User manual TORO POWER SHIFT SNOWTHROWER SERVICE MANUAL

[. . . ] POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents ­ Page 1 of 5 ABOUT THIS MANUAL SAFETY INSTRUCTIONS FOR YOUR SAFETY. . . IDENTIFICATION MODEL AND SERIAL NUMBERS SPECIFICATIONS MODELS 38500 AND 38505 MITSUBISHI POWERED 624 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 624 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 624 - TORQUE SPECIFICATIONS SPECIFICATIONS MODELS 38510 AND 38513 TECUMSEH POWERED 624 - ENGINE SPECIFICATIONS* TECUMSEH POWERED 624 - PRODUCT SPECIFICATIONS TORQUE SPECIFICATIONS SPECIFICATIONS MODELS 38520 AND 38525 MITSUBISHI POWERED 824 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 824 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 824 - TORQUE SPECIFICATIONS SPECIFICATIONS MODELS 38540 AND 38543 TECUMSEH POWERED 824 - ENGINE SPECIFICATIONS* TECUMSEH POWERED 824 - PRODUCT SPECIFICATIONS TECUMSEH POWERED 824 - TORQUE SPECIFICATIONS SPECIFICATIONS MODEL 38545 MITSUBISHI POWERED 828 - ENGINE SPECIFICATIONS* MITSUBISHI POWERED 828 - PRODUCT SPECIFICATIONS MITSUBISHI POWERED 828 - TORQUE SPECIFICATIONS SPECIFICATIONS MODEL 38570 BRIGGS AND STRATTON POWERED 828 - ENGINE SPECIFICATIONS* BRIGGS AND STRATTON POWERED 828 - PRODUCT SPECIFICATIONS BRIGGS AND STRATTON POWERED 828 - TORQUE SPECIFICATIONS SPECIFICATIONS MODEL 38573 TECUMSEH POWERED 828 - ENGINE SPECIFICATIONS* TECUMSEH POWERED 828 - PRODUCT SPECIFICATIONS TECUMSEH POWERED 828 - TORQUE SPECIFICATIONS POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents ­ Page 2 of 5 SPECIFICATIONS MODELS 38565 AND 38580 BRIGGS AND STRATTON POWERED 1132 - ENGINE SPECIFICATIONS* BRIGGS AND STRATTON POWERED 1132 - PRODUCT SPECIFICATIONS TORQUE SPECIFICATIONS SPECIAL TOOLS AND OTHER NECESSITIES TROUBLESHOOTING UNIT DOES NOT PROPEL FORWARD UNIT WILL NOT PROPEL BACKWARD NEUTRAL NOT IN CORRECT LOCATION SHIFT LEVER WILL NOT LOCK IN POWER SHIFT OR REVERSE OPERATOR CAN SHIFT BETWEEN FORWARD AND REVERSE WHILE TRACTION LEVER IS WHEELS WILL NOT SWING WHEN POWER SHIFTING MACHINE DOES NOT PROPEL IN A STRAIGHT LINE ENGINE KILLS WHEN AUGER OR TRACTION ARE ENGAGED POOR 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 POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents ­ Page 3 of 5 SECTION I POWER SHIFT CONTROLS - Continued CONTROL BOX SERVICE - DISASSEMBLY CONTROL BOX SERVICE - REASSEMBLY CONTROL BOX SERVICE - INSTALLATION CONTROL BOX SERVICE - ADJUSTMENTS SECTION 2 TRACTION AND IMPELLER CONTROLS OPERATION OPERATION - IMPELLER CONTROL OPERATION - IMPELLER LOCKING MECHANISM TRACTION AND IMPELLER CONTROLS TRACTION AND IMPELLER CONTROLS - INSPECTION TRACTION AND IMPELLER CONTROLS - REASSEMBLY TRACTION AND IMPELLER CONTROLS - TRACTION CABLE ADJUSTMENT TRACTION AND IMPELLER CONTROLS - IMPELLER CABLE ADJUSTMENT SECTION 3 DISCHARGE CHUTE CHUTE CONTROL DISCHARGE CHUTE DISCHARGE CHUTE - REMOVAL DISCHARGE CHUTE - INSTALLATION SECTION 4 IDLER SYSTEM IDLER SYSTEM - OPERATION IDLER SYSTEM - REMOVAL IDLER SYSTEM - DISASSEMBLY IDLER SYSTEM - REASSEMBLY IDLER SYSTEM - INSTALLATION IDLER SYSTEM - ADJUSTMENT SECTION 5 PIVOT AND LATCH SYSTEM PIVOT SYSTEM PIVOT SYSTEM - REASSEMBLY LATCH SYSTEM SECTION 6 TRANSMISSION TRANSMISSION - OPERATION TRANSMISSION - REMOVAL TRANSMISSION - DISASSEMBLY TRANSMISSION - REASSEMBLY TRANSMISSION - INSTALLATION SECTION 7 AUGER AUGER POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents ­ Page 4 of 5 SECTION 8 AUGER GEAR BOX AUGER GEAR BOX - OPERATION AUGER GEAR BOX - REMOVAL AUGER GEAR BOX - DISASSEMBLY AUGER GEAR BOX - REASSEMBLY AUGER GEAR BOX - INSTALLATION SECTION 9 IMPELLER AND PULLEY SYSTEM IMPELLER AND PULLEY - 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 POWER SHIFT SNOWTHROWER SERVICE MANUAL Table of Contents ­ Page 5 of 5 SECTION 14 DIFFERENTIAL KIT - Continued DIFFERENTIAL KIT - DISASSEMBLY DIFFERENTIAL KIT - ASSEMBLY DIFFERENTIAL KIT- INSTALLATION SECTION 15 LIGHT KIT LIGHT KIT 66-7930 - OPERATION LIGHT KIT 66-7930 - TESTING LIGHT KIT 66-7930 - LAMP REMOVAL LIGHT KIT 66-7930 - LAMP INSTALLATION LIGHT KIT 66-7930 - ALTERNATOR REMOVAL LIGHT KIT 66-9730 - ALTERNATOR INSTALLATION LIGHT KITS 66-7940 AND 66-7950 - OPERATION LIGHT KITS 66-7940 AND 66-7950 - LAMP REMOVAL LIGHT KIT 66-7940 AND 66-7950 - LAMP INSTALLATION SECTION 16 SNOW CAB SNOW CAB - OPERATION SNOW CAB - REMOVAL SNOW CAB - INSTALLATION SECTION 17 DRIFT BREAKER DRIFT BREAKER - OPERATION DRIFT BREAKER- DISASSEMBLY DRIFT BREAKER - ASSEMBLY ABOUT THIS MANUAL This service manual was written expressly for the Tor0 624, 824, 828 and 1132 Power Shift Snowthrowers. The Tor0 Company has made every to make the effort informationin this manual complete and correct. It is organized that so information used most often up front. As a result, you will find reference is information on safety, identification, specifications, special tods, troubleshooting and maintenance, all the front third the manual. [. . . ] Completedisassemblyoftheintermediateshaft out the roll pin. 3. Power Shift Snowthrowers 65 Transmission Transmission Disassembly (cont'd) 11. Inspectallcomponentsfordamageandwear. Transmission Reassembly NOTE: Use only Lubriplate@ Mag 1 GreaseToro part number 505-101) in the transmission. Its excellent performance at low temperatures greatly enhances the service life of the transmission. Make sure that the keysonthebushingsalignproperlywiththekey sets in the lower case. Intermediate Shaft:Beginreassemblyofthe Intermediate shaft by pressing in the coil pin so that it is centeredin the intermediate shaft. Slidethespeedreductiongearonthe so intermediate shaft that it properly engages the coil pin. Consult your notes or sketch out how many to find spacers fit between the speed reduction gear and the large 51-tooth gear. Slide the appropriate number of spacer washersonto the intermediate Shaft. Slide the 15-toothgear and sleeve onto the intermediate shaft, geared end first. Figure 83 Begin output shaft assembly pressing the by ball bearing onto the output shaft. Be sure to press only on the inner race when installing the bearing to prevent possible bearing damage. Space Between Sprocket and Bearing: 1. 22 -08 cm (. 48 2. 03') 9. NOTE:Maximumendplay is (. 030"). greater If than (. 030") add a thrust washer (Toro part number 257- 10)to either end of the shaft. Output Shaft: See Figure 83. 2. 3 . 4. 5. 6. 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. the appropriate numberthrust washers and one of bushing, flanged side first, on each end of the 66 8. Apply grease to the keyway and the O. D. Do not get grease in the bushing area as it may get "gummy" cause premature failure. Slide Power Shift Snowthrowers Transmission Transmission Reassembly the first half of the shift sleeve with the 19-tooth gear onto the output shaft, geared end first. Slide the four selectable gears onto the output shaft as shownin Figure 83 above. Apply grease second sleeve half then slide onto to 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 and the gear will 15-tooth turn together. Assemble the shift mechanism consistingof the sleeve, the two shift keys and shift collar. Slide the shift mechanism, shift keys onto the first, output shaft and into the appropriate slots the in gear sleeves. 19. [. . . ] Remove the two screwssecuring the impeller locking mechanism cover to the top of the right handle. See Figure133. NOTE: Do not tighten the mounting bolts until all parts of the cabhave been installed. 1. 5. Remove the fasteners securing the attaching bracket base to thehandlesandremovethe attaching bracket base. Remove the two screws securing the lever cover 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 screws previously the removed. Position and secure the right attaching bracket to the attaching bracket base using a 1/4-20 X 3/4" capscrew and locknut. See Figure 136. 5. Attaching Bracket Front Post Lever Cover Figure 134 2. Figure 136 6. Remove the two flange head capscrews securing the control panel to the handles (one on each side). [. . . ]