Toro 51603, Maintenance And Repair Manual

Page 1: ...ANER MAINTENANCE EXHAUST SYSTEM MAINTENANCE FLEXIBLE DRIVE SHAFT MAINTENANCE CARBURETOR ADJUSTMENTS MODEL TC 1 500 WITH TILLOTSON CARBURETOR ADJUSTMENT MODELS TC 300 TC 400 WITH WALBRO TROUBLESHOOTING AND TEST PROCEDURES DISASSEMBLY REPAIR REASSEMBLY INSTRUCTIONS WALBRO CARBURETOR OPERATION CUTTER HEAD TROUBLESHOOTING CLUTCH REPAIR ...

Page 2: ...GASOLINE POWERED TRIMMER MAINTENANCE REPAIR GUIDE MODEL NO 51630 1000001 UP 2000001 UP 2000001 UP COPYRIGHT C ALL RIGHTS RESERVED The Tor0 Company 1982 MINNEAPOLIS MN 55420 U S A Form 492 0266 ...

Page 3: ...ENTS PAGE Two cycle Engine Theory of Operation 1 Engine operation 1 Engine Specifications 3 Engine Torque Specifications 3 Air CleanerMaintenance 4 GeneralInformation 1 3 Maintenance Procedures 4 7 ExhaustsystemMaintenance 4 FlexibleDriveShaftMaintenance 5 Carburetor Adjustments Model TC 1500 Tillotson Carburetor 5 6 Carburetor Adjustments Models TC 300 TC 400 Walbro carburetor 6 7 TestingCylinder...

Page 4: ...port on the side of the cylinder The oil in thefuel airmixturelubricatesthe moving partswithin the crankcase 2 The fuel airmixtureistransportedthroughthe fueltransferportstothecombustion chamber where it is compressed ignited andthen expelled from the engine through the exhaust port Engine Operation The piston closes all engine ports as it movestoward the combustion chamber Fig 2 The moving piston...

Page 5: ...he burnt gases begin to be expelled from the com bustion chamber Fig 4 Mixture Compressed Closed Figure 4 Power Exhaust At a point of piston travel slightly before bottom dead center BBDC the fuel transfer ports on thesides c the cylinderwalls areuncoveredandthe com pressed fuel air mixture in thecrankcase is allowed to enter the combustion chamber where they help expel the burnt gases and charge ...

Page 6: ...adjusted and Factory adjusted and test run Procedures pp test run Adjusting Procedures Solid state capacitive discharge ignition CD1 1 29 1 67mm 051 066 in BTDC 22degreesBTDC 20 30mm 008 012 in ENGINE TORQUE SPECIFICATIONS tCooIing ShroudScrews Carburetor Mounting Screws NOTE MetricTorque Conversions inch pounds X1 152 kilogram centimeters foot pounds X 1383 kilogram meters TORQUE Kg cm Kg m TORQU...

Page 7: ... and IMPORTANT Make sure the peg inthe air cleaner housingfitsthroughthesmallhole in the felt filter Both filters must cover the opening in the air cleaner housing 7 Reinstallthe aircleaner cover bypressingthe cover in and up behind the choke lever and then press the lower mounting tab into the hole in the engine housing DO NOT FORCE 7 EXHAUST SYSTEM MAINTENANCE NOTE Some states require that aspar...

Page 8: ...tsoncarburetorusedontheTC 1500isnot serviceable If carburetion difficulties cannot be corrected by adjustment thecarburetormustbe replaced IMPORTANT The correct amount of line must be fed fromthetrimmer spoolbeforeadjustingthecar buretor to ensure thattheengineisadjustedfor operation while under load 1 Remove aircleaner cover by pressingup on bottom ofcover to release lowermountingtab and pressing...

Page 9: ...or maximum enginespeed 6 Recheck the idle adjustment CARBURETOR ADJUSTMENT MODELS TC 300 TC 400 WITH WALBRO CARBURETOR IMPORTANT Do not close the carburetor adjusting screws too tightly as damageto the screws and seats may result Also the correct amountof line must be fedfromthetrimmer spoolbeforeadjustingthe carburetor to ensure that the engine is adjusted for operation while under load 1 High Sp...

Page 10: ... preliminary checks before proceeding to sec ondary troubleshootingprocedures Preliminary Checks 1 Check for ignition a Check the start stop switch position 2 Check the spark plug refertospecifications Page 3 a To ensure the correct type b For damage to the insulator c For excessive carbon or burnt electrodes d For the correct gap e Check for spark refer to page 8 3 Check the fuel supply a Check t...

Page 11: ...embledby prying up the insertwith a flatscrewdriver Care shouldbe usedtoprevent damage to the insertandthe valve Fig 17 Figure 17 3 Remove the valve squeeze the valve to close it release it and holdit up toa light No light should be visible through thevalve If light canbe seen the valve should be cleaned or replaced 4 With the insert removed hold the capup to a light Light should be visible throug...

Page 12: ...TROUBLESHOOTI N G SHOOTI N G AND TEST PROCEDURES ...

Page 13: ...ich pass through the spitback choke assembly and carburetor 11 Remove the cooling shroud halves by removing the three screws which attach the shroud to the backing plate and gently prying open the latch next to the spark plug wire NOTE The TC300 and TC400have a single piece cooling shroud 12 Remove theflywheel by retainingthestarter cup with the starter cup wrench P N45 1390 and removing the flywh...

Page 14: ...DISASSEMBLY REPAIR REASSEMBLY INSTRUCTIONS Figure 19 ...

Page 15: ...ngth With the rope extended the starter pulley mustbe able to be rotated an additional 1 2 turn ina clockwise direction but not more than 11 2 turns Instructions page IO 6 To reassemble reverse steps 1 5 in Disassembly Starter Assembly Replacement 1 Followsteps 1 5 of Trimmer EngineDisas Instructions 2 Remove the Recoil StarterAssemblyfromthe Upper ShaftHousing Tube Retain the tube by passing abar...

Page 16: ... Valve Regulates engine speedas it exposes Pri mary Second and Third Idle holes then Nozzle for fuel delivery 9 PrimaryIdle Hole Only fuel source to engine atIdle position 10 Second Idle Hole Allows additional fuel flow on accelera tion 16 Circuit Plate Meters fuel from Metering Chamber to Low Speed and High Speed Circuits Metering Lever 17 MeteringDiaphragm Drawnupbyvacuum to activate 18 Metering...

Page 17: ...tter 10 Remove the metering lever screw and metering 3 Inspect the diaphragm for flatness and continu lever components including lever pin needle 11 Remove thecircuitplatescrewwiththedia cover gasket ity The diaphragm should have no holes The valve and spring flappervalvesshould be flatandfree from curling phragm andgasket 4 Blowthroughtheexternalpulseholeonthe bodycasting toinsurethatthereareno o...

Page 18: ...igh and low speed needles and setat approximately 1 and 1 4 turns open The high and low speed letters are indicated on the side of the carburetor casting The high speed needle is the long needle and the low speed needle is the short needle 6 Install the metering diaphragm and related com ponents as follows Installthe gasket over the locator pins onthe casting Next installthe metering diaphragm ove...

Page 19: ...ng Not seated in engine or cutting unit Not seated in engine or cutting unit I Bearing seized Cutting line Clutch slipping too short won t index Driver broken line swelled from moisture dirty line I tangled Cutting line not indexed often enough or prior to engine shut Off Driver or drum Bearing grease broken on clutch drum Power shaft snap ring out of groove some models clutch spring broken Unbala...

Page 20: ...ing the upper and lower sections of the clutch housing Separate the twosections by gently prying them apart 4 The clutch assembly shoes and springs can be 1390 Fig 25 Align the pins on the tool with the holes in the clutch assembly While supporting the opposite end of the power shaft with a piece removed with the multipurpose tool P N 45 of 3 16 inch squarekey stock turn the clutch assembly counte...

Page 21: ...orecounterclockwise The driver will turn off with it 4 Remove the washer and compression spring and 5 Clean the debris from the inside and outside of thedrum and remove any debris wrapped around the power shaft slide thedrum off the power shaft 6 Replace any worn or broken parts 7 Reassemble thetrimmer head in the reverse order Be certain that the roll pin on the power shaft is seated in the slot ...