CABLE 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.

TABLE OF CONTENTS

GENERAL INFORMATION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Identification and Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2

General Safety Instructions (Reproduced from Operator’s Manual) . . . . . . . . . . . . . . . .1 - 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3

Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3

Maintenance and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4

Toro Snowthrower Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4

Safety and Instruction Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 5

Fuel and Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 6

Mixing Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 6

Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7

Off-Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7

Emptying the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7

Preparing the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 8

Preparing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 8

Preparing the Snowthrower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 8

CONTROLS LOCATION & OPERATION

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

Starting the Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

Stopping the Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

Starting the Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

Stopping the Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

Snow Commander Service Manual i

TABLE OF CONTENTS

CONTROLS LOCATION & OPERATION (cont’d)

Adjusting the Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Chute Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Chute Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Upper Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Snow Commander Chute Handle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Chute Crank System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4

Gear Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

Gear Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

ENGINE REMOVAL / INSTALLATION

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Recoil Starter Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6

DRIVE SYSTEM

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

Drive System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

Drive System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4

Rotor Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

Rotor Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

ELECTRIC START SYSTEM

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

Switch Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

Plug Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

Motor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

Starter Pinion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

CHASSIS

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

Tilt Mechanism/Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

Pivot Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2

ii Snow Commander Service Manual

TABLE OF CONTENTS

MAINTENANCE

Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Checking the Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Adjusting the Rotor Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2

Adjusting the Pivot Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3

Checking the Pivot Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3

Adjusting the Pivot Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Replacing the Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Removing the Old Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Installing the New Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5

Replacing the Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Replacing the Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Replacing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Checking the Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 9

Specifications (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 11

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 11

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 11

Snow Commander Service Manual iii

THIS PAGE INTENTIONALLY LEFT BLANK

iv Snow Commander Service Manual

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

GENERAL INFORMATION

The Toro Snow Commanders are powered by a high

output version of the R tek engine (Figure 1). The main

difference between the standard R tek and the version

used on the Snow Commander is in the piston and

cylinder.

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 the 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 2 DSC-0037

(A) Ports

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

Snow Commander Service Manual 1 - 1

DSC-0138

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

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 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.

(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.

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.

Important

1 - 2 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.

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 snowthrower 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 B71.3–1995 standard and the ISO 8437:1989 standard. Information or terminology specific to Toro snowthrowers is enclosed in parenthesis.

• 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.

– Replace the fuel tank cap securely and wipe up

any spilled fuel.

• Use only 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.

• Let the 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

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

• 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.

• 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.

• Do not attempt to 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.

• If the 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 inspections.

• When cleaning, repairing, or inspecting, make certain that the rotor blades and all moving parts have stopped.

Snow Commander Service Manual 1 - 3

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 dropoffs 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

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.

• If a shield, safety device, or decal is damaged, illegible, or lost, repair or replace it before beginning operation.

• 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 cool 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.

• 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 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 not 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.

1 - 4 Snow Commander Service Manual

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

GENERAL INFORMATION

61-4790 (Electric-start model only)

104-0863 (Electric-start model only)

104-0874

104-4106 (Recoil-start model only)

104-4125

104-4135

104-2767

104-2775

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.

Important

containing methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas. Using these fuels can damage the fuel system.

Important

SAE 30 or 10W30), a two-cycle oil that is not NMMA TCW-certified, or a fuel mixed at the wrong gasoline-tooil 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.

Do not use methanol, gasoline

Do not use an automotive oil (such as

DANGER

When fueling under certain circumstances, a static charge can develop igniting the gasoline. A fire or explosion from gasoline can burn you and other and damage property.

• 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.

• If 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

gasoline-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.

• Fill the fuel tank outdoors, in an open area, and when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel 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.

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Important

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.

Do not use fuel additives except a fuel

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 the Fuel Tank

Important

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.

Do not overfill the fuel tank. The

2. Remove the key from the switch.

DANGER

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.

• 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

Important

position and on its wheels. Storing the snowthrower on its front housing may cause hard starting.

Store the snowthrower in its operating

WARNING

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.

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Gasoline 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. Add a 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. Run the 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.

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.

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, 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.

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CONTROLS LOCATION & 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 a recoil 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.

CAUTION

If you leave the snowthrower plugged into a power outlet, someone can inadvertently start the snowthrower and injure people or damage property.

Unplug the power cord whenever you are not starting the snowthrower.

Figure 5

(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

m-5067

Starting the Engine

1. Turn 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.

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.

Important

can overheat and damage the starter.

5. With the engine running, move the choke lever to the left slowly.

Running the electric starter extensively

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.

Stopping the Engine

Turn the key to the Off position and wait for all moving parts to stop before leaving the operating position.

Note: Take off your glove when you push in the primer so that air cannot escape from the primer hole.

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