Troy-Bilt Flurry 1400, Professional Shop Manual

Page 1: ...lity can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these instructions from time to time Therefore it may be necessary to obtain the latest mate...

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Page 3: ...s 7 Circuit failures 9 Tools 9 Switch 11 Circuit breakers 12 Motor 13 Switch box assembly 16 Servicing the switch box assembly 19 Returning to service 21 Schematic 21 Chapter 3 Belts and Pulleys Belts 23 Upper synchronous belt 24 Auger pulley 26 Motor pulley 27 Chapter 4 Auger Housing Components Rubber auger spiral replacement 29 Shave plate 29 Lower Discharge chute 30 Upper discharge chute 31 Aug...

Page 4: ...II For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 5: ...n or poor execution of the procedures described in the text If the person using this manual is uncomfortable with any procedures they encounter they should seek the help of a qualified technician or MTD Technical Support Safety This Service Manual is meant to be used along with the Operator s Manual Read the Operator s Manual and familiarize yourself with the safety and operational instructions fo...

Page 6: ...ny machinery Hearing protection in noisy environments Chemically resistant gloves when working with chemicals or solvents Respirator when working with chemical or solvents Appropriate tinted eye protection when cutting or welding Flame resistant headgear jacket chaps when cutting or welding WARNING WARNING CAUTION CAUTION Remember that some hazards have a cumulative effect A single exposure may ca...

Page 7: ...fer ence guide as well as a step by step procedure guide that does not require the user to hunt for informa tion Lubricant quantity and specification may be noted in the part of the text that covers maintenance and again in the section that covers assembly They may also be summarized in tables along with special instructions Whichever method is more appropriate will be used In many cases the infor...

Page 8: ...llows 1 Engineering level G Month of production G July 15 Day of the month 0 Last digit of the year P Plant it was built in 0 Assembly line number 0082 Number of unit built Additional technical and service information may also be available to our company authorized service center per sonnel through our company corporate offices regional parts distributors and regional service center field support ...

Page 9: ...r I is used to represent Amps The third and final value is Resistance Resistance is the opposition to current flow It is a restriction that slows down the flow of current Resistance is measured in Ohm s The greek letter omega Ω or the capital letter R is used to represent Ohm s Ohm s law Ohm s law states that voltage is the product of resis tance times current It is written as V I x R An example o...

Page 10: ...sumed to have 0 ohms if the proper size wire is used and there is no corrosion in the wire the resistance will be too small to worry about The light bulb uses 12 volts 4 amps x 3 ohms 12 volts The battery has 12 volts that equals the 12 volts used by the light bulb AC electricity AC electricity is used to provide electricity to homes and businesses because it can be easily transmitted over long di...

Page 11: ... be a lamp a motor a resistor a starter 3 All circuits must have a complete path back to the voltage source This is also known as having continuity 4 Most circuits have additional components like switches and fuses Types of circuits There are three ways a circuit can be wired They are Series Parallel Series parallel Series Series circuits are wired so that the current has only one path to follow S...

Page 12: ...so that current has multiple paths to follow See Figure 2 5 Series parallel Series parallel circuits have some sections wired in series and some in parallel See Figure 2 6 Figure 2 5 Figure 2 6 For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 13: ... its path back to the power source A common example of this is a blown fuse Increased resistance Increased resistance is as the name implies an increase in resistance Arguably the most common electrical failure and the hardest to find is when there is a loose connection or cor rosion It is not an open because there is some current that can get through but the increase in resistance is enough to af...

Page 14: ... be isolated from the circuit Inductive amp meter An inductive amp meter sometimes referred to as an amp clamp or clamp meter measures current following through a wire by the magnetic field created around the wire Clamp meters are very important when dealing with currents over 10 amps A DMM typically can not measure current over 10 amps Clamp meters are also helpful because they can read current i...

Page 15: ...ting the switch When testing the switch treat it as two switches the common terminal and the NO terminal as one switch and common to the NC terminal as another To test the switch 1 Disconnect the power supply 2 Remove and open the switch box assembly by following the steps described in the switch box section of this chapter 3 Remove the switch from the circuit 4 Set the DMM to the ohms scale Ω 5 W...

Page 16: ...n has to be pushed in to restore the connection between the contacts The circuit breaker may have to cool down for a few minutes before the breaker can be reset See Figure 2 10 To test a circuit breaker 1 Let the circuit breaker cool down for at least five minutes and reset the breaker NOTE If the circuit breaker will not reset unplug the wires from the breaker and let it cool down for five minute...

Page 17: ...e Figure 2 12 NOTE Paper clips can be inserted into the back side of the connectors and used as extensions for the DMM probes See Figure 2 12 6 Connect the snow thrower to a power source 7 Operate the control bail of the snow thrower 8 The DMM should read source voltage NOTE If the DMM does not read source voltage back trace the harness to find the problem before condemn ing the motor 9 If the DMM...

Page 18: ...he spacer in place when the motor is removed 6 Lift the motor and foam gasket out of the snow thrower NOTE If reusing the motor keep the foam gasket on it and protect the gasket from damage NOTE If the foam gasket is damaged it must be replaced To install a motor 1 Mount the motor to the side plate so that the black wire is on the top front side of the motor and the white wire is at the bottom rea...

Page 19: ...meets it See Figure 2 16 4 Connect the motor harness 5 Install the harness clip 6 Install the belts and the motor cover by following the procedures described in Chapter 3 Belts and Pul leys 7 Test run the motor in a safe area before returning it to service Figure 2 16 Sealant Foam gasket For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 20: ... 3 Slide the control bail out of the switch box assembly 4 Slip the harness out of the clip on the right side of the middle handle See Figure 2 18 5 Remove the two bolts that hold the switch box to the handle bar using a 7 16 wrench See Figure 2 19 Figure 2 17 Control bail Handle bar Figure 2 18 Harness Clip Figure 2 19 switch box Bolts For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts ...

Page 21: ...ar of the top motor cover to the bottom motor cover See Figure 2 21 8 Remove the three screws that hold the right side of the motor cover to the auger housing using a 2 phil lips screw driver See Figure 2 22 9 Remove the motor cover from the right side of the machine Figure 2 20 Screws Figure 2 21 Screw Figure 2 22 Screws For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 22: ... 2 23 11 Disconnect the harness from the motor harness 12 Install the switch box assembly by following the pre vious steps in reverse order 13 Test run the snow thrower in a safe area before returning it to service Figure 2 23 For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 23: ... thrower 2 Remove the safety key 3 Remove the three housing screws using T 20 torx driver See Figure 2 24 Remove the switch box by following the steps described in the switch box sec tion of this chapter 4 Carefully peel back the label on the switch box until the housing seam if fully exposed See Figure 2 25 5 Carefully split the housing Figure 2 24 Safety key Screws Figure 2 25 Seam For Parts Cal...

Page 24: ...t breaker A Pull the circuit breaker out of the housing NOTE The circuit breaker is a tight fit in the hous ing B Disconnect the wires C Install by following the previous steps in reverse order To remove replace the harness A Disconnect the wire that goes from the main harness to the switch B Disconnect the wire on the circuit breaker closest to the main harness assembly C Slide the main harness a...

Page 25: ... that the condition has been repaired 2 Cycle the circuit at least ten times 3 Allow the machine to cool down for a couple of hours 4 Re test the machine to verify the condition does not re appear 5 If the condition does not re appear return the machine back to service Schematic 9 3OXJ KLWH ZLUH 0RWRU LUFXLW EUHDNHU 6ZLWFK ODFN ZLUH For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 26: ...Snow Flurry 1400 22 For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 27: ...e reduction pulley to the auger This belt has a spring load idler to hold a constant tension on the belt This belt has a 3 5 1 reduction in speed spinning the auger at its most efficient speed Lower ribbed belt To change the lower belt 1 Unplug the power cord of the snow thrower 2 Remove belt cover by removing the five screws that hold it to the snow thrower using a 2 phillips screw driver See Fig...

Page 28: ...e the upper belt 1 Disconnect the power supply of the snow thrower 2 Remove the lower belt by following the procedures described in the lower ribbed belt section of this chapter 3 Remove the three screws that hold the right side of the motor cover to the auger housing using a 2 phillips screw driver See Figure 3 4 4 Remove the screw that holds the front left corner of the motor cover to the auger ...

Page 29: ...otor pul leys 10 Using a large flat head screw driver gently pry on the head of the reduction pulley bolt to apply tension to the belt 11 While holding tension on the belt tighten the reduc tion pulley nut using a 13mm wrench NOTE The prying force applied to the bolt head will pre vent the bolt from turning while tightening the nut 12 Install the lower belt and the covers by following 1 5 in rever...

Page 30: ...r ribbed belt section of this chapter 3 Block the auger by placing a piece of wood down the discharge chute See Figure 3 8 4 Remove the pulley nut using a 17mm wrench See Figure 3 9 NOTE The pulley nut has right hand threads 5 Slide the pulley off of the auger Figure 3 8 Piece of wood Figure 3 9 17mm wrench For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 31: ...s rotor shaft by inserting a flat head screw driver into the slot in the end of it on the fan side See Figure 3 11 4 Unthread the motor pulley in a counter clockwise direction using a large pair of pliers See Figure 3 12 5 Install the motor pulley by following the previous steps in reverse order NOTE Hand tighten the motor pulley onto the motor shaft NOTE DO NOT put a thread locking compound on th...

Page 32: ...Snow Flurry 1400 28 For Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 33: ...and bolts until they start to com press the rubber NOTE Over torquing the nuts and bolt can cause the bolt head to pull through the rubber 4 Test run the snow thrower in a safe area before returning it to service Shave plate To replace the shave plate 1 Disconnect the power supply of the snow thrower 2 Lay the snow thrower down on its side 3 Remove the three screws that hold the shave plate to the...

Page 34: ... from the lower chute 4 Tip the snow thrower back so that the chute opening is facing up 5 If necessary insert the springs into the detent ratchet 6 Apply a light coat of lithium grease to the teeth sec tion of the detent ratchet 7 Install the detent ratchet and spring in the auger housing so that the spring slide over the bosses in the housing See Figure 4 5 8 Insert the lower discharge chute int...

Page 35: ...ply of the snow thrower 2 Remove the lower belt by following the procedures described in Chapter 3 Belt and Pulleys 3 Remove the auger pulley by following the procedures described in Chapter 3 Belt and Pulleys 4 Remove both bearing retainers by removing the bearing retainer screws using a 7mm wrench See Figure 4 7 5 Remove the two screws that hold the right side panel to the auger housing using a ...

Page 36: ...one is the right 12 Remove the nuts and bolts that hold the rubber spi rals to the auger assembly using a 3 phillips screw driver and a 10mm wrench See Figure 4 10 13 Slide the left bearing and bearing cup off of the auger shaft See Figure 4 11 14 Slide the auger end mount off of the auger shaft 15 Remove the key 16 Remove the snap ring using a pair of retaining ring pliers Figure 4 9 Figure 4 10 ...

Page 37: ...emove the key 21 Remove the snap ring using a pair of retaining ring pliers 22 Install the auger by following the previous steps in reverse order NOTE Apply a small amount of releasable thread locking compound such as Loctite 242 blue to the screw that retains the right bearing 23 Test run the snow thrower in a safe area before returning it to service Figure 4 12 Screw and washer For Parts Call 60...

Page 38: ...oulder spacer and a washer under the reduction pulley See Figure 4 13 5 Remove the motor by following the procedures described in Chapter 2 Electrical 6 Remove the three bearing retainer screws using a 7mm wrench See Figure 4 14 7 Remove the screw that holds the roller axle to the side panel using a 10mm wrench NOTE A pair of locking pliers can be used to hold the axle while removing the screw See...

Page 39: ... the nut and bolt that holds the spacer and motor mounting plate to the side panel using a pair of 10mm wrenches See Figure 4 18 12 Remove the shoulder bolt spring and the idler pulley using a 16mm wrench and a 10mm wrench 13 Remove the idler bracket using a 10mm wrench and a 22mm wrench 14 Install the left side panel by following the previous steps in reverse order 15 Test run the snow thrower in...

Page 40: ...to the auger housing using a 2 phillips screw driver See Figure 4 19 4 Remove the three screws that hold the right side of the motor cover to the auger housing using a 2 phillips screw driver See Figure 4 20 5 Remove the three bearing retainer screws using a 7mm wrench See Figure 4 21 Figure 4 19 Screw Figure 4 20 Screws Figure 4 21 Bearing retainer screws For Parts Call 606 678 9623 or 606 561 49...

Page 41: ... screw that holds the roller axle to the side panel using a 10mm wrench 9 A pair of locking pliers can be used to hold the axle while removing the screw See Figure 4 15 10 Slide the side panel out from in between the lower handle and the auger housing 11 Install the right side panel by following the previous steps in reverse order 12 Test run the snow thrower in a safe area before returning it to ...

Page 42: ...apter 6 Remove the two carriage bolts and nuts that hold the lower handle bar to the bottom of the auger housing using a 10mm wrench See Figure 4 25 7 Remove the two screws that hold the left side panel to the auger housing using a 2 phillips screw driver See Figure 4 26 8 Slide the auger housing out of the snow thrower 9 Install the auger housing by following the previous steps in reverse order N...

Page 43: ...ddle section 1 Disconnect the power supply of the snow thrower 2 Slip the harness out of the clip on the right side of the middle handle See Figure 4 29 3 Remove the two wing nuts and carriage bolts that hold the upper handle to the middle handle 4 Gently spread the upper handle section while sliding it off of the snow thrower 5 Remove the two wing nuts and carriage bolts that hold the middle hand...

Page 44: ... 4 31 5 Remove the nuts and bolts that hold the lower han dle to the right side panels using a pair of 10mm wrenches 6 Remove the two carriage bolts and nuts that hold the lower handle bar to the bottom of the auger housing using a 10mm wrench See Figure 4 32 7 Slide the lower handle off of the snow thrower 8 Install the lower handle by following the previous steps in reverse order 9 Test run the ...

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