Toro 13AX61RG848, 37770, 37771, 37772, 37775 Service Manual
...
Consumer Products
Power Max™
Snowthrower
Service Manual
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ABOUT THIS MANUAL
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.
For information specifi c to the engines used on this unit, refer to the engine chapter of this book.
Power Max model years 2004 - 2005 are covered in this manual. The manual may also be specifi ed for use on later
model products.
We are hopeful that you will fi nd this manual a valuable addition to your service shop. If you have questions or
comments regarding this manual, please contact us at the following address:
The Toro Company
Consumer Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
The Toro Company reserves the right to change product specifi cations or this manual without notice.
Copyright© All Rights Reserved
©2005 The Toro Company
TABLE OF CONTENTS
SAFETY INFORMATION
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifi cations . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
Service Information . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the R tek Engine . . . . . . . . . . . . . . . . . . . . .
Primer Button . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank, Fuel Line, Fuel Filter . . . . . . . . . . . . . . . . . .
Prime Line Routing . . . . . . . . . . . . . . . . . . . . . . . .
Engine Shroud Assembly . . . . . . . . . . . . . . . . . . . . .
1 - 1
2 - 1
2 - 3
3 - 1
3 - 1
3 - 2
3 - 2
3 - 3
3 - 3
3 - 3
CONTROLS
Quick Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Control Interlock . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Operation, Replacement & Adjustment . . . . . . . . . .
Defl ector Cable
Defl ector Cable Adjustment
Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Rod Adjustment . . . . . . . . . . . . . . . . . . .
Auger Control . . . . . . . . . . . . . . . . . . . . . . .
Auger Cable Adjustment . . . . . . . . . . . . . . . . .
Auger Brake Adjustment . . . . . . . . . . . . . . . . .
Traction Control . . . . . . . . . . . . . . . . . . . . . .
Traction Cable Adjustment . . . . . . . . . . . . . . . .
Replace & Adjust Wheel Clutch Cables . . . . . . . . . . . . . .
4 - 1
4 - 1
4 - 1
4 - 3
4 - 4
4 - 5
4 - 5
4 - 7
4 - 7
4 - 8
4 - 8
4 - 8
4 - 9
4 - 9
4 - 10
4 - 10
4 - 11
4 - 11
ii Power Max Service Manual
TABLE OF CONTENTS
TABLE OF CONTENTS
BELT REPLACEMENT
Auger Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUGER HOUSING
Auger Housing Components . . . . . . . . . . . . . . . . . . . .
Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixed Scraper . . . . . . . . . . . . . . . . . . . . . . .
Scraper Replacement . . . . . . . . . . . . . . . . . .
Adjusting the Skids and Scraper - Fixed . . . . . . . . .
Pivoting Scraper . . . . . . . . . . . . . . . . . . . . .
Scraper Replacement & Adjustment . . . . . . . . . . .
Adjusting the Skids and Scraper - Pivoting . . . . . . . .
5 - 1
5 - 2
6 - 1
6 - 1
6 - 1
6 - 1
6 - 1
6 - 2
6 - 2
6 - 2
6 - 3
AUGER GEARBOX
Auger Gearbox Removal Primary Method . . . . . . . . . . . . .
Separating the Auger & Traction Assemblies
Secondary Method . . . . . . . . . . . . . . . . . . . .
Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . .
Auger Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Disassembly & Repair . . . . . . . . . . . . .
Failure Analysis . . . . . . . . . . . . . . . . . . . . . .
Gearbox Assembly . . . . . . . . . . . . . . . . . . . .
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM
General Description . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL CLUTCH TRACTION DRIVE SYSTEM
General Description . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System Reassembly . . . . . . . . . . . . . . . . . . . . .
7 - 1
7 - 4
7 - 5
7 - 6
7 - 6
7 - 6
7 - 7
7 - 8
8 - 1
8 - 1
8 - 6
9 - 1
9 - 1
9 - 9
iiiPower Max Service Manual
TABLE OF CONTENTS
TABLE OF CONTENTS
WHEEL CLUTCH TRACTION DRIVE SYSTEM (cont.)
Wheel Clutch Disassembly . . . . . . . . . . . . . . . . . . . .
Wheel Clutch Reassembly . . . . . . . . . . . . . . . . . . . . .
DISCHARGE CHUTE
Chute & Auger Cover Removal . . . . . . . . . . . . . . . . . .
Chute Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
Electric Start System . . . . . . . . . . . . . . . . . . . . . . . .
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 - 17
9 - 20
10 - 1
10 - 4
10 - 4
10 - 4
10 - 6
11 - 1
11 - 1
11 - 1
WHEELS and TIRES
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 - 1
12 - 1
iv Power Max Service Manual
General Information
SAFETY INFORMATION
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION read the instruction because it has to do
with your safety. Failure to comply with
the instruction may result in personal
injury or even death.
This manual is intended as a service and repair manual
only. The safety instructions provided herein are for
troubleshooting, service, and repair of the Power Max™
snowthrower. The Power Max™ snowthrower operator’s
Think Safety First
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark
plug wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they were
moving whenever the engine is running or has the
potential to start.
manual contains safety information and operating tips for
safe operating practices. Operator’s manuals are available through your parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Avoid asphyxiation...
Never operate an engine in a confined area without
proper ventilation.
Avoid injury due to inferior parts...
Use only original equipment parts to ensure that
important safety criteria are met.
Avoid injury to bystanders...
Avoid burns...
Do not touch the engine, muffler, or other components
which may increase in temperature during operation,
while the unit is running or shortly after it has been
running.
Avoid fires and explosions...
Avoid spilling fuel and never smoke while working with
any type of fuel or lubricant. Wipe up any spilled fuel or
oil immediately. Never remove the fuel cap or add fuel
when the engine is running. Always use approved,
labeled containers for storing or transporting fuel and
lubricants.
Always clear the area of bystanders before starting or
testing powered equipment.
Avoid injury due to projectiles...
Always clear the area of sticks, rocks, or any other
debris that could be picked up and thrown by the
powered equipment.
Avoid modifications...
Never alter or modify any part unless it is a factory
approved procedure.
1-1Power Max Service Manual
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1-2 Power Max Service Manual
SPECIFICATIONS
Engine RPM
2-cycle 4,000 +250 -250 RPM
4-cycle 3,300 +150 -150 RPM
Auger
26” 26” (66cm) Wide & 21.5” (54.6cm) High
28” 28” (71cm) Wide & 21.5” (54.6cm) High
Auger Speed 123 RPM @ engine RPM listed above
Impeller 12” Dia. (30.5cm)
Impeller Speed 1228 RPM @ engine RPM listed above
Chute Rotation 200 degrees
Defl ector tilt angle 70 degrees
Tires Semi pneumatic 15x500x6
Pressure 17-20 psi ( 116-137kPa)
Ground speeds
Forward 0.7, 1.1, 1.5, 1.9, 2.3, 2.7 mph
(1.1, 1.8, 2.4, 3.0, 3.7, 4.3 kph)
Reverse 1.0 & 1.6 mph
(1.6 & 2.5 kph)
Height 44.5” (113cm) Approx.
Overall Width 27.5” (69.8cm) and 29.5” (74.9cm)
Length 62” (157cm)
Weight 724= 210 lbs (462kg) 826= 238 lbs (526kg)
828 & 1028= 245 lbs (539kg) 1128= 253 lbs (556kg)
Fuel Capacity
2 cycle engine 1.46 US qts (1.38l)
4 cycle engine 4 US qts (3.8l)
Fuel/oil
2-cycle Fuel Unleaded regular grade gasoline mixed at a ratio of 50:1
2.6 oz. (80ml) oil / 1 US gallon (3.8l) gasoline.
2-cycle Required oil Toro 2 cycle oil or any 2-cycle oil that is NMMA TCW3
(ISO E GD) certifi ed as an acceptable substitute.
4-cycle Fuel Unleaded regular grade gasoline (do not mix with oil).
4-cycle Oil automotive detergent oil with a service classifi cation of
SH or higher Maximum capacity 26 oz. (770ml)
The recommended weight varies with the outside temperature
For Temps Above 32
For Temps Between 00 F and
320 F ( -180 C to 00 C)
For Temps Below 00 F (-180 C) use SAE 0W30
Auger Gearbox lubricant* SAE 90 gear oil with a rating of GL5 or higher
*A multi weight may be used such as 85-120 as long as it meets the GL rating. Place the
unit on level ground and fi ll to the fi ll/check plug. Maximum capacity 4 oz (118ml).
0
F (00 C) use SAE 30W
use SAE 5W30 or SAE 10W
2-1Power Max Service Manual
SPECIFICATIONS
The following parts should be lightly coated with an anti-seize
compound when assembling after making repairs.
1. The impeller shaft, before installing the impeller pulley.
2. The engine crankshaft before installing the engine pulley.
3. The full length of the auger shaft before installing the augers.
4. The outer 5” (12.7cm) of the axle before installing the wheels.
Accessories
• Drift Breaker
• Tire Chains
• Snow Cab
• Weight Kit (Required with Cab)
2-2 Power Max Service Manual
SPECIFICATIONS
Torque Specifications
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 to all fasteners which
do not have a specific requirement identified in the
service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects
the installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to
achieve the similar stress as a dry fastener. Torque
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1
(B) Grade 5
Figure 1
(C) Grade 8
The standard method of verifying torque shall be
performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.
Figure 2
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
2-3Power Max Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the
minimum proof load specified in SAE J429. The
tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
2-4 Power Max Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately
the nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of
2-5Power Max Service Manual
SPECIFICATIONS
Other Torque Specifications
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
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Typ e 1 , Ty pe 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Baseline Torque*
Type A Typ e B
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
2-6 Power Max Service Manual
SPECIFICATIONS
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 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
2-7Power Max Service Manual
SPECIFICATIONS
U.S. to Metric Conversions
To Conve r t Into Multiply By
Miles
Yar ds
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Tempera t u re
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Pounds/Sq. In. Kilopascal
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Gallons/Minute Liters/Minute
Fahrenheit Celsius
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.1383
1.152144
0.9463
3.785
3.785
1. Subtract 32°
2. Multiply by 5/9
2-8 Power Max Service Manual
ENGINE
Service Information
The Power Max snowthrowers have both 2-cycle and
4-cycle engines. The process for obtaining parts and
service information is different between them.
4-Cycle Engine
All 4 cycle models use a Tecumseh Snow King engine.
Service information can be obtained through Tecumseh
at the following address.
Tecumseh Products Company
Engine and Transmission Group
Service Division
900 North Street
Grafton, WI 53024
Phone 262-377-2700
2-Cycle Engine
All 2-cycle models use the Toro R tek engine. Service
is handled through the Toro system. Detailed engine
repair information is available in the “E” Engine Service
Manual, Form No. 492-0647.
Servicing the R tek Engine
Use the following process to service the R tek engine.
1. Remove the three screws across the front of the
engine shroud and 2 screws on each side where the
front and rear shroud meet (Fig. 003).
Fig 003 MVC-001X
2. Remove 4 screws securing the belt covers; remove
the belt covers. (Reassembly will be much easier if
the belt covers have been removed.
3-1Power Max Service Manual
ENGINE
3. Pull the front shroud forward and up to remove. Slide
the rear cover to the rear and rotate it clockwise to
slip over the electric starter button and extension
cord plug located in the left rear corner (Fig. 004).
Fig 004 MVC-900XB
Primer Button
When depressed the primer button pressurizes the
carburetor bowl. Fuel is forced up the main tube to
the carburetor venturi. This line and button are the
atmospheric vent for the carburetor bowl. If the line
is kinked or the vent hole in the bulb is plugged, the
carburetor may fl ood.
To remove the primer button, pull the primer line off the
stem and compress the tabs. The primer will push out to
the rear (Fig. 005).
Fig 005 MVC-865XA
Ignition Switch
To remove the ignition switch, pull the wire harness off
the switch terminals. The switch is a snap in type. To
remove the switch, depress the ears on the switch body
(Fig. 006) and push the switch out through the rear of
the shroud. Switch troubleshooting is provided in the
electrical section.
Fig 006 MVC-863XA
3-2 Power Max Service Manual
ENGINE
Fuel Tank, Fuel Line and Fuel Filter
To remove the fuel tank, unscrew the gas cap, slip the
tank out of the shroud and install the cap. If there is
fuel in the tank, clamp the line, or drain the tank into a
suitable container. Remove the fuel line and fuel fi lter.
The tank is held in place by the bracket and shroud
surrounding it (Fig. 007).
Fig 007 MVC-000
Primer Line Routing
The primer line connects to the back side of the primer
then is routed over the fuel line, over the foam block
(Fig. 008).
It should be gathered and secured to the ignition switch
wires. It then goes down to the primer fi tting on top of the
carburetor (Fig. 009).
Fig 009 MVC-866XA
Engine Shroud Assembly
1. Ensure the ignition switch is in place and the wire
harness is plugged in, the primer line is attached to
the primer and the primer body is secure in its slot,
and the fuel tank, fuel line and fi lter are properly
installed.
Fig 008 MVC-865XA
3-3Power Max Service Manual
ENGINE
2. Begin in the left rear corner; slip the shroud over
the electric start button and the plug terminal for the
extension cord (Fig. 010). Then rotate the shroud
clockwise into place.
Fig 010 MVC-893XC
3. While the engine shroud is still loose, install both belt
covers. Then install and secure the front and rear
engine covers to each other and to the chassis.
3-4 Power Max Service Manual
CONTROLS
QUICK STICK
Operation
The Quick Stick is a single lever control for chute sideto-side movement and vertical movement of the defl ector
(Fig. 011).
The defl ector up and down motion is unlatched inside
the quick stick itself and a cable controls the up and
down motion.
Removing the cover just behind the chute allows access
to the chute rotation gears and chute latch (Fig. 013).
Since these gears are plastic they do not require
lubrication. The latch cable adjustment is covered in the
control adjustment section.
Fig 011 MVC-775X
When the operator places their hand on the stick the
cover is depressed, which draws a cable to unlatch the
chute (Fig. 012). Side to side motion rotates the rod and
gear and causes the chute to pivot side to side.
Fig 013 MVC-772X
Removal
1. To remove the Quick Stick, unhook the Z bend and
disconnect the defl ector cable from the underside of
the Quick Stick (Fig. 014).
Fig 012 MVC-039F
Fig 014 MVC-870XA
4-1Power Max Service Manual
CONTROLS
2. On the underside of the control panel, remove the
two screws holding the Quick Stick cover in place
(Fig. 015).
Fig 015 MVC-1869X
3. Lift the front cover and pull forward to release the
latch tabs on the rear. Set the cover aside (Fig. 016).
4. Remove the two screws that retain the rod support
to the control panel (Fig. 017).
Fig 017 MVC-819X
5. Remove the two carriage bolts and nuts on the chute
control rod and lift the Quick Stick out of the control
panel. Note the location of the cable clamp, as it is
necessary for latch cable function (Fig. 018).
Fig 016 MVC-902X
Fig 018 MVC-725F
4-2 Power Max Service Manual
CONTROLS
Disassembly
1. To begin disassembly of the Quick Stick, remove the
screw retaining the blue lever cap and remove the
cap (Fig. 019).
Fig 019 MVC-546F
3. Remove the locknut and fl at washer from the
shoulder bolt. Slide the chute control rod off and
remove the rubber washer and friction plate
(Fig. 021).
Fig 021 MVC-832S
2. Remove the two screws on the right hand side of the
chute control cover (the part that looks like a ball).
Remove both halves and set aside (Fig. 020).
Fig 020 MVC-547F
4. Hold the Quick Stick so the three screws holding
the handle halves are facing up. Remove the three
screws and lift off the top handle half (Fig. 022).
Fig 022 MVC-8335X
4-3Power Max Service Manual
CONTROLS
5. Lift the metal latch pawl off the hex on the cable
lever. Lift out the latch trigger and spring. Note the
orientation of the pawl to the lever for reassembly
(Fig. 023).
Fig 023 MVC-837X
Reassembly
1. Begin assembly by dropping the latch spring over
the boss. The straight end of the spring should be
down with the hooked end up (Fig. 025).
Fig 025 MVC-759F
6. Rotate the cable until the barrel fi tting slides off the
cable lever (Fig. 024).
Fig 024 MVC-554F
2. Slide the latch trigger over the boss until it is fully
seated, making sure that the stop on the trigger
lever is above the stop on the quick lever, as shown.
While holding the trigger lever in place, rotate the
hooked end of the spring until it hooks under the
front edge of the trigger lever as shown (Fig. 026).
A
Fig 026 MVC-758F
A. Latch trigger
4-4 Power Max Service Manual
CONTROLS
3. Reverse the disassembly process for the remainder
of the assembly.
Installation
Reverse the removal process for installation.
Note: The cable clamp must be installed on the
chute control rod or the cable latch will not
function.
CONTROL INTERLOCK
For operator convenience there is an interlock between
the auger and traction lever. Once both are engaged
you only need to hold the auger lever. This allows a
free hand to change chute direction without having to
stop. The latch mechanism is located under the dash
(Fig. 027).
Disassembly
1. Disconnect the auger and traction cables from the
levers. If this is a wheel clutch model, disconnect the
wheel clutch cables (Fig. 028).
Fig 028 MVC-171X
Fig 027 MVC-872X
2. Remove the Shoulder Screw under the left handgrip
(Fig. 029). When it is removed the Lockout Latch,
Torsion Spring, Flat Washer, and Locknut will drop
out.
Fig 029 MVC-167X
4-5Power Max Service Manual
CONTROLS
3. To remove the lockout rod, go to the right hand end.
There are 2 roll pins on the right side (Fig. 030) and
one in the lockout cam on the left (Fig. 031).
Fig 030 MVC-169X
4. Once they are driven out the lockout rod can be
moved to the side and removed (Fig. 032). The
lockout link can now be removed from the lockout
rod.
Fig 032 MVC-172X
Fig 031 MVC-170X
5. Since the auger and traction levers pivot on the
lockout rod this is the method required to replace the
levers (Fig. 033).
Fig 033 MVC-174X
Note: Steps 1 and 2 above do not need to be done
in that order. In fact you can remove the rod
without removing the shoulder bolt and vice
versa.
4-6 Power Max Service Manual
CONTROLS
Assembly
Reverse the above process for assembly.
Note the spring on the lockout latch. The end with the
slight bend goes behind the lockout latch and the hooked
end goes over the small tab. It is easiest to install the
latch mechanism then hook the end of the spring with a
wire and pull it into place (Fig. 034).
CONTROL OPERATION,
REPLACEMENT, AND ADJUSTMENT
Defl ector Cable
1. To remove the defl ector cable, depress the tabs that
retain the cable in the bracket, under the control
panel. Disconnect the Z bend on the end (Fig. 035).
Fig 034 MVC-176X
Fig 035 MVC-870X
2. Remove the cable clamp and disconnect the cable
end from the defl ector. Reverse this process to
install a new cable (Fig. 036).
Fig 036 MVC-882X
4-7Power Max Service Manual
CONTROLS
Defl ector Cable Adjustment
Make sure the Quick Stick is in the maximum rear
position and centered (Fig. 037); ensure the defl ector
is in the full upward position. Draw the slack out of the
cable and secure the clamp (Fig. 036).
Fig 037 MVC-775X
Shift Rod Adjustment
1. The adjustment point is a trunion on the upper end
of the shift rod (Fig. 039).
Fig 039 MVC-561F
SHIFT LEVER
The shift lever on the control panel is connected to the
friction wheel in the traction drive by a shift rod. Moving
the shift lever moves the friction wheel to change wheel
direction and speed (Fig. 038).
2. Pull the shift rod and arm upward as far as they will
go. With the shift lever in R2, adjust the trunion to
take the slack out and resecure (Fig. 040).
Note: Excessive slack in the linkage may cause the
drive to be in reverse when shifted into fi rst
gear.
Fig 040 MVC-560F
Fig 038 MVC-901XA
4-8 Power Max Service Manual
CONTROLS
Auger Control
The bail on the right hand handle is the auger control.
Squeeze the bail and the cable causes an idler to pivot
tensioning the auger belt (Fig. 041).
Fig 041 MVC-816X
2. Loosen the jam nut. The cable is adjusted using the
turnbuckle on the lower end of the auger cable.
Note: When rotating the turnbuckle, hold the cable
so it does not twist (Fig. 041).
3. Remove the right side belt cover. Adjust the
turnbuckle until there is a 1/16” (1.5mm) gap
between the stop and the auger clutch assembly.
Secure the jam nut on the turnbuckle (Fig. 043).
Auger Cable Adjustment
1. The auger cable adjustment should be checked after
the fi rst 2 hours of use and annually thereafter. To
begin, ensure the auger lever is in the full up position
(Fig. 042).
Fig 042 MVC-901XA
Fig 043 MVC-876X
Beginning with 2005 production there are two holes
in the idler arm (Fig. 044). The idler pulley is initially
installed in the outer hole. If necessary, the idler
can be moved to achieve the correct tension. 2004
models have only one hole in the idler.
Fig 044 MVC-016X
4-9Power Max Service Manual
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