Toro POWER MAX HD User manual

FormNo.3424-820RevA
POWERMAX®HDService
Manual
OriginalInstructions(EN)

RevisionHistory
RevisionHistoryPage2POWERMAX®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®HDServiceManualPage3Preface
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.
PrefacePage4POWERMAX®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®HDServiceManualPage5Preface
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PrefacePage6POWERMAX®HDServiceManual
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–2
POWERMAX®HDServiceManualPage1–1Safety
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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:SafetyInstructionsPage1–2POWERMAX®HDServiceManual
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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®HDServiceManualPage1–3Safety: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:SafetyInstructionsPage1–4POWERMAX®HDServiceManual
3424-820RevA

Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
TorqueSpecications...........................................................................................................................2–3
EquivalentsandConversions.............................................................................................................2–8
U.S.toMetricConversions................................................................................................................2–9
POWERMAX®HDServiceManualPage2–1SpecicationsandMaintenance
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Specications
PowerMaxHD
Model38840/3885038841/388553884238843/3886038844/38865
SteeringAutomaticSteeringPowerSteering
Throw
DistanceUpto45ft.(13.5m)Upto52ft.(17.4
m)Upto60ft.(18.3m)
Clearing
Width28in.(71cm)32in.(81cm)28in.(71cm)32in.(81cm)
StarterRecoil/Electric
FuelCapacity0.92gal.(3.5L)1.2gal.(4.5L)
EngineLC175FDSLC180FDSLC185FDSLC190FDS
Displacement265cc302cc375cc420cc
EngineRPM3300±100
OilCapacity32oz.(0.95L)37oz.(1.1L)
SparkPlugChampionRN9YC/NGKBPR6ES/NHPSF7RTC
SparkPlug
Gap0.030in.(0.76mm)
Weight264lbs.(120kg)283lbs.(128kg)300lbs.(136kg)305lbs.(138kg)310lbs.(141kg)
Length62in.(157.5cm)
Width29.5in.(75cm)33.5in.(85cm)29.5in.(75cm)33.5in.(85cm)
Height44.5in.(113cm)
Speed6Forward—2Reverse
TirePressure17–20psi(116–137kPa)
SpecicationsandMaintenance:SpecicationsPage2–2POWERMAX®HDServiceManual
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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®HDServiceManualPage2–3SpecicationsandMaintenance:TorqueSpecications
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MetricBoltsandScrews
Figure2
1.Class8.82.Class10.9
SpecicationsandMaintenance:TorqueSpecicationsPage2–4POWERMAX®HDServiceManual
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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
#6-32UNC15±2169±2323±3260±34
#6-40UNF10±213±2147±2317±2192±2325±3282±34
#8-32UNC29±3328±3441±5463±56
#8-36UNF13±225±5282±3031±4350±4543±5486±56
#10-24UNC42±5475±5660±6678±68
#10-32UNF18±230±5339±5648±5542±5668±7768±79
1/4-20UNC48±753±7599±79100±101130±113140±151582±169
1/4-28UNF53±765±10734±113115±121299±136160±171808±192
5/16-18UNC115±15105±151186±169200±252260±282300±303390±339
5/16-24UNF138±17128±171446±192225±252542±282325±333672±373
ft-lb.ft-lb.N-mft-lb.N-mft-lb.N-m
3/8-16UNC16±216±222±330±341±443±558±7
3/8-24UNF17±218±224±335±447±550±668±8
7/16-14UNC27±327±337±450±568±770±795±9
7/16-20UNF29±329±339±455±675±877±8104±11
1/2-13UNC30±348±765±975±8102±11105±11142±15
1/2-20UNF32±453±772±985±9115±12120±12163±16
5/8-11UNC65±1088±12119±16150±15203±20210±21285±28
5/8-18UNF75±1095±15129±20170±18230±24240±24325±33
3/4-10UNC93±12140±20190±27265±27359±37375±38508±52
3/4-16UNF115±15165±25224±34300±30407±41420±43569±58
7/8-9UNC140±20225±25305±34430±45583±61600±60813±81
7/8-14UNF155±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®HDServiceManualPage2–5SpecicationsandMaintenance:TorqueSpecications
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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-mft-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cationsPage2–6POWERMAX®HDServiceManual
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SAEGrade8SteelSetScrews
RecommendedTorque
ThreadSize
SquareHeadHexSocket
1/4-20UNC140±20in-lb.73±12in-lb.
5/16-18UNC215±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.6-32UNC20±5in-lb.
No.8-32UNC30±5in-lb.
No.10-24UNC38±7in-lb.
1/4-20UNC85±15in-lb.
5/16-18UNC110±20in-lb.
3/8-16UNC200±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
TypeATypeBBaselineTorque*
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®HDServiceManualPage2–7SpecicationsandMaintenance:TorqueSpecications
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EquivalentsandConversions
DecimalandMillimeterEquivalents
FractionsDecimalsmmFractionsDecimalsmm
1/640.0156250.39733/640.51562513.097
1/320.031250.79416/320.5312513.484
3/640.0468751.19135/640.54687513.891
1/160.06251.5889/160.562514.288
5/640.0781251.98437/640.57812514.684
3/320.93752.38119/320.5937515.081
1/80.12503.1755/80.625015.875
9/640.1406253.57241/640.64062516.272
5/320.156253.96921/320.6562516.669
11/640.1718754.36643/640.67187517.066
3/160.18754.76211/640.687517.462
13/640.2031255.15945/640.70312517.859
7/320.218755.55623/320.7187518.256
15/640.2343755.95347/640.73437518.653
1/40.25006.3503/40.750019.050
17/640.2656256.74749/640.76562519.447
9/320.281257.14425/320.7812519.844
19/640.2968757.54151/640.79687520.241
5/160.31257.54113/160.812520.638
21/640.3281258.33453/640.82812521.034
11/320.343758.73127/320.8437521.431
23/640.3593759.12855/640.85937521.828
3/80.37509.5257/80.875022.225
25/640.3906259.92257/640.89062522.622
13/320.4062510.31929/320.9062523.019
27/640.42187510.71659/640.92187523.416
7/160.437511.11215/160.937523.812
29/640.45312511.50961/640.95312524.209
15/320.4687511.90631/320.9687524.606
31/640.48437512.30363/640.98437525.003
1/20.500012.70011.00025.400
1mm=0.03937in.0.001in.=0.0254mm
SpecicationsandMaintenance:TorqueSpecicationsPage2–8POWERMAX®HDServiceManual
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U.S.toMetricConversions
ToConvertIntoMultiplyBy
MilesKilometers1.609
YardsMeters0.9144
FeetMeters0.3048
FeetCentimeters30.48
InchesMeters0.0254
InchesCentimeters2.54
LinearMeasurement
InchesMillimeters25.4
SquareMilesSquareKilometers2.59
SquareFeetSquareMeters0.0929
SquareInchesSquareCentimeters6.452
Area
AcreHectare0.4047
CubicYardsCubicMeters0.7646
CubicFeetCubicMeters0.02832
Volume
CubicInchesCubicCentimeters16.39
Tons(Short)MetricTons0.9078
PoundsKilograms0.4536 Weight
OuncesGrams28.3495
PressurePounds/SquareInchKilopascal6.895
Foot-PoundsNewton-Meters1.356
Foot-PoundsKilogram-Meters0.1383
Work
Inch-PoundsKilogram-Centimeters1.152144
QuartsLiters0.9463
LiquidVolumeGallonsLiters3.785
LiquidFlowsGallons/MinuteLiters/Minute3.785
1.Subtractby32°
TemperatureFahrenheitCelsius2.Multiplyby5/9
POWERMAX®HDServiceManualPage2–9SpecicationsandMaintenance:TorqueSpecications
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SpecicationsandMaintenance:TorqueSpecicationsPage2–10POWERMAX®HDServiceManual
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