Toro 51644, 51645, TC3000, TC4000, TC5000 Service Manual

TC3, 4, 5000 GAS TRIMMER, MODELS 51643, 51644, 51645

Table of Contents – Page 1 of 4

ABOUT THIS MANUAL

SAFETY INFORMATION

FOR YOUR SAFETY...

SPECIFICATION

TOOL REQUIREMENTS:

TROUBLESHOOTING

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

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

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

TC3, 4, 5000 GAS TRIMMER, MODELS 51643, 51644, 51645

Table of Contents – Page 2 of 4

SECTION 2 FUEL SYSTEM - Continued 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 TC3000/TC4000 AIR GAP ADJUSTMENT - PREPARATION TC3000/TC4000 AIR GAP ADJUSTMENT TC3000/TC4000 AIR GAP ADJUSTMENT - REASSEMBLY TC5000 AIR GAP ADJUSTMENT - PREPARATION TC5000 AIR GAP ADJUSTM ENT TC5000 AIR GAP ADJUSTMENT - REASSEMBLY COIL - COIL - REMOVAL COIL - INSTALLATION

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

SECTION 5 CLUTCH SHOES AND FLYWHEEL CLUTCH SHOES AND FLYWHEEL - OPERATION CLUTCH SHOES AND FLYWHEEL - DISASSEMBLY 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 ISOLATION MOUNT (TC4000 AND TC5000 ONLY) - ISOLATION MOUNT - ISOLATION MOUNT - DISASSEMBLY ISOLATION MOUNT - REASSEMBLY

SECTION 6 ENGINE ENGINE - OPERATION ENGINE - REMOVAL FROM DRIVE TUBE

TC3, 4, 5000 GAS TRIMMER, MODELS 51643, 51644, 51645

Table of Contents – Page 3 of 4

SECTION 6 ENGINE - Continued ENGINE - DISASSEMBLY ENGINE - CLEANING AFTER DISASSEMBLY ENGINE - INSPECTION ENGINE - REASSEMBLY ENGINE - INSTALLATION ON DRIVE TUBE

SECTION 7 CONTROLS

CONTROL - DISASSEMBLY CONTROL - REASSEMBLY GRIP - REMOVAL GRIP - INSTALLATION

SECTION 8 HANDLE TC3000 HANDLE - REMOVAL FROM DRIVE TUBE TC3000 HANDLE - INSTALLATION ON DRIVE TUBE TC3000 HANDLE - ADJUSTMENT TC4000 HANDLE - REMOVAL FROM TUBE TC4000 HANDLE - INSTALLATION ON DRIVE TUBE TC4000 HANDLE - ADJUSTMENT TC5000 HANDLE - REMOVAL FROM DRIVE TUBE. TC5000 HANDLE - INSTALLATION ON DRIVE TUBE TC5000 HANDLE - ADJUSTMENT

SECTION 9 SHIELD

SHIELD - REMOVAL FROM DRIVE TUBE SHIELD - INSTALLATION ON DRIVE TUBE SHIELD - MOUNTING CUTTER KNIFE ON SHIELD

SECTION 10 GEARBOX

GEARBOX - REMOVAL GEARBOX - INSTALLATION ON DRIVE TUBE GEARBOX - SEAL REMOVAL GEARBOX - SEAL INSTALLATION

SECTION 11 DRIVE SHAFT AND TUBE

DRIVE SHAFT - DRIVE SHAFT - REMOVAL DRIVE SHAFT - INSTALLATION DRIVE TUBE - DRIVE TUBE - REMOVAL DRIVE TUBE - INSTALLATION

SECTION 12 LEECO MANUAL FEED HEAD

LEECO MANUAL FEED HEAD - SPOOL REMOVAL LEECO MANUAL FEED HEAD - LINE REPLACEMENT LEECO MANUAL FEED HEAD - SPOOL INSTALLATION

TC3, 4, 5000 GAS TRIMMER, MODELS 51643, 51644, 51645

Table of Contents – Page 4 of 4

SECTION 12 LEECO MANUAL FEED HEAD - Continued LEECO MANUAL FEED HEAD - DISASSEMBLY LEECO MANUAL FEED HEAD - INSPECTION LEECO MANUAL FEED HEAD - REASSEMBLY

SECTION 13 KAAZ MANUAL FEED HEAD

KAAZ MANUAL FEED HEAD - DISASSEMBLY KAAZ MANUAL FEED HEAD - LINE REPLACEMENT KAAZ MANUAL FEED HEAD - REASSEMBLY

SECTION 14 PLASTIC FIXED LINE HEAD

PLASTIC FIXED LINE HEAD - LINE REPLACEMENT PLASTIC FIXED LINE HEAD - REMOVAL

SECTION 15 METAL FIXED LINE HEAD

METAL FIXED LINE HEAD - LINE REPLACEMENT METAL FIXED LINE HEAD - REMOVAL METAL FIXED LINE HEAD - INSTALLATION

SECTION 16 TAP AND TRIM HEAD

TAP AND TRIM LINE REPLACEMENT - TAP AND TRIM SPOOL - TAP AND TRIM SPOOL - LINE REPLACEMENT TAP AND TRIM SPOOL - INSTALLATION TAP AND TRIM HEAD - DISASSEMBLY TAP AND TRIM HEAD - INSPECTION TAP AND TRIM HEAD - REASSEMBLY

SECTION 17 METAL BLADES

METAL BLADE - REMOVAL METAL BLADE - INSTALLATION

SECTION 18 HARNESSES STANDARD AND DELUXE HARNESS - ASSEMBLY

SECTION 19 SPARK ARREST O R MUFFL ER

SPARK ARRESTOR MUFFLER - REMOVAL SPARK ARRESTOR MUFFLER - INSTALLATION SPARK ARRESTOR MUFFLER - MAINTENANCE

ABOUT

This Service Manual was written expressly for the Tor0 TC3000, TC4000 and TC5000 Gas Powered Trimmers. The Tor0 Company had made every effort to

make the information

in

this manual complete and correct.

THIS

MANUAL

This manual was written with the service technician that information used most often is

information on safety, maintenance, specifications, special tools and

troubleshooting all

Disassembly, inspection and reassembly procedures are covered two-thirds of the manual and are grouped by component. We tried to cover 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 of 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 if you have any questions regarding this manual, please contact us at the following address:

in

the front third of

81

11

Bloomington, MN, USA 55420

up

front. As a result, you will find reference

the

manual.

The Tor0 Company

Lyndale Avenue South

in

mind.

It

is organized

in

so

the last

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.

(C)

The Toro Company

MINNEAPOLIS,

MN

1987

55420 -USA

Reference Information

Safety Information Specifications 2

Tool Requirements

TABLE OF CONTENTS

Page

1

5

Service Procedures

Section

Section 2 Fuel System

1

Troubleshooting Maintenance

Carburetor Page

operation 11 removal

disassembly 14

reassembly 16 installation 18 adjustment 18

Fuel Tank

removal 20 installation 20

6

8

14

Primer Pump

properuse 21 operation

disassembly 22 inspection 22

reassembly 22

Fuel Pickup Tube and Filter

service 23

Fuel Cap

operation 23 disassembly 24 inspection 24 reassembly 24

21

Service Procedures (cont'd)

TABLE

OF

CONTENTS

Page

Section

5

operation airgapadjustment coilremoval coil installation

Recoil Starter Recoil Mechanism

operation removal disassembly reassembly

installation

Starter Pulley

removal installation

Clutch and lsomount Clutch Shoes and Flywheel

operation disassembly

inspection

25 27 28 29

30 30 30 31

32

33 33

34 34

34

Section

6

removal reassembly

Clutch Drum and Housing

disassembly reassembly

lsomount

Engine

(TC4000

operation

disassembly reassembly

operation removal

disassembly cleaning after disassembly inspection

and TC5000 only)

from

drive tube

35 35

36 37

37

38

40

41 42

43

Service Procedures (cont’d)

Section 6 Engine (cont’d)) Page

TABLE

OF

CONTENTS

Section

8

7

reassembly installation on drive tube.

Control and Grip Control

disassembly 46

reassembly

Grip

removal installation

Handle

TC3000

removal from drive tube 48 Installation on drive tube. 48

adjustment

TC4000

removal from drive tube installation on drive tube. adjustment.

44

45

48 48 49

Section

9

10

TC5000

removal from drive tube installation on drive tube.

adjustment.

Shield

removal from drive tube installation on drive tube. mounting cutter knife on shield

Gearbox

removal from drive tube

installation on drive tube. sealremoval sealinstallation

49

50

52

53

54 54

Service Procedures (cont’d)

Drive Shaft

Drive

TABLE

removal 56 installation 56

Tube

removal 56 installation 57

OF

CONTENTS

Section

Section 14 Plastic Fixed Line Head

12

13

Leeco@ Manual Line Feed Head

sped

removal 58 linereplacement 58

installation 58

Head

disassembly 59 inspection 59 reassembly 59

Kaaz@ Manual Line Feed Head

head disassembly 61 linereplacement 61 headreassembly 62

linereplacement headremoval 63 headinstallation 64

63

Section 15 Metal Fixed Line Head

linereplacement headremoval headinstallation

Section 16 Tap and Trim@ Head

Spool

removal 67 linereplacement 67 installation 67

65

66

Service Procedures (cont’d)

TABLE

OF

CONTENTS

Section

Section 17

Section 18

Section 19

Tap and Trim@ Head (cont’d)

Head

disassembly 68 inspection 68

reassembly 68

Metal Blades

removal 69 installation 69

Harnesses

assembly

Spark Arrestor Muffler

removal 71 installation 71 maintenance 71

Page 16

70

SAFETY INFORMATION

This manual is intended

this safety symbol manual only. The safety instructions provided

means WARNING CAUTION product only. The individual Operator’s Manual will

A

INSTRUCTION Read the instruction TC3000. because Failure to comply with the instruction may result

PERSONAL SAFETY contain safety information on the operation of the

it

has to do

in

personal injury

with

or

FOR

or

safety.

death.

YOUR SAFE

manual are for the troubleshooting and service of the

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

as

TC4000.

Minneapolis,

or TC5000.

The Tor0 Company

Publications Department

81

11

Lyndale Avenue South

MN

TY...

a service and repair

55430

U.S.A.

in

this

I----

Avoid possible explosions Avoid unexpected starting of the engine Store fuel in a container designed for gasoline and Always disconnect the spark plug wire before never smoke while working around gasoline. attempting any cleaning, adjustment or repair.

Avoid fires Avoid contact with a moving cutter head Never allow the trimmer engine closer than one meter Always stay clear of the cutter head when the engine (three feet) to any combustible material. is running. The clutch is a mechanical device which

Avoid accidental misuse of fuel Always store fuel in an approved container that is properly labeled.

Avoid falls Always wipe up spilled fuel or oil.

Avoid asphyxiation Never operate an engine proper ventilation.

in

a confined area without

could fail. Do not rely on

from turning. Avoid blindness

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

Avoid hearing

Wear ear protection when running a gas trimmer.

loss

it

to keep the cutter head

1

Engine Specifications

SPECIFICATIONS

TC3000

and

TC4000

Service Specifications

2

SPECIFICATIONS

(cont'd)

TC3000 and TC4000 Service Specifications (Cont'd)

Piston Ring

Side

Clearance

0.020

(0.0008

TC5000 Service Specifications

to

0.060

0.0024")

mm

0.150

mm

.

(0.0059")

3

SPECIFICATIONS

Carburetor Specifications

Item Standard

Throttle Valve Needle Jet

1.4

to 1.6mm

(0.055

(cont'd)

to

0.W')

Idle Speed Adjusting Screw Adjust

Fastener Torques

Fastener

Crankcase Screws

(2500

kgm

0.4

to

so

0.5

idle

200

is

rpm

(3000

on

200

TCSOOO)

rpm on TC3000 and

in

Ibs

35 to 43

TC4000

TOOL

REQUIREMENTS:

Flywheel Puller Tor0 part number 41-7650 Dial Indicator

V

Spark Tester Tor0 part number41-7890

Tachometer

Feeler Gauge

Compression Gauge Metric Socket Set Spark Plug Socket #2 Phillips Screwdriver

12

oz.

Ball Peen Hammer

3/8”

Tor0

Drive

part number 42-2730

Magnetic Spark Plug Gapping Torque Wrench Threebond #1104 Tor0 part number

Loctite #242 Tor0 part number Micrometer Snap Ring Plier (inside Hex. Key Set

Blocks & Dial Indicator Stand

Tool

&

outside type)

505-80

505-76

5

TROUBLESHOOTING

Engine Does Not Produce Spark

Engine

Floods

During Starting

Engine Not Getting Fuel

crankcase

leak

TROUBLESHOOTING

Engine Lacks Power

Engine Has Low Compression

(cont’d)

Remedy

Engine Backfires (indicated by burnt air cleaner element)

Trimmer Vibrates Excessively

I

7

Maintenance

Air

Cleaner

Servicing of the air cleaner is recommended after every

25

hours of operation or more often in very dusty

conditions.

See

Figure

1.

Maintenance Muffler Decarbonizing the muffler is recommended after every

50

hours of operation or

drastically. See Figure

if

engine speed decreases

2.

AIR

1.

Remove the

FILTER

FILTER SCREEN

Figure

two

screws securing the air cleaner

1

GRID

FOAM FILTER

cover to the trimmer

Carefully remove the filter grid, foam filter and filter

2.

screen.

Figure

1.

Remove the three screws securing the muffler

2

cover to the trimmer.

2.

Remove the

two

nuts securing the muffler to the

engine.

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 hard wood.

Remove all loose particles.

Wash the foam filter in a soap and water solution

3.

and dry thoroughly. damage replace

4.

Saturate the foam filter with 5ml (one teaspoon) of

SAE

30

oil, then squeeze to distribute the oil evenly

If

the filter shows any sign of

it.

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

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

5.

If

the filter screen shows any signs of damage,

replace Reinstall the air cleaner components as shown in

6.

Figure

it.

1.

Note that the flat side of the filter grid

faces the foam filter. Tighten the air cleaner screws to

7.

(13

to

17.5

in Ibs)

0.15

to

0.20

kg m

8

IMPORTANT

the exhaust port. Stay clear

will

not be damaged.

4.

Inspect the inside of the muffler for excessive carbon buildup.

Use extreme care

If

carbon buildup appears to be

when

of

the piston

cleaning

restricting the exhaust flow, replace the muffler. Otherwise, clean the muffler by holding

it

vice grips and heating with a propane torch. Once

hot, break the carbon loose by hitting the muffler on

a

hard surface. Ensure that the muffler is

completely free

of

all carbon particles before

reinstalling.

5.

Reinstall muffler using a new muffler gasket and tighten all fasteners securely.

6.

Reinstall

the

muffler cover as shown in Figure

so

with a

1.

it

Maintenance Spark Plug

The TC3000, BMGA spark plug or the equivalent. Correct gap is mm

(0.024-0.028”).

for the spark plug is

1.

Stop the engine and pull

2.

Clean around the spark plug and remove the spark plug from

IMPORTANT: Replace spark plug.

TC4000

and the TC5000 each use an

The recommended servicing interval

25

hours of operation.

off

the spark plug wire.

the

engine using a 19mm

a

cracked, fouled or dirty

Do

not sand blast, scrape or clean

(3/4")

NGK

0.6-0.7

socket.

electrodes because engine damage could result

from

grit entering the cylinder.

3.

Set the plug gap to 0.6-0.7mm Figure

3.

I3

(.024-.028”)

.024

(0.6

0.7

See

.028"

mm)

5.

Push the pickup assembly back into the tank and install the gas cap.

Figure

4

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.

Figure

Reinstall the plug and gasket in the engine. Tighten

4.

to

1.2

kg m

(1

04

in Ibs)

3

Maintenance Fuel Filter Fuel filter replacement is recommended after every

hours of operation.

1. Drain the fuel from the fuel tank into a container designed for gasoline. Start the engine and run at idle speed 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 pickup tube above the filter. Pull the filter and hose fuel tank opening. See Figure

3.

Remove the filter by holding the black tubing and

pulling the filter straight

4.

Replace the filter assembly.

4.

off.

out

let

the

25

to

Be careful not

damage the cooling fins during

cleaning.

Maintenance Trimmer Implement

The trimmer implements require no lubrication. However, cleaning of the implement and the drive shaft area is recommended after every More frequent cleaning may be required very tall grass or

if

the implement area gets excessively

25

hours of operation.

if

trimming in

hot.

to

the

Refer

Table

of

Contents for the location of information on removal and cleaning of your particular implement.

Maintenance Preparation

for

Storage

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

it

1.

Drain

the

fuel from the tank into a container designed for gasoline. Start the engine and run at idle speed until

it

stops and all fuel

let

it

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

so

around the plug

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

9

Maintenance Preparation for Storage (cont’d)

4.

Pour 5ml (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 in Ibs).

the

spark plug. Tighten

DO

NOT CONNECT

it

PLUG

to

WIRE

1.2

kg m

TO

(104

THE

SPARK PLUG.

Maintenance Gearbox Lubrication Lubrication of

after every

1.

Remove the cutter implement from the trimmer. Refer to the Table

the

cutter head gearbox is recommended

40

hours of operation.

of

Contents for the location of information on removal of your particular implement.

2.

Remove the gear case cap and the spacer sleeve

from the drive shaft. See Figure

5.

3.

Clean any debris from under the gear case cap.

4.

Clean the grease fitting, then fill a general purpose number

the

2

lithium base grease until grease is forced out from around the drive Shaft.

5. Reinstall the spacer sleeve and

the

on the drive shaft.

6.

Reinstall the trimmer implement See the Table Contents for the location of information on installation of your particular implement.

gear case with

gear case cap

of

Figure

5

10

SECTION

Carburetor Operation

The carburetor used on the TC3000, TC4000 and the TC5000 is a diaphragm style carburetor. alternating pulses from the crankcase to pump fuel from the fuel tank to the carburetor.

It

1

uses

CARBURETOR

n

To adequately describe the function

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

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 Figure

of

the carburetor,

it

in order to

6.

it

PULSE PASSAGE

The pulses vary with the movement of the piston.

piston moves upward, vacuum is created which pulls the diaphragm toward the pulse hole. This movement results

in

three things happening on the pump cover side of the

diaphragm. See Figure

Figure

8.

PULSE

7

HOLE

As

the

PULSE

PASSAGE

Figure

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 Figure

6

7.

FUEL

PUMP

COVER

FUEL

INLET

CAVITY

Figure

8

1.

The oulet flapper valve cover. This seals the outlet passage to ensure that fuel is drawn only through the fuel inlet.

is

drawn toward the pump

11

Carburetor Operation

The

Diaphragm Pump

(cont’d)

2.

The inlet flapper valve is pulled open to allow fuel

to flow from the fuel line and into the fuel inlet cavity.

3.

Fuel is drawn into the fuel pump cavity.

As

the piston moves downward, another sequence

occurs which pumps the fuel from the pump cavity

into

the

the main diaphragm cavity. See Figure

9.

FUEL PUMP CAVITY

INLET

NEEDLE

Figure

1.

The exhaust stroke sends a positive pressure pulse

9

to the pump diaphragm which pushes the

diaphragm toward the pump cover.

2.

The positive pressure in the fuel pump cavity seals the inlet flapper valve to prevent fuel from being forced back into the fuel line.

3.

The outlet flapper valve is pushed open.

4.

Fuel is forced out of

the

pump cavity and past the

inlet needle.

I

MAIN

DIAPHRAGM

CAVITY INLET

Figure

10

NEEDLE

Carburetor Operation Fuel Metering Mixing

With the main diaphragm filled with fuel, the carburetor

meters the amount going into the engine by using the high speed mixture screw and the needle entering the intake port

with air to further atomize

of

the engine, the fuel is mixed

it

and increase its

jet.

Before

combustibility. The metering and mixing operation is described below:

See Figure

11.

n

THROTTLE VALVE

SECONDARY NEEDLE JET

NOTE:

The inlet needle is spring loaded in the

closed position. The spring pressure is very slight and is easily overcome by the force of the fuel coming through the passage.

5.

The fuel enters the main diaphragm cavity. Figure

NOTE:

reservoir

10.

The main diaphragm serves only as a

so

that fuel can be properly metered before entering the venturi. It does not do any pumping of fuel during normal operation.

6.

Once the positive pressure is gone, the needle

valve is reseated. This allows fuel to

be

drawn from the sealed main diaphragm cavity and into the carburetor throat on the intake stroke.

See

12

HIGH SPEED MIXTURE screw

CAVITY

Figure

1.

On the intake stroke, vacuum in the carburetor

11

throat draws fuel from the main diaphragm cavity. Note that as the intake stroke begins, the main diaphragm cavity is filled with fuel and that the diaphragm is bowed toward the cover.

Carburetor Operation Fuel Metering & Mixing (cont’d)

2.

The fuel is drawn through the hole in the top of the

main diaphragm chamber and past the high speed mixture screw. The high speed mixture screw

regulates the maximum amount of fuel

that

enter the carburetor throat.

3. The fuel is then drawn past the secondary needle which is attached to the throttlevalve.

It

moves with the throttle valve and regulates the amount of fuel allowed into the carburetor throat in proportion with the throttle setting.

4. The

venturi

is the portion of a carburetor throat that

is narrowed in order to increase air velocity. On the

TC1000 carburetor, the venturi size is variable and

is controlled by the postion See Figure

12.

of

the throttle valve.

can

6.

To better atomize the fuel, an air correction

jet

was added. The air correction jet allows filtered air to enter the carburetor throat perpendicular to the

normal air flow. This action creates turbulence in

the

venturi area and helps mix the fuel with air as

it

enters the carburetor throat.

7.

The air/fuel mixture enters the engine.

See

Figure 13.

Carburetor Operation The Primer System The TC3000, TC4000 and TC5000 trimmers use a primer

system that ensures fuel is present throughout the fuel system. When properly used, this primer system should not induce flooding.

The recommended procedure for priming is as follows: See Figure

14

THROTTLE

VALVE

Figure 12

5.

The vacuum in the venturi area draws the fuel past the secondary needle jet and into the carburetor throat.

VENTURI

CHOKE

OVERFLOW

LEVER

TUBE

\

Figure 14

Push the tickler button fully inward.

Manually pump the primer pump until a small amount of fuel is emitted from the overflow tube. Stop pumping the primer pump and release the tickler valve. The engine is now ready to start.

AIR

CORRECTION

Figure 13

JET

The operation

Figure 15.

1.

2.

13

of

the primer system is as follows:

When the tickler valve is depressed slightly, the inlet needle is unseated.

Depressing the tickler valve fully keeps the inlet needle unseated and also opens the overflow needle.

See

Carburetor Operation The Primer System (cont’d)

2.

Pull from the carburetor the overflow line and the fuel feed line. Remove the carburetor with attached throttle wire. Next, remove

the

two

screws with lock washers, that secure the carburetor onto the intake flange. See Figure

17.

MAIN

DIAPHRAGM

CAVITY

OVERFLOW

3.

Pumping the primer pump forces fuel into the

NEEDLE

Figure

TICKLER

15

BUTTON

entire fuel system. This action ensures that the fuel line, diaphragm pump, and main diaphragm cavity are all filled with fuel.

NOTE: If the tickler valve is not fully depressed during priming, the overflow valve will not open and fuel will be forced into the carburetor throat thereby flooding the engine.

4.

Releasing the tickler valve seats the overflow valve and the inlet needle. At this point the engine is ready for starting.

Carburetor Removal

1.

Remove the

two

screws with flat washers and lock washers, securing the air cleaner assembly and remove the assembly. See Figure

16.

Figure

3.

Remove the intake flange, gasket and insulators.

4.

Remove the

assembly

two

to

the cylinder and carefully remove the

17

screws securing the intake

intake flange, insulator gasket, insulator and plate. IMPORTANT: Before removing the intake

flange, note the position of the pulse orifice through the flange: this orifice should be positioned toward the fuel tank as corresponding orifice

in

the carburetor. The

it

matches a

intake flange can be incorrectly positioned. This will result

NOTE:

The screws securing the intake flange may

in

fuel starvation.

have become heat seized and difficult to remove.

They can be loosened by firmly tapping the

screwdriver into the screws. During reassembly, a sparse application of anti-seize compound to

these threads can prevent future heat seizure.

Carburetor Disassembly

1.

Separate the carburetor from the throttle by unscrewing the mixing chamber cap and removing the throttle cable and the attached throttle valve, needle jet, throttle spring and spring retainer. See Figure

18.

Figure

16

14

Figure

18

Carburetor Disassembly (cont'd)

2.

Remove the fuel pump by removing

the

with lock washers securing the pump cover then lifting

off

the pump diaphragm and pump cover

gasket.

NOTE:

The gasket and the diaphragm are extremely thin and may stick together giving appearance of one piece. Remember that the pump diaphragm seals against the pump cover and that the gasket seals against the carburetor body. See Figure 19.

4

screws

the

NOTE:

Before removing inlet needle pieces, inspect inlet needle arm height using a depth micrometer. The correct height is

(.055

to

.062”)

See Figure 21.

INLET NEEDLE

1.4

ARM

HEIGHT

INLET NEEDLE

Figure 21

to 1.6 mm

Figure 19

Remove the four screws with lock washers

3.

securing the main diaphragm cover assembly to

lift

off

the carburetor. Carefully

the main diaphragm

cover assembly.

NOTE:

The main diaphragm assembly and the main diaphragm packing are thin and may stick together giving the appearance of one piece, not

two.

Remember that the main diaphragm gasket

seals against the carburetor body. See Figure 20.

Remove the inlet needle pieces from the

carburetor by removing the inlet needle pin set screw and carefully lifting out the inlet needle arm with inlet needle pin, the inlet valve spring and the

inlet needle valve. See Figure 22.

INLET NEEDLE

ARM AND

Figure 20

15

Figure 22

5.

Remove the throttle adjusting screw, throttle adjusting screw spring and the high speed mixture

screw. See Figure

23.

Carburetor Disassembly (cont’d)

E-CLIP

GROOVES

SECONDARY NEEDLE

Figure

23

Figure

2.

Position the needle with the retainer clip into the

25

throttle valve.

3.

Install the special washer and spring clip as shown in Figure

26.

Push the needle assembly into the throttle valve and line up the slots in the special washer and the throttle valve.

Carburetor Reassembly

IMPORTANT

good condition.

1.

Install the placement

Make certain all parts are clean and

Do

not use worn or damaged parts.

E

clip on the throttle valve. Nominal

of

the E clip is in the middle groove. The upper groove will yield a leaner mixture and the lower groove yields a richer mixture.

25.

See

in

Figure

4.

Slide the throttle spring on the throttle cable and

26

position the throttle cable into its groove in the

throttle valve.

5.

Install the throttle adjusting screw with the

adjusting screw spring into the carburetor.

6.

Install the high speed mixture screw. Gently seat the screw, then back out approximately three turns to give a nominal setting.

full

Carburetor Reassembly

7.

Replace the inlet needle pieces by installing the

inlet

needle, the

(cont’d)

inlet

needle spring, the inlet needle

arm and secure with the screw. See Figure

/--

SCREW

27.

OVERFLOW

VALVE

INLET

NEEDLE

ARM

INLET

NEEDLE

INLET

NEEDLE

9.

Replace the main diaphragm parts by installing the main diaphragm gasket against the carburetor, the

main diaphragm assembly upon the main diaphragm gasket, the main diaphragm cover upon the main diaphragm assembly. When installing the main diaphragm assembly, position the shaft of the pin toward the inlet needle arm, not toward the tickler button.

NOTE:

Sealant is not recommended on these

gasket surfaces. Secure these pieces with four screws with lock

washers. See Figure

29.

CARBURETOR

Figure

27

BODY

Make certain the spring is securely seated in the inlet needle arm and that the inlet arm positively engages the inlet valve.

I

8.

Using the carburetor body surface as reference,

check the inlet valve height. Inlet valve height can

be checked with a height gauge or with an

accurate depth gauge. See Figure

28.

Carburetor Inlet Needle Valve Height

1.4

to

1.6

mm

(.055

to

.063”)

Figure

INLET

NEEDLE

ARM

HEIGHT

Replace the fuel diaphragm pump parts by

10.

29

installing the pump cover gasket against the carburetor, the pumpdiaphragm against the pump

cover gasket, the pump cover against the pump

INLET

NEEDLE

diaphragm and securing these pieces with four

screws with lock washers. See Figure

30.

SPRING

17

NOTE:

Sealant is not recommended on these

gasket surfaces. Install the throttle cable with attached throttle parts

11.

into the carburetor and secure by tightening the throttle fitting.

The carburetor is completely reassembled and ready for installation to the intake flange.

Carburetor Reassembly (cont’d)

3.

Ensure that the throttle cable is positioned as shown in Figure 32 to prevent throttle cable

damage.

Figure 30

Carburetor

I.

Install the intake flange with gaskets and heat

Installation

shield making certain that the pulse hole is not obstructed by any of the intake components. Secure by tightening the screws to .3 to (26 to 38 in Ibs). See Figure 31.

The proper order for installing the intake components is:

gasket heat shield gasket intake flange

.45

kg m

CORRECT

ROUTING

Figure 32

4.

Attach the fuel feed line and the overflow line to the carburetor.

5.

Place the air cleaner steel net, element and grid into the air cleaner cover and install the assembled

air cleaner onto the carburetor. Secure with the

screws with lock washers and flat washers.

Carburetor Adjustment Idle Speed

CAUTION: head whenever engine

Stay

clear

of

cutter

is

running.

two

Figure 31

2. Place the carburetor gasket on the intake flange making sure that the pulse hole is not obstructed. Install the carburetor.

Tighten the screws to .3 to

.45

kg m, (26 to 38 in

Ibs.)

1. With the engine running at operating temperature, the choke fully opened and,

no

load applied to the engine, turn the idle speed adjusting screw to achieve an idle in the range specified below.

TC3000

3000

&

TC4000

200 rpm

TC5000

2500

200

rpm

See Figure 33.

Figure 33

n

18

Carburetor Adjustment Mixture

A

1.

The

controls the fuel flow requirements during the engine's optimum demand. With the engine

running at operating temperature, the choke fully opened and, no load applied to the engine, turn the high speed mixture screw to obtain the highest

RPM.

from fully closed. Turning the screw clockwise will make the air/fuel

mixture lean (less fuel/more air).

Turning the screw counterclockwise will make the air/fuel mixture rich (more fuel/less air).

IMPORTANT: Turning the high speed mixture screw

CAUTION:

head whenever engine is running.

high

speed mixture screw (see Figure

This should be approximately2 to 3 turns

in

too tightly may damage the tip.

stay

clear

of

cutter

34)

out

throttle valve should travel to the top carburetor opening when the trigger is in throttle position.

3.

To adjust, loosen the jam nut on throttle cable and rotate the turnbuckle to increase or decrease the travel of the throttle valve. See Figure

--

TURNBUCKLE

JAM

NUT

34.

of

the

full

Carburetor Adjustment Throttle Valve

CAUTION: Stay clear head whenever engine is

running.

1.

Remove to the trimmer and remove the air cleaner as an assembly.

2.

Squeeze the throttle trigger and note the travel

throttle valve in the carburetor opening. The

two

screws securing the air cleaner cover

of

cutter

Figure

4.

Tighten the jam nut and check the adjustment.

5.

Reinstall the air cleaner cover assembly and secure using the

lock washers.

two

34

screws with flat washers and

of

6.

Check the idle speed and adjust to

Carburetor Adjustment

if

necessary.

Idle

Speed, page

Refer

18.

19

SECTION 2 FUEL SYSTEM

FUEL TANK

Fuel Tank Removal

I.

Loosen the hex screws that retain the fuel tank guard. Remove

the fuel tank guard. See Figure 35.

two

locknuts and the corresponding

Figure

35

3. Remove the fuel tank.

if

4. The bracket can be removed, removing the single machine screw retaining

the crankcase.

5.

The strap can be removed,

backing out the four Phillips fan housing screws approximately 3/16' each. This will provide sufficient clearance to remove the strap.

IMPORTANT: fan housing screws unless absolutely

necessary as loosening them

ignition coil air gap.

necessary, before running engine.

Fuel Tank Installation

1. With the fan housing loosely secured to the crankcase, slip the fuel tank strap into its slot on the underside of the engine. Tighten evenly the four

Phillips screws retaining the fan housing to the

crankcase to .4 to

Figure 37.

(TC5000

do

not forget to reset the air gap

only)

If

removal of the strap is

.5

kg m (35 to 43

necessary, by

if

necessary, by

Do

not loosen the

will

affect the

in

Ibs). See

it

to

2.

Loosen the locknut on the fuel tank strap screw

then turn the screw counterclockwise until the strip

is free from the bracket. See Figure 36.

Figure 36

Figure 37

NOTE:

loosened, the See

2.

Fasten the strap bracket to the underside of the crankcase using the single machine screw.

3. Start the fuel tank strap screw into the strap bracket and turn clockwise until the tank is seated on all

four pads.

locknut.

(TC5000

TC5000

only) If the fan housing was

air

gap must be reset before starting.

Air Gap Adjustment, page

DO

NOT OVERTIGHTEN. Tighten the

28.

Fuel Tank Installation (cont’d)

4. Slide the fuel tank guard into the lower fan housing and tighten the

the

two

corresponding locknuts.

5.

Slide the retaining ring onto the fuel line, then push

two

hex screws retaining

it.

Tighten

the line onto the fitting near the primer bulb. Slide

the retainer ring down, over the fitting, to secure the line. See Figure 38.

Push the tickler button fully inward.

Manually pump the primer pump until a small amount of fuel is emitted from the overflow tube. Stop pumping the primer pump and release the tickler valve. The engine is now ready to start.

Primer Pump Operation

The primer system on the TC3000, TC4000 and

is

used

on cold starts only and ensures that fuel is

present throughout the entire fuel system.

TC5000

It

relies on

manual pumping action to draw fuel into the primer and

to pump The primer pump uses a

it

into the fuel line and the carburetor.

two

step operation to pump fuel to the carburetor. Pushing on the primer diaphragm does the following: See Figure 40.

INLET CHECK BALL

OUTLET CHECK BALL

Figure 38

PRIMER PUMP

Primer Pump Proper Use Proper operation of the primer system is as follows:

See

Figure 39.

CHOKE LEVER

VALVE CUSHION

Figure 40

1. The inlet check ball seats.

2.

The outlet valve is pushed against the porousvalve

cushion to allow fuel or air (whatever is in the primer diaphragm) to pass into the fuel line and carburetor.

Releasing the primer diaphragm allows back

to

its

original shape which results in the

following: See Figure 41.

FUEL FLOW

\

VALVE CUSHION CHECK BALL

VALVE CUSHION

it

to come

OUTLET

OVERFLOW

TUBE

\

Figure 39

21

INLET CHECK BALL

~--~-

Figure 41

1.

The vacuum produced

by

the diaphragm seals the outlet check valve. This prevents fuel from being drawn from the fuel line.

Primer Pump Operation (cont'd)

2.

The inlet valve

is

drawn toward the porous valve cushion which allows fuel to be drawn from the pickup line inside the tank. This action fills the primer diaphragm with fuel and readies

next pump.

Primer Pump Disassembly

1.

Pull

the primer pump from the tank and remove the fuel line. The primer pump is press fit into the fuel tank. See Figure

42.

it

for the

Figure 42

2.

Unscrew the rubber cap/button from the pump. See Figure

43.

Figure

44

Primer Pump Inspection

1.

Inspect the disassembled primer pump for contamination or damaged parts.

2. Clean thoroughly in a mild soap and water solution.

3.

If

the primer pump is suspect after inspection, the

entire primer pump assembly should be replaced.

Primer Pump Reassembly

1.

Before reassembling, familiarize yourself with the configuration of the parts properly installed.

GASKET

E

See

\

Figure

to

ensure they are

45.

VALVE SEATE

n

3.

Carefully cushion, and

lift

Figure

out

the top valve seat with the valve

two

43

ball

valves. See Figure

4. Insert a thin, non-puncturing punch through the hole in the bottom of the pump and carefully push

out

gasket

A,

valve seat A with valve cushion, and

gasket B.

44

22

PUMP

BODY

Figure

Gasket

“B”

has

two

sizes of fuel orifices one large and one small. Gasket

"A"

has one size of fuel orifices both

large.

45

Primer Pump Reassembly (cont'd)

Valve seat through the seat. Valve seat partially cut into the seat. Gasket pump. Gasket outside.

Reassemble parts into the pump body. Position

2.

gasket nozzle of the pump body.

Place valve seat

3.

"A"

has a locating notch that is cut

"B"

has

"A"

and valve seat

"B”

B

so

the

small fuel orifice is toward the outlet

a locating notch that is

"A"

are inside the

and valve seat

A

with valve seats up, on gasket

"B”

B.

Push one valve cushion into valve seat

4.

covers the double holed fuel orifice. Place gasket

5.

A

on valve seat

A.

are to the

A

so

these elements and the fuel strainer located inside the pickup weight. Clean or replace as necessary.

Reassemble the pickup assembly making sure that

3.

the

pickup tube fits snugly on the top of the fiber

filter element.

If pickup tube removal is desired,

4.

removed by removing the primer pump as described under Primer Pump Disassembly, page

22.

Remove the fuel pickup tube by pulling

5.

tank. It is also pressed in.

Inspect the pickup tube for cracks or punctures

6.

and replace

it

Reinstall the fuel pickup tube by lightly coating the

7. barbed end with

the proper tank orifice.

if

necessary.

two

cycle oil and pressing

it

can be

it

out of the

it

into

Drop the

6.

in valve seat

7.

Place one valve cushion into valve seat covers the double-holed fuel orifice.

Set valve seat

8.

body with assembled parts.

Secure all parts by screwing the rubber cap/button

9.

on the pump body. Reinstall the pump into the tank opening and

10.

attach the fuel line.

Fuel Pickup Tube and Filter Service

1.

The fuel filter on the pickup tube can be inspected without removing the pickup assembly by "fishing" the filter out through the filter hole.

two

ball valves through gasket A to seat

A.

B

with valve cushion into the pump

See

so

Figure 46.

that

FUEL CAP

it

Fuel Cap Operation

The fuel tank cap on the TC3000, TC4000 and TC5000 somewhat complex due to the requirements of the application. The cap must vent in order to prevent a vacuum or pressure buildup within the tank but must also prevent leakage of fuel.

The cap accomplishes the above by using a system of valves which work under different conditions. When the tank is under pressure, the following occurs:

47.

UMBRELLA VALVE

PACKING

'I

ORIFICE

See

is

Figure

2.

Pull the pickup weight from the end of the tube and remove

the

fiber filter elements. Inspect both of

23

Figure 47

1.

The pressure passes through the packing orifice

so

that

it

can act upon the umbrella valve.

2.

The pressure passes through the

in

the valve holder and lifts the umbrella portion of

the umbrella valve

3.

Pressure passes into the top of the gas cap and isemitted to the atmosphere through the slits in the

threads of the gas cap.

off

its seat.

two

small orifices

Fuel Cap Operation (cont’d) When a vacuum occurs within the tank, the following

occurs: See Figure

48.

Fuel Cap Inspection

1.

It

is important that the fuel cap properly vents the tank. Inspect the gasket to ensure that the hole at the rounded end is unobstructed.

2.

Check the

two

small pressure outlet holes in the

holder to ensure that they are open.

3.

The stem of the umbrella valve allows air into the tank to compensate for the fuel being used by the engine. Ensure that

it

will open and close by holding the flat end lengthwise between your thumbs and squeezing. See Figure

50.

UMBRELLA

Figure

1.

Atmospheric pressure enters the top of the gas cap through the slits

2.

Because a vacuum in the tank means that higher

in

48

the gas cap threads.

VALVE

pressure is present outside the tank than within,

the higher pressure passes down the stem of the

umbrella valve and forces

3.

The higher pressure passes through the packing

the

stem orifice open.

orifice and enters the fuel tank thereby equalizing

the pressure.

Fuel Cap Disassembly

1.

Remove the fuel cap from the tank.

2.

Pry the gasket, holder and breather valve out of the tank cap. See Figure 49.

4.

Clean all fuel cap parts thoroughly.

Fuel Cap Reassembly

1.

Position the holder inside the gasket, then screw

this assembly into the fuel cap until

in the top of the fuel cap.

it

is fully seated

3.

Clean these parts thoroughly.

Figure 49

2.

Reinstall the cap on the fuel tank.

SECTION

IGNITION

3

Ignition Operation

The firing of the spark plug at the proper time is the

culmination of a number of components working

together. In the TC3000,

components used are:

Flywheel Ignition Coil

Trigger Module

Spark plug

See Figure

51.

TC4000,

SPARK PLUG,

and TC5000 the

flywheel magnets to cut through the coils to generate electricity. See Figure

52

IGNITION

COIL

Low voltage is produced in the primary coil which

to

low to produce a spark at the spark plug. The secondary coil serves

produced in the primary. To accomplish this, the secondary coil must have many more windings than the primary. The higher the ratio between the primary coil

a

Figure

The following describes the function of each of the above components.

Ignition Operation Flywheel

The flywheel is connected directly to the crankshaft and turns at the same speed as the engine. Imbedded in the flywheel are three magnets. These magnets rotate past the coil to generate electricity.

Imbedded in the opposite side of the flywheel is a steel counterweight which offsets the weight of the three magnets.

It

is not magnetic.

TRIGGER

51

MODULE

windings to secondary coil windings, the greater the voltage amplification will be.

However, even though the secondary coil in the TClOOO

has considerably many more windings than the primary, the voltage produced is still not high enough to produce spark across the spark plug electrodes. To further amplify the voltage, the trigger module is used

Ignition Operation Trigger Module

The trigger module amplifies the voltage in the

secondary coil by breaking the primary circuit just as the primary voltage reaches its peak. This breaking of the primary circuit results

field surrounding the primary coil. The collapse of the

primary magnetic field induces a large voltage surge in

the secondary which is sufficient to produce a spark across the spark plug electrodes.

is

sent

the trigger module. The primary voltage is much too

to

amplify the voltage

in

a rapid collapse of the magnetic

Ignition Operation Ignition Coil

It

The ignition coil is actually a transformer. close to the flywheel to allow the magnetic field of the

is positioned

Before getting into the actual electronics used inside the trigger module, of the voltage waveform produced by the flywheel magnets moving by the ignition coil.

it

is important to have an understanding

See

Figure

53.

25

lgnition Operation Trigger Module (cont'd)

The following is the process the trigger module uses to

break the primary circuit to produce spark:

55

See

Figure

PRIMARY VOLTAGE WAVEFORM

Figure

53

As

the magnets rotate past the coil, voltage is produced.

This voltage, when uninterrupted, is first positive, then

negative as the magnet passes by the coil. This effect is

caused by the Explanation of the trigger module also requires an

understanding of the

I

two

opposing poles of the magnet.

NPN

transistor. See Figure

C

(Collector)

54.

I

E

(Emitter)

Figure

1.

The magnet passes by the coil and induces an alternating voltage.

2.

As

the voltage begins to increase, (approximately

point "a" and current flows from point through

3.

Current current that

in

Figure

R3,

R4,

and Tr2. See Figure

Figure

l1

flowing through Tr2 induces a larger

12.

Note that current

l2

is much larger. See Figure

53)

transistor

55

56

l1

Tr2

"C'

is

very

57.

is

turned on

to

point

56.

small and

"D"

NPN-type

Figure

A

transistor requires across the base and emitter (points B and E in Figure

turned on,

above. At current, current

l1.

Thus, the transistor functions allows a small current to control a large one.

has

a certain minimum voltage that

54

above) before

it

allows a small current,

the

same time, the transistor allows a large

12,

to

flow from point C to

l2

will vary in proportion to the smaller current,

54

it

will "turn on". Once

l1,

to flow as shown

E.

The magnitude of

as

an amplifier in that

it

has

MTI

unit Ignition

it

4.

When the voltage

in "Figure

is

at the point

53,

Tr1 is still in the

coil

Spark

"a"

level as denoted

off

mode

Ground

plug

26

Ignition

5.

Operation Trigger Module (cont'd)

and allows no current

l3

or l4

to

flow.

As the voltage produced in the primary coil reaches

its

negative peak (point

"b

in

Figure 53),

transistor Tr1 is turned on and allows small current

l3

and large current l4 to

MTI

unit Ignition

flow.

See Figure 58.

coil

TERMINAL NUT

METAL SHELL

Ground

Spark

plug

Figure

6.

When transistor Tr1 turns on, nearly all of the

58

current flow through R4 and Tr2 is diverted through path l4 since

in

drop

Off.

7.

When Tr2 turns off, current

it

is the path of least resistance. This

current I1 results

in

transistor Tr2 turning

l2

drops rapidly and

causes the magnetic field surrounding the primary

in

coil to rapidly collapse. This voltage surge

to

produce a spark across the spark plug.

in

the secondary which is sufficient

Another task the trigger module performs is

turn causes a

to

limit the maximum revolutions per minute that the engine will attain.

It

does this by means of the ITDC (ignition timing

delay circuit) which can also be seen

in

Figure 55.

This circuit senses the engine speed, and, as it approaches 10,000 rpm,

it

delays the turning on of

transistor Tr1 slightly. This retards the timing and

prevents the engine from further acceleration.

CENTER LEG INSULATOR ELECTRODE

GROUND ELECTRODE GAP

Figure

59

The other important area is the insulator. The insulator prevents arcing from taking place in another portion of the plug, away from the electrodes. Because of the extremely high voltage present, even a slight crack or fouling of the head insulator can result in arcing and a malfunction of the plug.

AIR GAP ADJUSTMENT The space between the coil and the flywheel magnets is

called the "air gap". Because the coil mounting holes are oversized, air gap on the TC3000, TC4000, and TC5000

is adjustable.

It

is important

to

set

it

to the proper

specification to ensure strong spark and proper timing.

TC3000/TC4000 Air Gap Adjustment Preparation

1.

For convenience, remove the engine from

the

drive

tube as described under Engine Removal from

Drive Tube, page 40.

2.

With the recoil assembly on a hard flat surface, use

an impact wrench to remove the four fan housing screws. Remove the fan housing.

Ignition Operation Spark Plug

The spark plug is used to ignite the air/fuel mixture by

producing a spark just before the piston reaches top

dead center. shown

There are two critical areas important

in

Figure

A

spark plug

56.

is

typically constructed as

to

proper spark

TC3000/TC4000 Air Gap Adjustment

NOTE: If coil performance is suspect, check the air gap with a feeler gauge prior mounting screws.

0.020').

1. Loosen the

plug function. The first is that the electrodes are properly gapped and are clean. This ensures that a strong spark

will be present and that

it

occurs at the proper time.

Excessive gap or fouling can delay firing enough to

cause a

loss

of power or stalling.

27

to

loosening

It

should be 0.4

two

coil mounting screws. Position a

to

the

0.5 mm

two

(0.016

coil

to

feeler gauge between the coil and the flywheel near

one of the coil mounting screws and tighten. Repeat this procedure for the other end of the coil.

Air gap adjustment is now complete. See Figure

60.

TC3000/TC4000 Air Gap Adjustment (cont'd)

Figure

60

Figure 61

TC300O/TC4000 Air Gap Adjustment Reassembly

1. Install the fan housing. Tighten the screws to

0.5

kg m

(35

to

43

in Ibs).

2.

Install the plastic fan housing cover using three

i

Phillips screws.

3.

Mount the engine on the drive tube as described in Engine Installation on Drive Tube, page

0.4

to

45.

TC5000 Air Gap Adjustment Preparation

1. Remove the carburetor Carburetor Removal, page

2.

Remove the three screws securing the muffler cover and remove the cover.

as

described under

14.

Also

Figure 62

remove the

muffler at this time. TC5000 Air Gap Adjustment Reassembly

3.

Remove the screw securing the cylinder Cover to

the cylinder. Remove the cover.

1. Install the cylinder cover. Make sure that the coil wire and grommet are properly positioned in the

cylinder cover slot.

2. Install the muffler and muffler cover.

TC5000 Air Gap Adjustment

1. The coil on the TC5000 is mounted to the inside

of

3.

Install the carburetor as described in Section under Carburetor Installation, page 18.

the fan housing. The two coil mounting screws are located near the base of the cylinder. Loosen both coil mounting screws. See Figure 61

2.

Insert a feeler gauge between the coil and the

flywheel near one of the coil mounting screws. See

Figure 62. When the correct gap is achieved,

tighten the screw with an

8

mm open end wrench. described under Engine Removal from Drive

Repeat this procedure for the other coil mounting

Coil Removal

1.

Remove the engine from the drive tube as

Tube,

screw. This completes the air gap adjustment. 2. Remove the muffler cover and the cylinder cover.

28

page

I

40.

Coil Removal (cont'd) Coil Installation

3.

Remove the fuel tank as described under Fuel

20,

Tank Removal, page

to gain access to screws. Be sure to install the rubber insulating

ignition wiring.

4.

Pull

out

the

two

male connectors leading into the

female connector found beneath the carburetor.

5.

Position the engine assembly

so

that the recoil

1.

Install the trigger module using

gasket beneath

2.

Install the coil with the proper air gap by following

the procedure found under heading:

ADJUSTMENT,

housing is resting on a hard, flat surface. Remove

the four Phillips head screws retaining the fan

housing with an impact wrench and housing. (The

fan housing

TC5000

so

be careful not to damage any wires

has the coil mounted in the

lift

off

the fan

while removing the housing.)

6.

Remove the trigger module and gasket. See Figure

63.

it.

See Figure

page

27.

63.

two

machine

AIR

GAP

Figure

63

29

SECTION

4

RECOIL STARTER

Recoil Starter Operation An

exploded view of the recoil assembly used on the TC3000, TC4000 and the TC5000 is shown below. See Figure

64.

STARTER RETURN REEL

PULLEY CLOCKSPRING

FRICTION

The recoil mechanism shown in Figure follows:

The operator pulls the rope which

it

reel spinning. As the reel turns,

in

the recoil housing. The clock spring rewinds the rope

once the

“T”

handle is released.

winds up a clock spring

64

in

turn results

functions as

in

the

starter pulley and When the reel stops turning, the starter pawl is forced

back into

spring.

Recoil Mechanism Removal

1.

Recoil Mechanism Disassembly

1.

its

Remove the three (TC3000 and TC4000) or four

(TC5000) screws retaining the recoil housing to the

crankcase and remove the recoil starter unit. N0TE: There

starter housing. during removal from the crankcase.

Pull

out a loop of starter rope approximately

(12

inches) and tie a tight slip knot to keep rewinding. This loop will provide necessary to untie the knot from the See Figure

in

turn, forces the engine to turn over.

normal retracted position by the return

is

no spring tension against

It

should not fly

off

nor unwind

the

“T”

the

recoil

30

it

slack

handle.

from

66.

cm

Note that the pawl pivots kept in its normally retracted position by the return

spring. See Figure

As

the reel begins to turn, the pawl turns with

it

is

in contact with the friction plate which does not rotate. This contact between the pawl and the friction plate forces the pawl outward

65.

in

the recoil reel and that

Figure

65

so

that

it.

However,

it

engages the

it

is

Figure

Once the rope to slowly retract into the recoil housing.

2.

Remove the bind screw.

protection and leather gloves are recommended recoil housing.

3. Gently friction spring, and pawl.

“T”

handle has been removed, allow the

CAUTION: Once the

screw is removed, for the recoil spring to fly out of the recoil housing. Eye

during

lift

off

as an assembly the friction plate,

66

bind

it

is possible

servicing of the

30

Recoil Mechanism Disassembly (cont'd)

CAUTION:

plate and reel components carefully as jerking them out may cause the recoil spring to

come out of the recoil housing.

4.

Remove the return spring.

remove the friction

See

Figure 67.

CAUTION:

wire surrounding the spring

A

the

personal injury.

until the spring is installed in

the recoil housing. Removing

wire prematurely may result

Do

not remove

the

in

Figure 67

5.

Gently

pliers.

A

6. Untie the knot in the recoil rope and remove the rope from the recoil reel.

7.

If by carefully turning the recoil housing over (spring

side down) and rapping sure to stay clear of the spring when performing

this operation.

IMPORTANT

unless unsprung, the spring should be replaced.

lift

out the recoil reel with a needle nose

CAUTION:

from the recoil starter case, the

spring may fly

it

is necessary to remove the recoil spring, do

Do not remove

it

is

If the reel is jerked

out

of

position.

it

on a hard flat surface. Be

the

recoil spring

absolutely necessary. Once

so

Figure 68

2.

Insert one end of the recoil rope into the appropriate hole in the recoil reel. knot in that end of the rope and the hole making sure that no portion protrudes

out

of

the recess.

See

Figure 69.

Tie

pull

a single

it

down into

of

the rope

loop

Recoil Mechanism Reassembly

1.

If

the recoil spring was removed during

it

disassembly, replace the spring with the wire on

as

shown in Figure

with a

it

68.

new

one. Position

into the recoil housing

31

Figure 69

3.

Position the spring in the starter case spring's inner end is approximately from the shaft. This distance ensures that the reel

hook will engage the spring.

See

3

mm

Figure

so

(1/8

70.

that the

inch)

Recoil Mechanism Reassembly (cont'd)

reel back and forth slightly in order

to

properly mate.

6.

Insert the in Figure

pawl

return spring into position as shown

72.

to

get the parts

NOTE:

If

the spring jumped

out

of the recoil

housing, the recoil spring should be replaced.

4.

Wind

counterclockwise

side of the reel

the recoil rope onto the reel in a

direction (as viewed from the

without

the knot

in

it).

Hook the end

of the rope in the slot provided in one of the reel

flanges. Leave about

Figure

71.

15

cm

(6

inches) of rope.

See

Figure 72

7.

Place the friction plate, friction plate spring and pawl onto the recoil reel as an assembly. Make sure

that the end of the

pawl

return spring is properly

positioned on the outside of the pawl then install

the bind screw. Tighten

to

0.8

to

1.O

kg m (70

to

in Ibs). Prewind the spring approximately one and one half

8.

turns in a counterclockwise direction then slip the

end of the rope through the hole in the recoil housing.

Pull about 30 cm (12 inches) of rope

9.

recoil and

tie

a tight slip knot in

it.

out

of the

This will keep the

recoil rope from retracting into the housing during

'7"

installation of the Slide the

10.

“T”

handle then the metal reinforcement

handle.

onto the recoil rope. Secure by tying a knot in the end of the rope then inserting

top of the

Release the slip knot be giving

11.

“T”

handle.

it

into the

if

a sharp

slot

tug.

in the

80

Figure

5.

Position the recoil spring spring is about

to

ensure proper engagement

6.

Line up the end of the recoil spring with the

3mm

the reel and install the reel.

71

so

(1/8

inch) from the center post

It

may help to rock the

that

with

the end of the

the reel.

slot

in

Recoil Mechanism Installation

1.

Position the recoil starter gasket on the crankcase

and install the recoil starter. Tighten all retaining

so

screws evenly

as not to damage the recoil

housing.

NOTE:

The recoil housing is self-centering and

requires no special centering procedure.

Starter Pulley Removal

1.

Remove the recoil starter as described under Recoil Mechanism Removal, page

2.

Remove the starter pulley nut by turning counterclockwise. See Figure

73.

30.

it

3.

The starter pulley is threaded onto the crankshaft and is removed by turning

it

counterclockwise.

the engine turns while trying to remove

piece

of

and

tap to loosen.

wood on one

of

the starter pulley ratchets

Starter Pulley Installation

1.

Thread the starter pulley onto the crankshaft.

2.

Install the flywheel nut, tightening to

(87

to

113

m

3.

Install the recoil starter as described under Recoil

in Ibs).

Mechanism Installation.

1.O

it,

place a

to

1.3

If

kg

I

i

33

SECTION 5 CLUTCH SHOES AND FLYWHEEL

Clutch Shoes and Flywheel Operation

74.

200

TC4000

parts

rpm

The TC3000,

clutch. The clutch

spring. These

in Figure

Operation of the clutch is as follows:

1.

When the trimmer engine speed is less than spring holds the

clutch drum.

and TC5000 use a centrifugal type

is

constructed of two shoes and a

are fastened to the flywheel as shown

Figure

74

(3300

200

rpm on the TC5000) the

two

clutch shoes in, away from the

3900

3.

Remove the fan housing. IMPORTANT: (TCSOOO only). The coil

mounted to the inside of the fan housing on

TC5000.

lead,

only, and swing

in

a

Clutch Shoes and Flywheel Inspection

1.

Inspect the clutch pads for even wear.

the clutch shoes for evidence of cracking.

2.

Inspect the clutch drum (found in the fan housing) for roundness and even wear.

3.

Check the flywheel magnets using the screwdriver method:. Hold the handle end of a flat bladed screwdriver between your thumb and forefinger. Bring the tip of the screwdriver to within

of the magnet to be tested. The screwdriver should be drawn to the flywheel. be replaced. Repeat this step for each magnet on the flywheel. See Figure

To

avoid damaging

pull

up on the muffler side of the housing

the

fan housing out of the way

manner similar to that of opening a book.

the

coil ground

Also

3/4"

If

not, the flywheel should

75.

is

the

inspect

to

1"

2.

As

the engine speed reaches

(3300

force of the weights overcomes the spring and the

shoes make contact with the clutch drum. This

contact forces the drum to rotate with the engine

so

3.

Under deceleration, disengagement takes place at

a speed approximately

engagement speed. The difference between engagement and disengagement speeds occurs because the shoes resist disengagement slightly

when they are in contact with the clutch drum.

NOTE: Operating the trimmer for long periods of time near the engagement speed may cause the clutch to slip and overheat. This can result in peeling of the clutch shoes.

Clutch Shoes and Flywheel Disassembly

1.

Remove the engine from the drive tube as described under Engine Removal from Drive Tube, page

200

rpm on the TC5000) the centrifugal

that power is transmitted to the trimmer head.

40.

3900

400

rpm less than the

200

rpm

2.

With the recoil assembly on a hard flat surface, use an impact wrench to remove the screws.

four

housing

34

Figure

75

Clutch Shoes and Flywheel Inspection (cont'd)

4.

Check the flywheel for cracks or broken fins.

Clutch Shoes and Flywheel Removal

1.

Make note of

the

markings on the top of the clutch

shoes to ensure proper installation later.

2.

For convenience, remove the two fasteners

securing the coil

to

the block and move the coil to

the side.

3.

Using a strap wrench to hold the flywheel, remove the two bolts retaining the clutch shoes. The shoes, complete with the spring, can then be removed as an assembly.

earlier are facing up. Then slide a flat washer over

so

the threads of each bolt

between the flywheel and the clutch shoes. Figure

77.

that the washer rests

See

IMPORTANT: The flywheel

is

of

cast aluminum

design. Methods of holding the flywheel other

than with a strap-wrench may damage the

flywheel.

4.

Remove the flywheel nut by turning counterclockwise using a strap-wrench to hold the

flywheel.

5.

Remove the flywheel using Tor0 flywheel puller part number

41-7650.

Figure

See

76

Figure

76.

it

3.

Use

a small amount of Blue "Loctite" on the clutch

Figure

77

bolt threads and install the clutch shoe assembly.

Tighten the clutch bolts to

in

Ibs).

4.

Refer to

Coil

Installation, page

0.6

to

0.8

kg

m

29,

(52

for the

to

69

remainder of the reassembly procedure.

CLUTCH DRUM and CLUTCH HOUSING

Clutch Drum and Clutch

1.

Remove the snap ring from the drive shaft end of

Housing

Disassembly

the clutch drum.

2.

Press the clutch drum out of the clutch case by pressing on the drive shaft only.

NOTE:

IMPORTANT: Use of a knockoff tool may dimple

the races in the crankshaft ball bearing. This

could lead to early failure of the bearing.

6.

Replace any damaged or worn

parts.

Clutch Shoes and Flywheel Reassembly

1.

If

the flywheel was removed, install the flywheel key, then place the flywheel, fan side down, onto the crankshaft. Hold the flywheel using a strap wrench and tighten the flywheel nut to

(87

to

113

m

2.

!

Insert the clutch bolts through the clutch shoes

in Ibs).

1.O

to

1.3

kg

making sure that the markings you made note of

i

pressing or driving on the drive shaft. This will

dimple the ball bearings and could lead

premature failure. Whenever the clutch drum removed, the clutch housing

be

3.

Remove the large snap ring retaining the bearings.

4.

Press remove the washer.

5.

Inspect all parts and replace as necessary.

Clutch Drum and Clutch Housing Reassembly

The

TC3000

assembled as shown in Figure

Removing the clutch drum requires

replaced.

out

the bearing on an arbor press and

clutch drum and clutch housing are

78.

ball

bearing should

to

a

is

35

Clutch Drum and Clutch Housing Reassembly (cont’d)

The

TC4000

housing

CLUTCH

Figure

and

TC5000

is

assembled as shown

clutch drum and clutch

78

in

Figure

FAN

HOUSING

79.

Figure

5.

Install the small snap ring in the drive shaft end of

80

the housing.

6.

Check to ensure that the clutch drum rotates freely

and is true.

ISOLATION MOUNT (TC4000 and TC5000 only)

Figure

79

1.

Insert the washer into the clutch housing. Press a new bearing into the clutch housing.

2.

IMPORTANT Press only on the outer race of the bearing. Pressing on the inner race damage the race inside the bearing and may lead to premature failure.

3.

Install the large snap ring.

will

Isolation

Mount Operation

The TC4000 and TC5000 trimmers use a vibration isolation system called an Isolation Mount.

81.

See

Figure

__---

HOLDER

Clutch

USING

CUSHIONS

HOLDER

n

4.

Support the inner race

of

the clutch housing

bearing from the drive shaft end with a sleeve or deep well socket and press the clutch drum into the housing. See Figure

80.

36

Isolation Mount Operation (cont'd)

The system is constructed of

cushion holder. The cushions are positioned between the holder and the clutch housing and are actually the only

two

points of contact between the engine and the drive tube. This arrangement allows vibration to pass only through the amount

Under normal circumstances, the Isolation Mount should not require any maintenance for the life of the product. However, should be inspected and, compressed, should be replaced.

Isolation Mount Disassembly

1.

of

if

Remove the single locating screw and the

clamping screws that secure the engine to the drive tube and separate the engine from the drive tube. See Figure

two

rubber cushions and reduces the

vibration that is transmitted

an increase invibration is noted, the cushions

two

rubber cushions and a

to

if

found to be damaged or

82.

the operator.

two

3.

Inspect the rubber cushions for wear and damage.

if

Replace

Isolation Mount Reassembly

1.

Position the rubber cushions on the clutch housing

as shown in Figure

necessary.

83.

Figure

82

NOTE:

linkage.

2.

Remove the two allen screws that secure the two halves of the cushion holder and separate halves.

It

is not necessary to remove the throttle

the

Figure

NOTE:

the clutch housing is essential in minimizing vibration. Therefore, bonding the cushion to the

clutch housing with a cyanoacrylate type glue

(Super Glue@) is recommended.

Place the cushions bottom side of the engine. Secure the cushion holder with the two allen screws.

Position the engine properly on the drive tube and secure with the locating screw and the two clamping screws. cutter implement slightly in order to get the drive shaft and the clutch drum to mate properly.

Good contact between the cushions and

two

cushion holder halves around the

so

that the locating screw

83

is

on the

It

may be necessary to rotate the

37

SECTION

Engine Operation

The

engine used in the TC3000, TC4000, and

based upon a two-stroke, port to port design. The term "two-stroke" refers to the number of operations the piston goes through in order to complete a single combustion cycle. Those intake stroke (where an air/fuel mix is drawn into the combustion chamber) and an exhaust stroke (where the exhaust gases are purged from the combustion chamber).

The term port to port refers to the way in which the intake and exhaust gases enter and exit the engine. These engines use no valves, but rather, rely on the piston passing

flow

There are four major components that are involved in the

combustion cycle:

Their relative locations can be seen in Figure

by

the intake and exhaust ports to control the

of gases. Hence the term: port to port.

Piston Intake Port Exhaust Port Scavenger Ports

two

operations are called an

TC5000

84.

6

is

ENGINE

SCAVENGER

Figure

2.

As

the piston continues its upward stroke, vacuum

begins to build within the lower crankcase. That

vacuum will later be used to draw the intake

mixture.

See

Fig.

86.

85

EXHAUST PO SCAVENGER

INTAKE PORT

Figure

Proper operation of these engines relies on nine separate phases. Beginning with the piston at a midway point

of

its

upward stroke, those nine phases are

described below.

1.

The piston closes the scavenger ports. This prevents prevents equalization of pressures between the lower crankcase and the combustion

chamber. See Fig.

84

85.

VACUUM

Figure

86

3.

The piston covers the exhaust port which completely seals the combustion chamber. Fig.

87.

See

38

Engine Operation (cont'd)

EXHAUST

AIR/FUEL

MIXTURE

Figure 87

4.

The upward movement of the piston builds

pressure (compression) in the combustion chamber. See Fig. 88.

HIGH

PRESSURE

LOWER

1

CRANKCASE

Figure 89

6.

The spark plug fires before the piston reaches the top of its stroke. This sets air/fuel mixture sealed

off

combustion

in

the combustion chamber.

Note that the piston continues its upward movement even after the plug has fired. This "post combustion compression" continues until the piston reaches top dead center and results in a more complete burn. See Figure

90.

of

the

VACUUM

Figure 88

5.

The lower skirt of the piston rises above the intake port and allows a fresh air/fuel mixture to be drawn into the lower crankcase. See Figure 89.

Figure

90

7. The piston then begins its downward stroke. this occurs, pressure begins to build in the lower crankcase. See Figure 91.

39

As

Engine Operation (cont’d)

Figure 91 chamber completes the combustion cycle. The

8.

The exhaust port is uncovered by the piston and

See

the exhaust gases are allowed to exit.

Figure

92. Engine Removal From Drive Tube

1.

PORT

Drawing a fresh mixture into the combustion

complete cycle took one full turn of the crankshaft.

Pull the spark plug lead from the spark plug.

2.

Pull the ignition switch wires from the rear of the

throttle control grip.

See

EXHAUST

GASES

PRESSURE

Figure 94.

I

Figure

9. The scavenger ports are uncovered resulting in a fresh air/fuel mixture being forced into the

combustion chamber by the crankcase pressure. 4. Pull the throttle cable Note that this process is not 100% efficient and that

some exhaust gases are

air/fuel mixture.

See

92

mixed

Figure 93.

with the fresh screws. See Fig. 95.

3. Remove the control housing to the drive tube and remove the

throttle cable from the trigger.

5.

Loosen

the

A

needle nose plier may help.

Figure 94

two

screws retaining the throttle

Out

of the throttle Control grip.

locating

screw

and the clamping

.-

40

Engine Removal From Drive Tube (cont’d)

96

Figure

8.

Carefully pull the cylinder and cylinder gasket from the crankcase being careful not

to

damage the

cylinder bore or piston assembly. NOTE: The exhaust port is on the right side when

viewed from the recoil end.

Figure

95

6.

Pull the engine off the tube.

7.

Wipe off excessive grease, oil, and dirt, using

lintless rags and commercial degreaser.

8.

Look for obvious damage and wear, e.g. cracked

fuel lines, cracked dust covers, broken and

chipped cooling fins on the cylinder head, loose screws, or signs of leakage.

Engine Disassembly

1.

Remove the air cleaner and carburetor as

described under Carburetor Removal, page

2.

Remove the muffler cover, muffler and spark plug.

3.

Remove the clutch and flywheel as described under Clutch Shoes and Flywheel Removal, page

35.

4.

Remove the recoil assembly as described under Recoil Mechanism Removal, page

5.

Remove the nut securing the starter pulley crankshaft.

6.

Remove the starter pulley by turning counterclockwise until it Be careful not

7.

Remove the

See

Figure

to

two

96.

is

completely unscrewed.

lose the washer.

bolts securing the cylinder

crankcase.

30.

to

14.

the

NOTE: use a dial indicator

If

crankshaft axial (end) play

to

check the axial (end) play

is

suspect,

before disassembling the crankcase. Make note of this measurement See Figure

97.

maximum allowable end play

.55

mm

(.O20’)

Figure

From the flywheel end, remove the three screws

9.

97

with lockwashers securing the crankcase halves together and pull apart the crankcase halves.

it

Carefully remove the crankshaft with attached connecting rod and piston. Note that the

crankshaft ends are different. The keyway is used to house the flywheel key and will be on the end with the flywheel and coil.

See

Figure

98.

41

Engine Disassembly

10.

Remove the

(cont’d)

Figure

98

two

snap rings retaining the piston pin

in the piston.

11.

Carefully push

out

the piston pin and

lift

from the connecting rod. The connecting rod cannot be removed from the crankshaft. Note the

position of the dot on the head of the piston. Reinstall the piston with the dot in the same

direction.

See

Figure

99

the piston

KNOCK PINS

Figure

100

Engine Cleaning After Disassembly

1.

2.

Clean all

to

the solvent manufacturer’s recommendations.

Inspect all

parts

in appropriate solvents according

parts

for wear and damage. Make

certain that moving parts will move freely.

3.

Remove carbon from cylinder combustion chamber, exhaust port and piston. Carbon can be removed with a non-marring scraper. Be careful not

to

damage the cylinder’s chrome plated bore.

See Figure

101

RINGS

NOTE:

Figure

Before removing the piston rings, note

99

how they are installed. The hemispherically notched ends of the rings match the locating pins in the ring grooves.

12.

Use finger pressure

See

Figure

to

remove the piston rings

100.

from the piston.

Figure

4.

Decarbonize the muffler. Use a scraping

101

remove the carbon.

5.

If

the spark plug is

to

be reused, clean the spark

Plug.

6.

Clean the air filter element in soap and water.

Moisten the air filter element with clean,

light-weight engine oil before installation.

tool

to

n

Engine Cleaning After Disassembly (cont'd)

7.

Replace the fuel strainer on the pick-up tube inside

the fuel tank. See Figure 102.

Figure 102

8.

Clean the primer pump passages, Valve cushions

ball

and

valves.

2. Crankshaft Run-out

maximum allowable run-out:

0.06

mm (.0024')

With the crankshaft removed from the crankcase, support the crankshaft on V-blocks. The V-blocks should be positioned no closer than 4 mm (3116

inch) from the counter weights. Use a dial indicator

and measure run-out at the position shown in

Figure 104.

1

Engine Inspection

Do

Inspect all parts for wear and damage.

that are damaged or worn beyond specification.

1. Crankshaft Axial Play

0.55mm (0.020')

Axial play can only be measured when the crankshaft and crankcase are assembled. axial play was not measured during disassembly, reassemble the crankshaft and crankcase with bearings making certain to properly torque the crankcase screws to 0.4 to Ibs). See Figure 103.

not reuse parts

0.5

kg m (35 to 43 in

Figure 104

If any measurement is greater than the maximum allowable limit, the crankshaft should be replaced.

If

the

Off-size crankshaft bearings are not available.

Piston Ring End Gap

maximum allowable end gap:

.7

mm (0.027")

Insert a piston ring into the cylinder skirt, making certain the ring is not tilted. Use a piston to push in the ring and ensure the ring is perpendicular in the cylinder bore. Use a feeler gauge to measure the piston ring gap between the ends of the piston ring.

If

the measured clearance is greater than the

.7

mm (0.0279, the piston rings may require

replacement. See Figure 105.

Figure

103

NOTE:

certain that the piston to cylinder clearance is

within specification.

Before replacing the piston rings, make

Engine Inspection (cont'd)

4.

Cylinder Bore Use a bore gauge to measure the cylinder bore. By

itself, this measurement does not indicate much, however cylinder clearance. The cylinder can be used until

the chrome plating on the bore

("Exfoliates").

5.

Piston Diameter Use a micrometer to measure the diameter of the

piston in several places, recording the largest.

with the cylinder bore measurement, this

measurement is important only in determining the piston to cylinder clearance.

6.

Piston to Cylinder Bore Clearance

The difference between the recorded piston outer diameter and the cylinder bore measurement is the clearance. maximum allowable clearance, replacement of the piston, piston pin and needle bearing as a set is recommended.

it

is important in determining the piston to

Is

worn away

maximum allowable clearance

0.100

mm

(.004')

If

the difference is greater than the

As

1.

Use finger pressure to install the two piston rings

on the piston.

IMPORTANT The hemispherically notched

ends

of

the rings match the locating pins

ring

grooves.

(toward piston crown)

with a

2.

Install one of the piston pin retaining rings in the piston.

Insert the upper connecting

3.

connecting rod. Install the piston on the connecting rod by lightly

4.

lubricating the piston pin with clean engine oil, positioning the piston onto the connecting rod and pushing in the piston pin. If necessary, the piston pin can be driven into place by lightly tapping the pin with a hammer and a non-marring punch or drift pin.

Install the remaining piston pin retainer.

5.

if the main bearings have been removed, install the

6.

new main bearings into the crankcase. Lightly grease the lips

7.

prevent seal damage when the crankshaft installed.

'T.

Also

See Figure

Figure

of

note that the top side

of

the

ring

106.

106

rod

bearing into the

the crankcase oil seals to

in

the

is stamped

n

is

8.

Engine Reassembly

All

parts, even

Make certain all parts have been inspected and are within

specification.

Do not use worn and damaged parts. Use of worn and damaged parts may cause personal injury and engine failure.

if

new, should be thoroughly cleaned.

9.

Carefully install the crankshaft with attached connecting rod and piston into the crankcase

halves. Use sealant Three Bond

505-80)

halves. Position the gasket between the crankcase halves and assemble the crankcase halves with

connecting rod and attached piston.

on the gasket between the crankcase

1104

Foro part number

Engine Reassembly (cont'd)

Install the four screws with lock washers to secure the crankcase halves together. Tighten the screws to

0.4

to

0.5

kg m

(35

to

43

in Ibs)

10.

Install the cylinder upon the crankcase.

Position the cylinder gasket upon the crankcase.

Make sure the pulse hole opening in the gasket

lines up with the crankcase opening. Lightly

lubricate the bore

of

the cylinder with clean engine

oil and carefully slide the cylinder down the piston and onto the crankcase. Note that the exhaust port

is on the right when the engine is viewed from the

recoil starter end.

IMPORTANT The piston rings are aligned with

locating pins. Make sure that the end gap is

aligned with these pins when inserting the

piston into the cylinder.

11

Secure the cylinder onto the crankcase with the

two

hex head screws with lock washers. Tighten

the fasteners to

12.

Install the spark plug into the cylinder. Make certain the spark plug gap is set to

0.4

to

0.5

kg m

.6

(35

to

.7

to

43

mm

in Ibs).

(.024

.027").

13.

Screw on the starter pulley and secure with the nut

and the washer. Tighten to

113

in Ibs).

1.0

to

1.3

kg m

(87

to

NOTE:

It

may be necessary to turn the trimmer implement slightly to get the flex shaft and clutch drive shaft to mate.

2.

Align the holes in the clutch housing and the drive tube and install the locating screw. Tighten the

locating and clamping screw.

3.

Feed the throttle cable through the throttle control grip and insert the end into the recess in

4.

Place the switch

in

the throttle control housing.

the

trigger.

Test for proper operation of the switch. The switch should be open in the "on" position and closed in the

"off

position.

5.

Mate the secure with the

6.

Route the throttle cable and switch wires from the

two

throttle control case halves and

two

machine screws.

carburetor over the top of the tube. See Figure

107.

ROUTING

14.

Install the recoil assembly as described under

Recoil Mechanism Installation,

15.

Install the flywheel, clutch shoes, tank and coil as described under

Reassembly,

16.

Install the muffler and muffler cover.

17.

Install the carburetor and air cleaner as described

under

Carburetor Installation,

Clutch Shoes and Flywheel

page

36.

page

Engine Installation on Drive Tube

1.

Remove the locating screw from the clutch housing and mount the engine on the tube.

32.

18.

7.

Plug the

Figure

two

wires into the female connectors in

107

the throttle control. They may be connected either way as the ignition switch has no certain polarity.

8.

Adjust the carburetor as described under

Carburetor Adjustment,

page

19.

45

SECTION

7

CONTROLS

The control unit on the TC3000 and on/off switch and throttle control trigger and is mounted on the drive tube. The TC5000 control and grip is mounted on the right handle.

Adjacent to the control unit is a padded grip which covers the connectors for the ignition ground leads and a portion of the throttle cable.

Control Disassembly

1. Remove the throttle control case halves. See Figure 108.

two

screws and locknuts securing the

TC4000

houses the

Control Reassembly

1. Mount the right hand (as viewed from the rear of the trimmer) control half on the alignment hole just

in front of the grip. See Figure 108.

2.

Push

the

ends of the ignition kill wires into the holes

of

provided in the bottom matter which way they are connected because they have the same polarity.

3.

Mount the switch in the right control half as shown above in Figure 108.

CAUTION: Check to ensure

that the switch will kill the

engine. Use a Volt Ohm Meter

or

test light to check the switch. The switch should be closed the

"off

position and open

position.

4.

Place the throttle trigger over the lower mounting boss and insert the throttle cable into the trigger.

See Figure 108 above.

the switch.

in

It

the "on"

does not

in

Figure 108

2.

Disconnect the throttle cable and remove the

trigger.

3.

Disconnect the switch wires from the switch by

inserting a releaseholes located in the bottom of the switch. See Figure 109.

small

diameter drill or small wire into the

5.

Cover the assembly with the other control half and secure with the

Grip Removal

1. On the TC3000 and TC4000, remove the engine as described under Engine Removal, page

2.

Disconnect the of the grip.

Figure 1 10.

two

machine screws and locknuts.

two

ignition kill wires from the rear

A

needle nose pliers may help.

40.

See

_~-

Figure 109

46

Figure 1 10

3.

Remove the throttle control as described under Control Disassembly, page

46.

Grip Removal (cont'd)

4.

Slide the grip assembly

off

the tube.

5.

The ignition wire terminals may now

of

from the end

the grip.

be

removed

NOTE:

The grip is located on the tube with a plastic pin. The pin can be released by pulling or prying down on the throttle control end

while sliding

it

toward the end

of

the tube.

the grip

It

may

help to lubricate the tube with soapy water prior to

this procedure. See Figure

111.

Grip Installation

1.

Insert the switch wire terminals in the grip housing. Slip the rubber grip over the control housing.

2.

Lubricate the tube with a soap and water solution

3.

and slide the grip assembly onto the tube until the locating pin snaps into

4.

(TC3000

and TC4000 only) Reinstall the engine on

the

hole in the tube.

the drive tube as described under Engine

Installation on Drive Tube, page

5.

Push the grip.

two

ignition

It

does not matter which way they are

kill

wires into the rear

45.

connected because they have the same polarity. Mount the throttle control as described under

6.

Control Installation on Drive Tube, page

of

46.

the

Figure

111

47

SECTION

8

TC3000 Handle Removal

1. Remove the engine as described under

Removal from Drive Tube,

2. Remove the grip and the control unit as described

Grip Removal from Drive Tube,

under

3. Loosen the handle knob. See Figure 112.

from

-HANDLE

Drive Tube

Engine

page 40.

page 46.

KNOB

Figure 113

3. Hand tighten the handle knob.

TC4000 Handle Removal From Tube

1. Loosen the handle mount halves. See Figure 114.

five

machine screws securing the two

Figure 112

off

4. Slide the handle up, and (Soaping the drive tube may aid in removing the

handle.)

TC3000 Handle Installation on Drive Tube

1. With the engine, grip and control unit removed,

slide the handle onto the drive tube. (Soaping the handle may facilitate installation.)

2. Insert the carriage bolt into either side of the handle and secure with the knob.

3. Install the control and grip as described under

Installation on Drive Tube,

4. Mount the engine as described under

Installation on Drive Tube,

TC3000 Handle Adjustment

1. Loosen the handle knob.

2. Adjust to the desired handle height but do not cover the eye protection safety decal. See Figure

113.

the drive tube.

page

47.

page 45.

Grip

Engine

Figure 11

2.

Remove the

3.

If

desired, complete removal by removing the five machine screws and the mounting halves from the drive tube.

TC4000 Handle Installation

1. Position the handle mount halves on the drive tube between the eye protection and the

decals. See Figure 115.

"J"

handle from the mount halves.

4

on

Drive Tube

TC4000

TC4000 Handle Installation on Drive Tube

(cont'd)

2.

Position the handle mount approximately inches) from the control mount.

HANDLE ADJUSTMENT AREA

See

20

Figure

cm

11

(8

7.

Figure

115

Note: The mounting configuration shown in Figure

114

is most suitable for right handed operators.

Left handed operators may find

if

comfortable

the ounting halves are installed as

shown in Figure

116.

Figure

1 16

it

more

Figure

3.

Adjust the "J" handle

tilt

(about

4.

Tighten the machine screws to retain this setting.

15

degrees).

so

11

7

that

it

has a slight rearward

TC5000 Handle Removal From Drive Tube.

1.

Remove the

two

screws securing the control to the handle and remove the upper control half. Remove the throttle cable from the trigger and pull the throttle cable out of the grip. Loosely reinstall the

upper control half with the

2.

Pull

the

two

ignition kill wires out

grip. See Figure

11

8.

two

machine screws.

of

the rear

of

the

2.

Loosely fasten the handle mounts with the five machine screws and locknuts.

3.

Insert the

"J"

handle into the handle mount and adjust as described under TC4000 Handle Adjustment, page

49.

TC4000 Handle Adjustment

Described below is a suggested "nominal" setting for the

TC4000

handle. Once a nominal position is set, the

operator may wish to adjust as desired.

1.

Loosen the five machine screws that secure the handle mount to

the

drive tube about one turn

each.

49

Figure

11

8

TC5000 Handle Removal From Drive Tube (cont'd)

3.

Loosen the four nylon handle mount to the drive tube and

from the mount. See Figure 1

lock

nuts that secure the

pull

19.

the handles

Figure 121

Figure 119

4.

Remove the

lock

nuts and the handle mount from

the drive tube.

TC5000 Handle Installation on Drive Tube

1.

Loosely fasten the handle mount halves to the drive

tube with four carriage bolts and lock nuts.

2.

Before Inserting the handles into the handle mount, check to ensure that the retainer tabs are intact and are bent out slightly. See Figure 120.

Plug the

two

ignition kill wires into the rear of the

grip.

It

NOTE:

does not matter which way the wires are

connected since they have the same polarity.

it

Insert the handle with the control in

into the right

(as viewed from the engine end) side of the handle

left

mount. Insert the other handle into the

side of

the mount but do not tighten yet.

as

Adjust the handle

Handle Adjustment, page

described under TC5000

50.

TC5000 Handle Adjustment Described below is a suggested "nominal" setting for the

TC5000

handle. Once a nominal position is set, the

operator may wish to adjust as desired.

1. Loosen the four nuts on the bottom side of the handle mount and pull the halves apart slightly to unseat them from the drive tube.

2. Position the handle mount inches) from the clutch housing.

so

that

it

is

See

Figure 122.

35

cm (14

Figure 120

Before inserting the handle into the mount, remove

3.

the upper control half. Insert the throttle cable into the rear of the grip and attach the cable to the trigger as shown In Figure 121.

Figure 122

50

TC5000

Handle Adjustment (cont’d)

3. With the handle mount nuts still loose, rotate the handles

so

that they have a slight forward

Figure 123.

Figure 123

4.

Tighten the four lockwashers to secure the Setting.

tilt.

See

51

CAUTION: Never attempt any service

A

implement to come to a complete stop.

The shield is an important device which is intended to help prevent the operator’s feet from coming into contact

with the cutter implement and reduce the amount

flying debris. shield in place.

without first shutting

engine and allowing the

Do

not operate

of

the trimmer head

the

trimmer without the

off

the

of

4.

Remove nuts that secure the

the shield bracket.

5.

The shield bracket can be removed first removing the gearbox. Remove the gearbox

be removing the locating screw, and the

clamping screws then pulling the gearbox straight

off

6. Remove the shield bracket by loosening the clamping screws and sliding the bracket shaft.

the

four machine screws and nylon lock

two

portions of

shaft.

the

shield to

if

desired by

off

two

the

Shield Removal from Drive Tube

1.

Remove the cutter implement by inserting a flat

blade screwdriver into the hole in the top of the shield, then rotating the cutter implement clockwise (as viewed from the bottom of the

trimmer). See Figure 124.

CAUTION: Heavy gloves are recommended when installing or removing the blade to avoid lacerations.

Shield Installation on Drive

See

Figure 125.

SPACER

\

Figure

Tube

GEARBOX

125

Figure 124

2. Remove the dust cap from the drive shaft.

3.

Remove the three screws securing the shield to the

gearbox and, on units with serial numbers

60000001

and up, remove the grass wrap shield.

1.

If

the shield bracket was removed earlier, begin by sliding clamping screws at this time.

2. Before installing the gearbox make sure that the drive shaft is properly positioned in the drive tube. See Figure 126.

3.

Slide the gearbox onto the drive tube. necessary to rotate the cutter implement slightly to get the drive shaft to line up with the upper gear of

the gearbox. Remove the locating screw and visually line up the locating screw hole and the hole

in the drive tube. Insert the locating screw and

tighten single locating screw and screws.

it

onto the drive tube.

Do

52

not tighten the

It

may be

two

clamping

Shield Installation

2.5

on

Drive Tube (cont’d)

CM

(1”)

Shield Mounting Cutter Knife

A

single or dual line Tap and Trim@ cutter head may be

used as the cutter implement on any

trimmers. To ensure proper line length,

on

Shield

of

the straight shaft

a

cutter knife may

be mounted to the shield.

1.

Remove the original shield from the shield support by removing the four machine screws and lock nuts.

2.

(TC3000

and TC4000 only). Replace the original shield with a new shield, Tor0 part number 61-4571.

Figure 126

4.

Install the

two

portions of the shield as shown in

Figure 125. Secure with the four machine screws

and nylon

5.

On units with serial numbers

lock

nuts.

6000001

and up, place the grass wrap shield around the drive shaft. See Figure 125.

6. Secure the shield (and grass wrap shield on certain units) to the gearbox with the three Phillips head machine screws.

7. Tighten the

two

clamping screws on the shield

bracket.

8.

Install the dust

9.

Mount

the

cap

on the gearbox drive shaft.

cutter implement on the drive shaft and tighten by inserting a flat bladed screwdriver into the

slot

in

the top of the shield and turning the

cutter implement counterclockwise.

(TC5000)

Using the cutter knife as a template, drill

three holes in the shield. See Figure 127.

part

3. Mount the cutter knife (Toro

number on the shield using three machine screws and nylon lock nuts (Toro part numbers 32105-8 and 3296-2 respectively). See Figure 127.

Figure 127

61

-4540)

53

SECTION

10

GEARBOX

The gears inside the gearbox used on the Tor0 straight shaft trimmers are not replaceable individually. damaged or defective, the gearbox must be replaced as an entire unit.

Regular maintenance is important in ensuring long

from the gearbox.

hours of use with a number 2 general purpose lithium base grease.

Gearbox Removal

1.

Remove the cutter implement by inserting a flat blade screwdriver into the hole in the top of the

shield, then rotating the cutter implement clockwise (as viewed from the bottom of the trimmer).

A

lacerations.

It

should be lubricated after every

See

Figure 128.

CAUTION:

a

brush or saw blade trimmer, grasp heavy gloves

Whenever removing

from

it

with a rag or

to

the

avoid

If

life

40

Gearbox Installation on Drive Tube

1. Before installing drive shaft is properly positioned in the drive tube. See Figure 129.

2. Slide the gearbox onto the drive tube. necessary to rotate the cutter implement slightly to

get the drive shaft to line up the gearbox. Remove the locating screw and visually line

in the drive tube. Insert the locating screw and tighten the single locating screw and

screws. See Figure 130

the

gearbox make sure that the

2.5

CM

(1")

with

the upper gear of

up

the locating screw hole and the hole

two

It

may be

clamping

Figure 128

2. Remove the dust cap from the drive shaft.

3. Remove the three screws securing the shield to the gearbox and, on units with serial numbers 6OOOOOO1 and up, remove the grass wrap shield.

4.

Remove the four machine screws and nylon lock nuts that secure the the shield bracket

5.

Loosen the screws securing the gearbox to the drive tube and remove the gearbox.

two

portions of the shield to

and

remove the shield.

clamping screws and one locating

54

--

Figure 130

GEARBOX

SHIELD

BRACKET

Gearbox Installation On Drive Tube (cont’d)

3.

Install the Figure

and nylon

4.

On units with serial numbers

two

portions

130.

Secure with the four machine screws

lock

nuts.

of

the shield as shown in

6000001

and up, place the grass wrap shield around the drive shaft. See Figure

5.

Secure the shield (and grass wrap shield on sertain

130.

units) to the gearbox with the three Phillips head machine screws.

6.

Tighten the

two

clamping screws on the shield

bracket.

8.

Install the dust cap on the gearbox drive shaft.

9.

Mount the cutter implement on the drive

shaft

and tighten by inserting a flat bladed screwdriver into the slot in the top

of

the shield and turning the

cutter implement counterclockwise.

Gearbox Seal Removal

A

seal is

used

in the lower portion of the gearbox to keep

contaminants from entering as well as to retain grease

within the gearbox.

CAUTION:

Whenever removing

a brush or saw blade from

trimmer, grasp

it

with a rag a

heavy gloves to avoid

lacerations.

2.

Remove the dust cap from the drive shaft.

3.

Remove the sleeve from the cutter head drive shaft by grasping with a pliers and pulling straight

See Figure

132.

the

off.

1.

Remove the cutter implement by inserting a flat bladed screwdriver into the hole in the top of the shield, then rotating the cutter implement clockwise (as viewed from the bottom of the

trimmer). See Figure

131.

SCREWDRIVER

4.

Figure

Remove the seal.

132

Gearbox Seal Installation

1.

Press the new seal into the gearbox with hollow portion of the seal facing the gearbox. Use a inch socket to press

2.

Lubricate the sleeve with grease and slide on the

splined shaft until

3.

Install the dust cap on the gearbox drive shaft.

4.

Mount the cutter implement on the drive shaft and

it

in.

it

bottoms

out.

tighten by inserting a flat bladed screwdriver into the slot in the top of the shield and turning the cutter implement counterclockwise.

11/4

Figure

131

55

SECTION

The drive tube and shaft assemblies used on the TC3000,

TC4000

is made of steel and is hardened on both ends. For positive engagement with the clutch and gearbox, a nine tooth spline is used on both ends.

The drive tubes vary slightly in dimension between the three straight shaft trimmers, but are similarly constructed. Each use an aluminum tube that houses five oil impregnated bushings. These bushings are positioned approximately every nine inches inside the shaft. They are supported by rubber grommets that hold them in place. See Figure 133.

and TC5000 utilize a common shaft. This shaft

GROMMET

2.3

CM

(9)-

11

BUSHING

DRIVE SHAFT AND TUBE

2.

Loosen the the drive tube, then pull the gearbox and shield assembly

3. Pull the drive shaft from the tube being careful not to damage the splined end.

4. Inspect the shaft for excessive wear and evidence of overheating. necessary, replace both the shaft and the drive

tube.

Drive Shaft Installation

1. Grease the splined ends of the shaft to ensure that

they are easy to remove

necessary.

the shaft with motor

2.

Slide the shaft into the drive tube until

the splined clutch shaft and bottoms out. The shaft

should extend approximately

the drive tube when

135.

two

shield bracket screws closest to

off

the drive tube.

If

it appears replacement is

if

future service is

Also,

lubricate the smooth portion of

oil.

2.5

cm (1 inch) from

it

is fully seated. See Figure

it

engages

n

Figure 133

Neither the drive tube nor the drive shaft is serviceable.

If

either is worn to the point where the shaft begins to

vibrate excessively, both should be replaced.

DRIVE

Drive Shaft Removal

1. Remove the locating screw and loosen the two

SHAFT

clamping screws on the cutter head gearbox. See Figure 134.

a

2.5

CM

(1")

Figure 135

3. Remove the locating screw from the gearbox and slide the gearbox and shield assembly onto the drive tube.

4. Visually align the locating screw and the hole in the

drive tube, then install and tighten the locating

screw.

5.

Tighten the two gearbox clamping screws and the shield bracket screws to secure the assembly.

DRIVE TUBE

Figure 134

Drive Tube Removal

1. Remove the engine as described under Engine

Removal from Drive Tube, page

56

40.

Drive Tube Removal (cont'd)

2.

Remove the handle as described under TC3000 Handle Removal from Drive Tube, page TC4000 Handle Removal from Drive Tube, page

48,

or TC5000 Handle Removal from

Drive Tube, page

3.

Remove the control and grip as described under

49.

Grip Removal, page 46.

4.

Remove the gearbox locating screw then loosen

the four other screws denoted by arrows in Figure

136.

48,

7.

Inspect the tube for excessive wear, bends or

excessive heat. Replace

NOTE:

shaft

If

it

is necessary

should also be closely inspected as

if

necessary.

to

replace the tube, the

also require replacement.

Drive Tube Installation

1.

Mount the control and grip on the drive tube as

described under Grip Installation, page

2.

Mount the engine on the drive tube as described

under Engine Installation on Drive Tube, page

45.

3.

Grease the splined ends of the drive shaft easy disassembly in the future. Lubricate the shaft with motor oil, and install into the drive tube. Approximately the end of the drive tube once

4.

Mount the gearbox and shield assembly by first

2.5

cm

(1

inch) will extend beyond

it

is firmly seated.

removing the locating screw. Push the gearbox

and shield assembly onto the tube and visually align the locating holes.

47.

to

ensure

it

may

Figure 136

5.

Remove the gearbox and shield assembly.

6. Remove the drive shaft from the tube being careful to

damage the splined ends of the shaft.

not

5.

Secure the gearbox and shield by tightening the

four screws denoted by arrows in Figure 36.

6. Mount the handle as described under TC3000 Handle Installation on Drive Tube, page

TC4000 Handle Installation on Drive Tube,

page

49,

or TC5000 Handle Installation on

Drive Tube, page

50.

48,

57

SECTION

CAUTION: Never attempt any service of the trimmer head

without first allowing the

A

come to a complete stop.

engine and the implement to

12

LEECO(R)

MANUAL FEED HEAD

To replace the trimmer line, first measure the

1. appropriate length of line:

.095

n

20

--

feet

Leeco(R) Manual Feed Head Spool Removal 1,. Remove the knob on the bottom of the line feed

assembly by holding the drum while turning the

knob

clockwise.

IMPORTANT: The knob is under slight spring pressure. Be sure to remove prevent the entire trimmer head from falling

the shaft.

2.

Remove the spring and spool.

Leeco(R) Manual Feed Head Line Replacement Replacement trimmer line is available from your local

Toro retailer in either single line pieces or in 1-3 Ib bulk packages.

The Leeco@ head uses either 38

feet

of 0.095”

line.

A

replacement monofilament line of

.095"

diameter. Use of improper line could

result

in

personal injury.

See Figure 137.

Figure 137

the

knob slowly to

feet

of

0.080"

line Or

CAUTION:

any type

string-like material as trimmer line. Use only Tor0 approved

Do

not substitute

of

wire

or

.080”

other

or

off

20

IMPORTANT: The Leeco(R) Head cuts with a dual line, however,

HALF.

Using a

2.

point then holes in the hub of the the holes until the mark you made is between the two holes in the hub.

felt

tip pen, mark the line at the halfway

feed

-----

MARK

2.

Wind the line on the spool in the direction of the arrow shown on the spool. Use no more than the

recommended amount of line as

extend beyond the spool flanges and cause

binding. Avoid criss-crossing to help prevent line advancing problems later.

Leeco(R) Manual Feed Head Spool Installation

1.

Before installing the spool, inspect the two eyelets for wear and sharp edges. Replace

2.

Insert one end of the line into each of the two

eyelets and making sure that the line on the does not unwind. See Figure 139.

3. Place the spring on the cutter head shaft and secure with the knob, turning the knob in counterclockwise to tighten.

IMPORTANT:

DO

NOT CUT THE LINE IN

one end through each of the two

spool.

Pull the line through

See

Figure

-I-

Do

not over-tighten.

138.

it

will otherwise

if

necessary.

spool

Leeco(R) Manual Feed Head Spool Installation

(cont'd)

Figure 139

head assembly from the drive shaft.

3. Hold the drum stationary while turning the knob clockwise to remove the knob. Hold onto the knob firmly as

it

is under slight spring pressure. Remove

the knob, spring and spool.

Leeco(R) Manual Feed Head Inspection

1. Inspect the drum, spool and knob for any damage

which may impair their operation. Replace as

required.

2.

Inspect the eyelets for wear and sharp edges. Replace

if

necessary. They can be replaced

individually.

3.

Remove the cutter head shaft from the drum and inspect for damage. Replace

if

necessary.

Leeco(R) Manual Feed Head Reassembly

1.

Push the drum making sure that they bottom

two

eyelets into the

slots

provided in the

out.

4. Cut

off

any excess line

so

that

it

does not strike the

shield when fully extended.

Leeco(R) Manual Feed Head Disassembly

the

1. Remove blade screwdriver into one of the top of the shield.

head

head assembly by inserting a medium

two

See

Figure 140. This prevents the

from rotating.

slots in the

2.

Install the cutter head shaft into the drum as shown in Figure 141.

ADAPTER

SHAFT

2.

Turn the head

Figure 140

clockwise

SCREWDRIVER

to loosen and remove the

59

Figure 141

3.

Wind line onto spool

as

described under Leeco(R) Manual Line Feed Head Line Replacement, page

58.

4.

Install the spool and line assembly into the drum,

threading one line through each of the eyelets. Figure 142.

See

Leeco(R) Manual Feed Head Reassembly (cont’d)

n

Figure

Place the spring on the cutter head shaft and

5.

142

secure with the knob.

NOTE:

Rotate the knob counterclockwise to

tighten.

Reinstall the head assembly onto the drive shaft by

6.

turning counterclockwise. Insert a medium blade screwdriver into one

140

to prevent the drive shaft from rotating.

Cut

off

7.

any excess line

of

the slots shown in Figure

so

that

it

does not strike the

shield.

60

SECTION

CAUTION: Never attempt any service of the trimmer head

A

implement to come to a completer

Kaaz(R) Manual Feed Head Disassembly

1.

Grasp the cutter head to prevent remove the knob by turning Figure

without first shutting engine and allowing the

143.

13

it

from turning and

it

clockwise.

KAAZ(R)

off

the

stop.

See

MANUAL

Kaaz(R) Manual Feed Head Line Replacement Replacement trimmer line is available from your local

Tor0 retailer in either single pieces or in 1-3 Ib. bulk

packages.

A

replacement monofilament line of

.095”

result

1.

To replace the trimmer line, first measure the appropriate length of line:

FEED HEAD

CAUTION: any type of wire string-like material as trimmer line. Use only Tor0 approved

diameter. Use of improper line could

in

personal injury.

Do

not substitute

or

.080'

other

or

SLOTS

I

Figure

2.

Pull the drum and spool assembly from the drive shaft.

143

SCREWDRIVER

20

feet

IMPORTANT The Kaaz(R) Head cuts with a dual line, however,

2.

Using a halfway point.

3.

Thread the line through the retainer shown in Figure 144 until the mark and the retainer are aligned.

MARK

DO

NOT CUT THE LINE IN

felt

tip pen, mark the trimmer line at the

Figure 144

HALF.

3.

Separate the drum, spool and spring being careful not to lose the parts and replace as necessary.

NOTE: Inspect the internal diameter of the eyelets to ensure they are smooth. Burrs or sharp edges could cause the line to break at the eyelets.

two

eyelets. Inspect for damaged

61

4. Wind the arrow. Avoid criss-crossing the line as it may lead to line advancing problems later.

NOTE: smaller flange as this may create binding.

line

on the spool in the direction

Do

not allow the line to extend beyond the

of

the

Kaaz(R) Manual Feed Head Reassembly

1.

Prepare for reassembly by placing the spring on

the drum as shown in Figure

145.

SPOOL

Thread one eyelet onto each end of the trimmer

2.

line and position the spool (with the small flange

toward the spool) above the drum.

Push the eyelets into the slots in the drum making

3.

sure that they bottom out. Place the spool and drum assembly on the cutter

4.

head shaft with the spool facing the shield. Secure with the knob by turning counterclockwise.

5.

IMPORTANT

spool

flange line

Make sure the ratchets on the

up

with the recesses in the

drum before tightening.

Figure

145

SPRING

EYELET

Adjust the length of the line

6.

so

that it does not

extend beyond the flange edge of the shield.

SECTION

CAUTION: Never attempt any

of

service

without first allowing the

A

come to a complete stop.

Plastic Fixed Line Head Line Replacement

engine and the implement to

the trimmer head

14

PLASTIC

2.

3.

FIXED

Plastic Fixed Line Head Removal

1. Remove the existing cutter line from the spool. Remove the cotter pin from the cutter head shaft. Insert a flat bladed screwdriver into the slot in the

top of rotating during spool removal. Remove the nut by turning clockwise (as viewed from the bottom of the spool). See Figure 147.

LINE

the

shield to prevent the cutter head from

HEAD

The plastic

in

diameter and

1.

2.

3.

fixed

line head uses nylon line 2.5mm (.105")

40

cm (16') in length.

CAUTION:

any type of wire or other

string-like material as trimmer

A

replacement monofilament line of

(.105”)

could result

To

replace the trimmer line, first cut the line to 40

cm (16') length. Mark the center of the line with a

Thread the line through the cutter head guides as

shown in Figure 146. Make sure that the centerline mark lines up on the cutter head shaft.

line. Use only Tor0 approved

diameter. Use of improper line

in

personal injury or death.

Do

not substitute

felt

2.5

tipped marker.

mm

SCREWDRIVER

Figure 147

4.

Remove the spool.

5.

Inspect the spool for damage. Pay particular attention to the eyelets. Burrs in this area can lead to line breakage at the eyelet. See Figure 148.

Figure 146

Figure 148

63

Plastic NOTE: The following parts are required when installing

the plastic fixed line head on a

TC5000

1.

Fixed

Line Head Installation (cont’d)

for the first time:

Cotter

CAUTION: Never attempt any service

A

come to a complete stop.

Mount the cutter head on the shaft.

without first allowing the engine and the implement to

of

TC3000,

Part Number

41-5410

3272-1

the trimmer head

See

Figure

or

149.

2.

Loosely secure with the hex nut.

NOTE: The nut has left hand threads necessary to turn started.

3.

Insert a flat bladed screwdriver into the slot in the top of the shield to prevent the cutter head from rotating as shown in Figure

4.

Tighten the nut and install the cotter pin to prevent

the nut from backing out.

5.

Install the trimmer line as described under Plastic Fixed Line Head Line Replacement, page

it

counterclockwise

147.

so

it will be

to get

it

63.

Figure

149

GRASS

WRAP

SHIELD

HEAD

64

SECTION

15

METAL FIXED LINE HEAD

2.

Remove the cotter pin from the cutter head shaft.

CAUTION: Never attempt any service of the trimmer head without first allowing the

A

come to a complete stop.

Metal

Fixed

The aluminum fixed or 3.3 mm (.130") line. Because of the added load put on the engine when using the thicker line, be sure to cut the line to the proper length:

1.

To

replace the trimmer line, first cut the line to the

proper length mentioned above.

2.

Mark the center of the line with a felt tipped marker.

3. Thread the line through the cutter head guides as shown in Figure 150. Make sure that the centerline mark lines up on the cutter head shaft.

engine and the implement to

Line Head Line Replacement

line

head uses either

2.5

mm (.105')

3. Insert a flat bladed screwdriver into the slot in the top of the shield to prevent the cutter head from rotating during spool removal. Remove the nut by

turning the spool). See Figure 151.

I

clockwise

Figure 151

(as viewed from the bottom of

SCREWDRIVER

Figure 150

1.

Center

of

line

2.

Outer projections

IMPORTANT While lines with the metal fixed line head, best cutting results are obtained by using only one line.

it

3.

Position

in

slot

is

possible to use two

4.

Remove the spool being careful not to lose the insert.

5.

Inspect the spool for damage. Pay particular attention to the area where the line exits the spool. Burrs in this area can lead to premature line breakage at the point where Figure 152.

it

exits the spool.

See

Metal

Fixed

Line Head Removal

1. Remove the existing cutter line from the spool.

65

1.

Cotter

Figure 152

2.

Check

for

burrs

Metal Fixed Line Head Installation NOTE: The following parts are required when installing

fixed

the metal for the first time:

Part Plate Washer Nut

Cotter Pin

A

come to

1. Place the insert around the flange on the lower gearbox cover. See Figure 153.

line head on a TC3000,

CAUTION: Never attempt any service without first allowing the engine and the implement to

a

complete stop.

of

the trimmer head

TC4000

Part Number 41-4430 41-5410 3272-1

or TC5000

Mount the cutter head.

2. Place the plate washer on the shaft and loosely

3.

secure the cutter head assembly with the nut. NOTE: The cut

necessary to Insert a flat bladed screw driver into the slot in the

4. top of the shield to prevent the cutter head from

rotating as shown in Figure 151.

Tighten the nut and install the cotter pin to prevent the nut from backing out. See Figure 154.

has

left hand threads

it

counterclockwise to get

so

it

will be

started.

Figure 153

Figure 154

7.

Cotter

5.

Install the trimmer line as described under Metal Fixed Line Head Line Replacement, page

65.

SECTION

CAUTION: Never attempt

any service of the trimmer

A

and allowing the implement to come to a

complete stop.

TAP AND TRIM@ LINE REPLACEMENT

Tap and Trim@ Spool Removal

1. Insert a medium blade screwdriver into one of the two slots on the bottom of the spool and twist 1/4 turn to release the spool. See Fig. 155.

head without first

shutting

off

16

the engine

TAP

AND

2.

TRIM@

1. To wind replacement line on the spool, first hook one end of the line into the keyhole slot in the top

flange of the spool. See Fig. 156.

Wind the line on the spool in the direction arrow. Use no more than otherwise extend beyond the spool flanges and cause binding. Avoid criss-crossing to help prevent line advancing problems later.

HEAD

Figure 156

38

feet of line as

of

it

the

will

Figure 155

2.

Remove the spool.

Tap and Trim@ Spool Line Replacement

Prewound Tap and Trim@ spools are available through

If

your local Toto retailer. down to Tap and Trim@ Spool Installation below.

While prewound economical approach is to wind new line on the existing spool. Tor0 monofilament line can be purchased in bulk under

Tor0

part

number 41-6830 for one pound or

41-6830

for 3 pounds.

A

Use only Tor0 approved replacement monofilament line of

of

improper line

injury.

using a prewound spool, skip

spools

are convenient, a more

CAUTION: substitute any type of wire or other string-like material as trimmer line.

.080”

could

result in personal

Do

diameter. Use

not

3.

Hook the end of the line in one provided in the upper flange the line tight while installing the spool.

4. Cut the line protruding from only 1/2 inch remains.

Tap and Trim@ Spool Installation

1. Align the keys molded into the core with the eyelet on the drum. It may be necessary to depress the

core and rotate to get the keys to line up properly. See Fig. 157

of

the

of

the spool to keep

the

keyhole slot

two

so

slots

that

\

Figure 157

I

67

Tap and Trim Spool Installation (cont'd)

2.

With the trimmer line still in the slot in the top of the

spool

flange, thread the line through the eyelet in

the drum.

3.

Align the two screwdriver slots with the keys in the

spool

core and push the

4.

Pull

on the line to release

partially onto the core.

it

from the

spool;

then push the spool firmly onto the core until

"snaps" into place.

TAP AND TRIM@ HEAD

Tap and Trim@ Head Disassembly

Insert a medium Made screwdriver into one of the

1.

two slots on the bottom of the spool and twist

turn to release the

Remove the

2.

While holding the drum stationary, unscrew the

3.

spool

core and driver assembly by rotating them counterclockwise.

flange

1/4

2.

Center the spring on the drive shaft and then place the washer, driver and core onto the shaft assembly. See Fig.

it

SPRING

WASHER

158.

CORE

DRIVER

as

an

Remove the core, the driver,

4.

the

washer and the

spring.

Pull the drum up and

5.

off

the drive shaft.

Tap and Trim@ Head Inspection

1.

Inspect the drum for any obvious damage to the plastic.

2.

Make sure that the eyelet in the drum

that the areas that contact

the

is

trimmer line are

smooth.

3.

Check that the rivet directly opposite the eyelet is still

in

place. (The purpose of the rivet is to

counterbalance the eyelet.)

Tap and Trim@ Head Reassembly

1.

Mount the drum on the drive shaft making sure that

it

mates properly with the coil pin.

intact and

Figure

3.

Screw the core and driver onto holding the drum.

the driver in order to get

158

the

drive shaft while

It

may be necessary to press

it

started on the threads.

Screw the driver/core assembly on finger tight.

4.

Make sure that the core indexes freely on the

driver.

5.

Install the spool as described under Tap and Trim@

Spool

Installation, page

67.

on

SECTION

Tor0 offers straight shaft trimmer line. The eight tooth blade is designed for cutting brush and heavy weeds up to about

1.3 cm (1/2 inches). The eighty tooth blade should be used in heavy brush and (3/4") are present.

When using either blade, a harness is required to help maintain adequate control.

Metal Blade Removal

1. Remove the cotter pin from the cutter head drive

2. Insert a flat bladed screwdriver into the slot in the top of the shield to prevent the blade from rotating

two

20 cm

CAUTION: Never attempt any service of the trimmer head

A

implement to come to a complete stop.

shaft.

during removal. See Figure 159.

without first shutting engine and allowing

(8

inches) blades that

if

scrub trees greater than 2 cm

off

the

fit

the

Blade Adapter Kit for Gas Trimmer, Tor0 part number

41-4440.

1. Mount the blade on the cutter head shaft. There

fit

should be a perfect cover flange and the hub on the blade.

IMPORTANT with the teeth pointing Make sure that they are pointing as shown Figure

160.

It

between the lower gearbox

is important to install the blade

in

the correct direction.

in

SLOTS

Figure 159

3. Remove the nut securing the blade by turning clockwise (the nut uses left hand threads).

4. Remove the blade adapter and blade. Inspect the

blade for damage or cracks and replace necessary.

Figure

2.

Place the blade adapter on the shaft and loosely secure with the hex nut.

NOTE: The hex nut uses therefore must be turned counterclockwise to tighten.

3.

Insert a flat bladed screwdriver into the slot in the top of the shield to prevent the blade from turning while tightening the nut.

CAUTION: The metal blades are very sharp.

if

recommended when installing

or removing the blade.

160

left

hand threads and

See

Figure 159.

teeth

gloves are

on

the

Metal Blade Installation Note: If you are installing either the saw blade or the

brush blade for the first time, you will require the Metal

4. Insert a cotter pin in the shaft to prevent the hex

nut

from backing

out.

69

SECTION

Standard and Deluxe Harness Assembly

1.

(TC3000

control. See Figure 161.

and

TC4000)

Slip the ring into the throttle

18

HARNESSES

n

I

Figure 162

Figure 161

(TC5000)

the tube approximately

isomount housing. Secure with the machine screw. See Figure 162.

3.

Adjust the harness rotates in a nearly level plane with a slight forward

tilt.

4.

(Deluxe Harness Only) Fasten the belt by

threading the loose end through the buckle.

Figure 163.

Mount the clamp and ring assembly onto

15

cm (6 inches) below the

so

that the trimmer line or blade

nut

and

See

Figure 163

SECTION

19

Spark

Arrestor

Muffler

Spark arrestor mufflers are available for the straight shaft

trimmers. These mufflers use a metal screen at the

muffler

chamber. They are recommended when trimming in dry areas and

may

Spark Arrestor Muffler Removal

1. Remove the three screws that secure the muffler

to

prevent sparks from exiting

be

required by state or

cover to the engine and remove the cover. Figure

164.

local

laws.

the

muffler

See

3.

Spark Arrestor Muffler Maintenance

After every

muffier body should be removed and soaked in a

commercial carbon remover per the manufacturer’s

instructions.

1.

2.

Install the new muffler cover with three Phillips head screws.

50

hours of use, the arrestor screen and

Remove the muffler as described under Spark

Arrestor Muffler Removal, page 71.

Remove the

arrestor to the muffler. See Figure 165

two

screws securing the spark

Figure 164

2.

Remove the engine and the Phillips head screw near the fuel

tank. Remove the muffler.

3.

Remove the the arrestor screen screen.

Spark Arrestor Muffler Installation

1. If installing the spark arrestor muffler for the first time, remove the original muffler cover and muffler.

2.

Place the muffler gasket on the studs and install

the muffler. Secure with the

Phillips head screw.

two

nuts securing the muffler to

two

Phillips head screws that secure

to

the muffler and remove the

two

hex nuts and

the

3.

Soak the muffler and the spark arrestor screen in a commercial carbon remover per the manufacturer’s instructions.

4.

Blow out any loose carbon with compressed air.

IMPORTANT Before reinstalling the muffler, be sure

to

remove

damage may result.

5.

Reinstall the muffler as described under Spark

Arrestor Muffler Installation, page 71.

all

loose carbon particles

or

engine

71

Toro 51644, 51645, TC3000, TC4000, TC5000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual