Service Manual

ManualsBrandsToro ManualsCordless Snow BlowersPower Clear 21 in. 60-Volt Lithium-Ion Brushless Cordless Electric Snow Blower with Two 6.0 Ah Batteries and Charger

FormNo.3438-775RevA

60VMAXe21PowerClear®Snow

ThrowerwithFlex—ForcePower

System®ServiceManual

Published:May2020

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

Summary of content (88 pages)

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Form No. 3438-775 Rev A 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual Published: May 2020 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
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Revision History Revision History Page 2 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A
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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.
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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.
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Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
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Preface Page 6 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A
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Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
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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.
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Think Safety First (continued) 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.
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Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of 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.
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Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–3 Equivalents and Conversions............................................................................................................. 2–8 U.S.
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Specifications 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Model 39901/39902 Throw Distance Up to 12 m (40 ft) Clearing Width 53 cm (21 inches) Weight 27.2 kg (60 lb) Length 145 cm (57 inches) Width 53 cm (21 inches) Height 72 cm (28.
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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.
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Metric Bolts and Screws g272209 Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–4 Class 10.
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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 N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
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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-lb N • m ft-lb 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.
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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 N •m M12 X 1.5 Class 8.
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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.
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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.
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Specifications and Maintenance: Torque Specifications Page 2–10 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A
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Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
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GEARS The Systematic approach to defining, diagnosing and solving problems.
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Error Beep Table Error Type Number of Beeps Communication Error 2 Time Out Error 3 Motor Driver Error Motor Driver Error Hall Sensor Error Motor Driver Error Communication Low Error from Battery, Low Power Motor Driver Block Error Internal Error Code Communication High Error from Battery Communication Motor Error 4 5 6 7 8 9 10 11 12 Current Error 13 Precharge Error 14 Gryoscope Error 15 Temp Error 16 Calibration Error 18 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power Sys
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General Troubleshooting See Operator’s Manual for troubleshooting information.
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Chapter 4 Battery Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Battery Track Assembly Replacement ...............................................................................................
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General Information This is a 60 volt MAX snowthrower.
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Service and Repairs Battery Track Assembly g320492 Figure 3 1. Battery Container Skirt 3. 60v Charger 2. Battery Track Assembly 4.
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Battery Track Assembly Replacement Battery Track Assembly Removal 1. Park the machine on a level surface and wait for all moving parts to stop. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 2. Lift the battery cover and remove the battery from the machine. 3. Pull and remove the chute control rod from the machine. 4.
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Battery Track Assembly Removal (continued) g320276 Figure 5 8. Remove the 3 screws securing the battery container skirt to the battery container. Remove the battery container skirt from the machine. g320289 Figure 6 9. Flip the machine over so the auger housing is facing the floor. Remove the 2 screws securing the battery track assembly to the battery container.
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Battery Track Assembly Removal (continued) g320309 Figure 7 10. Flip the machine over so the wheels are on the ground. Remove the 2 screws securing the battery track assembly to the battery container. Remove the battery track assembly from the battery container skirt. g320308 Figure 8 Battery Track Assembly Installation 1. Install the battery track assembly into the battery container. Install the 2 screws securing the battery track assembly to the battery container. Torque the screws to 1.1-1.
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Battery Track Assembly Installation (continued) g320308 Figure 9 2. Flip the machine over so the auger housing is facing the floor. Install the 2 screws securing the battery track assembly to the frame. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). g320309 Figure 10 3. Flip the machine over so the wheels are on the ground. Install the battery container skirt onto the battery container. Install the 3 screws securing the battery container skirt to the battery container. Torque the screws to 1.1-1.
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Battery Track Assembly Installation (continued) g320289 Figure 11 4. Install the 2 screws securing the battery container skirt to the battery container. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). g320276 Figure 12 5. Connect all the wire attachments to the motor driver. 6. Install the 4 screws securing the motor driver to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10–15 in-lb).
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Battery Track Assembly Installation (continued) g320303 Figure 13 7. Install the 2 screws securing the controller cover to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). 8. Install the chute control rod into the machine. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 9.
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Battery: Service and Repairs Page 4–10 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A
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Chapter 5 Drive System Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Ribbed V-Belt Replacement ............................................................................................................... 5–4 Rotor Replacement .........
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General Information This is a free wheeling snowthrower with no drive assist.
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Service and Repairs Rotor Assembly g320450 Figure 14 1. RH Sideplate Cap 5. LH Extension 2. Ball Bearing 6. Ribbed Belt 3. RH Extension 7. Rotor Pulley Asm 4. Rotor 8.
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Ribbed V-Belt Replacement Ribbed V-Belt Removal 1. Park the machine on a level surface and wait for all moving parts to stop. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 2. Lift the battery cover and remove the battery from the machine. 3. Remove the plastic screw securing the belt cover to the LH frame plate assembly.
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Ribbed V-Belt Removal (continued) 5. Remove the rotor pulley assembly from the rotor shaft. g320312 Figure 17 6. Remove ribbed V-belt from the rotor pulley assembly and the motor pulley. Ribbed V-Belt Installation 1. Install the rotor pulley assembly onto the rotor shaft. Install the Belleville washer and new screw securing the rotor pulley assembly to the rotor shaft. Torque screw to 10–12.4 N • m (90-110 in-lb). 2. Apply Loctite to threads of motor pulley. 3.
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Ribbed V-Belt Installation (continued) g320499 Figure 18 1. Plastic Screw 2. Screws WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 5. Install the battery into the machine. Rotor Replacement Rotor Removal 1. Park the machine on a level surface and wait for all moving parts to stop.
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Rotor Removal (continued) g320292 Figure 19 5. Remove the 2 screw securing the LH frame plate to the housing g320272 Figure 20 6. Remove the 3 screws securing the RH frame plate to the housing and the RH extension.
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Rotor Removal (continued) g320293 Figure 21 7. Remove the 3 screws securing the RH frame plate to the housing. g320294 Figure 22 8. Remove the 2 screws securing the RH frame plate to the housing.
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Rotor Removal (continued) g320274 Figure 23 9. Slide and remove the rotor assembly from the housing. g321114 Figure 24 Rotor Installation 1. Slide and install the rotor assembly to the housing. 2. Install the 2 screws securing the RH frame plate to the housing. Torque the screws to 2.8–4 N • m (25–35 in-lb).
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Rotor Installation (continued) g320274 Figure 25 3. Install the 3 screws securing the RH frame plate to the housing. Torque the screws to 2.3–2.8 N • m (20–25 in-lb).
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Rotor Installation (continued) 4. Install the 3 screws securing the RH frame plate to the housing and RH extension. Torque the screws to 5–6.8 N • m (45–60 in-lb). g320293 Figure 27 5. Install the 2 screw securing the LH frame plate to the housing. Torque the screws to 2.8–4 N • m (25–35 in-lb). g320272 Figure 28 6. Install the 3 screws securing the LH frame plate to the housing and the LH extension. Torque the screws to 5–6.8 N • m (45–60 in-lb).
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Rotor Installation (continued) g320292 Figure 29 7. Install the ribbed V-belt. Ribbed V-Belt Installation (page 5–5) WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 8. Drive System: Service and Repairs Install the battery into the machine.
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Chapter 6 Chute Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Chute Gear Replacement .................................................................................................................. 6–4 Chute Replacement ................
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General Information This snowthrower is equipped with a manual rotation chute and throw distance selection.
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Service and Repairs Chute Assembly g320445 Figure 30 1. Battery Cover 2. 3. 4. 5. Chute Shroud Controller Cover Gear Bracket 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A 6. 7. 8. 9. 10.
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Chute Gear Replacement Chute Gear Removal 1. Park the machine on a level surface and wait for all moving parts to stop. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 2. Lift the battery cover and remove the battery from the machine. 3. Pull and remove the chute control rod from the machine. 4.
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Chute Gear Removal (continued) g320276 Figure 32 8. Remove the 3 screws securing the battery container skirt to the battery container. Remove the battery container skirt. g320289 Figure 33 9. Remove the 4 screws and washers securing the battery container to the bulkhead. Remove the battery container from the bulkhead.
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Chute Gear Removal (continued) g320297 Figure 34 10. Remove the 3 screws securing the shroud to the rear chute. Remove the shroud from the rear chute. 11. Remove the 2 screws securing the LH frame assembly plate to the bulkhead. g320271 Figure 35 12. Remove the 2 screws securing the RH frame assembly plate to the bulkhead.
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Chute Gear Removal (continued) g320273 Figure 36 13. Remove the 2 screws and 2 washers securing the upper bulkhead to the upper housing. g320494 Figure 37 1. 2. Screw Washer 14. Remove the 2 screws securing the lower bulkhead to the lower housing. Remove the bulkhead from the housing.
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Chute Gear Removal (continued) g324235 Figure 38 15. Remove the 2 screws securing the gear bracket to the rear chute and the housing. g320270 Figure 39 16. Remove the gear bracket and attached sector gear from the chute gear. 17. Remove the chute gear from the rear chute. Chute Gear Installation 1. Install the chute gear on the rear chute so that the chute gear arrow is aligned between the two vertical lines on the chute .
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Chute Gear Installation (continued) g321111 Figure 40 2. Clock the sector gear to the chute gear by aligning the middle dot of the sector gear between the two does of the chute gear. g321112 Figure 41 3. Install the 2 screws securing the gear bracket to the rear chute and housing. Torque the screws to 1.1-1.7 N • m (10-15 in-lb).
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Chute Gear Installation (continued) g320270 Figure 42 4. Install the 2 screws and 2 washers securing the upper bulkhead to the upper housing. Torque the screws to 2.26–2.82 N• m (20–25 in-lb). g320494 Figure 43 1. 5. Chute: Service and Repairs 2. Screw Washer Install the 2 screws securing the lower bulkhead to the lower housing. Torque the screws to 2.26–2.82 N• m (20–25 in-lb).
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Chute Gear Installation (continued) g324235 Figure 44 6. Install the 2 screws securing the RH frame plate assembly to the bulkhead. Torque the screws to 2.26–2.82 N• m (20–25 in-lb). g320273 Figure 45 7. Install the 2 screws securing the LH frame plate assembly to the bulkhead. Torque the screws to 2.26–2.82 N• m (20–25 in-lb).
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Chute Gear Installation (continued) g320271 Figure 46 8. Install the shroud onto the rear chute. Install the 3 screws securing the shroud to the rear chute. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). 9. Install the battery container to the bulk head. Install the 4 screws and washers securing the battery container to the bulkhead. Torque the screws to 1.1-1.7 N • m (10-15 in-lb).
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Chute Gear Installation (continued) 10. Install the 2 screws securing the battery container skirt to the battery container. Torque the screws to 1.1-1.7 N • m (10-15 in-lb) g320276 Figure 48 11. Install the 3 screws securing the battery container skirt to the battery container. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). g320289 Figure 49 12. Connect all wiring to the motor driver. 13. Install the 4 screws securing the motor driver to the battery container skirt. Torque the screws to 1.1-1.
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Chute Gear Installation (continued) g320303 Figure 50 14. Install the 2 screws securing the controller cover to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). 15. Install the chute control rod. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 16. Install the battery into the machine.
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Chute Removal (continued) g320296 Figure 51 5. Lift and remove the rear chute and chute from the housing. g321113 Figure 52 Chute Installation 1. Install the chute and rear chute onto the housing. 2. Install the 4 screws securing the rear chute to the housing. Torque the screws to 1.7–2.3 N • m (15–20 in-lb).
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Chute Installation (continued) g320296 Figure 53 3. Install the chute gear. Chute Gear Installation (page 6–8) WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 4. Install the battery into the machine.
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Chapter 7 Controls Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Dash Panel Assembly Replacement ..................................................................................................
PAGE 64
General Information This snowthrower is equipped with a push button motor start and safety switch located in the handle lever.
PAGE 65
Service and Repairs Dash Panel Assembly g320410 Figure 54 1. Handle Screw 4. Flange Nut 2. Bail Key 5. Chute Control Rod 3.
PAGE 66
Dash Panel Assembly Replacement Dash Panel Assembly Removal 1. Park the machine on a level surface and wait for all moving parts to stop. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 2. Lift the battery cover and remove the battery from the machine. 3. Remove the 2 screws securing the controller cover to the battery container skirt.
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Dash Panel Assembly Removal (continued) g320304 Figure 56 6. Remove the screw securing battery container skirt to the battery container.
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Dash Panel Assembly Removal (continued) 7. Remove the harness from the battery container. g320305 Figure 58 8. Remove the 5 screws securing the front and rear dash panels. g320298 Figure 59 9. Remove the 4 flange nuts and 4 handle screws securing the front and rear dash panels onto the upper handle assembly.
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Dash Panel Assembly Removal (continued) g320295 Figure 60 10. Separate the front and rear dash panels from the upper handle assembly. Dash Panel Assembly Installation 1. Position the front and rear dash panels onto the upper handle assembly. 2. Install the 4 nuts and 4 handle screws securing the front and rear dash panels onto the upper handle. Torque the flange nuts to 4.5–5.6 N • m (40–50 in-lb). g320295 Figure 61 3. Install 5 screws securing the front and rear dash panels. Torque the screws to 1.
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Dash Panel Assembly Installation (continued) g320298 Figure 62 4. Route the harness through the battery container. 5. Install the screw securing battery container skirt to the battery container. Torque the screw to 1.1-1.7 N • m (10-15 in-lb).
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Dash Panel Assembly Installation (continued) 6. Connect the harness to the motor driver. g320304 Figure 64 7. Install the 4 screws securing the motor driver to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). g320303 Figure 65 8. Install the 2 screws securing the controller cover to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10-15 in-lb).
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Dash Panel Assembly Installation (continued) WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 9. Install the battery into the machine.
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Chapter 8 Motor Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Motor Driver Replacement ................................................................................................................. 8–4 Motor Replacement................
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General Information This snowthrower comes with a pulley installed and a 60 volt motor. The 60 volt motor is not serviceable.
PAGE 75
Service and Repairs Motor and Motor Driver Assembly g320493 Figure 66 1. Motor Driver 2. 60v Snowblower Motor 60V MAX e21 Power Clear® Snow Thrower with Flex—Force Power System® Service Manual 3438-775 Rev A 3.
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Motor Driver Replacement Motor Driver Removal 1. Park the machine on a level surface and wait for all moving parts to stop. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 2. Lift the battery cover and remove the battery from the machine. 3. Pull and remove the chute control rod from the machine. 4.
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Motor Driver Installation (continued) g320303 Figure 68 3. Install the 2 screws securing the controller cover to the battery container skirt. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). 4. Install the chute control rod. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 5. Install the battery into the machine.
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Motor Removal (continued) 5. Remove the 2 screws securing the battery container skirt to the battery container. g320276 Figure 69 6. Remove the 3 screws securing the battery container skirt to the battery container. Remove the battery container skirt. g320289 Figure 70 7. Remove the 4 screws and 4 washers securing the battery container to the bulk head. Remove the battery container from the machine.
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Motor Removal (continued) g320297 Figure 71 8. Remove the 3 screws securing the shroud to the rear chute. Remove the shroud from the machine. 9. Remove the 2 screws securing the LH frame assembly plate to the bulkhead. g320271 Figure 72 10. Remove the 2 screws securing the RH frame assembly plate to the bulkhead.
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Motor Removal (continued) g320273 Figure 73 11. Remove the 2 screws and 2 washers securing the upper bulkhead to the upper housing. g320494 Figure 74 1. 2. Screw Washer 12. Remove the 2 screws securing the lower bulkhead to the lower housing. Remove the bulkhead from the housing.
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Motor Removal (continued) g324235 Figure 75 13. Remove the plastic screw securing the belt cover to the LH frame plate assembly. Remove the 3 screws securing the belt cover to the housing. Remove the belt cover from the machine. g320499 Figure 76 1. Plastic Screw 2. Screws 14. Remove the screw and Belleville washer securing the rotor pulley assembly to the rotor shaft.
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Motor Removal (continued) g323087 Figure 77 15. Remove the rotor pulley assembly from the rotor shaft. g320312 Figure 78 16. Remove the ribbed V-belt from the rotor pulley assembly and the motor pulley. 17. Remove the 3 screws securing the motor to the LH frame plate. Remove the motor from LH frame plate.
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Motor Removal (continued) g320288 Figure 79 g320311 Figure 80 Motor Installation 1. Route motor pulley through LH frame plate pass-through hole.
PAGE 84
Motor Installation (continued) 2. Install the 3 screws securing the motor to the LH frame plate. Torque the screws to 8.5–11.3 N • m (75–100 in-lb). g320288 Figure 81 3. Install the rotor pulley assembly to the rotor shaft. Install the Belleville washer and new screw securing the rotor pulley assembly to the rotor shaft. Torque screw to 10–12.4 N • (90-110 in-lb). g323087 Figure 82 4. Apply Loctite to the motor pulley threads. 5.
PAGE 85
Motor Installation (continued) g320499 Figure 83 1. Plastic Screw 2. Screws 7. Install the bulkhead onto the housing. Install the 2 screws and 2 washers securing the upper bulkhead to the upper housing. Torque the screws to 2.26–2.82 N• m (20–25 in-lb). g320494 Figure 84 1. 8. 2. Screw Washer Install the 2 screws securing the lower bulkhead to the lower housing. Torque the screws to 2.26–2.82 N• m (20–25 in-lb).
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Motor Installation (continued) g324235 Figure 85 9. Install the 2 screws securing the RH frame assembly plate to the bulkhead. Torque the screws to 2.26–2.82 N• m (20–25 in-lb). g320273 Figure 86 10. Install the 2 screws securing the LH frame assembly plate to the bulkhead. Torque the screws to 2.26–2.82 N• m (20–25 in-lb).
PAGE 87
Motor Installation (continued) g320271 Figure 87 11. Install the shroud to the rear chute. Install the 3 screws securing the shroud to the rear chute. Torque the screws to 1.1-1.7 N • m (10-15 in-lb). 12. Install the battery container to the bulk head. Install the 4 screws and 4 washers securing the battery container to the bulk head. Torque the screws to 2.26–2.82 N• m (20–25 in-lb). g320297 Figure 88 13. Install the battery container skirt to the battery container.
PAGE 88
Motor Installation (continued) g320289 Figure 89 14. Install the 2 screws securing the battery container skirt to the battery container. g320276 Figure 90 15. Install the motor driver into the machine. Motor Driver Installation (page 8–4) 16. Install the chute control rod. WARNING When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Do not allow metal tools to short between the battery terminals and metal parts of the machine. 17.