Toro 38079, 38087, 38500, 38505, 38510 Service Manual

POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 1 of 5

ABOUT THIS MANUAL

SAFETY INSTRUCTIONS

FOR YOUR SAFETY...

IDENTIFICATION MODEL AND SERIAL NUMBERS

SPECIFICATIONS MODELS 38500 AND 38505 MITSUBISHI POWERED 624 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 624 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 624 - TORQUE SPECIFICATIONS

SPECIFICATIONS MODELS 38510 AND 38513 TECUMSEH POWERED 624 - ENGINE SP ECIFIC ATIONS* TECUMSEH POWERED 624 - PRODUCT SPECIFICATIONS TORQUE SPECIFICATIONS

SPECIFICATIONS MODELS 38520 AND 38525 MITSUBISHI POWERED 824 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 824 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 824 - TORQUE SPECIFICATIONS

SPECIFICATIONS MODELS 38540 AND 38543 TECUMSEH POWERED 824 - ENGINE SP ECIFIC ATIONS* TECUMSEH POWERED 824 - PRODUCT SPECIFICATIONS TECUMSEH POWERED 824 - TORQUE SPECIFICATIONS

SPECIFICATIONS MODEL 38545 MITSUBISHI POWERED 828 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 828 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 828 - TORQUE SPECIFICATIONS

SPECIFICATIONS MODEL 38570 BRIGGS AND STRATTON POWERED 828 - ENGINE SPECIFICATIONS* BRIGGS AND STRATTON POWERED 828 - PRODUCT SPECIFICATIONS BRIGGS AND STRATTON POWERED 828 - TORQUE SPECIFICATIONS

SPECIFICATIONS MODEL 38573 TECUMSEH POWERED 828 - ENGINE SP ECIFIC ATIONS* TECUMSEH POWERED 828 - PRODUCT SPECIFICATIONS TECUMSEH POWERED 828 - TORQUE SPECIFICATIONS

POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 2 of 5

SPECIFICATIONS MODELS 38565 AND 38580 BRIGGS AND STRATTON POWERED 1132 - ENGINE SPECIFICATIONS* BRIGGS AND STRATTON POWERED 1132 - PRODUCT SPECIFICATIONS TORQUE SPECIFICATIONS

SPECIAL TOOLS AND OTHER NECESSITIES

TROUBLESHOOTING UNIT DOES NOT PROPEL FORWARD UNIT WILL NOT PROPEL BACKWARD NEUTRAL NOT IN CORRECT LOCATION SHIFT LEVER WILL NOT LOCK IN POWER SHIFT OR REVERSE OPERATOR CAN SHIFT BETWEEN FORWARD AND REVERSE WHILE TRACTION LEVER IS WHEELS WILL NOT SWING WHEN POWER SHIFTING MACHINE DOES NOT PROPEL IN A STRAIGHT LINE ENGINE KILLS WHEN AUGER OR TRACTION ARE ENGAGED POOR SNOWTHROW ING PERFORMANC E IMPELLER OR AUGER DOES NOT TURN TRACTION OR IMPELLER DOES NOT DISENGAGE CHUTE PLUGS WITH SNOW SCRAPER CATCHES ON UNEVEN PAVEMENT SNOWTHROWER LEAVES SNOW BEHIND RAPID SKID AND SCRAPER W EAR FRONT END RISES

MAINTENANCE

MAINTENANCE - DRAINING GASOLINE MAINTENANCE - CHAIN LUBRICATION MAINTENANCE - CHANGING CRANKCASE OIL MAINTENANCE - AUGER GEAR BOX OIL SERVICE MAINTENANCE - IMPELLER DRIVE BELT ADJUSTMENT MAINTENANCE - TRACTION DRIVE BELT ADJUSTMENT MAINTENANCE - REPLACING DRIVE BELTS MAINTENANCE - DRIVE CHAIN ADJUSTMENT MAINTENANCE - SPARK PLUG SERVICE PREPARING SNOWTHROWER FOR STORAGE

SECTION I POWER SHIFT CONTROLS

CONTROL BOX OPERATION OPERATION - LATCH RELEASE MECHANISM CONTROL BOX OPERATION - REVERSE CONTROL CONTROL BOX OPERATION - SHIFT LOCKOUT CONTROL BOX OPERATION - INDEXING MECHANISM CONTROL BOX SERVICE CONTROL BOX SERVICE - TESTING

POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 3 of 5

SECTION I POWER SHIFT CONTROLS - Continued CONTROL BOX SERVICE - DISASSEMBLY CONTROL BOX SERVICE - REASSEMBLY CONTROL BOX SERVICE - INSTALLATION CONTROL BOX SERVICE - ADJUSTMENTS

SECTION 2 TRACTION AND IMPELLER CONTROLS

OPERATION OPERATION - IMPELLER CONTROL OPERATION - IMPELLER LOCKING MECHANISM TRACTION AND IMPELLER CONTROLS TRACTION AND IMPELLER CONTROLS - INSPECTION TRACTION AND IMPELLER CONTROLS - REASSEMBLY TRACTION AND IMPELLER CONTROLS - TRACTION CABLE ADJUSTMENT TRACTION AND IMPELLER CONTROLS - IMPELLER CABLE ADJUSTMENT

SECTION 3 DISCHARGE CHUTE

CHUTE CONTROL DISCHARGE CHUTE DISCHARGE CHUTE - REMOVAL DISCHARGE CHUTE - INSTALLATION

SECTION 4 IDLER SYSTEM

IDLER SYSTEM - OPERATION IDLER SYSTEM - REMOVAL IDLER SYSTEM - DISASSEMBLY IDLER SYSTEM - REASSEMBLY IDLER SYSTEM - INSTALLATION IDLER SYSTEM - ADJUSTMENT

SECTION 5 PIVOT AND LATCH SYSTEM

PIVOT SYSTEM PIVOT SYSTEM - REASSEMBLY LATCH SYSTEM

SECTION 6 TRANSMISSION

TRANSMISSION - OPERATION TRANSMISSION - REMOVAL TRANSMISSION - DISASSEMBLY TRANSMISSION - REASSEMBLY TRANSMISSION - INSTALLATION

SECTION 7 AUGER

AUGER

POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 4 of 5

SECTION 8 AUGER GEAR BOX

AUGER GEAR BOX - OPERATION AUGER GEAR BOX - REMOVAL AUGER GEAR BOX - DISASSEMBLY AUGER GEAR BOX - REASSEMBLY AUGER GEAR BOX - INSTALLATION

SECTION 9 IMPELLER AND PULLEY SYSTEM

IMPELLER AND PULLEY - OPER ATION IMPELLER AND PULLEY - REMOV AL IMPELLER AND PULLEY - INST ALL ATION

SECTION 10 FRONT HOUSING

FRONT HOUSING - OPERATION FRONT HOUSING - INSTALLATION SKIDS - OPERATION SKIDS - REMOVAL SKIDS - INSTALLATION SCRAPER- OPERATION SCRAPER- REMOVAL SCRAPER- INSTALLATION

SECTION 11 CONTROL PANEL AND HANDLES

CONTROL PANEL - OPERATION CONTROL PANEL - INSTALLATION HANDLES RIGHT HANDLE - INSTALLATION LEFT HANDLE - REMOVAL LEFT HANDLE- INSTALLATION

SECTION 12 WHEELS, TIRES AND CHAINS

WHEELS - OPERATION WHEELS - REMOVAL WHEELS- INSTALLATION TIRES - OPERATION TIRES - SERVICE CHAINS - OPERATION CHAINS- INSTALLATION

SECTION 13 ENGINES ENGINES - SERVICE INFORMATION

SECTION 14 DIFFERENTIAL KIT

DIFFERENTIAL KIT - OPERATION DIFFERENTIAL KIT - REMOVAL

POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 5 of 5

SECTION 14 DIFFERENTIAL KIT - Continued DIFFERENTIAL KIT - DISASSEMBLY DIFFERENTIAL KIT - ASSEMBLY DIFFERENTIAL KIT- INSTALLAT ION

SECTION 15 LIGHT KIT

LIGHT KIT 66-7930 - OPERATION LIGHT KIT 66-7930 - TESTING LIGHT KIT 66-7930 - LAMP REMOVAL LIGHT KIT 66-7930 - LAMP INSTALLATION LIGHT KIT 66-7930 - ALTERNATOR REMOVAL LIGHT KIT 66-9730 - ALTERNATOR INSTALLATION LIGHT KITS 66-7940 AND 66-7950 - OPERATION LIGHT KITS 66-7940 AND 66-7950 - LAMP REMOVAL LIGHT KIT 66-7940 AND 66-7950 - LAMP INSTALLATION

SECTION 16 SNOW CAB

SNOW CAB - OPERATION SNOW CAB - REMOVAL SNOW CAB - INSTALLATION

SECTION 17 DRIFT BREAKER

DRIFT BREAKER - OPERATION DRIFT BREAKER- DISASSEMBLY DRIFT BREAKER - ASSEMBLY

ABOUT THIS MANUAL

This service manual was written expressly for the Tor0 624, 824, 828 and

Power Shift Snowthrowers. The Tor0 Company has made every effort to make the information in this manual complete and correct.

This manual was written with the service technician in mind.

information used most often information on safety, identification, specifications, special tods, troubleshooting

and maintenance, all in the front third of the manual.

Disassembly, inspection and reassembly procedures are covered in the last two-thirds of the manual and are grouped by component. common repair with its own section or sub-section. For example, you will find that auger service and auger gearbox service are addressed separately.

And,

because the Power Shift Snowthrower sections will include some component theory. This information can be found at the front of each service procedure section.

We are hopeful that you will you have any questions the following address:

is

up front.

find

this manual a valuable addition to your shop.

or

comments regarding this manual, please contact

The

81II

Lyndale Avenue South

Minneapolis,

As

a result, you will find reference

is

a relatively complex machine, most

Tor0 Company

MN

55420

It

is organized

We

tried

1132

so

that

to cover each

If

us

at

The Tor0 Company reserves the right to change product specifications or this

manual without notice.

@COPYRIGHT

The

Minneapolis,

ALL

Toro

RIGHTS

Company

MN

55420

RESERVED

1989

-USA

TABLE

Reference Information Page

OF CONTENTS

I

Safety Instructions

5

Service Procedures

Section

1

Identification Specifications

Tool Requirements Troubleshooting

Maintenance

Power Shift Controls Page

control Box Operation

gear selector control latch release mechanism

reversecontrol shiftlockout

indexing mechanism

Control Box Service

removal testing disassembly

31 32

36

41 41

41

43

45

6

7

Section

Power Shift Snowthrowers

2

Traction and Impeller Controls

Operation

Traction and Impeller Controls

reassembly installation adjustments

tractioncontrol impellercontrol

impeller locking mechanism

disassembly inspection reassembly

traction cable adjustment impeller cable adjustment

1

48 49

50 50

50

51 52 52

53 53

Table of Contents

TABLE

Service Procedures (cont’d)

OF

CONTENTS

(cont’d)

Section

3

4

Discharge Chute

Chute Control

operation 54 knobremoval knob installation upper rod removal

upper rod installation lower rod removal lower rod installation

Discharge Chute

operation removal installation 56

Idler System

operation 57

removal 57 disassembly reassembly installation adjustment

54

55

56

57 58

58

59

Section

!

Section 6 Transmission

5

Pivot and Latch System

Pivot System

operation disassembly reassembly 61

latch System

disassembly 61 reassembly 62

operation

removal disassembly reassembly installation 67

60

63

64

65

Table

of

Contents

2

Power Shift Snowthrowers

TABLE-

Service Procedures (cont’d)

Section 7 Auger Page

OF

CONTENTS

(cont’d)

Section

Section 10 Front Housing

8

9

operation removal installation 70

Auger Gearbox

operation 71

removal 71 disassembly 71 reassembly 72

Impeller and Pulley System

operation 75 removal 75 installation 76

Front Housing

operation 78 removal 78 installation 78

69

Section

11

Skids

operation 78 removal 78 installation 78

Scraper

removal 79 installation 79

Control Panel and Handles

Control Panel

operation removal installation

Handles

right handle removal 81 right handle installation

left handle removal left handle installation

80

80 80

82

83

84

Power

Shift

Snowthrowers

3

Table

of

Contents

TABLE

Service Procedures (cont’d)

OF

CONTENTS

(cont’d)

Section 12

Section

Section 14

Section

13

15

Wheels and Tires

wheels tires chains

Engines

servicing information 87

Differential

Light

Kii

Kit

operation 88 removal 88 disassembly 88 reassembly installation

Kit

66-7930 operation 91 testing 91 lampremoval 91 lamp installation 92 alternator removal 92 alternator installation

Page

85

86

89

92

Table

Section

Section 17

of

Contents

16

Light

Kits

66-7940 and 66-7950 operation 93 lampremoval lamp installation

Snow Cab

operation removal 95 installation

Drift Breaker

operation 98 removal 98 installation 98

4

94

95

Power Shift Snowthrowers

SAFETY

INSTRUCTIONS

Servicing of any outdoor power' equipment requires

A

statements have been placed thoughout this information on the operation of the Power Shift manual to enhance safety. Whenever you Snowthrowers. encounter instruction because Failure to comply with the instruction may result

in

personal injury or death.

I

care and common sense to prevent injury. "CAUTION"

the

word CAUTION Read the

it

has to do with safety.

FOR

YOUR

This manual is intended as a service and repair manual

only. The safety instructions provided in this manual are for the troubleshooting and service of the product only. The individual Operator's Manuals will contain safety

Operator's Manuals with complete operational safety instruction are available through:

The Toro Company

Publications Department

8111

Lyndale Avenue South

Minneapolis, MN

55420

U.S.A.

SAFETY

Avoid electrocution

Always use a grounded three wire plug and cord when

starting or troubleshooting a snowthrower equipped

with and electric starter. Avoid possible fires and explosions

Use a container designed for gasoline. gasoline and never smoke while working around gasoline.

Avoid fires and falls Wipe up any spilled fuel or oil.

Avoid lacerations and amputations Stay clear of all moving parts when running the machine. Treat all moving parts as the engine is running or has the potential to start.

Avoid burns Do not touch engine while running or shortly after running.

Avoid falls Do not operate snowthrower at fast speeds on slippery surfaces.

if

they were moving whenever

Avoid

spilling

Avoid asphyxiation Never operate an engine in a confined area without proper ventilation.

Avoid possible eye injuries Wear eye protection when working with springs or cables.

Avoid unexpected starting of engine Always turn before attempting any cleaning, adjustment or repair.

Avoid accidental misuse of fuel Always store fuel that is properly labeled.

Avoid possible injury due to inferior parts Use only Toro original safety criteria are met.

Avoid injury to bystanders Always clear area of bystanders before starting or testing a snowthrower.

off

key and disconnect spark plug wire

in

a container designed for gasoline

parts

to insure that important

Power Shift Snowthrowers

5

Safety !nstructions

Model

and

Serial

Numbers

The snowthrower itself has a model number and a serial number. The are stamped on a decal which is located on back engine mounting plate. These numbers are required number must be included on warranty claims related to whenever a warranty claim is being filed on a Toro

two

identification numbers: Each engine also has a model and serial number.

two

numbers

of

the location of these numbers. Engine

part.

Consult the engine manufacturers manual for the

model

a failed engine component. This applies even when the claim is being filed

to

The Toro Company.

and serial

Power Shift Snowthrowers

SPECIFICATIONS

MODELS

38500 AND 38505

Mitsubishi Powered 624 Engine Specifications*

I

Choke

Primer

manual

I

--yes

(no methanol and not

r

SAE10,

set gap to

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer's service manual.

API

rating

0.72

SE

mm

more

or

SF

(.028')]

than

10%

ethanol)

Mitsubishi Powered 624 Product Specifications

Transmission

Item Specification

Manufacturer

Type

Toro gearbox, 4 forward, 2 reverse gears

pulley/belt chain Lubriplate(R) Mag

-I_

1

Power

Shift

Snowthrowers

0.43

0.88

2.09

3.22

4.67

2.09

3.22

liters kph kph kph kph kph kph

(14.5

(0.55

(1.30 (2.00 (2.90

(1.30

(2.00

7

oz)

mph) mph) mph)

624

Specifications

~-

SPECIFICATIONS

MODELS

38500 AND 38505

Mitsubishi Powered

Auger Item

Housing Width Housing Height Diameter Flights

Gearbox Capacity

Impeller

624

Product Specifications (cont'd)

Specification

61

.O

cm

(24)

53.3

cm

(21")

cm

35.6

two,

1O:l

0.133

(14”)

8.89

cm

(3.5")

90

EP

gear oil, API rating

liters

(4.5

oz)

deep

(38505

serrated1

of

GL-5 or GL-6

Chute

Throat Diameter Angle

of

Rotation

Deflector Angle

Rear Suspension Item Specification

Standard pivoting axle Optional pivoting axle with differential

Item Specification

Type low pressure pneumatic, with tube

Diameter Width Tread self cleaning lug type

of

Tilt

14.0

200"

75"

35.6

10.2

cm

(5.5")

cm

(14.00")

cm

(4.00")

a

Power

Shift

Snowthrowers

SPECIFICATIONS

MODELS

38500

AND

38505

Mitsubishi Powered

Wheels and Tires (cont’d)

Tire Pressure

Dimensions

I

Item

Accessories

624

Product Specifications (cont’d)

Specification

Mitsubishi Powered

Fastener Toque Traction Gear Case Screws 1.38 kg

-Chain Guard Screws Pivot

Power Shift Snowthrowers

Arm

Shoulder Bolts

Auger Gearbox Screws 1.38 kg

Control Box Belt Guide Screws

Nuts

624

Torque Specifications

m

(120

in

Ibs)

m

(10 in

(120 in

(205

(70 in

9

Ibs)

in

Ibs)

Ibs) Ibs),

Ibs)

0.12 kg

3.45

kg m (300 in

m

2.36 kg

0.12 kg m (10 in

1.84 kg m (160 in Ibs)

0.81 kg

m

note tightening order, page 73

624

Specifications

I

SPECIFICATIONS MODELS 38510

Tecumseh Powered 624 Engine Specifications*

_I-

AND

38513

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer’s service manual.

Tecumseh Powered 624 Product Specifications

Transmission

I

Item

Input Drive pulley/belt

output

Drive chain

Specification Toro Manufacturer

4

gearbox,

forward, 2 reverse gears

624

Specifications

10

Power

Shift Snowthrowers

Tecumseh Powered

Auger

Impeller

624

Product Specifications (cont'd)

30.5

cm

(12'”)

Chute

Throat Diameter Angle

of

Deflector Angle

I

Rear Suspension

Item

Type pivoting axle Optional

Wheel and Tires

Rotation

of

Tilt

14.0

cm

I

200"

75"

pivoting axle

(5.5”)

with

differential

I I

Power

Shift

Snowthrowers

11

624

Specifications

SPECIFICATIONS MODELS 38510 AND 38513

Tecumseh Powered

Wheels and Tires (cont'd)

Track Width

Dimensions

I

Item

Weight

624

Product Specifications (cont'd)

61

.O

cm (24") to outside

.5

to 1

.O

kg/cm2 (7

Specification

138.4 cm (54.5")

63.5

cm (25.0")

104.1 cm (41

100 kg (220 I bs)

.O'”)

[handle height 91.4 cm (36.O'”)

of

tires

to

15 psi) [must be equal on both sides] Pressure

I I I

Torque Specifications

Fastener Traction Gear Case Screws Chain Guard Screws Pivot Arm Shoulder Bolts

Auger Gearbox Screws

Impeller Shaft Set Screws Impeller Lever Screw

Control Box Belt Guide Screws

624

Specifications

Nuts

Torque

1.38 kg m (120 in Ibs)

0.12 kg

3.45 kg m (300 in Ibs)

1.38 kg m (120 in Ibs), note tightening order, page 73

2.36 kg m (205 in Ibs)

0.12 kg m (10 in Ibs)

1.84 kg m (160 in

0.81 kg m (70 in Ibs)

m

(10 in

12

Ibs)

I---

Power Shift Snowthrowers

Mitsubishi Powered 824 Engine Specifications*

Item

Manufacturer Type

Rated Horsepower Engine Speed (fast no load) Carburetor Type Choke Primer

Throttle Control

Fuel unleaded gasoline (no methanol and not more than 10% ethanol) Fuel Tank 4.7 liters

Recommended Oil Oil Capacity Spark Plug NGK BP-4HS [set gap to 0.72 mm (.028')

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer's service manual.

Specification Mitsubishi

4-stroke, side valve, gasoline

8

HP

4000

float

manual

yes

I

yes, mounted on engine

I

electronic

SAE 10W30 or SAE 10, API rating SE or SF

0.80

150 rpm

liters (27

(5

quarts)

oz)

Mitsubishi Powered 824 Product Specifications

Transmission

Second Forward Gear 2.09 kph (1.30 mph) Third Forward Gear Fourth Forward Gear 4.67 kph (2.90 mph) First Reverse Gear Second Reverse Gear

3.22 kph (2.00 mph)

2.09 kph (1.30 mph)

3.22 kph

(2.00

mph)

Power Shift Snowthrowers

13

824

Specifications

SPECIFICATIONS MODELS 38520 AND 38525

Mitsubishi Powered

Auger

Housing Width

I

ltem

824

Product Specifications (cont'd)

61

.O

cm

(24")

I

[

Stopping Time less than five seconds

Rear Suspension ltem

Type pivoting axle Optional pivoting axle with differential

824

Specifications

Power

Shift

Snowthrowers

SPECIFICATIONS

MODELS

38520

AND

Mitsubishi Powered 824 Product Specifications (cont'd)

Wheels and Tires (cont'd)

I

Item

Track Width

I

Specification

61.O cm (24") to outside of tires

38525

Pressure

Dimensions

Accessories

.5

to

1.O

56-2700

66-6200

66-7960 66-7950

38038

66-6660

kg/cm2 (7 to 15 psi) [must be equal on both sides]

)

[handle height 91.4 cm (36.0'”)

or 68-9500

Mitsubishi Powered 824 Torque Specifications

in

Ibs),

note tightening order, page 73

Power

Shift Snowthrowers

15

824

Specifications

_I

SPECIFICATIONS

MODELS

38540

AND

38543

Tecumseh Powered

824

Engine Specifications*

Specification

Tecumseh 4-stroke, side valve gasoline

8 HP

+

200,

150

3300

float

manual

Yes yes, mounted on engine

electronic unleaded gasoline (no methanol and not more than

3.8

liters (4

SAE 5W30

0.71

Champion

liters

qts)

or

(24

RJ-17LM

rpm

_-

SAE 10, API

oz)

or Autolite

of

SE

AR7N

or

SF

[set gap to

I

-_._-I-

I---

_._.___

10%

0.76

ethanol)

mm

(.030'))

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual

manufacturer's service manual.

Tecumseh Powered

Transmission

824

Product Specifications

or

the engine

824

Specifications

16

Power Shift Snowthrowers

SPECIFICATIONS MODELS 38540 AND 38543

Tecumseh Powered

Auger

Impeller

Item Diameter Blades Throwing Capacity, mass-distance Stopping Time

824

Product Specifications (cont'd)

Specification

30.5

cm

(12')

three 818 kg/min less than fie seconds

(1800

Ibs/min)

12.2

m (40

ft)

Chute

Rear Suspension

Wheel and Tires

Specification

14.0 cm

200"

75"

(5.5')

Power Shift Snowthrowers

17

824

Specifications

SPECIFICATIONS

MODEL

38540

AND

38543

Tecumseh Powered

Wheels and Tires (cont’d)

Dimensions

824

Product Specifications (cont’d)

15

psi) [must

eight

91.4

be

equal

cm

on

(36.0’)

-~I--

both si

Tecumseh Powered

824

Specifications

824

Torque Specifications

18

Power Shift Snowthrowers

Mitsubishi Powered

828

Engine Specifications*

*

For more engine specifications, see

manufacturer's service manual.

Mitsubishi Powered

Transmission

828

Toro

Gas Consumer Gas Engine Specification Manual or the engine

Product Specifications

Power

Shift

Snowthrowers

19

828

Specifications

SPECIFICATIONS

MODEL

38545

Mitsubishi Powered

Impeller

Item Specification Diameter

Blades Throwing Capacity, mass-distance Stopping Time

828

Product Specifications (cont'd)

30.5

cm

four

909

kg/min

less than five seconds

(12")

(2000

Ibs/min),

12.2

m

(40

ft)

Chute Item

Throat Diameter Angle

of

Rotation

Deflector Angle of Tilt

Rear Suspension

Wheel and Tires Item

Type low pressure, pneumatic with tube Diameter

Width

Tread

Specification

14.0

200° 75"

Specification

40.6

12.7

self cleaning lug type

cm

cm cm

(5.5")

(16.00')

(5.00')

828

Specifications

20

Power Shift Snowthrowers

SPECIFICATIONS MODEL

38545

Mitsubishi Powered

Wheels and Tires (cont'd)

I

Item

Track

Width

Pressure

Dimensions

Accessories

828

Product Specifications (cont'd)

64.8

cm

(25.5')

.5

to

1.O

kg/cm2

to outside

(7

to

of

tires

15

psi) [must be equal

on

both sides]

I

Mitsubishi Powered

Power Shift Snowthrowers

828

Torque Specifications

21

828

Specifications

SPECIFICATIONS

MODEL

38570

Briggs and Stratton Powered

Champion RCJ-8 or Autolite AR7N [set gap to

828

Engine Specifications*

_I-

.76

mm

(.030'”)

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer's service manual.

Briggs and Stratton Powered

Transmission

828

Product Specifications

SPECIFICATIONS

MODEL

38570

Briggs

Auger

Impeller

and

Stratton

Powered

828

Product Specifications (cont'd)

i

r'

Chute

Wheel and

Tires

self-cleaning lug

tread

Power

Shift Snowthrowers

23

828

Specifications

SPECIFICATIONS

MODEL

38570

Briggs and Stratton Powered 828 Product Specifications (cont'd)

Wheels and Tires (cont'd)

Specification

Track Width 64.8 cm (25.5) to outside

.5 to

1.O

Pressure

Dimensions Item

Length

Width

Height

Weight

Specification

138.4 cm

73.7 cm

106.7 cm (42.0') (handle height 94.0 crn [37"])

109.1

kg/cm2 (7 to

(54.5")

(29.0")

kg m (240 Ibs)

of

tires

15

psi) [must be equal

on

both sides]

Briggs and Stratton Powered 828 Torque Specifications

Power

Shift

Snowthrowers

SPECIFICATIONS

MODEL

Tecumseh Powered 828 Engine Specifications*

38573

Item

Manufacturer

Ignition Type electronic

Fuel Tank

oil

Capacity

Spark Plug Champion

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer's service manual.

Specification

Tecumseh

yes, mounted on engine

unleaded gasoline (no methanol and not more than

3.8

liters

(4

quarts)

SAE

5W30

or

SAE10, API

RJ-17LM

or

Autolite

rating

of

SE

AR7N

or SF

[set gap to

0.76

10%

ethanol)

mm

(.030'”)

Tecumseh Powered 828 Product Specifications

Transmission

Specification

Toro

4

Manufacturer

gearbox,

pulley/belt chain Lubriplate(R) Mag

0.43

0.88

2.09

3.22

4.67

2.09

3.22

forward, 2 reverse gears

1

liters

(14.5 oz)

kph

(0.55

mph)

kph

(1.30

mph)

kph

(2.00

mph)

kph

(2.90

mph)

kph

(1.30

mph)

kph

(2.00

mph)

Power

Shift

Snowthrowers

25

828

Specifications

Tecumseh Powered

Impeller

828

Product Specifications (cont'd)

Specification

30.5

cm

(12")

four

909

kg/min

less than five seconds

(2000

lbs/min)

12.2

rn

(40

ft)

Rear Suspension Item

Optional pivoting axle

Wheel

I

Item

I

Type Diameter

Tread

828

Specifications

and

Tires

Specification

low

pressure, pnuematic, tube type

40.6

cm

(16.00")

with

differential

Power

Shift

Snowthrowers

I I

SPECIFICATIONS MODEL

38573

Tecumseh Powered 828 Product Specifications (cont'd)

Wheels and Tires (cont'd)

I

Item

Pressure

Dimensions

Width Height

Weight

Accessories

Specification

64.8

crn

(25.5") to outside

.5

to

1.0

kg/cm2

cm

73.7

106.7

109.1

(29.0")

crn

(42.0') [handle height

kg m (240 Ibs)

(7 to

15

of

psi)

tires

[must

94.0

be

cm

equal on both

(37")]

I

sides]

I

Tecumseh Powered 828 Torque Specifications

Torque

1.38 kg

0.12

3.45

1.38

2.36

0.12 kg

1.84

0.81

Power Shift Snowthrowers

m

(120

in Ibs)

kg

rn

(10

in

Ibs)

kg

m

(300 in Ibs)

kg m

(120

in Ibs), note tightening order, page 73

kg

m (205 in

m

(10

kg

m

(160

kg m (70 in Ibs)

in Ibs)

-_I__.

in

27

Ibs)

I_.--

--__-

828

Specifications

SPECIFICATIONS

MODELS

38565 AND 38580

Briggs and Stratton Powered 1132 Engine Specifications*

no methanol and not more

_.-

*

For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine

manufacturer’s service manual.

Briggs and Stratton Powered 1132 Product Specifications

1132

Specifications

28

Power Shift Snowthrowers

Briggs and Stratton Powered

Auger

Impeller

1132

Product Specifications (cont'd)

Chute

Rear Suspension

Wheel and Tires

Item

Type

Diameter Width Tread

Specification

low

pressure, pneumatic tube type

40.6

cm

(16.00'1

12.7 cm

self cleaning lug type

(5.00')

I

Power Shift Snowthrowers

29

1132

Specifications

SPECIFICATIONS MODELS 38565 AND 38580

Briggs and Stratton Powered

Wheels and Tires (cont'd)

Track Width

Pressure

64.8

.5

1132

cm

to

1.O

Product Specifications (cont'd)

(25.5")

kg/cm2

to outside

(7

to

of

tires

15

psi) [must be equal on both sides]

Torque Specifications

1132

Specifications

30

Power Shift Snowthrowers

SPECIAL TOOLS AND OTHER NECESSITIES

The Power Shift Snowthrowers do not require any complex tools for most servicing. Servicing can be accomplished with the following:

Necessary

Complete English Socket Wrench Set (1/4" thru 1") Complete English End Wrench Set (1/4" through 1")

Phillips Screwdrivers Standard Screwdrivers Pocket Knife Rubber Mallot Pliers (regular, needle nose and linesman) Snap Ring Pliers (outside)

Tools

it

is a

In addition to those tools,

following

Lubricants, Sealants and Adhesives

on

hand:

good

idea to have the

Power Shift Snowthrowers

31

Special Tools

TROUBLESHOOTING

Unit Does Not Propel Forward

Remedy

Check tire pressure, lock differential, install chains Position klik Pin through wheel and Adjust cable

Adjust traction cable Remove ice accumulation in lower belt cover. Repair gear or jaw damage

Unit will not Propel Backward

Possible Causes

Wheels not pinned to axle Reverse cable too loose Traction belt slipping Reverse bevel gear or jaw

clutch malfunction

Remedy

Position klik pin through wheel and axle Adjust reverse cable

Adjust traction cable

Repair reverse gear or jaw clutch damage

axle

I

Neutral Not in Correct Location

I I

Possible Causes Remedy

Lower shift rod not adjusted correctly Shift bracket incorrectly assembled Reassemble control box correctly

Adjust lower shift rod

I

Shift Lever Will Not Lock in Power Shift or Reverse

Possible Causes Remedy

Lockout lever Lockout lever binding Lockout lever spring malfunction

tabs

broken Replace lockout lever

Free by spraying with WD40 Replace lock out lever spring

Power

Shift

Snowthrowers

I

TROUBLESHOOTING

(cont'd)

Operator Can Shift Between Forward and Reverse While Traction Lever is Engaged

Possible Causes Lock out lever tabs broken Lockout lever binding Lock out lever spring malfunction Replace lock out lever spring

Remedy Replace lock out lever

Free by spraying with WD40

I

Wheels Will Not Swing When Power Shifting

Possible Causes Indexing mechanism out

sequence with wheels Insufficient traction

of

Remedy Release shift lever then

Assist axle swing by lifting on handles slightly during Power Shift

Units with differential: push down on handles, lock differential

Adjust latch cable

Free pivot arms

push

into Power Shift again

I

Machine Does Not Propel in a Straight Line

I

Possible Causes Remedy Uneven tire pressure

Uneven traction on pavement Skids not adjusted evenly Both wheels not pinned to axle Position klik pin through both wheel and axle

Adjust tire pressure to Consider chain installing chains

Adjust

skids

.5

to

.O

1.0

kg/cm2

Engine Kills When Auger or Traction are Engaged

Possible Causes Engine not sufficiently warmed up Debris jammed

Auger or impeller frozen with ice

in

auger or impeller

Remedy

Allow engine to warm

Clear auger and impeller

Allow snowthrower to warm

up

before engagement

(7

to

15

psi) equally.

-I

I

Power Shift Snowthrowers

33

Troubleshooting

TROUBLESHOOTING

Poor Snowthrowing Performance

Impeller or Auger Does Not Turn

Remedy Clear debris Allow snowthrower to warm Adjust impeller belt

(cont'd)

Gear malfunction

in

auger gearbox

Traction or Impeller Does

-Possible Causes Cable too tight Belt guide broken Incorrect belt

Chute Plugs With Snow

Possible Causes Engine rpm too slow Belt slippage

Tighten pulley fasteners

Replace auger bolt Tighten impeller shaft fasteners Repair auger gearbox

Not

Disengage

Replace belt guide Check parts catalog for correct belt

Always throw snow at full throttle Adjust impeller belt

Ground speed not matched

Snow too wet

Troubleshooting

in

Select slower gear in heavy conditions, faster gear

Sand, paint and wax chute and rough areas in housing and chute

Allow snow to melt or freeze

34

Power Shift Snowthrowers

light conditions

TROUBLESHOOTING

Scraper Catches on Uneven Pavement

Snowthrower Leaves Snow Behind

Remedy

(cont’d)

per Operator’s Manual

Scraper improperly adjusted or worn Skids improperly adjusted or worn

Adjust scraper Adjust skid

Rapid Skid and Scraper Wear

Possible Causes

Operator snowthrowing with wheels in rear position unnecessarily

Defective or scraper

Remedy

Use forward wheel position

Replace skid or scraper

Front End Rises

___-

for

light snow

Power

Shift

Snowthrowers

35

Troubleshooting

CAUTION: To prevent accidental starting of the engine

while performing maintenance, rotate the ignition key to

off

and remove

it

from the switch. Next, pull the wire

off

the spark plug and make sure the wire does not

accidentally touch the plug.

Maintenance Draining Gasoline

Stop the engine and pull the wire

1.

2.

Remove the cap from the fuel tank and use a

off

spark plug.

pump-type syphon to drain fuel into clean gas can. NOTE: This is the only procedure recommended

for draining

fuel.

CAUTION: Since gasoline is highly flammable,

it

drain

outdoors and make sure the engine is cool to prevent a potential fire hazard. Wipe up any gasoline that may have spilled.

Do

not drain gasoline near any open flame or where the gasoline fumes may be ignited by a spark.

Do

not smoke a cigar, cigarette or a pipe when handling gasoline.

Maintenance Chain Lubrication

1.

Annually lubricate the drive chain with chain lubricant. See Figure

1.

Wipe up any excess oil.

just before changing oil because warm oil flows better and carries more contaminants the cold oil.

1.

Pull the wire

off

the spark plug and make sure the

wire does not contact the plug accidentally.

2.

Clean the area around the oil drain cap. Next, slide the oil drain pan below the drain extension; then remove the oil drain cap.

3.

After all the oil is drained, install the oil drain cap.

4.

Position the snowthrower on a level surface. Next,

fill

the crankcase with oil. See Specifications

Section for capacity

See

Figure

Oil

Drain

of

your engine. Wipe up any

2.

Extension

oil that may have spilled.

Box

Maintenance Auger Gear

The auger gear box is filled with oil at the factory

regular maintenance is not required. However,

Oil Service

if

the oil

so

must be replaced in gear box:

Figure

1

Maintenance Changing Crankcase Oil

2

Initially change oil after the first

operation; thereafter, change oil after every

hours of engine

25

hours of

engine operation or annually. If possible, run the engine

1.

Drain gasoline from the fuel tank. Wipe up any spilled gas.

2.

Position the snowthrower on a level surface.

3.

Clean the area around pipe plug removed. See Figure

4.

Put a drain pan below the front of auger box and

3.

remove the pipe plug.

Tip the snowthrower forward and hold

5.

all oil drains from the gear box. Carefully let the snowthrower down to its normal

6.

position. Make sure it is on a level surface. Next, full the auger gear box with

85-95

EP

transmission oil to the point

7.

Install pipe plug in gear box.

GL-5

or

Power Shift Snowthrowers

so

it

up until

GL-6

of

overflow.

dirt is

SAE

Maintenance Auger Gear Box Oil Service (cont'd)

Figure

3

Maintenance Impeller Drive Belt Adjustment

If

the auger/impeller

belt

slips resulting in decreased

snowthrowing performance, an adjustment is required. WHENEVER ADJUSTMENT

1.

Remove the three flanged head capscrews

A

NEW BELT

IS

REQUIRED.

IS

INSTALLED, AN

securing the belt cover to engine frame and slide belt cover up the cables.

2.

Check idler and brake adjustment. There should

be

a minimum clearance of 3 mm

(1/8”)

between the tab on the impeller idler arm and the brake arm. See Figure

clearance, the

4.

If there is less than 3 mm

belt

must be replaced.

(1/8'”)

Rotate the bottom jam nut upward to increase belt

4.

tension.

NOTE: When adjusting the cable, always rotate

the nut one turn at a time.

belt

NOTE: Do not adjust the

too tight because may cause the auger/impeller to turn when the auger/impeller is in

the

disengaged position.

occurs, readjust the lever by loosening belt

tension. Tighten upper jam nut against bracket.

5.

CAUTION: Improper adjustment may cause injury if auger/impeller turns when the lever disengages. Use only genuine Toro replacement

parts.

Recheck the idler and brake adjustment referring

6.

to step Reinstall the belt cover.

7.

Check tension of belt by operating the auger.

8.

2.

belt slips, repeat procedure.

If

this

If

the

it

Figure

3.

Loosen the upper jam nut securing the auger/

4

impeller cable to the mounting bracket. See Figure

5.

Power Shift Snowthrowers

Maintenance Traction Drive Belt Adjustment

If

the traction belt slips during operation, an adjustment

is

required. Whenever the belt is replaced, an

adjustment is required.

1.

Loosen the upper jam nut securing the traction

cable to the mounting bracket.

2.

Rotate the bottom jam nut upward to increase belt

tension.

37

Maintenance

Maintenance Traction Drive Belt Adjustment

(cont'd)

NOTE:

When adjusting cable, always rotate nut

one turn at a time.

3.

Tighten the upper jam nut against the bracket.

4.

Check the tension of the belt by operating the machine. If the belt slips, repeat the procedure.

CAUTION: Do not adjust the belt too tight because

it

may cause the snowthrower to creep

when traction lever is in the disengaged position.

If

this occurs, readjust by loosening belt tension.

Maintenance Replacing Drive Belts If

the auger/impeller belt or traction belt become worn, glazed, stretched, oil-soaked, or otherwise defective, belt replacement is required.

1.

Pull wire

off

the spark plug and make sure

it

does

not contact the plug accidentally.

2.

Remove the three thread forming screws holding the belt cover in place, and slide the belt cover up cables.

7.

If

replacing the traction belt, slide the mid section

of the on pulley and belt

off

crankshaft and remove

belt from transmission pulley.

8.

On the control cable which corresponds to the belt being replaced, loosen the jam nuts securing

cable to bracket. Cable must

be

free to slide in the

bracket when changing the belt(s).

9.

Reinstall the belts by reversing procedure. Make sure tabs

in

half sheave are inserted into the

mounting grooves in the auger/impeller pulley

when reinstalling.

NOTE:

Make sure the idler pulleys are aligned with the belts when reinstalling idler pulley assembly.

10.

Readjust the belts, referring to Maintenance Impeller Drive Belt Adjustment or Maintenance

Traction Drive Belt Adjustment, pages

38.

CAUTION: Improper adjustment may cause injury

if

auger/impeller turns when the lever

disengages. Use only genuine Toro replacement

parts.

37

and

3.

Move the speed shift control to

4.

Remove the two flanged head capscrews

N,

neutral.

securing the idler pulley assembly to the engine frame. Remove the idler pulley assembly. See Figure

5.

Remove the capscrew and lockwasher securing

6.

Figure

6

the half sheave to front of pulley assembly.

Maintenance Drive Chain Adjustment

The drive chain must be adjusted to maintain

1/8-3/8

of an inch deflection at mid span between transmission and axle sprocket. Check chain deflection after every

25

hours of operation.

1.

Check deflection of the chain by lifting up on the chain with moderate pressure at mid span. There should be

1/8-3/8”

specified an adjustment is required.

deflection.

If

deflection is not as

See

Figure

Deflection

3/8”

7.

6.

Slide auger/impeller half sheave and belt crankshaft and remove belt from impeller pulley.

Maintenance

off

38

Figure

7

Power Shift Snowthrowers

I

Maintenance Drive Chain Adjustment (cont'd)

NOTE:

To

adjust the drive chain,

the

snowthrower must be tipped up on the auger housing. However, before the snowthrower is tipped, siphon all

gasoline from fuel tank.

2.

Make sure the wheels are positioned in rear

position. Move the shift control into

2nd

gear and

tip the snowthrower up onto auger housing.

3.

Loosen the four flanged head capscrews (two each side) securing transmission frame to engine frame. See Figure

4.

Lightly

9

mm

lift

up on the transmission frame until 3 to

(1/8

to 3/8”) chain deflection is attained, then

8.

retighten the flanged head capscrews.

Figure

NOTE:

lifting

Do not pry or use excessive force when

the transmission frame, as transmission

8

damage may occur.

NOTE:

If

gear shift lever

is

not aligned with the Power Shift slot in control panel (see Figure inset), shift rod length must beadjusted as follows:

a. Disconnect the

move

the

jam

b. Rotate the

ball

joint from bellcrank and

nut

up shift rod. See Figure

ball

joint up or down until the gear

shift lever is aligned with the Power Shift slot. c. Reinstall

the

ball

joint to the bellcrank and

tighten the jam nut.

5.

Recheck the chain deflection and lower the snowthrower to

its

normal position.

9.

9

Figure

9

Maintenance Spark Plug Service Check the Specifications Section for the proper spark

plug and gap. Since the air gap between the center and side electrodes of the spark plug increases gradually

during normal engine operation, install a new plug after

25

hours of engine operation.

1.

Clean the area around the spark plug

so

foreign

matter cannot fall into cylinder when plug is

removed.

2.

Pull the wire

off

the spark plug and remove the

plug from cylinder head.

NOTE:

A

cracked, fouled, or dirty spark plug must

be replaced. Do not sand blast, scrape or clean

the electrodes because grit may eventually

release from the plug and fall into the cylinder. The result will likely be engine damage.

3.

Set air gap between electrodes of new spark plug. See Figure cylinder head. Torque plug to

wrench

10.

Next, install the spark plug in the

15

is

not used, tighten plug firmly.

ft-lb. If torque

Power Shift Snowthrowers

39

Maintenance

Maintenance Spark Plug Service (cont’d)

2.

Start the engine and let

it

run until

it

stops because

there is no gasoline in the fuel system.

Remove the spark plug from the cylinder head.

3.

Next, pour

two

teaspoons of engine oil into spark plug hole in cylinder head. Install the spark plug in the cylinder head,

but

do not install the wire on the plug. Then pull recoil starter slowly to distribute the oil on the inside of the cylinder.

Lubricate the snowthrower: refer to Maintenance

4.

Chain Lubrication, page

36.

Change crankcase

oil: see Operator’s Manual. Clean the snowthrower. Touch up chipped

5.

surfaces with paint. Sand the affected areas before painting. Use a rust preventative to prevent metal parts from rusting.

Figure

4.

Push the wire onto the spark plug.

10

Preparing Snowthrower For Storage

1.

Siphon or remove the gasoline from the fuel tank, referring to Maintenance Draining Gasoline, page

36.

Wipe up any gasoline that may have

spilled.

Tighten all screws and nuts.

6.

If

any parts are

damaged, repair or replace them.

7.

Store the snowthrower in cover

it

to give protection.

The snowthrower may be stored tipped up on the

8.

a

clean, dry place and

auger housing. Make sure to drain gas before tipping snowthrower.

SECTION

1

POWER SHIFT CONTROLS

CAUTION:

require working with some of- the moving prevent accidental starting of performing service, take the following precautions:

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

CAUTION:

feature of being able to for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain Wipe up any gasoline that may have spilled.

Do

spark.

Do

Servicing the Power Shift Snowthrower will this motion down to a bellcrank that moves the linkage

parts.

To

the

engine while

off

and remove.

off

the spark plug.

The Power Shift Snowthrower has the

be

stood on the front housing

it

outdoors and make sure the engine not drain the gasoline near any open flame or not smoke when handling gasoline.

is

cool.

on top of the transmission.

Operation Latch Release Mechanism

A

latch mechanism holds

forward or rear position. See Figure

the

pivot arms

12.

in

either a

Power Shift Snowthrowers

41

Power Shift Controls

Control

Box

Operation Reverse Control (cont'd)

in reverse. The other is when the wheels are Power Shifted from the forward to the rear position.

Figure

14

Before trying to understand the Power Shift control box, first take a moment to understand what is happening on

top of the gearbox. The transmission is spring loaded

into the forward gears.

In

order to reverse the

transmission, the reverse cable must be pulled about

2.0

cm

(3/4”)

to move the sliding jaw from the forward

bevel gear to the reverse bevel gear. See Figure

15.

Figure

16

17

When the shift lever is pushed into the Power Shift slot, a tab on the index wheel contacts a tab on the reverse bellcrank every other time the Power Shift is cycied. See Figure

18.

Figure

15

The upper end of the reverse cable is connected to the

reverse bellcrank. The reverse bellcrank will rotate and

tension the cable when the operator shifts into reverse

or when he or she Power Shifts the wheels to the rear position. See Figure

When the gearshift lever is pulled into one

16.

of

the reverse slots, the reverse lever (visible through the reverse slots in the control panel) is pushed toward the back of the snowthrower. The reverse lever is connected to the reverse bellcrank reverse bellcrank and tensions the cable. See Figure

Power

Shift

so

Controls

that as

it

pivots,

it

rotates the

17.

42

Figure

The contact between the bellcrank

to

rotate.

18

two

tabs forces the reverse

Power Shift Snowthrowers

1

Control The

index

Box

Operation Reverse Control (cont'd)

wheel

is

necessary because

the

wheels must alternate between forward backward movement when Power Shifting. bellcrank and the wheels power forward when the

the

When Power Shifting

wheels forward, the indexing mechanism does nothing but index. The tabs On the bottom

traction lever is engaged.

Of

the index wheel miss the tab On the reverse

See

Figure

20.

Control Transmission damage could result

Box

Operation Shift

Lockout

if

the operator were to shift the transmission into reverse while the unit were moving forward and vice versa. To prevent this, a shift lockout is used. This lockout physically prevents the operator from switching directions without first stopping the unit.

The lockout base pivots on a shoulder bolt and rotates whenever the shift lever is moved to either the Power Shift or reverse slots. See Figure Note however, that 19.

the lockout base does not rotate when the gearshift lever

is

moved from side to side.

When the wheels are to be moved to the rear position,

a

corresponding tab on the reverse bellcrank and the

wheels power backward when the traction lever

engaged. See Figure 21.

Figure 20

tab on the bottom of the index wheel contacts a

is

Figure 19

When

engaged, the

the

traction lever on the left handle

lockout

base

is

free

to

move in either

is

not

direction. However, once the traction lever is engaged, the

two

tabs on the lockout lever engage the lockout base. This prevents the shift lever from being moved forward or backward.

An added benefit

of

the shift lockout is that

it

allows the operator to lock the gearshift lever in either the Power Shift or reverse slots by depressing the traction lever.

This allows the operator one hand operation

of

Power Shift or reverse leaving the other hand free to rotate the chute.

Control

An indexing mechanism is used of wheel movement while Power Shifting. This

Box

Operation Indexing Mechanism

to

control the direction

is

necessary because the wheels need to alternate between forward and reverse when the Power Shift

is

cycled.

Figure

21

The index tang and a flat spring control the rotation of

the index wheel. When the shift lever is pushed into the Power Shift slot, the index tang rotates the index wheel

1/8

revolution and then prevents the wheel from rotating backwards when the tabs on the index wheel and reverse bellcrank make contact. See Figure

As

the shift lever returns to its "at rest" position,

22.

the

index wheel has a natural tendency to turn backwards due to the pressure from the index tang. The flat spring

prevents backward rotation by engaging the index

wheel at one of the teeth.

Power Shift Snowthrowers

43

Power Shift Controls

Control

Box

Operation Indexing Mech. (cont'd)

4. Using a 1/2" deep well socket, remove the four nylon locknuts securing the power shift control box to the control panel.

See

Figure 24.

Figure 22

The index wheel is mounted on a piece called the index

fits

wheel lever. This piece rotate slightly.

It

provides the small amount of rotation

inside the lever latch and can

necessary to index the index wheel.

CONTROL

Control

BOX

SERVICE

Box

Service Removal

1. Tip the snowthrower up onto the auger housing.

2. Pull the shift selector knob

off

of the shift selector

lever.

3. Disconnect the shift rod from the power shift control box. See Figure 23.

Figure 24

5.

Remove the latch cover from the latch lever,

6.

Disconnect the latch control cable and the reverse

cable from the power shift control box.

7. Remove the power shift control box as an assembly, from the control panel.

Control Box Service Testing

All

major functions of the power shift control box can be

tested, with the Power Shift control box removed from

so,

the control panel. To do

hole at the end

of

the reverse lever.

insert a 7/16' bolt into the

1. Check for proper operation of the shift lockout mechanism. With the lock

shown in Figure 25, the lock

out

lever in the position

out

base should prevent the shift lever from forward and backward movement.

Power Shift Controls

Figure 23

.44

Figure

2.

When the lockout lever is pulled back to the

25

position shown in Figure 26, the shift lever should

be

free to move forward and backward.

Power Shift Snowthrowers

Control

Box

Service Testing ( cont’d)

serve the indexing wheel underneath the latch lever. See Figure

28.

Figure

3.

The reverse lever is spring loaded forward

26

reverse lever return spring. Check for proper operation of the reverse lever by

pulling backward. Reverse bellcrank movement

as shown in Figure

27

should be noticed.

by

the

Figure 28

Check to insure that the indexing wheel is free to

rotate clockwise when viewed from the bottom of

the power shift control box.

Also

check to insure

that both the flat spring and the index tang are

spring loaded toward the index wheel. Now observe the index wheel as you again cycle

the latch lever. The tabs on

the

bottom of the index

wheel and on the reverse bellcrank should

alternate between meeting and missing on each subsequent cycle. See Figure

29.

Figure 27

4.

The latch lever is spring loaded clockwise by the latch lever return spring.

Check for proper operation of the latch lever and the indexing mechanism by repeatedly rotating the latch lever about clockwise and then releasing gently

60

degrees counter

(if

allowed to spring back quickly, the “stop” on the bottom of the latch lever may break.) Every other time the latch lever is cycled, the reverse lever should

move toward the back of the Power Shift control

box

as

it

did in Figure 27.

5.

If a problem is noticed in step 4 of testing, the indexing mechanism may not be functioning

properly.

To

check the indexing mechanism, ob-

Power Shift Snowthrowers

Control See Figure

1.

45

Figure 29

Box

Service Disassembly

30.

With the Power Shift control box removed from the

control panel, begin disassembly by disconnecting the reverse lever return spring from the Power Shift control box and removing the

reverse lever.

Power Shift Controls

Control

Box

Service Disassembly (cont’d)

2. Disconnect the latch lever return spring from the latch lever mechanism. Remove the snap ring

from the latch lever stud and pull

Lockout

off

the

Lockout

latch lever.

Figure 30

If necessary, pry

3.

off

the push nut holding the index tang and remove the index tang, index tang spring, and the stud from the latch lever.

Control

Box

Service Reassembly

1. If necessary, reassemble the index wheel lever assembly as shown in Figure 31.

Figure 31

2.

Install

the

index tang into the latch lever with the pin, making sure that the torsion spring position shown in Figure 32.

I._____----~

is

in the

I

NOTE:

This may damage the index tang or the latch lever. Flattening the tabs on the push nut prior to removal may prevent damage.

4.

Next, remove the index lever and,

if

desired, pry

the push nut from the end of the index wheel.

Remove the flat spring from the index lever.

NOTE:

This may damage the latch lever. Flattening the tabs on the push nut prior to removal may prevent damage.

Remove the reverse bellcrank from the stud along

5.

with the torsion spring.

Remove the bolt securing the lock out base to the

6.

Power Shift control frame and remove the lock out base.

Remove the special nylon locknut securing the

7.

shift lever to the Power Shift control frame and remove the shift bracket.

Remove the shoulder bolt securing the shift lever

8.

to the shift yoke and remove the shift lever. Next,

pull the shift yoke from the power shift control box frame and finally, remove the small nylon bushings from the control box frame.

Figure 32

3.

Push the

two

small shift yoke bushings into the control box frame. Note that the wider flange should be toward the outside in both cases. Assemble the shift yoke and shift bracket with the Belleville washer and nylon locknut. Make sure

Power Shift Snowthrowers

Control

Box

that

the

bracket. See Figure

Service Reassembly (cont'd)

flats on the yoke align with the shift

33.

Figure

4.

On

1989

and newer units, insert the yoke bushing into the yoke. Insert the shift lever into the shift lever yoke, making sure that the shift lever bends forward. Secure with the flat washer and nylon locknut. Make sure the shift lever recesses in the yoke bushings and that the connectors between the yoke bushings face the rear of the machine. (If installed with the connectors forward, binding will result when the shift lever is moved forward and backward.) Figure

34.

33

fits

into the

See

Figure

6.

Mount the shift lockout lever to control box using the shoulder bolt, flat washer

and nylon locknut. See Figure

35

36.

the

power shift

Figure

34

5.

Slip the lock secure with nylon locknut. Make sure that the lockout base

moves freely after installation. See Figure

Power Shift Snowthrowers

out

base over the shift lever and

the

shoulder bolt, flat washer and the

35.

47

Figure

36

Power Shift Controls

Control

7.

Box

Service Reassembly (cont’d)

NOTE:

compound Toro corrosion and subsequent binding.

Slip the reverse bellcrank and torsion spring onto the stud as shown in Figure wheel lever assembly onto the stud. Make sure that the ends

positions shown in Figure

NOTE:

anti-seize compound Toro part number

to prevent corrosion and subsequent binding.

Coat the shoulder

part

of

the

bolt

with an anti-seize

number

torsion spring are in the

505-109)

37.

Slide the index

38.

Coat the reverse bellcrank with an

to prevent

505-109)

lever back and forth to insure that the index wheel is rotating properly. Secure with the flat washer and snap ring. See Figure

NOTE:

compound Toro part number corrosion and subsequent binding.

9.

Next, install

return spring as shown in Figure that the boss at the bottom engages the reverse bellcrank.

Coat the latch lever with an anti-seize

the

reverse lever and reverse lever

38.

505-109)

39.

of

the reverse lever

to prevent

Make sure

Figure

Install the latch lever and spring into the position

8.

shown in Figure

38.

37

38

Once installed, rotate the latch

Figure

10.

Make sure that all three control box springs are in

the position shown in Figure

Control

1.

2.

Box

Service Installation

Install the end of the reverse cable into the reverse bellcrank from the bottom of the reverse bellcrank. Secure with the cable sheath. Adjust as described in Control Service Adjustments, page

Insert the end small hole in the top

described in Control

49.

page

two

of

39

40.

jam nuts at the end

of

49.

the latch release cable into the

of

the latch lever. Adjust as

Box

Service -Adjustments,

the

Box

Power

Shift

Controls

48

Power

Shift

Snowthrowers

Control

3.

Box

Service Installation (cont'd)

Install the latch lever cover with 2 Phillips screws.

Do

not overtighten. Adjust the latch cable as

described in Control

Lockout Lever

Box

-Adjustments, page

49.

Control

1.

Box

Service Adjustments

Latch Cable Adjustment: Adjust the latch control cable by removing slack between the end sheath and the end of the cable.

Do

beyond the point of removing slack. See Figure

42.

of

the

not tighten

U

I

Figure

4.

Install the Power Shift control box on the control panel, making sure that the reverse lever properly mounted on the upper left stud. Secure

with

4

nylon locknuts. Before proceeding, be sure

all levers are working smoothly.

5.

Attach the lower shift rod to the shift bracket with the nylon locknut certain that the ball joint is in the position shown or the shift mechanism will not work properly.

as

40

shown

in

Figure

41.

is

Make

Figure

2.

Reverse Cable Adjustment: Adjust the reverse cable

so

that there is 1.5 mm (1/16") side play in

42

the reverse bellcrank as shown in Figure

cable is too loose, cable is too tight,

loss

of reverse will result.

loss

of the forward gears

occur.

Figure

43

43.

If

the the

will

Lower

Shift

Rod

Figure

41

6. Push the rubber-shift knob onto

it

is fully seated. Note that

it

is a press

installed the knob should point forward.

Power Shift Snowthrowers

the

shift lever until

fit

only. Once

49

3.

Shift

Lever Adjustment: The shift

adjusted when the transmission and the lever slides

power shift slot.

right

down the center of the

If

adjustment is necessary,

lever is properiy

is

in second gear

remove the lower shift rod from the bellcrank near the transmission and manually place the bellcrank in second (ie. second notch from the top). Loosen the jam nut at the ball joint and move

up

or down until the shift lever rides in the center

of

the power shift slide. Secure by attaching the

ball joint

to

the bellcrank with a nylon locknut and

the

ball joint

tightening the jam nut.

Power Shift Controls

CAUTION: Servicing the Power Shift Snowthrower will require working with some of the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to Pull the wire

off

the spark plug.

off

and remove.

Make sure the wire does not accidentally touch

the spark plug.

CAUTION: The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain

it

outdoors and make sure the engine

is

cool.

Wipe up any gasoline that may have spilled.

Do not drain the gasoline near any open flame or spark. Do not smoke when handling gasoline.

OPERATION

Operation Traction Control

Traction is controlled by means of the lever on top of the

left

handle. See Figure

44.

The lever is spring loaded in

the disengaged position. The transmission can be

engaged by pushing down on the lever.

Impeller Lever

Traction

Lever

Figure

45

Control inputs are transferred down to the idler assembly through

the

cable attached to the release cam. The top end of the traction cable is protected by a rubber boot to help prevent corrosion and icing.

Operation Impeller Control The impeller control is the lever located on top of the

right handle. See Figure

44

above.

It

is spring loaded in the disengaged position. The auger is engaged by depressing the lever.

Control input is transferred to the idler assembly at the auger pulley by means of

a

cable. There is a boot at the

top end of the auger cable to help prevent corrosion and

icing.

Figure

The traction lever

is

rigidly fastened to the cross rod that

passes underneath the control panel. See Figure

44

45.

Also attached to the cross rod is a trip lever (that actuates the shift lockout mechanism) and a cam release (that controls the impeller locking mechanism). Both are keyed to the traction lever rod.

Traction and Impeller Controls

Operation Impeller Locking Mechanism

As

a convenience feature, there is an impeller locking

mechanism that holds the impeller control in the

if

engaged position

the traction lever is also engaged. This feature lets the operator throw snow and propel the unit with one hand, leaving the other free to position the chute.

The impeller locking mechanism

is

comprised of only

four pieces. They are:

locking tang release cam locking latch torsion spring

The mechanism is disabled whenever the traction lever is in the disengaged position. See Figure

50

Power Shift Snowthrowers

46.

Operation Impeller

When the traction lever is engaged, the locking latch is free to rotate and engage the locking tang.

47.

NOTE: The impeller locking mechanism will work regardless of the order

depressed.

Locking

Figure

in

Mechanism (cont’d)

46

See

Figure

which the levers are

Figure

48

3.

Remove the push nut and the machine screw

the

right side of the impeller lever. See Figure

from

49.

Figure

If the traction lever is released while the impeller locking mechanism locking latch to release the impeller control. See Figure

48.

TRACTION AND IMPELLER CONTROLS

Traction and Impeller Controls Disassembly

1.

locking mechanism cover to the handle and remove the cover. Check the locking mechanism components for proper operation.

2.

Remove the

the right handle.

is

engaged, the release cam will push the

Remove the

two

cables from the cable holder on

47

Phillips screws securing the

Figure

Remove the hex head screw securing the traction

4.

control to the cross rod. Slowly pull

5.

releasing the locking tang and the release cam. Remove the locking tang and the release cam

from the cables and set them aside. Remove the E-clip securing the locking latch to

6.

the right handle and remove the locking latch and torsion spring.

Press out the impeller lever bushing and remove

7.

the auger lever. Continue removal of the cross rod by pulling

a.

from the

Set the trip lever aside. Completely remove the cross rod being careful

9.

not to lose the traction lever spacer. Press out the traction lever bushing and remove

10.

the traction lever from the

the

left

handle until the trip lever is released.

49

cross rod from the handles

left

handle.

it

out

Power Shift Snowthrowers

51

Traction and Impeller Controls

Traction and Impeller Controls Inspection

1.

Inspect all bushings checking for wear and replace as necessary.

2.

Check all rotating parts for corrosion and/or excessive wear. Lubricate with an anti-seize compound (Toro

part

number

505-109)

or replace

as necessary.

3.

Check the trip lever and release cam to insure that

the keys securing them to the cross rod are still

intact.

Traction and Impeller Controls Reassembly See Figure

50.

5.

Push the cross rod through the impeller lever bushing until

6.

Find the traction cable and install

it

protrudes-about

13

mm

extension spring into the release cam as shown in Figure

52.

NOTE: The recessed side of the release

face the control panel.

7.

Hook the extension spring into the slot provided in the right handle then mount the release cam onto the cross rod.

(1/2").

it

and the

cam

will

Figure

50

1.

Position the traction lever in the

left

handle and press in the traction lever

its

normal location on

bushing. NOTE: The traction lever bushing is reversible.

2.

Place

the

traction lever spacer inside the traction

lever and insert the cross rod through the traction

lever.

3.

Install the trip lever onto the cross rod as shown

in Figure

51.

Figure

8.

Fasten the impeller cable to the locking tang shown in Figure

9.

Position the locking tang inside the impeller lever

52.

52

and then push the cross rod all the way through. Secure with the Phillips screw.

10.

Install

the

torsion spring and the lock latch onto

the spindle and secure with the E-clip. See Figure

52

for proper spring orientation.

11.

Position both traction and impeller cables into the cable holder,

12.

Secure the cross rod to the traction lever with the

but

do not tighten at this time.

hex head screw and locknut.

13.

Before assembling any further, verify that everything works as described under Traction and Impeller Controls Operation, page

14.

Install a new push nut on the right end of the cross rod. Be sure to align the tabs in the push nut

from the keyway to insure retention.

15.

Install the locking mechanism cover with the

screws.

as

50.

90"

two

Figure

51

Traction and Impeller Controls Traction Cable Adjustment

4.

Position the impeller lever on the right handle and press in the impeller lever bushing.

The

traction

system

power from the engine. Therefore, the belt doesn't

NOTE: The impeller lever bushing is reversible. require much tension to drive the wheels.

Traction and Impeller Controls

52

very

Power

little

of

the

Shift

Snowthrowers

A

available

Traction and Impeller Controls Traction Cable Adjustment (cont'd)

1.

Check for proper tension by pushing the front housing wall. Proper traction belt tension is achieved when the wheels spin on a concrete floor in second gear,

but do not in fourth.

2.

Adjust tension by loosening the two jam nuts at the upper end of the traction cable. To increase tension, rotate the nuts sheath moves down. To decrease tension, the end of the sheath must be moved closer to the traction lever.

of

the snowthrower against a protected

so

that the

end

of

the

.23

mm to

.30

mm

(.009”

to

.012")

CAUTION: cause the snowthrower to creep when the

traction lever is

Traction and Impeller Controls Impeller Cable Adjustment

The impeller drive system will in some conditions transmit most of the power available from the engine. Therefore the tension

1.

Depress the impeller lever. Proper tension is

achieved when there is

between coils Figure

53.

Do

not overtighten because

in

the disengaged position.

on

this belt is fairly high.

.25

mm

(.010”)

of

the impeller cable spring.

it

may

clearance

See

Figure

2.

Adjust tension by loosening the the top of the auger cable. Increase tension by

rotating the nuts moves down. Decrease tension by moving the end of the sheath toward the impeller lever.

NOTE: Do not overtighten as impeller and auger to turn when the lever is in the disengaged position.

53

so

that the end

two

of

it

may cause the

jam nuts at

the sheath

Power Shift Snowthrowers

53

Traction and Impeller Controls

CAUTION: Servicing the Power Shift Snowthrower will require working with some of the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the Ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

CAUTION: The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel tank prior to such service taking the following precautions:

Drain

it

Wipe up any gasoline that may have spilled.

Do

not drain the gasoline near any open flame or spark. Do not smoke when handling gasoline.

CHUTE CONTROL

Chute Control Operation

The control for the discharge chute of the Toro Power

Shift Snowthrower was designed

would turn

rotated.

See

off

the spark plug.

outdoors and make sure the engine is cool.

In

the same direction that the input knob was

Figure

54.

off

and remove.

so

from

that the chute

the

The chute rotates from extreme

200

arc of

Chute Control Knob Removal NOTE:

I.

2.

3.

Chute Control Knob Installation

1.

degrees in about six turns of the crank.

Do

not remove

To remove the knob, use a pocket knife to pry the square knob cover.

Remove the push nut by drilling through the

tabs in the pushnut and prying

Remove the knob.

Install the knob on the

the

Figure

left

to right through an

knob unless necessary.

See

Figure

55

off.

rod,

recessed side

off

55.

two

up.

Figure

The operator provides control input by turning the chute

control knob at the control panel. This rotation is transmitted to the chute by means of a constant velocity joint and which drives the teeth on the chute.

two

shafts. The final shaft turns a worm gear

54

2.

Press on a new pushnut using an

socket.

3.

Reinstall the knob cover using a small amount of

clear silicone

Chute Control Upper

1.

Remove the

56.

NOTE: Do not remove the knob unless necessary.

2.

Pull the upper control panel. Do not lose the rubber washer above the gear.

3.

If desired, remove the upper removing the control panel.

if

necessary.

Rod

Removal

roll

pin in the upper gear. See Figure

rod

assembly out through the

two

Phillips screws from beneath the

Power Shift Snowthrowers

11

rod

bushing by

mm

(7/16'”)

Chute Control

Upper

Rod

Removal

(cont'd)

3.

Slide the upper rod through the bracket then slip

the rubber washer on the end of the rod. Install

the gear on

4.

Secure the gear with the roll pin.

the

rod with the teeth facing down.

Chute Control Upper See Figure

57.

Figure

Rod

56

Installation

Chute Control Lower

1.

Remove the roll pin from the lower rod gear.

2.

Pull

the rod from the worm gear bracket and then

forward to remove

3.

If desired, remove the worm gear bracket.

Chute Control Lower

See Figure

58.

Rod

it

from

Rod

Figure

Removal

the bracket.

Installation

58

Figure

1.

Mount the upper rod bushing on the control panel.

2.

Slide the upper rod assembly through the control panel from the top.

57

1.

Loosely mount the worm gear bracket with the carriage bolt, washer and locknut.

Insert the lower rod into the joint bracket.

2.

Place the worm gear in the worm gear bracket and

3.

slide the lower rod into

4.

Install the lower rod gear with the teeth facing rear of machine.

Adjust the worm gear bracket by pushing

5.

the

chute until the teeth on the chute and the worm

gear are just touching. Check for binding by

rotating the control knob. move the worm gear bracket out slightly and recheck.

DISCHARGE CHUTE

Discharge Chute Operation

CAUTION! Keep hands, discharge chute area. The impeller at the bottom of the discharge chute rotates rapidly and could cause severe injury

if

contacted. If the chute should

it.

it

toward

If

binding is noticed,

feet

and loose clothing from the

the

Power Shift Snowthrowers

55

Discharge Chute

Discharge Chute Operation (cont'd) clog, always stop the engine, wait for all moving parts

to stop, disconnect spark plug lead and then use a tool,

such as a broom handle, to clear the obstruction.

Discharge Chute Removal

1.

Remove the three socket head machine screws at the base of the chute.

2.

Remove the chute.

CAUTION! chute guard in place. inadvertent contact with the impeller.

Do

not operate the snowthrower without the

It

is there to help prevent

Discharge Chute Installation See Figure

CAUTION! When throwing snow, never direct the

discharge at people, pets or personal property as debris

or ice could

See Figure The discharge chute rotates through an arc of

be

picked up and thrown.

59.

200"

for

convenient directioning of snow while throwing. The chute rotates on a ring that is welded to the front

housing assembly. Three retainers hold the chute on the ring and allow

it

to rotate.

Directional changes are the result of manual inputs from the operator and are transmitted through the control rod assembly and the worm gear. The chute itself has teeth

manufactured into

it

which mate

with

the worm gear.

60.

Figure

59

The chute deflector is hinged and gives the operator greater control over the vertical and horizontal distances the snow is thrown.

A

piano hinge is used to

reduce the amount of snow blown through the hinge. Nylon washers hold the top of the chute in position and

allow

it

to be moved without the use of tools when the

locknut is properly tightened.

The chute deflector is not removable or replaceable separately.

Figure

1.

Lightly grease the chute ring with a

60

#2

lithium

base grease.

2.

Loosen the nut under the worm gear bracket to facilitate installation of the chute.

Place the chute on the chute ring with the

3.

facing

forward.

Install

the

two

rear chute retainers

chute

using socket head machine screws and nylon locknuts.

Install the front chute retainer being sure that the

4.

chute guard is trapped by the chute guard bracket.

Adjust the worm gear bracket by pushing

5.

it

toward the chute until the teeth on the chute and the worm gear are just touching. Check for binding by rotating the control knob.

If

binding is noticed, move the worm gear bracket out slightly and recheck.

Discharge Chute

56

Power Shift Snowthrowers

SECTION

IDLER SYSTEM

4

CAUTION! Servicing the Power require working with some of the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch the spark plug

CAUTION! The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain

Wipe up any gasoline that may have spilled

Do not drain the gasoline near any open flame or spark Do not smoke when handling gasoline

Idler System Operation See Figure 61

off

the spark plug

it

outdoors and make sure the engine is cool

Shift

off

and remove

Snowthrower will

The impeller idler pulley is set up similarly, again rotating

about a plastic bushing and using return and the other to prevent over-tensioning.

Also

rotating about the same shaft is the brake arm.

so

spring loaded

the

impeller pulley whenever there is no tension on the impeller cable. When the impeller is engaged, the impeller idler arm pulls the brake pulley.

Idler

System Removal

1. Remove the three cap screws securing the belt

cover to the snowthrower frame.

2. Remove the the idler assembly to the snowthrower frame. Figure 62.

that the brake pad is pressing against

two

hex head cap screws securing

two

springs, one for

off

of the impeller

It

is

See

3.

Figure 61

two

The idler assembly is comprised of for the traction belt and one for the impeller belt and the

auger brake.

The traction idler pulley rotates about a plastic bushing

two

and is centered by the idler to the disengaged position once tension is

released from the cable. The other spring is attached to

the traction cable and prevents over-tensioning.

Power Shift Snowthrowers

springs. The lower spring returns

idler pulleys, one

4.

Idler System Disassembly

1.

2.

57

Figure 62

Pull the idler assembly from the frame and

two

disconnect the arm bracket. See Figure

Remove the hex head cap screw and nylon lock nut from the idler arm bracket and remove the

traction and impeller cables.

De-tension the impeller brake torsion spring by moving the short end of bracket tang.

Remove the snap ring and Belleville washer from

the

idler pin on the impeller brake side.

idler springs from the lower

63.

the

spring

off

the idler arm

Idler System

Idler System Disassembly (cont'd)

1.

Insert a hex head cap screw into each of the idler pulleys.

Figure

CAUTION !

Eye protection and heavy gloves are recommended when installing spring.

Check the impeller pulley brake pad for excessive

3.

wear and remove if necessary. Remove by grasping with a needle nose plyers and rotating.

Pull the idler pin from the idler arm bracket and

4.

remove the Remove the

5.

arms. Remove the fastener retaining the cables and

6.

remove the cables.

The torsion spring is under tension.

two

idler arms.

two

idler return springs from the idler

63

NOTE:

the short race of each idler pulley bearing.

Secure with the nylon locknuts and check for free rotation of each idler pulley

2.

Mount the using Figure

3.

Insert the secure with the idler pin using Figure guide.

4.

Hook the holes on the idler arms.

5.

If

apply a small amount arm and install the brake pad.

6.

Slip the torsion spring into the brake arm with the short side of the spring on the opposite end of the brake pad. Slip onto the idler pin and secure with

a

NOTE:

time.

7.

Grasp the short end

needle nose plyers and slip into the tang on the idler arm bracket.

See Figure

The head of each cap screw must be on

two

idler arms onto the idler bushing

64

as a guide.

two

idler arms into the idler bracket and

two

idler return springs into the lower

the impeller pulley brake pad was removed,

of

adhesive onto the brake

belt,

washer and snap ring.

Do

not attempt to tension the spring at this

of

the torsion spring with a

65

64

as a

Remove the idler bushing from the idler arm pivots

7.

and inspect for wear. Replace Check the traction idler pulley and impeller idler

8.

pulleys for free rotation on the idler arms. necessary, remove and replace the pulleys.

Idler System Reassembly See Figure

64.

Figure

64

if

necessary.

If

Figure

CAUTION!

Eye protection and heavy gloves should be worn when performing this procedure.

Idler System Installation

1.

Find the impeller cable and insert the spring end into the upper hole on the impeller idler arm, then slip the end of the impeller cable sheath into the slot provided at the top

The torsion spring is under tension.

65

of

the idler bracket.

Power Shift Snowthrowers

Idler System Installation (cont’d)

2.

Find the traction

cable

and insert the end of the traction spring into the upper hole on the traction idler arm, then install the end of the sheath into the slot provided at the top of the idler arm bracket.

3.

Secure both cables with the hex head cap screw and nylon locknut. See Figure

Figure

66.

66

4.

Hook both idler return springs onto the corresponding tabs provided at the bottom of the idler arm bracket as shown back in Figure

5.

Insert the idler assembly into the snowthrower frame and secure the

NOTE:

Verify that the brake pad is still in place

two

hex head

cap

screws.

after installing idler assembly.

6.

Mount the belt cover

onto

the snowthrower frame

and secure with the three self-tapping screws.

7.

Adjust the traction and impeller cables described below.

Idler

System Adjustment

52

See Traction Cable Adjustment, page Cable Adjustment, page

53

for information on proper

and Impeller

idler adjustment.

63.

as

Power Shift Snowthrowers

59

Idler System

SECTION

5

PIVOT AND LATCH SYSTEM

CAUTION! Servicing the Power Shift Snowthrower will position, the latch rod and the latch plate retain require working with some of the moving prevent accidental starting of the engine while performing service, take

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug

CAUTION! The Power Shift Snowthrower has the feature of being able to for service and storage. Always drain the fuel from the tank prior to such service taking the following precautions:

Drain

Wipe up any gasoline that may have spilled

Do not drain the gasoline near any open flame or spark

Do

not smoke when handling gasoline.

PIVOT SYSTEM

off

it

outdoors and make sure the engine is cool

the

following precautions:

off

and remove

the spark plug

be

stood on the front housing

parts.

To arms. See Figure

The latch rod rests in either of the

normal operation. However, when power shifting, the latch cable pulls up on the latch plate thereby allowing the latch rod to move freely past the stops on the latch plate.

68.

Figure

68

two

stops during

the

pivot

Pivot System Operation

The Power Shift snowthrower, like most snowthrowers,

uses a chain to transfer power from the transmission to the rear axle. However, unlike any other snowthrower, the Power Shift snowthrower allows the wheels to pivot forward and backward, thereby transferring weight to and from the front end. See Figure

Figure

67.

67

Power for the swinging action is provided by the

transmission. For instance,

move the wheels from the forward to the rear position, the latch plate transmission powers the wheels backwards by driving

in reverse. The standard rear axle is solid, providing no differential

action. An optional differential

information on the differential kit, see Section

Differential Kit, page

Pivot System Disassembly

1.

Remove the klik pin securing the wheel to the axle and remove the wheel and tire assembly. Also remove the thrust washer that fits between the wheel and the pivot arm.

2.

Remove the right half of the chain guard.

3.

Remove the nylon locknut that secures the latch rod to the

4.

I

Remove the nylon locknuts and Belleville washers

from the pivot arm pivot bolts. (Thread forming

screws secured the latch rod on

is

moved out of the way, then the

88.

left

hand pivot arm.

if

the operator wishes to

kt

is available. For more

'88

units only.)

14,

The pivot arms pivot about an axis coincident with the

output shaft. This is important because it prevents

changes in chain tension as the axle swings. Once in

Pivot and Latch System

60

NOTE: The

from the pivot arms. It

be removed at this time.

pivot

bolts

may be difficult to remove

is

Power

not necessary that they

Shift

Snowthrowers

Pivot System Disassembly (cont’d)

5.

Remove the left hand pivot arm complete with the

chain guard.

6.

Remove the latch rod, pivot arm, and rear axle

assembly by slipping the chain

off

sprocket.

7.

Remove chain guard from the

8.

Remove the latch rod from

left

hand pivot arm.

the

right hand pivot

arm.

9.

If necessary, remove the bushings from the pivot arms using an arbor press.

If

10.

desired, remove the pivot bolts. They may flare somewhat once installed and may have to be pressed out with an arbor press.

11.

If

necessary, remove the roll pins from the axle.

Pivot System Reassembly

See

Figure

69.

the large

6.

Insert the latch rod, pivot arm, and axle assembly into the proper location on the right side of the chassis. Be sure to slip the chain over the sprocket.

NOTE: There must be a Belleville washer between the frame and the pivot arm. The serrated side of the Belleville washer should face

7.

Slide the

left

pivot arm and chain guard assembly

the

pivot arm.

over the axle and into position. NOTE: Make sure all washers are in place. There

should be a Belleville washer (serrated side

toward the pivot arm) between the pivot arm the chassis, a large flat washer (between the end

of the latch rod and the pivot arm), and a thrust

washer between the roll pin and the pivot arm when

it

is installed correctly. See Figure

and

70.

8.

Secure the assembly by tightening the pivot arm bolts and nuts, and the nuts on the latch rod.

9.

Mate the right half of the chain guard with the half and secure with the three Phillips screws.

Figure

69

10. Coat the end of the axle with an anti-seize compound Toro part number 505-109).

1.

Press new bushings into both pivot arms.

2.

Install the chain guard on the left hand pivot arm.

apply in the bushing area as “gummy”.

11. Slide the thrust washers over the end of the

3.

Press roll pins into the two inner holes on the axle and slide thrust washers on each end

so

that they

rest against the roll pins.

4.

Install the latch rod into the right hand pivot arm, Secure the wheels with the klik pin. Use the outer making sure that there is a large flat washer on hole each side of the pivot arm. Don’t tighten the nylon hole

and install the wheel assemblies. Note that the

part of the hub with the hole in Rotate wheel to distribute anti-seize compound,

if

free wheeling is desired, or use the inner

if

drive is desired.

locknut at this time.

5.

Insert the axle into the right pivot arm and latch rod assembly. The sprocket will be on the

of the axle when

it

is installed correctly. Latch System Disassembly

left

side

LATCH

SYSTEM

Figure

70

Do

it

may become

it

faces outward.

left

not

axle

NOTE: Make sure there is between the roll

Power

Shift

Snowthrowers 61 Pivot and

a

thrust washer 1. Remove the panel fastener from the latch plate

and the pivot arm. and slip out the end of the latch cable.

Latch

System

Latch System Disassembly

2.

Pull the latch plate down to detension the latch

plate spring, then remove the nylon locknuts on

either side of the latch plate.

3.

Remove the latch plate and latch plate spring from

the snowthrower frame.

Latch System Reassembly

See Figure

71

2.

Place the latch plate in position.

3.

Secure the latch plate with the

two

shoulder bolts and the nylon locking nuts. Make sure that the head of the bolts are on the inside of the frame.

4.

Swing the latch plate up into position and slip the cable into the slot provided. Secure the cable with

a

new panel fastener. See Figure

Figure

72

72.

Figure

71

1.

Position the latch plate spring on the right side

the frame.

of

5.

Check to insure that the latch plate operates correctly and does not bind.

6.

Complete latch plate servicing by reassembling

the pivot and drive assembly as described under

Pivot System Reassembly, page

61.

Pivot

and

Latch System

~-

SECTION

CAUTION! Servicing the Power Shift Snowthrower will require working with some of the moving prevent accidental starting of the engine while performing service, take the following precautions:

6

parts.

TRANSMISSION

To

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch the spark plug.

CAUTION! The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following precautions:

Drain

it

Wipe up any gasoline that may have spilled.

Do not drain the gasoline near any open flame or spark. Do not smoke when handling gasoline.

Transmission Operation

The transmission used on the Power Shift Snowthrower

is similar in concept to that used in Toro Rear Drive Rear Baggers although the Power Shift gearbox has

directional capability as well as speed reduction. Six separate systems work together to transfer power from the input pulley to the output sprocket.

off

the spark plug.

outdoors and make sure the engine is cool.

off

and remove.

Figure

NOTE: The jaw clutch has no intermediate position. should always bevel gears.

be

completely engaged with one

73

of

It

the

Input

System: The input system is straight forward,

consisting of a large pulley, a hub, and a pinion gear.

The assembly is supported in the case by a

See Figure

Bevel Gears: See Figure freely with respect to the intermediate shaft and the gears on the intermediate shaft. They are driven in opposite directions by the input pinion gear.

The reverse bevel gear is supported on the intermediate

shaft by a bushing because transmission is in forward. The forward bevel gear rides on the first gear hub. bevel gear because it rotates on the hub only when the

transmission is in reverse. The sliding jaw clutch is coupled to the fixed gear cluster.

It

is free to slide back and forth between the two bevel

gears. The direction of rotation of

is determined by which bevel gear the sliding jaw clutch engages.

73.

74.

The bevel gears rotate

it

freewheels while the

No

bushing is used on the forward

the

ball

bearing.

fixed gear cluster

Fixed Gear Cluster: The fixed gear cluster and the sliding jaw clutch rotate as an assembly on the intermediate shaft. See Figure

Selectable Gear Cluster: The selectable gear cluster consists of four independent gears, two sleeves and the shift mechanism. freely on the output shaft and each is supported by a bushing.

NOTE: The sleeve closest to the sprocket gear in the speed reduction system.

See

Figure

74

75.

76.

The sleeves rotate

is

also the first

Power Shift Snowthrowers

63

Transmission

Transmission Operation (cont'd)

and number three speed reduction gears. Gears and three are joined and therefore rotate at the same speed.

The number three speed reduction gear transmits

power to

four gear and the output shaft are splined together,

power is transmitted to the output shaft and sprocket.

NOTE: The number four speed reduction gear is the only component on the output shaft that the output

the

number four gear. Because the number

is

shaft.

coupled to

two

Figure

The four gears are driven by the gears opposite them

on the intermediate shaft. The selectable gears rotate

freely on the sleeves when the transmission is in neutral.

However, when the transmission is in gear, the shift mechanism engages

and the sleeves rotate together.

Shift Mechanism: See Figure consists of collar and the shift fork. Control input from the operator rotates the shift fork

desired gear. Speed Reduction Gear Set: In order to bring the speed

of the transmission down to one acceptable for snowthrowing, a speed reduction gear set was incorporated. See Figure

The first gear in the speed reduction gear set is also the sleeve in which the shift keys slide. Therefore, when the transmission is in gear, the number one speed reduction gear rotates. This transmits power to the number

two

one

sliding shift keys, a shift sleeve, a shift

so

76

of the gears

77.

that the sliding keys engage the

78.

so

that the gear

The shift mechanism

two

Transmission Removal

NOTE:

steps, the use of air tools is recommended. However, do not use air tools to tighten or loosen self-tapping screws in aluminum. Thread damage could result.

1.

Figure

Because transmission removal requires many

Stand the unit on the front housing to provide

better access to the transmission. Don't forget to drain the fuel first as described at the beginning of this section.

77

78

Transmission

64

Power Shift Snowthrowers

Transmission Removal various operations of the transmission. Check for

2.

Disconnect the lower shift rod from the bellcrank proper operation of the jaw clutch and bevel on the back of the transmission. gears. Check the gear selection shift fork to insure

that the shift mechanism is working correctly.

3.

Remove the belt cover from the underside of the inspect for broken gear teeth and-worn bushings

off

unit and slip the belt

4.

Remove the cover plate from behind the

the transmission pulley. at this time.

transmission.

5.

Remove the pivot system, as described under

Pivot

System Disassembly, page

6.

Remove the latch system as described under Latch System Disassembly, page

7.

Remove the

transmission frame to

two

rear nylon locknuts securing the

the

snowthrower frame and

60.

61.

swing the assembly down, out of the unit. Be

careful not to damage the reverse cable.

Figure

79.

See

Figure

80

Also

4.

If

further disassembly is required, remove the input shaft, the intermediate shaft and the output shafts. Remove all excess grease, then clean in a

solvent bath.

5.

Remove the three self tapping screws from the

input pulley. Complete disassembly of the input

shaft by removing the pinion through bolt and nut and inspect the components for damage or wear and replace as necessary.

Figure

8.

Remove the four self-tapping screws from the top the output shaft, taking note of spacer position. of the transmission frame while supporting 'the transmission to prevent

9.

Remove the reverse cable clamp and the reverse or take notes to insure proper replacement. cable from the top of

80.

79

it

from falling.

the

transmission*

See

Figure

6.

Carefully pull the gears, sleeves and spacers from

NOTE:

The number of washers used and

position will vary from year to year. Draw a sketch

7.

Inspect the inside and outside teeth on the gears,

the sleeves and the bushings for damage or wear and replace as necessary.

Transmission Disassembly

1.

Remove the roll pins on the top

of

the transmission that secure the gear selector control arm and the direction control arm to the shift forks. Remove the

two

control arms.

2.

Remove the six hex head screws holding the gear

See

Figure

80.

box halves together and remove the upper gear case half.

3.

With the gear

a

counter clockwise direction, checking the by pressing

box

open, rotate the input pulley in

8.

If

desired, the ball bearing can be removed from the output shaft by supporting the inner race of the bearing and then pressing the output shaft out using an arbor press. Be careful not to press on the outer race of the bearing or damage to the bearing may result.

9.

Remove the gears, sleeves, spacers and bushings

from the intermediate shaft.

10.

Complete disassembly of the intermediate shaft

out

the roll pin.

their

Power Shift Snowthrowers

65

Transmission

Transmission Disassembly (cont'd)

11. Inspect all components for damage and wear. Replace as necessary.

Transmission Reassembly NOTE: Use only Lubriplate@ Mag 1 Grease Toro part

number 505-101) in the transmission. Its excellent performance at low temperatures greatly enhances the service life of the transmission. See Figure 81.

intermediate shaft. Install into the proper location in

the

lower transmission case. Make sure that the

keys on the bushings align properly with the key

sets in the lower case. See Figure

82.

Figure 82

Figure 81

Intermediate Shaft: Begin reassembly of the

1. Intermediate shaft by pressing in the coil pin

that

it

is centered in the intermediate shaft.

2.

Slide the speed reduction gear on the

so

that

it

intermediate shaft

properly engages the

coil pin. Consult your notes or sketch to find out how many

3.

spacers fit between the speed reduction gear and

the large 51-tooth gear. Slide the appropriate

number of spacer washers onto the intermediate Shaft.

Slide the 33-tooth and the 51 -tooth gear onto the

4.

26 tooth gear.

Slide the assembly, large gear first, onto the

5. intermediate shaft.

Apply grease to the spline and hub on the 15 tooth

6.

gear. Slide the 15-tooth gear and sleeve onto the intermediate shaft, geared

end

first. Make sure that the geared end mates completely with the 26-tooth gear.

so

NOTE: Maximum end play is

than

(.030")

add a thrust washer (Toro part number

(.030").

If greater

257- 10) to either end of the shaft.

9.

Output

Shaft: See Figure

Figure

83

83.

Begin output shaft assembly by pressing the bearing onto the output shaft. Be sure to press only on the inner race when installing the bearing

to prevent possible bearing damage.

Space Between Sprocket and Bearing:

1.22

-08

cm (.48

2.03')

ball

7.

Slide the large thrust washer

)if

used) over the

splined portion of the 15-tooth gear and follow

with the forward bevel gear, the jaw clutch, and the

reverse bevel gear. Complete intermediate shaft assembly by sliding

8.

the appropriate number

bushing, flanged side first, on each end

of

thrust washers and one

of

the

Transmission

66

Slide the large 42-tooth speed reduction gear onto the output shaft with the hub side first. Then consult your notes and slide on the appropriate number of thrust washers.

11.

Apply grease to the keyway and the

Do

sleeve.

it

may get "gummy" cause premature failure. Slide

not get grease in the bushing area as

O.D.

of ths

Power Shift Snowthrowers

Transmission Reassembly

the

first half of the shift sleeve with the 19-tooth

gear onto the output shaft, geared end first. Slide the four selectable gears onto the output

12.

83

shaft as shown in Figure

Apply grease to second sleeve half then slide onto

13. the output shaft, flanged end last. Make sure that the tabs properly engage the recesses

19-tooth gear sleeve. When properly assembled, the outer sleeve half and the 15-tooth gear will turn together.

above.

on

the

19. Assemble the input pinion, ball bearing, hub and pulley as shown in Figure

85.

Assemble the shift mechanism consisting

14. sleeve, the

grease to the shift collar groove.

Slide the shift mechanism, shift keys first,

15. output shaft and into the appropriate slots gear sleeves.

Complete assembly of the output shaft by

16. installing the correct number of spacers and the output bushing, flanged end first.

Install the assembled output shaft into the lower

17. transmission case. Use Loctite(R) (Toro part number 505-103) to secure the outer race of the bearing to lower gearcase. Check for proper operation of the various components, making sure that there is neither excessive play nor binding. lower case.

install the

18. Make sure that both shift collar grooves have been

greased.

two

shift keys and

Align

the bushing keys with keysets in the

two

shift forks as shown in Figure 84.

the

shift collar. Apply

of

onto

in

the

the the

Figure

20. Use a small amount of Loctite(R) (Toro part number 505-103) to secure the outer race of the bearing to the lower gear case half. Be careful not

to get Loctite@ on the pinion or the hub.

21. Rotate the input pulley in a counterclockwise direction and check for proper operation of the entire transmission.

22. Apply (14.5 oz) of Lubriplate(R) Mag 1 grease (Toro

part

number under gears first, then top. Also grease shift forks. Install upper gear case half.

23. Press the gear selector control arm and the directional control arm onto the shift forks

shown

in

Figure

505-101)

86.

85

to gears

in

transmission.

Fill

as

Power

Shift

Snowthrowers

Figure

84

67

Figure

86

Secure with the Again, check to insure that the transmission

operates freely, then secure the halves with the six self tapping hex head screws. Coat screws with oil to prevent them from seizing.

two

roll pins.

two

1.38 kg m (120 in Ibs)

gear case

Transmission

Transmission Installation

NOTE: Because of the number of steps involved, air tools are recommended. However, do not use air tools when installing or removing self-tapping screws from aluminum. Damage to the threads could result.

Apply an anti-seize compound (Toro part number

1. 505-109)

to all pivot and contact points on top

of

the transmission including detent button, detent

box, link and bellcrank. Before installing the transmission, check to be

2. sure the input shaft and all controls on top of the transmission are working correctly.

Insert the end of the reverse cable spring into the

3.

directional control arm and install the reverse cable clamp.

Secure the transmission to the transmission frame

4.

with the four transmission screws and Belleville washers (serrations up).

Fasten thetransmission frame to the snowthrower

5.

frame with the four hex head cap screws.

Slip the traction belt onto the transmission pulley.

6.

Install the latch plate as described under Latch

7.

System Installation, page 62. Install the pivot and drive assembly as described

8.

under Pivot System Reassembly, page Fasten the lower plastic belt cover to the frame

9.

using the

two

self tapping screws. The tabs on

61.

the edge of the cover should be located behind

the bulkhead plate.

10.

Place the transmission in second gear by pushing

the rear of the bellcrank to the top of

pulling down

Install the rear cover plate with 4 nylon lock nuts.

11.

Check chain adjustment, as described under

12.

2

clicks. See Figure

Figure

87

its

travel, then

87.

Maintenance Drive Chain Adjustment, page

38.

Install the lower shift rod into the bellcrank and

13.

adjust per instructions under Control Service Shift Lever Adjustment, page

14.

Check latch cable adjustment as described under

Box

Control

49.

page Check proper adjustment of the reverse cable as

15.

described under Control Cable Adjustment, page

Service Latch Cable Adjustment,

Box

Service Reverse

49.

Box

Power Shift Snowthrowers

SECTION

CAUTION! Servicing the Power Shift Snowthrower will

require working with some of the moving parts. To prevent accidental starting of the engine while

performing service, take the following precautions:

7

AUGER

Rotate the ignition key to

Pull

the wire Make sure the wire does not accidentally touch the spark plug.

CAUTION! The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the tank prior to such service taking the following

precautions:

Drain

it

Wipe up any gasoline that may have spilled.

Do not drain the gasoline near any open flame

spark.

Do

not smoke when handling gasoline.

AUGER

Auger Operation The auger on

turned at a relatively slow rate of speed

by the auger gear box. It’s purpose is three fold. Firstly,

it

breaks hard packed snow and ice to facilitate its

movement. Secondly,

screw type action to the impeller. Thirdly, the patented drum meters the snow before feeding it to the impeller to reduce the possibility of clogging at the impeller.

off

the spark plug.

outdoors and make sure the engine is

the

two

stage Power Shift snowthrower is

off

and remove.

fuel

from the

(125

to

126

it

conveys the snow by a cork

cool.

or

rpm)

Figure

5.

Pull the auger half from the auger shaft.

6.

Inspect all or repair as necessary.

Auger Installation

1.

Loosen the four nylon locknuts securing the

flange bearing to the side plate. This will insure

proper centering of the flange bearing when the side plate is reinstalled.

2.

Coat the auger shaft with an anit-seize compound

(Toro part number

onto the auger shaft. Do not apply anti-seize to the

bushing area.

NOTE: be sure to install them on the correct sides! (When installed incorrectly the auger will move the snow

toward the side plate rather than the impeller). The

auger half is installed correctly when the augers

are positioned as shown in Figure

parts

for damage and wear and replace

If

both auger halves have been removed,

88

505-109)

and slide the auger

89.

Auger Removal There are

removed separately. The following describes removal one of the auger drums.

1.

2.

3.

4.

Power Shift Snowthrowers

two

augers, a left and a right. They can be

Remove the augerthrough bolt as shown in Figure

88.

This will allow free wheel movement of the

auger to facilitate removal of some of the nuts and

bolts.

Remove the bolt and accompanying washer at the end of the auger shaft.

Remove the skid and the skid bracket. Remove the remaining five side plate fasteners

and remove the side plate.

of

69

Figure

89

Auger

Auger Installation

Slide the side plate

3.

onto the auger shaft and secure with the top five cap screws and lock nuts.

4.

Fasten the

housing and

(cont'd)

and

auger bearing assembly Tighten the four

skid

support bracket to the auger

loosely

install the

skid.

5.

Support shaft is centered in the hole in the side plate.

6.

Secure the auger half to the auger shaft using the long cap screw and nylon lock nut.

7.

Adjust the scraper and skids as described under Skids Installation and Scraper Installation, pages

78

the

and

auger

cap

79.

so

that the end

screws and nylon lock nuts.

of

the auger

70

SECTION

8

AUGER GEAR

BOX

CAUTION! Servicing the Power

require working with some of the moving parts. prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to off and remove. 1. Disassemble the snowthrower as described in, Pull the wire off the spark plug. under Impeller and Pulley Removal, page Make sure the wire does not accidentally touch

the spark plug. 2. Remove the auger halves from the auger shaft by

CAUTION! The Power Shift Snowthrower has the auger halves and the auger shaft. feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following Auger

precautions: 1. Remove the drain plug from the auger gear box

Drain

it

outdoors and make sure the engine is cool.

Wipe up any gasoline that may have spilled.

Do

not drain the gasoline near any open flame or 2. Remove the six self tapping flange head screws

spark. holding the

Do

not smoke when handling gasoline.

Auger Gear Box Operation The auger gear box is a

meaning that its input and output shafts are at

degrees to each other. The auger box accomplishes this by using a worm and helical gear combination. See Figure

90.

Shift

Snowthrower'

90

degree transmission,

will

To

90

ment. Do not use Lubriplate(R) Mag 1 grease in the auger gear box.

Auger Gear Box Removal

removing the carriage bolts passing through the

Gear

and drain the gear box lubricant into an approved container for recycling.

3.

Separate the gearbox halves. NOTE: Be careful not the distort or damage the

gear box halves when prying the

4.

Before disassembling further, inspect all parts for

wear and/or damage making note

require replacement. Before removing the seals, bushings and thrust

5.

bearing from the input shaft, remove any

corrosion and/or burrs from the shaft.

Disassembly

two

gear box halves together.

two

halves apart.

of

those which

75.

Figure

The auger gear box also provides speed reduction for the auger. The impeller, when at full throttle, turns at approximately 1250 rpm, while the auger turns at 125 to

126 rpm under the same conditions.

Lubrication is supplied by an pressure

This is necessary because of the temperatures and

pressures provided by a worm helical gear arrange-

(EP)

gear oil with an

90

SAE

API

90

weight extreme

rating of

GL-5

or

GL-6.

Remove the bushings, seal, thrust bearings,

6.

spacers and snap ring from the input shaft. overstress

7.

Remove the output shaft along with the helical gear and spacers from the gear box half.

Remove the helical gear, spacers and the

8.

woodruff key from the output shaft.

If

9.

necessary, remove the seals and bushings from the gear box halves by pressing out on an arbor press with an appropriately sized pilot.

NOTE: the blue Hylomar@ sealant (Toro part number 505-105) from the gear box halves.

without being removed. However, remove any

excess oil in the tongue and groove area. NOTE:

will use a different sealant that will affect these

instructions. Look for forthcoming information in Service Bulletin form.

the

snap ring during removal.

('88

and

'89

units only) Do not scrape off

It

'90

and newer Power Shift Snowthrowers

Do

not

will reseal

Power

Shift

Snowthrowers 71 Auger Gearbox

Auger Gear

See Figure 91.

Box

Reassembly

Slide the helical gear onto the auger shaft

5.

it

covers the woodruff key.

Slide one thick thrust washer onto each

6.

auger shaft

Input

7.

shaft until attempt to stretch Figure

so

that they are next to the helical gear.

Shaft:

Slide the snap ring onto the input

it

is properly seated in

it

over the worm gear end). See

93.

its

so

that

end

of

the

groove (do not

NOTE:

groove. If should

Slide the thrust washer, a thrust bearing and

8.

another thrust washer onto the input shaft they rest against the snap ring.

Slide the

9. first, onto the input shaft.

The snap ring should not spin freely in the

it

does,

it

has been overstressed and

be

replaced.

93

Figure

oil

impregnated bushing, flanged side

so

that

Figure 92

Install new seals in the gear box halves. Press the

2.

seals hollow side inward from the outside of the gear box until they bottom out on the oil impregnated bushings.

Clean the gear box halves, but do not scrape the

3.

original HyIomar(R) sealant from the mating surfaces. Apply a light coat of Hylomar(R) sealant

(Toro

part

number groove area. Allow the sealant to dry somewhat, until the surface has flashed (turned dull and

tacky: at least

Auger Shaft:

4.

by placing the woodruff key in the keyway at the center of the auger shaft.

505-105)

15

minutes).

Begin assembly of the auger shaft

to the tongue and

Coat the inside surface of the seal with gear oil,

10.

then slide the seal, hollow side toward the inside of the gear

Once the Hylomar(R) sealant Foro part number

11.

505-105) on the gear case halves has flashed, slip the auger shaft into the half of the gear case with the plug in key.

Lay the input shaft into the left gear box half,

12.

making sure that the thrust bearing components,

the seal, and the bushings are in their proper

locations. See Figure Slide the right gear case half over the auger shaft

13. and mate the

Coat the auger gearbox screws with

14.

seizing. Secure with the six flanged head self tapping capscrews. Tighten to Ibs) in the order shown in Figure

box.

it

until

it

bottoms

two

gear box halves.

Power

94.

out

on the woodruff

oil

1.38

kg m

95.

Shift

Snowthrowers

to prevent

(120

in

Auger Gearbox Reassembly (cont’d)

anti-seize compound to the bushing area as

become’ “gummy”.

it

may

Figure

Auger Gearbox Screw Torque

1.38 kg m (120 in

94

Ibs)

NOTE:

to install them correctly as shown. See Figure

Failure to do

toward the side plates rather than the impeller.

Loosen the flange bearing at

4.

housing to allow assembly is installed.

Slide the flanged bearings on the ends of

5.

auger shaft. Slide the auger assembly into the front housing

6.

and loosely secure the auger flange bearings to the side plates with the hex head screwsand nylon locknuts. See Figure

The auger halves are different,

so

will result in snow being moved

the

rear of the front

it

to re-center when the auger

96.

so

be

sure

80.

the

Figure

15. Fill with Pressure gear oil, with an API rating of

GL-6.

505-22)

Auger Gear Box Installation

1.

Drain the fuel from the tank using a crank type pump.

2. Secure the impeller to the auger shaft with flanged head cap screws and nylon locknuts.

3.

Coat the auger shaft with an anti-seize compound

(Toro

halves onto the auger shaft. Do not apply

(4.5

oz) of

Apply Permatex(R) (Toro part number

to plug.

part

number

95

SAE

505-109)

90 weight Extreme

and slide the auger

GL-5

or

two

Figure

7.

Prop the auger in the hole in the side plate. Once centered, tighten

the flanged bearing fasteners.

sides.

8. Tighten the three fasteners securing the impeller shaft flange bearing to housing.

9.

Install the large flat washer and the capscrew into

the end of the auger shaft.

10. Bring the and secure with the

11.

Slip the impeller belt over the impeller pulley and install the idler assembly as shown in Figure

12.

Check for proper operation of the impeller and

traction belts then install the upper belt cover with the three self tapping flanged head screws.

13. Install the chute worm gear assembly with the carriage bolt and nylon locknut. For more information on this, see Discharge Chute Installation, page

so

two

halves of the snowthrower together

96

that they auger shaft is centered

Do

this to both

the

rear of

Do

this to both sides.

six

flanged head capscrews.

56.

the

front

97.

Power Shift Snowthrowers

73

Auger Gearbox

Auger Gear Box Installation (cont’d)

14.

Stand the snowthrower on the front housing and install the lower belt cover using the

two

flanged

head self tapping capscrews. Secure the auger halves to the auger shaft by

15.

installing the long shank hex head screws through

the auger

shaft.

NOTE: The head of the capscrews should rest

against the spacers.

Check to insure the skids and scraper are properly

16.

adjusted. For more information on this see Skids

Installation, page

17.

Complete impeller servicing by performing a final

79.

78,

and Scraper

operational check.

Figure

97

Power Shift Snowthrowers

SECTION

CAUTION! Servicing the Power Shift Snowthrower will

require working with some of the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch the spark plug.

CAUTION! The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank .prior to such service taking the following

precautions:

Drain

it

Wipe up any gasoline that may have spilled. Do not drain the gasoline near any open flame or spark.

Do

not smoke when handling gasoline.

off

the spark plug.

outdoors and make sure the engine is cool.

9

off

and remove.

IMPELLER

AND

2.

3.

4.

PULLEY

Set the Power Shift Snowthrower back into its

normal position and remove the top from in front of the engine and slide cables, out of the way.

Remove the chute worm gear assembly from the front housing and set aside.

Before separating the front housing from the

snowthrower frame, support the rear of the front

housing (that houses the impeller) with blocks. This will prevent the unit from falling when the fasteners are removed. Remove the six cap

screws that fasten the front housing to the frame

and

separate the

SYSTEM

two

halves. See Figure

belt

it

99.

cover

up the

Impeller and Pulley Operation

The impeller is a fan which rotatesat approximately

rpm.

It

propels the snow fed to the chute. The impeller shaft. The impeller shaft also drives the auger through the auger gear box. by an oil impregnated bushing and at the back of the front housing by a flange bearing. The impeller shaft is driven by a pulley, power supplied to that pulley by engine crankshaft and the idler shown in Figure

It

is supported at the auger gear box

it

by the auger through

is

connected to the impeller

1250

the

98.

Figure

99

Figure

Impeller and Pulley Removal

1.

Stand the Power Shift Snowthrower on the front housing and remove the belt cover from the bottom

pulley.

Power Shift Snowthrowers

of

the frame. Slip the impeller belt

98

off

the

75

Impeller and Pulley System

Impeller and Pulley Removal (cont'd)

9. Remove the impeller from the Impeller shaft by removing the

locknuts. Be careful not to lose the

hub inserts. (On impeller to the

two

flanged cap screws and nylon

two

'88

units, set screws retained the

shaft.)

impeller

10. If impeller bearing servicing is necessary, remove the flange bearing from the rear of the housing by removing the three nylon locknuts.

1 1. Inspect all parts for damage and wear and replace

as necessary.

Impeller and Pulley Installation

1. If the impeller bearing was removed, reassemble the bearing as shown in Figure 101. Note that the flanged portion of the oil impregnated bearing faces forward.

The entire flange bearing must fit behind the front

housing.

Also

notice the the hollow head set screw

faces up when correctly installed.

3.

Prepare for impeller installation by making sure that the inserts are in place on the impeller hub and by coating the impeller shaft with an anti-seize compound (Toro part number 505-109). Fasten the impeller to the impeller shaft with the flanged cap screws screws were used on

NOTE:

When the flanged head cap screws are

and

nylon locknuts. (Set

'88

product.)

two

installed correctly, the heads will be against the inserts.

4.

Slide the impeller into the front housing making sure that the bearings at the end of the auger shaft have not fallen

Installation,

off.

page

If

they have, consult Auger

70,

for information on how to

reassemble. Secure the auger shaft bearings to the side plates

using the eight cap screws and nylon locknuts.

See Figure

103.

I

Figure 101

2. Loosely fasten the flange bearing to the rear of the front housing using Figure 102 as a guide.

I

Figure 102

NOTE:

ween the components of the flange bearing.

Do

not sandwich the front housing bet-

Figure 103

Install the cap screws and large washers

5.

ends of the auger shaft. Lightly tighten the hollow head set screw in the

6.

impeller shaft bearing.

Tighten the three nylon locknuts securing the

7.

impeller flange bearing to the front housing.

Coat the impeller shaft with an anti-seize

9. compound (Toro part number

505-109)

the woodruf key and the impeller pulley. Be sure to tighten both square head set screws. Remove all end play from impeller shaft but

NOTE:

3/8”,

Tighten the square head set screws with a

12 pt. socket.

do

not preload.

Set Screw Torque:

2.3

kg m (205 in Ibs)

0

n

the

and install

Impeller and Pulley System

76

Power

Shift

Snowthrowers

Impeller and Pulley Installation (cont’d)

10.

To

facilitate reassembly of the

two

snowthrower

halves, remove the idler assembly and set aside.

11.

Prop the rear of the front housing and bring the traction unit up to meet the front housing. Secure

with the

12.

Slip the impeller belt over the impeller pulley.

13.

Reinstall the idler assembly using the

six

flange head cap screws.

two

head cap screws.

flange

14.

Install the top

belt

cover using

two

flange head self

tapping screws.

15.

Install the chute worm gear assembly to the bracket on the left side of the front housing. See Discharge Chute Installation, page 56 for more information

16. Stand the snowthrower install the lower belt cover, again using

if

necessary.

on

the front housing and

two

head cap screws.

17.

Check to insure that all parts are operating correctly.

flange

Power Shift Snowthrowers

77

Impeller and Pulley System

SECTION

CAUTION! Servicing the Power

require working with some of the moving parts. prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

off

the spark plug.

Shift

off

and remove. pages

Snowthrower will

10

To

FRONT

3.

Install the chute assembly as described under Discharge Chute Installation, page

4.

Adjust

Skids Installation and Scraper Installation,

SKIDS

HOUSING

the scraper

78

and

79

skids

as

described

56.

under

CAUTION! The Power Shift Snowthrower has the feature for Service and Storage. Always drain the fuel from the tank Prior to such Service taking the following

precautions:

FRONT HOUSING

Front Housing Operation

The front housing is very durable and should rarely

require servicing, however

the following procedure.

1.

2.

3.

Of

being able to be Stood on the front housing

Drain

it

outdoors and make sure the engine is cool.

Wipe up any gasoline that may have spilled.

Do not drain the gasoline near any open flame or

spark. to the pavement.

Do not smoke when handling gasoline.

if

the damage occurs, use

Remove the chute assembly as described under Discharge Chute Removal, page

Remove the impeller and auger assembly as described under Impeller Removal, page

Remove the scraper as described under Scraper

Removal, page

75.

79.

and

56.

Pulley System

Skids Operation

The purpose of the skids is to provide more contact area with the ground. When properly adjusted, they slow wearing

wearing

For convenience, the skids are turned inward to allow cleaning along side obstacles. The skids are adjustable to help insure that the snowthrower cleans right down

Skids Removal

1.

Remove the skids by removing the cap screws securing them to the side plates.

2.

Inspect the skids. Replace when the outside edge of the skid begins wearing away.

Skids Installation

1.

With the wheels in the rear position, loosen the

lock nut on the skid support bracket to insure that

it

gets proper placement when the new skid is put

on.

2.

Install the skid as shown in Figure

of

the scraper. The skids are intended to be a

part.

two

flanged

104.

4.

Inspect for damage and repair or replace the housing as necessary.

Front Housing Installation

1.

If

the front housing was replaced or painted be sure that all safety decals are also replaced and are in the proper location.

2.

Install the impeller and auger assembly as

described under Impeller and Pulley System

Installation, page

76.

78

Figure

104

Power Shift Snowthrowers

Skids Installation (cont'd)

skid

NOTE: The pads of the

3.

Adjust the skids

(1/8'”)

clearance between the scraper and the

so

that the scraper has

are turned inboard.

3

ground. Make sure that the pad is riding flat. Adjust higher

if

operating on a crushed rock or gravel

surface.

SCRAPER

Scraper Operation

The scraper on

1989

and newer Power Shifts is

adjustable. This is to insure that snow is removed as

close to the ground as possible.

Scraper Removal See Figure

105.

mm

3.

Inspect the scraper. Replace when

within

.64

cm

(1/4”)

from the bottom of the front

the

scraper is

housing and has been adjusted as low as

Scraper Installation

1.

Begin scraper installation by first checking tire pressure in both tires. Make sure that they are both

equal

and

psi).

Also

sitting on

between

make sure that the snowthrower is

a

level surface. This will insure proper

.5

and

1.O

kg/cm2

(7

positioning of the scraper.

2.

Loosen the

skid

mounting screws

so

that the skids are free to move and will not interfere with scraper adjustment.

3.

install the front flanged cap screw, securing the scraper, side plate and the skid

4.

On a flat surface with the snowthrower

on

each side.

normal operating position, support the auger is

.32

cm

(1/8'”)

off

the ground.

5.

Move the scraper

so

that

it

contacts the flat

surface all the way across, then tighten the

flanged cap screws securing

side plate. This locks

the remainder of

the

it

and the skids to the

it

in proper position

fasteners can be installed

without affecting adjustment.

it

will go.

and

in

so

15

the

so

it

two

that

Figure

1.

Remove the

2.

Remove the front flanged cap screw from the skid

and

remove the scraper.

six

carriage bolts from the scraper.

105

6.

Push the handles down

so

that the snowthrower

rests on the handles and secure the scraper with

the six carriage bolts and nylon locknuts.

7.

Adjust the skids with the scraper in the new

position as described under Skids Installation,

page

78.

Power Shift Snowthrowers

79

Front Housing

SECTION

CAUTION! Servicing the Power Shift Snowthrower will require working with some of the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions:

11

CONTROL PANEL AND HANDLES

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

CAUTION! The Power Shift Snowthrower has the

feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain it outdoors and make sure the engine is cool. Wipe

up

Do not drain the gasoline near any open flame or spark. Do not smoke when handling gasoline.

CONTROL PANEL

Control Panel Operation

The control panel is an important component in the

Powershift, as

directional control the control box, as well as providing a place for instructions. easily by using the following procedure:

Control Panel Removal

Stand the snowthrower on the front housing

1.

that the handle grips are vertical.

Remove the cover on

2.

in Figure Drive the

3.

and pull of the control panel. Be careful not to lose the rubber washer.

Release the connector from the bottom of the

4.

ignition switch by pressing on the tabs near the end of the terminals and pulling the connector

Squeeze the

5.

pull the ignition switch

control panel.

off

the spark plug.

any gasoline that may have spilled.

it

houses the key switch, the chute,

106.

roll

pin from the upper chute rod gear

the

chute control

two

off

and remove.

It

can

be

serviced relatively

so

the

right handle as shown

rod

out through the top

off.

tabs on the ignition switch then

out

through the top of the

Figure

6.

Remove the nut securing the lower shift

shift

bracket as shown

Figure

7.

Remove the shift knob from the shift lever.

Twisting the shift knob will facilitate removal.

8.

Remove the four nylon locknuts securing the control box to the control panel and remove the control box (set the control box on top of the

recoil, being careful not to damage reverse

9.

Remove the screws securing the control panel to the handles and remove the control panel. Refer to Figure

10.

If

from the control panel.

Control Panel Installation See Figure

Stand the snowthrower on the front housing to

1.

facilitate servicing of the control panel.

or

latch cables).

two

necessary, remove the chute control

108.

106

in

Figure

107

capscrews and

107.

two

rod

to the

or

bend the

self-tapping

107.

rod

bearing

Control Panel and Handles

80

Power Shift Snowthrowers

Control Panel Installation (cont'd)

8.

Push the shift knob onto the the shift knob may facilitate installation.

9.

Insert the ignition switch

the front of the unit.

10.

Push the electrical connector onto the bottom of

the ignition switch.

shift

so

that the terminalsface

lever. Twisting

Figure

2.

If installing a new control panel, be sure that all original decals are in place and location. They provide important safety

information for the operator.

3.

Install the control panel between the and secure with two capscrews and two self-tapping screws.

4.

Coat the two studs with an anti-seize compound

(Toro part number See Figure

109.

108

505-109)

in

to prevent corrosion.

the

two

proper

handles

NOTE:

go on in either direction.

11.

If

with

12.

Insert the chute control rod down through

of

lower chute rod bracket. Assemble the chute gear as shown in Figure

13.

Install the impeller lever cover with screws.

There is no polarity,

the

chute control bushing was removed, install

two

Phillips screws.

the chute control bushing

Figure

so

110.

110

the connector can

the

top

and

insert into the

rod

two

machine

Figure

5.

Install the Power Shift control box onto the control panel making sure that the reverse lever slides

onto the reverse lever spindle.

6.

Secure the Power Shift control box with four nylon locknuts.

7.

Secure the lower shift rod to the shift bracket using a washer and nylon locknut. Adjust as described under Control Adjustment, page

Box

49.

109

Service

Shift

Lever

14.

Check to insure that all controls are operating

if

correctly and adjust

HANDLES

Right Handle Removal

1.

Snip

the

cable ties securing the traction, reverse,

impeller and latch cables to the handle.

2.

Remove the impeller locking mechanism cover plate on the right handle.

3.

Loosen the jam nuts on the upper end of the traction and impeller cables. from the cable holder.

4.

Remove the push nut from the right end of the torque rod. Be careful not to scratch the impeller

lever.

NOTE:

nut may facilitate removal.

Flattening the locking tabs

necessary.

Pull

the cables loose

on

the push

Power Shift Snowthrowers

81

Control Panel and Handles

Right Handle

5.

Remove the

Removal

small

hex head capscrew and locknut

(cont'd)

that secures the torque rod to the traction lever.

Pull the torque rod out about enough to clear

6.

Spread the impeller lever slightly and remove the

the

impeller lever.

5

cm

release cam.

7.

Remove the self-tapping screw from the impeller lever and remove the locking tang.

8.

Remove the flanged head capscrew and the self-tapping screw that secure the right handle

the control panel.

9.

Remove the four nylon locknuts securing the rear

cover plate to the lower handles. See Figure

(2”),

just far

111.

to

1.

Place the right handle onto the studs coming from

the frame and secure with the

two

flanged head

capscrews.

2.

Secure the coverplate with the four nylon locknuts.

NOTE:

handle brackets! See Figure

3.

Slip the impeller lever bushing onto the cross rod,

The coverplate goes on top of the lower

111

above.

then place the impeller lever into position. Slide the cross rod through the

left

impeller lever hole and snap the impeller lever bushing in place. Figure

112.

See

NOTE:

control rod

10.

Remove the

lower handle

11.

If

It

is not necessary to remove the lower

from

the shifting bellcrank.

Figure

two

flanged head capscrews from the

and

111

remove the right handle.

necessary, remove the impeller lever bushing

and the impeller lever from the right handle.

12.

Remove the impeller lever return spring from the

right handle.

13.

Remove the E clip securing the locking latch to right handle and remove the locking latch and locking latch spring from the stud.

14.

Complete disassembly by removing the handle grip from the right handle.

Right

Handle Installation

NOTE:

If installing a new handle, be sure that the

warning decal is in place. The warning decal states the

importance of adjusting the cables to make sure that the

auger and transmission disengage completely.

Figure

4.

Install the latching lever return spring and the

112

release cam onto the cross rod. Insert the end of the traction cable into the release

5.

cam and loosely secure the cable

in

the cable

bracket.

Insert the end of the impeller cable into the locking

6.

tang and install in the impeller lever as shown in Figure

113.

Secure with the small self-tapping

screw.

7.

Secure the cross rod to the traction lever with the small capscrew and nylon locknut.

82

Power Shift Snowthrowers

Right Handle Installation (cont'd)

6.

Remove the small hex head capscrews and nylon locknuts securing the cross rod to the traction lever.

Figure

Press the push nut onto the end of the cross rod

8.

113

to secure the impeller lever.

NOTE: Make sure the tab on the push nut is at

to the keyway to insure proper retention Secure the control panel to the handle using the

9.

flanged head capscrew and self-tapping screw.

If the locking latch and the locking latch spring

10.

were removed, install now. Secure with the Refer to Figure

Secure the cables with

11.

Adjust the impeller and traction cables as

12.

113

above.

two

cable ties.

described under Traction and Impeller Controls

Traction Cable Adjustment and Traction and Impeller Controls Impeller Cable Adjustment, page

49.

Install the cover plate on the right handle

with the

Complete handle replacement by checking all

13.

two

small machine screws.

controls and making adjustments as required.

E

90"

clip.

7.

Pull the cross rod from

Figure

114

the

impeller lever control

panel and traction lever.

NOTE: The release cam, impeller bushing, trip lever and traction lever spacer will all be once the cross rod is removed. Be careful not to loose them.

8.

Remove the flanged head capscrew and small self-tapping screw securing the

control panel. See Figure

115.

left

handle to the

loose

Left Handle Removal

1.

Stand the snowthrower on the front housing to

facilitate handle removal.

2.

Snip the cable ties securing the wiring harness to the left handle.

3.

Drive out the roll pin securing the upper chute directional gear to the upper chute control rod. Remove the gear and the rubber washer, then pull the upper chute rod from the control panel.

4.

Remove the impeller locking mechanism cover from the right handle.

5.

Remove the push nut securing the impeller lever to the cross rod. Refer to Figure

114.

NOTE: Flattening the locking tabs on the push nut may facilitate removal.

Power Shift Snowthrowers

83

Figure

9.

Remove the four nylon locknuts securing the rear

115

cover plate to the lower handle brackets and the

rear cover plate.

10.

Remove the two flanged head capscrews securing the lower handle to the frame and remove the left handle complete with the front chute control rod.

Control Panel and Handles

Left Handle Removal (cont’d)

11.

If necessary, drive the roll pin from the forward chute control rod and gear and remove the chute control rod from the right angle bracket.

12.

Complete disassembly by removing the handle grip from the left hand handle.

Place the chute worm gear into the worm gear

3.

bracket then place the left handle onto the studs while inserting the lower control rod into the chute worm gear.

Move the rear cover plate into position on the four

4.

studs and secure with four nylon locknuts.

Left Handle Installation See Figure

116.

Traction

Lever

NOTE:

The rear cover plate

fits

outside the handle

bracket.

5.

7.

Install the the

Secure the

two

flanged head capscrews securing

left

handle to the frame.

left

handle to the control panel using

the self-tapping screw and the flanged head

capscrew. Insert the upper chute control rod through the

8.

control panel and the right angle bracket while installing the rubber washer and the upper chute

directional gear. Secure with the roll pin.

Place the traction lever into position on the left

9.

handle and loosely fasten in placewith the traction

lever bushing.

Place the traction lever spacer inside the traction

10.

lever then slip the cross

rod

through the trip lever. Make sure that the traction and impeller cables are installed into the release cam and locking latch

then push the cross rod through both

components. Secure with

a

new push nut.

1.

Stand

Figure

the

Power Shift Snowthrower onto the front

116

housing to facilitate installation.

2.

Insert the lower chute control rod into the right

angle bracket and secure the gear with the roll pin.

NOTE:

Install the locking latch cover plate on the right

11.

hand handle using the

The release cam is keyed to the cross rod.

two

small machine screws

with star washers.

Secure the

12.

left

end of the cross rod to the traction

lever with the small capscrew and nylon locknut. Secure the ignition switch wire to the

13.

with

two

cable ties.

14.

Complete handle replacement by checking all

left

controls and making adjustments as required.

handle

Control Panel and Handles

Power Shift Snowthrowers

SECTION

CAUTION! Servicing the Power Shift Snowthrower will require working with some prevent accidental starting of the engine performing service, take the following precautions:

12

of

the moving parts. To

WHEELS,

while

TIRES

AND CHAINS

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

CAUTION! The Power Shift Snowthrower has the feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following precautions:

Drain Wipe up any gasoline that may have spilled. Do not drain the gasoline near any open flame or spark. Do not smoke when handling gasoline.

WHEELS

Wheels Operation

The wheels used on the Power Shift Snowthrower are

one piece design steel wheels. They can

driving modewhere the wheel is rigidly fixed to the axle

or in a free wheeling mode where the wheel is allowed

to spin on the axle.

Wheels Removal

1.

To remove the wheels, simply remove the klik pin from the wheel and axle and pull the wheel

off

the spark plug.

it

outdoors and make sure the engine is cool.

off

and remove.

be

used in a

off.

Figure

TIRES

Tires Operation The tires used on the Power Shift Snowthrower are

special low pressure design which provides maximum traction in nearly all conditions. The tires are tube type and are 35.5 cm (14') in diameter and are 10.1 cm

in width on

cm (28”) and 81 cm (32") units have slightly large tires:

40.6

pressure should be between

15 psi) and be equal on both sides.

Tires

If a puncture or flat occurs, The Toro Company

recommends taking the wheel and tire assembly tire professional for repair or replacement. economically practical proper equipment.

cm

(16')

Service

61

cm

(24")

in diameter and 12.7 cm

117

(4")

snowthrowers while thos on 71

(5")

in

width. Tire

.5

and 1.0 kg/cm2

(7

and

to

It

is not

to

attempt servicing without the

a

Wheels Installation

1. Before installing the wheel coat the axle with an anti-seize compound

corroding

2. Install the wheel in the desired location; inboard for free wheeling or with the klik pin through the wheel and axle holes for

Power Shift Snowthrowers

to

the axle.

to

prevent the wheel from

driving.

See Figure 117.

CHAINS

Chains Operation Chains are available for the Power Shift Snowthrowers.

However, in most conditions the low pressure tires will provide better traction.

chains will actually decrease traction because they fill the tread on the tire. If conditions exist where chains are desired, they can be installed as follows.

85

In

fact,

in

some conditions,

Wheels and Tires

Chains Installation

Remove the wheel and tire assembly from the

1.

rude.

Lay the chains out front and install on the wheel

2.

tire assembly making sure that the special clip is on the outside air

out

of

Figure Hook the inside clip first, then hook the outside

3.

118.

of

the wheel tire assembly. Letting

the tire

will

facilitate installation. See

special clip. NOTE: When chains are installed, the free wheel

mode may not

through the holes in

used. The klik pin

the

wheel and the outer hole

must

be

in the axle to provide sufficient clearance between the chains and the pivot arm bolt.

pass

Figure

4.

Check tire pressure to make sure that

.5

and

1.O

kg/cm2

118

(7-15)

equal.

it

is between

psi and that both are

Power Shift Snowthrowers

SECTION

13

Engines Service Information

A

number of different engines are

used

on the Power Shift Snowthrowers. Manufacturer. include Briggs and Stratton, Mitsubishi and Tecumseh. See Figure

119

below to determine the manufacturer of the engine on

the unit you are servicing.

SPECIFICATIONS

Name Manufacturer

624 624 624 624 824 824 824 824 828 1132 828 828 1132

Engine

Mitsubishi Mitsubishi Tecumseh Tecumseh Mitsubishi Mitsubishi Tecumseh Tecumseh Mitsubishi Briggs Briggs

8

Tecumseh

Briggs

8

Figure

8

Stratton Stratton

Stratton

119

Sold

In

U.S.

Int'l U.S. Int'l

us.

Int'l

us.

Int'l

Int'l Int'l

U.S.

Int'l

us.

Some information on specifications and maintenance of

the engines can be found in the Specifications and

Maintenance Sections

in

the front of the book.

However, because the engine manufacturers have each published their own manual for these engines, complete

servicing information is not included in this

If

you

require a manual for one of the engines please

book.

contact the engine manufacture at one the following addresses:

Briggs and Stratton

PO.

Box

702

Milwaukee, WI

53201

Mitsubishi Heavy Industries America, Inc.

699

North Wheeling

Suite

101

Mount Prospect,

IL

Road

60056

Tecumseh Products Company

900

North Street

Grafton, WI

53024

Be sure to include engine model and serial number with

your request.

If

you have difficulty obtaining engine service manuals from any of the above manufacturers, please feel free to contact

us

at the following address:

The Toro Company

8111

Lyndale Avenue South

Bloomington,

MN

55420

Power

Shift

Snowthrowers

a7

Engines

SECTION

14

DIFFERENTIAL

KIT

CAUTION!

require working with some of the moving parts. prevent accidental starting of the engine while performing service, take the following precautions:

Rotate the ignition key to Pull the wire

Make sure the wire does not accidentally touch

the spark plug

CAUTION!

feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain Wipe up any gasoline that may have spilled Do not drain the gasoline near any open flame or spark Do not smoke when handling gasoline.

Differential

Servicing the Power Shift Snowthrower will

off

and remove

off

the spark plug

The Power Shift Snowthrower has the

it

outdoors and make sure the engine is cool

Kit

Operation

To

Differential

1. Stand the Power Shift snowthrower onto the front

2. Remove

3.

Kit

Removal

auger housing to facilitate service.

the

klik pins, wheels and wheel washers

from the axle. Remove the three Phillips head screws securing

the

two

halves of the chain guard and remove the

right half of the chain guard. See Figure 121

See Figure 120.

Figure 120 See Figure 122.

kit,

Model

The Power Shift differential

improve maneuverability of the Power Shift snowthrower. other wheel in turns. The advantages of the differential

kit

will be most noticable when traction is good and the

snowthrowing job requires many turns. However, as with automobile differentials, when one

wheel loses traction, the other this issue, the Power Shift differential kit was designed with the capability of being easily locked to provide rigid

axle performance when conditions dictate.

It

allows one wheel to rotate faster than the

38038,

will

not drive. To address

can greatly

Figure 121

4.

Remove the large nut and the flanged head bolt

left

from the left pivot arm. Pull the the axle and latch rod.

5.

Remove the flanged head capscrew from the right pivot arm, then pull the right pivot arm, complete

with latch rod and axle, out slightly to remove the

chain from the sprocket. Once the chain is clear, remove the differential

Differential Kit Disassembly

1. Remove the four nylon locknuts securing the sprocket to the differential and remove the sprocket.

2. Drive the roll pin from the locking cover side axle and remove the locking cover.

3.

Remove the of the axle.

4.

Remove the four nuts and allen head capscrews securing the the differential.

two

kit

from the snowthrower.

keys from the locking cover side

halves of the differential and split

pivot arm

of

off

the

Differential

Kit

88

Power Shift Snowthrowers

Differential

Locking

5.

Kt

Disassembly (cont’d)

Cover

Figure

122

Remove the cross shaft and the two cross shaft gears from the differential.

6.

If

further disassembly is required, remove the snap rings securing the bevel gears to the axle and remove the gears and differential case halves from

the axles.

4.

Install

the

two

keys into the keyways on the long

axle shaft, then slide the locking cover onto the

it

shaft making sure that

moves freely over the

keys.

5.

Drive the roll pin into the locking cover half of the axle.

6.

Mount the sprocket onto the differential and secure with four nylon lock nuts.

Kt

Differential

1.

Stand the Power Shift snowthrower onto the front

Installation

housing to facilitate installation.

2.

If

the differential

kt

is being installed for the first

time, select the correct sprocket for the differential. Use the list in Figure

123

or match the number of teeth on the original sprocket with one in the

kt.

Differential

Kt

Sprocket Data

7.

Inspect the spindle and the four gears for wear.

8.

Inspect the differential case halves for wear by

placing the case halves on the axle and checking for excessive play. Excessive play indicates that the bushings are worn. If this occurs, replace the differential case halves.

Differential Refer to Figure

1.

Kt

Assembly

122

above.

Place a bevel gear in one of the case halves and

secure to one of the axles with the snap ring.

Repeat for the other axle and case half.

NOTE:

Although there is a male and female differential case half, they are otherwise symmetrical and can be placed on either axle half.

2.

Spread Bentonite@ grease, (available from Tecumseh/Peerless), onto

the

bevel gears, and the cross shaft then slide the cross shaft pinions onto the cross shaft.

3.

Install the cross shaft and cross shaft pinion assembly into a differential case half and assembly the case halves.

NOTE:

Make sure there is adequate lubricant, but

do not overfill.

3.

Slide a thrust washer onto each end of the axle.

4.

Slide the axle through the pivot arm and attach chain. Fasten the right hand pivot arm to

frame, being sure to install the special washer

between the pivot arm and frame. Tighten the

flanged head pivot bolt and the nylon locknut. See

Figure

5.

If in the differential

124.

necessary, install the new chain guard included

kt

onto the

left

hand pivot arm

with the two self-tapping capscrews.

the

Power Shift Snowthrowers

89

Differential

Kt

Differential

Kit

Installation (cont'd)

7.

Install the right hand half

of

the chain guard with

the three Phillips screws. Slide the thrust washers then the wheels onto

8.

each end of the If

9.

this is the first time the differential

axle.

Secure with klik pins.

installed and the product was produced in

install the new belt cover as shown in Figure 125. This belt cover provides clearance for the differential when the wheels are in the forward

position.

kt

is

being

'88,

Figure 124

6.

Slide the thick washer onto the latch rod then

install the the frame. Secure the flanged head capscrew

left

pivot arm, again being sure to install

special washer between the pivot arm and the

left

hand pivot arm with the

and

the nylon locknut.

Figure 125

10.

Check for proper operation of all controls and adjust

if

necessary.

90

Power Shift Snowthrowers

SECTION

15

LIGHT

KIT

CAUTION:

require working with some of the moving parts. To

prevent accidental starting of the engine while

performing service, take the following precautions:

Rotate the ignition key to Pull the wire Make sure the wire does not accidentally touch

the spark plug.

CAUTION:

feature of being able to be stood on the front housing for service and storage. Always drain the fuel from the tank prior to such service taking the following

precautions:

Drain

Wipe up any gasoline that may have spilled.

Do not drain the gasoline near any open flame or

spark.

Do

The Toro Company has made light

Power Shift Snowthrowers to facilitate snow removal on short winter days. There are three different light although two of the comes with the light and an alternator while the other two come only with the light.

Both light Power Shift engines use unregulated alternators, it is normal for the intensity of the light to increase with engine speed.

Servicing the Power Shift Snowthrower will

off

and remove.

off

the spark plug.

The Power Shift Snowthrower has the

it

outdoors and make sure the engine

not smoke when handling gasoline.

kits

available for

kits

are nearly identical. One kit

kits

use approximately 15 Watts. Since all

is

cool.

kits,

alternator complete circuit. See Figure 126.

When measuring the voltage across the lamp, the minimum A.C. values should

2000 rpm

3600

rpm 12.0 volts A.C.

so

that the lamp and alternator make a

Figure 126

be

obtained:

Voltage

8.0

Volts A.C.

10.5 Volts A.C.

Light

Kit 66-7930

This light kit fits Power Shift Snowthrowers with Tecumseh Engines. The kit includes the light and bracket, as do the others, but alternator that is necessary since the Tecumseh Power Shift engines do not come standard with alternators.

The alternator produces 1 Amp A.C. current. It can be

checked as described below under Light

Testing.

Kit 66-7930

Light

1. If you encounter problems with the light, check the fuse to see that

2. Test

Power Shift Snowthrowers

for

jumper wires between the lamp wires and the

Operation

it

also includes a "bolt-on"

Testing

it

has not blown.

proper alternator operation be running

Kt

66-7930

first

If the the above values are not obtained, the alternator or the wires coming from the alternator are defective and should be replaced.

3.

Check the lamp by connecting battery. If it does not light, either the lamp or the

wires going to the lamp are defective.

Light

Kit

66-7930

1. Disconnect the lamp wires from the alternator at the connector.

2.

Remove the two locknuts from the U-bolt and remove the lamp assembly from the handle.

3.

Remove the flange head and remove the lamp.

4.

If

necessary, remove the carriage bolt securing the

U-bracket to the lamp mount.

91

Lamp Removal

it

to a 12 Volts D.C.

bolt

from the U-bracket

Light

Kit

Light

Kit

66-7930

1.

Using the U-bolt, washers and nuts supplied in

Lamp

Installation

loosely secure the lamp mount to shown in Figure

127.

the

kit,

handle as

6.

Remove the alternator shaft.

Kit

Light

1.

2.

66-9730

Remove the recoil

If the recoil assembly has a center plug housing, push Figure

128.

Alternator Installation

it

out and proceed to step

If

not

so

if

still on the unit.

equipped, refer to step

4.

in

3.

the

See

Figure

Route the wires and the fuse holder inside the

2.

127

channel and through the U-bolt.

3.

Secure the U-bracket to the lamp mount with a carriage bolt, lock washer and nut. Do not overtighten the nut or lamp adjustment will be

difficult.

4.

Secure the lamp assembly to the U-bracket with

two

a flange head screw,

lock washers and a flange nut. Place a washer on each side between the U-bracket and the lamp bracket. Do not overtighten.

Light Kit

1.

66-7930

Snip the

Alternator Removal

tie

straps securing the harness to the

handle.

2.

Disconnect the lamp wires from the alternator

wires at the connector.

3.

Remove the three self tapping screws from the

alternator and remove the alternator assembly from the recoil.

4.

Remove the light connector from the alternator receptacle.

5.

Take note of the position of the recoil handle.

Remove the fasteners securing the recoil to the shroud and remove the recoil assembly.

Figure

Drill the center hole in recoil housing as follows:

3.

128

a. Position the recoil assembly (pulley side up) on a flat surface suitable for drilling.

b. Using the center hole in the pulley assembly as a guide. See Figure through

c.

Locate thedepressed drill starts (three) in the front

4.

the

housing.

Remove all debris after drilling.

side of housing. See Figure Using caution not to hit

5.

housing, drill three

129.

Drill a

1/4"

diameter hole

130.

the

recoil pulley under

1/8”

diameter holes through

housing. Remove all debris after drilling.

6.

The

is supplied with

two

different alternator

kit

shafts. Use the longer shaft on snowthrower models

and

Install the alternator shaft coupler onto the

7.

38540, 38543,

3851 3

use the short shaft.

or

38573.

On models

flywheel nut as far as possible. Place the centering tube on alternator shaft.

8.

38510

Power Shift Snowthrowers

Light

Kit 66-9730

Alternator Installation (cont'd)

Secure the alternator to the recoil assembly with

three self tapping screws.

12.

Plug the lamp assembly into the light connector.

13.

Secure the wire harness to the handle with straps. Insure

the

wire harness does not interfere

tie

with the operation of the control levers or cables.

Light

Kits

66-7940

two

These

light part number units while the

and

66-7950

kits

are essentially the same. The

66-7940

kt

fits Briggs and Stratton powered

with part number

66-7950

Operation

fits

kt

with

units with Mitsubishi engines. They include the lamp and the mounting hardware. The lamp can be switched on and

Off

Drill

Starts

Figure

129

130

Power for the light

kt

comes from the alternator on the engine. Refer to the tables below to determine whether your engine was equipped with an alternator and,

if

so,

the type and amount of current that is produced.

Mitsubishi Alternator Data

Alternator kits can

These kits come with a flywheel, single circuit alternator and ignition

coil

as well as the necessary mounting hardware. For models 38500

and 38505, order

38545,

and

order

part

be

added to

number

1988

65-0610.

65-2170.

Mitsubishi powered units.

For

models 38520, 38525

9.

Slide the recoil assembly onto centering tube and

align the mounting holes. Insure the starter handle

is in the proper location and secure the assembly to the blower housing with the previously removed fasteners. Remove the centering tube.

10.

Plug the light connector into the alternator

receptacle.

11.

Slide the alternator onto the alternator shaft. Align the mounting holes and position the receptacle down and away from the control lever and linkage.

Power Shift Snowthrowers

93

Light

Kt

Toro 38079, 38087, 38500, 38505, 38510 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual