Consumer Products Power Max™ Snowthrower Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK
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 specific 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.
TABLE OF CONTENTS SAFETY INFORMATION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 SPECIFICATIONS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 ENGINE Service Information . . . . . . Servicing the R tek Engine . . . Primer Button . . . . . . . . . Ignition Switch . . . . . . . . . Fuel Tank, Fuel Line, Fuel Filter Prime Line Routing . . . . . . Engine Shroud Assembly . . . . . .
TABLE OF CONTENTS BELT REPLACEMENT Auger Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Traction Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 AUGER HOUSING Auger Housing Components . . . . . . . . . . . . . Skids . . . . . . . . . . . . . . . . . . . . . . . . . Scraper . . . . . . . . . . . . . . . . . . . . . . . Fixed Scraper . . . . . . . . . . . . . . . . Scraper Replacement . . . . . . . . . . . Adjusting the Skids and Scraper - Fixed . . Pivoting Scraper .
TABLE OF CONTENTS WHEEL CLUTCH TRACTION DRIVE SYSTEM (cont.) Wheel Clutch Disassembly . . . . . . . . . . . . . . . . . . . . 9 - 17 Wheel Clutch Reassembly . . . . . . . . . . . . . . . . . . . . . 9 - 20 DISCHARGE CHUTE Chute & Auger Cover Removal . . . . . . . . . . . . . . . . . . Chute Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . .
SAFETY INFORMATION General 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.
THIS PAGE INTENTIONALLY LEFT BLANK 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 Deflector 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.
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.
SPECIFICATIONS Torque Specifications Fastener Identification 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. 2 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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) 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.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 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.
SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals 1/64 1/32 3/64 1/16 5/64 3/32 1/8 mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 9/64 0.140625 3.572 0.15625 3.969 11/64 0.171875 4.366 0.1875 4.762 0.203125 5.159 5/32 3/16 13/64 7/32 0.21875 5.556 15/64 0.234375 5.953 0.2500 6.350 17/64 0.265625 6.747 1/4 9/32 0.28125 7.144 19/64 0.296875 7.541 0.3125 7.
SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
ENGINE Service Information Servicing the R tek Engine The Power Max snowthrowers have both 2-cycle and 4-cycle engines. The process for obtaining parts and service information is different between them. Use the following process to service the R tek engine. 4-Cycle 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). All 4 cycle models use a Tecumseh Snow King engine.
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). 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 Fig 004 MVC-865XA MVC-900XB Ignition Switch Primer Button When depressed the primer button pressurizes the carburetor bowl.
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 filter. The tank is held in place by the bracket and shroud surrounding it (Fig. 007). It should be gathered and secured to the ignition switch wires. It then goes down to the primer fitting on top of the carburetor (Fig. 009).
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.
CONTROLS The deflector up and down motion is unlatched inside the quick stick itself and a cable controls the up and down motion. QUICK STICK Operation The Quick Stick is a single lever control for chute sideto-side movement and vertical movement of the deflector (Fig. 011). Fig 011 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.
CONTROLS 2. On the underside of the control panel, remove the two screws holding the Quick Stick cover in place (Fig. 015). 4. Remove the two screws that retain the rod support to the control panel (Fig. 017). Fig 017 Fig 015 3. Lift the front cover and pull forward to release the latch tabs on the rear. Set the cover aside (Fig. 016). Fig 016 5. Remove the two carriage bolts and nuts on the chute control rod and lift the Quick Stick out of the control panel.
CONTROLS Disassembly 1. To begin disassembly of the Quick Stick, remove the screw retaining the blue lever cap and remove the cap (Fig. 019). 3. Remove the locknut and flat washer from the shoulder bolt. Slide the chute control rod off and remove the rubber washer and friction plate (Fig. 021). Fig 021 Fig 019 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). 4.
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 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). MVC-837X Fig 025 6. Rotate the cable until the barrel fitting slides off the cable lever (Fig. 024). Fig 024 MVC-759F 2.
CONTROLS 3. Reverse the disassembly process for the remainder of the assembly. 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). 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.
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 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. MVC-169X Fig 032 MVC-172X 5. Since the auger and traction levers pivot on the lockout rod this is the method required to replace the levers (Fig. 033).
CONTROLS Assembly CONTROL OPERATION, REPLACEMENT, AND ADJUSTMENT Reverse the above process for assembly. Deflector Cable 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). 1. To remove the deflector cable, depress the tabs that retain the cable in the bracket, under the control panel.
CONTROLS Deflector Cable Adjustment Shift Rod Adjustment Make sure the Quick Stick is in the maximum rear position and centered (Fig. 037); ensure the deflector is in the full upward position. Draw the slack out of the cable and secure the clamp (Fig. 036). 1. The adjustment point is a trunion on the upper end of the shift rod (Fig. 039). Fig 039 Fig 037 MVC-775X 2. Pull the shift rod and arm upward as far as they will go.
CONTROLS 2. Loosen the jam nut. The cable is adjusted using the turnbuckle on the lower end of the auger cable. 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). 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.
CONTROLS To determine if the pulley should be moved, proceed as follows: remove the right side belt cover. With the engine off, engage the auger lever. If there is more than 1” 2.5cm) gap between the idler arm and the stop, move the pulley to the inner hole (Fig. 045). If the gap is less than 1” (2.5cm) keep the pulley in the outer hole. If adjustment is necessary, loosen the bolt through the welded washer/nut and rotate the washer/nut to achieve the gap. Secure the bolt (Fig. 046).
CONTROLS Traction Cable Adjustment 1. The traction lever should be in the full upright position with some slack in the traction cable to begin adjustment (Fig. 047). 2. Adjust using the turnbuckle; hold the cable to prevent twisting (Fig. 048). Fig 049 MVC-895X REPLACE AND ADJUST WHEEL CLUTCH CABLES (wheel clutch models only) Fig 048 MVC-894X 3. Locate the traction rod on the left side just below the belt cover. Clutch Cable Replacement 1.
CONTROLS 2. Remove nut and washer that attach the cable clamp to the handle (Fig. 051). Fig 051 4. Reach under the shift plate and compress the small ears on the cable fitting (Fig. 052). The cable fitting can then be pushed out of the shift plate. 4-12 Fig 053 MVC-889XYL 3. Slip the cable Z bend out of the wheel clutch lever on the handle. Fig 052 5. Disconnect the lower end of the cable from the shift collar (Fig. 053). MVC-899X MVC-898XB Assembly 1.
CONTROLS 2. Hook the upper end of the cable to the wheel clutch lever and install the cable clamp to the handle. Go to Adjusting Clutch Cables for the adjustment procedure before securing the clamp. 2. Pull the cable jacket down gently until the wheel clutch lever is down and the slack is out of the cable, and then tighten the cable clamp nut securely (Fig. 056). 3. Install the covers and test run the unit. Adjusting Clutch Cables 1. Loosen the cable clamp nut (Fig. 055). Fig 056 MVC-889XYL 3.
THIS PAGE INTENTIONALLY LEFT BLANK 4-14 Power Max Service Manual
BELT REPLACEMENT AUGER BELT 1. To replace the belts begin by removing both belt covers (Fig. 058). (On 2-cycle models only, remove 3 screws holding the front half of the engine shroud to the chassis and the rear shroud. The belt cover slides under the front of the engine shroud so this will make belt cover removal much easier.) 3. Remove the brake assembly for more working room. Disconnect the spring, then remove the two bolts through the side plate (Fig. 060). B A C Fig 060 A. Spring B.
BELT REPLACEMENT 5. Remove the bolt securing the engine pulley to the crankshaft. If necessary, you can hold the hub between the pulley and engine to keep the crankshaft from turning. Remove the pulley flange and the auger belt from the crankshaft (Fig. 062). TRACTION BELT To replace the traction belt, perform steps 1-5 above to remove the auger belt. Then proceed with the following steps. 1. Slip the center section of the crankshaft pulley off the crankshaft (Fig. 064).
BELT REPLACEMENT 3. Move the link to the side and let it rest in the saddle provided (Fig. 066). Reach down alongside the link and remove the belt from the lower pulley. Then remove the belt from the crankshaft pulley. Fig 066 Belt Adjustment Belt adjustments are made by adjusting the control cables. See the Controls Section for the procedure. MVC-888XB 4. Reverse the process to install a new belt. 5. Check for proper clearance between the belt and belt guide.
THIS PAGE INTENTIONALLY LEFT BLANK 5-4 Power Max Service Manual
AUGER HOUSING AUGER HOUSING COMPONENTS SCRAPER The Power Max snow throwers are offered in two widths: 26” and 28” (66cm and 71cm). The augers, auger shaft, housing, and scrapers are made in both widths, but all other auger components are the same. The auger case halves, gears, impeller and impeller shaft, chute, etc. are interchangeable. The scraper is a replaceable surface attached to the leading edge of the auger housing.
AUGER HOUSING Adjusting the Skids and Scraper - Fixed Scraper models 1. Check the tire pressure. It must be between 17 and 20 psi (116-137 kPa) and the same on both sides so the machine sets level. 2. Loosen the nuts that secure both skids so the skids can slide up and down easily. 3. Support the side plates so they are at least ½” (13mm) above a level surface (Fig. 070). Pivoting Scraper A pivoting scraper is more complex but has advantages when used on paved surfaces.
AUGER HOUSING Adjusting the Skids and Scraper - Pivoting Scraper Models 1. Check the air pressure in the tires. They must be between 17 and 20 psi (116-137 kPa) and the same on both sides so the machine sets level. 2. Move the snowthrower onto a level surface. 3. Loosen the nuts that secure both skids to the auger sides until the skids slide up and down easily. 4. For use on a smooth paved surface, push down on the handles to raise the auger. This will allow the scraper to move fully forward.
THIS PAGE INTENTIONALLY LEFT BLANK 6-4 Power Max Service Manual
AUGER GEARBOX The auger gearbox contains a worm gear and a helical gear. It is driven by a clutched belt from the engine. 2. (All models) Remove the two-piece belt cover (Figs. 073 and 074). The first step in making repairs to the auger gearbox is to remove the auger assembly from the auger housing. AUGER GEARBOX REMOVAL, PRIMARY METHOD (MINIMUM DISASSEMBLY) 1. (2-cycle models only) Remove the 3 screws connecting the front and rear engine cover.
AUGER GEARBOX 3. Remove the belt guide around the crankshaft pulley (Fig. 075). Be careful to avoid bending the guide. 5. Remove the brake spring (Fig. 077). Fig 077 Fig 075 MVC-008X MVC-007F 6. Remove the auger brake assembly (Fig. 078). 4. Remove 2 capscrews for the auger brake assembly (Fig. 076).
AUGER GEARBOX 7. Remove the crankshaft pulley capscrew (Fig. 079), the front section of the pulley and the belt. Fig 079 MVC-011X 8. Loosen the 2 set screws on the auger pulley. A long extension and a ratchet will be necessary (Fig. 080). Fig 080 Power Max Service Manual 9. Remove two capscrews on each side that secure the auger bearings to the auger side plate (Fig. 081). Fig 081 MVC-769X 10. Disconnect the spring on both ends of the pivoting scraper (Fig. 082).
AUGER GEARBOX 11. Pull the auger forward a little, slide the pulley from the auger gearbox input shaft and pull the key out of the shaft. The auger assembly should pull out to the front. SEPARATING THE AUGER AND TRACTION ASSEMBLIES SECONDARY METHOD Note: If you cannot remove the pulley from the input shaft, it will be necessary to separate the auger and traction assemblies to get better access to the auger pulley. See Separating the Auger and Traction Assemblies, page 7-4.
AUGER GEARBOX 3. Remove the two carriage bolts on the chute control rod (Fig. 086). GEARBOX INSTALLATION 1. Apply a light coat of anti-seize to the auger shafts and the impeller shaft. Install the impeller and augers and secure with the capscrews and locknuts. On models with the pivoting scraper, install the scraper over the ends of the auger shaft. Slide the auger shaft bearings on the ends of the auger shaft. 2. Insert the impeller shaft through the bearing in the rear of the auger housing.
AUGER GEARBOX AUGER GEARBOX REPAIR 4. The impeller shaft can now be removed (Fig. 089). Lubrication The proper lubricant is 90-weight gear oil. A multi-weight such as 85-120 is acceptable as long as it encompasses the 90-weight rating. The oil must also have an extreme pressure (EP) rating of GL5 or higher. With the gearbox setting approximately level, fill until oil runs out of the fill/ check plug. Total capacity is about 4 oz. (118ml). A B Gearbox Disassembly and Repair 1.
AUGER GEARBOX 9. Now inspect the worm and worm gear. If either are damaged replace them both. When gears run together, they develop wear patterns unique to the two of them. Replacing only one gear will result in early failure (Fig. 090). Occasionally a drop of two of oil will get between the bushing and ring. When the auger drive is disengaged, the ring will relax and that oil might drip into the auger housing. At this rate the machine can be used for several years without any significant oil loss.
AUGER GEARBOX Gearbox Assembly 1. Use a wire brush or fine sandpaper to clean the auger shaft. A clean, smooth shaft will help avoid damage when installing new bushings and seals. Clean the old seal material from the case mating surfaces. Scrape, then use liquid gasket remover. (Fig. 092). Fig 092 DSC-1167 2. If new bushings are to be installed in the gear case halves, now is the time.
AUGER GEARBOX 5. To assemble the worm shaft, start with the end opposite the worm. Install a snap ring (sharp edge towards the rear of the gearbox), thrust washer, thrust bearing, thrust washer, bushing and seal. There is also a bushing on the worm end of the seal (Fig. 095). 7. Clean the case halves by scraping; then apply a liquid gasket remover. To ensure a good seal case halves must be clean and dry. Apply a thin coat of Hylomar (Toro PN 505-129) to both halves.
THIS PAGE INTENTIONALLY LEFT BLANK 7-10 Power Max Service Manual
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM In forward the wheel will contact the left side of the drive plate (Fig. 099). GENERAL DESCRIPTION The traction drive system begins with a belt from the engine crankshaft to a combination pulley/drive plate. The belt is tensioned by a spring loaded idler so the pulley/drive plate rotates whenever the engine is running (Fig. 098). A B A Fig 099 A. Friction Wheel Fig 098 MVC-009F.jpg A. Idler MVC-003A.jpg B.
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM 2. Remove the upper and lower covers and bottom pan (Fig. 100). 4. Pull the right hand end of the shaft out of the traction housing. Optional: The chain contains a master link, which also can be removed (Fig. 102). 5. Slide the shaft out of the sprocket, slip the chain off, then remove the sprocket. Note: There is a thrust washer that may stick to the bushing on the sprocket (Fig. 102). A B A C Fig 100 A. Upper Cover B. Lower Cover MVC-9012X.jpg C.
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM 6. Remove the large hairpin on either end of the axle (Fig. 103). 8. Remove the two capscrews securing the bearing retainers to each side of the traction frame. Slide the bearings and retainers off the hex shaft (Fig. 105). The bearings are secured to the retainers with Loctite and are replaced as an assembly. A A Fig 103 MVC-1900X.jpg A. Hairpin Cotter Fig 105 MVC-864XYZ.jpg A. Bearing Retainer 7. Slide the axle a little to the right.
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM 10. Now the shift rod bracket and hex shaft can be moved to separate the shift rod from the trunion (Fig. 107). 11. Remove the hairpin from the speed control link (Fig. 108). This is most easily accessed from the top of the machine. The link is on the left side under the belt cover. Slide the link out of the pulley pivot assembly. A B A Fig 107 A. Shift Rod MVC-1002X.jpg Fig 108 B. Trunion MVC-897X.jpg A.
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM 13. Remove the snap ring from both ends of the pulley pivot assembly shaft (Fig. 110). The nylon bushings can be removed now or when the pulley pivot assembly is removed. 15. Slip the belt off of the pulley and slide the pivot assembly to the side to remove the rod ends from the side plate (Fig. 112). A A Fig 112 Fig 110 MVC-1007X.jpg MVC-1004X.jpg A. Pivot Assembly A. Snap Ring 14.
NON-WHEEL CLUTCH TRACTION DRIVE SYSTEM Reassembly Reassemble in reverse order. Reassembly notes: 1. If you removed the master link from the chain, it must be assembled with the closed end of the master link going in the direction of rotation in forward gear (Fig. 114). Fig 114 MVC-051X.jpg 2. Fastener Torque A. All fasteners seated against plastic should be securely tightened but not deform the plastic. B. Self tapping screw for the ends of the intermediate shaft. 170 - 300 in-lbs. (196 - 345kg/com). 3.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 2. Remove upper and lower covers (Fig. 116). GENERAL DESCRIPTION The Freewheel Steering system is used on 28” models. Handle mounted triggers allow clutching the wheels simultaneously or independently, so one or both wheels can “freewheel.” This feature makes turning, reversing, and traction control simple and efficient. When the drive is engaged, it is engaging the friction wheel.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 4. Remove 2 cap screws securing the bearing retainers that hold the hex shaft to each side of the traction assembly and remove both bearing retainers (Fig. 118). 6. Remove extension spring - Unhook spring from lower clutch collar and housing (Fig. 120). Note: This will ease removal and reinstallation of the drive chains. Fig 120 Fig 118 MVC-786.jpg MVC-897springX.jpg 7.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 8. Unbolt upper end of shift brace from housing (Fig. 122 and 123). Fig 122 9. Remove both roller chains from 32-tooth gears and lift wheel clutch assembly from traction unit (Fig. 124). MVC-2200X.jpg Fig 124 MVC-900XC.jpg Note: Install a screw and washer into each end of the shaft to keep the parts from sliding off (Fig. 125). Fig 123 MVC-894XYX.jpg Fig 125 MVC-901XB.jpg To continue with disassembly of the clutch mechanism, go to page xx.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 10. Remove both hairpins on either side of the axle of 44-tooth gear (Fig. 126). Fig 126 MVC-853X.jpg 11. Remove woodruff key from one side of axle shaft by sliding the 44-tooth gear inward towards the center of the shaft to expose the woodruff key. Pry up on the outside edge of the key to remove it (Fig. 127). 12. Slide axle shaft out through bearing retainer one at a time, holding onto the 44 tooth gear (Fig. 128). Fig 128 13.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 14. Now you can remove the other half of the axle shaft with the 44-tooth gear (Fig. 130). Fig 132 Fig 130 MVC-860X.jpg MVC-860XYZ.jpg 16. If not already done, remove the bearing retainer that holds the hex shaft (Fig. 133). 15. Remove the two screws from the shift rod bracket and remove the traction control lever and bracket assembly from the friction wheel (Fig. 131 and 132). Fig 133 Fig 131 Power Max Service Manual MVC-864XYZ.jpg MVC-859X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 17. Remove hex shaft clutch assembly / friction wheel from housing (Fig. 134). Fig 134 MVC-867X.jpg 18. Remove friction wheel from hex shaft by removing the 3 nuts and bolts that hold the friction wheel to the plate on the hex shaft (Fig. 135). 19. Move snowthrower to the upright position and remove belt cover (Fig. 136). Fig 136 20. Remove extension cover (Fig. 137). Fig 137 Fig 135 9-6 MVC-861XB.jpg MVC-862X.jpg MVC-858X2.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 21. Remove hairpin cotter connecting speed control linkage to the pivot pulley plate assembly (Fig. 138). Fig 138 MVC-863XB.jpg 22. Remove extension spring from housing (Fig. 139). Fig 139 Power Max Service Manual 23. Slide speed control linkage from pivot pulley plate assembly (Fig. 140). Fig 140 MVC-865XB.jpg 24. Turn the snowthrower back onto the auger housing. MVC-864X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 25. Remove retaining ring from both sides of housing (Fig. 141) and slide the nyliner bushing off the pivot pulley plate shaft (Fig. 142). Fig 141 MVC-866XB.jpg 26. Tilt pivot pulley assembly to release the traction belt tension and remove belt from traction pulley (Fig. 143). Fig 143 MVC-868X.jpg 27. Remove the pivot pulley plate assembly from the housing (Fig. 144). Fig 142 MVC-866Xny.jpg Fig 144 9-8 MVC-869X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 28. Remove the locknut from pivot pulley and separate pulley from pivot plate (Fig. 145 and Fig. 146). DRIVE SYSTEM REASSEMBLY 1. Install pivot plate assembly into the housing and install belt. The idler pulley should be pushed away from you to install the pivot plate (Fig. 147). A Fig 145 MVC-870XB.jpg Fig 147 MVC-036X.jpg A. Idler Pulley 2. Install the two bushings and the two “C” clips onto the pivot plate shaft (Fig. 148). Fig 146 MVC-010X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 3. Install the speed control linkage through the pivot plate and install the hair clip into the hole of the speed control linkage on the outside of the pivot plate (Fig. 149). A Fig 151 B Fig 149 A. Hairpin Cotter MVC-039X.jpg B. Speed Control Link 4. Install long end of spring to cut out on the pivot plate (Fig. 150) and the short end of the spring to the frame (Fig. 151). MVC-041X.jpg 5. Install friction wheel assembly.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 6. Before mounting the friction wheel assembly, install the chains onto the 8-tooth sprockets making sure the closed end of the master link is going in the direction of rotation in the forward gears (Fig. 153 and 154). 7. Install both bearing retainers (If both were removed) (Fig. 155). Fig 155 Fig 153 MVC-864XYZ.jpg MVC-051X.jpg 8.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 9. Make sure the axle bearing end that is holding the axle shaft is on the bottom (Fig. 157). Fig 157 MVC-857X.jpg 10. 44-tooth gears should have hub facing inward (Fig. 158). A Fig 158 11. Slide one end of the axle shaft with tube into the housing (Fig. 159). Fig 159 MVC-052X.jpg 12.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 13. Insert the woodruff key onto the axle shaft evenly and make sure the 44-tooth gear can ride over the shaft freely (Fig. 161). 15. Lightly coat the 44-tooth sprocket with anti-seize (Fig. 163). Fig 163 Fig 161 MVC-2205X.jpg MVC-059X.jpg 14. Position the hole for the hairpin cotter between the 2 washers and push the hairpin cotter into place (Fig. 162). Repeat for the other side. 16.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 17. Install wheel clutch assembly with the brace shift plate facing away and up towards housing making sure collars are correctly installed with the “RIGHT” and “LEFT” facing inward and the right and left flanges are facing you (Fig. 165). A 19. Attach the shift brace plate to the housing (Fig. 167). B Fig 167 Fig 165 A. Left Collar MVC-2200X.jpg MVC-894XYX.jpg 20. Torque the two intermediate shaft screws to 170 to 300 in-lbs. (19.2 to 33.9 Nm) (Fig. 168). B.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 21. Install the 2 extension springs from the lower part of the shift collar flange (Fig. 169) to the housing (Fig. 170). 22. Install Z bend of the clutch cable from outside to inside of the shift collar (Fig. 171). Fig 171 Fig 169 MVC-876XYZ.jpg MVC-032XZV.jpg 23. Install shift rod / traction rod lever onto the housing (Fig. 172) making sure the traction control fits into the friction wheel (Fig. 173). Fig 170 MVC-899XB.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 25. Install the upper and lower covers, with the upper cover over lapping the lower cover (Fig. 175). Fig 173 MVC-031XYX.jpg Fig 175 MVC-2193X.jpg 24. Install the lower cover (Fig. 174). 26. Connect the shift linkage to the shift rod / traction rod lever (Fig. 176). Fig 174 MVC-872XYY.jpg Fig 176 9-16 MVC-874XYY.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 27. Wheels are installed with the “V” tread rotation forward (Fig. 177). WHEEL CLUTCH DISASSEMBLY 1. Remove 11-tooth gear from 32-tooth gear by sliding it from the shaft (Fig. 179). Fig 177 MVC-880X1.jpg Fig 179 MVC-876XB.jpg 28. Bolt wheel hub to axle shaft and torque to 115 + 15 in-lbs. (12.99 + 1.7 Nm) (Fig. 178). 2. Slide off washer behind the 11-tooth gear (Fig. 180). Fig 178 MVC-884XT.jpg Fig 180 MVC-877X.jpg 29.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 3. Remove 32-tooth sprocket gear and the thrust washer from the shaft (Fig. 181). 5. Unbolt the 4 guide collars from the shaft (Fig. 183). Fig 183 Fig 181 MVC-881X.jpg MVC-878XB.jpg 4. Remove shift collar and flat washer from the shaft (Fig. 182). 6. Remove the wheel clutch components from the other end of the shaft (Fig. 184). Note: Shift collars are marked right and left hand at the top of the inside flange (A).
WHEEL CLUTCH TRACTION DRIVE SYSTEM 7. Remove the 3 (per gear) compression springs from under the pawls and set aside (Fig. 185). Fig 185 MVC-884XB.jpg 9. Remove the retainer plate off of the gear hub (Fig. 187). Fig 187 MVC-888XWC.jpg 8. Remove 6 (per side) T-27 torx screws that hold the pawl supports (Fig. 186). Fig 186 Power Max Service Manual MVC-886X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 10. Remove pawl pins and pawls with from the 32-tooth gear (Fig. 188 and Fig. 189). WHEEL CLUTCH REASSEMBLY Note: Apply a light coat of SAE 30W oil to intermediate shaft before assembly. 1. Set the 32-tooth gear on a flat surface and install pawls. Apply a light coat of oil Toro part no. 505-5 to dowel pins then install dowel pins into the pawl assembly (Fig. 190). Fig 188 MVC-889XWC.jpg Fig 190 MVC-902XWC.jpg 2.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 3. Clamp or hold gear and turn it over to properly install the 3 pawl supports and torx screws (Fig. 192). Fig 192 MVC-904X.jpg 4. Torque the T-27 torx screws to 100 to 125 in-lbs. (11.3 to 14.1 Nm) (Fig. 193). 5. Install the 4 guide collars to shaft with shift brace plate (Fig. 194). Fig 194 MVC-1909X.jpg 6. Torque the screws no more then 50 - 70 in-lbs. (5.65 – 7.9 Nm). 7. Slide flat washers next to guides (Fig. 195). Fig 193 MVC-905XWC.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 8. Install RIGHT and LEFT collar. Note: The top flanges of the shift collars have “left” and “right” stamped into them (Fig. 196). Install accordingly on the right and left ends of the shaft with the shift brace plate oriented as shown (Fig. 197). 9. Install compression springs under the pawls (Fig. 198). Fig 198 9-22 Fig 196 MVC-880X.jpg Fig 197 MVC-1915X.jpg MVC-001XB.jpg 10. Slide thrust washer onto the 32-tooth sprocket gear (Fig. 199). Fig 199 MVC-002X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 11. Slide the complete 32-tooth gear sprocket onto the shaft (Fig. 200). 13. Make sure 11-tooth gear slides on so it is flush with the end of the shaft (Fig. 202). Fig 200 Fig 202 MVC-1180X.jpg 14. Make sure the pawls are up against the thrust washer and the springs are not binding and are compressing properly (Fig. 203). 12. Install flat washer (Fig. 201). Fig 201 MVC-1177X.jpg Fig 203 Power Max Service Manual MVC-1184X.jpg MVC-006X.
WHEEL CLUTCH TRACTION DRIVE SYSTEM 15. Apply a light coat of anti seize to the 11-tooth gear (Fig. 204). Repeat the process for the opposite side. Refer to the drive system reassembly procedure, beginning with step 17 on page 9-14. After installation into the housing, rotate left and right collars fully to the stop. Ensure that the mechanism operates smoothly. Check each of the 6 pawls to ensure that it returns fully when the shift collar is released.
DISCHARGE CHUTE 3. Remove the single screw between the gear and the chute (Fig. 208). CHUTE AND AUGER COVER REMOVAL 1. Disconnect the deflector cable from the deflector (Fig. 206). Fig 208 Fig 206 MVC-3878X 2. Remove the single screw retaining the gear cover, lift the front of the cover, and slide it to the rear (Fig. 207). 4. Remove two screws that secure the cable clamp bracket and the chute support bracket to the chute (Fig. 209).
DISCHARGE CHUTE 5. Lift the chute and deflector off of the auger cover (Fig. 210). Fig 210 MVC-885X 6. There is a ring on the base of the chute that is secured with three screws (Fig. 211). Fig 211 7. If necessary the deflector can be separated from the chute by removing the hinge (Fig. 212). Fig 212 8. The last chute component is the chute guide. It is attached to the auger cover with one screw in front and tabs on the rear (Fig. 213).
DISCHARGE CHUTE If the auger cover is to be removed the first step is to remove both of the belt covers (Fig. 214). Assemble in reverse order. The metal seal is installed under the mounting flange on the left rear corner of the auger housing. (Fig. 216). Note: Do not over-tighten to the point the cover starts to deform. Just seating the nut is enough; the nylock feature will keep if from loosening. Fig 214 MVC-893XA The auger cover is attached to the auger housing with carriage bolts and locknuts (Fig.
DISCHARGE CHUTE 2. Raise the front of the cover and slide it to the rear (Fig. 218). CHUTE GEARS Operation The chute gears are located on top of the support tube under a cover. These gears connect the Quick Stick to the chute and provide the means to rotate the chute side to side. Disassembly 1. To disassemble the chute gears, begin by removing the screw on the chute gear cover (Fig. 217). Fig 218 MVC-144X 3. Remove the locknut and washer from the bottom of the 3 shoulder screws (Fig. 219).
DISCHARGE CHUTE 4. Loosen the screw securing the latch cable and unhook the cable from the latch (Fig. 220). Fig 220 6. Remove the shoulder bolt from the chute gear (Fig. 222). MVC-152X Fig 222 5. Raise the front of the face gear and slide it off the chute rod (Fig. 221). Fig 221 Power Max Service Manual MVC-154X 7. The chute gear is attached to the bracket by two screws. Remove the screws and lift the gear off the bracket. Note: a plastic spacer is under the bracket.
DISCHARGE CHUTE Assembly 1. Attach the chute gear to the bracket with the two screws. 4. The face gear has a rib molded into it and the chute gear has 2. Line up the ribs and place the face gear mount onto the support tube (Fig. 225). 2. Place the spacer cupped side up on the support tube, then set the gear and bracket down on it. The shoulder bolt goes through and it secured with the washer and locknut (Fig. 223). Fig 225 Fig 223 MVC-818X MVC-160X 5.
DISCHARGE CHUTE 6. The gear lash for the chute gears must now be set. No actual measurement is necessary. The 3 shoulder bolts on the face gear mount are in slotted holes. Push the face gear mount forward to fully engage in the gears. Snug one or two of the locknuts, hold the chute latch back and rotate the chute using the quick stick (Fig. 227). It should move smoothly. If not move the face gear mount as needed. Secure the 3 locknuts. Fig 227 8. Install the gear cover and screw. MVC-164X 7.
THIS PAGE INTENTIONALLY LEFT BLANK 10-8 Power Max Service Manual
ELECTRICAL Power Max models have 3 very simple electrical systems. Each is separate from the other so a problem in one area will not affect the others. ELECTRIC START SYSTEM The wires run from the ignition coil, under the blower housing, over the foam pad to the ignition switch. The other wire runs from the switch to the cylinder head bolt. Make sure to secure the wires to the primer line with a wire tie (Fig. 229). All models have an electric start system standard.
THIS PAGE INTENTIONALLY LEFT BLANK 11-2 Power Max Service Manual
WHEELS AND TIRES WHEELS TIRES There is a difference in the way the wheel is attached to the axle, depending on the drive system used. The tires on all models are 15” tubeless X-Trac tires. They are directional so they must be installed as shown, looking forward from the operator position (Fig. 233). On the standard machine the wheel is connected to the axle by a click pin. This allows the pin to be removed from the wheel and just placed in the axle. This makes the machine free wheel for easy transport.
THIS PAGE INTENTIONALLY LEFT BLANK 12-2 Power Max Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK
Power Max™ Service Manual Form no.
