Toro Power Max Heavy Duty 828 OAE Snowthrower User manual

FormNo.3424-820RevA

POWERMAX®HDService

Manual

OriginalInstructions(EN)

RevisionHistory

RevisionHistoryPage2

POWERMAX®HDServiceManual

3424-820RevA

Preface

ThisservicemanualwaswrittenexpresslyforT oroservicetechnicians.TheT oroCompanyhasmade

everyefforttomaketheinformationinthismanualcompleteandcorrect.

Basicshopsafetyknowledgeandmechanical/electricalskillsareassumed.TheTableofContentslists

thesystemsandtherelatedtopicscoveredinthismanual.

Wearehopefulthatyouwillndthismanualavaluableadditiontoyourserviceshop.Ifyouhaveany

questionsorcommentsregardingthismanual,pleasecontactusatthefollowingaddress:

TheToroCompany

RLC/SWSCustomerCareDepartment

8111LyndaleAvenueSouth

Bloomington,MN55420

TheToroCompanyreservestherighttochangeproductspecicationsormakechangestothismanual

withoutnotice.

POWERMAX®HDServiceManual

Page3

Preface

3424-820RevA

ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•Installingsafetyequipment(shields,guards,seatbelts,brakes,andR.O.P .S.

components)thatmayhavebeenremoved

•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation

•Aspecicfastenertighteningsequence

•Componentorientationthatmaynotbeobvious

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent

thanwhatisrecommendedintheStandardT orqueTables.

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s

Manualforcommonlyuseduidspecicationsandcapacities.

Preface

Page4

POWERMAX®HDServiceManual

3424-820RevA

TableofContents

Preface................................................................................................................3

Chapter1:Safety............................................................................................1–1

SafetyInstructions.......................................................................................1–2

Chapter2:SpecicationsandMaintenance....................................................2–1

Specications...............................................................................................2–2

TorqueSpecications...................................................................................2–3

Chapter3:Troubleshooting.............................................................................3–1

GeneralTroubleshooting..............................................................................3–3

Chapter4:Engine...........................................................................................4–1

GeneralInformation.....................................................................................4–2

ServiceandRepairs.....................................................................................4–3

Chapter5:Controls.........................................................................................5–1

GeneralInformation.....................................................................................5–2

ServiceandRepairs.....................................................................................5–3

Chapter6:Belts...............................................................................................6–1

GeneralInformation.....................................................................................6–2

ServiceandRepairs.....................................................................................6–3

Chapter7:AugerHousing...............................................................................7–1

GeneralInformation.....................................................................................7–2

ServiceandRepairs.....................................................................................7–3

Chapter8:AugerGearbox..............................................................................8–1

GeneralInformation.....................................................................................8–2

ServiceandRepairs.....................................................................................8–3

Chapter9:WheelClutchTractionDriveSystem..............................................9–1

GeneralInformation.....................................................................................9–2

ServiceandRepairs.....................................................................................9–3

Chapter10:DischargeChute........................................................................10–1

GeneralInformation...................................................................................10–2

ServiceandRepairs...................................................................................10–3

AppendixA......................................................................................................A–1

ElectricalDrawingAbbreviations...................................................................A–2

ElectricalSchematicwithHandWarmers......................................................A–3

ElectricalSchematic.....................................................................................A–4

POWERMAX®HDServiceManual

Page5

Preface

3424-820RevA

Preface

Page6

POWERMAX®HDServiceManual

3424-820RevA

Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

ThinkSafetyFirst...............................................................................................................................1–2

POWERMAX®HDServiceManual

Page1–1

Safety

3424-820RevA

SafetyInstructions

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldcauseseriouspermanentinjury,disability,or

death.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjuryand/ordamage

topropertyorequipment.

ThinkSafetyFirst

Avoidunexpectedstartingofengine…

Alwaysturnofftheengine,removetheignitionkeyanddisconnectthesparkplug

wire(s)beforecleaning,adjusting,orrepair.

Avoidlacerationsandamputations…

Stayclearofallmovingpartswhenevertheengineisrunning.Treatallnormally

movingpartsasiftheyweremovingwhenevertheengineisrunningorhas

thepotentialtostart.

Avoidburns…

Donottouchtheengine,mufer,orothercomponents,whichmaybehotduring

operation,whiletheunitisrunningorshortlyafterithasbeenrunning.

Avoidresandexplosions…

Useextremecareinhandlingfuel.Itisammableanditsvaporsareexplosive.

Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.Avoid

spillingfuelandneversmokewhileworkingwithanytypeoffuelorlubricant.

Wipeupanyspilledfueloroilimmediately.Neverremovethefuelcaporadd

fuelwhentheengineisrunning.Alwaysuseapproved,labeledcontainersfor

storingortransportingfuelandlubricants.Donotaddordrainfuelinanenclosed

space.Donotstorethemachineorfuelcontainerwherethereisanopename,

spark,orpilotlight,suchasonawaterheaterorotherappliance.

Avoidasphyxiation…

Donotoperateanengineinaconnedareawithoutproperventilation.

Avoidinjuryfrombatteries…

Safety:SafetyInstructions

Page1–2

POWERMAX®HDServiceManual

3424-820RevA

Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,eyes

andclothing.Batterygasescanexplode.Keepcigarettes,sparksandames

awayfromthebattery.

Avoidinjuryduetoinferiorparts…

Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteriaaremet.

Avoidinjurytobystanders…

Alwayscleartheareaofbystandersbeforestartingortestingpowered

equipment.

Avoidinjuryduetoprojectiles…

Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbepickedup

andthrownbythepoweredequipment.

Avoidmodications…

Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.

Avoidunsafeoperation…

Alwaystestthesafetyinterlocksystemaftermakingadjustmentsorrepairson

themachine.RefertotheElectricalsectioninthismanualformoreinformation.

Avoidelectricalshock…

Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.They

canbesourcesofshock.De-energizethesystemifyouarehavingtodorepairs.

Iftestingelectricalcomponentsensureyouareworkinginadryenvironment.

HydraulicSystem...

Releaseallpressureinthehydraulicsystembeforeperforminganyworkon

thesystem.Keepyourbodyandhandsawayfrompin-holeleaksornozzles

thatejecthydraulicuidunderhighpressure.Donotuseyourhandstosearch

forleaks.Hydraulicuidescapingunderpressurecanhavesufcientforceto

penetratetheskinandcauseseriousinjury.Seekmedicalattentionrightawayif

hydraulicuidgetsintheskin.

PersonalProtectiveEquipment…

Useappropriatepersonalprotectiveequipment(PPE)forprotectingyourself

frompotentialhazardsintheenvironmentinwhichyouwillwork.Eachprocess

outlinedinthismanualmayneeddifferentPPEtoprotecttheserviceperson.

UsetheproperPPEforthetaskathand.

Tools…

Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatarebrokenorin

disrepair.Usethepropertoolfortheproperapplication.

Lifts,Hoists,andJacks…

Alllifts,hoists,andjacksshouldbeusedinaccordancewiththemanufacturer

information.Inspectlifts,hoists,andjackspriortouse.Donotoverloadlifts,

hoists,andjacks.Donotworkunderasuspendedload.Ensurechockblocks

areusedonequipmentthatcanmove.Useliftsorjacksandjackstandsthat

areratedtosupportthetotalweightofthemachineandanyattachments.Do

notrelyonjackstosupportthemachine.Ifyouareunsureoftheoperationof

anylifts,hoists,andjacksdonotuse.

FireExtinguishers…

Theproperclassofreextinguishershouldbeusedincaseofre.

ClassAextinguishersareforordinarycombustiblematerialssuchaspaper,

wood,cardboard,andmostplastics.Thenumericalratingonthesetypesof

POWERMAX®HDServiceManual

Page1–3

Safety:SafetyInstructions

3424-820RevA

extinguishersindicatestheamountofwateritholdsandtheamountofreitcan

extinguish.Geometricsymbol(greentriangle).

ClassBresinvolveammableorcombustibleliquidssuchasgasoline,

kerosene,greaseandoil.ThenumericalratingforclassBextinguishers

indicatestheapproximatenumberofsquarefeetofreitcanextinguish.

Geometricsymbol(redsquare).

ClassCresinvolveelectricalequipment,suchasappliances,wiring,circuit

breakersandoutlets.NeverusewatertoextinguishclassCres-theriskof

electricalshockisfartoogreat!ClassCextinguishersdonothaveanumerical

rating.TheCclassicationmeanstheextinguishingagentisnon-conductive.

Geometricsymbol(bluecircle).

ABC

Fireextinguishersareadrychemicaltypeusedformultiplepurposes.See

aboveinformationfordescription.

Ensurereextinguishersareserviceableandreplaceanythataredischargedor

outofinspectiondates.

Safety:SafetyInstructions

Page1–4

POWERMAX®HDServiceManual

3424-820RevA

Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

TorqueSpecications...........................................................................................................................2–3

EquivalentsandConversions.............................................................................................................2–8

U.S.toMetricConversions................................................................................................................2–9

POWERMAX®HDServiceManual

Page2–1

SpecicationsandMaintenance

3424-820RevA

Specications

PowerMaxHD

Model

38840/3885038841/38855

38842

38843/3886038844/38865

SteeringAutomaticSteeringPowerSteering

Throw

Distance

Upto45ft.(13.5m)

Upto52ft.(17.4

m)

Upto60ft.(18.3m)

Clearing

Width

28in.(71cm)32in.(81cm)28in.(71cm)32in.(81cm)

StarterRecoil/Electric

FuelCapacity0.92gal.(3.5L)1.2gal.(4.5L)

Engine

LC175FDSLC180FDSLC185FDSLC190FDS

Displacement265cc302cc375cc420cc

EngineRPM3300±100

OilCapacity32oz.(0.95L)37oz.(1.1L)

SparkPlugChampionRN9YC/NGKBPR6ES/NHPSF7RTC

SparkPlug

Gap

0.030in.(0.76mm)

Weight

264lbs.(120kg)283lbs.(128kg)300lbs.(136kg)305lbs.(138kg)310lbs.(141kg)

Length

62in.(157.5cm)

Width

29.5in.(75cm)33.5in.(85cm)29.5in.(75cm)33.5in.(85cm)

Height

44.5in.(113cm)

Speed

6Forward—2Reverse

TirePressure

17–20psi(116–137kPa)

SpecicationsandMaintenance:Specications

Page2–2

POWERMAX®HDServiceManual

3424-820RevA

TorqueSpecications

Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For

criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora

torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthe

servicemanual.

Thesetorquespecicationsfortheinstallationandtighteningoffastenersshall

applyforallfastenerswhichdonothaveaspecicrequirementidentiedin

theservicemanual.Thefollowingfactorsshallbeconsideredwhenapplying

torque:cleanlinessofthefastener,useofathreadsealant(Loctite),degreeof

lubricationonthefastener,presenceofaprevailingtorquefeature,hardness

ofthesurfaceunderneathofthefastener’shead,orsimilarconditionwhich

affectstheinstallation.

Asnotedinthefollowingtables,torquevaluesshouldbereducedby25%for

lubricatedfastenerstoachievethesimilarstressasadryfastener.T orquevalues

mayalsohavetobereducedwhenthefasteneristhreadedintoaluminumor

brass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum

orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.

Thestandardmethodofverifyingtorqueshallbeperformedbymarkingalineon

thefastener(headornut)andmatingpart,thenbackofffastener1/4ofaturn.

Measurethetorquerequiredtotightenthefasteneruntilthelinesmatchup.

FastenerIdentication

InchSeriesBoltsandScrews

Figure1

1.Grade13.Grade8

2.Grade5

POWERMAX®HDServiceManual

Page2–3

SpecicationsandMaintenance:TorqueSpecications

3424-820RevA

MetricBoltsandScrews

Figure2

1.Class8.82.Class10.9

SpecicationsandMaintenance:TorqueSpecications

Page2–4

POWERMAX®HDServiceManual

3424-820RevA

StandardTorqueforDry,ZincPlated,andSteelFasteners(InchSeries)

ThreadSizeGrade1,

5,&8

Fasteners

withThin

HeightNuts

SAEGrade1Bolts,Screws,

Studes&Semswith

RegularHeightNuts(SAE

Grade2orBetterNut)

SAEGrade5Bolts,Screws,

Studs&SemswithRegular

HeightNuts(SAEGrade

5orBetterNut)

SAEGrade8Bolts,Screws,

Studs&SemswithRegular

HeightNuts(SAEGrade

8orBetterNut)

In-lb.In-lb.N-cmIn-lb.N-cmIn-lb.N-cm

#6-32UNC

15±2169±2323±3260±34

#6-40UNF

10±213±2147±23

17±2192±2325±3282±34

#8-32UNC

29±3328±3441±5463±56

#8-36UNF

13±225±5282±30

31±4350±4543±5486±56

#10-24UNC

42±5475±5660±6678±68

#10-32UNF

18±230±5339±56

48±5542±5668±7768±79

1/4-20UNC

48±753±7599±79100±101130±113140±151582±169

1/4-28UNF

53±765±10734±113115±121299±136160±171808±192

5/16-18UNC

115±15105±151186±169200±252260±282300±303390±339

5/16-24UNF

138±17128±171446±192225±252542±282325±333672±373

ft-lb.ft-lb.

N-m

ft-lb.

N-m

ft-lb.

N-m

3/8-16UNC

16±216±222±330±341±443±558±7

3/8-24UNF

17±218±224±335±447±550±668±8

7/16-14UNC

27±327±337±450±568±770±795±9

7/16-20UNF

29±329±339±455±675±877±8104±11

1/2-13UNC

30±348±765±975±8102±11105±11142±15

1/2-20UNF

32±453±772±985±9115±12120±12163±16

5/8-11UNC

65±1088±12119±16150±15203±20210±21285±28

5/8-18UNF

75±1095±15129±20170±18230±24240±24325±33

3/4-10UNC

93±12140±20190±27265±27359±37375±38508±52

3/4-16UNF

115±15165±25224±34300±30407±41420±43569±58

7/8-9UNC

140±20225±25305±34430±45583±61600±60813±81

7/8-14UNF

155±25260±30353±41475±48644±65667±66904±89

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch

asLoctite.

Torquevaluesmyhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The

specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial

strength,lengthofthreadengagement,etc.

ThenominaltorquevalueslistedaboveforGrade5and8fastenersarebasedon75%oftheminimum

proofloadspeciedinSAEJ429.Thetoleranceisapproximately±10%ofthenominaltorquevalue.

Thinnutsincludejamnuts.

POWERMAX®HDServiceManual

Page2–5

SpecicationsandMaintenance:TorqueSpecications

3424-820RevA

StandardTorqueforDry,ZincPlated,andSteelFasteners(MetricSeries)

Class8.8Bolts,Screws,StudswithRegular

HeightNuts(Class8orStrongerNuts)

Class10.9Bolts,Screws,StudswithRegular

HeightNuts(Class10orstrongerNuts)

ThreadSize

in-lb.N-cmin-lb.N-cm

M5X0.857±6644±6878±8881±90

M6X1.096±101085±113133±141503±158

ft-lbs.

N-m

ft-lbs.

N-m

M8X1.2519±226±328±338±4

M10X1.538±452±554±673±8

M12X1.7566±790±1093±10126±14

M16X2.0166±17255±23229±23310±31

M20X2.5325±33440±45450±46610±62

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch

asLoctite.

Torquevaluesmayhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The

specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial

strength,lengthofthreadengagement,etc.

Thenominaltorquevalueslistedabovearebasedon75%oftheminimumproofloadspeciedinSAE

J1199.Thetoleranceisapproximately±10%ofthenominaltorquevalue.Thinheightnutsincludejam

nuts.

SpecicationsandMaintenance:TorqueSpecications

Page2–6

POWERMAX®HDServiceManual

3424-820RevA

SAEGrade8SteelSetScrews

RecommendedTorque

ThreadSize

SquareHeadHexSocket

1/4-20UNC

140±20in-lb.73±12in-lb.

5/16-18UNC

215±35in-lb.145±20in-lb.

1/2-13UNC75±15ft-lb.50±10ft-lb.

3/8-16UNC35±10ft-lb.18±3ft-lb.

WheelBoltsandLugNuts

ThreadSizeRecommendedTorque**

7/16-20UNFGrade565±10ft-lb.

88±14N-m

1/2-20UNFGrade580±10ft-lb.

108±14N-m

M12X1.25Class8.880±10ft-lb.

108±14Nm

M12X1.5Class8.880±10ft-lb.

108±14Nm

**Forsteelwheelsandnon-lubricatedfasteners.

ThreadCuttingScrews(ZincPlatedSteel)

Type1,Type23,orTypeF

ThreadSizeBaselineTorque*

No.6-32UNC

20±5in-lb.

No.8-32UNC

30±5in-lb.

No.10-24UNC

38±7in-lb.

1/4-20UNC

85±15in-lb.

5/16-18UNC

110±20in-lb.

3/8-16UNC

200±100in-lb.

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining

specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

ConversionFactors

in-lb.X11.2985=N-cm

ft-lb.X1.3558=N-m

N-cmX0.08851=in-lb.

N-cmX0.73776=ft-lb.

ThreadCuttingScrews(ZincPlatedSteel)

ThreadsperInch

ThreadsSize

TypeATypeB

BaselineTorque*

No.6182020±5in-lb.

No.8151830±5in-lb.

No.10121638±7in-lb.

No.12111485±15in-lb.

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining

specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

POWERMAX®HDServiceManual

Page2–7

SpecicationsandMaintenance:TorqueSpecications

3424-820RevA

EquivalentsandConversions

DecimalandMillimeterEquivalents

FractionsDecimals

mm

FractionsDecimals

mm

1/64

0.0156250.397

33/64

0.51562513.097

1/32

0.031250.794

16/32

0.5312513.484

3/64

0.0468751.191

35/64

0.54687513.891

1/16

0.06251.588

9/16

0.562514.288

5/64

0.0781251.984

37/64

0.57812514.684

3/32

0.93752.381

19/32

0.5937515.081

1/8

0.12503.175

5/8

0.625015.875

9/64

0.1406253.572

41/64

0.64062516.272

5/32

0.156253.969

21/32

0.6562516.669

11/64

0.1718754.366

43/64

0.67187517.066

3/16

0.18754.762

11/64

0.687517.462

13/64

0.2031255.159

45/64

0.70312517.859

7/32

0.218755.556

23/32

0.7187518.256

15/64

0.2343755.953

47/64

0.73437518.653

1/4

0.25006.350

3/4

0.750019.050

17/64

0.2656256.747

49/64

0.76562519.447

9/32

0.281257.144

25/32

0.7812519.844

19/64

0.2968757.541

51/64

0.79687520.241

5/16

0.31257.541

13/16

0.812520.638

21/64

0.3281258.334

53/64

0.82812521.034

11/32

0.343758.731

27/32

0.8437521.431

23/64

0.3593759.128

55/64

0.85937521.828

3/8

0.37509.525

7/8

0.875022.225

25/64

0.3906259.922

57/64

0.89062522.622

13/32

0.4062510.319

29/32

0.9062523.019

27/64

0.42187510.716

59/64

0.92187523.416

7/16

0.437511.112

15/16

0.937523.812

29/64

0.45312511.509

61/64

0.95312524.209

15/32

0.4687511.906

31/32

0.9687524.606

31/64

0.48437512.303

63/64

0.98437525.003

1/2

0.500012.70011.00025.400

1mm=0.03937in.0.001in.=0.0254mm

SpecicationsandMaintenance:TorqueSpecications

Page2–8

POWERMAX®HDServiceManual

3424-820RevA

U.S.toMetricConversions

ToConvert

IntoMultiplyBy

MilesKilometers1.609

YardsMeters0.9144

FeetMeters0.3048

Feet

Centimeters

30.48

InchesMeters0.0254

Inches

Centimeters

2.54

LinearMeasurement

InchesMillimeters25.4

SquareMilesSquareKilometers

2.59

SquareFeetSquareMeters

0.0929

SquareInchesSquareCentimeters

6.452

Area

AcreHectare0.4047

CubicYardsCubicMeters

0.7646

CubicFeetCubicMeters

0.02832

Volume

CubicInchesCubicCentimeters

16.39

Tons(Short)

MetricTons0.9078

PoundsKilograms0.4536 Weight

OuncesGrams

28.3495

Pressure

Pounds/SquareInch

Kilopascal6.895

Foot-PoundsNewton-Meters1.356

Foot-PoundsKilogram-Meters0.1383

Work

Inch-Pounds

Kilogram-Centimeters

1.152144

Quarts

Liters0.9463

LiquidVolume

Gallons

Liters3.785

LiquidFlows

Gallons/MinuteLiters/Minute

3.785

1.Subtractby32°

TemperatureFahrenheit

Celsius

2.Multiplyby5/9

POWERMAX®HDServiceManual

Page2–9

SpecicationsandMaintenance:TorqueSpecications

3424-820RevA

SpecicationsandMaintenance:TorqueSpecications

Page2–10

POWERMAX®HDServiceManual

3424-820RevA

Page is loading ...

Related papers

Other documents