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TORO TWO ST E SNOWTHROWER DRIVE SYST S N L/LAWN-BOY AG EM MA UA
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 TWO ST/LAWN-BOY AGE SNOWTHROWER DRIVE SYST S EM 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
Service Manual
Drive Systems
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.
Two Stage Snowthrower Drive Systems Manual
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 - 1
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 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.
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.
Introduction - 2 Two Stage Snowthrower Drive Systems Manual
THIS PAGE INTENTIONALLY LEFT BLANK
Auger Gearbox Service
1 - 2 Two Stage Snowthrower Drive Systems Manual
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
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
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
MVC-529/MVC-531
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).
Figure 6
MVC-530
Auger Gearbox Service
1 - 4 Two Stage Snowthrower Drive Systems Manual
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).
Figure 11
MVC-533
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.
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
2. Drain the fuel and oil and stand the machine up on
its auger. Support or brace to prevent tipping
(Figure 13).
Figure 13
2768-027
3. Disconnect the chute crank rod at the auger
(Figure 14).
Figure 14
MVC-534
4. Remove the lower cover from the traction
assembly.
1
1
.
A
ccess
h
o
l
e
Two Stage Snowthrower Drive Systems Manual 1 - 5
Auger Gearbox Service
5. There are 4 locknuts in the forward part of the
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).
Figure 15
2768-025
6. Now perform steps 1 - 9 under “GEARBOX
REMOVAL” on page 1 - 1.
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 16
MVC-526
2. Disconnect the chute crank rod at the auger
(Figure 17).
Figure 17
MVC-534
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-535
4. Now perform steps 1 - 8 under “GEARBOX
REMOVAL” on page 1 - 1.
1
1
.
L
oc
k
nu
t
Auger Gearbox Service
1 - 6 Two Stage Snowthrower Drive Systems Manual
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).
Figure 19
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.
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 self-
aligning bearing.
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).
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).
Figure 21
2773-012
7. Secure the 4 cap screws on the self-aligning
bearing. Install the thrust washer and key.
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).
1
1
.
B
ear
i
ng an
d
fl
ange
1
1
.
U
se pu
ll
ey
t
o remove gap
Two Stage Snowthrower Drive Systems Manual 1 - 7
Auger Gearbox Service
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.
Figure 22
MVC-533
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).
Figure 23
2773-055/2773-066
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).
Figure 24
2773-060
5. The impeller shaft can now be removed
(Figure 25).
Figure 25
2773-061
Auger Gearbox Service
1 - 8 Two Stage Snowthrower Drive Systems Manual
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
1577-028
1
.
LH
auger gearcase
ASM
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
5
:
1
.
A
uger gearcase
ASM
,
RH
5:1:1. Bushing
5:1:2. Seal-oil
6. Shaft-auger, 24”
9. Key-woodruff
10. Impeller shaft
11. Seal-oil
12
.
B
us
hi
ng-
i
npu
t
13. Bushing-worm
14. Washer-thrust
15. Bearing-thrust
16. Ring-retaining, Ext.
17. Screw-HWH
18. Plug-SQH pipe
Two Stage Snowthrower Drive Systems Manual 1 - 9
Auger Gearbox Service
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.
Figure 27
2773-061
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.
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.
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
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.
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
2773-067
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.
Figure 29
MVC-710
1
1
.
Wi
per r
i
ng
1
1
.
Fl
us
h
Auger Gearbox Service
1 - 10 Two Stage Snowthrower Drive Systems Manual
3. Insert the keys into the shaft and slide the large
worm gear into place. Note: There is a large letter
“R” and an arrow on one side of the gear. This
gear MUST be installed such that the R and the
arrow are on the right hand side and the arrow is
pointing forward (Figure 30). This is a two piece
gear that is bonded together. If it is installed
backwards, the forces try to separate the gear and
can result in failure.
Figure 30
30
4. Install the thrust washers and slide the case
halves on. Note the direction to keep the markings
on the gear on the right side.
5. There are two versions of the impeller shaft. One
has the worm separate and the other has the
worm as part of the impeller shaft.
6. On models with worm separate from the
impeller shaft — Assemble the parts on the
impeller shaft. From the inside out, the order is as
follows: seal, bushing, thrust washer, thrust
bearing, thrust washer, key, worm, thrust washer,
retaining ring (sharp edge towards the front) and
bushing (Figure 31).
Figure 31
37-6962
On models with worm integral with the
impeller shaft — This version is assembled
starting on the end opposite the worm. Start with
the snap ring (sharp edge towards the rear), thrust
washer, thrust bearing, thrust washer, bushing
and seal. There is also a bushing on the worm end
of the shaft (Figure 32).
Figure 32
38086-01
1
1
.
L
e
tt
er
“R”
an
d
arrow
1
.
B
us
hi
ng
2. Ring-snap
3. Washer-thrust
4. Gear
5. Washer-thrust
6. Bearing-thrust
7
.
W
as
h
er-
th
rus
t
8. Bushing-input
9. Ring-quad
10. Key-woodruff
11. Shaft-impeller
1
.
I
mpe
ll
er s
h
a
ft
2. Seal-oil
3. Bushing-input
4
.
B
us
hi
ng-
th
rus
t
5. Bearing-thrust
6. Ring-snap
Two Stage Snowthrower Drive Systems Manual 1 - 11
Auger Gearbox Service
7. Apply a VERY light coat of Loctite™ Blue #242 or
quivalent to the outer diameter of the bearing.
Loctite™ should not squeeze out when everything
is tightened (Figure 33).
Figure 33
2773-059
8. Some models use a gasket and some do not. For
those with a gasket use a small amount of grease
to stick the open ends of the gasket in place
during assembly. Otherwise this gasket is
intended to seal to a clean dry surface.
9. The 824XL seals in a different manner. The
mating surfaces must be clean and dry. Then a
thin coat of Hylomar (Toro PN 505-129) is applied
to BOTH halves. Allow it to cure until it is dull and
tacky, 15 minutes or so, then assemble.
10. All models. Apply a light coat of oil or anti-seize to
the gear case screws. Tighten them in an X
pattern to 120 in/lbs. (15kg/m) (Figure 34).
Note: Some models have 8 gear case screws;
others have 9.
Figure 34
MVC-709
11. Fill the gearbox with lubricant. See the chart on
Introduction page 1 for the proper lubricant for
your model.
1
2
7
4
8
6
3
5
9
1 - 12 Two Stage Snowthrower Drive Systems Manual
THIS PAGE INTENTIONALLY LEFT BLANK
Two Stage Snowthrower Drive Systems Manual 2 - 1
Chapter 2 — Belts, Controls and Linkages
INTRODUCTION
All models use two belts. One to drive the auger and a
second to drive the traction system. The auger drive
uses a combination idler and brake to engage the belt
for driving and to disengage the belt and apply the
brake for stopping.
The traction drive uses a constantly tensioned belt. The
clutching and shifting are done through the drive plate
and friction disc.
REPLACING THE AUGER/IMPELLER
DRIVE BELT
When the auger/impeller drive belt becomes worn,
stretched, oil-soaked, or otherwise damaged, replace
the belt.
1. Turn the engine off and disengage all controls.
2. Pull the wire off of the spark plug and ensure the
wire does not contact the spark plug.
3. Remove the two screws that hold the belt cover in
place and set the cover aside (Figure 35).
Figure 35
M-2671
4. Remove the belt guide; do not bend (Figure 36).
Figure 36
M-3331
5. Slip the auger belt off the pulleys. Note: On some
models (typically the 824 and the 824XL) the
auger belt brake will not back off far enough to
remove the belt. Remove the front screws and
loosen the rear screw that fastens the brake arm
assembly to the chassis (Figure 37).
Figure 37
M-2678
6. Slip the new belt over the pulleys. Install any parts
that were removed.
1
.
U
pper
b
e
lt
cover
2
.
S
crew
(3)
1
.
E
ng
i
ne cran
k
s
h
a
ft
screw, lock washer
and washer
2. Engine pulley sheave
3. Auger/impeller drive
belt
4. Large auger/impeller
pulley
5
.
Idl
er pu
ll
ey
6. Center engine pulley
7. Belt guide
8. Traction belt
9. Traction pulley
10. Traction idler pulley
11. Screw, washer, lock
washer
1
.
R
ear screw
2. Front screw
3
.
Idl
er pu
ll
ey spr
i
ng
Belts, Controls and Linkages
2 - 2 Two Stage Snowthrower Drive Systems Manual
7. The belt guide must be checked and adjusted.
With the engine off, engage both the auger and
traction controls. Adjust the belt guide so that
there is approximately 1/8 inch (.3 cm) clearance
between the belt guide and the belt.
Check auger belt adjustment. See “CONTROL AND
LINKAGE ADJUSTMENT” on page 2 - 7 for the linkage
adjustment procedures.
REPLACING THE TRACTION BELT
The models covered in this manual use three different
methods of tensioning the traction belt. As the
tensioning method affects the belt replacement
process, they are separated by model number.
Replacing the Traction Belt — Toro
Models 38065, 38080, 38085
When traction drive belt (Figure 38) becomes worn,
stretched, oil-soaked, or otherwise damaged, replace
the belt.
Figure 38
13299-32
1. Pull high tension wire off spark plug and make
sure it does not contact the plug accidentally.
2. Remove two thread forming screws holding belt
cover in place, and set belt guard aside.
3. Move auger drive control to DISENGAGE and
wheel drive control to N, neutral. Next, remove
auger drive belt from engine pulley and large
auger/impeller pulley.
4. Loosen two capscrews (securing traction idler arm
to front of engine. Next, remove traction drive belt
from engine pulley and large traction pulley.
5. Install new belt around large traction pulley. Next,
loop belt over engine pulley, making sure that belt
is on inside of traction idler pulley and wire belt
guide.
6. Reinstall auger belt around large auger/impeller
pulley. Next, loop belt over engine pulley, making
sure that belt is on inside of auger/impeller, idler
pulley and wire belt retainer. Slide idler arm and
pulley assembly against belt to remove belt slack
and tighten capscrews.
Note: Tension belt only enough to remove slack.
Do not over-tension.
7. With the engine off, engage the auger lever.
Adjust the belt guide so it is within 1/8 inch (.3 cm)
of the belt.
8. Install belt cover with two thread forming screws.
9. Install high tension lead and test operate unit to
check traction. If little or no traction is evident,
proceed to step 10. If traction operation is
satisfactory, proceed to operate machine.
10. Remove high tension lead from spark plug and
remove belt guard. Loosen two capscrews
securing traction idler arm and slide idler arm and
pulley assembly further against belt. Move
assembly a minimal amount to assure belt is not
over tensioned.
1
.
T
rac
ti
on
d
r
i
ve
b
e
lt
2. Auger/impeller drive
belt
3. Auger/impeller pulley
and idler
4
.
C
apscrews,
t
rac
ti
on
idler
5. Traction idler pulley
6. Traction pulley
7. Belt guide
Belts, Controls and Linkages
2 - 4 Two Stage Snowthrower Drive Systems Manual
11. Install a new belt around the large traction pulley.
12. Loop the belt over the engine pulley, ensuring that
the belt is on the inside of the belt guide
(Figure 40).
13. Tip the snowthrower forward and block it so that it
cannot fall.
14. Hook the spring into the notch in the bottom edge
of the side plate (Figure 42).
15. Replace the bottom cover with the four screws.
16. Set the snowthrower upright.
17. Install the auger/impeller drive belt around the
large auger/impeller pulley and engine pulley,
ensuring that the belt is on the inside of the idler
pulley and belt guide (Figure 40).
18. Adjust the belt guide so that there is 1/8 in. (0.3
cm) of clearance between the belt and the guide,
and secure the belt guide.
19. Install the belt cover.
Replacing the Traction Belt —
Lawn-Boy Model 28232 and Toro Models
38053, 38066, 38078, 38083, 38084, 38086
When traction belt (Figure 43) becomes worn, oil–
soaked or otherwise damaged, belt replacement is
required.
Figure 43
M-3331
1. Pull wire off spark plug and make sure it does not
contact the plug accidentally.
2. Remove (3) screws holding belt cover in place
and set cover aside (Figure 44).
Figure 44
M-2671
1
.
E
ng
i
ne cran
k
s
h
a
ft
screw, lock washer
and washer
2. Engine pulley sheave
3. Auger/impeller drive
belt
4. Large auger/impeller
pulley
5
.
Idl
er pu
ll
ey
6. Center engine pulley
7. Belt guide
8. Traction belt
9. Traction pulley
10. Traction idler pulley
11. Screw, washer, lock
washer
1
.
U
pper
b
e
lt
cover
2
.
S
crew
(3)
Belts, Controls and Linkages
2 - 6 Two Stage Snowthrower Drive Systems Manual
15. Reinstall (2) screws that secure auger brake arm
assembly. Make sure tabs fit into holes in left side
of machine (Figure 48).
Figure 48
M-2678
16. While someone squeezes the auger/impeller
control lever (Figure 49) against the handgrip,
reinstall belt guide using (2) screws, (2) washers,
and (2) lock washers removed previously. Check
and readjust belt guide, making sure it does not
contact any part of the engine pulley.
Figure 49
M-4035
17. Check and adjust auger drive linkage. Refer to
steps 5–7 of "Auger/Impeller Drive Control
Linkage — All Other Models" on page 2 - 8.
18. Reinstall idler pulley spring.
19. Reinstall belt cover with (3) screws.
20. Make sure that auger and impeller are not rotating
when auger/impeller control lever is disengaged.
While standing in the operator position behind the
handles, look around to the side of the auger
housing. If the auger and impeller are rotating, a
large screw head on the side of the auger housing
will be rotating (Figure 50). If the auger and
impeller are rotating when the engine is
running and the auger/impeller control lever is
not engaged, immediately stop the unit. Refer
to "Adjusting Auger/Impeller Drive Belt" on
page 2 - 7.
IMPORTANT: Do not operate unit if auger and
impeller rotate when auger/impeller control lever
is not engaged.
Figure 50
M-2680
1
.
T
a
b
s
i
n
h
o
l
es
1
.
A
uger
/i
mpe
ll
er
control lever
2. Traction control lever
3
.
S
pee
d
se
l
ec
t
or
4. Discharge chute
control
1
.
L
arge screw
h
ea
d
Two Stage Snowthrower Drive Systems Manual 2 - 7
Belts, Controls and Linkages
CONTROL AND LINKAGE ADJUSTMENT
Note: Before making any control adjustments, verify
that the handles are secured to the traction frame. If
the handles move at all, the linkages will not maintain
adjustment.
Auger Control Adjustment — Toro Models
38065, 38080, 38085
Install Auger Drive Control Rod
1. Move auger drive control backward to
DISENGAGE and hold it in that position.
2. Rotate clevis at end of auger drive control rod until
holes in clevis line up with hole in bent rod
(Figure 51). Next, secure clevis and bent rod
together with clevis pin and cotter pin.
Figure 51
13299-4
3. Tighten the jam nut firmly against top of clevis.
Note: Move auger drive control forward to
ENGAGE. If excessive force is required to move
the control, adjust the auger drive control: refer to
Adjusting Auger/Impeller Drive Belt (below).
Adjusting Auger/Impeller Drive Belt
If auger slips, which means the auger drive belt is
slipping, an adjustment is required. When a new auger/
impeller drive belt is installed, an adjustment may also
be required.
1. Loosen jam nut from clevis at bottom of auger
drive control rod (Figure 52). Next, remove cotter
pin and clevis pin holding clevis to bent rod.
Figure 52
13299-33
2. Rotate clevis counterclockwise — out — to
increase belt tension. By contrast, rotate clevis
clockwise — in — to decrease belt tension.
3. Connect clevis to bent rod with clevis pin and
cotter pin. Next, tighten jam nut against top of
clevis.
4. Check tension of belt by operating the auger. If
belt still slips, or if the auger does not stop when
disengaged, adjust clevis again.
IMPORTANT: Do not adjust belt too tight because
the belt will wear out quickly or possibly cause
damage to the snowthrower.
1
.
Cl
ev
i
s
2. Clevis pin and
cotter pin
3
.
B
en
t
ro
d
4. Jam nut
1
.
J
am nu
t
2. Clevis
3
.
Cl
ev
i
s p
i
n an
d
cotter pin
4. Bent rod
Belts, Controls and Linkages
2 - 8 Two Stage Snowthrower Drive Systems Manual
Auger/Impeller Drive Control Linkage —
All Other Models
There are two adjustment mechanisms used. One has
a clevis with a jam nut. The other has a rod going
through a loop with a flange nut on either side.
1. Thread a hex flange nut (flange side down) onto
upper control rod located on right handle
(Figure 53).
Figure 53
654
2. Install lower link through outer hole in lower
control rod.
3. Insert upper control rod through loop in lower link
control rod.
4. Thread a flange lock nut (flange side up) onto
bottom of upper control rod below loop in lower
link.
5. Check the distance between the top of the
handgrip and the bottom of the auger/impeller
control lever (Figure 54). This is a preliminary
setting only.
Figure 54
665
6. Remove the belt cover (refer to "REPLACING
THE AUGER/IMPELLER DRIVE BELT",
page 2 - 1, steps 1-2). Compress the auger/
impeller control lever and check that the slack is
removed from the auger drive belt when the lever
is 1-2 inches (2.5-5 cm) above the handgrip
(Figure 54).
7. Adjust the clevis or two flange nuts to obtain this
dimension, then tighten the two nuts or jam nut
securely (Figure 55).
Figure 55
649
8. The auger must stop when the handgrip is
released. If it does not stop, adjust the clevis or
flange units on the auger rod.
1
.
T
rac
ti
on ro
d
2. Loop
3. Lower traction rod
4
.
Fl
ange nu
t
5. Locking flange nut
1
.
T
rac
ti
on con
t
ro
l
lever
2. Handgrip
3
.
4
3/8
i
n.
(11
cm
)
4. 1 to 2 in. (2.5 to
5 cm)
1
.
J
am nu
t
2. Clevis
3. Upper control rod
4
.
L
ower con
t
ro
l
ro
d
5. Clevis pin
6. Cotter pin
Produktspecifikationer
| Varumärke: | Toro |
| Kategori: | SLR kamera |
| Modell: | 38056 |
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