Amerisun PowerSmart DB7651 User manual

Rev 1.0 3-23-13
Auger Belt Tension Adjustment –DB7651
WARNING Entanglement Hazard - Before
performing any adjustment procedures, make sure the
engine is off and remove the spark plug wire from the
spark plug to ensure the engine cannot accidently start.
Never adjust belt tension with the engine running.
Note: During operation the augers turn at a slower
speed than the impeller, this is normal. The augers
are used to chop and cut the snow and direct it
into the impeller which is rotating at a high speed
to throw the snow up and out of the chute.
Over time, the auger cable tension may loosen and
or the auger belt may stretch. The auger cable will
require periodic adjustment to compensate for
these changes. Ideally, the cable should just be
barely tight when the auger handle is in the
released (disengaged) position.
Note: The proper operating tension for a typical V-
belt drive is - the lowest tension at which the belt
will not slip under a loaded condition.
DB7651 Controls and Cables
1. Drive Control Engagement Handle
2. Drive Speed Control Lever
3. Auger Control Engagement Handle
4. Chute Rotation Crank Handle
5. Drive Speed Cables
6. Auger Control Cable
7. Drive Control Cable
8. Drive Control Cable Adjustment Plate Slip Cover
The auger cable is located on the left side (when
standing behind the snow blower) and is made up
of an upper and lower cable connected by an
adjustment plate. The adjustment plate is located
in-line with the cable below the control handle and
is covered by a black plastic slip cover. The
adjustment plate is used to adjust auger belt
tension.
Adjustment Plate
1. Upper Auger Cable (Always in upper center hole)
2. Adjustment Plate
3. Lower Auger Cable
4. Cable Pulley
5. Adjustment Plate Lower Cable Opening
6. Slip Cover
1. Stop the engine.
2. Disconnect the upper cable from the auger
control handle.
Upper Auger Cable Connection

Rev 1.0 3-23-13
3. Slide up the slip cover to access the adjustment
plate.
Cable Adjustment Plate
4. Adjustment is made by changing the position of
the lower cable in the adjustment plate holes
(1 to 9). Only move the lower cable diagonally one
hole at a time from its original position.
Note: The upper cable end must be in the upper
single center hole of the adjustment plate. Do not
change the position of the upper cable.
4. Connect the upper cable to the control handle.
5. Start the engine and engage the auger to test
the operation of the auger.
Note: With the auger control handle at the full
released position, the cable should be barely tight.
Some slack in the cable may be required to ensure
the auger pulley tension pulley is not engaging the
belt. There should be no auger movement with the
auger handle released. If the auger is turning when
the auger handle is released, loosen the belt
tension by readjusting the cable as necessary. Do
not over tension the cable.

Rev 1.0 4-11-13
Auger Belt Removal –DB7651
WARNING Entanglement Hazard - Before
performing any service procedures, make sure the
engine is off and remove the spark plug wire from the
spark plug to ensure the engine cannot accidently start.
Note: Record component position before disassembly, to
assist in reassembly.
1. Disconnect the upper cable from the auger control
handle.
2. Remove 2 hex head screws and remove belt cover.
3. Loosen the belt guide pin hex head screw (installed
on engine crankcase) and rotate the pin away from the
pulley.
4. Left Side - Loosen the hex nuts attaching the auger
housing to the main frame.
5. Right Side –Remove the hex nuts, lock washers and
flat washers attaching the auger housing to the main
frame.

Rev 1.0 4-11-13
6. Remove the belt from the drive pulley while pulling
the right side of the auger housing away from the main
frame just enough to access the belt and auger pulley.
7. Push the auger tension pulley arm to move the auger
brake away from the belt to allow removal of the belt.
1. Auger Brake
8. Remove the auger belt.
Auger Belt Installation –DB7651
WARNING Entanglement Hazard - Before
performing any service procedures, make sure the
engine is off and remove the spark plug wire from the
spark plug to ensure the engine cannot accidently start.
NOTICE: Before installing the auger belt, see Auger Belt
and Related Component Inspection and repair or
replace any components as required.
1. Inspect the new belt to ensure it is the correct size
and type.
Original - Gates Truflex G 4LXP885
Alternate –MTD 954-0101A
2. Push the auger tension pulley arm to move the auger
brake to allow access for installation of the belt into the
auger pulley.
1. Auger Brake
3. Route the belt to the inside of the tension pulley and
install the auger belt onto the drive pulley while pulling
the auger housing into position with the main frame.

Rev 1.0 4-11-13
4. Install and/or tighten the hex nuts attaching the
auger housing to the main frame. Tighten all fasteners
securely, do not over tighten.
5. With the belt installed on both pulleys and tension
pulley in position, move the belt guide pin to within
3/16 to 3/8 in. from the belt seated in the pulley and
tighten the pin in position.
Note: The belt guide pin helps keep the belt in the pulley
when the belt is disengaged. The pin should not be tight
to the belt. The pin should be loose enough to allow the
belt to spin freely but not allow the belt to jump off the
pulley.
6. Connect the lower auger cable to the cable
adjustment plate.
7. Adjust auger belt tension; see Auger Cable Tension
Adjustment DB7651.
WARNING -Ensure the belt cover is installed and all
safety guards are in place before the engine is started
and at all times when the engine or machine are
operating.
8. Install belt cover using 2 hex head screws.
NOTICE: After initial belt installation and adjustment,
re-adjustment of the belt is recommended after a period
of operation. Belt tension should be checked periodically
to ensure proper tension is maintained.
A loose belt will cause:
Premature belt wear / damage /cracking /
fraying
Belt slipping (“squealing may also be heard”)
No or erratic/slow auger operation –poor
performance
A tight belt will cause:
Premature belt wear / damage / breaking
/stretching
Belt overheat / burning
Loss of auger engagement control (always
engaged)
Tension pulley damage
Pulley bearing damage
Auger Belt and Related
Component Inspection
When replacing your snow blower auger belt it is
important to determine the cause of the failure (if
applicable) and take corrective action to avoid repeated
failure.
Inspect the belt:
Correct size and type
Fraying or peeling apart
Missing pieces
Cracks and tears
Burning
Uneven wear patterns
General damage
Foreign material on belt, oil, grease, dirt etc

Rev 1.0 4-11-13
Inspect the auger pulleys:
Broken sheave or hub
Loose or missing mounting bolts
Bent or “out-of-round” condition (pulley does
not spin true on shaft)
Misaligned pulleys
Pulley Alignment
1. Drive Pulley
2. Tension Pulley
3. Auger Pulley
Foreign material on pulleys, oil, grease, dirt etc
Misaligned tension pulley
Tension pulley loose or damaged
Tension pulley and arm assembly operation
oDoes the tension arm move freely in
both engage and disengage directions
without binding?
oMisaligned tension pulley, the pulley
should move parallel to the belt and be
centered to the belt
oCheck return spring operation and
tension
Inspect the auger engagement handle and cable:
Cable and connection damage
Free movement (from engage to disengaged
positions)
Binding or improperly routed cable
Cable pulley(s) damage, misalignment and
binding
Cable adjustment plate damaged or improper
installation
Handle damaged or binding at pivot