Tosnowps

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

TECUMSEH POWERED 624 - ENGINE SPECIFICATIONS*
TECUMSEH POWERED 624 - PRODUCT SPECIFICATIONS
TORQUE SPECIFICATIONS


TECUMSEH POWERED 824 - TORQUE SPECIFICATIONS
SPECIFICATIONS MODEL 38545


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

TECUMSEH POWERED 828 - TORQUE SPECIFICATIONS

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 SNOWTHROWING PERFORMANCE
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 WEAR
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
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
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- 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
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 - 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
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.As a result, you will find reference
information onsafety, identification, specifications, specialtods, troubleshooting
and maintenance, allin the front thirdof the manual.
Disassembly, inspection and reassembly procedures are covered

in the last
two-thirdsof the manual and are grouped
by component. We tried to cover each
common repair withits 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 is a relatively complex machine, most
sections will include some component theory. This information can be found at the
front of each service procedure section.
find this manual a valuable additionto your shop. If

We are hopeful that you will
you have any questionsor comments regarding this manual, please contact us at
the followingaddress:
The Tor0 Company

81II Lyndale AvenueSouth
Minneapolis, M N 55420
The Tor0 Company reserves the right

to change product specifications or this
manual without notice.
@COPYRIGHT ALL RIGHTS RESERVED

The Toro Company 1989
Minneapolis, MN 55420 -USA
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 41
latch release mechanism 41
reversecontrol 41
shiftlockout 43
indexing mechanism 43
Control Box Service

removal
testing
disassembly 45
reassembly
installation 48
adjustments 49
Section 2 Traction and Impeller Controls
Operation
tractioncontrol 50
impellercontrol 50
impeller locking mechanism 50
Traction and ImpellerControls
disassembly 51
inspection 52
reassembly 52
traction cable adjustment 53
impeller cable adjustment 53
Power Shift Snowthrowers 1 Table of Contents

TABLE OF CONTENTS (cont’d)
Service Procedures (cont’d)
Section 3 Discharge
Chute
Chute Control
operation 54
knobremoval 54
knobinstallation 54
upper rod removal 54
upper rod installation 55
lower rod removal 55
lower rod installation 55
Discharge Chute
operation 55
removal 56
installation 56
Section 4 Idler System

operation 57
removal 57
disassembly 57
reassembly 58
installation 58
adjustment 59
Section 5 Pivot
andLatch
System
Pivot System
!
operation 60
disassembly 60
reassembly61
latch System
disassembly 61
reassembly62
Transmission
Section
6
operation 63
removal 64
disassembly 65
reassembly
installation 67
Table of Contents Snowthrowers

2 Shift Power
TABLE-OF CONTENTS (cont’d)
Section
operation 69
removal 69
installation70
Section 8 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 79
Section 11 Control Panel and Handles
Control Panel
operation 80
removal 80
installation 80
Handles
right handle removal 81
right handle installation 82
left handle removal 83
left handle installation 84
Power Shift Snowthrowers 3 Table of Contents

TABLE OF CONTENTS (cont’d)
res12 Section
and Wheels Page
wheels 85
tires 85
chains 86
Section 13 Engines
servicing information 87
Section
14 DifferentialKit
operation 88
removal88
disassembly 88
reassembly 89
installation 89
Section 15 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 94
lamp installation 94
Section 16 Snow Cab

operation 95
removal95
installation 95
Section
17 Drift
Breaker
operation 98
removal98
installation 98
Table of Contents 4 Power Shift Snowthrowers

SAFETY INSTRUCTIONS
A Servicingofanyoutdoor
power' equipment requires
care and common sense to
preventinjury. "CAUTION"
statementshavebeen placed thoughout this
manual to enhance safety.Whenever you
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.
encounter the word CAUTIONRead the Operator's Manuals with complete operational safety
instruction because it has to do with safety.
instruction are available through:
Failure to comply with the instruction may
result in personal injury
or death. The Toro Company
Publications Department
8111 Lyndale Avenue South
Minneapolis,MN 55420 U.S.A.
I
FOR YOUR SAFETY
Avoid electrocution Avoid asphyxiation

Always use a grounded three wire plug and cord when Never operate an engine in a confined area without
starting or troubleshooting a snowthrower equipped proper ventilation.
with and electric starter. Avoid possible eye injuries
Avoid possible firesand explosions Weareye protection when working with springs or
Use a container designed for gasoline. Avoid spilling cables.
gasolineandneversmokewhile working around Avoid unexpectedstarting of engine
gasoline. Always turn off key and disconnect spark plug wire
Avoid fires and falls before attempting any cleaning, adjustment or repair.
Wipe up any spilled fuel or oil.
Avoid accidental misuse offuel
Avoid lacerations and amputations Always store fuel in a container designed for gasoline
that is properly labeled.
Stay clear of all moving parts when running the machine.
Treat all moving parts as
if they were moving whenever
Avoid possible injury due to inferior parts
the engine is running or has the potential
to start.
Use only Toro original parts to insure that important
Avoid burns safety criteria are met.
Donot touch engine while running or shortly after
Avoid injury to bystanders
running.
Alwaysclearareaofbystandersbeforestartingor
Avoid falls testing asnowthrower.
Do not operate snowthrower at fast speeds on slippery
surfaces.
Power Shift Snowthrowers 5 Safety !nstructions

Model and Serial Numbers
The snowthrower itself has two identificationnumbers: Eachenginealsohas amodelandserialnumber.

a model number anda serial number. Thetwo numbers Consulttheenginemanufacturersmanualforthe
are stamped on a decal which is located on of back
the location ofthesenumbers.Engine model andserial
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 part.
Toro a failed engine component. This applies even when the
claim is being filed
to The Toro Company.
Power Shift Snowthrowers

Mitsubishi Powered 624 Engine Specifications*
Choke I manual
Primer 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.
Mitsubishi Powered 624 Product Specifications

Transmission
Item Specification
Manufacturer Toro
Type gearbox, 4 forward, 2 reverse gears
pulley/belt -I_
chain
Lubriplate(R) Mag1
0.43 liters (14.5 oz)
0.88 kph (0.55 mph)
2.09 kph (1.30mph)
3.22kph (2.00mph)
4.67 kph (2.90mph)
2.09 kph (1.30mph)
3.22 kph (2.00mph)
~-
Power Shift Snowthrowers 7 624 Specifications

Mitsubishi Powered624 Product Specifications (cont'd)

Auger
Item Specification
Housing Width 61.O cm (24)
Housing Height 53.3 cm (21")
Diameter 35.6cm (14”)
Flights two, 8.89 cm (3.5")deep (38505serrated1
1O:l
90 EP gear oil, APIrating of GL-5 or GL-6
Gearbox
Capacity 0.133liters (4.5oz)
Impeller
Chute
Throat Diameter 14.0cm (5.5")

Angle of Rotation 200"
Deflector Angleof Tilt 75"
Rear Suspension
Item Specification
ting Standard
axle pivoting
Optional
Item Specification
Type tube with
pneumatic,
pressurelow
Diameter 35.6cm (14.00")
Width 10.2cm (4.00")
ng self Tread type lug
a Power Shift Snowthrowers

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 m (120in Ibs)
C
-hani Guard Screws 0.12 kg m (10 in Ibs)
Pivot Arm Shoulder Bolts 3.45 kg m (300 in Ibs)
Auger
Gearbox
Screws
1.38
kg m (120
in Ibs), note
tightening
order,
page
73 I
2.36 kg m (205in Ibs)
0.12 kg m (10 in Ibs)
Control Box Nuts 1.84 kg m (160 in Ibs)
Belt Guide Screws 0.81 kg m (70 in Ibs)

SPECIFICATIONS MODELS 38510AND 38513
Tecumseh Powered 624 Engine Specifications*
_I-
manufacturer’s service manual.
Tecumseh Powered 624 Product Specifications

Transmission
Item Specification
Toro Manufacturer
gearbox, 4 forward, 2 reverse gears
elt Drive I Input
output Drive chain
624 Specifications 10 Power Shift

Snowthrowers
Tecumseh Powered 624 Product Specifications (cont'd)
Auger
Impeller
30.5 cm (12'”)
Chute
Diameter Throat 14.0 cm (5.5”) I

Angle of Rotation I 200" I
I Deflector
Angle of Tilt 75"
Rear Suspension
I t e m
Type axle pivoting
Optional pivoting axlewith differential
Wheel and Tires


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] Pressure
Dimensions
I Item Specification
138.4 cm (54.5") I
63.5 cm (25.0") I
104.1 cm (41.O'”)[handle
height
91.4 cm (36.O'”) I
Weight 100 kg (220 Ibs)
Torque Specifications
Fastener Torque
Traction Gear Case Screws 1.38 kg m (120in Ibs)
Chain Guard Screws 0.12 kg m (10 in Ibs)
I---
Pivot Arm Shoulder Bolts 3.45 kg m (300in Ibs)

Auger Gearbox Screws 1.38 kg m (120in Ibs), note tightening order, page 73
Impeller Shaft Set Screws 2.36 kg m (205in Ibs)
Impeller Lever Screw 0.12 kg m (10 in Ibs)
Control BoxNuts 1.84 kg m (160in Ibs)
Belt Guide Screws 0.81 kg m (70 in Ibs)
624 Specifications 12 Power Shift Snowthrowers

Mitsubishi Powered 824 Engine Specifications*
Item Specification
Manufacturer Mitsubishi
Type 4-stroke, side valve, gasoline
Rated Horsepower 8 HP
Engine Speed (fast no load) 4000 150 rpm
Carburetor Type float
Choke manual
Primer yes
Throttle
Control Imounted
yes, engine
on
I electronic
ethanol)
10%
unleaded
than
Fuel
more
methanol
gasoline
not
(no
and
4.7 Tank Fuel liters (5 quarts)
Recommended Oil SAE 10W30 or SAE 10, APIrating SE or SF
Capacity
Oil (27
0.80 liters oz)
BP-4HS
NGK
Spark
gap
Plug
[set tomm
0.72 (.028')
Mitsubishi Powered 824 Product Specifications

Transmission
Second
Forward
Gear
2.09
(1.30
kph
mph)
Third Forward Gear 3.22kph(2.00mph)
Fourth
Forward
Gear
4.67
(2.90
kph
mph)
First Reverse Gear 2.09 kph (1.30 mph)
Second Reverse Gear 3.22 kph (2.00mph)


Auger
Width Housing 61.O cm (24") I
I ltem
[ Stopping
Time less than five seconds
Rear Suspension
ltem
g Type
axle pivoting
Optional
824 Specifications Power Shift Snowthrowers

Mitsubishi Powered 824 Product Specifications (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(36.0'”)
Accessories
56-2700
66-6200or 68-9500
66-7960
66-7950
38038
66-6660
Mitsubishi Powered 824 Torque Specifications
in Ibs), note tightening order, page 73
_I
Power Shift
Snowthrowers 15 824 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 (.030'))

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

Transmission
824 Specifications Snowthrowers

16 Shift Power

Auger
Impeller
Item Specification
Diameter 30.5cm (12')
Blades three
Throwing Capacity, mass-distance 818 kg/min (1800Ibs/min) 12.2 m (40 ft)
Stopping Time less thanf i e seconds
Chute
Specification
14.0 cm (5.5')
200"
75"
Rear Suspension
Wheel and Tires
Snowthrowers
Power
Shift 17 824 Specifications
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 (36.0’)

- ~ I - -
Tecumseh Powered824 Torque Specifications

18 Shift Power
Mitsubishi Powered828 Engine Specifications*
* For more engine specifications, seeToro Gas Consumer Gas Engine Specification Manual or the engine
Mitsubishi Powered828 Product Specifications

Transmission

Impeller
Item Specification
Diameter 30.5 cm (12")
Blades four
Throwing Capacity, mass-distance 909 kg/min (2000 Ibs/min), 12.2 m (40ft)
Stopping Time less than five seconds
Chute
Item Specification
Throat Diameter 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 12.7 cm (5.00')
Tread self cleaning lug type

20 Shift Power
SPECIFICATIONS MODEL38545

I Item
Track Width 64.8 cm (25.5') to outside of tires I
Pressure .5 to 1.O kg/cm2 (7 to 15 psi)
[must be equal on both
sides]
I
Dimensions
Accessories
Mitsubishi Powered828 Torque Specifications
Shift Power 21 828 Specifications

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

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

Auger
Impeller
Chute
Wheel and Tires
i
r'
self-cleaning lug tread


828 Product Specifications (cont'd)
Specification
Width
Track 64.8 cm (25.5)
outside
to of tires
Pressure .5 to 1.O kg/cm2 (7 to15 psi) [must be equalon both sides]
Dimensions
Item Specification
Length 138.4 cm (54.5")
Width 73.7 cm(29.0")
Height 106.7 cm(42.0') (handle height 94.0 crn [37"])
Weight 109.1 kg m (240 Ibs)

828 Torque Specifications

Item Specification
Manufacturer 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
Spark
Plug
Champion RJ-17LM or Autolite AR7N [set
gap to 0.76 mm (.030'”)

Transmission
Specification
Toro
Manufacturer gearbox, 4 forward, 2 reverse gears
pulley/belt
chain
Lubriplate(R) Mag1
0.43 liters (14.5 oz)
0.88kph (0.55 mph)
2.09 kph (1.30 mph)
3.22 kph (2.00mph)
4.67 kph (2.90mph)
2.09kph (1.30 mph)
3.22kph (2.00mph)

Impeller
Specification
30.5 cm (12")
four
909 kg/min (2000 lbs/min) 12.2 rn (40 ft)
less than five seconds
Rear Suspension
Item Specification
axle pivoting
Optional with differential
Wheel and Tires

I Item
I Type type low pressure,
tube pnuematic, I
Diameter 40.6 cm (16.00") I
Tread
828 Specifications Power Shift Snowthrowers

SPECIFICATIONS MODEL38573

I Item Specification I
64.8 crnto(25.5")
outside of tires
Pressure .5 to 1.0 kg/cm2 (7 to 15 psi) [must be equal
both
on sides]
Dimensions
Width 73.7 cm (29.0") I

Height 106.7 crn (42.0') [handle height94.0cm (37")]
Weight Ibs)m (240
109.1 kg
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)
1.38 kg m (120 in Ibs), note tightening order, page 73
2.36 kg m (205 inIbs)
--__-
0.12 kg m (10 in Ibs)
-_I__.
1.84 kg m (160 in Ibs)

0.81 kg m (70 in Ibs)

Briggs and Stratton Powered 1132 Engine Specifications*
_.-
no methanol and not more
manufacturer’s service manual.
Briggs and Stratton Powered 1132 Product Specifications

28 Shift Power
Auger
Impeller
Chute
Rear Suspension
Wheel and Tires

Item Specification
Type low pressure, pneumatictube type
Diameter 40.6 cm (16.00'1
Width cm 12.7 (5.00') I
Tread self cleaning lug type
I

Track
Width 64.8 cm (25.5")to outside of tires
Pressure .5 to 1.O kg/cm2 (7 to 15 psi)
[must be equal
both
onsides]
Torque Specifications
1132 Specifications 30 Power Shift Snowthrowers

SPECIAL TOOLS AND OTHER NECESSITIES
ThePowerShiftSnowthrowers do notrequireany In addition to those tools, it is agood idea to have the
complextoolsformostservicing.Servicingcanbe following on hand:
accomplished with the following:
Necessary Tools Lubricants, Sealantsand Adhesives
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)
Power Shift Snowthrowers 31 Special Tools

TROUBLESHOOTING
Unit Does Not Propel Forward

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

Remove ice accumulationin lower belt cover.
Repair gear or jaw damage
Unit will not Propel Backward

Possible Causes Remedy
Wheels not pinnedto axle Position klik pin through wheel and axle
Reverse cabletoo loose Adjust reverse cable
Traction belt slipping Adjust traction cable
Reverse bevel gear or jaw Repair reverse gear or jaw clutch damage
clutch malfunction
Neutral Not in Correct Location

I I
Remedy
Causes
Possible
Lowershift rodnotadjustedcorrectly Adjust lower shift rod
I
I ShiftbracketincorrectlyassembledReassemblecontrolboxcorrectly
Shift Lever Will Not Lockin Power Shift or Reverse

Possible
leverLockout
lever lockout
Replace
tabs broken I
Lockout lever binding Free by spraying with WD40
Lockout lever spring malfunction Replace lock out lever spring

TROUBLESHOOTING (cont'd)
Operator Can Shift BetweenForwardand Reverse While Traction Leveris

Engaged
Lock out lever tabs broken Replace lock out lever
Lockout lever binding Free
spraying
with
by WD40
I LockoutleverspringmalfunctionReplace lockoutleverspring
Wheels Will Not Swing When Power Shifting

Indexing mechanism outof Release
shift
lever
then push into Power
Shift
again I
sequence with wheels
Insufficient traction Assist axle swingby lifting on
handles slightly during Power Shift
Units with differential: push down
on handles, lock differential
Adjust latch cable
Free pivot arms
Machine Does Not Propelin a Straight Line

Remedy I Possible Causes
Uneven tire pressure
Uneven traction onpavement
Skids not adjusted evenly
Adjust tire pressureto .5 to 1.0 .O kg/cm2 (7 to 15 psi) equally.
Consider chain installing chains
Adjust skids
-II
Both wheels not pinned to axle Position klik pin through both wheelandaxle
Engine Kills When Auger or Traction are Engaged

Engine not sufficiently warmed up Allow engineto warm up before engagement
Debris jammedin auger or impeller Clear auger and impeller
Auger or impeller frozen with ice Allow snowthrowerto warm
Power Shift Snowthrowers 33 Troubleshooting

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 Always throw snow at full throttle
Belt
slippage Adjust impeller belt
Ground speed not matched in light conditions
Select slower gearin heavy conditions, faster gear
Sand, paint and wax chute and rough areas

in housing and chute
Snow too wet Allow snowto melt or freeze
Troubleshooting 34 Power Shift Snowthrowers

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. off
Next, pull the wire
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. Clean the area around the
oil draincap. Next, slide
the oil drain pan below the drain extension; then
Maintenance Draining Gasoline remove theoil drain cap.See Figure 2.
1. Stop the engine and pull the wireoff spark plug. Oil Drain Extension
2. Remove thecapfromthefueltankand use a
pump-type syphonto drain fuel into clean gas can.
NOTE: This is the only procedure recommended
for drainingfuel.
CAUTION:Sincegasoline is highly flammable,
drain it outdoors and make sure the engine cool is
to prevent a potential fire hazard. Wipe up any
gasoline thatmayhavespilled. Do notdrain
gasoline near any open flame or where the
gasoline fumes may be ignited by aspark. Do not
smoke a cigar, cigarette or a pipe when handling 3. After all the oil is drained, install the oil drain cap.
gasoline.
4. Position the snowthrower on a level surface. Next,
fill the crankcase
with
oil.
See Specifications
Section for capacity of your engine. Wipe up any
Maintenance Chain Lubrication oil thatmay have spilled.
1. Annuallylubricatethedrivechainwithchain
lubricant. See Figure1. Wipe up any excess oil.
Maintenance Auger Gear Box Oil Service
The auger gear box is filled with oil at the factory so
regular maintenance is not required. However, if the oil
must be replacedin gear box:
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 so dirt is
removed. See Figure3.
4. Put a drain pan below the front
of auger box and
remove the pipe plug.
5. Tip the snowthrower forward and holdit up until
Figure 1 all oil drains from the
gear box.
6. Carefully let the snowthrower down to its normal
Maintenance Changing Crankcase Oil position. Make sureit is on a level surface. Next,
Initially changeoilafterthefirst 2 hoursofengine fulltheaugergearboxwith GL-5 or GL-6 SAE
operation; thereafter, changeoil afterevery 25 hours of 85-95 EP transmission oilto the pointof overflow.
engine operation or annually. If possible, run the engine
7. Install pipe plug
in gear box.

Maintenance Auger Gear Box Oil Service (cont'd)
Figure 3
4. Rotate thebottom jam nut upward
to increase belt
Maintenance Impeller Drive Belt Adjustment tension.
If the auger/impeller belt slips resulting in decreased NOTE: When adjusting the cable, always rotate
snowthrowing performance, an adjustment is required. the nut oneturn at a time.
WHENEVER A NEWBELT IS INSTALLED, AN
ADJUSTMENT IS REQUIRED. NOTE: Do not adjust the belt too tight becauseit
may cause the auger/impeller to turn when the
1. Remove the three flanged headcapscrews auger/impeller isin the disengaged position.If this
securing the belt cover
to engine frame and slide occurs,readjust the lever by looseningbelt
belt cover up the cables. tension.
2. Checkidlerandbrakeadjustment.Thereshould 5. Tighten upper jam nut against bracket.
be a minimum clearance of3 mm (1/8”) between
the tab on the impeller idler arm and the brake CAUTION: Improper adjustment maycause
3 mm (1/8'”)
arm. See Figure4. If there is less than injury if auger/impeller turns when the lever
clearance, thebelt must be replaced. disengages. Use only genuineToro replacement
parts.
6. Recheck the idler and brake adjustment referring
to step 2.
7. Reinstall the belt cover.
8. Check tension of belt I f the
by operating the auger.
belt slips, repeat procedure.
Maintenance Traction DriveBelt Adjustment

If the traction belt slips during operation, an adjustm
is required. Whenever thebelt is replaced, an
adjustment is required.
1. Loosentheupperjamnutsecuringthetraction
cable to the mounting bracket.
2. Rotate thebottom jam nut upwardto increase belt
Figure 4 tension.
3. Loosentheupperjamnutsecuringtheauger/
impellercable to themountingbracket.See
Figure 5.
Power Shift Snowthrowers 37 Maintenance

Maintenance Traction Drive Belt Adjustment 7. If replacing the traction belt, slide the mid section
(cont'd) of the on pulley andoffbelt crankshaft and remove
transmission
NOTE: When adjusting cable, always rotate nutpulley.
from belt
one turn at a time. 8. On thecontrolcablewhichcorresponds to the
3. Tighten the upper jam nut against the bracket. belt being replaced, loosen the jam nuts securing
cable to bracket. Cable must
be free to slide in the
4. Checkthetensionofthebelt byoperatingthe bracket when changing the belt(s).
machine. If the belt slips, repeat the procedure.
9. Reinstallthebelts byreversingprocedure.Make
CAUTION: Do not adjust the belt too tight suretabs in halfsheaveareinserted intothe
because it may cause the snowthrowerto creep mountinggrooves in theauger/impellerpulley
when traction lever isin the disengaged position. when reinstalling.
If this occurs, readjust by loosening belt tension.
NOTE: Make sure the idler pulleys are aligned
with the belts when reinstalling idler pulley
Maintenance Replacing Drive Belts assembly.
If the auger/impeller belt or traction belt become worn,
10. Readjustthebelts,referring to Maintenance
glazed, stretched, oil-soaked, or otherwise defective,
Impeller Drive Belt Adjustment
or Maintenance
belt replacement is required.
Traction Drive Belt Adjustment, pages37 and
1. Pull wireoff the spark plug and make sureit does 38.
not contact the plug accidentally.
CAUTION: Improper adjustmentmaycause
2. Remove the three thread forming screws holding injury if auger/impeller turns when the lever
the belt coverin place, and slide the belt cover up disengages. Use only genuine Toro replacement
cables. parts.
3. Move the speed shift control to N, neutral.
Maintenance Drive Chain Adjustment
4. Remove thetwoflangedhead capscrews
securing the idler pulley assembly
to the engine The drive chain must be adjusted to maintain 1/8-3/8 of
frame.Remove the idler pulleyassembly.See an inch deflection at mid span between transmission
Figure 6. and axle sprocket. Check chain deflection after25every
hours of operation.
1. Check deflection of the chain by lifting up on the
chain with moderate pressure at mid span. There
should be1/8-3/8”deflection. If deflection is not as
specified an adjustment is required. See Figure 7.
Figure 6 3/8”
Deflection
5. Remove thecapscrewandlockwashersecuring
the half sheaveto front of pulley assembly.
6. Slideauger/impellerhalfsheaveandbelt off
crankshaft and remove belt from impeller pulley.
Figure 7
Maintenance 38 Power Shift Snowthrowers
I
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 frameto engine
frame. See Figure8.
4. Lightly lift up on the transmission frame until 3 to
9 mm (1/8 to 3/8”)chain deflection is attained, then
retighten the flanged head capscrews.
Figure 9
Maintenance Spark Plug Service

Check the Specifications Section for the proper spark
plug and gap. Since the air gap between the center a
side electrodes of the spark plug increases gradually
Figure 8 during normal engine operation, install a newplug after
NOTE: Do not pry or use excessive force when 25 hours of engine operation.
lifting thetransmissionframe,astransmission 1. Clean the area around the sparkplug so foreign
damage may occur. mattercannotfallintocylinderwhenplugis
NOTE: If gear shift lever is not aligned with the removed.
Power Shift slot in control panel (see Figure 9 2. Pull the wire off the spark plug and remove the
inset), shiftrod length must beadjusted as follows: plug from cylinder head.
a. Disconnect the ball joint from bellcrank and NOTE: A cracked, fouled, or dirty spark plug must
move the jam nut up shift rod. See Figure 9. be replaced. Do not sand blast, scrape or clean
b. Rotate theball joint up or down until thegear the electrodes because grit may eventually
shift lever is aligned
with thePower Shift slot. release from the plug and fallinto the cylinder. The
result will likely be engine damage.
c.Reinstall the ball joint to thebellcrankand
tighten the jamnut. 3. Set air gap between electrodes of new spark plu
See Figure 10. Next, install the spark plug in the
5. Recheck the chain deflection
and
lower the cylinder head. Torque plug to 15 ft-lb. If torque
snowthrowerto its normal position. wrench is not used, tighten plug firmly.
Power Shift Snowthrowers 39 Maintenance

Maintenance Spark Plug Service (cont’d) 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. Lubricate the snowthrower: refer
to Maintenance
Chain Lubrication, page 36.Change crankcase
oil: see Operator’s Manual.
5. Clean the snowthrower. Touch up chipped
surfaceswithpaint.Sandtheaffectedareas
before painting. Use a rust preventative
to prevent
metal parts from rusting.
Figure 10 6. Tightenallscrewsandnuts. If anypartsare
4. Push the wire onto the spark plug. damaged, repair or replace them.
7. Store the snowthrowerin a clean, dry place and
cover it to give protection.
Preparing Snowthrower For Storage
1. Siphon or remove the gasoline from the fuel tank, 8. The snowthrower may be stored tipped up on the
referring to Maintenance Draining Gasoline, augerhousing.Makesure to drain gas before
page 36. Wipe up any gasoline that may have tipping snowthrower.
spilled.
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. A latch mechanism holds the pivot arms in either a
Pull the wireoff the spark plug. forward or rear position. See Figure12.
Make sure the wire does not accidentally touch
the spark plug.
CAUTION: ThePowerShiftSnowthrowerhas the

feature of being ableto 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 engineis 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.
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 forwardto 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
2.0 cm (3/4”) to move the sliding jaw from the forward
bevel gearto the reverse bevel gear. See Figure 15.
Figure 17
When the shift lever is pushed
into thePower Shift slot,
a tabon 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 ofthe 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 Figure16.
When the gearshift lever one of the reverse
is pulled into
slots, the reverse lever (visible through the reverse slots
in the control panel) is pushed toward the back of the 1
snowthrower.Thereverselever is connected to the Figure 18

reversebellcrank so thatas it pivots, it rotatesthe The contact between the two tabs forces the reverse
reverse bellcrank and tensions the cable. See17. Figure bellcrank to rotate.
Power Shift Controls 42 Power Shift Snowthrowers

Control Box Operation Reverse Control (cont'd) When Power Shiftingthe wheels forward, the indexing
The indexwheel isnecessary becausethe wheels must mechanism does nothing but index. The tabs On the
alternate
between
forward
backward
movement bottom Of the index wheel miss thetab On the reverse
Shifting.
Power
when the
forward
when
power
wheels
the
bellcrank
and
traction lever is engaged.See Figure 20.
Control Box Operation Shift Lockout

Transmission damage could resultif the operator were
to shift the transmission into reverse while the unit were
moving forwardand 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 notwhen rotate
the gearshift lever
is moved from sideto side.
Figure 20
When the wheels areto be movedto the rearposition,
a tab on the bottom of the index wheel contacts a
corresponding tab on the reverse bellcrank and the
wheelspowerbackwardwhenthetractionlever is
engaged. See Figure 21.
Figure 19
When the traction lever on the lefthandle is not
engaged, the lockout base is free to move in either
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 benefitof the shift lockout is that it allows the
operator to lock the gearshift leverin either the Power Figure 21
Shift or reverse slots by depressing the traction lever. The index tang and a flat spring control the rotation of
This allows the operator one hand operation of Power the index wheel. When the shift lever is pushed
into the
Shift or reverse leaving the other handtofree rotate the Power Shift slot,the index tang rotates the index wheel
chute. 1/8 revolution and then prevents the wheel from rotatin
backwardswhenthetabsontheindexwheeland
Control Box Operation Indexing Mechanism reverse bellcrank make contact. See Figure22.
An indexing mechanism is usedto control the direction As the shift lever returns
to its "at rest" position,
the index
ofwheelmovementwhilePowerShifting.This is wheel hasa natural tendency to turn backwards due to
necessarybecause the wheelsneed to alternate the pressure from theindextang.Theflatspring
between forward and reverse when the Power Shift is preventsbackwardrotation by engagingtheindex
cycled. wheel at one of the teeth.

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 22 Figure 24
The index wheel is mounted on a piece called the index 5. Remove the latch cover from the latchlever,
wheel lever. This piece fits inside the lever latch and can 6. Disconnect the latch control cable and reverse
the
rotate slightly. It provides the small amount of rotation cable from the power shift control box.
necessary to index the index wheel.
7. Remove the power shift control box asan
assembly, from the controlpanel.
CONTROL BOX SERVICE
Control Box Service Testing
Control Box Service Removal All major functions of the power control
shift box can be
1. Tip the snowthrower up onto the auger housing. tested, with the Power Shift control box removed from
2. Pull the shift selector knoboff of the shift selector the control panel. To do so, insert a 7/16' bolt into the
lever. hole at the end of the reverse lever.
3. Disconnecttheshift rod fromthepowershift 1.Checkforproperoperationoftheshiftlockout

control box.See Figure 23. mechanism. With the lock out lever in the position
shown in Figure25,the lock out baseshould
prevent the shift lever from forward and backward
movement.
Figure 25
2. When the lockout
lever
is
pulled
back to the
position shown in Figure 26, the shift lever should
be free to move forward and backward.
Figure 23
Power Shift Controls .44 Power Shift Snowthrowers

Control Box Service Testing ( cont’d) serve the indexing wheel underneath the latch
lever. See Figure28.
Figure 26
3. The reverse lever is spring loaded forward by the Figure 28
reverse lever return spring.
Check to insure that the indexing wheel is free
to
Check for proper operation of the reverse lever by rotate clockwise when viewed from the bottom o
pulling backward. Reverse bellcrank movement the power shift control box.Also check to insure
as shown in Figure 27 should be noticed. 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 latchlever. The tabs
on the bottom of the index
wheeland 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 60 degrees counter Figure 29
clockwise and then releasing gently (if allowed to
spring back quickly, the “stop” on the bottom of Control Box Service Disassembly
the latch lever may break.) Every other time the
latch leveriscycled,thereverselevershould See Figure30.
move toward the back of the Power Shift control 1. With the Power Shift control box removed from the
box as it did in Figure 27. control panel, begin disassembly by
disconnecting the reverse lever return spring fr
5. Ifaproblemisnoticed in step 4 oftesting,the
indexingmechanismmaynotbefunctioning the PowerShift control box and removing the
properly. To check the indexing mechanism, ob- reverse lever.

Control Box Service Disassembly (cont’d) Control Box Service Reassembly
2. Disconnect the latch lever return spring from the 1.Ifnecessary,reassemble theindexwheellever
latch levermechanism.Remove the snap ring shown
assembly
as in Figure
31.
from the latch lever stud and off the
pull
latch lever.
Lockout
Lockout
Figure 31
2. Install the index tang into the latch lever with the
pin, making sure that the torsion springis in the
Figure 30 position shownin Figure 32.
3. If necessary,pry offthe push nut holding the index I._____----~ I
tangandremovetheindextang,indextang
spring, and the stud from the latch lever.
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 pushnutprior to
removal may prevent damage.
5. Remove the reverse bellcrank from the stud along
with the torsion spring.
6. Remove the bolt securing lock
the out baseto the
Power Shiftcontrol frame and remove the lock out
base.
7. Remove the special nylon locknut securing the
shift lever to the Power Shift control frame and
remove the shift bracket.
Figure 32
8. Remove the shoulder bolt securing the shift lever
3. Pushthe two smallshiftyokebushings into the
to the shift yoke and remove the shift lever. Next,
controlboxframe.Notethatthewiderflange
pull the shift yoke from the power shift control box
shouldbetowardtheoutside in both cases.
frame and finally, remove the small nylon bushings
Assemble the shift yoke and shift bracket with the
from the control boxframe.
Belleville washer and nylon locknut. Make sure

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 Figure 35
rear of the machine. (If installedwiththe
6. Mounttheshiftlockoutlever to the powershift
connectors forward, binding will result when the
control box using the shoulder bolt, flat washer
shift lever is moved forward and backward.)See
and nylon locknut. See Figure36.
Figure 34.
Figure 34
5. Slipthelock out baseover theshiftleverand
secure withthe shoulder bolt, flat washer and the
nylon locknut. Make sure that the lockout base
moves freely after installation. See Figure
35. Figure 36

Control Box Service Reassembly (cont’d) lever back and forth to insure that the index wheel
NOTE: Coat the shoulder bolt with an anti-seize is rotating properly. Secure with the flat washer
compound Toro part number 505-109) to prevent and snap ring. See Figure 38.
corrosion and subsequent binding. NOTE: Coatthelatchleverwithananti-seize
7. Slip the reverse bellcrank and torsion spring onto compound Toro part number505-109)to prevent
the stud as shown in Figure 37. Slide the index corrosion and subsequent binding.
wheel lever assembly onto the stud. Make sure 9. Next,install the reverseleverandreverselever
thattheends of the torsion spring are in the return spring as shown in Figure 39. Make sure
positions shownin Figure 38. that the boss at the bottom of the reverse lever
NOTE: Coat the reverse bellcrank with an engages the reverse bellcrank.
anti-seize compoundToro part number505-109)
to prevent corrosion and subsequent binding.
Figure 37
Figure 39
10. Make sure that all three control box springs are
in
the position shownin Figure 40.
Control Box Service Installation

1. Install the end of the reverse into
cablethereverse
bellcrank from the bottom of the reverse bellcrank.
Secure with the two jam nuts at the end of the
cable sheath. Adjust as describedin Control Box
Service Adjustments, page 49.
Figure 38 2. Insert the end of the latch release cable into the
8. Install the latch lever and spring into the position small hole in thetop of the latchlever. Adjust as
shown in Figure38.Once installed, rotate the latch described in Control Box Service-Adjustments,
page 49.
Power Shift Controls 48 Power Shift Snowthrowers

Control Box Service Installation (cont'd) Control Box Service Adjustments
3. Install the latch lever cover with2 Phillips screws.
1. Latch Cable Adjustment:Adjust the latch control
Do notovertighten.Adjustthelatchcableas
described in Control Box -Adjustments, page49. 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.
Lockout Lever
Figure 42
2. ReverseCableAdjustment:Adjustthereverse
cable so that there is1.5 mm (1/16") side play in
the reverse bellcrank as shown in Figure43. If the
cable istoo loose,loss of reversewill result.If the
cable is too tight, loss of the forward gears will
U occur.
I
Figure 40
4. Install the Power Shift control box on the control
panel,makingsurethatthereverselever is
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 rodto the shift bracket with
the nylon locknut as shown in Figure 41. Make
certain that the ball joint inisthe position shown
or the shift mechanism will not work properly.
Figure 43
3. Shift LeverAdjustment:Theshiftleverisproperiy
adjusted when the transmission is in second gear
and the lever slidesright down the center of the
powershiftslot. If adjustment is necessary,
remove the lower shift rod from the bellcranknear
Lower Shift Rod the transmission and manually place the bellcrank
in second (ie. second notch from the top). Loosen
the jam nut at the joint
ball and movethe ball joint
Figure 41
up or down until the shift lever ridesin the center
6. Push the rubber-shift knob onto the shift lever until of the power shift slide. Secureby attaching the
it is fully seated. Note that
it is a press
fit only. Once ball jointto the bellcrank with a nylon locknut and
installed the knob should point forward. tightening the jam nut.

CAUTION: Servicing the Power Shift Snowthrower will
requireworkingwithsomeofthemovingparts. To
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
precautions:
Figure 45
Wipe up any gasoline that may have spilled. Control inputs are transferred down to the idlerassem-
Do not drain the gasoline near any open flame or bly throughthe cable attachedto the release cam. The
spark. top end of the traction cable is protected by a rubber
Do not smoke when handling gasoline. boot to help prevent corrosion and icing.
OPERATION
Operation Impeller Control
Operation Traction Control The impeller control is the lever located ontop of the
right handle. See Figure44 above. It is spring loadedin
Traction is controlled
by means of the leveron top of the
thedisengagedposition.Theaugerisengagedby
left handle. See Figure44. The leveris spring loaded in
depressing the lever.
thedisengagedposition. The transmissioncan be
engaged by pushing down on the lever. Control input is transferred
to the idler assembly at the
auger pulleyby means ofa cable. There is a boot at the
Impeller top end of the auger cable
to help prevent corrosion and
Lever icing.
Traction Lever
Operation Impeller Locking Mechanism

As a convenience feature, there is an impeller locking
mechanismthatholds the impeller control in the
engaged positionif the tractionlever is also engaged.
This feature lets the operator throw snow and propel the
unit with one hand, leaving the other to position
free the
chute.
The impeller locking mechanism is comprised of only
Figure 44 four pieces. They are:
The traction leveris rigidly fastenedto the cross rod that lockingtang
passes underneath the control panel. See Figure 45. releasecam
Alsoattached to thecrossrodisatriplever(that locking latch
actuates the shiftlockout mechanism)andacam torsion spring
release (that controls the impeller locking mechanism). Themechanism isdisabledwheneverthetractionlever
Both are keyed to the traction lever rod. is in the disengaged position. See Figure46.
Traction and Impeller Controls 50 Power Shift Snowthrowers

Operation Impeller Locking Mechanism (cont’d)
Figure 46
When the tractionlever is engaged, the locking latch is Figure 48
free to rotate and engage thelocking tang. See Figure 3. from
Removethe push nut and the machine screw
47. 49.
the right side of the impeller lever. See Figure
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. Slowly pull the cross rod from the handles
releasing the locking tang and therelease cam.
Figure 47
Remove the locking tang and the release cam
If the traction
lever is released whilethe impeller locking from the cables and set them aside.
mechanism is engaged, the release cam will push the
6. Remove the E-clip securing the locking latchto
locking latchto release the impeller control. See Figure
the right handle and remove locking
the latch
and
48.
torsion spring.
7. Press out the impeller lever bushing and remove
TRACTION AND IMPELLER CONTROLS
the auger lever.
a. Continue removal of the cross rod by pulling it out
Traction and Impeller Controls Disassembly from theleft handle until thetrip lever is released.
1. Remove the two Phillipsscrewssecuringthe Set thetrip lever aside.
locking mechanismcover to thehandleand
remove the cover. Check the locking mechanism 9. Completely remove the cross rod being careful
components for proper operation. not to lose the traction lever spacer.
2. Remove the two cables from the cable holder on 10. Press out the tractionlever bushing and remove
the righthandle. the traction lever from the
left handle.
Power Shift Snowthrowers 51 Traction and Impeller Controls

Traction and Impeller Controls Inspection 5. Pushthecross rod throughtheimpellerlever
1. Inspect all bushings checking for wearand bushing untilit protrudes-about13 mm (1/2").
replace as necessary. 6. Findthetractioncableandinstall it andthe
2. Checkall rotating partsforcorrosionand/or extension springinto therelease cam as shownin
excessive wear. Lubricate with ananti-seize Figure 52.
compound (Toropart number 505-109) or replace NOTE: The recessed side of the releasecam will
as necessary. face the control panel.
3. Check thetrip lever and release camto insure that 7. Hooktheextensionspring into the slotprovided
the keys securing themto the cross rod are still in the right handle then mount the release cam
intact. onto the cross rod.
Traction and Impeller Controls Reassembly

See Figure5 0 .
Figure 52
8. Fastentheimpellercable to the locking tang as
Figure 50 shown in Figure 52.
1. Position the traction leverin its normal location on 9. Position the locking tang inside the impellerlever
the left handleandpress in the traction lever and then push the cross rod all the way through.
bushing. Secure with the Phillips screw.
NOTE: The traction lever bushing is reversible. 10. Install the torsion spring and the lock latch onto
the spindle and secure with the E-clip. See Figure
2. Place the traction lever spacer inside the traction
52 for proper spring orientation.
lever and insert the cross rod through the traction
lever. 11. Position both traction and impeller cables into the
3. Install the trip lever onto the cross rod as shown cable holder,but do not tighten at this time.
in Figure 51. 12. Secure the cross rod
to the traction lever with the
hex head screw and locknut.
13. Beforeassemblingany further, verifythat
everything works as described under Traction
and Impeller Controls Operation, page50.
14. Install a new push nut on the right end of the cross
rod. Be sure to align the tabsin the push nut90"
from the keyway to insure retention.
15. Install the locking mechanism cover with the two
screws.
Figure 51 Traction and Impeller Controls Traction Cable

Adjustment A
4. Positiontheimpellerleverontherighthandleand The traction system very little of the available

press in the impeller lever bushing.
powerfromtheengine.Therefore,thebeltdoesn't
NOTE:Theimpellerleverbushingisreversible.requiremuchtension to drivethewheels.
Traction and Impeller Controls 52 Power Shift Snowthrowers

Traction and Impeller Controls Traction Cable
Adjustment (cont'd)
.23 mm to .30mm (.009”to .012")
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. 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. To decrease tension, the end
of the sheath must be moved to closer
the traction
lever.
CAUTION: Do not overtighten because it may

cause the snowthrower to creepwhen the
traction lever is in the disengaged position.
Traction and Impeller Controls Impeller Cable Figure 53

Adjustment 2. Adjust tension by loosening the two jam nuts at
The impellerdrivesystem will in someconditions the top of the auger cable. Increase tension by
transmit most of the power available from the engine. rotating the nuts so that the end of the sheath
Therefore the tensionon this belt is fairly high. moves down. Decrease tension by moving the
end of the sheath toward the impeller lever.
1. Depress the impeller lever.Propertensionis
achieved when there is .25 mm (.010”) clearance NOTE: Do not overtighten as it may cause the
between coils of the impeller cable spring. See impeller and augerto turn when the lever in
isthe
Figure 53. disengagedposition.
Power Shift Snowthrowers 53 Traction and Impeller Controls

CAUTION: Servicing the Power Shift Snowthrower will The chute rotates from extreme left to right through an
requireworkingwithsomeofthemovingparts. To arc of200 degrees in about six turns of the crank.
Chute Control Knob Removal
Rotate the Ignition keyto off and remove. NOTE: Do not removethe knob unless necessary.
Make surethe wire does not accidentally touch I. To remove the knob, use a pocket knifeto pry off
the spark plug. the squareknob cover. See Figure 55.
CAUTION:ThePowerShiftSnowthrowerhasthe
for service and storage. Always drain the fuel
from the
precautions:
Drain it outdoors and make sure the engine is cool.
spark.
CHUTE CONTROL
Figure 55
Chute Control Operation 2. Remove the push nut by drilling through thetwo
The control for the discharge chuteof the Toro Power tabs in the pushnut and pryingoff.
ShiftSnowthrowerwasdesigned so that the chute 3. Remove
the
knob.
would turnInthe same direction that the input wasknob
rotated. See Figure 54.
Chute Control Knob Installation
1. Install the knob on the rod, recessed side up.
2. Press on a newpushnutusingan 11 mm (7/16'”)
socket.
3. Reinstall the knob cover using a small amount of
clear siliconeif necessary.
Chute Control Upper R o d Removal

1. Remove the roll pin in the upper gear. See Figure
56.
NOTE: Do not remove the
knob unless necessary.
Figure 54 2. Pulltheupper rod assemblyout throughthe
The operator provides control inputby turning the chute controlpanel.Donotlosetherubberwasher
control knob at thecontrol panel.This rotationis above the gear.
transmittedto the chute by means ofa constant velocity 3. If desired,removetheupper rod bushing by
joint and two shafts. The final shaft turns a worm gear removingthe two Phillips screwsfrombeneaththe
which drives the teeth on the chute. control panel.
54 Power Shift Snowthrowers

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

Figure 56 See Figure58.
Chute Control Upper Rod Installation

See Figure57.
Figure 58
1. Loosely mount the worm gear bracket with the
carriage bolt, washer and locknut.
2. Insert the lower
rod into the joint bracket.
3. Place the worm gearinthe worm gear bracket and
it.
slide the lower rod into
4. Install the lower rod gear with the teeth facing
the
rear of machine.
5. Adjust the worm gear bracket by pushing it toward
the chute until the teeth
on the chute and the worm
geararejusttouching.Checkforbindingby
rotating the control knob. If binding is noticed,
move thewormgearbracketoutslightlyand
recheck.
DISCHARGE CHUTE
Figure 57 Discharge Chute Operation

CAUTION! Keep hands, feet and loose clothing from the
1. Mount the upperrod bushingon the controlpanel.
discharge chute area. The impeller atbottomthe of the
2. Slide the upper rod assembly through the control discharge chute rotates rapidly and could cause severe
panel fromthe top. injury if contacted. If the chute should
Power Shift Snowthrowers 55 Discharge Chute

Discharge Chute Operation (cont'd) 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,
such as a broom handle, to clear the obstruction. 2. Remove thechute.
CAUTION! Do not operate the snowthrower without the
chuteguard in place. It is there to helpprevent Discharge Chute Installation
inadvertent contact with the impeller. See Figure60.
CAUTION!When throwing snow,never direct the
discharge at people, pets or personal property as debris
or ice couldbe picked up and thrown.
See Figure59.
The discharge chute rotates through an arc of for
200"
convenient directioning of snow while throwing.
The chute rotates on aring 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 intoit which matewith the worm gear.
Figure 60
1. Lightly grease the chute ring with a #2 lithium
base grease.
2. Loosen the nut under the worm gear bracket to
facilitate installationof the chute.
3. Place the chute on the chute ring with chute
the
facing forward. Installthe two rear chute retainers
Figure 59 usingsocketheadmachinescrewsandnylon
locknuts.
The chute deflector is hinged and gives the operator
greater control over thevertical and horizontal 4. Install the front chute retainer being sure that the
distances the snowis thrown. A piano hinge is used to chute guard is trapped by the chuteguard
reduce the amount of snow blown through the hinge. bracket.
Nylon washershold thetop of the chutein position and 5. Adjust the worm gear bracket by pushing it toward
allow it to be moved without the use of tools when the the chute until the teeth on the chute and the worm
locknut is properly tightened. geararejusttouching.Checkforbindingby
rotating the control knob. If binding is noticed,
The chute deflector is not removable or replaceable
separately. move thewormgearbracketoutslightlyand
recheck.
Discharge Chute 56 Power Shift Snowthrowers

SECTION 4 IDLER SYSTEM
CAUTION! Servicing the Power Shift Snowthrower will The impeller idler pulley
is set up similarly, again rotating
requireworkingwithsomeofthemovingparts. To about a plastic bushing and using two springs, one for
prevent accidental starting of the engine while return and the other
to prevent over-tensioning.
Also rotating about the same shaft is the brakeIt is arm.
Rotate theignition key to off and remove spring loadedso that the brake pad is pressing against
Pull the wireoff the spark plug the impeller pulley whenever there is no tensionon the
Make sure the wire does not accidentally touch impellercable. When theimpeller is engaged, the
the spark plug impeller idler arm pulls the brake off of the impeller
pulley.
CAUTION!ThePower ShiftSnowthrowerhasthe
feature of being ableto be stood on the front housing Idler System Removal
1.Remove thethreecapscrewssecuringthebelt
cover to the snowthrower frame.
precautions:
2.Remove the two hexheadcapscrewssecuring
Drain it outdoors andmake sure the engine is cool
the idler assembly See
to the snowthrower frame.
Wipe up any gasolinethat may have spilled
Figure 62.
Do not drain thegasolinenear any open flame or
spark
Do not smoke when handlinggasoline
Idler System Operation

See Figure
61
Figure 62
3. Pull the idler assembly from the frameand
disconnect the two idler springs from the lower
arm bracket. See Figure 63.
Remove the hex head cap screw and nylon lock

4.
Figure 61 nut from the idler arm bracket and remove the
two idler
The idler assembly is comprised of pulleys, one traction and impeller cables.
for the traction belt and one for the impeller belt and the
auger brake. Idler System Disassembly
The traction idler pulley rotates about a plastic bushing1. De-tensiontheimpellerbraketorsionspringby
and is centered two by springs. The lower spring returns moving the short end theofspring off the idler arm
the idler to the disengaged position once tension is bracket tang.
released from thecable. The other spring is attached to
2. Remove the snap ring and Belleville washer from
the traction cable and prevents over-tensioning.
the idler pin on the impeller brake side.
Power Shift Snowthrowers 57 Idler System

Idler System Disassembly (cont'd) 1. Insert a hex head cap screw into each of the idler
pulleys.
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
2. Mountthe two idler arms onto the idler bushing
using Figure64 as a guide.
3. Insert thetwo idler arms into the idler bracket
and
secure with the idler pin using Figure 64 as a
guide.
4. Hookthe two idler return springs into the lower
holes on the idler arms.
Figure 63 5. If theimpellerpulleybrakepadwasremoved,
CAUTION! The torsion spring is under tension. apply a small amount of adhesive onto the brake
Eye protectionand heavyglovesare arm and install the brake pad.
recommended when installing spring. 6. Slip the torsion spring into the brake arm with the
3. Check the impeller pulley brake pad for excessive short side of the spring on the opposite end of the
wear and remove if necessary.Remove by brake pad. Sliponto the idler pin and secure with
grasping with a needle nose plyers and rotating. a belt, washer and snap ring.
4. Pull the idler pin from the idler arm bracket and NOTE: Do not attemptto tension the spring at this
remove thetwo idler arms. time.
5. Remove the two idler return springs from the idler7. Grasp the short end of the torsion spring with a
arms. needle nose plyers and slipinto the tang on the
idler arm bracket.
6. Remove thefastenerretainingthecablesand
remove the cables. See Figure65
7. Removethe idler bushing from the idler arm pivots

and inspect for wear. Replace
if necessary.
8. Check the traction idler pulley and impeller idler
pulleysforfreerotation on theidlerarms. If
necessary, remove and replace the pulleys.
Idler System Reassembly

See Figure 64.
Figure 65
CAUTION! The torsion spring is under tension.
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
intotheupperholeontheimpelleridlerarm,then
slip theend of the impeller cable sheathinto the
Figure 64 slot provided at thetop of the idler bracket.

Idler System Installation (cont’d) 4. Hookbothidlerreturnspringsontothe
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 thetop of the idler arm bracket. frame and secure the two hex headcap screws.
3. Secure both cables with the hex head cap screw NOTE: Verify that the brake pad is still in place
See Figure66.
and nylon locknut. 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 as
described below.
Idler System Adjustment

See Traction Cable Adjustment,page 52 and Impeller
Cable Adjustment,page 53 for information on proper
Figure 66 idler adjustment.
Power Shift Snowthrowers 59 Idler System

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.
prevent accidentalstarting of the engine while
performing service, takethe following precautions:
Rotate the ignition keyto off and remove
Pull the wireoff the spark plug
the sparkplug
CAUTION! ThePower ShiftSnowthrower has the

feature of being able to be stood on the front housing
precautions:
Drain it outdoors and make sure the engine cool
is
Wipe up any gasoline that may have spilled
Figure 68
spark The latch rod rests in either of the two stops during
Do not smoke when handling gasoline. normal operation. However, when power shifting, the
latch cable pulls up on the latch plate thereby allowing
the latch rodto move freely past the stops on the latch
PIVOT SYSTEM
plate.
Power fortheswingingaction is providedbythe
Pivot System Operation transmission. For instance, if the operator wishes to
The Power Shift snowthrower, like most snowthrowers, move the wheels from the forwardto the rear position,
uses a chainto transfer power from the transmission to the latch plate is movedoutof the way, thenthe
the rear axle. However, unlike any other snowthrower, transmission powers the wheels backwardsby driving
the Power Shift snowthrower allows the wheels to pivot in reverse.
forward and backward, thereby transferring weight to
and from the front end. See Figure67. The standard rear axleis solid, providing no differential
action. An optional differentialkt is available. For more
information on thedifferentialkit, see Section 14,
Differential Kit, page 88.
Pivot System Disassembly

1. Remove the klikpin securing thewheel 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 left hand pivot arm.
4. Remove the nylon locknuts and Belleville washers
I from
the
pivot
arm
pivot
bolts.
(Thread
forming
Figure 67 screws
secured
latch
the rod on '88only.)
units
The pivot arms pivot about an axis coincident with the NOTE: The pivot bolts may be difficultto remove
outputshaft.Thisisimportantbecause it prevents from the pivot arms.It is not necessary that they
changes in chain tension as the axle swings. Once in be removed at this time.
Pivot and Latch System 60 Power Shift Snowthrowers

Pivot System Disassembly (cont’d) 6. Insert the latch rod, pivot arm, and axle assembly
5. Remove the left hand pivot arm complete with the into the proper location on the right side of the
chain guard. chassis.Besure to slip the chain overthe
sprocket.
6. Remove thelatchrod,pivot arm,andrearaxle
assembly by slipping the chain off thelarge NOTE: There must be a Belleville washer between
sprocket. the frame and the pivot arm. The serrated side of
the Belleville washer should face
the pivot arm.
7. Remove chain guard from theleft hand pivot arm.
7. Slide the left pivot arm and chain guard assembly
8. Removethe latch rod from the righthandpivot over the axle and into position.
arm.
NOTE: Make sureall washers are in place. There
9. Ifnecessary,removethebushingsfromthepivot should be aBellevillewasher(serratedside
arms using an arbor press. toward the pivot arm) between the pivot and arm
10. If desired, remove the pivot bolts. They may flare the chassis, a large flat washer (between the end
somewhatonceinstalledandmayhave to be of the latch rodand the pivot arm), and a thrust
pressed out with an arbor press. washer between the roll pin and the pivot arm
when it is installed correctly. See Figure
70.
11. If necessary, remove the roll pins from the
axle.
Pivot System Reassembly

See Figure 69.
Figure 70
8. Secure the assembly by tightening the pivot arm
bolts and nuts, and the nuts on latch
the rod.
9. Mate the right half of the chain guard with the left
half and secure with the three Phillips screws.
Figure 69 10. Coat the endof the axle with ananti-seize

compound Toro part number 505-109). Do not
1. Pressnewbushings into both pivot arms. apply in thebushingareaas it maybecome
2. Install the chain guard on the left hand pivot arm. “gummy”.
11. Slide the thrust washers over the end of the axle
3. Press roll pins into the two inner holes on the axle and install the wheel assemblies. Note that the
and slide thrust washers on each so end
that they part of the hub with thehole in it faces outward.
rest against theroll pins. Rotate wheelto distribute anti-seize compound,
4. Installthelatchrodintotherighthandpivot arm,Securethewheelswiththeklikpin.Usetheouter
makingsurethatthereisalargeflatwasheronhole if freewheelingisdesired,orusetheinner
eachsideofthepivotarm.Don’ttightenthenylonhole if driveisdesired.
locknut at this time.
5. Inserttheaxle intotherightpivotarmandlatch LATCH SYSTEM
rod assembly. The sprocket will be onleftthe
side
of the
axle
when it is
installed
correctly. Latch System
Disassembly
NOTE:Makesure there is a thrust washer 1.Remove thepanelfastenerfromthelatchplate
the roll pin and
between the
pivot
arm.
and
slip
out
the
end
of
the latch cable.

61 Pivot and Latch System
Latch System Disassembly 2. Placethe latch plate in position.
2. Pullthe latch plate down to detensionthelatch 3. Secure the latch plate with thetwo shoulder bolts
plate spring, then remove the nylon locknuts on and the nylon locking nuts. Make sure that the
either side of the
latch plate. head ofthe boltsare on the inside of the frame.
3. Removethe latch plate and latch plate spring from4. Swing the latch plate up into position and slip the
the snowthrower frame. cable into the slot provided. Secure the cable with
a new panel fastener. See Figure 72.
Latch System Reassembly
See Figure 71
Figure 72
5. Check to insurethatthelatchplateoperates
correctly and does not bind.
Figure 71
6. Completelatchplateservicingbyreassembling
1. Position the latch plate spring on the right side
of the pivot and drive assembly as described under
the frame. Pivot System Reassembly, page 61.
Pivot and Latch System

~-
SECTION 6 TRANSMISSION
CAUTION! Servicing the Power Shift Snowthrower will
requireworkingwithsomeofthemoving parts. To
the spark plug.
CAUTION!ThePowerShiftSnowthrowerhasthe
precautions:
Figure 73
Do not drain the gasoline near any open flame or NOTE: The jaw clutch has no intermediate position.It
spark. should alwaysbe completely engaged with oneof the
Do not smoke when handling gasoline. bevel gears.
Transmission Operation
The transmission used on the Power Shift Snowthrower
is similarin 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 pulleyto the output sprocket.
Input System: The input system is straight forward,
consisting of a large pulley, a hub, and a pinion gear.
The assemblyis supportedin the case by b aal l bearing.
See Figure73.
Bevel Gears: See Figure 74. The bevel gears rotate
freely with respect to the intermediate shaft and the Figure 74
gearsontheintermediateshaft.Theyaredriven in
opposite directions by the input piniongear. Fixed Gear Cluster: The fixed gear cluster and the
sliding jaw clutch rotate as an assembly on the
The reverse bevel gear is supported on the intermediate intermediate shaft. See Figure75.
shaft by a bushing because it freewheels while the
transmission isin forward. The forward bevel gear rides Selectable Gear Cluster: The selectable gear cluster
on the first gear hub.No bushing is used on the forward consists of four independent gears, two sleeves andthe
bevel gear becauseit rotates on the hub only when the shiftmechanism. See Figure 76. Thesleevesrotate
transmission isin reverse. freely on the output shaft and each is supportedby a
to the fixed gear cluster. bushing.
The sliding jaw clutch is coupled
It is freeto slide back and forth between the two bevel
gears. Thedirection of rotation of the fixed gear cluster NOTE: The sleeve closest to the sprocketis also the first
is determined by which bevel gear the sliding jaw clutch gear in the speed reduction system.
engages.
Power Shift Snowthrowers 63 Transmission

Transmission Operation (cont'd) and number three speed reduction gears. Gears two
and three are joined and therefore rotate at the same
speed.
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
is coupled to
only component on the output shaft that
the output shaft.
Figure 77
Figure 76
The four gears are drivenby 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,theshift
mechanism engagesone of the gearsso that the gear
and the sleeves rotate together.
Shift Mechanism: See Figure77. The shift mechanism
consists of two sliding shiftkeys, a shift sleeve, a shift Figure 78
collar and the shift fork. Control input from the operator
so that the sliding keys engage the
rotates the shift fork
desired gear. Transmission Removal
Speed Reduction Gear Set:In order to bring thespeed NOTE: Because transmission removal requires many
of the transmission down to one acceptable for steps, the use of air tools is recommended. However,
snowthrowing, a speed reduction gearsetwas do not use air tools to tighten or loosen self-tapping
incorporated. See Figure78. screws in aluminum. Thread damage could result.
The first gearin the speed reduction gear setis also the 1. Standtheunitonthefronthousing to provide
sleeve in which the shift keys slide. Therefore, when the betteraccess to thetransmission.Don'tforget to
transmission is in gear, the number one speed reduction drain the fuel first
as described at the beginning of
gear rotates. This transmits power to the numbertwo this section.
Transmission 64 Power Shift Snowthrowers

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
unitandslipthebelt off thetransmissionpulley.atthistime.
4. Remove thecoverplatefrombehindthe
transmission.
5. Remove thepivot system,asdescribedunder
Pivot System Disassembly, page 60.
6. Remove thelatch systemasdescribedunder
Latch System Disassembly, page 61.
7. Remove the two rear nylon locknuts securing the
transmission frameto the snowthrower frame and
swing the assembly down, out of the unit. Be
carefulnot to damagethereversecable. See
Figure 79.
Figure 80
4. If furtherdisassemblyisrequired,removethe
input shaft, the intermediate shaft and the output
shafts. Removeall excess grease, then clean in a
solvent bath.
5. Remove thethreeselftappingscrewsfromthe
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 79
6. Carefully pull the gears, sleeves and spacers from
8. Remove thefourself-tappingscrewsfromthe top theoutputshaft,takingnoteofspacerposition.
of the transmission frame while supporting 'the
NOTE: The number of washers used and their
transmission to prevent it from falling.
position will vary from year
to year. Drawa sketch
9. Remove thereversecableclampandthereverseortakenotes to insureproperreplacement.
cable from the top of the transmission* See Figure 7. Inspect the inside and outside teeth on the gears,
80. the sleeves and the bushings for damage or wear
and replace as necessary.
Transmission Disassembly 8. If desired, the ball bearing can be removed from
1. Remove theroll pins on thetop of the transmission the output shaft by supporting the inner race of
that secure the gear selector control arm and the the bearing and then pressing the output shaft
direction control
arm to the shift forks. Remove the using an arbor press. Be careful notto press on
two control arms. See Figure 80. the outer race of the bearing or damage to the
2. Remove the six hex head screws holding the gear bearing may result.
box halves together and remove the upper gear 9. Remove the gears, sleeves, spacers and bushings
case half. from the intermediate shaft.
3. Withthegear box open, rotatetheinputpulley in 10. Completedisassemblyoftheintermediateshaft
a counter
clockwise
direction,
checking
the
by
pressing out the
roll
pin.

Transmission Disassembly (cont'd) intermediate shaft. Install into the proper location
11.Inspectallcomponentsfordamageandwear. in the lower transmission case. Make sure that the
Replace as necessary. keysonthebushingsalignproperlywiththekey
sets in the lower case. See Figure82.
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.
Figure 82
NOTE:Maximumendplay is (.030").If greater
Figure 81 than (.030")
add a thrust washer (Toro part number
257- 10)to either end of the shaft.
1. Intermediate Shaft:Beginreassemblyofthe
Intermediate shaft by pressing in the coil pin so 9. Output Shaft: See Figure 83.
that it is centeredin the intermediate shaft.
2. Slidethespeedreductiongearonthe
intermediate shaftso that it properly engages the
coil pin.
3. Consult your notes or sketchto find out how many
spacers fit between the speed reduction gear and
the large 51-tooth gear.Slide the appropriate
number of spacer washersonto the intermediate
Shaft.
4. Slide the 33-tooth and the 51 -tooth gear onto the
26 tooth gear. Figure 83
5. Slidetheassembly,largegearfirst,ontothe Begin output shaft assembly by pressing theball

intermediate shaft. bearing onto the output shaft. Be sure to press
only on the inner race when installing the bearing
6. Apply greaseto the spline and hub on the tooth
15 to prevent possible bearing damage.
gear. Slide the 15-toothgear and sleeve onto the
intermediate shaft, geared end first. Make sure Space Between Sprocket and Bearing:
that the geared end mates completely with the
26-toothgear. 1.22 -08 cm (.48 2.03')
7. Slide the large thrust washer )if used) over the Slide the large 42-tooth speed reduction gear onto
splined portion of the 15-toothgear and follow theoutputshaftwiththehubsidefirst.Then
with the forward bevel gear, the jaw clutch, and theconsult your notes and slide on the appropriate
reverse bevel gear. number of thrust washers.
8. Complete intermediate shaft assembly by sliding 11. Apply grease to the keyway and the O.D. of ths
the appropriate number of thrust washers and one sleeve. Do not get grease in the bushing area as
bushing, flanged side first, on each end of the it may get "gummy" cause premature failure. Slide
Transmission 66 Power Shift Snowthrowers

Transmission Reassembly 19. Assemble the input pinion, ball bearing, hub and
the first half of the shift sleeve with the 19-tooth pulley as shownin Figure 85.
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. Assemble the shift mechanism consistingof the
the shift collar. Apply
sleeve, the two shift keys and
grease to the shift collar groove.
Figure 85
15. Slide the shift mechanism, shift keys onto
first, the
output shaft and into the appropriate slots
in the 20. UseasmallamountofLoctite(R) (Toro part
gear sleeves. number 505-103) to secure the outer race of the
bearing to the lower gear case half. Be careful n
16. Complete assembly of the output shaft by to get Loctite@ on the pinion or the hub.
installing the correct number of spacers and the
output bushing, flanged end first. 21.Rotate theinputpulley in acounterclockwise
direction and check for proper operation of the
17. Install the assembled output shaft into the lower entire transmission.
transmissioncase.UseLoctite(R) (Toro part
number 505-103) to secure the outer race of the 22. Apply (14.5 oz) of Lubriplate(R) Mag 1grease (Toro
bearing to lowergearcase.Check for proper part number 505-101) to gears intransmission. Fill
operationofthevariouscomponents,making under gears first, then top. Also grease shift for
surethatthere is neitherexcessiveplaynor Install upper gear case half.
binding. Align the bushing
keys with keysetsin the 23.Press the gearselector control armandthe
lower case. directional control arm onto the shift forks as
18. install the two shift forks as shown in Figure 84. shown in Figure 86.
Make surethat both shift collar grooves have been
greased.
Figure 86
Secure with thetwo roll pins.
Again,check to insure that the transmission
operates freely, then secure the two gear case
halves with the sixself tapping hex head screws.
Coat screws with oil to prevent them from seizing.
Figure 84 1.38 kg m (120 in Ibs)

Transmission Installation 10. Place the transmissionin second gearby pushing
to the top of its travel, then
the rear of the bellcrank
NOTE: Because of the number of steps involved, air pulling down2 clicks. See Figure87.
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. Before installing the transmission, check to be
sure the input shaft and all controls top on of the
transmission are working correctly.
3. Insert theend ofthe reverse cable spring
into the
directionalcontrolarmandinstallthe reverse
cable clamp.
4. Secure the transmissionto the transmission frame Figure 87
with the four transmission screws and Belleville 11. Install the rear cover plate with
4 nylon locknuts.
washers (serrations up).
12. Checkchainadjustment,asdescribedunder
5. Fasten thetransmissionframe to the snowthrower Maintenance Drive Chain Adjustment, page
frame with the four
hex head cap screws. 38.
6. Slip the traction belt onto the transmission pulley.13. Install the lower shift rod into the bellcrank and
7. Install the latch plate as described under Latch adjust per instructions under Control Box
System Installation, page 62. Service Shift Lever Adjustment,page 49.
8. Install the pivot and drive assembly as described 14. Check latch cable adjustment as described under
under Pivot System Reassembly, page 61. Control Box Service Latch Cable Adjustment,
page 49.
9. Fasten the lower plastic belt cover to the frame
using the two self tapping screws. The tabs on 15. Check proper adjustment of the reverse cable as
the edge of the cover should be located behind described underControl Box Service Reverse
the bulkhead plate. Cable Adjustment,page 49.

SECTION 7 AUGER
prevent accidentalstarting of the engine while
the spark plug.
fuel from the
for service and storage. Always drain the
tank prior to such service taking the following Figure 88
precautions:
5. Pull the auger half from the auger shaft.
Drain it outdoors and make sure the engine iscool.
Wipe up any gasoline that may have spilled. 6. Inspect allpartsfor damage and wear and replace
Do not drain the gasoline near any open flame or or repair as necessary.
spark.
Do not smoke when handling gasoline. Auger Installation
1. Loosenthefournylon locknuts securingthe
flange bearing to the side plate. This will insure
AUGER
proper centering of the flange bearing when the
side plateis reinstalled.
Auger Operation
2. Coat the auger shaft with ananit-seizecompound
The augeron the two stage Power Shift snowthroweris (Toro part number505-109) and slide the auger
turned at a relatively slow rate of (125
speed to 126 rpm) onto the auger shaft. Do not apply anti-seize
to the
by the auger gear box. It’s purpose is three fold. Firstly, bushing area.
it breaks hard packed snow and ice to facilitate its
movement. Secondly, it conveys the snow by a cork NOTE: If both auger halves have been removed,
screw type actionto the impeller. Thirdly, the patented be sureto install them on the correct sides! (Whe
drum meters the snow before feedingtoitthe impeller installed incorrectly the auger will move the sno
to reduce thepossibilityof clogging at the impeller. toward the side plate rather than the impeller).
auger half is installed correctly when the augers
are positioned as shown in Figure 89.
Auger Removal
There are two augers, a left and a right. They can be
removed separately. Thefollowing describes removal of
one ofthe auger drums.
1. Remove theaugerthrough boltas shown in Figure
88. This will allow free wheel movement of the
auger to facilitate removal of some of the nuts and
bolts.
2. Remove thebolt and accompanying washer at the
end ofthe auger shaft.
3. Remove the skid and the skid bracket.
4. Remove theremaining five sideplatefasteners
Figure 89
and remove the side plate.
Power Shift Snowthrowers 69 Auger

Auger Installation (cont'd) 5. Support the auger soend
the
that of the auger
shaft is centered in the hole in the side plate.
3. Slidethesideplate and auger
bearing
assembly Tighten
the
four cap screws and nylonlock nuts.
onto theauger shaft and secure with the
top five
cap screws andlock nuts. 6. Secure the auger halfto the auger shaft using the
long cap screw and nylon lock nut.
4. Fastenthe skid supportbracket to theauger 7. Adjust the scraper and skids as described under
housing andloosely install theskid. Skids Installation and Scraper Installation,
pages 78 and 79.
70
SECTION 8 AUGERGEAR BOX
CAUTION! Servicing the Power Shift Snowthrower'will ment. Do not use Lubriplate(R) Mag1 greaseinthe auger
requireworkingwithsomeofthemovingparts. To gearbox.
Auger Gear Box Removal
Rotate the ignition
key to off
and
remove.
Disassemble
1. the
snowthroweras
described
in,
Pull
wire
the
spark
offplug.
under Impeller and Pulley Removal,
page 75.
shaft
auger
thehalves
from
auger
Remove
the2.plug.
spark
the by
removing the carriage bolts passing through the
CAUTION! ThePowerShift
Snowthrowerhas
theauger
halves
andthe
augershaft.
tank prior to such service taking the following Auger Gear Disassembly
precautions: box gear
auger
Remove
the from
1. plugdrain the
and drain the gear box lubricant into an appro
container for recycling.
Do notdrainthegasolinenearanyopenflameor2.Removethesixselftappingflangeheadscrews
spark. the
together.
halves box two gear
holding
3. Separate thegearboxhalves.
NOTE: Be careful not the distort or damage the
Auger Gear Box Operation gear box halves when pryingtwo the
halves apart.
Theaugergear box is a 90 degreetransmission,
meaningthatitsinputandoutputshaftsareat 90 4. Before disassembling further, inspect all parts for
degrees to each other. The augerbox accomplishes this wear and/or damage making note of those which
by using a worm and helical gear combination. See require replacement.
Figure 90. 5. Before removing the seals, bushings and thrust
bearing from the input shaft, remove any
corrosion and/or burrs from shaft.
the
6. Remove thebushings,seal, thrust bearings,
spacers and snap shaft. Do not
ring from the input
overstress the snap ring during removal.
7. Remove the output shaft along with the helical
gear and spacers from
the gear box half.
8. Remove thehelical gear, spacers and the
woodruff key from the output shaft.
9. If necessary, removethe seals and bushings from
the gear box halvesby pressing out on an arbor
Figure 90 press with an appropriately sized pilot.
The auger gear box also providesspeed reduction for NOTE: ('88 and '89 units only) Do not scrape off
the auger. The impeller, when at full throttle, turns at theblueHylomar@sealant(Toropartnumber
approximately 1250 rpm, while the auger turnstoat 125 505-105) from the gear box halves. It will reseal
126 rpm under the same conditions. withoutbeingremoved.However,removeany
excess oil in the tongue and groove area.
Lubrication is supplied by an SAE 90 weight extreme
pressure (EP) gear oil with anAPI ratingof GL-5 or GL-6. NOTE: 9 ' 0 and newer Power Shift Snowthrowers
Thisisnecessarybecauseofthetemperaturesand will use a different sealant that will affect these
pressures provided by a worm helical gear arrange- instructions. Look for forthcoming informationin
Service Bulletin form.
Power Shift Snowthrowers 71 Gearbox Auger

Auger Gear Box Reassembly 5. Slide the helical gear onto the auger so
shaft
that
See Figure 91. it covers the woodruff key.
6. Slide one thick thrust washer ontoend of the

each
auger shaftso that they are next
to the helical gear.
7. Input Shaft: Slide the snap ring onto the input
in its groove (do not
shaft untilit is properly seated
attempt to stretch it over the worm gear end). See
Figure 93.
NOTE: The snapring should not spin freely in the

groove. If it does, it has been overstressed and
should be replaced.
Figure 93
8. Slidethethrustwasher,athrustbearingand
so that
another thrust washer onto the input shaft
they rest against the snap ring.
9. Slide the oil impregnated bushing, flanged side
first, onto the input shaft.
10. Coat the inside surface of the seal with gear oil,
then slide the seal, hollow side toward the inside
of the gearbox.
11. Once the Hylomar(R) sealant Foro part number
Figure 92 505-105) on the gear case halves has flashed, slip
2. Install new seals
in thegear box halves. Press the the auger shaftinto the half of the gear case with
seals hollow side inward from the outside of the the plug init until it bottoms out on the woodruff
gear box until they bottom out on theoil key.
impregnated bushings. 12. Lay the input shaft into the left gear box half,
3. Clean the gear box halves, but do not scrape the making sure that the thrust bearing components,
original HyIomar(R) sealant from the mating theseal,andthebushingsare in their proper
surfaces. Apply a light coat of Hylomar(R) sealant locations. See Figure94.
(Toro part number 505-105) to the tongue and 13. Slide the right gear case half over the auger shaft
groove area. Allow the sealant to dry somewhat, and mate thetwo gear box halves.
untilthesurfacehasflashed(turneddulland
tacky: at least15 minutes). 14. Coat the auger gearbox screws oil with
to prevent
seizing.
Secure
with
the
six
flanged
head
self
4. Auger Shaft: Begin assembly of the auger shaft tapping capscrews. Tightento 1.38 kg m (120in
by placing the woodruff key in the keyway at the Ibs) in the order shown in Figure
95.
center of the auger shaft.

Auger Gearbox Reassembly (cont’d) anti-seize compound
to the bushing area itas
may
become’“gummy”.
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 of the
auger shaft.
6. Slide the auger assembly into the front housing
and loosely secure the auger flange bearingsto
Figure 94 the side plates with the hex head screwsand n
locknuts. See Figure96.
Auger Gearbox Screw Torque

1.38 kg m (120 in Ibs)
Figure 96
7. Prop the auger so that they auger shaft is centered
inthe holeinthe side plate. Once centered, tighte
theflangedbearingfasteners. Do this to both
sides.
8. Tightenthethreefastenerssecuringtheimpeller
Figure 95 shaft flange bearing to the rearof the front
housing.
15. Fill with (4.5 oz)of SAE 90 weightExtreme
Pressure gear oil, with an API rating of GL-5 or 9. Install the large flat
washer and the capscrewinto
GL-6. Apply Permatex(R) (Toro part number the end of the auger shaft. Do this to both sides.
505-22) to plug. 10. Bring thetwo halves of the snowthrower together
and secure with thesix flanged head capscrews.
Auger Gear Box Installation 11. Slip the impeller beltover the impeller pulley and
1. Drainthefuelfromthetankusingacranktype install the idler assembly as shownin Figure 97.
pump. 12. Check for proper operation of the impeller and
2.Secure theimpeller to theaugershaftwith two traction belts then install the upper belt cover
flanged head cap screws and nylon locknuts. the three self tapping flanged head screws.
3. Coat theaugershaftwithananti-seizecompound 13. Installthechuteworm gearassemblywiththe

(Toro part number 505-109) and slide the auger carriage bolt and nylon locknut. For more
halves onto the auger shaft. Do not apply information on this, see Discharge Chute
Installation, page 56.
Power Shift Snowthrowers 73 Gearbox Auger

Auger Gear Box Installation (cont’d) 14. Stand the snowthrower on the front housing and
two flanged
install the lower belt cover using the
capscrews.
tapping self head
15. 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. For more information on this see
Skids
Installation,page 78, andScraper
17. Complete impeller servicingby performing a final

operational check.
Figure 97

SECTION 9 IMPELLER AND PULLEY SYSTEM
CAUTION! Servicing the Power Shift Snowthrower will 2. Set the PowerShiftSnowthrowerback intoits
requireworkingwithsomeofthemovingparts. To normal position and remove the top belt cover
prevent accidentalstarting of the engine while from in front of the engine and slide it up the
performing service, take the following precautions: cables, out of the way.
Rotate the ignition keyto off and remove. 3. Remove the chute worm gear assembly from the
Pull the wireoff the spark plug. front housing and set aside.
Make sure the wire does not accidentally touch 4. Beforeseparatingthefronthousingfromthe
the spark plug. snowthrower frame, support the rear of the front
housing (that houses the impeller) with blocks.
CAUTION!ThePowerShiftSnowthrowerhasthe This will prevent the unit from falling when the
feature of being able to be stood on the front housing fastenersareremoved.Remove the sixcap
for service and storage. Always drain the fuel from the screws that fasten the front housing to the frame
tank .prior to such service taking the following and separate thetwo halves. See Figure99.
precautions:
spark.
Impeller and Pulley Operation

The impellerisafan which rotatesat approximately 1250
rpm. It propels the snow fedto it by the auger through
thechute.Theimpeller is connected to the impeller Figure 99
shaft. The impeller shaft also drives the auger through
the auger gear box.It is supported at 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 bythe
engine crankshaft and the idler shown in Figure 98.
Figure 98
Impeller and Pulley Removal

1. StandthePowerShiftSnowthroweronthefront
housingandremovethebeltcoverfromthe
bottom of the frame. Slip the impeller belt
off the
pulley.
Power Shift Snowthrowers 75 SystemPulley

Impeller and
Impeller and Pulley Removal (cont'd) The entire flange bearing must fit behind the front
9.Remove theimpellerfromtheImpellershaft by housing. Also notice the the hollow head set screw
removing thetwo flanged cap screws and nylon faces up when correctly installed.
locknuts. Be careful not to lose the two impeller Prepareforimpellerinstallationbymakingsure
3.
hub inserts. (On'88 units, set screws retained the that the inserts are in place on the impeller hub
impeller to the shaft.) and by coating the impeller shaft with an anti-seize
10. If impeller bearing servicing is necessary, remove compound (Toro part number 505-109). Fasten
the flange bearing from the rear of the housing by the impeller to the impeller shaft with the two
removing the three nylon locknuts. flanged capscrews and nylon locknuts. (Set
screws were used on'88 product.)
11. Inspect all parts for damage and wear and replace
as necessary. NOTE: When the flanged head cap screws are
installed correctly, the heads will be against the
inserts.
Impeller and Pulley Installation
4. Slidetheimpeller intothefronthousingmaking
1. Iftheimpellerbearingwasremoved,reassemble sure that the bearings at the end of the auger shaft
the bearing as shown in Figure 101. Note that the have not fallen off. If they have, consult Auger
flanged portion ofthe oilimpregnatedbearing Installation, page 70, for information on how to
faces forward. reassemble.
Secure the auger shaft bearings
to the side plates
using the eight cap screws and nylon locknuts.
See Figure103.
I
Figure 101
2. Loosely fastenthe flange bearing
to the rear of the
front housing using Figure 102 as a guide.
Figure 103
5. Install the cap screws and large washers
0n the
ends ofthe auger shaft.
6. Lightly tighten the hollow head set screw in the
impeller shaft bearing.
7. Tightenthethreenylonlocknutssecuringthe
impeller flange bearing
to the front housing.
9. Coat the impeller shaft with an anti-seize
compound (Toro part number 505-109) and install
the woodruf key and the impeller pulley. Be sure
to tighten both square head set screws. Remove
all end play from impeller shaftdobut
not preload.
I
Figure 102 NOTE: Tighten the square head set screws with a
3/8”, 12 pt. socket.
NOTE: Do not sandwich the front housing bet-
ween the components of the flange bearing. Set Screw Torque:
2.3 kg m (205 in Ibs)
Pulley
m andImpeller 76 Power Shift Snowthrowers
Impeller and Pulley Installation (cont’d) 14. Install thetop belt cover usingtwo flange head self
tapping screws.
10. To facilitate reassembly of the two snowthrower 15. Installthechutewormgearassembly to the

halves, removethe idler assembly and set aside. bracket on the left side of the front housing. See
Discharge Chute Installation, page56for more
11. Prop the rear of the front housing and bring the information if necessary.
traction unit upto meet the front housing. Secure
with thesix flange head cap screws. 16. Stand the snowthrower on the front housing and
two flange
install the lower belt cover, again using
12. Slip the impeller belt over the impeller pulley. head cap screws.
13. Reinstall the idler assembly using the two flange 17. Check to insurethat all parts areoperating
head cap screws. correctly.
Power Shift Snowthrowers 77 Impeller and Pulley System

SECTION 10 FRONT HOUSING
CAUTION!Servicing the PowerShift Snowthrower will 3. Installthechuteassemblyasdescribedunder
require working with some of the moving parts. To Discharge Chute Installation, page 56.
prevent accidentalstarting of the engine while 4. Adjust the scraper and skids as described under
Skids Installation and Scraper Installation,
Rotate the
ignition
key to off and
remove.
pages 78 and 79
SKIDS
the spark plug.
CAUTION! ThePowerShiftSnowthrowerhasthe Skids Operation

feature Of being ableto be Stood on the front housing The purpose of the skids to provide
is more contact
area
for Service and Storage. Always drain the fuel from the with the ground. When properly adjusted, they slow
tank Prior to such Service taking the following wearing of the scraper. The skids are intended
to be a
precautions: wearing part.
Drain it outdoors and make sure the engine is cool. For convenience, the skids are turned inwardto allow
Wipe up any gasoline that may have spilled. cleaning along side obstacles. The skids are adjustable
Do not drain the gasoline near any open flame or to help insure that the snowthrower cleans right down
spark. to the pavement.
Skids Removal
FRONT HOUSING 1. Removetheskids byremovingthe two flanged
cap screws securing them
to the side plates.
Front Housing Operation 2. Inspect the skids. Replace when the outside edge
The front housing is very durable and should rarely of the skid begins wearing away.
require servicing, however if the damage occurs, use
the following procedure.
Skids Installation
1. Remove the chute assembly as described under 1. Withthewheels in therearposition,loosenthe
Discharge Chute Removal, page56. lock nut on the skid support bracket
to insure that
2. Removetheimpellerandaugerassemblyas it gets proper placement when the new skid is put
described under Impeller and Pulley System on.
Removal, page75. 2. Install the skid as shown in Figure 104.
3. Remove the scraper as described under Scraper
Removal, page 79.
4. Inspectfordamageandrepairorreplacethe
housing as necessary.
Front Housing Installation

1. If thefronthousing wasreplacedorpaintedbe
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
Figure 104

Skids Installation (cont'd) 3. Inspect the scraper. Replace when the scraper is
NOTE: The pads ofthe skid are turned inboard. within .64 cm (1/4”) from the bottomof the front
housing and has been adjusted lowas it will go.
3. Adjusttheskids so thatthescraperhas 3 mm
(1/8'”) clearancebetweenthescraperandthe
ground. Make sure that the pad is riding flat. Adjust
higher if operating on a crushed rock or gravel Scraper Installation
surface. 1. Beginscraperinstallation by firstcheckingtire
pressure in both tires.Make sure that theyboth are
equal and between .5 and 1.O kg/cm2 (7 and 15
SCRAPER
psi). Also makesurethatthesnowthroweris
sitting on a level surface. This will insure proper
Scraper Operation positioning of the scraper.
Thescraper on 1989 and newerPowerShifts is 2. Loosen theskid mounting screwsso that the skids
adjustable. This is to insure that snow is removed as are freeto move andwill not interfere with scraper
close to the groundas possible. adjustment.
3. installthefrontflangedcap screw,securingthe
Scraper Removal on each side.
scraper, side plate and the skid
See Figure105.
4. On a flatsurfacewiththesnowthrower in the
normal operating position, support the auger
so it
is .32cm (1/8'”) off the ground.
5. Move thescraper so that it contactstheflat
surface all the way across, then tighten the two
flanged cap screws securing it and the skids
to the
side plate. This locksit in proper positionso that
the remainder of the fasteners can be installed
without affecting adjustment.
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.
Figure 105 7. Adjusttheskidswiththescraper in the new

position as described underSkids Installation,
1. Remove the six carriage bolts from the scraper. page 78.
2. Removethe front flanged cap screw from the skid
and remove the scraper.
Power Shift Snowthrowers 79 Front Housing

SECTION 11 CONTROLPANELANDHANDLES
the spark plug.
CAUTION!ThePower ShiftSnowthrowerhasthe
precautions: Figure 106
Drain it outdoors and make sure the engine is cool. 6. rod to the
Remove the nut securing the lower shift
Wipe up any gasoline that may have spilled. shift bracket as shownin Figure 107.
spark.
CONTROL PANEL
Control Panel Operation

The control panel is an important component in the
Powershift,as it housesthekeyswitch,thechute,
directional control the control box, as well as providing
a place for instructions. It can be serviced relatively Figure 107
easily by using the following procedure: 7. Remove the shift knob from the shift lever.
Twisting the shift knob will facilitate removal.
Control Panel Removal 8. Remove thefournylonlocknutssecuringthe
1. Stand the snowthrower on the front housing so control box to the control panel and remove the
that the handle grips are vertical. control box (set the control box on top of the
2. Remove the cover onthe right handle as shown recoil, being careful not to damage or bend the
in Figure 106. reverse or latch cables).
3. Drive the roll pin from the upper chute rodgear 9. Remove the two capscrewsand two self-tapping
and pullthe chute controlrod out through the top screws securing the control panel
to the handles
of the control panel. Be careful not to lose the and remove the control panel. Refer
to Figure 107.
rubber washer. 10. rod bearing
If necessary, remove the chute control
4. Release the connector from the bottom of the from the controlpanel.
ignition switch by pressing on the tabs near the
off.
end of the terminals and pulling the connector Control Panel Installation
5. Squeeze the two tabs on the ignition switch then See Figure108.
out through thetop of the
pull the ignition switch 1. Standthesnowthroweronthefronthousing to
control panel. facilitate
servicing
control
the
panel.
of
Control Panel and Handles 80 Power Shift Snowthrowers

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. Insert the chute control
rod down throughthe top
of the chute control bushingand insert into the
Figure 108 chute
lower rod bracket.
Assemble chute
the rod
2. If installing a new control panel,besurethatall gear as shownin Figure 110.
original decals are in place and in the proper
location. Theyprovideimportantsafety
information for the operator.
3. Install the control panel between the two handles
and secure with two capscrews and two
self-tapping screws.
4. Coat the two studs with an anti-seize compound
(Toro part number505-109) to prevent corrosion.
See Figure109.
Figure 110
13. Install the impeller lever cover with two machine
screws.
14. Check to insurethatallcontrolsareoperating
correctly and adjustif necessary.
HANDLES
Right Handle Removal

1. Snip the cable ties securing the traction, reverse,
impeller andlatch cablesto the handle.
Figure 109 2. Remove the impeller locking mechanism cover
plate on the right handle.
5. Install thePower Shift control box onto the control
panelmakingsurethatthereverseleverslides 3. Loosen the jam nuts on the upper end of the
onto the reverse lever spindle. traction and impeller cables.Pull the cables loose
from the cable holder.
6. Secure the Power Shift control box with four nylon
locknuts. 4. Remove the push nut from the right end of the
torque rod. Be careful not
to scratch the impeller
7. Secure the lower shift
rodto the shift bracket using
lever.
a washer and nylon locknut. Adjust as described
under Control Box Service Shift Lever NOTE: Flattening the locking tabs on the push
Adjustment, page 49. nut mayfacilitate removal.
Power Shift Snowthrowers 81 Control Panel and Handles

Right Handle Removal (cont'd) 1. Place the right handle onto the studs coming from
5. Removethe small hex head capscrew and locknut the frame and securewith the two flanged head
that secures the torquerod to the traction lever. capscrews.
Pull the torque rod out about 5 cm (2”),just far 2. Secure thecoverplatewiththefournylon
enough to clear the impeller lever. locknuts.
6. Spread the impeller lever slightly and remove the NOTE: The coverplate goes ontop of the lower
release cam. handle brackets! See Figure111 above.
7. Remove theself-tappingscrewfromtheimpeller 3. Slip the impeller lever bushing onto the cross rod,
lever and remove the locking tang. then place the impeller lever into position. Slide
8. Remove theflangedheadcapscrewandthe the cross rod through the left impeller lever hole
self-tapping screw that secure the right handle
to and snap the impeller lever bushing in place. See
the controlpanel. Figure 112.
9. Remove the four nylon locknuts securing the rear

cover plateto the lower handles. See Figure111.
NOTE: It is not necessary to remove the lower
control rod from the shifting bellcrank.
Figure 111
10. Remove the twoflanged head capscrews from the
lower handleand remove the right handle.
11. If necessary,remove theimpellerleverbushing
and the impeller lever from the right handle.
12. Remove the impeller lever return spring from the
right handle. Figure 112
13. Remove the E clip securing the locking latch to 4. Install the latching lever return spring and the
right handle and remove the locking latch and release camonto the cross rod.
locking latch spring from stud.
the 5. Insert the end of the traction into
cablethe
release
14. Completedisassembly byremovingthehandle cam and loosely secure the cable in the cable
grip from the right
handle. bracket.
6. Insert the end of the impellerinto cable
the locking
Right Handle Installation tang and installin the impeller lever as shown in
Figure 113. Secure with the small self-tapping
NOTE: Ifinstallinganewhandle,besurethatthe
screw.
warning decal isin place. The warning decal states the
importance of adjusting the cables
to make sure that the 7. Secure the cross
rod to the tractionlever with the
auger and transmission disengage completely. small capscrew and nylon locknut.

Right Handle Installation (cont'd) 6. 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" 7. Pull the cross rod from the impeller lever control
to the keywayto insureproper retention panel andtraction lever.
9. Secure the control panel
to the handle using the NOTE:Thereleasecam,impellerbushing, trip
flanged head capscrew and self-tapping screw. lever and traction lever spacer will all be o
l ose
10. If the locking latch and the locking latch spring once the cross rod is removed. Be careful not to
were removed, install now. Secure with the E clip. loose them.
Refer to Figure 113 above.
8. Removetheflangedheadcapscrewandsmall
11. two cable ties.
Secure the cables with self-tapping screw securing theleft handle to the
control panel. See Figure 115.
12. Adjust the impeller and traction cables as
described under Traction andImpeller Controls
Traction Cable Adjustmentand Traction and
Impeller Controls Impeller Cable Adjustment,
page 49. Install the cover plate on the right handle
with thetwo small machine screws.
13. Completehandlereplacement bycheckingall
controls and making adjustments as required.
Left Handle Removal

1. Standthesnowthroweronthefronthousing to
facilitate handle removal.
2. Snipthecabletiessecuringthewiringharness to
the lefthandle.
3. Driveouttherollpinsecuringtheupperchute
directional gear to the upper chute control rod.
Remove the gear andthe rubber washer, then pull Figure 115
the upper chute rod from the control panel.
9. Remove the four nylon locknuts securing the rear
4. Remove theimpellerlockingmechanismcover cover plateto the lower handle brackets and the
from the righthandle. rear cover plate.
5. Remove the push nut securing the impeller lever 10. Remove thetwoflanged head capscrews
to the cross rod. Refer
to Figure 114. securing the lowerhandle to theframeand
NOTE: Flattening the locking tabs on the push nut remove the left handle complete with the front
may facilitate removal. chute control rod.
Power Shift Snowthrowers 83 Control Panel and Handles

Left Handle Removal (cont’d) 3. Place the chute worm gear into the worm gear
11. Ifnecessary,drivethe roll pin from the forward bracket then place the left handle onto the studs
chute control rod and gear and remove the chute while inserting the lower control rod into the chute
control rod from the right angle bracket. worm gear.
12. Completedisassembly byremovingthehandle 4. Move the rear cover plate into position on the four
grip from the left hand handle. studs and secure
with four nylon locknuts.
NOTE: The rear cover plate

fits outside the handle
Left Handle Installation bracket.
See Figure116.
5. Install thetwo flanged head capscrews securing
the left handle to the frame.
Traction Lever 7. Secure the left handle to the control panel using
the self-tappingscrewandtheflangedhead
capscrew.
8. Insert the upper chute control rod through the
control panel and the right angle bracket while
installing the rubber washer and the upper chute
directional gear. Securewith the rollpin.
9. Place the traction lever into position on the left
handle and loosely fasten in placewith the traction
lever bushing.
10. Place the traction lever spacer inside the traction
lever then slip the crossrod through thetrip lever.
Make sure that the traction and impeller cables are
installed into the release cam and locking latch
thenpushthecrossrodthroughboth
components. Secure witha new push nut.
NOTE: The release cam

is keyedto the cross rod.
11. Install the locking latch cover plate on the right
hand handle using the two small machine screws
with star washers.
12. Secure theleft end ofthe cross rod
to the traction
lever with the small capscrew and nylon locknut.
Figure 116
13. Secure the ignition switch wire
to the left handle
1. Stand the Power Shift Snowthrower onto the front
with two cable ties.
housing to facilitate installation.
14. Completehandlereplacement bycheckingall
2. Insertthelowerchutecontrolrodintotheright
controls and making adjustments as required.
angle bracket and secure the gear with the roll pin.
Control Panel and Handles Power Shift Snowthrowers

SECTION 12 WHEELS, TIRES AND CHAINS
requireworkingwithsome of themovingparts. To
prevent accidentalstartingof the engine while
the spark plug.
tank prior to such service takingthefollowing
precautions: Figure 117
Wipe up any gasoline that may have spilled. TIRES
spark. Tires Operation
The tires used on the Power Shift Snowthrower area
special low pressure design which provides maximum
traction in nearly all conditions. The tires are tube type
WHEELS
and are 35.5 cm (14') in diameter and are 10.1cm (4")
in width on61 cm (24") snowthrowers while thos on 71
cm (28”) and 81 cm (32") units have slightly large tires:
Wheels Operation 40.6 cm (16') in diameter and 12.7 cm (5") in width. Tire
The wheels used on the Power Shift Snowthrower are pressure should be between.5 and 1.0 kg/cm2 (7and
one piece design steel wheels. They canbe used in a 15 psi) and be equal on both sides.
driving modewhere the wheel rigidly
is fixed to the axle
or in a free wheeling mode where the wheel is allowed
Tires Service
to spin on the axle.
If a puncture or flat occurs,TheToroCompany
recommends taking the wheel and tire assembly to a
tireprofessionalforrepairorreplacement. It isnot
Wheels Removal economically practicalto attempt servicing without the
1. To remove the wheels, simply remove the klik pin proper equipment.
from the wheel and axle and pull the wheel off.
CHAINS
Wheels Installation
1.Beforeinstallingthewheelcoattheaxlewithan Chains Operation
anti-seize compound to prevent the wheel from Chains are available for the Power Shift Snowthrowers.
corroding to the axle. However, in most conditions the low pressure tires will
2. Installthewheel inthedesiredlocation;inboard providebettertraction. In fact, in someconditions,
for free wheeling or with the klik pin through the chains will actually decrease traction because they fill
driving. See Figure 117.
wheel and axle holes for the tread on the tire. If conditions exist where chains
desired, they can be installed as follows.
Power Shift Snowthrowers 85 Wheels and Tires

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. The klik pin must pass Figure 118
through theholesin the wheel and the outer hole
in the axleto provide sufficient clearance between 4. Check tire pressure to make sure thatit is between
the chains and the pivot arm bolt. .5 and 1.O kg/cm2 (7-15) psi and that both are
equal.

SECTION 13
Engines Service Information However, becausethe engine manufacturers have each
A number of different engines are used on the Power published their own manual for these engines, compl
Shift Snowthrowers. Manufacturer. include Briggs and servicing information is not included
in this book.
Stratton,MitsubishiandTecumseh.SeeFigure 119 If you require a manual for one ofthe engines please
below to determine themanufacturer of the engine on contact the engine manufacture at one the following
the unit you are servicing. addresses:
Briggs and Stratton
PO. Box 702
SPECIFICATIONS Milwaukee, WI 53201
Engine
Name Manufacturer Sold In Mitsubishi Heavy Industries America, Inc.
624 Mitsubishi U.S. 699 North WheelingRoad
624 Mitsubishi Int'l
624 Tecumseh U.S. Suite 101
624 Tecumseh Int'l
824 Mitsubishi us. Mount Prospect, IL 60056
824 Mitsubishi Int'l
824 Tecumseh us. Tecumseh Products Company
824 Tecumseh Int'l
828 Mitsubishi Int'l 900 North Street
1132 Briggs 8 Stratton Int'l Grafton, WI 53024
828 Briggs 8 Stratton U.S.
828 Tecumseh Int'l
1132 Briggs 8 Stratton us. Be sureto include engine model and serial number with
your request.
If you have difficulty obtaining engine service manuals
Figure 119 from any of the above manufacturers, please feel to fre
contact us at the following address:
Some informationon specifications and maintenance of
The Toro Company
the engines can be found in the Specifications and
8111 Lyndale Avenue South
Maintenance Sectionsin the frontof the book.
Bloomington, MN 55420
Power Shift Snowthrowers a7 Engines

SECTION 14 DIFFERENTIAL KIT
CAUTION! Servicing the Power Shift Snowthrower will Differential Kit Removal
requireworkingwithsomeofthemovingparts. To 1. Stand the Power Shift snowthrower onto the front
prevent accidentalstarting of the engine while auger housingto facilitate service.
performing service, take the
followingprecautions:
2.Remove the klik pins, wheels and wheel washers
Rotate the ignition keyto off and remove from theaxle.
Make sure the wire does not accidentally touch 3. Remove thethreePhillipsheadscrewssecuring
the sparkplug the two halves ofthe chain guard and remove the
right half of the chain guard. See Figure 121
CAUTION! ThePowerShiftSnowthrowerhasthe
precautions:
Drain it outdoors andmake sure the engine is cool
spark
Differential Kit Operation
See Figure 120. Figure 121

4. Remove thelargenutandtheflangedheadbolt
from the left pivotarm. Pull the left pivot arm off
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
kit from thesnowthrower.
Differential Kit Disassembly

122. Figure See 120 Figure
1.Remove thefournylonlocknutssecuringthe
kit, Model38038,can greatly
The Power Shift differential
sprocket to the differential andremove the
improve maneuverability of the PowerShiftsnow-
thrower. It allows one wheel to rotate faster than the sprocket.
other wheel in turns. The advantages of the differential 2. Drive the roll pin from the locking cover side of the
kit will be most noticable when traction is good and the axle and remove thelocking cover.
snowthrowingjob requires many turns.
3. Remove the two keys from the locking cover side
However,as with automobile differentials, when one of the axle.
wheel loses traction, the otherwill not drive.To address
this issue, the Power Shift differential kit was designed 4. Removethefournutsandallenheadcapscrews
with the capabilityof being easily lockedto provide rigid securing thetwo halves ofthe differential and split
axle performance when conditions dictate. the differential.
Differential Kit 88 Power Shift Snowthrowers

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
Locking Cover secure with four nylon
lock nuts.
Differential Kt Installation
1. Stand the Power Shift snowthrower onto the front
housing to facilitate installation.
2. If the differential kt is being installed for the first
time, select the correct sprocket for the
Figure 122 differential. Use the list in Figure 123 or match the
number of teeth on the original sprocket with one
5. Remove the cross shaft and the two cross shaft in the kt.
gears from the differential.
6. If further disassembly is required,removethe snap Differential Kt Sprocket Data
rings securing the bevel gears to the axle and
remove the gears and differential case halves from
the axles.
7. Inspect the spindle and the four gears for wear.
8. Inspectthedifferentialcasehalvesforwearby
placing thecase halveson the axle and checking
for excessive play. Excessive play indicates that
the bushings are worn. If this occurs, replace the
differential case halves.
Differential Kt Assembly
Refer to Figure 122 above.
1. Place a bevel gear in one of the case halves and
secure to one of the axles with the snap ring.
Repeat forthe other axle and case half.
NOTE: Althoughthereisamaleandfemale
differential case half, they areotherwise
symmetrical and can be placed on either axle half.
3. Slide a thrust washer onto each end of the axle.
2. Spread Bentonite@ grease, (available from
Tecumseh/Peerless), onto the bevelgears,and 4. the
Slide the axle through the pivot arm and attach
the cross shaft then slide the cross shaft pinions chain.Fastentherighthandpivotarm to the
onto the crossshaft. frame, being sure to install the special washer
between the pivot arm and frame. Tighten the
3. Installthecross shaftandcrossshaftpinion flanged head pivot bolt and the nylon locknut. S
assembly into a differential casehalfand Figure 124.
assembly the case halves.
5. If necessary, install the new chain guard included
NOTE: Make sure there is adequate lubricant, but in the differential kt onto the left hand pivot arm
do not overfill. with the two self-tapping capscrews.
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.
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. Slidethethick washer ontothelatchrodthen
install theleft pivot arm, again being sure
to install
the special washer between the pivot arm and the Figure 125
frame. Secure the left hand pivot arm with the
10. Checkforproperoperationofallcontrolsand
flanged head capscrewand the nylon locknut.
adjust if necessary.

SECTION 15 LIGHT KIT
CAUTION: Servicing the Power Shift Snowthrower will alternator so that the lamp and alternator make a
requireworkingwithsomeof the moving parts. To complete circuit. See Figure 126.
the spark plug.
CAUTION: ThePowerShiftSnowthrowerhasthe
precautions:
spark.
The Toro Company has made light kits availablefor Figure 126
Power Shift Snowthrowers to facilitate snow removal on
short winter days. There are three different light kits, When measuringthe voltage across the lamp, the
althoughtwo of the kits arenearlyidentical.Onekit minimum A.C. values shouldbe obtained:
comes with the light and an alternator while the other
two come only with the light. Voltage
Both light kits use approximately 15 Watts. Since all 2000 rpm A.C.
8.0 Volts
Power Shift engines use unregulated alternators, it is 10.5 Volts A.C.
normal for the intensity of the light to increase with
3600 rpm 12.0 volts A.C.
engine speed.
If the the above values are not obtained, the

Light Kit 66-7930 Operation
alternator or the wires coming from the alternato
This light kit fits Power Shift Snowthrowers with are defective and should be replaced.
TecumsehEngines.The kit includesthe light and
bracket, asdo the others, but it also includes a "bolt-on" 3. Check the lamp by connectingit to a 12 Volts D.C.
alternator that is necessary since the Tecumseh Power battery. If it does not light, either the lamp or the
Shift enginesdo not come standard with alternators. wires goingto the lamp are defective.
The alternator produces 1 Amp A.C. current. It can be

checked as described below under Light Kt 66-7930 Light Kit 66-7930 Lamp Removal
Testing. 1. Disconnect the lamp wires from the alternator at
the connector.
Light Kit 66-7930 Testing 2. Removethe twolocknutsfromtheU-boltand
1. Ifyouencounterproblemswiththelight, first remove the lamp assembly from the handle.
check the fuseto see thatit has not blown. 3. Removetheflangehead bolt from the U-bracket
Test
2. for properalternator
operation
be
running and remove the lamp.
jumper wires between the lamp wires and the 4. If necessary, remove the carriage
bolt securing the
U-bracket to the lamp mount.
Power Shift Snowthrowers 91 Light Kit

Light Kit 66-7930 Lamp Installation 6. Remove thealternatorshaft.
1. Using the U-bolt, washers and nuts supplied
in kit,
loosely secure the lamp mountto the handle as Light Kit 66-9730 Alternator Installation
shown in Figure 127.
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. SecuretheU-bracket to thelampmountwitha
carriage bolt, lock washerandnut. Do not Figure 128
overtighten the nut or lamp adjustment will be
difficult. 3. Drill the center hole
in recoil housing as follows:
a. Position the recoil assembly (pulley side up) on
4. Secure the lamp assembly to the U-bracket with
a flat surface suitable for drilling.
aflangeheadscrew, two lock washersand a
flange nut. Place a washer on each side between b. Using the center hole
in the pulley assembly as
the U-bracketand the lampbracket.Donot a guide. See Figure129. Drill a1/4" diameter hole
overtighten. through the housing.
c. Remove all debris after drilling.
Light Kit 66-7930 Alternator Removal
4. Locate thedepressed drill starts (three)
inthe front
1. Snipthe tie strapssecuringtheharness to the side of housing. See Figure
130.
handle.
5. Using caution not to hit the recoil pulley under
2. Disconnectthelampwiresfromthealternator housing, drill three 1/8” diameter holes through
wires at the connector. housing. Removeall debris after drilling.
3. Remove thethreeselftappingscrewsfromthe 6. The kit is supplied with two different alternator
alternator and remove the alternator assembly shafts.Usethe longershaftonsnowthrower
from the recoil. models38540, 38543, or 38573. On models38510
4. Remove thelightconnectorfromthealternator and 38513 use the short shaft.
receptacle. 7. Install the alternator shaft coupler onto the
5. Take note of theposition of therecoil handle. flywheel nut as far as possible.
Remove the fasteners securing the recoil to the 8. Place
the
centering
tube on alternator
shaft.
shroud and remove the recoil assembly.

Light Kit 66-9730 Alternator Installation (cont'd) Secure the alternatorto the recoil assembly with
three self tapping screws.
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. Thekt with
part number 66-7940fits Briggs and Stratton powered
units while the
kt with part number 66-7950fits units with
Mitsubishiengines.Theyinclude thelampandthe
mounting hardware. The lamp can be switchedon and
Off
Power for the light

kt comes from the alternator on the
engine. Referto the tables below
to determine whether
so,
your engine was equipped with an alternator ifand,
the type and amount of current that is produced.
Figure 129
Mitsubishi Alternator Data
Drill Starts
Alternator kits can be added to 1988 Mitsubishi powered units.

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 part number 65-0610. For models 38520, 38525
Figure 130
and 38545, order part number 65-2170.
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

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 alight only.
However, international units have a 12 volt starter kt
available as an option. The single circuit alternator is
also usedto charge the battery when thevolt 12starter
kt is added. A rectifier is included as part of the volt
12
starter kt. It converts A.C. to D.C. and allows charging
of the battery.
NOTE: Charging of the starter battery when the light is
on is minimal. Therefore, supplemental charging may \
be necessary.
Briggs and Stratton Single Circuit: The Briggs and

Stratton single circuit alternatorusestheflywheel
magnets to produce 5 Amps A.C. at 12 Volts and 3600
rpm. It is designed to power a light kt. Because this
alternator produces alternatingcurrent, it cannot be Figure 131
used to charge a battery. 2. Route the wires and the fuse holder inside the
channel and through the U-bolt.
Briggs and Stratton Dual Circuit: TheBriggsand
Stratton Dual Circuit Alternator is actually two separate 3. SecuretheU-bracket to thelampmountwith a
coils housedin a single alternator. Both alternators use' carriage bolt, lock washer and nut.Do not
the flywheel magnets to generate electricity. The A.C. overtighten the nut or lamp adjustment will be
circuit produces5 Amps to power the light kt.The D.C. difficult.
circuit produces aboutAmps 3 andis usedto charge a 4. Secure the lamp assemblyto the U-bracket with
12 Volt battery. A 12 Volt battery is usedin an optional a flangeheadscrew, two lock washersand a
12 Volt electric starting kit on international units. The flange nut. Place a washer on each side between
dual circuit alternator is not used on domestic units theU-bracketandlampbracket. Do not
since a 12 Volt starter kt is not available in the U.S.A. overtighten.
5. Connect the short jumper wire to the lamp wire
Light Kits 66-7940 and 667950 Lamp Removal assembly.
1. Disconnect the lamp wires from the alternator at 6. On the right side of the engine, plug the jumper
the connector. wire connector into the connector (two
2.Remove thetwolocknutsfromthe U-bolt and connectors on Mitsubishi powered units) coming
remove the lamp assembly from the handle. from the alternator.
3. Remove theflangeheadboltfromtheU-bracket 7. On kit 66-7940 only (Briggs and Stratton powered
and remove the lamp. units), ground thering end of the jumper wire by
connecting it to aconvenientfasteneronthe
4. If necessary, remove the carriagebolt securing the engine, frameor handle. Make sure there is good
U-bracketto the lamp mount. metallic contact between the fastenerandthe
connector.
Light Kt 66-7940 and 66-7950 Lamp Installation 8. Tighten all fasteners.
1. Using the U-bolt, washersand nuts supplied in the
9. Make sure wire harness does not interfere with
kt, loosely secure the lamp mountto handle as
shown in Figure 131. operation of control levers or cables.

SECTION 16 SNOW CAB
CAUTION:ServicingthePowerShiftSnowthrowerwill
the spark plug.
CAUTION:ThePowerShiftSnowthrowerhasthe
precautions:
spark.
Snow Cab Operation

Thesnow cab protects the operator from wind and Figure 132
blowing snow while snowthrowing. It mounts to the
handles of Power Shift Snowthrowers. Construction is
of a metal frame and vinyl shell. Two cab kits were
available at the time this manual was published: part
numbers 66-6200and 68-9500.The two kits are identical
with the exception of the tops. 66-6200 uses a vinyltop
while 68-9500 uses a rigid plastic top. See Figure132.
Snow Cab Removal

Removal ofthe Snow Cabis most easily accomplished
without disassembling the cab.
1. Remove the rear fasteners securing the cab frame Figure 133
to the attaching bracketbase. See Figure132. Tip 6. Re-installthelevercover to the top oftheright
the cab forward so that it balances. handle.
2. Remove thetwo fasteners securing the cab frame
to the loop clamps just beneathcontrol
the panel. Snow Cab Installation
3. Remove the cab from thehandles. Installation and assembly are best accomplished at the
4. Remove the two screwssecuring the impeller same time. See Figure134.
locking mechanism cover to the top of the right NOTE: Do not tighten the mounting bolts untilparts
all
handle. See Figure133. of the cabhave been installed.
5. Remove the fasteners securing the attaching
bracket base to thehandlesandremovethe 1. Remove the two screws securing the lever cover
attaching bracketbase. to the righthandle.
Power Shift Snowthrowers 95 Cab Snow

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 Figure 136

2. Remove the two flange head capscrews securing
the control panel to the handles (one on each 6. Place theloop clamp around the right handle just
side). Loosely secure the attaching bracket base below the control panel. Secure thelegfront
of the
to the handles with the flange head capscrews right attaching bracketto the loop clamp with a
removed. See Figure135. 1/4-20 X 2" capscrew and locknut. Make sure the
control cables are outside the clamp. Repeat the
procedure on the left side of the machine.
7. Mount the horizontal curved bow to the front legs

of the attaching brackets with two 1/4-20 X 3/4"
capscrews and locknuts. See Figure 137. Welded
clipsonthecurvedbowmustbepositioned
between the post and the attaching bracket.
8. Mounteachsideoftheverticalbow to the
attachingbracketsandrearofthehorizontal
curved bow with a 1/4-20 X 3/4” capscrew, flat
FlangeHeadCapscrew
washer and locknut. See Figure 138 and inset.
Figure 135 When properly assembled, the capscrew head
should be inside the cab and the vertical bow
3. Pivottheattachingbracketbaserearwarduntil shouldbepositionedbetweentheattaching
there isapproximately .64 cm (1/4") space bracket and the horizontal curved bow. Tighten
betweenthebracketandcontrolpanelthen thecapscrews so that the vertical bow is
tighten the flange head capscrews securing the perpendicular to the plane of the horizontal bow.
bracket to the handles.

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
to the upper ends of the front posts with four 14. If assembling kit 68-9500, mount the plastictop to
1/4-20X 3/4" capscrews and locknuts. See Figure the top frame and secure with four 1/4-20X 3/4
139. capscrews, 1/4”flat washers and locknuts.
10. Tighten all fasteners to secure the assembly. NOTE: If the headlight kit is to be installed, it will
be necessaryto cut two slots in cab directly above
11. Carefullyunfoldtheshellandpositionoverthe the mounting holes in the handle. Disconnect the
frame. See Figure 140 wire and run through the hole in the cab. Secure
12.Tiethe bottom oftheshellaroundthecontrol headlight to handle as describedin the headlight
cables. kit installation instructions.
Power Shift Snowthrowers 97 Snow Cab

SECTION 17 DRIFT BREAKER
CAUTION: Servicing the Power Shift Snowthrower will
Rotate the ignition keyto off and remove
the sparkplug
CAUTION: ThePowerShiftSnowthrowerhasthe
feature of being ableto be stoodon the front housing
fuel from the
for service and storage. Always drain the
precautions:
Drain it outdoors and make sure the engine is
cool
spark
Do not smoke when handlinggasoline
Drift Breaker Operation

Kit facilitates the removal
The Toro Drift Breaker of snow
that is above thetop of the auger housing. It extends 3. Mount a side breakerto each side of the housing
the height of the auger housing by34 cm, (1 3.5"). Snow with carriage bolts and locknuts.
See Figure 142.
above the housing is sliced by the sides and the top of
the drift breaker bars
so that the snow falls and does not
impede the forward motion of the snowthrower.
pass is
Best results areobtained when less than a full
taken.
Drift Breaker Disassembly

1. Remove thecarriageboltandlocknutssecuring
the top breaker to the side breakers and remove
the top breaker.
2.
Remove thecarriageboltssecuringtheside
breakers to thehousingandremovetheside
breakers.
Drift Breaker Assembly

1. If this is the original installation, center punch the
two mounting holes atthe location indicated in
Figure 141. Do this to each side of the housing.
(Use the templatein the kit if available).
Figure 142
2. At the location punched, drill an8.33mm (21/64")
4. Mount the top breaker over the ends of the sidee
hole
breakers. Secure on each end with a carriage bolt
and locknut.

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POWER SHIFT SNOWTHROWER SERVICE MANUAL

Table of Contents – Page 1 of 5

ABOUT THIS MANUAL

FOR YOUR SAFETY...

SPECIFICATIONS MODELS 38500 AND 38505

SPECIFICATIONS MODELS 38510 AND 38513

SPECIFICATIONS MODELS 38520 AND 38525

SPECIFICATIONS MODELS 38540 AND 38543

SPECIFICATIONS MODEL 38545

SPECIFICATIONS MODEL 38570

SPECIFICATIONS MODEL 38573

SPECIFICATIONS MODELS 38565 AND 38580

SPECIAL TOOLS AND OTHER NECESSITIES

SECTION I POWER SHIFT CONTROLS

SECTION I POWER SHIFT CONTROLS - Continued

SECTION 2 TRACTION AND IMPELLER CONTROLS

SECTION 3 DISCHARGE CHUTE

SECTION 4 IDLER SYSTEM

SECTION 5 PIVOT AND LATCH SYSTEM

SECTION 8 AUGER GEAR BOX

SECTION 9 IMPELLER AND PULLEY SYSTEM

SECTION 10 FRONT HOUSING

SECTION 11 CONTROL PANEL AND HANDLES

SECTION 12 WHEELS, TIRES AND CHAINS

SECTION 14 DIFFERENTIAL KIT

SECTION 14 DIFFERENTIAL KIT - Continued

SECTION 15 LIGHT KIT

SECTION 16 SNOW CAB

SECTION 17 DRIFT BREAKER

Disassembly, inspection and reassembly procedures are covered

find this manual a valuable additionto your shop. If

The Tor0 Company

The Tor0 Company reserves the right

@COPYRIGHT ALL RIGHTS RESERVED

Section 1 Power Shift Controls Page

control Box Operation

Control Box Service

Section 2 Traction and Impeller Controls

Power Shift Snowthrowers 1 Table of Contents

Section 4 Idler System

Table of Contents Snowthrowers

Section 8 Auger Gearbox

Section 9 Impeller and Pulley System

Section 11 Control Panel and Handles

Power Shift Snowthrowers 3 Table of Contents

Section 15 Light Kit

Light Kii 66-7930

Section 16 Snow Cab

Table of Contents 4 Power Shift Snowthrowers

FOR YOUR SAFETY

Avoid electrocution Avoid asphyxiation

Power Shift Snowthrowers 5 Safety !nstructions

The snowthrower itself has two identificationnumbers: Eachenginealsohas amodelandserialnumber.

Power Shift Snowthrowers

Mitsubishi Powered 624 Engine Specifications*

(no methanol and not

r SAE10, API rating SE or SF

set gapto 0.72mm (.028')]

Mitsubishi Powered 624 Product Specifications

Power Shift Snowthrowers 7 624 Specifications

Mitsubishi Powered624 Product Specifications (cont'd)

Throat Diameter 14.0cm (5.5")

a Power Shift Snowthrowers