Form No.
Revision History Revision History Page 2 POWER MAX® HD Service Manual 3424-820 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 POWER MAX® HD Service Manual 3424-820 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil. The numerical rating for class B extinguishers indicates the approximate number of square feet of fire it can extinguish. Geometric symbol (red square). Class C fires involve electrical equipment, such as appliances, wiring, circuit breakers and outlets.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–3 Equivalents and Conversions............................................................................................................. 2–8 U.S.
Specifications Power Max HD Model Steering 38840/38850 38842 38841/38855 Automatic Steering Up to 45 ft. (13.5 m) Up to 52 ft. (17.4 m) Clearing Width 28 in. (71 cm) 32 in. (81 cm) Starter Engine Displacement Up to 60 ft. (18.3 m) 28 in. (71 cm) 0.92 gal. (3.5 L) 1.2 gal. (4.5 L) LC175FDS LC180FDS LC185FDS LC190FDS 265cc 302cc 375cc 420cc 3300 ± 100 32 oz. (0.95 L) 37 oz. (1.1 L) Spark Plug Champion RN9YC/NGK BPR6ES/NHPS F7RTC Spark Plug Gap 0.030 in. (0.76 mm) Weight 264 lbs.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–4 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) In-lb. In-lb.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb. N-cm in-lb. N-cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lbs. N-m ft-lbs. N-m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb. 73 ± 12 in-lb. 5/16 - 18 UNC 215 ± 35 in-lb. 145 ± 20 in-lb. 1/2 - 13 UNC 75 ± 15 ft-lb. 50 ± 10 ft-lb. 3/8 - 16 UNC 35 ± 10 ft-lb. 18 ± 3 ft-lb. Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb. 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb. 108 ± 14 N-m M12 X 1.25 Class 8.8 80 ± 10 ft-lb. 108 ± 14 Nm M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–10 POWER MAX® HD Service Manual 3424-820 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting See Operator’s Manual for troubleshooting information.
Troubleshooting: General Troubleshooting Page 3–4 POWER MAX® HD Service Manual 3424-820 Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Engine Replacement..........................................................................................................................
General Information Models 38840/38850 use Toro engine LC175FDS Models 38841/38855 use Toro engine LC180FDS Models 38843/38844/38860/38865 use Toro engine LC190FDS Models 38842 use Toro engine LC185FDS Engine: General Information Page 4–2 POWER MAX® HD Service Manual 3424-820 Rev A
Service and Repairs Engine Assembly Figure 3 1. Engine (high speed idle 3300 ± 100 RPM, carburetor bowl drain screw 62-88 in-lbs. (7.1–10.1 Nm)) 6. Torque to 120-160 in-lbs. (13.8–18.4 Nm) 2. LED Light Asm. 7. Torque to 150 ± 15 in-lbs. (17.25 ± 1.7 Nm) 3. Light Bracket 8. Engine Plate Asm. 4. Belt Cover 9. Torque to 110 ± 20 in-lbs. (12.65 ± 2.3 Nm) 5. Belt Guide (0.06 ± 0.03 in. (0.15 ± 0.
Engine Figure 4 1. LC185/LC190 Engine Engine: Service and Repairs 2.
Engine Replacement Engine Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the light from the cover. Figure 5 3. Remove the belt cover. 4. Remove the belts and pulleys. 5. Remove the 2 bolts securing the QUICK STICK® rod. Remove the QUICK STICK® rod. 6. Remove the 4 (2 per side) motor mount bolts. Figure 6 7. Using a proper lifting device, lift the engine away from the machine.
Engine Removal (continued) Figure 7 Engine Installation 1. Using a proper lifting device, place the engine into position on the machine. 2. Apply loctite and install the 4 (2 per side) motor mount bolts. Torque bolts to 150 ± 15 in-lbs. (12.25 ± 1.7 Nm). 3. Install the QUICK STICK® rod. Secure with 2 bolts. CAUTION When installing the traction belt, make sure the belt is riding on top of the traction pulley sheaves to ensure the belt does not break. 4. Install the belts and pulleys. 5.
Chapter 5 Controls Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 QUICK STICK® Replacement ........................................................................................................... 5–6 Control Interlock Replacement.......
General Information For the new generation of Power Max HD models, handles are reinforced and units have welded square tube handles for models 38843, 38844, 38860, 38865 only.
Service and Repairs QUICK STICK® Assembly Figure 8 1. 2. 3. RH Quick Stick Globe Chute Rod Lever Cap 6. 7. 8. Chute Control Lever Asm. LH Quick Stick Globe Chute Control Rod 4. Latch Trigger 9. Deflector Control Cable 5.
Handles and Controls Assembly Figure 9 1. Auger Cable 7. Lockout Link 13. Traction Cable 2. 3. Handle Lock Lockout Cam 8. 9. Lockout Rod Handle Return Torsion Spring 14. 15. Clutch Cable Wire Harness 4. Handle Lockout Spring 10. Console Brace 16. Shift Rod 5. 6. Cam Collar Lockout Latch 11. 12.
Handle Bracket Figure 10 1. 2. Lower Handle Bracket Handle Asm. POWER MAX® HD Service Manual 3424-820 Rev A 3.
QUICK STICK® Replacement QUICK STICK® Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Unhook the Z-bend and disconnect the deflector cable from the underside of the Quick Stick. Figure 11 3. On the underside of the control panel, remove the 2 screws holding the Quick Stick cover in place. Figure 12 4. Lift the front cover and pull forward to release the latch tabs on the rear. Set the cover aside.
QUICK STICK® Removal (continued) Figure 13 5. Remove the 3 carriage bolts and nuts on the chute control rod and lift the Quick stick out of the control panel. Note: Notice the location of the cable clamp for latch cable function. 6. Remove the top cover. 7. Disconnect the chute cable. Figure 14 QUICK STICK® Disassembly 1. Remove the screw retaining the blue lever cap.
QUICK STICK® Disassembly (continued) Figure 15 2. Remove the 2 screws on the RH of the Quick Stick globe (the part that looks like a ball). Remove both halves and set aside. Figure 16 3. Remove the locknut from the shoulder bolt. Slide the chute control rod off and remove the friction washer. 4. Hold the Quick Stick so that the 5 screws holding the handle halves are facing up. Remove the 5 screws and lift off the top handle half.
QUICK STICK® Disassembly (continued) Figure 17 5. Lift the metal latch pawl off the hex on the cable lever. Remove the latch trigger and spring. Note: Notice the orientation of the pawl to the lever for reassembly. Figure 18 6. Rotate the cable until the barrel fitting slides off the cable lever.
QUICK STICK®Reassembly 1. Place the latch spring over the boss. The straight end of the spring should be down with the hooked end facing up. Figure 20 2. Slide the latch trigger over the boss until it is fully seated, making sure that the stop on the trigger lever is above the stop on the quick lever. While holding the trigger lever in place, rotate the hooked end of the spring until it hooks under the front edge of the trigger lever. 3.
Control Interlock Removal (continued) Figure 21 3. Remove the shoulder screw under the RH handgrip. When removed, the lockout latch, extension spring, flat washer, and locknut will drop out. Figure 22 4. To remove the lockout rod, go to the RH end. There are 2 roll pins on the LH side and 1 in the lockout cam on the RH side.
Control Interlock Removal (continued) Figure 23 5. Once the roll pins are driven out, the lockout rod can be moved to the side and removed. The lockout link can now be removed from the lockout rod. 6. Remove the levers. Note: Steps 1 and 2 above, do not need to be done in that order. It’s possible to remove the rod without removing the shoulder bolt. Figure 24 Control Interlock Installation Note: Notice the spring on the lockout latch.
Control Interlock Installation (continued) 2. Install the lockout link onto the lockout rod. 3. Install the lockout cam and auger lever. 4. Install the 2 roll pins on the LH side and the pin in the lockout cam on the RH side. 5. Install the lockout latch, extension spring, flat washer, and locknut. Install the shoulder screw under the RH handgrip 6. If this is a wheel clutch model, connect the wheel clutch cables. Connect the auger and traction cables to the levers.
Deflector Cable Removal (continued) Figure 26 4. Remove the cable clamp on the traction housing. Deflector Cable Installation 1. Connect the cable end to the deflector. Secure with a cable clamp. 2. Connect the Z-bend end to the machine. 3. Install the cable onto the bracket. Secure with tabs. 4. Connect the cable clamp to the traction housing. Deflector Cable Adjustment Make sure the Quick Stick is in the maximum rear position and centered; ensure the deflector is in the full upward position.
Shift Lever Adjustment The shift lever on the control panel is connected to the friction wheel in the traction frame by a shift rod. Moving the shift lever changes the friction wheel location. Figure 28 Shift Rod Adjustment 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. Note: The adjustment point is a trunnion on the upper end of the shift rod. Figure 29 2. Pull the shift rod and arm upward as far as they will go.
Shift Rod Adjustment (continued) Figure 30 Auger Control The bail on the RH handle is the auger control. Squeeze the bail and the cable causes an idler to pivot the tensioning in the auger belt. Clutch Cables Replacement and Adjustment (Wheel Clutch Models Only) Clutch Cable Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Drain the fuel tank and stand the machine on the auger housing. Remove the rear cover.
Clutch Cable Removal (continued) 3. Remove the nut and washer that attach the cable clamp to the handle. 4. Slip the cable barrel end out of the wheel clutch lever on the handle. 5. Reach under the shift plate and compress the small ears on the cable fitting. The cable fitting can then be pushed out of the shift plate. 6. Disconnect the lower end of the cable from the shift collar. Figure 32 Clutch Cable Installation 1.
Clutch Cable Installation (continued) 3. Install the covers and test run the unit.
Chapter 6 Belts Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Auger Belt Replacement .................................................................................................................... 6–4 Traction Belt Replacement ......
General Information Some Power Max HD units use a new double-V auger drive belt.
Service and Repairs Auger Drive Components Figure 34 9. V-Belt 1. Torque to 100 ± 10 in-lbs. (11.5 ± 1.15 Nm) 2. Idler Pulley 10. Traction Pulley Asm. (friction plate-dry and free from oil) 3. 4. Traction Idler Arm Impeller Idler Pulley 11. 12. Drive Link Friction Wheel Plate 5. Apply Anti-Seize 13. V-Belt 6. Brake Arm 14. Impeller Pulley Single Sheave (pulley grooves-dry and free from oil) 7. Impeller Clutch Arm Asm. 15. Pulley Hub 8.
Auger Belt Replacement Auger Belt Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the belt covers. Figure 35 3. Remove the belt guide. Avoid bending the guide. Figure 36 4. Remove the bolt securing the engine pulley to the crankshaft. If necessary, hold the hub between the pulley and engine to keep the crankshaft from turning. Remove the pulley and the auger belt from the crankshaft.
Auger Belt Removal (continued) Figure 37 5. Remove the fuel from the machine. 6. Remove the auger belt from the impeller pulley. 7. Tip the unit onto the front. Remove the bottom cover. Depress the auger lever to allow brake to be released. 8. Pull the belt out of the bottom of the machine. Figure 38 Auger Belt Installation 1. 2. 3. 4. 5. POWER MAX® HD Service Manual 3424-820 Rev A Using the auger lever, release the brake. Install the belt through the bottom of the machine.
Auger Belt Installation (continued) 6. Install the pulley and the auger belt to the crankshaft .Apply Loctite 243 (blue) to the bolt. Install the bolt securing the engine pulley to the crankshaft. 7. Install the belt guide. CAUTION When tightening the crank bolt, the engine must be cranked to prevent pinching the traction belt between the pulley sheaves. Failure to do so will damage the traction belt and crank bolt will have a low torque upon first use. Traction Belt Replacement Traction Belt Removal 1.
Traction Belt Installation (continued) Figure 40 5. Install the pulley flange and the auger belt to the crankshaft .Apply Loctite 243 (blue) to the bolt. Install the bolt securing the engine pulley to the crankshaft. 6. Install the belt guide. CAUTION When tightening the crank bolt, the engine must be cranked to prevent pinching the traction belt between the pulley sheaves. Failure to do so will damage the traction belt and crank bolt will have a low torque.
Belts: Service and Repairs Page 6–8 POWER MAX® HD Service Manual 3424-820 Rev A
Chapter 7 Auger Housing Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Fixed Scraper.....................................................................................................................................
General Information The new Power Max HD models utilize an all new gearcase featuring a horizontal parting line and heavy duty steel gears.
Service and Repairs Main Frame and Auger Housing Figure 41 1. Traction Frame 5. Ball Bearing 2. Side Drift Breaker 6. Bearing Retainer 3. Auger Housing 7. Scraper Blade 4.
Fixed Scraper The fixed scraper is bolted solidly to the auger housing, it is intended to be raised slightly off the ground to minimize catching on pavement cracks and solid objects. The amount that is should be raised depends on how rough the ground is. The scraper is adjustable as the mounting holes are slotted. Figure 42 Scraper Replacement The scraper is attached with 5 carriage head bolts with locknuts for the 28 in. model, 7 carriage head bolts with locknuts for the 32 in. model.
Chapter 8 Auger Gearbox Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Auger and Traction Assemblies ......................................................................................................... 8–4 Auger Gear Box Replacement .
General Information The auger gearbox contains a worm gear and helical gear. It is driven by a clutched belt from the engine.
Service and Repairs Gearbox, Auger and Impeller Figure 43 1. Torque to 33 ± 3 ft-lbs. (3.8 ± 0.3 Nm) 4. 2. RH Auger 5. Apply light coat of anti-seize on shaft, ½ in. outside of holes Impeller 3. Auger Gearcase Asm. (apply light coat of anti-seize) 6.
Auger and Traction Assemblies Separating the Auger and Traction Assemblies 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the 2 screws securing the cover. Figure 44 3. Remove the belt guide around the crankshaft pulley, avoid bending the guide. See Belt Replacement chapter. Figure 45 4. Remove the face gear cover. 5. Disconnect the chute control cable. 6. Disconnect the deflector cable from the deflector.
Separating the Auger and Traction Assemblies (continued) Figure 46 7. Remove the 2 carriage bolts on the chute control rod. Figure 47 8. Support the auger and traction housings with blocks of wood. 9. Remove the friction wheel plate return spring. 10. Remove the 3 cap screws on each side, connecting the auger to the traction assembly and separate the sections.
Separating the Auger and Traction Assemblies (continued) Figure 48 11. Once separated, the auger pulley is in the open. 12. Remove the pulley from the input shaft. 13. Remove the 4 housing bolts on the outside of the auger housing. 14. Slide the gear case, augers, and impellers out of the housing. Auger Gear Box Replacement Auger Gear Box Installation 1. Apply a thin coat of anti-seize to the auger shafts and the impeller shaft. Install the impeller and augers, secure with cap screws and locknuts.
Chapter 9 Wheel Clutch Traction Drive System Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 Traction Drive System Replacement (Wheel Clutch Models) .............................................................
General Information The handle mounted triggers allow clutching the wheels simultaneously or independently, one or both wheels can “freewheel.” This feature makes turning, reversing, and traction control simple and efficient. When the drive is engaged, it is engaging the friction wheel. The hex shaft turns and drives the chain(s) to the 32–tooth sprocket by driving the 44–tooth gear powering the wheels.
Service and Repairs Traction Drive Assembly (Wheel Clutch Models) Figure 49 1. 2. 3. Slotted Roll Pin Centered in Shaft Trunnion Friction Wheel (needs to be dry and free from oil) 13. 14. 15. LH Shift Collar Pawl Pin Retainer Dowel Pin (apply light coat of oil) 4. Hex Shaft (apply light coat of oil) 16. Clutch Pawl 5. 6. 8–Tooth Gear Pinion Shift Rod 17. 18. 11T Gear Asm. Torque to 100-125 in-lbs. (11.5–14.4 Nm) 7. Bearing Retainer 19.
Autoturn Drive Assembly Figure 50 1. Hex Shaft (apply light coat of oil) 2. LH and RH tires must by oriented with “V” tread rotating 9. forward RH Tube Axle 10. 3. Intermediate Bearing Retainer 11. 8–Tooth Pinion Gear 4. 11–Tooth Gear 12. Transmission (apply a coating of grease) Sprocket (apply a coating of grease) 5. Axle Bushing 13. LH Tube Axle 6. HD Intermediate Shaft 14. Roller Chain (master link clip toward center of unit) 7. HD Base Axle 15. Torque to 50–70 in-lbs. (19.5–34.
Traction Drive System Replacement (Wheel Clutch Models) Traction Drive System Removal (Wheel Clutch Models) 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the fuel from the machine. 3. Disconnect the shift linkage and tip the machine forward on auger housing. 4. Remove the upper and lower covers. Figure 51 5. Remove the 2 cap screws securing the bearing retainers securing the hex shaft to each side of the traction assembly.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 53 7. Remove the 2 extension springs by unhooking the springs from the lower clutch collar and housing. Figure 54 8. Remove the clutch cables by rotating the shift collar up to release tension. Maneuver the Z-bend of the cable end out of the upper clutch collar.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 55 9. Remove the 2 bolts on the end of the shift brace from the housing. Figure 56 10. Remove both roller chains from the 32–tooth gears. Lift the wheel clutch assembly from the traction unit.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 57 Note: Install a screw and washer onto each end of the shaft to keep the parts from sliding off. Figure 58 11. Remove both bolts on either side of the axle from the 44–tooth gear.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 59 12. Slide the axle shaft out through the axle bushing one at a time, holding onto the 44–tooth gear. Figure 60 13. Slide the tube of the axle shaft though the housing. 14. Remove the other half of the axle shaft with the 44–tooth gear.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 61 15. Remove the hex shaft bearing retainers. 16. Remove the hex shaft clutch assembly/friction wheel from the housing. Figure 62 17. Remove the friction wheel from the hex shaft by removing the 3 nuts and bolts that secure the friction wheel to the trunnion on the hex shaft.
Traction Drive System Removal (Wheel Clutch Models) (continued) Figure 63 18. Remove the belt cover. Figure 64 19. Remove the extension spring from the housing. 20. Remove the pivot pulley bolts on either side of the housing. 21. Remove the pivot pulley plate assembly from the housing. Traction Drive System Installation (Wheel Clutch Models) 1. Install the pivot plate assembly onto the housing and install the belt. The idler pulley should be pushed away to install the pivot plate. 2.
Traction Drive System Installation (Wheel Clutch Models) (continued) 6. Before installing the axle with the 44–tooth sprockets, apply a light coat of anti-seize to the outer 5 inches of both ends of the axle shaft. Apply a light coat to the inside diameter at both ends of the tube (about 4 inches). Figure 65 7. Install the axle shaft with the 44–tooth gear. 8. Insert the tube of the axle shaft through the housing. 9. Install the other axle. 10. Lightly coat the 44–tooth sprocket with grease. 11.
Traction Drive System Replacement (Autoturn Models) Traction Drive System Removal (Autoturn Models) 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the fuel from the machine. 3. Disconnect the shift linkage and tip the machine forward on the auger housing. 4. Remove both wheels and wheel keys. 5. Remove the upper and lower covers. 6. Remove the 2 screws securing the bearing retainers and hex shaft to each side of the traction assembly.
Traction Drive System Removal (Autoturn Models) (continued) Figure 67 12. Remove the stub shaft, transmission, and axle from the machine. Figure 68 Traction Drive System Installation (Autoturn Models) 1. 2. 3. 4. 5. 6. Install the axle, transmission, and stub shaft onto the machine. Place the axle into position on the housing. Slide the axle bearing into position. Install the snap ring securing the axle bearing to the housing. Install the hex shaft and friction wheels. Install both bearing retainers.
Traction Drive System Installation (Autoturn Models) (continued) 9. Tip machine backwards, off the auger housing. 10. Connect the shift linkage. 11. Put fuel into the machine. Wheel Clutch Replacement Wheel Clutch Disassembly 1. Remove the 11–tooth gear from the intermediate shaft. Figure 69 2. Slide the washer behind the 11–tooth gear off the shaft. 3. Remove the 32–tooth sprocket and the thrust washer from the shaft. Figure 70 4. Remove the shift collar and flat washer from the shaft.
Wheel Clutch Disassembly (continued) Note: Shift collars are marked right and left at the top of the inside flange. Figure 71 5. Unbolt the 4 guide collars from the shaft. Figure 72 6. Remove the wheel clutch components from the other end of the shaft. 7. Remove the 3 (per gear) compression springs from under the pawls and set aside.
Wheel Clutch Disassembly (continued) Figure 73 8. Remove the 6 (per side) T-27 torx screws that secure the pawl retainer plate. 9. Remove the retainer plate off of the sprocket hub. Figure 74 10. Remove the pawl pins and pawls from the 32–tooth sprocket. 11. Repair or replace defective components. Wheel Clutch Reassembly Note: Apply a light coat of SAE 30W oil to intermediate shaft before assembly. 1. Set the 32–tooth sprocket on a flat surface and install the pawls. 2.
Wheel Clutch Reassembly (continued) 3. Clamp or hold the gear and turn it over to properly install the 3 pawl supports and torx screws. 4. Torque the T-27 torx screws to 100–125 in-lbs. (11.3–14.1 Nm). 5. Install the 4 guide collars to the shaft with the shift brace plate. Figure 75 6. Torque the screws to 50–70 in-lbs. (5.65–7.9 Nm). 7. Slide the flat washers into position next to the guides. 8. Install the RIGHT and LEFT collar into position.
Wheel Clutch Reassembly (continued) Figure 77 11. Slide the complete 32–tooth gear sprocket onto the shaft. Figure 78 12. Install the flat washer. 13. Make sure the 11–tooth gear slides on so it is flush with the end of the shaft.
Wheel Clutch Reassembly (continued) Figure 79 14. Make sure the pawls are up against the thrust washer and the spring are not binding and are compressing properly. Figure 80 15. Apply a light coat of grease to the 11–tooth gear. Repeat the process for the opposite side. 16. Assembly can now go back into the housing.
Wheel Clutch Reassembly (continued) Figure 81 POWER MAX® HD Service Manual 3424-820 Rev A Page 9–21 Wheel Clutch Traction Drive System: Service and Repairs
Wheel Clutch Traction Drive System: Service and Repairs Page 9–22 POWER MAX® HD Service Manual 3424-820 Rev A
Chapter 10 Discharge Chute Table of Contents General Information ............................................................................................................................ 10–2 Service and Repairs ........................................................................................................................... 10–3 Chute and Face Gear Cover Replacement ...................................................................................... 10–4 Chute Gear Replacement ..............
General Information The new Power Max HD snow blowers are all made with steel discharge chutes.
Service and Repairs Chute Assembly Figure 82 1. 2. 3. 4. Face Gear Cover Face Gear Face Gear Mount Upper Deflector Asm. 7. 8. 9. 10. Deflector Link Chute Gear Chute Latch Lower Chute Asm. 5. 6. Deflector Gasket Middle Deflector Asm. 11. 12. Chute Guide Chute Post Asm.
Chute and Face Gear Cover Replacement Chute and Face Gear Cover Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the cable from the clamp and deflector link. Figure 83 3. Remove the screw retaining the gear cover. Lift the front of the cover and slide towards the rear. Figure 84 4. Remove the bolt on the chute gear.
Chute and Face Gear Cover Removal (continued) Figure 85 5. Remove the chute. Chute and Face Gear Cover Installation 1. Install the chute. Secure with a bolt on the face gear. 2. Install the front of the cover into position. Secure with a screw. Chute Gear Replacement Chute Gear Removal 1. Park the machine on a level surface. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the screw on the face gear cover. 3. Raise the front of the cover and slide towards the rear. 4.
Chute Gear Installation (continued) 5. Install the end of the latch cable in the latch and install the cable conduit into the cable anchor.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic with Hand Warmers...........................................................................................A–3 Electrical Schematic...........................................................................................................................
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BM Brown BU Blue GN Green GY Gray OR Orange PK Pink R or RD Red T Tan VIO Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
Electrical Schematic with Hand Warmers , Drawing Rev A, Sheet 1 3424-820 Rev A Page A–3
Electrical Schematic Page A–4 3424-820 Rev A , Drawing Rev , Sheet
