Toro 51603, 51604, 51630 Service Manual

GAS TRIMMER GUIDE, MODELS 51630, 51603, 51604

Table of Contents – Page 1 of 1

FOREWORD

GENERAL INFORMATION

MAINTENANCE PROCEDURES AIR CLEANER 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

GASOLINE POWERED TRIMMER

&

MAINTENANCE

REPAIR GUIDE

MODEL

NO.

51630

1000001

2000001 2000001 & UP

& &

UP

COPYRIGHT(C)

The

MINNEAPOLIS, MN

Tor0

ALL

Company

RIGHTS

55420

RESERVED

-

1982

U.S.A.

Form

492-0266

FOREWORD'

This Maintenance and Repair Guide will provide you

accomplish the maintenance and repair of gasoline-powered flexible line trimmers powered by

the new The number of repair procedures for this line of engine;s has been limited for simplicity and

economy The repairs are easy to accomplish. even for operators or mechanics who have

limited experience Should you require additional information concerning these trimmers.

us Address inquiries to:

General Information

Two-cycle Engine -Theory of Operation

Engine operation Engine Specifications

Engine Torque Specifications

Maintenance Procedures

Air Cleaner Maintenance

Exhaust system Maintenance Flexible Drive Shaft Maintenance Carburetor Adjustments; Model TC-1500 (Tillotson Carburetor) Carburetor Adjustments; Models TC-300 & TC-400 (Walbro carburetor)

Troubleshooting and Test Procedures

Preliminary Checks:

Testing Cylinder Compression Compression Test Procedure Checking For Spark

Checking Fuel Tank Engine Troubleshooting Chart

Checking Fuel Tank Checking the Stop Switch

Disassembly. Repair. Reassembly Instructions

Trimmer Engine Removal. Disassembly. Replacement

Starter Rope Replacement Starter Assembly Replacement

Walbro Carburetor Operation Walbro Carburetor Servicing

Cutter Head Troubleshooting Chart Clutch Repair

Automatic Line Feed Repair

line

of the lightweight two-cycle engines manufactured by The Tor0 Company

in

the repair of small two-cycle engines

TABLE

venting

OF

with

complete information necessary to

The Tor0 Company

8111

Lyndale Avenue South

Minneapolis

Attn.. Service Department

CONTENTS

......................................

MN

we

urge you to write to

55420

PAGE

1-3

1 1

3 3

4-7

4

5

5-6 6-7

7-9

7 7

7 8

8

9 8

8

10-18

10 12

13 14

16 17

18

GENERAL INFORMATION

Two-cycle

Two-cycle engines are used on TORO Trimmers because of their:

1.

Light weight.

2.

Excellent power-to-weight ratio

3.

Ability to operate

4. Easy maintenance

5. Simple construction

The

TORO

TC-300 and TC-400 Trimmers is a third-port, loop-

scavenged design. This design name describes the path combustion chamber, and the exhausting of spent gases (Fig.

Engine Theory

in

any position

Two-cycle Engine used on the TC-1500,

of

the fuel/air mixture into the crankcase and

1

of

Operation

Engine Operation The piston closes all engine ports as

the combustion chamber (Fig. creates high pressure and partial vacuum

,

2).

The moving piston

in

the combustion chamber

in

the crankcase.

it

moves toward

st Port

\

transfer

(Both

Cylinder)

Figure

In

a loop-scavenged engine flow of the fuel/air mixture can be described as follows: (See Fig.

1.

The fresh fuel/air mixture enters the crankcase through the third-port on The oil

moving parts

2.

The fuel/air mixture is transported through the fuel transfer ports to the combustion chamber where from the engine through the exhaust port.

it

1).

in

the fuel/air mixture lubricates the

within

is compressed, ignited, and then expelled

1

with

a third-port, the

the

side of the cylinder.

the crankcase.

Figure

Compression Stroke

At a point slightly before top dead center (BTDC) of the piston travel, the spark from the plug ignites the fuel air mixture (Fig. port opens allowing the fresh fuel/air mixture to rush into the crankcase to equalize the partial vacuum.

Piston

at or

T.D

Near

Exhaust

Closed

Lubricates

C.

Port

Fresh Fuel/Air Mixture

Moving

3).

Parts

Figure

Ignition

2

Also, at this time, the third-

Spark

Fuel/Air Mixture

Ignites

I

Open

3

1

GENERAL

INFORMATION

The combustion chamber force the piston down the cylinder, closing the third-port and increasing the pressure the bottom of the stroke, the exhaust port opens and the burnt gases begin to be expelled from the combustion chamber (Fig.

banding gases from the burning fuel

e expanding

in

the crankcase. At a point approaching

4).

in

the

Closed

At a point of piston travel slightly before bottom dead center

the

pressed fuel/air mixture in the crankcase to expel the burnt gases and charge the chamber fa

the

(BBDC)

cylinder walls, are uncovered and the com-

enter

following piston stroke (Fig.

the fuel transfer ports, on the sides

is

allowed

the combustion chamber where they help

5).

c

Mixture Compressed

Figure

Power/Exhaust

4

Exhaust/Fuel transfer

Figure

5

ENGINE

SPECIFICATIONS

(Model51630) (Model51603)

Genuine TOR0 Two-Cycle Oil or other high quality two-cycle oil, BIA

TC

TC300

32:1

or

unleaded regular leaded

approved

.40

(13.5

TC400

(model 51604)

oz.)

CooIing~Shroud Carburetor Mounting Screws

Screws

t

Fillotson ModelSP-1A

with

self contained fuel

pump, accelerator pump and filter screen

pump and

Factory adjusted and

Procedures-pp. test run.

filter

screen

Solid state,-capacitive discharge ignition(CD1)

1.29-1.67mm(-051-066 in.)BTDC .20-.30mm (.008-.012

WalbroWa-120series with

self

contained fuel

Factory adjusted and test run.

Adjusting Procedures

22degrees BTDC

in.)

ENGINE TORQUE SPECIFICATIONS

TORQUE-Kg-cm/Kg-m

.35-41Kg-cm

23-35Kg-cm

29-40Kg-cm-15-35

12-23Kg-cm10-20in-lbs

~.TORQUE-in.-lbs/ft-lbs

30-45in.-lbs. 20-30in-lbs

in.-lbs.

NOTE: Metric Torque Conversions:

inch-pounds X1.152= kilogram-centimeters foot-pounds

X

.1383

=

kilogram-meters

29-40Kg-cm 23-35kg-cm

25-35in.-lbs.

3

MAINTENANCE PROCEDURES

AIR CLEANER MAINTENANCE

Check and clean the foam air cleaner element every eight operating hours, and the felt air cleaner once season.

1.

Remove the air cleaner cover by pressing up on

the bottom of the cover to release the lower

mounting tab and pressing

to release the upper tab.

2.

Carefully remove the filter clip or filter retainer.

Remove the foam filter and felt filter (Figures

and

7).

Air Cleaner Housing

in

on front

DO

NOT FORCE.

of

the cover

a

6

5.

Inspect the felt filter. If solvent and air dry of ,damage

6.

Reinstall the felt filter, foam filter, and filter clip or retainer

it

must be replaced.

in

the air cleaner housing (Figures 6 and

it

is dirty, wash

it.

If the filter shows any sign

it

in

7).'

IMPORTANT: Make sure the peg

housing fits through the small hole filter. Both filters must cover the opening air, cleaner housing.

7.

Reinstall the air cleaner cover by pressing the cover

in,

and up, behind the choke lever and then

press the lower mounting tab into the hole engine housing.

DO

NOT FORCE.

in

the air cleaner

in

the

clean

felt

in

the

in

the

Air Cleaner Housing

Felt Filter

Press Here to Remove

Figure

6

EXHAUST

NOTE: Some states require that a spark arrester be attached to the muffler if the trimmer is to be used forested areas, or on other public lands. Be sure to check your local state laws before using your gasoline powered trimmer.

An important part of the maintenance procedure for

all

two-cycle engines is the cleaning or decarboning

of

the

unobstructed flow of exhaust gases and particles

from the combustion chamber. A severely carboned

muffler, spark arrester screen. and/or exhaust port

will

cause poor starting and low power output of the

trimm'er engine.

1.

Remove the muffler shield, screen, muffler and

exhaust gasket.

2.

Soak the screen

build-up

3.

Clean the muffler baffle holes inside the muffler

with a screwdriver.

4.

Check the cylinder exhaust port. If necessary,

remove the carbon deposits from the port using a

SYSTEM

exhaust system. This is done to assure the

with

wiiden

stick (Fig.

MAINTENANCE

in

solvent and remove the carbon

a wire brush, or replace the screen.

8).

in

3.

Wash the foam filter and dry thoroughly. If the filter shows any sign of damage or deterioration, replace

4.

Saturate the foam filter SAE

30

oil. Squeeze the filter to distribute the oil

evenly and to remove excess oil. A damp element

is necessary to ensure proper functioning of the

air cleaner.

4

in

a soap and water solution

it.

with

one teaspoon (5ml)

Figure

8