POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents – Page 1 of 5 ABOUT THIS MANUAL SAFETY INSTRUCTIONS FOR YOUR SAFETY...
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
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 CO
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 - OPERATION IMPELLER AND PULLEY - REMOVAL IMPELLER AND PULLEY - INSTALLATION SECTION 10 FRONT HOUSING FRONT HOUSING - OPERATION FRONT HOUSING - INSTALLATION SKIDS - OPERATION SKIDS - REMOVAL SKIDS - INSTALLATION SCRAPER-
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- INSTALLATION 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 - LA
ABOUT THIS MANUAL This service manual was written expressly for the Tor0 624, 824, 828 1132and Power Shift Snowthrowers. The Tor0 Company has made every to effort make the informationin this manual complete and correct. This manual waswritten with the service technician in mind. It is organizedso that information used most oftenis up front.
TABLE OF CONTENTS Reference Information Page I Safety Instructions 5 Identification 6 Specifications 7 ToolRequirements 31 Troubleshooting 32 Maintenance 36 Service Procedures Section 1 Power Shift Controls Page control Box Operation gear selectorcontrol latch release mechanism 41 41 reversecontrol shiftlockout indexing mechanism 41 43 43 Control Box Service removal testing disassembly 45 reassembly installation adjustments Section 2 48 49 Traction and Impeller Controls Operation tr
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) Section 3 Discharge Chute Chute Control operation knobremoval 54 54 knobinstallation upper rod removal upper rod installation lower rod removal lower rod installation 54 54 55 55 55 Discharge Chute operation removal installation Section 4 55 56 56 Idler System operation removal disassembly reassembly installation adjustment Section 5 57 57 57 58 58 59 Pivot and Latch System Pivot System operation disassembly reassembly61 ! 60 60 latch Sys
TABLE-OF CONTENTS (cont’d) Service Procedures (cont’d) Section operation removal installation70 Section 8 69 69 Auger Gearbox operation71 removal71 disassembly 71 reassembly72 Section 9 Impeller and Pulley System operation75 removal75 installation76 Section Front 10 Housing Front Housing operation78 removal78 installation 78 Skids operation 78 removal78 installation 78 Scraper removal79 installation Section 11 79 Control Panel and Handles Control Panel operation removal installation 80 80 80 Ha
res12 TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) and Section Page Wheels wheels tires chains Section 13 85 85 86 Engines servicing information 87 Section 14 DifferentialKit operation 88 removal88 disassembly 88 reassembly installation Section 15 89 89 Light Kit Light Kii 66-7930 operation 91 testing91 lampremoval 91 lamp installation 92 alternator removal 92 alternator installation 92 Light Kits 66-7940 and 66-7950 operation 93 lampremoval lamp installation Section 16 94 94 Snow
SAFETY INSTRUCTIONS A This manual is intended as a service and repair manua only. The safetyinstructions provided in this manual are for the troubleshooting and service of the product onl The individual Operator's Manuals will contain safety information on the operation of the PowerShift Snowthrowers. Servicingofanyoutdoor power' equipment requires care and common sense to preventinjury. "CAUTION" statementshavebeen placed thoughout this manual to enhance safety.
Model and Serial Numbers The snowthrower itself has two identificationnumbers: a model number anda serial number. Thetwo numbers are stamped on a decal which is located on of back the engine mounting plate. These numbers are required whenever a warranty claim is being filed on a Toro part. Eachenginealsohas amodelandserialnumber. Consulttheenginemanufacturersmanualforthe location ofthesenumbers.Engine model andserial number must be included on warranty claims related to a failed engine component.
SPECIFICATIONS MODELS 38500 AND 38505 Mitsubishi Powered 624 Engine Specifications* Choke Primer I manual I--yes (no methanol and not more than 10% ethanol) r SAE10, API rating SE or SF set gapto 0.72mm (.028')] * For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine manufacturer's service manual.
SPECIFICATIONS MODELS 38500 AND 38505 Mitsubishi Powered624 Product Specifications (cont'd) Auger Item Housing Width Housing Height 53.3 cm (21") 35.6cm (14”) two, 8.89 cm (3.5")deep (38505serrated1 Diameter Flights 1O:l 90 EP gear oil, APIrating of GL-5 or GL-6 Gearbox Capacity 0.133liters (4.5oz) Impeller Chute Throat Diameter Angle of Rotation 14.0cm (5.5") 200" Deflector Angleof Tilt 75" Rear Suspension Item ting ng Specification 61.
SPECIFICATIONS MODELS 38500 AND 38505 Mitsubishi Powered624 Product Specifications (cont’d) Wheels and Tires (cont’d) Specification Tire Pressure Dimensions I Item Accessories Mitsubishi Powered624 Torque Specifications Fastener Toque TractionGearCaseScrews1.38kg C -hani Guard Screws Pivot Arm Shoulder Bolts Auger Gearbox Screws 1.38 kg m (120in Ibs) 0.12 kg m (10 in Ibs) 3.45 kg m (300 in Ibs) m (120 in Ibs), note tightening order, page 73 2.36 kg m (205in Ibs) I 0.
elt Drive SPECIFICATIONS MODELS 38510AND 38513 Tecumseh Powered 624 Engine Specifications* _ I - * For more engine specifications, see Toro Gas Consumer Gas Engine Specification Manual or the engine manufacturer’s service manual.
Tecumseh Powered 624 Product Specifications (cont'd) Auger Impeller 30.5 cm (12'”) Chute Diameter Throat Angle of Rotation I Deflector Angle I I 14.0 cm (5.
SPECIFICATIONS MODELS 38510 AND 38513 Tecumseh Powered 624 Product Specifications (cont'd) Wheels and Tires (cont'd) Track Width 61.O cm (24") to outside of tires .5 to 1.O kg/cm2 (7to 15 psi) [must be equal on both sides] Dimensions I Item Specification 138.4 cm (54.5") 63.5 cm (25.0") 104.1 cm (41.O'”)[handle height 91.4 Weight cm (36.O'”) 100 kg (220 Ibs) Torque Specifications Fastener Traction Gear Case Screws Torque 1.38 kg m (120in Ibs) Chain Guard Screws 0.
Mitsubishi Powered 824 Engine Specifications* Item Specification Manufacturer Mitsubishi Type Rated Horsepower 4-stroke, side valve, gasoline Engine Speed (fast no load) 4000 Carburetor Type float Choke manual Primer yes Throttle Control 8 HP 150 rpm Imounted yes, I engine on electronic ethanol) 10% unleaded than Fuel more methanol gasoline not (no and 4.7 Tank Fuel Recommended Oil Capacity Oil liters (5 quarts) SAE 10W30 or SAE 10, APIrating SE or SF 0.
g SPECIFICATIONS MODELS 38520 AND 38525 Mitsubishi Powered824 Product Specifications (cont'd) Auger Width Housing I ltem [ Stopping Time I 61.
SPECIFICATIONS MODELS 38520 AND 38525 Mitsubishi Powered 824 Product Specifications (cont'd) Wheels and Tires (cont'd) I Item I Specification Track Width 61.O cm (24") to outside of tires Pressure .5to 1.O kg/cm2 psi) 15 [must to(7 equal beboth on sides] Dimensions ) [handle height 91.4 cm(36.
SPECIFICATIONS MODELS 38540 AND 38543 Tecumseh Powered 824 Engine Specifications* Specification Tecumseh 4-stroke, side valvegasoline I 8 HP 3300 + 200, 150 rpm float manual _- Yes yes, mounted on engine electronic unleaded gasoline (nomethanoland not more than10% ethanol) _ . _ I - 3.8 liters (4 qts) SAE 5W30or SAE 10, API of SE or SF I - 0.71 liters (24 oz) _._.___ Champion RJ-17LM or AutoliteAR7N [set gapto 0.76 mm (.
SPECIFICATIONS MODELS 38540 AND 38543 Tecumseh Powered 824 Product Specifications (cont'd) Auger Impeller Item Specification Diameter 30.5cm (12') Blades three Throwing Capacity, mass-distance 818 kg/min (1800Ibs/min) Stopping Time less thanf i e seconds 12.2 m (40 ft) Chute Specification 14.0 cm (5.
SPECIFICATIONS MODEL 38540 AND 38543 Tecumseh Powered 824 Product Specifications (cont’d) Wheels and Tires (cont’d) 15 psi) [must be equal on both si Dimensions eight 91.4 cm (36.
Mitsubishi Powered828 Engine Specifications* * For more engine specifications, seeToro Gas Consumer Gas Engine Specification Manual or the engine manufacturer's service manual.
SPECIFICATIONS MODEL 38545 Mitsubishi Powered828 Product Specifications (cont'd) Impeller Item Specification Diameter Blades 30.5 cm (12") four Throwing Capacity, mass-distance 909 kg/min (2000 Ibs/min), 12.2 m (40ft) Stopping Time less than five seconds Chute Item Throat Diameter Specification 14.0 cm (5.5") Angle of Rotation 200° Deflector Angle of Tilt 75" Rear Suspension Wheel and Tires Item Specification Type low pressure, pneumatic with tube Diameter 40.6 cm (16.00') Width 12.
SPECIFICATIONS MODEL38545 Mitsubishi Powered828 Product Specifications (cont'd) Wheels and Tires (cont'd) I Item Track Width 64.8 cm (25.5') to outside of tires Pressure .5 to 1.
SPECIFICATIONS MODEL 38570 Briggs and Stratton Powered 828 Engine Specifications* _ I - Champion RCJ-8 or Autolite AR7N [set gap to.76 mm (.030'”) * For more engine specifications, seeToroGas Consumer Gas Engine Specification Manual or the engine manufacturer's service manual.
SPECIFICATIONS MODEL 38570 Briggs and Stratton Powered 828 Product Specifications (cont'd) Auger Impeller Chute Wheel and Tires i r' 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 of tires Width Track 64.8 cm (25.5) outside to Pressure .5 to 1.O kg/cm2 (7 to15 psi) [must be equalon both sides] Dimensions Item Specification Length Width 138.4 cm (54.5") Height 73.7 cm(29.0") 106.7 cm(42.0') (handle height 94.0 crn [37"]) Weight 109.
SPECIFICATIONS MODEL 38573 Tecumseh Powered 828 Engine Specifications* Item Manufacturer Specification Tecumseh yes, mounted on engine electronic Ignition Type unleaded gasoline (no methanol and not more than 10% ethanol) Tank Fuel 3.8liters (4 quarts) SAE 5W30 or SAE10, API rating of SE or SF oil Capacity RJ-17LM or Autolite AR7N [set gap Spark Plug Champion * to 0.76 mm (.
Tecumseh Powered 828 Product Specifications (cont'd) Impeller Specification 30.5 cm (12") four 909 kg/min (2000 lbs/min) 12.2 rn (40 ft) less than five seconds Rear Suspension Specification Item with differential axle pivoting Optional Wheel and Tires I I Item Type Diameter type tube pnuematic, low pressure, 40.6 cm (16.
SPECIFICATIONS MODEL38573 Tecumseh Powered 828 Product Specifications (cont'd) Wheels and Tires (cont'd) I Item 64.8 outside crnto(25.5") Pressure I Specification of tires .5 to 1.0 kg/cm2 (7 to 15 psi) [must be equal both on sides] Dimensions I Width 73.7 cm (29.0") Height 106.7 crn (42.0') [handle height94.0cm (37")] Weight 109.1 kg Ibs)m (240 Accessories Tecumseh Powered 828 Torque Specifications Torque 1.38 kgm (120in Ibs) I_.-- 0.12 kg rn (10 in Ibs) 3.45 kg m (300 in Ibs) 1.
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 (cont'd) Auger Impeller Chute Rear Suspension Wheel and Tires Shift Item Specification Type Diameter low pressure, pneumatictube type 40.6 cm (16.00'1 Width cm 12.7 Tread self cleaning lug type Power (5.
SPECIFICATIONS MODELS 38565 AND 38580 Briggs and Stratton Powered 1132 Product Specifications (cont'd) Wheels and Tires (cont'd) Track Width 64.8 cm (25.5")to outside of tires Pressure .5 to 1.
SPECIAL TOOLS AND OTHER NECESSITIES ThePowerShiftSnowthrowers do notrequireany complextoolsformostservicing.
TROUBLESHOOTING Unit Does Not Propel Forward Remedy Check tire pressure,lock differential, install chains Position klik Pin through wheel and axle Adjust cable cable traction I Adjust Remove ice accumulationin lower belt cover.
TROUBLESHOOTING (cont'd) Operator Can Shift BetweenForwardand Reverse While Traction Leveris Engaged Possible Causes I Lock out lever tabs broken Remedy Replace lock out lever Lockout lever binding Free spraying with by LockoutleverspringmalfunctionReplace WD40 lockoutleverspring Wheels Will Not Swing When Power Shifting Possible Causes Remedy Indexing mechanism outof sequence with wheels Release shift lever then Insufficient traction Assist axle swingby lifting on handles slightly during Powe
TROUBLESHOOTING (cont'd) Poor Snowthrowing Performance Impeller or Auger Does Not Turn Remedy Clear debris Allow snowthrowerto warm Adjust impeller belt Tighten pulley fasteners Replace augerbolt Tighten impeller shaft fasteners Gear malfunctionin auger gearbox Repair auger gearbox Traction or Impeller Does Not Disengage -Possible Causes Cable too tight Belt guide broken Replace belt guide Incorrect belt Check parts catalog for correct belt Chute Plugs With Snow Possible Causes Enginerpm too slow Al
TROUBLESHOOTING (cont’d) Scraper Catches on Uneven Pavement perOperator’s Manual Snowthrower Leaves Snow Behind Remedy Scraper improperly adjusted or wornAdjust scraper Skids improperly adjusted or worn Adjust skid Rapid Skid and Scraper Wear Causes Possible Remedy Operator snowthrowing with wheels Use forwardwheel positionfor light snow in rear position unnecessarily ___Defective or scraper Replace skid or scraper Front End Rises Power Shift Snowthrowers 35 Troubleshooting
CAUTION: To prevent accidental starting of the engine just before changing oil because warm oil flows better while performing maintenance, rotate the ignitionto key and carries more contaminants the cold oil. off and removeit from the switch. Next, pull the wire off the spark plug andmakesurethewiredoesnot 1. Pull the wireoff the spark plug andmake sure the accidentally touch the plug. wire does not contact the plug accidentally. 2.
Maintenance Auger Gear Box Oil Service (cont'd) Figure 3 4. Maintenance Impeller Drive Belt Adjustment If the auger/impeller belt slips resulting in decreased snowthrowing performance, an adjustment is required. WHENEVER A NEWBELT IS INSTALLED, AN ADJUSTMENT IS REQUIRED. 1. Remove the three flanged headcapscrews securing the belt cover to engine frame and slide belt cover up the cables. 2. Checkidlerandbrakeadjustment.
Maintenance Traction Drive Belt Adjustment 7. (cont'd) transmission pulley. from NOTE: When adjusting cable, always rotate nut one turn at a time. 8. 3. Tighten the upper jam nut against the bracket. 4. Checkthetensionofthebelt byoperatingthe machine. If the belt slips, repeat the procedure. CAUTION: Do not adjust the belt too tight because it may cause the snowthrowerto creep when traction lever isin the disengaged position. If this occurs, readjust by loosening belt tension. 9.
Maintenance Drive Chain Adjustment (cont'd) NOTE: To adjust thedrive chain, the snowthrower must be tipped up on the auger housing. However, beforethesnowthrower is tipped,siphonall gasolinefrom fuel tank. 2. Makesure the wheelsarepositioned in rear position. Move the shift control into 2nd gear and tip the snowthrower up onto auger housing. 3. Loosenthefourflangedheadcapscrews(two each side) securing transmission frame to engine frame. See Figure8. 4.
Maintenance Spark Plug Service (cont’d) Figure 10 4. 2. Start the engine andit run let untilit stops because there is no gasoline in the fuel system. 3. Removethespark plugfromthecylinder head. Next, pourtwo teaspoons of engineoil intospark 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. 4.
SECTION 1 POWER SHIFTCONTROLS CAUTION: Servicing the Power Shift Snowthrower will this motion down to a bellcrank that moves the linkage requireworkingwithsome of-themoving parts. To on top of thetransmission. prevent accidental starting of the engine while performing service, take the following precautions: Operation Latch Release Mechanism Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug.
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 16 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.
When Power Shiftingthe wheels forward, the indexing Control Box Operation Reverse Control (cont'd) mechanism does nothing but index. The tabs On the The indexwheel isnecessary becausethe wheels must bottom Of the index wheel miss the tab On the reverse alternate between forward backward movement Shifting. Power when the forward when power wheels the bellcrank and traction lever is engaged.See Figure 20.
Control Box Operation Indexing Mech. (cont'd) 4. Usinga1/2"deepwellsocket,removethefour nylon locknuts securing the power shift control box to the controlpanel. See Figure 24. Figure 24 Figure 22 5. The index wheel is mounted on a piece called the index fits inside the lever latch and can 6. wheel lever. This piece rotate slightly. It provides the small amount of rotation necessary to index the index wheel. 7.
serve the indexing wheel underneath the latch lever. See Figure28. Control Box Service Testing ( cont’d) Figure 26 3. The reverse lever is spring loaded forward by the reverse lever return spring. Figure 28 Check for proper operation of the reverse lever by pulling backward. Reverse bellcrank movement as shown in Figure 27 should be noticed. Check to insure that the indexing wheel is free to rotate clockwise when viewed from the bottom o the power shift control box.
Control Box Service Disassembly (cont’d) 2. Disconnect the latch lever return spring from the latch levermechanism.Remove the snap ring from the latch lever stud and pull off the latch lever. Control Box Service Reassembly 1.Ifnecessary,reassemble theindexwheellever shown assembly as in Figure 31. Lockout Lockout Figure 31 2. Figure 30 3. If necessary,pry offthe push nut holding the index tangandremovetheindextang,indextang spring, and the stud from the latch lever.
Control Box Service Reassembly (cont'd) that the flats on the yoke align with the shift bracket. See Figure33. Figure 33 4. On 1989and 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 fits into the recesses in the yokebushingsandthatthe connectors between the yoke bushings face the rear of the machine. (If installedwiththe 6.
lever back and forth to insure that the index wheel is rotating properly. Secure with the flat washer and snap ring. See Figure 38. Control Box Service Reassembly (cont’d) NOTE: Coat the shoulder bolt with an anti-seize compound Toro part number 505-109) to prevent corrosion and subsequent binding. 7. Slip the reverse bellcrank and torsion spring onto the stud as shown in Figure 37. Slide the index wheel lever assembly onto the stud.
Control Box Service Adjustments Control Box Service Installation (cont'd) 3. Install the latch lever cover with2 Phillips screws. Do notovertighten.Adjustthelatchcableas described in Control Box -Adjustments, page49. Lockout 1. Latch Cable Adjustment:Adjust the latch control cable by removing slack between the end of the sheath and the end of the cable. Do not tighten beyond the point of removing slack. See Figure 42. Lever Figure 42 2.
CAUTION: Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make surethe wire does not accidentally touch the spark plug. CAUTION:ThePower ShiftSnowthrowerhasthe feature of being able to be stood on the front housing for service and storage.
Operation Impeller Locking Mechanism (cont’d) Figure 46 When the tractionlever is engaged, the locking latch is free to rotate and engage thelocking tang. See Figure 3. 47. Figure 48 Removethe push nut and the machine screw from the right side of the impeller lever. See Figure 49. NOTE:Theimpeller locking mechanismwillwork regardless of the order in which the levers are depressed. Figure 49 4. Remove the hex head screw securing the traction control to the cross rod. 5.
Traction and Impeller Controls Inspection 1. Inspect all bushings checking for wearand replace as necessary. 2. 3. 5. Pushthecross rod throughtheimpellerlever bushing untilit protrudes-about13 mm (1/2"). 6. Findthetractioncableandinstall it andthe extension springinto therelease cam as shown in Figure 52. Checkall rotating partsforcorrosionand/or excessive wear. Lubricate with ananti-seize compound (Toropart number 505-109) or replace as necessary.
Traction and Impeller Controls Traction Cable Adjustment (cont'd) 1. Checkforpropertension bypushingthefront housing of the snowthrower against a protected wall. Propertraction belt tension is achieved when the wheels spin on a concrete in second floor gear, but do not in fourth. 2. .23 mm to .30mm (.009”to .012") Adjust tension by loosening the two jam nuts at the upper end of the traction cable.To increase tension, rotate the nuts so that the end of the sheath moves down.
left to right through an CAUTION: Servicing the Power Shift Snowthrower will The chute rotates from extreme arc of200 degrees in about six turns of the crank. requireworkingwithsomeofthemovingparts. To prevent accidental starting of the engine while performing service, take the following precautions: Chute Control Knob Removal Rotate the Ignition key to off and remove. NOTE: Do not removethe knob unless necessary. Pull the wireoff the spark plug. I.
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 the rod with the teeth facing down. 4. Secure the gear with the roll pin. Chute Control Lower Rod Removal 1. Remove the roll pin from the lower rod gear. 2. Pull the rod from the worm gear bracket and then forward to remove it from the bracket. 3. If desired, remove the worm gear bracket. Chute Control Lower Rod Installation See Figure58.
Discharge Chute Removal 1. Remove the three socket head machine screws at clog, always stop the engine, wait for all moving parts the base of the chute. to stop, disconnect spark plug lead and then use a tool, 2. Remove thechute. such as a broom handle, to clear the obstruction. Discharge Chute Operation (cont'd) CAUTION! Do not operate the snowthrower without the Discharge Chute Installation chuteguard in place. It is there to helpprevent inadvertent contact with the impeller. See Figure60.
SECTION 4 IDLER SYSTEM The impeller idler pulley is set up similarly, again rotating about a plastic bushing and using two springs, one for return and the other to prevent over-tensioning. CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidental starting of the engine while performing service, take the following precautions: Also rotating about the same shaft is the brakeIt is arm.
Idler System Disassembly (cont'd) Insert a hex head cap screw into each of the idler pulleys. 1. NOTE: The head of each cap screw must be on theshortraceofeachidlerpulleybearing. Secure with the nylon locknuts and check for free rotation of each idler pulley Figure 63 CAUTION! The torsion spring is under tension. Eye protectionand heavyglovesare recommended when installing spring. 2. Mountthe two idler arms onto the idler bushing using Figure64 as a guide. 3.
4. Hookbothidlerreturnspringsontothe Idler System Installation (cont’d) corresponding tabs provided at the bottom of th 2. Find the traction cable andinserttheendofthe idler arm bracket as shown back in Figure 63. traction spring into the upper hole on the traction idler arm, then install the end of the sheath into 5.the Inserttheidlerassembly intothe snowthrower slot provided at the top of the idler arm bracket. frame and secure the two hex headcap screws. 3.
SECTION 5 PIVOTANDLATCHSYSTEM CAUTION!Servicing the Power Shift Snowthrower will position, the latch rod and thelatch plate retainthe pivot requireworkingwithsomeofthemoving parts. Toarms.See Figure 68.
Pivot System Disassembly (cont’d) 5. Remove the left hand pivot arm complete with the chain guard. 6. Remove thelatchrod,pivot arm,andrearaxle assembly by slipping the chain off thelarge sprocket. 7. Remove chain guard from theleft hand pivot arm. 8. Removethe latch rod from the righthandpivot arm. 9. Ifnecessary,removethebushingsfromthepivot arms using an arbor press. 10. If desired, remove the pivot bolts. They may flare somewhatonceinstalledandmayhave to be pressed out with an arbor press. 11.
Latch System Disassembly 2. Pullthe latch plate down to detensionthelatch plate spring, then remove the nylon locknuts on either side of the latch plate. 3. 2. Placethe latch plate in position. 3. Secure the latch plate with thetwo shoulder bolts and the nylon locking nuts. Make sure that the head ofthe boltsare on the inside of the frame. Removethe latch plate and latch plate spring from4. the snowthrower frame. Swing the latch plate up into position and slip the cable into the slot provided.
SECTION 6 TRANSMISSION CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemoving parts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. CAUTION!ThePowerShiftSnowthrowerhasthe feature of being ableto be stood on the front housing for service and storage.
and number three speed reduction gears. Gears two and three are joined and therefore rotate at the same speed. Transmission Operation (cont'd) Thenumberthreespeedreductiongeartransmits power to the number four gear. Because the number 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 is coupled to the output shaft.
Transmission Removal various operations transmission. of the for Check 2. Disconnectthelowershiftrodfromthebellcrankproperoperationofthejawclutchandbevel on the back of the transmission. gears. Check the gear selection shift fork to insure that the shift mechanism is working correctly. Also 3. Remove thebeltcoverfromtheundersideoftheinspectforbrokengearteethand-wornbushings off thetransmissionpulley.atthistime. unitandslipthebelt 4. Remove thecoverplatefrombehindthe transmission. 5.
intermediate shaft. Install into the proper location in the lower transmission case. Make sure that the keysonthebushingsalignproperlywiththekey sets in the lower case. See Figure 82. Transmission Disassembly (cont'd) 11.Inspectallcomponentsfordamageandwear. Replace as necessary. Transmission Reassembly NOTE: Use only Lubriplate@ Mag 1 GreaseToro part number505-101) in thetransmission. Its excellent performance at low temperatures greatly enhances the service life of the transmission. See Figure 81.
Transmission Reassembly the first half of the shift sleeve with the 19-tooth gear onto the output shaft, geared end first. 12. Slide the four selectable gears onto the output shaft as shownin Figure 83 above. 13. Apply greaseto second sleeve half then slide onto the outputshaft, flanged end last. Make sure that the tabs properly engage the recesses on the 19-tooth gear sleeve. When properly assembled, the outer sleeve half and15-tooth the gear willturn together. 14.
Transmission Installation 10. 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. Damageto the threads could result. 1. Apply an anti-seize compound (Toro part number 505-109) to all pivot and contact points on top of the transmission including detent button, detent box, link and bellcrank. 2.
AUGER SECTION 7 CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidentalstarting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. CAUTION!ThePowerShiftSnowthrowerhasthe feature of being ableto be stood on the front housing for service and storage.
Auger Installation (cont'd) 3. 4. 5. Slidethesideplate and auger bearing assembly Tighten the four onto theauger shaft and secure with the top five 6. cap screws andlock nuts. Fastenthe skid supportbracket to theauger housing andloosely install theskid. 7. 70 Support the auger soend the that of the auger shaft is centered in the hole in the side plate. cap screws and nylonlock nuts. Secure the auger halfto the auger shaft using the long cap screw and nylon lock nut.
SECTION 8 AUGERGEAR BOX CAUTION! Servicing the Power Shift Snowthrower'will To requireworkingwithsomeofthemovingparts. prevent accidental starting of the engine while performing service, take the following precautions: ment. Do not use Lubriplate(R) Mag1 greaseinthe auger gearbox. Auger Gear Box Removal the snowthrower as described in, Impeller and Pulley Removal, page Rotate the ignition key to off and remove. Disassemble 1. Pull wire the spark offplug.
Auger Gear Box Reassembly 5. Slide the helical gear onto the auger so shaft that it covers the woodruff key. 6. Slide one thick thrust washer ontoend each of the auger shaftso that they are next to the helical gear. 7. Input Shaft: Slide the snap ring onto the input shaft untilit is properly seated in its groove (do not attempt to stretch it over the worm gear end). See Figure 93. See Figure 91. NOTE: The snapring should not spin freely in the groove.
anti-seize compound to the bushing area itas may become’“gummy”. Auger Gearbox Reassembly (cont’d) NOTE: The auger halves are different, so be sure to install them correctly as shown. See Figure 80. Failure to doso will result in snow being moved toward the side plates rather than the impeller. 4. Loosen the flange bearing the at rear of the front housing to allow it to re-center when the auger assembly is installed. 5. Slide the flanged bearings on the ends auger shaft. 6.
Auger Gear Box Installation (cont’d) 14. capscrews. tapping self 15. Stand the snowthrower on the front housing and install the lower belt cover using the two flanged head Secure the auger halves to the auger shaft by installing the long shank hex head screws through the augershaft. NOTE: The head of the capscrews should rest against the spacers. 16. Check to insure the skids and scraper are properly adjusted.
SECTION 9 IMPELLER AND PULLEY SYSTEM CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidentalstarting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. 2.
Impeller and Pulley Removal (cont'd) 9.Remove theimpellerfromtheImpellershaft by removing thetwo flanged cap screws and nylon locknuts. Be careful not to lose the two impeller hub inserts. (On'88 units, set screws retained the impeller to the shaft.) The entire flange bearing must fit behind the front housing. Also notice the the hollow head set screw faces up when correctly installed.
Impeller and Pulley Installation (cont’d) 10. To facilitate reassembly of the two snowthrower halves, removethe 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 thesix flange head cap screws. 12. Slip the impeller belt over the impeller pulley. 13. Reinstall the idler assembly using the two flange head cap screws. Power Shift Snowthrowers 14. Install thetop belt cover usingtwo flange head self tapping screws.
SECTION 10 FRONT HOUSING CAUTION!Servicing the PowerShift Snowthrower will require working with some of the moving parts. To prevent accidentalstarting of the engine while performing service, take the following precautions: 3. 4. Skids Installation and Scraper Installation, 78 and 79 remove. pages Rotate the ignition key to off and Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug.
Skids Installation (cont'd) NOTE: The pads ofthe skid are turned inboard. 3. Inspect the scraper. Replace when the scraper is within .64 cm (1/4”) from the bottomof the front housing and has been adjusted lowas it will go. Adjusttheskids so thatthescraperhas 3 mm (1/8'”) clearancebetweenthescraperandthe ground. Make sure that the pad is riding flat. Adjust Scraper Installation higher if operating on a crushed rock or gravel surface. 1. Beginscraperinstallation by firstcheckingtire pressure in both tires.
SECTION 11 CONTROLPANELANDHANDLES CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. CAUTION!ThePower ShiftSnowthrowerhasthe feature of being ableto be stood on the front housing for service and storage.
Control Panel Installation (cont'd) 8. Push the shift knob onto the shift lever. Twisting the shift knob may facilitate installation. 9. Insert the ignition switchso that the terminalsface the frontof the unit. 10. Push the electrical connector onto the bottom of the ignition switch. NOTE: There is no polarity,so the connector can go onin either direction. 11. If the chute control bushingwas removed, install with two Phillips screws. 12.
Right Handle Removal (cont'd) 5. Removethe small hex head capscrew and locknut that secures the torquerod to the traction lever. Pull the torque rod out about 5 cm (2”),just far enough to clear the impeller lever. 6. Spread the impeller lever slightly and remove the release cam. 7. Remove theself-tappingscrewfromtheimpeller lever and remove the locking tang. 8. Remove theflangedheadcapscrewandthe self-tapping screw that secure the right handle to the controlpanel. 9.
6. Right Handle Installation (cont'd) Removethe small hex head capscrews and nylon locknuts securing the cross rod to the traction lever. Figure 113 8. Press the push nut onto the end of the cross rod to secure the impeller lever. Figure 114 NOTE: Make sure the tab on the push nut is at90" to the keywayto insureproper retention 7. 9. Secure the control panel to the handle using the flanged head capscrew and self-tapping screw. 10.
3. Left Handle Removal (cont’d) 11. Ifnecessary,drivethe roll pin from the forward chute control rod and gear and remove the chute control rod from the right angle bracket. Place the chute worm gear into the worm gear bracket then place the left handle onto the studs while inserting the lower control rod into the chute worm gear. 4. Move the rear cover plate into position on the four studs and secure with four nylon locknuts. 12. Completedisassembly byremovingthehandle grip from the left hand handle.
SECTION 12 WHEELS, TIRES AND CHAINS CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsome of themovingparts. To prevent accidentalstartingof the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. CAUTION!ThePowerShiftSnowthrowerhasthe feature of being ableto be stood on the front housing for service and storage.
Chains Installation 1. Remove the wheel and tire assembly from the rude. 2. Lay the chains out front and install on the wheel tire assembly making sure that the special clip is on the outside of the wheeltire assembly. Letting air out of the tire will facilitate installation. See Figure 118. 3. Hook the inside clip first, then hook the outside specialclip. NOTE: When chains are installed,the free wheel mode may not be used.
SECTION 13 Engines Service Information A number of different engines are used on the Power Shift Snowthrowers. Manufacturer. include Briggs and Stratton,MitsubishiandTecumseh.SeeFigure 119 below to determine themanufacturer of the engine on the unit you are servicing.
SECTION 14 DIFFERENTIAL KIT CAUTION! Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemovingparts. To prevent accidentalstarting of the engine while performing service, take the followingprecautions: Rotate the ignition keyto off and remove Pull the wireoff the spark plug Make sure the wire does not accidentally touch the sparkplug Differential Kit Removal 1. Stand the Power Shift snowthrower onto the front auger housingto facilitate service. 2.
Differential Kt Disassembly (cont’d) 4. Install the two keys into the keyways on the long axle shaft, then slide the locking cover onto the shaft making sure that it moves freely over the keys. 5. Drive the roll pin into the locking coverhalf of the axle. 6. Mountthesprocketonto the differentialand secure with four nylon lock nuts. Locking Cover Differential Kt Installation 1. Stand the Power Shift snowthrower onto the front housing to facilitate installation. 2.
Differential Kit Installation (cont'd) 7. Install the right hand half of the chain guard with the three Phillips screws. 8. Slidethethrustwashersthenthewheelsonto each end of the axle. Secure with klik pins. 9. If this is the first time the differentialkt is being installed and the product was produced in '88, 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. Figure 124 6.
LIGHT KIT SECTION 15 alternator so that the lamp and alternator make a complete circuit. See Figure 126. CAUTION: Servicing the Power Shift Snowthrower will requireworkingwithsomeof the moving parts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug.
Light Kit 66-7930 Lamp Installation 1. Using the U-bolt, washers and nuts supplied in kit, loosely secure the lamp mountto the handle as shown in Figure 127. 6. Remove thealternatorshaft. Light Kit 66-9730 Alternator Installation 1. Remove the recoil if still on the unit. 2. Iftherecoilassemblyhasacenterplug in the housing, push it out and proceed to step 4. See Figure 128. If not so equipped, refer to step 3. Figure 127 2. Routethewiresandthefuseholderinsidethe channel and through the U-bolt. 3.
Secure the alternatorto the recoil assembly with three self tapping screws. Light Kit 66-9730 Alternator Installation (cont'd) 12. Plug the lamp assemblyinto the lightconnector. 13. Securethewireharness to thehandlewith tie straps. Insurethe wire harness does not interfere with the operation of the control levers or cables. Light Kits 66-7940 and 66-7950 Operation These two light kits are essentiallythe same.
Light Kits 66-7940 and 66-7950 Operation (cont'd) Mitsubishi Single Circuit: The Mitsubishi single circuit alternator uses the magnets in the flywheelto produce current in the alternator. The current produced 4000 at rpm is approximately 1.25 Amps at 12 Volts. The current is not rectified. Typically this alternator be willused to power a light only. However, international units have a 12 volt starter kt available as an option.
SECTION 16 SNOW CAB CAUTION:ServicingthePowerShiftSnowthrowerwill requireworkingwithsomeofthemoving parts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove. Pull the wireoff the spark plug. Make sure the wire does not accidentally touch the spark plug. CAUTION:ThePowerShiftSnowthrowerhasthe feature of being ableto be stood on the front housing for service and storage.
Snow Cab Installation (cont'd) 4. Install the new impeller locking mechanism cover to the right handle with two the screws previously removed. 5. Position and secure the right attaching bracketto the attaching bracket base using a1/4-20 X 3/4" capscrew and locknut. See Figure136. Attaching Bracket Front Post Lever Cover Figure 134 2. Remove the two flange head capscrews securing the control panel to the handles (one on each side).
Snow Cab Installation (cont'd) Figure 139 Figure 137 Corner Post Figure 138 13. Snap the vinyl shell around the frame until secu in place. 9. Mount the top frame to the rear vertical bow and top to 14. If assembling kit 68-9500, mount the plastic to the upper ends of the front posts with four the top frame and secure with four 1/4-20 X 3/4 1/4-20X 3/4" capscrews and locknuts. See Figure capscrews, 1/4”flat washers and locknuts. 139.
SECTION 17 DRIFT BREAKER CAUTION: Servicing the Power Shift Snowthrower will requireworkingwithsomeofthemoving parts. To prevent accidental starting of the engine while performing service, take the following precautions: Rotate the ignition keyto off and remove Pull the wireoff the spark plug Make surethe wire does not accidentally touch the sparkplug CAUTION: ThePowerShiftSnowthrowerhasthe feature of being ableto be stoodon the front housing for service and storage.
