Toro 51641 Service Manual

TC1000 GAS TRIMMER, MODEL 51641

Table of Contents – Page 1 of 3

ABOUT THIS MANUAL

SAFETY INSTRUCTIONS

FOR YOUR SAFETY

MAINTENANCE MAINTENANCE - AIR CLEANER MAINTENANCE - MUFFLER MAINTENANCE - SPARK PLUG MAINTENANCE - FUEL FILTER MAINTENANCE - COOLING SYSTEM MAINTENANCE - TRIMMER IMPLEMENT MAINTENANCE - FLEX SHAFT MAINTENANCE - PREPARATION FOR STORAGE

SPECIFICATIONS ENGINE SPECIFICAT IONS SERVICE SPECIFICATIONS

SPECIFICATIONS CARBURETOR SPECIFICATIONS

TOOL REQUIREMENTS:

TROUBLESHOOTING ENGINE DOES NOT PRODUCE SPARK ENGINE FLOODS DURING STARTING ENGINE NOT GETTING FUEL

TROUBLESHOOTING ENGINE LACKS POWER ENGINE HAS LOW COMPRESSION ENGINE BACKFIRES (INDICATED BY BURNT AIR CLEANER ELEMENT)

SECTION 1 CARBURETOR CARBURETOR OPERATION CARBURETOR OPERATION - THE DIAPHRAGM PUMP CARBURETOR OPERATION - FUEL METERING & MIXING CARBURETOR OPERATION - THE PRIMER SYSTEM CARBURETOR - REMOVAL CARBURETOR - DISASSEMBLY CARBURETOR - REASSEMBLY CARBURETOR - INSTALLATION CARBURETOR ADJUSTMENT - IDLE SPEED CARBURETOR ADJUSTMENT - MIXTURE CARBURETOR ADJUSTMENT - THROTTLE VALVE

TC1000 GAS TRIMMER, MODEL 51641

Table of Contents – Page 2 of 3

SECTION 2 FUEL SYSTEM FUEL TANK - FUEL TANK - REMOVAL FUEL TANK - INSTALLATION PRIMER PUMP - PRIMER PUMP - PROPER USE PRIMER PUMP - OPERATION PRIMER PUMP - DISASSEMBLY PRIMER PUMP INSPECTION PRIMER PUMP REASSEMBLY FUEL PICKUP TUBE AND FILTER SERVICE FUEL CAP - FUEL CAP - OPERATION FUEL CAP - DISASSEMBLY FUEL CAP - INSPECTION FUEL CAP - REASSEMBLY

SECTION 3 IGNITION IGNITION OPERATION IGNITION OPERATION - FLYWHEEL IGNITION OPERATION - IGNITION COIL IGNITION OPERATION - TRIGGER MODULE IGNITION OPERATION - SPARK PLUG AIR GAP ADJUSTMENT AIR GAP ADJUSTMENT - PREPARATION AIR GAP ADJUSTMENT - REASSEMBLY COIL - COIL - REMOVAL COIL - INSTALLATION

SECTION 4 RECOIL STARTER RECOIL STARTER - OPERATION RECOIL STARTER - REMOVAL RECOIL STARTER - INSTALLATION RECOIL STARTER - REEL DISASSEMBLY RECOIL STARTER - REEL REASSEMBLY RECOIL STARTER - STARTER PULLEY DISASSEMBLY RECOIL STARTER - STARTER PULLEY REASSEMBLY

SECTION 5 CLUTCH AND FLYWHEEL CLUTCH SHOES AND FLYWHEEL - OPERATION CLUTCH SHOES AND FLYWHEEL - INSPECTION CLUTCH SHOES AND FLYWHEEL - REMOVAL CLUTCH SHOES AND FLYWHEEL - REASSEMBLY CLUTCH DRUM AND CLUTCH HOUSING - CLUTCH DRUM AND CLUTCH HOUSING - CLUTCH DRUM AND CLUTCH HOUSING - REASSEMBLY

SECTION 6 ENGINE ENGINE - OPERATION ENGINE - REMOVAL FROM DRIVE TUBE ENGINE - DISASSEMBLY ENGINE - CLEANING AFTER DISASSEMBLY

TC1000 GAS TRIMMER, MODEL 51641

Table of Contents – Page 3 of 3

SECTION 6 ENGINE - Continued ENGINE - INSPECTION ENGINE - REASSEMBLY ENGINE - INSTALLATION ON DRIVE TUBE

SECTION 7 CONTROLS

CONTROL AND GRIP - REMOVAL FROM DRIVE TUBE CONTROL AND GRIP - INSTALLATION ON DRIVE TUBE

SECTION 8 HANDLE HANDLE - REMOVAL FROM DRIVE TUBE HANDLE - INSTALLATION ON DRIVE TUBE HANDLE - ADJUSTMENT

SECTION 9 SHIELD SHIELD - KNIFE REPLACEMENT SHIELD - REMOVAL FROM DRIVE TUBE SHIELD - INSTALLATION ON DRIVE TUBE

SECTION 10 CUTTER HEAD BEARINGS CUTTER HEAD BEARINGS - REMOVAL CUTTER HEAD BEARINGS - INSTALLATION

SECTION 11 FLEXIBLE DRIVE SHAFT

FLEXIBLE DRIVE SHAFT - REMOVAL FLEXIBLE DRIVE SHAFT - SERVICE FLEXIBLE DRIFT SHAFT - INSTALLATION

SECTION 12 DRIVE TUBE DRIVE TUBE - REMOVAL DRIVE TUBE - SERVICE DRIVE TUBE - INSTALLATION

SECTION 13 TAP AND TRIM HEAD

TAP AND TRIM SPOOL - TAP AND TRIM SPOOL - REMOVAL TAP AND TRIM SPOOL - LINE REPLACEMENT TAP AND TRIM SPOOL - REMOVAL TAP AND TRIM HEAD - TA P AND TRIM HEAD - DISASSEMBLY TAP AND TRIM HEAD - INSPECTION TAP AND TRIM HEAD - REASSEMBLY

SECTION 14 FLEX BLADE

FLEX BLADE - REMOVAL FROM DRIVE SHAFT FLEX BLADE - INSTALLATION ON DRIVE TUBE

SECTION 15 ACCESSORIES STANDARD AND DELUXE HARNESS - ASSEMBLY

ABOUT

THIS

MANUAL

This Service Manual was written expressly for the

Powered Trimmer. The Tor0 Company had made every effort to make the information in this manual complete and correct.

This manual was written with the service technician in mind. It

so

that information used most often is up front. As a result, you will find reference information on safety, maintenance, specifications, special tools and troubleshooting all in the front third of the manual.

Disassembly, inspection and reassembly procedures are covered in the last

two-thirds of the manual and are grouped by component. each common repair with its own section or sub-section. For example, you will find that air gap adjustment and ignition coil replacement are called out separately.

And, because certain components are often difficult to troubleshoot without a good understanding of how they work, we have included some component theory. This information can be found at the beginning of most service procedure sections.

We

are hopeful that you will find this manual a valuable addition to your shop. If you should come across any errors or regarding this manual, please contact us at the following address:

The Tor0 Company

8111 Lyndale Avenue South

Minneapolis, MN, USA

TOR0

if

you have any questions

55420

TClOOO Gas

is

organized

We

tried to cover

The Tor0 Company reserves the right to change product specifications or this manual without notice.

The Tor0 Company gratefully acknowledges the assistance of Mitsubishi Heavy Industries, Ltd. in the production of this manual.

COPYRIGHT RIGHTS

Tor0 Company

MINNEAPOLIS,

MN

55420

RESERVED

1987

U.S.A.

Reference Information

For Your Safety 1

TABLE

OF

CONTENTS

Page

Maintenance

Specifications

Tool

Requirements 7

Troubleshooting

Service Procedures

Section 1

Carburetor

operation removal 13

disassembly 13 reassembly 15

installation 17 adjustment 17

2

5

8

Page

10

I

Section

2

Fuel System

Fuel Tank

removal 19 installation 19

Primer Pump

properuse 19 operation 19

disassembly inspection

reassembly

Fuel Pickup Tube and Filter

service

Fuel Cap

operation 21 disassembly

inspection reassembly

20

20 20

21

22

Service Procedures

j

Section 3

(continued)

Ignition

operation 23 air gap adjustment 25 coil removal 26

coil installation 26

Page

Section 4

Section

Section 6

5

Recoil Starter

operation 27 removal 27

installation 27 reel disassembly 27

reel reassembly 28 starter pulley disassembly 29 starter pulley reassembly 29

Clutch

Clutch Shoes and Flywheel

operation 30 inspection 30 removal reassembly 31

Clutch Drum and Clutch Housing

disassembly 31 reassembly 31

Engine

operation 32 removal from drive tube 34

disassembly 35

cleaning after disassembly 36 inspection 37

reassembly 38 installation on drive tube 39

30

Section 7

Section 8

Section 9

Controls

Control and Grip

removal from drive tube 40 installation on drive tube 40

Handle

removal from drive tube 41 installation on drive tube 41 adjustment 41

Shield

knife replacement 42 removal from drive tube 42

installation on drive tube 42

Service Procedures

(continued)

I

Section 10

Section 11

Section 12

Section 13

Cutter Head Bearings

removal installation

Flexible Drive Shaft

removal installation

Drive Tube

removal service installation

Tap and Trim@ Head

Tap and Trim@ Spool

Tap and Trim@ Head

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

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

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

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

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

removal line replacement installation

disassembly

inspection

reassembly

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

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

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

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

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

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

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

Page

43 43

44

45

46 46 46

47 47 47

Section 14

Section 15

Flex Blade

removal from drive shaft 48 installation on drive tube

Accessories

Standard and Deluxe Harness

assembly

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

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

48

49

PERSONAL SAFETY

INSTRUCTION Read the instruction because it has to Failure to comply with

the instruction may result

or death.

SAFETY

do

with the safety.

in

personal injury

INSTRUCTIONS

This manual is intended as a service and repair manual only. The safety instructions provided in this manual are for the troubleshooting and service of the product only. The individual Operator's Manual will contain safety information

on

the operation of the TC1000.

Operator's Manuals with complete operational safety instructions are available through:

The Toro Company

Publications Department

8111

Lyndale Avenue South

Minneapolis, MN

55420

U.S.A.

FOR

Avoid possible explosions Store fuel in a container designed for gasoline and never smoke while working around gasoline.

Avoid fires Never allow the trimmer engine closer than one meter (three feet) to any combustible material.

Avoid accidental misuse of fuel Always store fuel in a container designed for gasoline that is properly labeled.

Avoid falls Always wipe up spilled fuel or oil.

Avoid asphyxiation

Never operate an engine in a confined area

without proper ventilation.

. .

.

. . .

.

. .

YOUR

SAFETY

gas

.

trimmer.

Avoid unexpected starting of the engine Always disconnect the spark plug wire before attempting any cleaning, adjustment or repair.

Avoid contact with a moving cutter head. Always stay clear engine is running. The clutch is a mechanical device which could fail.

the cutter head from turning. Avoid blindness

Always wear eye protection when repairing or running a gas trimmer.

Avoid hearing Wear ear protection when running a

. . .

loss

of

the cutter head when the

Do

not rely on it to keep

. .

.

. .

.

1

MAINTENANCE

Maintenance

Air

Cleaner

Servicing of the air cleaner is recommended afterevery25 hours of operation or more often in very dusty conditions.

See Fig.

AIR

1.

FILTER GRID

Maintenance Muffler

Decarbonizing the muffler

every

50

hours of operation or if engine speed

is

recommended after

decreases drastically.

1.

Remove the three screws securing the muffler cover to the trimmer. See Fig.

careful not to

lose

the spacer and gasket

material beneath the spark plug protector

screw.

SPACER

2.

Be

Figure

1.

Remove the two screws securing the air

1

cleaner cover to the trimmer

2.

Carefully remove the filter grid, foam filter

and filter screen.

3.

Wash the foam filter in a soap and water solution and dry thoroughly.

If

the filter

shows any sign of damage, replace it.

4.

Saturate the foam filter with

SAE

30

teaspoon) of

oil, then squeeze to

5

ml (one

distribute the oil evenly and to remove excess oil. The element should be damp but not wet.

5.

Wash the filter screen in a clean solvent and air dry.

If

the filter screen shows any signs of

damage, replace it.

6.

Reinstall the air cleaner components as shown in Fig.

1.

Note that the flat side of the

filter grid faces the foam filter.

Figure

2.

Remove the screw securing the muffler

2

and gasket to the muffler body. See Fig.

MUFFLER

BOD

LID

lid

3.

7.

Tighten the air cleaner screws to kg m

(9

to

13

in Ibs)

0.1

to

0.15

2

P\

Maintenance Muffler (cont'd)

3.

Rotate the engine crankshaft until the piston totally covers the exhaust port. Clean the exhaust port area by using a clean flat piece of hardwood. Remove all loose particles.

IMPORTANT Use extreme care when cleaning the exhaust port. Stay clear of the piston

so

it will not be damaged.

4. Clean any carbon buildup inside the muffler body.

5.

Make sure the muffler gasket is still useable (replace muffler body and muffler lid to trimmer.

6. Reinstall muffler cover and tighten all fasteners securely. Be sure to install the spacer

underneath the spark plug protector as

shown in Figure 2.

if

necessary) and install gasket,

pickup tube above the filter. Pull the filter and hose out the fuel tank opening. See Fig. 4.

r'l

Maintenance Spark Plug

The TC1000 uses an equivalent. Correct gap is 0.6-0.7 mm (0.024-

0.028"). The recommended servicing interval for the spark plug is 25 hours of operation.

1. Stop the engine and pull off the spark plug wire.

2. Clean around the spark plug and remove the spark plug from the engine using a 19mm

(3/4 inch) socket.

IMPORTANT: Replace a cracked, fouled dirty spark plug. clean electrodes because engine damage could result from grit entering the cylinder.

3. Set the plug gap to 0.6-0.7mm (0.24-0.28").

4. Reinstall the plug and gasket in the engine. Tighten to 1.2 kg m (104 in Ibs).

Maintenance Fuel Filter

Fuel filter replacement is recommended after every 25 hours of operation.

1.

Drain the fuel from the fuel tank into a container designed for gasoline. Start the engineand let it run at idlespeed until it stops and all fuel is expended.

2. Remove the fuel tank cap. Insert a clean wire with a hooked end into the tank and hook the

NGK

BM6A spark plug or

Do

not sand blast, scrape

or

Figure 4

3. Remove the filter by holding the black tubing and pulling the filter straight off.

4.

Replace the filter assembly.

5.

Push the pickup assembly back into the tank

and install the gas cap.

Maintenance Cooling System

Before each use, visually inspect the cooling air

inlet, the cooling fins, and the openings around the muffler for debris. Obstruction of these areas could lead to overheating and possible engine damage.

IMPORTANT: Be careful not cooling fins during cleaning.

Maintenance Trimmer Implement

The trimmer implements require no lubrication.

However, cleaning

drive shaft area is recommended after every 25 hours of operation. More frequent cleaning may be required

implement area gets excessively hot. Refer to either

Flex Blade,

and cleaning of your particular implement.

if

trimming in very tall grass or

page 48, for information on removal

of

the implement and the

Tap and Trim Head@,

to

damage

page 46, or

if

the

3

Maintenance Flex Shaft

After every 40 hours of operation, the flexible drive shaft should be removed from the drive shaft housing and all surfaces should be evenly greased with a number 2 general purpose lithium

base grease.

1. Remove the machine screw and nylon locknut that secures the bearing housing to the

drive tube. See Fig.

5.

Figure

5

2. Pull the bearing housing, shield and trimmer implement off the drive tube as an assembly.

3.

Using a needle nosed pliers, pull the flexible

shaft out of the drive tube.

4. Grease the entire length of the shaft with a light coat of #2 general purpose lithium base

grease.

5.

Insert the flexible shaft into the nylon sleeve.

Make sure that the shaft seats properly in the clutch drum. Proper seating is obtained when the flexible shaft is 10 mm inside the drive tube. See Fig.

6

(3/8

inch)

6.

Mount the bearing housing, shield and trimmer implement assembly on the drive tube. It may be necessary to turn the trimmer

implement slightly in order to get the flexible shaft to mate properly with the cutter head drive shaft.

7.

Install the machine screw that fastens the

bearing housing to the drive tube and secure with a new nylon locknut.

Maintenance Preparation for Storage

The following procedure is recommended to ensure proper operation of the trimmer before storage of more than a month.

1. Drain the fuel from the tank into a container designed for gasoline. Start the engine and

let it run at idle speed until it stops and all fuel is expended.

2. Remove dirt and grime from external parts of the trimmer. Ensure that the cooling fins are clean.

3.

Pull the spark plug wire off the spark plug. Clean around the plug

so

that debris will not fall into the spark plug hole when the plug is removed. Remove the spark plug.

4. Pour 5 ml (one teaspoon) of two-cycle oil into the spark plug hole. This will prevent corrosion from damaging internal engine components.

5.

Pull the recoil starter handle several times to distribute the oil throughout the engine.

6.

Reinstall the spark plug. Tighten it to 1.2 kg m (104 in Ibs). DO NOT CONNECT PLUG

WIRE

TO THE SPARK PLUG.

DRIVE

Figure

TUBE

6

FLEX

SHAFT

4

Engine Specifications

SPECIFICATIONS

Type

Bore x Stroke

Displacement Compression Ratio

Continuous Rated Output Maximum Output

Maximum Torque Engine Rotation Idle Speed Clutch Engagement Speed Fuel Fuel Tank Capacity

Carburetor

Ignition System

Spark Plug Starting System Lubrication

Air Cooled, 2 cycle, gasoline

x

30 mm (1.02 x 1.18 in.)

26

15.9 cc

.________--

(0.97

cu. in.)

8.0 to 1

0.5

PS

@

7000

rpm

(0.50

BHP

@

7000

rpm)

0.8

PS

@

7000

rpm

0.07

kg m

@

7000

Counterclockwise 3000

300

rpm

(0.55

rpm (6.0 in Ibs

(as

BHP

@

7000

rpm)

@

_______.___-

7000

viewed from PTO end)

rpm)

3900 300 rpm

32 parts unleaded gasoline to 1 part B.I.A. certified 2 cycle

0.4

I

(13.5

02)

.__-

Diaphragm with piston valve

Solid state, transistorized

NGK BM-6A, Champion

CY6,

or AC

CS45

Recoil Oil mixed directly with gasoline

oil

Service Specifications

I

Item

Spark Plug Gap

Ignition Coil Air Gap

Crankshaft Runout

Cylinder Diameter

Piston Diameter

Piston to Cylinder Clearance

Piston Ring

Piston Ring Side Clearance

Standard Dimension

0.6 to

0.7

mm

(0.024 to 0.028")

0.5

0.4 to

mm

(0.016 to 0.020")

0

to

0.05

mm

(0

to .002")

26.00 to 26.02 mm (1.0236 to 1.0244")

______-

25.94 to 25.96 mm (1.021 to 1.022")

0.04 to 0.08 mm

(.00016 to 0.0032")

0.1 to 0.3 mm (0.004 to 0.012")

0.02 to 0.06 mm

(0.0008 to 0.0024)

__-

Allowable Limit

N/A

0.06 mm (.0025")

Until plating exfoliates

See piston to cylinder clearance

0.05

mm

0.7

mm

0.15 mm

5

Carburetor Specifications

SPECIFICATIONS

Item

Throttle Valve Needle Jet High Speed Mixture Screw

Idle Speed Adjusting Screw

Inlet Needle Arm Height (from body surface)

Valve Spring Valve Opening Pressure Valve Closing Pressure

Fastener Torques

Standard

Clip positioned in middle groove

3 turns out 1/2 turn

Adjust

__-

1.4

so

idle is 2300 to 2700 rpm

to 1.6 mm

(0.055

to 0.063")

TOOL

Flywheel Puller Toro P/N 41-7650 Dial Indicator

REQUIREMENTS

Spark Tester Toro P/N 41-7890 Magnetic Tachometer Toro P/N 42-2730 Spark Plug Gapping

Feeler Gauge Torque Wrench (14/16) Compression Gauge Threebond #1104 Toro P/N Metric Socket Set

Spark Plug Socket Micrometer

#2 Phillips Screwdriver Snap Ring Plier (inside

12

oz.

Ball Peen Hammer Hex. Key Set

Needle Nose Pliers

3/8"

Drive Loctite #242 Toro P/N 505-76

V

Blocks

&.

Dial Indicator Stand

Tool

505-80

&

outside type)

7

Engine Does Not Produce Spark

Engine Floods During Starting

TROUBLESHOOTING

control and turn switch around

eplace trigger module

Possible Causes

Operator not Depressing Tickler Valve

During Priming Stale Gasoline Mix fresh fuel Choke Not Opening Replace damaged

Incorrect Gas:Oil Ratio

Tank not Venting Properly

Debris in Carburetor

Engine Not Getting Fuel

Possible Causes

Fuel Tank Empty Fuel Filter Clogged

Gas Cap not Venting Properly Diaphragm Pump not Functioning

Remedy

Explain proper starting procedure to operator

Use fuel with Repair Clean carburetor

Remedy

Fill fuel tank Replace fuel filter Replace defective fuel line Repair or replace gas cap

Rebuild carburetor

or

broken parts

32.1

gasoil ratio

replace gas cap

Crankcase Leak

Repair leak

_____-

TROUBLESHOOTING

Engine Lacks Power

Possible Causes Remedy

Grass Wound around Trimmer Head Clean trimmer head

Gas:Oil Ratio Stale Fuel Carburetor Improperly Adjusted Adjust carburetor Flywheel Key Sheared or Missing

Low Compression

Engine Has Low Compression

Possible Causes Remedy

Insufficient Oil in Fuel

Piston Rings Excessively Worn Air Leak in Lower Crankcase Replace lower crankcase seals Air Leak in Cylinder Mounting Area Air Leak at Spark Plug

;s,”

;3;h;;;pi

Replace flywheel key

“Low

See

Use fuel with gasoil ratio Rebuild engine

Replace gasket and tighten mounting bolts Replace defective plug or cylinder

I

ratio

Compression”

I

Engine Backfires

Possible Causes

Muffler and Exhaust Port Plugged with Carbon

Sheared or Missing Flywheel Key Operator Constantly Revving Engine

(indicated by burnt air cleaner element)

Decarbonize muffler and exhaust ports

Replace flywheel key Educate Operator

I

__.-

9

SECTION

1

Carburetor Operation

The carburetor for the TC1000 is a diaphragm

style carburetor. It uses alternating pulses from the crankcase to pump fuel from the fuel tank to the carburetor.

To adequately describe the function of the car-

buretor, it is necessary to break its operation

down into three systems:

-The Diaphragm Pump Fuel Metering and Mixing System

The Primer System

Carburetor Operation The Diaphragm Pump

The diaphragm pump requires alternating positive and negative air pressures working upon it in

order to fluctuate and perform a pumping function. The source of the positive and negative pressures is the lower crankcase where these pressures are alternately being created by the up and down movement of the piston.

Transfer of these pressure pulses is accomplished by a passage which leads from the lower crankcase, to a point just below the intake port. See Fig.

7.

PULSE PASSAGE

PULSE PASSAGE PULSE HOLE

Figure

The pulses

As

the piston moves upward, vacuum is created

vary

with the movement of the piston.

8

which pulls the diaphragm toward the pulse hole. This movement results in three things happening on the pump cover side of the diaphragm. See Fig.

1.

The outlet flapper valve is drawn toward the

9.

pump cover. This seals the outlet passage to ensure that fuel is drawn only through the fuel inlet.

2.

The inlet flapper valve is pulled open to allow

fuel toflowfrom thefuel line

into

thefuel inlet

cavity.

3.

Fuel is drawn into the fuel pump cavity.

Figure

7

From there, the passage leads through the intake flange and into the carburetor. It /terminates in the diaphragm chamber at a point called the pulse hole. See Fig.

8

10

FUEL PUMP

FUEL INLET

COVER

CAVITY

Figure

._I

9