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Toro POWER MAX HD Service Manual
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Toro POWER MAX HD Service Manual

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Form No. 3424-820 Rev A
POWER MAX® HD Service
Manual
Original Instructions (EN)

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Summary of Contents for Toro POWER MAX HD

  • Page 1 Form No. 3424-820 Rev A POWER MAX® HD Service Manual Original Instructions (EN)
  • Page 2 Revision History Revision History Page 2 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. POWER MAX® HD Service Manual Page 3 Preface...
  • Page 4 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. components) that may have been removed •...

  • Page 5: Table Of Contents

    Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–3 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
  • Page 6 Preface Page 6 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 POWER MAX® HD Service Manual Page 1–1 Safety 3424-820 Rev A...

  • Page 8: Safety Instructions

    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.
  • Page 9 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…...
  • Page 10 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.
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–3 Equivalents and Conversions......................2–8 U.S. to Metric Conversions ........................ 2–9 POWER MAX® HD Service Manual Page 2–1 Specifications and Maintenance 3424-820 Rev A...

  • Page 12: Specifications

    Specifications Power Max HD Model 38842 38840/38850 38841/38855 38843/38860 38844/38865 Steering Automatic Steering Power Steering Throw Up to 52 ft. (17.4 Up to 45 ft. (13.5 m) Up to 60 ft. (18.3 m) Distance Clearing 28 in. (71 cm) 32 in. (81 cm) 28 in.

  • Page 13: Torque Specifications

    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.
  • Page 14 Metric Bolts and Screws Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–4 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 15 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
  • Page 16 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb.
  • Page 17 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 ±...
  • Page 18 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 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...
  • Page 19 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement 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 Area Square Inches...
  • Page 20 Specifications and Maintenance: Torque Specifications Page 2–10 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 21 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 POWER MAX® HD Service Manual Page 3–1 Troubleshooting 3424-820 Rev A...
  • Page 22 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 23: General Troubleshooting

    General Troubleshooting See Operator’s Manual for troubleshooting information. POWER MAX® HD Service Manual Page 3–3 Troubleshooting: General Troubleshooting 3424-820 Rev A...
  • Page 24 Troubleshooting: General Troubleshooting Page 3–4 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 25 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Engine Replacement.......................... 4–5 POWER MAX® HD Service Manual Page 4–1 Engine 3424-820 Rev A...
  • Page 26 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...
  • Page 27 Service and Repairs Engine Assembly Figure 3 Engine (high speed idle 3300 ± 100 RPM, carburetor Torque to 120-160 in-lbs. (13.8–18.4 Nm) bowl drain screw 62-88 in-lbs. (7.1–10.1 Nm)) LED Light Asm. Torque to 150 ± 15 in-lbs. (17.25 ± 1.7 Nm) Light Bracket Engine Plate Asm.
  • Page 28 Engine Figure 4 LC185/LC190 Engine LC175/LC180 Engine Engine: Service and Repairs Page 4–4 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 29 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.

  • Page 30: Chapter 4: Engine

    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.
  • Page 31 Chapter 5 Controls Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 QUICK STICK® Replacement ......................5–6 Control Interlock Replacement......................5–10 Control Replacement and Adjustment....................5–13 Shift Lever Adjustment ........................5–15 Clutch Cables Replacement and Adjustment (Wheel Clutch Models Only)........5–16 POWER MAX®...

  • Page 32: General Information

    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. Controls: General Information Page 5–2 POWER MAX® HD Service Manual 3424-820 Rev A...

  • Page 33: Service And Repairs

    Service and Repairs QUICK STICK® Assembly Figure 8 RH Quick Stick Globe Chute Control Lever Asm. Chute Rod LH Quick Stick Globe Lever Cap Chute Control Rod Latch Trigger Deflector Control Cable Latch Link POWER MAX® HD Service Manual Page 5–3 Controls: Service and Repairs 3424-820 Rev A...
  • Page 34 Handles and Controls Assembly Figure 9 Lockout Link Auger Cable Traction Cable Handle Lock Lockout Rod Clutch Cable Wire Harness Lockout Cam Handle Return Torsion Spring Handle Lockout Spring Console Brace Shift Rod Cam Collar Clutch Mount Lever Lockout Latch Clutch Lever Controls: Service and Repairs Page 5–4...
  • Page 35 Handle Bracket Figure 10 Lower Handle Bracket Cleanout Stick Bracket Handle Asm. POWER MAX® HD Service Manual Page 5–5 Controls: Service and Repairs 3424-820 Rev A...

  • Page 36: Quick Stick® Replacement

    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.
  • Page 37 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.
  • Page 38 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.
  • Page 39 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. Figure 19 POWER MAX®...

  • Page 40: Control Interlock Replacement

    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.
  • Page 41 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.
  • Page 42 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.

  • Page 43: Control Replacement And Adjustment

    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.
  • Page 44 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.

  • Page 45: Shift Lever Adjustment

    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.

  • Page 46: Clutch Cables Replacement And Adjustment (Wheel Clutch Models Only)

    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.
  • Page 47 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.
  • Page 48 Clutch Cable Installation (continued) 3. Install the covers and test run the unit. Controls: Service and Repairs Page 5–18 POWER MAX® HD Service Manual 3424-820 Rev A...

  • Page 49: General Information

    Chapter 6 Belts Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Auger Belt Replacement ........................6–4 Traction Belt Replacement ......................... 6–6 POWER MAX® HD Service Manual Page 6–1 Belts 3424-820 Rev A...
  • Page 50 General Information Some Power Max HD units use a new double-V auger drive belt. Belts: General Information Page 6–2 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 51 Service and Repairs Auger Drive Components Figure 34 Torque to 100 ± 10 in-lbs. (11.5 ± 1.15 Nm) V-Belt Idler Pulley Traction Pulley Asm. (friction plate-dry and free from oil) Traction Idler Arm Drive Link Impeller Idler Pulley Friction Wheel Plate Apply Anti-Seize V-Belt Brake Arm...
  • Page 52 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.
  • Page 53 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.
  • Page 54 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.
  • Page 55 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.
  • Page 56 Belts: Service and Repairs Page 6–8 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 57 Chapter 7 Auger Housing Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Fixed Scraper............................. 7–4 Scraper Replacement ........................7–4 POWER MAX® HD Service Manual Page 7–1 Auger Housing 3424-820 Rev A...

  • Page 58: General Information

    General Information The new Power Max HD models utilize an all new gearcase featuring a horizontal parting line and heavy duty steel gears. Auger Housing: General Information Page 7–2 POWER MAX® HD Service Manual 3424-820 Rev A...

  • Page 59: Service And Repairs

    Service and Repairs Main Frame and Auger Housing Figure 41 Traction Frame Ball Bearing Side Drift Breaker Bearing Retainer Auger Housing Scraper Blade Skid POWER MAX® HD Service Manual Page 7–3 Auger Housing: Service and Repairs 3424-820 Rev A...

  • Page 60: Fixed Scraper

    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.
  • Page 61 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 ......................8–6 POWER MAX® HD Service Manual Page 8–1 Auger Gearbox 3424-820 Rev A...

  • Page 62: General Information

    General Information The auger gearbox contains a worm gear and helical gear. It is driven by a clutched belt from the engine. Auger Gearbox: General Information Page 8–2 POWER MAX® HD Service Manual 3424-820 Rev A...

  • Page 63: Service And Repairs

    Service and Repairs Gearbox, Auger and Impeller Figure 43 Torque to 33 ± 3 ft-lbs. (3.8 ± 0.3 Nm) Apply light coat of anti-seize on shaft, ½ in. outside of holes RH Auger Impeller Auger Gearcase Asm. (apply light coat of anti-seize) LH Auger POWER MAX®...

  • Page 64: Auger And Traction Assemblies

    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.
  • Page 65 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.

  • Page 66: Auger Gear Box Replacement

    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.
  • Page 67 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) ............. 9–5 Traction Drive System Replacement (Autoturn Models) ..............9–13 Wheel Clutch Replacement......................9–15 POWER MAX®...

  • Page 68: General Information

    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.

  • Page 69: Service And Repairs

    Service and Repairs Traction Drive Assembly (Wheel Clutch Models) Figure 49 Slotted Roll Pin Centered in Shaft LH Shift Collar Trunnion Pawl Pin Retainer Friction Wheel (needs to be dry and free from oil) Dowel Pin (apply light coat of oil) Hex Shaft (apply light coat of oil) Clutch Pawl 8–Tooth Gear Pinion...
  • Page 70 Autoturn Drive Assembly Figure 50 LH and RH tires must by oriented with “V” tread rotating Hex Shaft (apply light coat of oil) forward RH Tube Axle Sprocket (apply a coating of grease) Intermediate Bearing Retainer 8–Tooth Pinion Gear 11–Tooth Gear Transmission (apply a coating of grease) Axle Bushing LH Tube Axle...

  • Page 71: Traction Drive System Replacement (Wheel Clutch Models)

    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.
  • Page 72 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.
  • Page 73 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.
  • Page 74 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. Wheel Clutch Traction Drive System: Service and Repairs Page 9–8 POWER MAX®...
  • Page 75 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.
  • Page 76 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.
  • Page 77 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.
  • Page 78 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.

  • Page 79: Traction Drive System Replacement (Autoturn Models)

    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.
  • Page 80 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. Install the axle, transmission, and stub shaft onto the machine. 2. Place the axle into position on the housing. 3.

  • Page 81: Wheel Clutch Replacement

    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.
  • Page 82 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.
  • Page 83 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.
  • Page 84 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.
  • Page 85 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. POWER MAX®...
  • Page 86 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.
  • Page 87 Wheel Clutch Reassembly (continued) Figure 81 POWER MAX® HD Service Manual Page 9–21 Wheel Clutch Traction Drive System: Service and Repairs 3424-820 Rev A...
  • Page 88 Wheel Clutch Traction Drive System: Service and Repairs Page 9–22 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 89 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 ........................ 10–5 POWER MAX® HD Service Manual Page 10–1 Discharge Chute 3424-820 Rev A...

  • Page 90: General Information

    General Information The new Power Max HD snow blowers are all made with steel discharge chutes. Discharge Chute: General Information Page 10–2 POWER MAX® HD Service Manual 3424-820 Rev A...

  • Page 91: Service And Repairs

    Service and Repairs Chute Assembly Figure 82 Face Gear Cover Deflector Link Face Gear Chute Gear Face Gear Mount Chute Latch Upper Deflector Asm. Lower Chute Asm. Deflector Gasket Chute Guide Middle Deflector Asm. Chute Post Asm. POWER MAX® HD Service Manual Page 10–3 Discharge Chute: Service and Repairs 3424-820 Rev A...

  • Page 92: Chute And Face Gear Cover Replacement

    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.

  • Page 93: Service And Repairs

    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.
  • Page 94 Chute Gear Installation (continued) 5. Install the end of the latch cable in the latch and install the cable conduit into the cable anchor. Discharge Chute: Service and Repairs Page 10–6 POWER MAX® HD Service Manual 3424-820 Rev A...
  • Page 95 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic with Hand Warmers...................A–3 Electrical Schematic...........................A–4 POWER MAX® HD Service Manual Page A–1 Foldout Drawings 3424-820 Rev A...

  • Page 96: Electrical Drawing Abbreviations

    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 Black BR or BM Brown Blue Green Gray Orange Pink R or RD Violet W or WH White Y or YE Yellow...

  • Page 97: Electrical Schematic With Hand Warmers

    Electrical Schematic with Hand Warmers , Drawing Rev A, Sheet 1 3424-820 Rev A Page A–3...

  • Page 98: Electrical Schematic

    Electrical Schematic Page A–4 3424-820 Rev A , Drawing Rev , Sheet...

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