Toro 51200, 51225, 51300, 51325, 51400 Service Manual
...
ELECTRIC TRIMMER/WEEDER SERVICE MANUAL
Table of Contents – Page 1 of 4
TRIMMER/WEEDER MODELS
FOREWORD
TOOL REQUIREMENTS
AUTOMATIC LIN E FEED ASSEMBLY
TROUBLE SHOOTING GUIDE
AUTOMATIC LINE FEED ASSEMBLY SERVICE INSTRUCTIONS
1.1 REMOVE SPOOL CAP (FIG. 1.1)
1.11 REMOVING DIFFICULT SPOOL CAPS CORDLESS TRIMMERS (FIG 1.11A).
900, 1100, AND 1200 TRIMMERS (FIG. 1.11B)
1.2 CHECK FOR GRASS OR DIRT INSIDE DRUM. CLEAN INSIDE DRUM
1.3 CHECK FOR LINE TIGHT ON SPOOL
1.31 REWIND SPOOL CORRECTLY (FIG. 1.31)
1.4 CHECK FOR WORN DRIVER TEETH (FIG. 1.4)
1.41 REPLACE DRIVER ALL UNITS EXCEPT 1978 CORDLESS (FIG. 1.41A)
1.5 CHECK FOR DIRTY OR DAMAGED CORE (FIG. 1.5)
1.51 CLEAN OR REPLACE CORE
1.6 1978 CORDLESS TRIMMER -CHECK FOR DRUM RUBBING MOTOR (FIG.
1.61 REPLACE DRUM AND MOTOR WITH NEW STYLE (FIG. 1.61)
900 AND 1100 TRIMMERS
TROUBLE SHOOTING GUIDE
WIRING DIAGRAM
SERVICE INSTRUCTIONS
2.0 CHECK FOR LINE/GRASS STOPPING HEAD ROTATION (FIG. 2.0)
2.01 CLEAN HEAD AND TEST (FIG. 2.01)
2.1 OPEN MOTOR HOUSING AND INSPECT MOTOR (FIG. 2.1)
2.11 REPLACE MOTOR (FIGS. 2.11A, 2.11B)
2.2 SPIN MOTOR BY HAND
2.21 CHECK DRUM (FIG. 2.21)
2.22 REPLACE DRUM (FIG. 2.22) SERIAL NOS. 800001-899999
2.23 BAD BEARING - REPLACE MOTOR OR TRIMMER (FIG. 2.23)
2.3 CHECK MOTOR BRUSHES (FIG. 2.3)
2.31 REPLACE MOTOR OR TRIMMER
2.4 CHECK MOTOR BRUSH SPRINGS (FIG. 2.4)
2.41 SECURE SPRING/REPLACE MOTOR OR TRIMMER (FIG. 2.41)
2.5 CHECK HARNESS CONNECTIONS AT MOTOR
2.51 SECURE CONNECTION AT MOTOR (FIG. 2.51)
2.6 CHECK LOWER HARNESS (FIG. 2.6)
2.61 REPLACE LOWER HARNESS (FIGS. 2.61A, 2.61B)
2.7 TEST SWITCH CONNECTIONS (FIG. 2.7)
ELECTRIC TRIMMER/WEEDER SERVICE MANUAL
Table of Contents – Page 2 of 4
SERVICE INSTRUCTIONS - continued
2.71 SECURE LOOSE CONNECTIONS
2.8 TEST SWITCH (FIGS. 2.8A, 2.8B)
2.81 REPLACE SWITCH (FIG. 2.81)
2.9 TEST UPPER HARNESS (FIG. 2.9)
2.91 REPLACE UPPER HARNESS
1200 TRIMMER
TROUBLE SHOOTING
WIRING DIAGRAM
SERVICE INSTRUCTIONS
3.0 CHECK FOR LINE/GRASS STOPPING HEAD ROTATION (FIG. 3.0)
3.01 CLEAN HEAD AND TEST (FIG. 3.01)
3.1 OPEN MOTOR HOUSING AND INSPECT MOTOR (FIG. 3.1)
3.11 REPLACE MOTOR (FIG. 3.11A, 3.11B)
3.2 SPIN MOTOR BY HAND
3.21 CHECK DRUM (FIG. 3.21)
3.22 REPLACE DRUM (FIG. 3.22) SERIAL NOS. 800001-899999.
3.23 BAD BEARING -- REPLACE MOTOR OR TRIMMER (FIG. 3.23)
3.3 CHECK MOTOR BRUSHES (FIG. 3.3)
3.31 REPLACE MOTOR OR TRIMMER
3.4 CHECK MOTOR BRUSH SPRINGS (FIG. 3.4)
3.41 SECURE SPRING/REPLACE MOTOR OR TRIMMER (FIG. 3.41)
3.5 TEST BRIDGE RECTIFIER (FIG. 3.5A, 3.5B)
3.51 REPLACE BRIDGE RECTIFIER
3.6 CHECK HARNESS CONNECTIONS AT RECTIFIER
3.61 SECURE CONNECTION AT RECTIFIER
3.7 CHECK LOWER HARNESS (FIG. 3.7)
3.71 REPLACE LOWER HARNESS
3.8 TEST SWITCH CONNECTIONS (FIG. 3.8)
3.81 SECURE LOOSE CONNECTIONS
3.9 TEST SWITCH (FIG. 3.9A, 3.9B)
3.91 REPLACE SWITCH (FIG. 3.91)
4.0 TEST UPPER HARNESS (FIG. 4.0)
4.01 REPLACE UPPER HARNESS
CORDLESS TRIMMER
TROUBLE SHOOTING GUIDE
WIRING DIAGRAM
ELECTRIC TRIMMER/WEEDER SERVICE MANUAL
Table of Contents – Page 3 of 4
SERVICE INSTRUCTIONS
5.0 CHECK FOR LINE/GRASS STOPPING HEAD ROTATION (FIG. 5.0)
5.01 CLEAN HEAD AND TEST (FIG. 5.01)
5.1 INSPECT UPPER TO LOWER HARNESS CONNECTION (FIG. 5.1)
5.11 SECURE UPPER TO LOWER HARNESS CONNECTION (FIG. 5.11)
5.2 CHECK BATTERY CONNECTIONS (FIG. 5.2)
5.21 SECURE BATTERY CONNECTIONS
5.3 TEST OUTPUT VOLTAGE OF BATTERY CHARGER (FIG. 5.3)
5.31 REPLACE BATTERY CHARGER
5.4 CHECK CHARGER OUTPUT AT BATTERY CONNECTIONS (FIG. 5.4)
5.41 REPLACE UPPER WIRING HARNESS
5.5 CHARGE BATTERY FOR 48 HOURS AND TEST (FIG. 5.5)
5.51 REPLACE BATTERY AND CHARGE FOR 48 HOURS
5.6 INSPECT MOTOR
5.61 REPLACE MOTOR (FIG. 5.61)
5.7 SPIN MOTOR BY HAND
5.71 CHECK DRUM (FIG. 5.71)
5.72 REPLACE DRUM SERIAL NOS. 800001-9115104
5.73 BAD BEARING - REPLACE MOTOR OR TRIMMER
5.8 CHECK HARNESS CONNECTIONS AT MOTOR
5.81 SECURE MOTOR CONNECTIONS (FIG. 5.81)
5.9 TEST LOWER HARNESS (FIG. 5.9)
5.91 REPLACE LOWER HARNESS
6.0 TEST SWITCH CONNECTIONS
6.01 SECURE LOOSE CONNECTIONS
6.1 TEST SWITCH (FIGS. 6.1A, 6.1B)
6.11 REPLACE SWITCH
6.2 TEST UPPER HARNESS (FIGS. 6.2A, 6.2B)
6.21 REPLACE UPPER HARNESS
6.3 REPLACE MOTOR
PARTS CATALOG
TORO TRIMMER 900 HANDLE ASSEMBLY
PARTS
TORO TRIMMER 900 MOTOR AND HOUSING ASSEMBLY
PARTS
TORO TRIMMER 900 HANDLE ASSEMBLY
PARTS
TORO TRIMMER 900 MOTOR AND HOUSING ASSEMBLY
PARTS
TORO TRIMMER 1100 HANDLE ASSEMBLY
PARTS
ELECTRIC TRIMMER/WEEDER SERVICE MANUAL
Table of Contents – Page 4 of 4
TORO TRIMMER 1100 MOTOR AND HOUSING ASSEMBLY
PARTS
TORO TRIMMER 1100 HANDLE ASSEMBLY
PARTS
TORO TRIMMER 1100 MOTOR AND HOUSING ASSEMBLY
PARTS
TORO TRIMMER 1200 HANDLE ASSEMBLY
PARTS
TORO TRIMMER 1200 MOTOR AND HOUSING ASSEMBLY
PARTS
TORO TRIMMER 1200 HANDLE ASSEMBLY
PARTS
TORO TRIMMER 1200MOTOR AND HOUSING ASSEMBLY
PARTS
TORO CORDLESS TRIMMER UPPER CASE ASSEMBLY
PARTS
TORO CORDLESS TRIMMER MOTOR HOUSING ASSEMBLY
PARTS
TORO CORDLESS TRIMMER UPPER CASE ASSEMBLY
PARTS
TORO CORDLESS TRIMMER MOTOR HOUSING ASSEMBLY
PARTS
OUTDOOR
APPLIANCE
DIVISION
--
Electric
.
I
Trimmer/
SERVICE
Weeder
MANUAL
CORDLESS TRIMMER/WEEDER
900
HOME DUTY TRIMMER/WEEDER
..
.
Model Number 51550
L
Model Numbers 51200
and 51225
1100 HEAVY DUTY TRIMMER/WEEDER
Model Numbers 51300
MARCH
1979
This service repair manual
Complete Trouble Shooting Guides, Wiring Diagrams and Service Instructions are included.
is
The manual
line feeding devices used in the four different trimmers. The second section deals with the
900 and 1100 Trimmers, the third with the 1200 and the fourth with the Cordless. The fifth
section contains an illustrated
The Trouble Shooting Guides
pattern which will enable you to find
Shooting Guide
need only refer to this same number in the service section for complete repair instructions.
divided into five sections. The first section concerns
is
numbered in the lower right hand corner. After finding the problem, you
is
written for use by Authorized Toro Appliance Service Dealers.
itself
with the automatic
Parts
Catalog for each model.
at
the beginning of the first four sections follow a systematic
a
problem quickly. Each section of the Trouble
TABLE
Automatic Line Feed Assembly
Trouble Shooting Guide
Service Instructions.
900
&1100
Trouble Shooting Guide
Wiring Diagram
Service
1200
Trouble Shooting Guide
Wiring Diagram
Service Instructions.
Cordless Trimmer 21-30
Trouble Shooting Guide
Wiring Diagram
Service Instructions.
Parts Catalog
900 Trimmer Model No. 51 200 8000001 9000100. 32-33
900 Trimmer Model No. 51 225
1100 Trimmer/Model No. 51300
1100 Trimmer/Model No. 51325
..
1200 Trimmer/Model No. 51400 . 8000001 . 9000100..
1200 Trimmer
Cordless Trimmer/Model No. 51550
Cordless Trimmer/Model No. 51550
Trimmers
I
Instructions
Trimmer
.......................................................
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/
.................................................
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......................................................
...............................................
Model No. 51425 . 9000101 & Up.
...........................................
................................................
................................................
...............................................
............................................
OF
CONTENTS
. .
.
9000101 & Up.
.
8000001 . 9000100..
.
9000101 & Up.
.
8000001 . 9115104
.
91 15105 & Up
....................
........................
..................
.......................
..................
.......................
..........
.....
.....................
1-4
3-4
5-11
7 . 1 1
13-19
14
15
15-19
22-23
24
24-30
31-47
34-35
36-37
38-39
40-41
42-43
44-45
46-47
2
6
7
No. 2 Phillips Screwdriver
Small Standard Screwdriver
Medium Standard Screwdriver
Large Standard Screwdriver
Long Nose Pliers
Diagonal Cutting Pliers
Electrical Terminal Crimping Pliers
Scribe or Awl
TOOL REQUIREMENTS
No. 54 Drill Bit (or object similar in size and hardness)
VOM Multimeter
Continuity Tester (or use mulitimeter)
1/8" Pin Punch
Small Hammer
(or
similar support system)
1979
-
U.S.A.
COPYRIGHT
The
"US.
Toro
&
Foreign Patents Pending"
MINNEAPOLIS, MN
Vise
Extension Cord
110 Volt A.C. Power Source
ALL
RIGHTS RESERVED
Company
-
55420
AUTOMATIC LINE FEED ASSEMBLY
900
Home Duty
Trimmer/Weeder
Model Numbers 51 200 and
1100
Heavy
Trimmer/ Weeder
Model Numbers 51300 and 51325
1200
Professional
51
225
Duty
Trimmer/Weeder
Model Numbers 51400 and 51425
Cordless
Trimmer/
Model Number 51550
Weeder
1
2
I-
.g-
I-
i
-I
0
I---
--
'
-1
.I
0
0
TROUBLE
SHOOTING
t
>
I-
I-
r
GUIDE
lr'
AUTOMATIC LINE
FEED ASSEMBLY
SERVICE
CAUTION: THIS TOOL
INSULATED. TO MAINTAIN ITS ENGINEERED SAFETY STANDARDS USE ONLY
GENUINE TORO REPLACEMENT PARTS.
THESE APPLIANCES FROM ALL POWER
SOURCES BEFORE ATTEMPTING ANY
REPAlRS.
1.1
REMOVE SPOOL CAP (fig. 1.1)
Insert widest possible blade screwdriver
snugly into one of the two window slots
on the spool hub and twist the screwdriver 1 /4 turn.
IS
DOUBLE
INSTRUCTIONS
I
Figure 1.1 1
CHECK FOR GRASS
1.2
DRUM. CLEAN INSIDE DRUM.
With the spool cap removed, thoroughly
out
clean
spect for any damage.
1.3
CHECK FOR LINE TIGHT ON SPOOL
The line must be wrapped firmly but free
to unwind easily during use. There should
be no loose line protruding from the
wrapped line.
the drum area and visually in-
b
OR
DIRT INSIDE
Figure 1.1
1.11
REMOVING DIFFICULT SPOOL CAPS
.CORDLESS TRIMMERS (fig.
If
the spool
break the spool cap out with
is
difficult to remove, pry or
Figure 1.1
la
l.lla)
a
screwdriver.
1.31
1.4
*-
REWIND SPOOL CORRECTLY (fig. 1.31)
a
Hook one end of the line into
on the spool, allowing no more than 1/8
of
inch
direction of arrows on spool. Wind in
level rows between spool flanges.
CHECK
Remove the spool cap to check the driver.
Inspect the driver teeth to insure that they
are not severely rounded off or completely
missing.
line to protrude. Wind line in
Figure 1.31
FOR
WORN
DRIVER TEETH (fig.l.4)
groove
900,1100,
Hold the drum steady and unscrew the
spool in counter-clockwise direction. With
the spool and core removed, pry the spool
off the core.
AND
1200
TRIMMERS
(fig.
1.11
b)
Figure 1.4
3
1.41 REPLACE DRIVER
ALL UNITS EXCEPT 1978 CORDLESS
(fig. 1.41
Remove the spool. Unscrew the core,
with driver, from the motor shaft. Gently
release the pressure the spring
against the spool core. To install the new
driver, reverse procedures.
a)
SERVICE
is
applying
INSTRUCTIONS
Inspect the spool core after removing the
spool cap. Look for broken or worn teeth
that would allow the driver to skip. A build-
of
up
driver from indexing.
dirt inside the core would stop the
1.51 CLEAN OR REPLACE CORE
Remove and replace core
ment in section 1.41.
as
driver replace-
1.6 1978 CORDLESS TRIMMER -CHECK FOR
DRUM RUBBING MOTOR
The head assembly was "press-fit" on the
motor shaft up to the heat sink.
possibly be hitting against the base of the
motor.
(fig.
.
1.6)
It
could
,-
Figure 1.41
CORDLESS 8000001 & UP
On the Cordless Trimmer (Serial No.
8000001-9115104)
pressed on
driver to remove
is
beige colored Cordless Trimmer (Serial
No. 9115105
the motor shaft. Replace the white driver
by firmly pushing
while rigidly supporting the opposite end
of the motor shaft. Note that the motor
shaft and white driver both have
side.
at
&
a
(fig.
1.41
a
white driver was
the factory. Pry off the
it.
Note: If the driver
up),
it
is
threaded onto
it
on the motor shaft,
a
b)
flat
Figure
1.6
1.61 REPLACE DRUM AND MOTOR WITH
(fig.
NEW STYLE
Replace the
a
with
# 88151 Automatic Line Feed Assembly.
To replace these components, please refer to section
# 88150 Motor Assembly and
1.61)
# 88140
2.6
and
Motor Assembly
2.7.
Figure 1.41 b
1.5 CHECK FOR DIRTY OR DAMAGED
(fig.
CORE
1.5)
Figure 1.5
4
88140~188141 88150w/88151
Figure
1.6
1
900
Home
Duty
Trimmer/ Weeder
Model Numbers 51200 and 51225
and
1100
Heavy
Duty
Trimmer/ Weeder
Model Numbers 51300 and 51325
I-
TROUBLE SHOOTING GUIDE
WIRING
-
WIRING HARNESS
UPPER
SWfTCH -SINGLE SPEED
.
SERVICE INSTRUCTIONS
INSULATED. TO MAINTAIN ITS ENGINEERED SAFETY STANDARDS USE
GENUINE TORO REPLACEMENT PARTS.
ONLY
DIAGRAM
IRING HARNESS - LOWER
CONNECTOR
CONNECTOR
I
THESE APPLIANCES FROM ALL POWER
SOURCES BEFORE ATTEMPTING ANY
2.0 CHECK
HEAD ROTATION
2.01 CLEAN HEAD AND TEST
assembly. While cleaning the head assembly,
drum and the motor for build-up. Refer
to section 1 for further details on the
automatic line feed assembly.
2.1 OPEN MOTOR HOUSING AND INSPECT
MOTOR
FOR
LINE/GRASS STOPPING
(fig. 2.0)
Depending on the environmental condi-
the
tions and
dures during trimmer use, the head assem-
bly could jam with debris, thus stopping
the head from turning or slowing
Remove any debris from about the head
be sure to check the
(fig. 2.1)
customer’s operating proce-
it
down.
(fig. 2.01)
area
between the
Figure 2.0
Figure 2.0 1
Remove the decal on the motor housing.
all
Remove
ings together. Gently separate the
halves and inspect the motor for charred
or broken wires, etc.
the screws that hold the hous-
two
7
2.1
REPLACE
MOTOR
(figs. 2.1
SERVICE
la,
2.1lb)
INSTRUCTIONS
When replacing the motor
to remove the automatic line feed assembly. Refer to section 1 for head disassem-
To
bly.
wire cutters and nip the connector in the
center of the factory crimp; pull the wires
out. Remove the roll pin by rigidly supporting the armature shaft (to prevent
bending) and driving the roll pin out.
remove the wire connectors, use
Figure 2.11a
it
is
necessary
2.22
Deformed
Figure 2.21
REPLACE DRUM
SERIAL
A
After removing the spool, driver, core and
spring
the ring and slide the spool off the shaft.
Install with 1979 parts.
SERIAL
After removing the
spring, the drum will slide off the motor
shaft. Install the new drum and reassemble.
NOS.
retaining ring
as
described in section 1, pry out
NOS.
(fig.2.22)
800001
is
used to secure the drum.
Figure 2.22
900101
spool,
and
Correct
-
899999.
UP.
driver, core and
CYA
Figure 2.1 1 b
2.2 SPIN MOTOR BY HAND
Spin the motor with your hand and notice
the feel of the armature;
freely. Visually check for excessive
commutator wear, armature end-play and
bearing to shaft fit. A binding or scraping
sound when the motor
a
evidence of
drum.
2.21 CHECK DRUM
A deformed drum means that plastic deformation has occurred to the drum
motor shaft. The drum may have slipped
up the motor shaft. A
be the spool not located inside the drum
correctly. A deformed drum must be
replaced.
bad bearing or a deformed
(fig. 2.21)
it
should turn
is
turned could be
tell-tale
sign would
at
the
2.23 BAD BEARING
TRIMMER
To pin-point
inspect for
bearing. Carefully watch the bearing.
should not spin in
the bearing while turning the motor;
drop or two of 30 wt. oil may be
is
needed to free-up the motor. If the bearing
section 2.1
warranty.
is
at
(fig. 2.23)
-
REPLACE MOTOR OR
a
defective motor bearing,
a
burned or charred shaft
its
casing. Lubricate
fault, replace the motor
1
or, replace the trimmer if in
Figure 2.23
at
all
as
the
It
a
that
per
8
SERVICE INSTRUCTIONS
2.3
CHECK MOTOR BRUSHES
Using
carefully push the brush into
away from the commutator. When released
the brush should spring back into position
against the commutator. Excessively worn
motor brushes will not make proper
contact with the commutator. Motor
brushes are not replaceable.
2.31 REPLACE MOTOR OR TRIMMER
a
scribe or other sharp object,
Figure 2.3
(fig. 2.3)
its
holder
Figure 2.41
2.5 CHECK HARNESS CONNECTIONS AT
MOTOR
Visual inspection alone will not suffice.
at
Try moving the wires
nections; the wires may slip out of the
connectors.
the motor con-
Refer to section 2.1 1 for motor replace-
ment, or replace the trimmer if in warranty.
2.4 CHECK MOTOR BRUSH SPRINGS
During shipment the motor brush spring
may have been jarred out of position,
causing no brush to armature contact and
disabling the motor.
Figure
2.4
(fig. 2.4)
2.51 SECURE CONNECTION AT MOTOR
(fig. 2.51)
Secure the loose connections
to harness junctions by recrimping the
existing connectors or installing new
connectors.
Note:Use
! A
only,
Do not use side cutters or wire cutters.
electrical crimping pliers
at
the motor
2.41 SECURESPRING / REPLACEMOTOR OR
TRIMMER
Lifting the brush spring back into position,
restore brush to armature contact. In some
cases
motor, or trimmer if in warranty.
(fig.
2.41)
the spring may be missing; replace
Figure 2.51
9
2.6
CHECK LOWER HARNESS
SERVICE
(fig. 2.6)
INSTRUCTIONS
2.61
Remove
separate the handle grip sections. Using
a
continuity tester, insert one of
into the switch alongside either of the
lower harness leads. Insert the other
tester probe into the proper connector
the motor (note lead wire color). Check
both leads for complete circuits.
all
the Phillips head screws and
Figure 2.6
its
probes
REPLACE LOWER HARNESS
(figs. 2.61 a, 2.61b)
Disconnect the ends
both the motor and the switch terminals.*
Pull the harness out of the tube(s).
place with new harness. Care should
so
be taken
when replacing the motor housings and
handle grips.
that wires are not pinched
of
the harness from
at
Re-
Figure 2.6b
2.7
TEST SWITCH CONNECTIONS
Try pulling gently on the
into the switch to be certain that both
(fig.
2.7)
w
wires leading
*
To remove each wire from the switch,
proceed
a.
b. Carefully pull wire out of switch.
c.
as
follows:
Insert
ject) into the switch alongside the
wire.
Remove drill bit.
a
#54
drill bit (or similar ob-
Figure 2.6a
2.71
2.8
Figure 2.7
SECURE LOOSE CONNECTIONS
If any of the wires leading to the switch
are loose, reinsert them firmly into the
switch. If they do not stay inserted, replace the switch (refer to section 2.81).
TEST SWITCH
Connect the tester leads
should be continuity
is
depressed. Replace any switch that
shows no current flow on either or both
sides.
(figs. 2.8 a, 2.8b)
as
only
when the switch
shown. There
10
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