Toro 38660, 38661, 38662, 38663, 38664 Service Manual

RESIDENTIAL PRODUCTS

TWO STAGE SNOW

ENGINE SERVICE MANUAL

LC175FDS (265cc) LC180FDS (302cc)

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. An electronic version of this service manual is available on the Toro Dealer Portal. We are hopeful that you will find this manual a valuable addition to your service shop. If you have any questions or comments regarding this manual, please contact us at the following address:

The Toro Company Residential and Landscape Contractor Service Training Department 8111 Lyndale Avenue South Bloomington, MN 55420

Chapter 1 – General Service Information

1

Chapter 2 - Engine Service / Maintenance

2

Chapter 3 - Engine Disassembly and Service

3

Chapter 4 - Electrical

4

NOTES:

1

Chapter 1 – General Service Information

Safety 2

Service Rules 3

Engine Model / Serial Number Location 3

Engine Fastener Torque Specification 4 General Specifications 5 Engine Specifications - 265cc / 175FDS 6 Engine Specifications - 302cc / 180FDS 7 Troubleshooting 8

1

Safety

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 Toro engine. The Toro operator’s manual contains safety

information and operating tips for safe operating practices.

Avoid Unexpected Engine Start - Turn off engine and disconnect the spark plug before servicing engine.

Avoid Lacerations and Amputations - Stay clear of all moving parts while the engine is running.

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.

Avoid Asphyxiation - Never operate an engine in a confined area without proper ventilation.

Avoid Injury From Batteries - Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Battery gases can explode. Keep cigarettes, sparks, and flames away from batteries.

Avoid Injury Due To Inferior Parts - Use only original equipment parts to ensure that important safety criteria are met.

Avoid Injury To Bystanders - Always clear the area of bystanders before starting or testing power 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 power equipment.

Avoid Modifications - Never alter or modify any part unless it is a factory approved procedure.

2

1. Only use genuine Toro parts and lubrication products.

2. Always install new gaskets, O-rings and seals when assembling engine.

3. Always torque fasteners to specification and in sequence.

4. Always lubricate friction components with clean engine oil or engine assembly lube when assembling engine.

1

Engine Model and

Serial Numbers

Engine Model

Serial Number

Oil Drain

Service Rules

Engine Model / Serial Number Location

The engine model and serial number are stamped into the crankcase, above the oil drain.

XXX-XXXX XXXXXXXXXXX

3

Item

Fastener Size

Torque

Specification

Cylinder Head Bolts

M10

35 ft-lbs (48 Nm)

Connecting Rod Bolts

M8

14 ft-lbs (19Nm)

Flywheel Nut

M16

80 ft-lbs (109 Nm)

Valve Adjust Lock Nut

M6

11 ft-lbs (15 Nm)

Rocker Arm Studs

M8

22 ft-lbs (30 Nm)

Crankcase Cover Bolts

M8

22 ft-lbs (30 Nm)

Exhaust Studs

M8

6 ft-lbs (8 Nm)

Exhaust Pipe Nuts

M8

22 ft-lbs (30 Nm)

Air Cleaner Nuts

M6

7.5 ft-lbs (10 Nm)

Oil Drain Plug

M10

17 ft-lbs (23 Nm)

Oil Drain Tube

M12

22 ft-lbs (30 Nm)

Fuel Shut-off Knob Screws

M4

18 in-lbs (2 Nm)

Switch box screw

M4

12 in-lbs (1.5 Nm)

Valve Cover Bolts

M6

7 ft-lbs (10 Nm)

Start Motor Mounting Bolts

M8

19 ft-lbs (26 Nm)

Spark Plug

-

22 ft-lbs (30 Nm)

Fuel Drain Screw

M6

7.5 ft-lbs (10 Nm)

Standard Torque Values

M5 Bolt / Nut

4.5 ft-lbs (6 Nm)

M6 Bolt / Nut

7.5 ft-lbs (10 Nm)

M8 Bolt / Nut

19 ft-lbs (26 Nm)

M10 Bolt / Nut

28 ft-lbs (38 Nm)

M12 Bolt / Nut

41 ft-lbs (55 Nm)

Engine Fastener Torque Specifications

4

MODEL

265cc / LC175FDS

302cc / LC180FDS

Engine Type

OHV Single Cylinder, Four Stroke, Forced Air Cooling

Displacement (cc)

265

302

Bore × Stroke (mm)

75×60

80×60

Compression Ratio

8.2:1

8.9:1

Dry Weight

66.1 lbs. (30Kg)

70.5 lbs. (32Kg)

Engine Idle RPM

1700 - 2000 RPM

Engine Operating RPM

3200 – 3400 RPM

Oil Capacity

30 - 32 oz. (0.89 - 0.95 l)

Fuel Type

Unleaded Gasoline, 87 Octane

Fuel Capacity

1.05 Gallons (4l)

Engine Rotation

Counter-clockwise (from P.T.O. side)

Ignition System

T.C.I Transistorized Magneto

Lubrication System

Splash

Starting System

Recoil and Electric

Cylinder

Aluminum with Cast Iron Bore

70.57 lbs. (32Kg)

1

General Specifications

5

Part

Item

Standard

Service Limit

Cylinder

Sleeve Inside Diameter

2.953 - 2.954” (75.015-75.025 mm)

2.959” (75.17 mm)

Piston

Skirt Outside Diameter

2.951 - 2.952” (74.970-74.980 mm)

2.939” (74.65 mm)

Clearance to Cylinder

0.00059 - 0.002” (0.015-0.052 mm)

0.0047” (0.12 mm)

Piston Pin Bore Inside Diameter

0.7087 - 0.7089” (18.002-18.008 mm)

0.7103” (18.042 mm)

Piston Pin Clearance

0.000078 - 0.00055” (0.002-0.014mm)

0.0031” (0.08 mm)

Piston Pin

Outside Diameter

0.7083 - 0.7085” (17.992-17.998 mm)

0.7067” (17.95 mm)

Piston Rings

Ring To Groove (Top and Middle)

0.00059 - 0.00177” (0.015-0.045 mm)

0.0059” (0.15 mm)

End Gap (Top and Middle)

0.0079 - 0.0157” (0.2-0.4 mm)

0.0394”(1.0 mm)

End Gap (Oil Ring)

0.0079 - 0.0275” (0.2-0.7 mm)

0.0394” (1.0 mm)

Width (Top and Middle)

0.077 - 0.078” (1.97-1.99 mm)

0.069” (1.75 mm)

Connecting Rod

Small End Inside Diameter

0.7088 - 0.7093” (18.006-18.017 mm)

0.7114” (18.07 mm)

Big End Inside Diameter

1.3 - 1.3003” (33.02-33.03 mm)

1.3019” (33.07 mm)

Big End Oil Clearance

0.00157 - 0.00259” (0.04-0.066 mm)

0.00472” (0.12 mm)

Big End Side Clearance

0.0039 - 0.0275” (0.1-0.7 mm)

0.0394” (1.0 mm)

Crankshaft

Crankpin Outside Diameter

1.2979” - 1.2984” (32.966-32.981 mm)

1.296” (32.92 mm)

Valves

Clearance (cold) (intake)

0.0059” (0.15 mm)

－

Clearance (cold) (exhaust)

0.0078” (0.20 mm)

－

Stem Diameter (intake)

0.258 - 0.259” (6.565-6.580 mm)

0.2535” (6.44 mm)

Stem Diameter (exhaust)

0.2576 - 0.2582” (6.545-6.560 mm)

0.252” (6.40 mm)

Valve Guides

Inside Diameter (intake, exhaust)

0.2598 - 0.2604” (6.60-6.615 mm)

0.2624” (6.66 mm)

Stem to Guide Clearance (intake)

0.00039 - 0.00145” (0.01-0.037 mm)

0.000393” (0.10 mm)

Stem to Guide Clearance (exhaust)

0.00197 - 0.00303” (0.05-0.077 mm)

0.0047” (0.12 mm)

Valve Seats

Seat Width

0.0315 - 0.0394” (0.8-1.0 mm)

0.0787” (2.0 mm)

Valve Springs

Free Length

1.535” (39 mm)

1.476” (37.5 mm)

Camshaft

Height (intake)

1.2455 - 1.2501” (31.636-31.754 mm)

1.234” (31.35 mm)

Height (exhaust)

1.2470 - 1.2533” (31.674 -31.834 mm)

1.2342” (31.35 mm)

Outside Diameter (bearing)

0.6285 - 0.6292” (15.966-15.984 mm)

0.6267” (15.92 mm)

Crankcase Cover

Camshaft Hole Diameter

0.6299 - 0.6306” (16.0-16.018 mm)

0.6318” (16.05 mm)

Spark Plug

Gap

0.0275 - 0.0314” (0.7-0.8 mm)

－

Stator

(12V-37.5W)

Resistance

0.21-0.31Ω

－

Ignition Coil

Resistance (primary)

1.0-1.6Ω

－

Resistance (secondary)

10.5 KΩ +/- 15%

－

Gap to Flywheel

0.011- 0.019” (.3-.5 mm)

－

Carburetor

Float Height

0.539” (13.7mm)

Engine Specifications - 265cc / 175FDS

6

Part

Item

Standard

Service Limit

Cylinder

Sleeve Inside Diameter

3.4651 - 3.4655” (80.015-80.025 mm)

3.4712” (80.17 mm)

Piston

Skirt Outside Diameter

3.1484 - 3.1488” (79.97-79.98 mm)

3.1437” (79.85 mm)

Clearance to Cylinder

0.00059 - 0.002” (0.015-0.052 mm)

0.0047” (0.12 mm)

Piston Pin Bore Inside Diameter

0.7087 - 0.7089” (18.002-18.008 mm)

0.7103” (18.042 mm)

Piston Pin Clearance

0.000078 - 0.00055” (0.002-0.014mm)

0.0031” (0.08 mm)

Piston Pin

Outside Diameter

0.7083 - 0.7085” (17.992-17.998 mm)

0.7067” (17.95 mm)

Piston Rings

Ring To Groove (Top and Middle)

0.00059 - 0.00177” (0.015-0.045 mm)

0.0059” (0.15 mm)

End Gap (Top and Middle)

0.0079 - 0.0157” (0.2-0.4 mm)

0.0394”(1.0 mm)

End Gap (Oil Ring)

0.0079 - 0.0275” (0.2-0.7 mm)

0.0394” (1.0 mm)

Width (Top and Middle)

0.077 - 0.078” (1.97-1.99 mm)

0.069” (1.75 mm)

Connecting Rod

Small End Inside Diameter

0.7088 - 0.7093” (18.006-18.017 mm)

0.7114” (18.07 mm)

Big End Inside Diameter

1.3 - 1.3003” (33.02-33.03 mm)

1.3019” (33.07 mm)

Big End Oil Clearance

0.00157 - 0.00259” (0.04-0.066 mm)

0.00472” (0.12 mm)

Big End Side Clearance

0.0039 - 0.0275” (0.1-0.7 mm)

0.0394” (1.0 mm)

Crankshaft

Crankpin Outside Diameter

1.2979” - 1.2984” (32.966-32.981 mm)

1.296” (32.92 mm)

Valves

Clearance (cold) (intake)

0.0059” (0.15 mm)

－

Clearance (cold) (exhaust)

0.0078” (0.20 mm)

－

Stem Diameter (intake)

0.258 - 0.259” (6.565-6.580 mm)

0.2535” (6.44 mm)

Stem Diameter (exhaust)

0.2576 - 0.2582” (6.545-6.560 mm)

0.252” (6.40 mm)

Valve Guides

Inside Diameter (intake, exhaust)

0.2598 - 0.2604” (6.60-6.615 mm)

0.2624” (6.66 mm)

Stem to Guide Clearance (intake)

0.00039 - 0.00145” (0.01-0.037 mm)

0.000393” (0.10 mm)

Stem to Guide Clearance (exhaust)

0.00197 - 0.00303” (0.05-0.077 mm)

0.0047” (0.12 mm)

Valve Seats

Seat Width

0.0315 - 0.0394” (0.8-1.0 mm)

0.0787” (2.0 mm)

Valve Springs

Free Length

1.535” (39 mm)

1.476” (37.5 mm)

Camshaft

Height (intake)

1.257 - 1.264” (31.953-32.113 mm)

1.244” (31.60 mm)

Height (exhaust)

1.246 - 1.253” (31.66 -31.82 mm)

1.232” (31.30 mm)

Outside Diameter (bearing)

0.6285 - 0.6292” (15.966-15.984 mm)

0.6267” (15.92 mm)

Crankcase Cover

Camshaft Hole Diameter

0.6299 - 0.6306” (16.0-16.018 mm)

0.6318” (16.05 mm)

Spark Plug

Gap

0.0275 - 0.0314” (0.7-0.8 mm)

－

Stator

(12V-37.5W)

Resistance

0.21-0.31Ω

－

Ignition Coils

resistance (primary)

1.0-1.6Ω

－

resistance (secondary)

10.5 KΩ +/- 15%

－

gap to flywheel

0.011- 0.019” (.3-.5 mm)

－

Carburetor

Float Height

0.539” (13.7mm)

1

Engine Specifications - 302cc / 180FDS

7

Troubleshooting

Hard Starting / Poor Running

- Incorrect Fuel (Level, Age, Octane, Ethanol Content)

- Fuel System Contamination and / or Carburetor Debris

- Primer System Incorrect Function

- Incorrect Oil Level

- Spark Plug (Incorrect Gap, Fouled, Loose or Faulty)

- Air Intake Restriction

- Air Intake System Leaks

- Ignition Coil to Flywheel Gap Incorrect

- Weak / No Spark

- Choke / Linkage

- Operating RPM Incorrect

- Governor Adjustment Incorrect

- Engine Valve Clearance out of Specification

- Low Compression or Excessive Leakdown

Overheating

- Incorrect Oil Level

- Cylinder Head Gasket Leak

- Debris Build-Up Restricting Air Flow

8

1

2

Chapter 2 - Engine Service / Maintenance

Engine Oil Change Procedure 10 Spark Plug Service 11 Valve Clearance Inspection and Adjustment 12 Engine Governor – Zero Point Setting 13 Engine Idle Speed 14 Fuel Filter Replacement 15

9

A

B

Engine Oil Change Procedure

1. Run engine to warm engine oil.

2. Remove the ignition key.

3. Remove oil dipstick.

4. Position oil drain pan under oil drain plug.

5. Firmly hold the oil drain tube (A) in position. Remove the oil drain plug (B).

6. Completely drain the engine oil.

7. Firmly hold the oil drain tube (A) in position. Install the oil drain plug (B) - torque to 17 ft-lbs (23 Nm).

8. Add oil through the dipstick tube. Wipe the dipstick clean and fully insert it into the dipstick tube.

9. Remove the dipstick and check the oil level – Add oil if needed until the proper oil level is reached NOTE: DO NOT overfill the engine oil

10. Fully install the dipstick.

11. Properly dispose of the used engine oil.

Engine Oil Capacity:

30 to 32 oz. (0.89 to 0.95 l)

Engine Oil Type:

API classification of SF,SG, SH, SJ, SL, or higher.

10

0.0275 - 0.0314” (0.7-0.8 mm)

2

Valve Cover

Spark Plug

Spark Plug Service

NOTE: Spark plugs of the wrong size or incorrect heat range can cause severe engine damage.

High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems

1. Disconnect the spark plug boot and thoroughly clean the spark plug area.

2. Remove the spark plug from the engine.

3. Inspect the spark plug for excessively worn electrodes, chips or cracks in the insulator, or excessive deposits.

4. Measure the electrode gap and adjust if necessary. Spark Plug Gap: 0.0275 - 0.0314” (0.7-0.8 mm)

5. Install spark plug and torque to specification - 22 ft-lbs (30 Nm).

6. Fully install the spark plug boot on the plug.

11