GAS TRIMMER GUIDE, MODELS 51630, 51603, 51604 Table of Contents – Page 1 of 1 FOREWORD GENERAL INFORMATION MAINTENANCE PROCEDURES AIR CLEANER MAINTENANCE EXHAUST SYSTEM MAINTENANCE FLEXIBLE DRIVE SHAFT MAINTENANCE CARBURETOR ADJUSTMENTS -- MODEL TC-1 500 WITH TILLOTSON CARBURETOR ADJUSTMENT -- MODELS TC-300, TC-400 WITH WALBRO TROUBLESHOOTING AND TEST PROCEDURES DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS WALBRO CARBURETOR OPERATION CUTTER HEAD TROUBLESHOOTING CLUTCH REPAIR
GASOLINE POWERED TRIMMER GUIDE MAINTENANCE & REPAIR MODEL NO.51630 COPYRIGHT(C) ALL 1000001 & UP 2000001 & UP 2000001 & UP RIGHTS RESERVED The Tor0 Company - 1982 MINNEAPOLIS, M N 55420 U.S.A.
FOREWORD' This Maintenance and Repair Guide will provide you with complete information necessary to accomplish the maintenance and repair of gasoline-powered flexible line trimmers powered by the new line of the lightweight two-cycle engines manufactured by The Tor0Company The number of repair procedures for this line of engine;s has been limited for simplicity and economy The repairs are easy to accomplish.
GENERAL INFORMATION Two-cycle Engine Theory Two-cycleenginesareusedon because of their: of Operation TORO Trimmers 1. Light weight. Engine ,Operation The piston closes all engine ports as it moves toward the combustion chamber(Fig. 2). The moving piston creates high pressure in the combustion chamber and partial vacuumin the crankcase. 2. Excellent power-to-weight ratio 3. Ability to operate in any position 4. Easy maintenance 5.
GENERAL INFORMATION Thee expandnig banding gases from the burning fuel in the combustionchamberforcethepiston downthe cylinder,closing the third-port andincreasingthe pressure in the crankcase. At a point approaching the bottomof the stroke, the exhaust port opens and the burnt gases begin to be expelled from the combustion chamber (Fig. 4).
ENGINE SPECIFICATIONS TC300 TC (Model51630)(Model51603) TC400 (model51604) 32:1 or unleaded regular leaded Genuine TOR0 Two-CycleOil or other high quality two-cycle oil,BIA approved .40 (13.5 oz.) Fillotson ModelSP-1A withcontained self fuel pump, accelerator pump and pumpandfilterscreen Factory adjusted and WalbroWa-120serieswith self contained fuel filter screen Factory adjusted and testrun. Adjusting Procedures Procedures-pp. run. test Solid state,-capacitive discharge ignition(CD1) 22degreesBTDC 1.
MAINTENANCE PROCEDURES AIR CLEANER MAINTENANCE Check and clean the foam air cleaner element every eight operating hours, and the felt air cleaner aonce season. 1. Remove the air cleaner cover by pressing up on thebottom of the cover to releasethelower mounting tab and pressing in on frontof the cover to release the upper tab. DO NOT FORCE. 2. Carefully remove the filter clip or filter retainer. Remove the foam filter and felt filter (Figures 6 and 7). Air Cleaner Housing 5. Inspect the felt filter.
IMPORTANT:WHENREMOVINGCARBONDEPOSITS,CLOSETHEPORT WITH THEPISTON TO PREVENT LOOSE CARBON DEPOSITS FROM FALLING INTO THE CYLINDER. TAKE CARE NOT TO SCRATCH THE PISTON. DONOTUSE A METAL TOOL SUCHAS A SCREWDRIVER. 5. Reassemble the mufflercomponents. Use a fresh exhaust gasket. FLEXIBLE DRIVE SHAFT MAINTENANCE The flexible drive shaft has been lubricated at the factory. After approximately every 40 hours of operation, the shaft should be removed from its housing and its entire surface coated with a No.
MAINTENANCE PROCEDURES 3. Adjust Idle First: 2. Low Speed Screw (L) (Fig. 13) 4. If necessary, idle speed canbeincreasedby turning the idlestop screw clockwise (Fig. 12). 3. Idle Screw(Fig. 13) With engine idling, rotate the Low Speed Screw (L) for the leanest fuel mixture that allows stable idle, and acceleration without hesitation. Figure 12 speed position and adjust the HighSpeed Screw (H) for maximum enginespeed. 6. Recheck the idle adjustment.
MAINTENANCE PROCEDURES 4. Start the engine and let it warm up for approximately 3-5 minutes. Do not adjust the carburetor when the engineis cold. The adjustments should be made at the temperatures that the trimmer will be used. Allow the engine to idle. If necessary, re-adjust the idle speed to keep the engine fromstalling (3000-3500 RPM onthe TC400, 3000-4500 on theTC300) CAUTION: DONOTRUNTHE TRIMMER INDOORS WITHOUT ADEQUATE VENTILATION.EXHAUST FUMES ARE POISONOUS AND COULD BE DEADLY IF INHALED. 5.
TROUBLESHOOTING AND TEST PROCEDURES Checking for Spark Checking Fuel Tank Venting 1. Pull off the spark plug cap and remove the spark Plug. The fuel tankcap vent allows air into the as tank fuel is consumed. If this vent isblocked with dust or dirt, the engine will eventuallystall. 2. Inspect the spark plug for wear, carbon deposits and damage. Replacethe plug if damaged, burnt or fouled. 3. Check for the correctspark plug gap and adjust if necessary to .020-.024 in ( 5 .
TROUBLESHOOTINGSHOOTING AND TEST PROCEDURES
DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS Trimmer Engine Removal, Disassembly, Replacement 8. Remove the throttle and switch, assemblies and Iift, the engine from the Left Hand Case. I 1. Drain the gas from the trimmer gas tank and remove the spark plug high tension wire. 9. Removethe air cleaner elements and retaining clip. 2. Remove the air cleaner cover by pressing up on 10, Remove the carburetor by removing the Phillips head screws whichpass through the spitback/ choke assembly and carburetor.
DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS Figure 19
Starter Rope Replacement 1. Follow steps 1-5 of Trimmer & EngineDisassembly/AssemblyInstructions. NOTE: Do not removethe Recoil StarterAssembly fromthe Upper Shaft Housing Tube. 2. Remove the damaged rope from the pulley. 3. Knot one end of the replacement rope. Align the cut-outsections of theDrum and themetal Ratchet Cover.Feed the un-knotted end of the rope through the clearance hole and intorope the groove in the Drum (Figure20). the end of the roperemainingthroughthe guideslot in theretainer.
DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS WALBRO CARBURETOR OPERATION Alternate fuel pumpsystem to accommodate internal pulseand/or external fuel source. 1. EngineImpulse:ActuatesFuelPumpDiaphragm alternating pressure-vacuum pulses. with 2. Fuel Pump Diaphragm: Fluctuates in response t o engine impulse. Transfers fuel throughFuel PumpValves. 3. Fuel Inlet: Fuel drawnfrom tank. 4. Inlet Valve: Responds t o Fuel Pump Diaphgram. Opens during vacuum pulse. Closes during pressure pulse. 5.
DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS WALBRO CARBURETOR SERVICING -Metering DiaphragmCover -Metering Diaphragm Assembly Metering Lever Inlet Needle Metering Diaphragm Gasket V Circuit Plate Assembly Circuit Check Valve Circuit PlateGasket Throttle Valve Screw Throttle Valve ,Idle Needle Hi Speed Needle Fuel Inlet Screen Throttle Shaft Assembly Fuel Pump Diaphragm Fuel Pump Gasket Idle Adjust Screw Fuel Pump Cover Figure 22 Carburetor Disassembly (Referto Fig. 22): 1. Remove thefuelpump cover.
DISASSEMBLY, REPAIR, REASSEMBLY INSTRU'CTIONS Carburetor Re-Assembly 1 . Install a new filter screen with any appropriate hollow tube or tool of approximately ,300inch diameter. NOTE: The screen must be pushed in far enough to be below the fuel inlet hole. 2. Inspect the circuit plate for flatness and correct if necessary. 3. Inspect thenewcircuitplate diaphragmand gasket for flatness.
TROUBLESHOOTING AND TEST PROCEDURES CUTTERHEADTROUBLESHOOTING of Difficulty Binding I Reduced cutting ability Cutting line too short, won't index Clutch slipping Driver broken,' lineswelled from moisture, I dirty, line tangled Cutting line not indexed often enough or prior to engine shut Cutting line fails to advance Cutting line pulls back into drum (or tangles) Off Not seated in engine or cutting unit Line spool fails to turn RPM too low Clutch fails to engage Clutch fails to disengage at i
i DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS CLUTCH REPAIR The clutch consists of two assemblies: (Fig.24): A. The upper housing containing the upper power shaft,ballbearing,oil shield, clutch spacer, clutch assembly and B. The lowerbearinghousingandclutchdrum which isthreaded to the lower housing shaft. NOTE: The oilshieldwasnot used in early production of the TC-400 clutch assembly. Also, the upper power shaft with the snap ring was changed to a machined shaft with a shoulder.
DISASSEMBLY, REPAIR, REASSEMBLY INSTRUCTIONS AUTOMATIC LINE FEED REPAIR 1. Drain thegasoline from the fuel tank and remove the high tension wire from the spark plug. 2. Insert a medium flat screw driver in one of the two window slots in the spool hub and twist. The spool will snap off. (Fig. 26). NOTE: Use aswide a screw driver as will fit in the slot so as not to damage the cap. 3. Hold the drum securely, and unscrew the spool core counterclockwise. The driver will turn off with it. 4.
