TC3, 4, 5000 GAS TRIMMER, MODELS 51643, 51644, 51645 Table of Contents – Page 1 of 4 ABOUT THIS MANUAL SAFETY INFORMATION FOR YOUR SAFETY...
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
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
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 META
ABOUT THIS MANUAL 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 informationin this manual completeand correct. This manual was written with the service technician in mind. It is organized so that information usedmost often is up front. As a result, you will findreference information on safety, maintenance, specifications, special tools and troubleshooting all in the front third of the manual.
TABLE OF CONTENTS Reference Information Page SafetyInformation 1 Specifications2 Tool Requirements 5 Troubleshooting 6 Maintenance 8 Service Procedures Page Section 1 Carburetor operation11 removal disassembly reassembly installation adjustment 18 Section 2 14 14 16 18 Fuel System Fuel Tank removal installation20 20 Primer Pump properuse 21 operation disassembly22 21 inspection22 reassembly22 Fuel Pickup Tube and Filter service Fuel Cap operation23 disassembly24 inspection reassembly24
TABLE OF CONTENTS Service Procedures (cont'd) Page operation airgapadjustment coilremoval coil installation 25 27 28 29 Recoil Starter Recoil Mechanism operation removal disassembly reassembly installation Starter Pulley removal installation Section 5 33 33 Clutch and lsomount Clutch Shoes and Flywheel operation disassembly inspection removal reassembly Clutch Drum and Housing disassembly reassembly lsomount (TC4000and TC5000 only) operation disassembly reassembly Section 6 30 30 30 31 32 34 34 34 3
6 TABLE OF CONTENTS Service Procedures (cont’d) Section reassembly installation on drivetube. Section 7 44 45 Control and Grip Control disassembly 46 reassembly Grip removal installation Section 8 Handle TC3000 removal from drive tube 48 Installation on drivetube. adjustment TC4000 removal from drive tube installation on drivetube. adjustment. TC5000 removal from drive tube installation on drivetube. adjustment.
TABLE OF CONTENTS Service Procedures (cont’d) Drive Shaft removal 56 installation 56 Drive Tube removal 56 installation57 Section 12 Leeco@ManualLineFeedHead sped removal linereplacement 58 installation 58 58 Head disassembly 59 inspection 59 reassembly Section 13 59 Kaaz@ManualLineFeedHead head disassembly 61 linereplacement 61 headreassembly 62 Section14PlasticFixedLineHead linereplacement headremoval 63 headinstallation 64 Section 15 63 Metal Fixed Line Head linereplacement headremoval headin
TABLE OF CONTENTS Service Procedures (cont’d) (cont’d) Head Trim@ Section and Tap 16 Page Head disassembly68 inspection reassembly68 Section 17 68 Metal Blades removal69 installation 69 Section 18 Section 19 Harnesses assembly Spark Arrestor Muffler removal71 installation71 maintenance71 70
SAFETY INFORMATION Thismanual is intended as aserviceandrepair in this manual only. The safety instructions provided manualareforthetroubleshootingandserviceofthe A t h i s safety symbol means WARNING or CAUTION product individual The only. Operator’s Manual will PERSONAL SAFETY INSTRUCTION Read the instruction because it has todo with safety. Failure to comply with the instruction may result in personal injuryor death. contain safety information on the operation the of TC3000. TC4000. TC5000.
SPECIFICATIONS Engine Specifications TC3000 and TC4000 Service Specifications 2
SPECIFICATIONS (cont'd) TC3000andTC4000ServiceSpecifications(Cont'd) Piston Ring Side Clearance 0.020 to 0.060 mm 0.150 mm (0.0008 to 0.0024") (0.0059") .
SPECIFICATIONS (cont'd) Carburetor Specifications Standard Item Throttle Valve Needle Jet 1.4 to 1.6mm (0.055 to 0 . W ' ) IdleSpeedAdjustingScrewAdjust so idle is (3000 200 rpmonTC3000and (2500 200 rpm on TCSOOO) Fastener Torques Fastener kgm Crankcase Screws 0.4 to 0.
TOOL REQUIREMENTS: Flywheel Puller number Tor0 part41-7650 Dial Indicator Magnetic V Blocks & Dial Indicator Stand Spark Tester Tor0 number41-7890 part Tachometer Spark Plug GappingTool Tor0number part 42-2730 Feeler Gauge Torque Wrench Compression Gauge Threebond #1104 Tor0 part number 505-80 Metric Socket Set 3/8” Drive Loctite #242 Tor0 number part 505-76 Spark Plug Socket Micrometer #2 Phillips Screwdriver Snap Ring Plier (inside& outside type) 12 oz. Ball Peen Hammer Hex.
TROUBLESHOOTING Engine Does Not Produce Spark Engine Floods During Starting Engine Not Getting Fuel crankcase leak
TROUBLESHOOTING (cont’d) EngineLacksPower Engine Has Low Compression I Remedy Engine Backfires (indicated by burnt air cleaner element) Trimmer Vibrates Excessively 7
Maintenance Air Cleaner Maintenance Muffler Servicing ofthe air cleaner is recommended after every Decarbonizing the muffler is recommended after every 25 hoursofoperationormoreoften in verydusty 50 hoursofoperationor if engine speed decreases conditions. drastically. See Figure 2. See Figure 1. FILTER GRID AIR FOAM FILTER FILTER SCREEN Figure 2 Figure 1 1. Removethethreescrewssecuringthemuffler cover to the trimmer. 2. Removethe two nutssecuringthemuffler to the engine. 3. 1.
5. Maintenance Spark Plug Push the pickup assembly back into the tank and install the gas cap. The TC3000,TC4000 and the TC5000 each use NGK an BMGA spark plug or the equivalent. Correct0.6-0.7 gap is mm (0.024-0.028”). Therecommendedservicinginterval for the spark plug 25 is hours of operation. 1. Stop the engine and pull off the spark plug wire. 2. Clean around the spark plug and remove the spark plug fromthe engine usinga 19mm (3/4") socket. IMPORTANT: Replacea cracked, fouled or dirty spark plug.
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.Pulltherecoilstarterhandleseveraltimes distribute theoil throughout the engine. 6. 3. Clean any debris from under the gear case cap. 4. Clean the grease fitting, then fill the gear case with a general purpose number 2 lithium base grease until grease is forced out from around the drive Shaft. to 5.
SECTION 1 CARBURETOR Carburetor Operation Thecarburetorused onthe TC3000, TC4000andthe TC5000 is a diaphragm style carburetor. It uses alternating pulses from the crankcase to pump fuel from the fuel tank to the carburetor.
CarburetorOperation 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.
6. 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 mixturescrew.Thehighspeedmixturescrew regulates the maximum amount of fuel that can enter the carburetor throat. 7. To better atomize the fuel, an air correctionjet was added. The air correction jet allows filtered air to enter the carburetor throat perpendicular to the normal air flow.
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 Figure17. Figure 17 MAIN DIAPHRAGM CAVITY OVERFLOW NEEDLE TICKLER BUTTON Figure 15 3. Pumpingtheprimerpumpforcesfuelintothe entire fuel system.
NOTE: Before removing inlet needle pieces, inspectinletneedlearmheightusingadepth micrometer. The correct height is 1.4 to 1.6 mm (.055to .062”)See Figure 21. Carburetor Disassembly (cont'd) 2. Remove the fuel pump by removing the 4 screws with lock washers securing the pump cover then lifting off the pump diaphragm and pump cover gasket. INLET NEEDLE ARM HEIGHT NOTE: The gasket and the diaphragm are extremely thin and may stick together giving the appearanceofonepiece.
Carburetor Disassembly (cont’d) E-CLIP GROOVES SECONDARYNEEDLE Figure 25 Figure 23 2. Positiontheneedlewiththeretainerclipintothe 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 thethrottle valve. Figure 26 Carburetor Reassembly IMPORTANT Make certain all parts are cleanand in good condition. Do not use wornor damaged parts. 1. Installthe E clip on thethrottlevalve.
9. Carburetor Reassembly (cont’d) 7. Replacetheinletneedlepiecesbyinstallingthe inlet needle, theinlet needle spring, the inlet needle arm and securewith thescrew. See Figure27. OVERFLOW /--VALVE INLET NEEDLE ARM Replace the main diaphragm parts by installing the main diaphragm gasket against the carburetor, the main diaphragm assembly upon the main diaphragmgasket,themaindiaphragmcover upon the main diaphragm assembly.
3. Carburetor Reassembly (cont’d) Ensurethatthe throttlecableispositioned as shown in Figure32 to prevent throttle cable damage. CORRECT ROUTING Figure 30 Carburetor Installation I. Installtheintakeflangewithgasketsandheat shield making certain that the pulse hole is not obstructedbyany of theintakecomponents. Secure by tightening the screws to .3 to .45 kg m (26 to 38 in Ibs). See Figure 31. Figure 32 The proper order for installing the intake components is: gasket heat shield gasket intakeflange 4.
throttlevalveshouldtravel to the top of the carburetoropeningwhenthetriggeris in full throttle position. Carburetor Adjustment Mixture A 1. CAUTION: stay clear of cutter head whenever engine is running. 3. To adjust, loosen the jam nut on throttle cable and rotate the turnbuckleto increase or decrease the travel of the throttle valve. See Figure 34. -- The high speed mixture screw (see Figure 34) controlsthefuelflowrequirementsduringthe engine's optimum demand.
SECTION 2 FUEL SYSTEM 3.Removethe FUEL TANK fueltank. if necessary, by 4.Thebracketcanberemoved, it to removing the single machine screw retaining Fuel Tank Removal the crankcase. I. Loosenthe two locknutsandthecorresponding hex screws that retain the fuel tank guard. Remove 5. The strap can be removed, if necessary, by the fuel tank guard. See Figure 35. backing out the four Phillips fan housing screws approximately 3/16' each. This will provide sufficient clearanceto remove the strap.
Pushtheticklerbuttonfullyinward. Manuallypumptheprimerpumpuntilasmall 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. Fuel Tank Installation (cont’d) 4. Slide the fuel tank guard into the lower fan housing and tighten the two hex screws retaining it. Tighten the two corresponding locknuts. 5. Slide the retaining ring onto the fuel line, then push the line onto the fitting near the primer bulb.
Primer Pump Operation (cont'd) 2. Theinletvalve 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 readiesit for the next pump. Primer Pump Disassembly 1. Pull the primer pump from the tank and remove the fuel line. The primer pump is pressinto fit the fuel tank. See Figure42. Figure 44 Primer Pump Inspection 1. Inspect the disassembled primer pump contamination or damaged parts. 2. Clean 3.
these elements and the fuel strainer located inside the pickup weight. Clean or replace as necessary. Primer Pump Reassembly (cont'd) Valve seat "A"has a locating notch that is cut through theseat. Valve seat "B"has a locating notch that is partially cut into the seat. Gasket "A"and valve seat"A" are inside the pump. Gasket"B” and valve seat"B” are to the outside. 3. Reassemble the pickup assembly making sure that the pickup tube fits snugly on the top of the fiber filter element. 4.
Fuel Cap Operation (cont’d) When a vacuum occurs within the tank, the following occurs: See Figure48. Fuel Cap Inspection 1. It is important that the fuel cap properly vents the tank. Inspect the gasket to ensure that the hole at rounded end the is unobstructed. 2. Checkthe two smallpressureoutletholes 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.
SECTION 3 IGNITION flywheel magnets to cut through the coils to generate electricity. See Figure52 Ignition Operation The firing of the spark plug at the proper time is the culminationof a numberofcomponentsworking together. In the TC3000, TC4000, andTC5000the components used are: IGNITION COIL Flywheel Ignition Coil Trigger Module Spark plug See Figure51. SPARK PLUG, Low voltage is produced in the primary coil which is sent to the trigger module.
lgnition Operation Trigger Module (cont'd) The following is the process the trigger module uses to break the primary circuitto produce spark:See Figure 55 Figure 55 PRIMARY VOLTAGE WAVEFORM 1. Figure 53 2. 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 two opposing poles of the magnet. Themagnetpasses bythecoilandinducesan alternating voltage.
Ignition Operation Trigger Module (cont'd) and allowsno current l3 or l4 to flow. 5. TERMINAL NUT As the voltage produced in theprimarycoil reaches its negative peak (point" b in Figure 53), transistor Tr1 is turned on and allows small current l3 and large current l4 toflow. See Figure 58. METAL SHELL MTI unit Ignition coil INSULATOR Ground LEG CENTER ELECTRODE Spark plug GROUND ELECTRODE GAP Figure 59 Figure 58 6. The other important area is the insulator.
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 0.4 to 0.5 kg m (35to 43 in Ibs). 2. Installtheplasticfanhousingcoverusingthree Phillips screws. 3. Mount the engine on the drive tube as described in Engine Installation on Drive Tube, page 45. i TC5000 Air Gap Adjustment Preparation Remove 1. the carburetor as described under Carburetor Removal, page 14.
Coil (cont'd) Removal 3. Remove the fuel tank as described under Fuel 20, to gain access to Tank Removal, page ignition wiring. Coil Installation 1. Install the trigger module using two machine screws. Be sure to install the rubber insulating gasket beneathit. See Figure 63. 4. Pull out the two male connectors leading into the female connector found beneath the carburetor. 5. Positiontheengineassembly so thattherecoil housing is resting on a hard, flat surface.
SECTION 4 RECOIL STARTER starter pulley andin turn, forces the engine to turn over. 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 PULLEY RETURN When the reel stops turning, the starter pawl is forced backinto its normalretractedposition by thereturn spring. REEL CLOCKSPRING Recoil Mechanism Removal 1.
Recoil Mechanism Disassembly (cont'd) CAUTION: Do not remove the wire surroundingthespring until the spring is installed in the recoil housing. Removing the wire prematurely may result in personal injury. A CAUTION: remove the friction plate and reel components carefully as jerking them out may cause the recoilspring to come outof the recoilhousing. 4. Removethereturnspring. See Figure67. Figure 68 2. Figure 67 5. Gently lift outtherecoilreelwithaneedlenose pliers.
reel back and forth slightlyin order to get the parts to properly mate. Recoil Mechanism Reassembly (cont'd) 6. NOTE: If thespringjumped out oftherecoil housing, the recoil spring should be replaced. 4. Wind the recoil rope onto the reel in a counterclockwise direction (as viewed from the side ofthe reelwithout the knotin it). Hook the end of the rope in the slot provided in one of the reel flanges. Leave about 15 cm (6inches) of rope. See Figure 71.
3. Starter Pulley Removal 1. Removetherecoilstarterasdescribedunder Recoil Mechanism Removal, page 30. 2. Remove the starter pulley nut by turning counterclockwise. See Figure73. it The starter pulley is threaded onto the crankshaft and is removed by turning it counterclockwise. If the engine turns while trying to remove it, place a piece of wood on one of the starter pulley ratchets and tap to loosen. Starter Pulley Installation 1. Thread the starter pulley onto the crankshaft. Ii 33 2.
SECTION 5 CLUTCH SHOES AND FLYWHEEL Clutch Shoes and Flywheel Operation The TC3000,TC4000 and TC5000 usea centrifugal type clutch. The clutch is constructed of two shoes and a to the flywheel as shown spring. Theseparts are fastened in Figure74. 3. Remove thefanhousing. IMPORTANT: (TCSOOO only). The coil is mountedto the inside of the fan housing the on TC5000.
Clutch Shoes and Flywheel Inspection (cont'd) 4. Check the flywheel for cracks or broken fins. earlier are facing up. Then slide a flat washer over the threads of each bolt so that the washer rests between the flywheel and the clutch shoes. See Figure 77. ClutchShoesandFlywheelRemoval 1. Make note of the markings on thetop 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 to coil the side. 3.
Clutch Drum and Clutch Housing Reassembly (cont’d) CLUTCH FAN HOUSING Figure 80 Figure 78 The TC4000 and TC5000 clutch drum and clutch housing is assembled as shownin Figure 79. 5. Install the small snap ring in the drive shaft end of the housing. 6. Check to ensure that theclutch drum rotates freely and is true. ISOLATION MOUNT (TC4000 and TC5000 only) Isolation Mount Operation TheTC4000andTC5000trimmersuse avibration isolation system called an Isolation Mount. See Figure 81.
Isolation Mount Operation (cont'd) The system is constructedtwo of rubber cushions and a cushion holder. The cushions are positioned between the holder and the clutch housing and are actually the only two points of contactbetweentheengineandthe drive tube. This arrangement allows vibration to pass only through thetwo rubber cushions and reduces the to the operator. amount of vibration that is transmitted 3. Inspect the rubber cushions for wear and damage. Replace if necessary.
SECTION 6 ENGINE Engine Operation The engine usedin the TC3000, TC4000, andTC5000 is based upon a two-stroke, port to port design. The term "two-stroke"refers to thenumberofoperationsthe pistongoesthrough in order to completeasingle combustion cycle. Thosetwo operations are called an 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).
Engine Operation (cont'd) AIR/FUEL MIXTURE EXHAUST LOWER CRANKCASE 1 Figure 89 6. Figure 87 4. The upward movement of the pressure (compression) chamber. See Fig. 88. piston builds in the combustion The spark plug fires before the piston reaches the top of its stroke. This sets off combustion of the air/fuel mixture sealed in the combustion chamber. Note that the piston continues its upward movement even after the plug has fired.
Engine Operation (cont’d) PORT Drawing fresh mixture a combustion into the The combustion cycle. completes chamber the 91 Figure complete cycle took one full turn of the crankshaft. 8. Theexhaust port is uncovered by the piston and the exhaust gases are allowed to exit. See Figure 92. RemovalEngine Tube From Drive 1. Pull the spark plug lead from the spark plug. 2. Pull the ignition switch wires from the rear of the A needle nose plier may help. throttle control grip. See Figure 94.
Engine Removal From Drive Tube (cont’d) Figure 96 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. NOTE: If crankshaft axial (end) play is suspect, use a dial indicator to check the axial (end) play before disassembling the crankcase. Make note of this measurement See Figure97. Figure 95 maximum allowable end play .55 mm (.O20’) 6.
Engine Disassembly(cont’d) RINGS KNOCK PINS Figure 98 Figure 100 10. Remove thetwo snap rings retaining the piston pin in the piston. 11. Engine Cleaning After Disassembly 1. Clean all parts in appropriatesolventsaccording to the solvent manufacturer’s recommendations. Carefully pushout the piston pin and lift the piston fromtheconnectingrod. Theconnecting rod cannot be removed from the crankshaft. Note the 2. position ofthe dot on the headofthepiston. Reinstallthe pistonwiththedot in thesame 3.
Engine Cleaning After Disassembly (cont'd) 7. Replace the fuel strainer on thepick-up tube inside the fuel tank. See Figure 102. Crankshaft 2. Run-out maximum allowable run-out: 0.06 mm (.0024') 1 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 indicat andmeasurerun-outatthepositionshownin Figure 104. Figure 102 8.
Engine Inspection (cont'd) 1. Use finger pressure to install the two piston rings on the piston. IMPORTANT The hemispherically notched ends of the rings match thelocating pins in the ring grooves. Also note that thetop side (toward piston crown) of the ring is stamped with a 'T. See Figure 106. 4. Cylinder Bore Use a bore gauge to measure the cylinder bore. By itself, this measurement does not indicate much, however it is importantin determining the piston to cylinder clearance.
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) 2. 10. Install the cylinder upon the crankcase. Position the cylinder gasket upon the crankcase. Make sure the pulse hole opening in the gasket 3. linesupwiththecrankcaseopening.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 4.
SECTION 7 CONTROLS Control Reassembly The control unit on the TC3000 andTC4000 houses the on/off switch and throttle control trigger and is mounted1.Mounttherighthand(asviewedfromtherearof onthedrivetube.TheTC5000controland gripis thetrimmer)controlhalfonthealignmentholejust mounted on the right handle. in front of the grip. See Figure 108. Adjacent to the control unit is a padded grip which 2. covers the connectors for the ignition ground leads and a portionof the throttle cable. 3. Control Disassembly 1.
5. Grip Removal (cont'd) 4. Slide the grip assembly off the tube. NOTE: The grip is located on the tube with a Grip plastic pin. Thepin can be released by pulling or 1. prying down on the throttle controlofend the grip while slidingit toward the endof the tube. It may 2. help to lubricate the tube with soapy water to prior this procedure. See Figure111. 3. Figure 111 47 The ignition wire terminals may now be removed from the endof the grip.
SECTION 8 TC3000 Handle Removal from Drive Tube 1.Removetheengineasdescribedunder Removal from Drive Tube,page 40. Engine 2. Remove the grip and the control unit as described page 46. under Grip Removal from Drive Tube, 3.Loosen thehandleknob.SeeFigure112. Figure 113 3.Handtightenthehandleknob. -HANDLE TC4000 Handle Removal From Tube 1. Loosen the five machine screws securing the two handle mount halves. See Figure 114. KNOB Figure 112 4. Slide off thedrivetube.
Position the handle mount approximately20 cm (8 inches) from the control mount. See Figure 117. 2. TC4000 Handle Installation on Drive Tube (cont'd) HANDLEADJUSTMENT ADJUSTMENTAREA Figure 115 Figure 117 Note: The mounting configuration shown in Figure 114 is most suitable for right handed operators. Left handed operators may find it more comfortable if the ounting halves are installed as shown in Figure 116. 3. Adjust the"J" handle so that it has a slight rearward tilt (about 15 degrees). 4.
TC5000 Handle Removal From Drive Tube (cont'd) 3. Loosenthefournylon lock nutsthatsecurethe handle mount to the drive tube and pull the handles from themount. See Figure119. Figure 121 Plug thetwo ignition kill wires into the rear of the grip. NOTE: It does not matter which way the wires are connected since they have the same polarity. Figure 119 4. Insert the handle with the control in it into the right (as viewed from the engine end) side of the handle mount.
TC5000 Handle Adjustment (cont’d) 3.Withthehandlemountnutsstillloose,rotatethe handles so that they havea slight forwardtilt. See Figure 123. Figure 123 4. Tighten the four lockwashers to secure the Setting.
CAUTION:Neverattemptany service of thetrimmerhead withoutfirstshutting off the engine and allowing the implement to come to a complete stop. A 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 of flying debris. Do not operate the trimmer without the shield in place. 4. Remove the four machine screws and nylon lock nuts that secure thetwo portions of the shield to the shield bracket. 5.
Shield Mounting Cutter Knife on Shield A single or dual line Tap and Trim@ cutter head may be used asthe cutter implement on of any the straight shaft trimmers. To ensure proper line length, a cutter knife may be mountedto the shield. Shield Installation on Drive Tube (cont’d) 1. Remove the original shield from the shield support by removing the four machine screws and lock nuts. 2. (TC3000andTC4000only).Replacetheoriginal shieldwithanewshield,Tor0partnumber 61-4571. 2.
SECTION 10 GEARBOX The gears inside the gearbox used on the Tor0 straight Gearbox Installation on Drive Tube shaft trimmers are not replaceable individually. If damaged or defective, the gearbox must be replaced as 1.Beforeinstalling the gearboxmakesurethatthe an entire unit. drive shaft is properly positioned in the drive tube. See Figure 129. Regular maintenance is important in ensuring long life from the gearbox.
Gearbox Installation On Drive Tube (cont’d) 3. Install the two portions of the shield as shown in Figure 130. Secure with the four machine screws and nylonlock nuts. 4. 5. CAUTION: Whenever removing a brush orsaw blade fromthe trimmer, grasp it with a rag a heavy gloves to avoid Onunitswithserialnumbers 6000001 andup, lacerations. place the grass wrap shield around the drive shaft. See Figure130. Remove the dust cap from the drive shaft. Secure the shield (and grass wrap shield on sertain 2.
SECTION 11 DRIVE SHAFT AND TUBE 2. Loosenthe two shieldbracketscrewsclosest to The drivetube and shaft assemblies used on the TC3000, thedrivetube,thenpullthegearboxandshield TC4000 and TC5000 utilize a common shaft. This shaft assembly off the drive tube. ismadeofsteelandishardenedon both ends.For positive engagement with the clutch and gearbox, a nine 3. Pull the drive shaft from the tube being careful not tooth spline is used on both ends. to damage the splined end.
7. Drive Tube Removal (cont'd) 2. Remove thehandleasdescribedunderTC3000 Handle Removal from Drive Tube, page 48, TC4000 Handle Removal from Drive Tube, page 48, orTC5000 HandleRemoval from Drive Tube, page49. 3. Remove thecontrolandgrip asdescribedunder Grip Removal, page 46. 4. Remove thegearboxlocatingscrewthenloosen the four other screws denoted by arrows in Figure 136. NOTE: If it is necessary to replace the tube, the shaft should also be closely inspected as it may also require replacement.
SECTION 12 LEECO(R) MANUAL FEED HEAD 1. line: CAUTION:Never attempt any service of thetrimmer head without first allowing the engine and the implement to come to a complete stop. of Toreplacethetrimmerline,firstmeasurethe length appropriate A 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. See Figure 137. .
Leeco(R) Manual Feed Head Spool Installation (cont'd) head assembly from the drive shaft. 3. Hold thedrumstationarywhileturningtheknob 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 whichmayimpairtheiroperation.Replaceas required. 2. Inspecttheeyeletsforwearandsharpedges. Replace if necessary.Theycanbereplaced individually. 3.
Leeco(R) Manual Feed Head Reassembly (cont’d) n Figure 142 5. Place the spring on thecutterheadshaftand secure with the knob. NOTE: Rotatetheknobcounterclockwise tighten. to 6. Reinstall the head assembly onto the drive shaft by turning counterclockwise. Insert a medium blade screwdriver into one of the slots shownin Figure 140 to prevent the drive shaft from rotating. 7. Cut off any excess line so that it does not strike the shield.
SECTION 13 KAAZ(R) MANUAL FEED HEAD 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. CAUTION: Never attempt any service of thetrimmer head without first shutting off the engine and allowing the implement to come to a completerstop. A CAUTION: Do not substitute anytype of wire or other string-like material as trimmer line. Use only Tor0 approved replacement monofilament lineof .080' or .
Kaaz(R) Manual Feed Head Reassembly 1. Prepareforreassembly byplacingthespringon the drum as shown in Figure 145. they SPOOL 2. Thread one eyelet onto each end of the trimmer line and position the spool (with the small flange toward the spool) above the drum. 3. Pushtheeyelets intotheslots in thedrummaking sure bottom out. that 4. Place the spool and drum assembly on the cutter head shaft with the spool facing the shield. 5. Secure with the knob by turning counterclockwise.
SECTION 14 PLASTIC FIXED LINE HEAD Plastic Fixed Line Head Removal 1. Remove the existing cutter line from the spool. CAUTION: Never attempt any service of thetrimmer head without first allowing the engine and the implement to come to a complete stop. A 2. Remove the cotter pin from the cutter head shaft. 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.
2. Plastic Fixed Line Head Installation (cont’d) NOTE: The following parts are required when installing theplasticfixedlineheadona TC3000, or TC5000 for the first time: Part Number 3272-1 CAUTION:Never attempt any service of thetrimmer head without first allowing the engine and the implement to come to a complete stop. A 1. Mountthecutterheadontheshaft. See Figure 149.
SECTION 15 METAL FIXED LINE HEAD CAUTION: Never attempt any service of thetrimmer head without first allowing the engine and the implement to come to a complete stop. A 2. Remove the cotter pin from the cutter head shaft. 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 clockwise (as viewed from the bottom of the spool). See Figure 151.
Metal FixedLine Head Installation NOTE: The followingparts are required when installing TC4000 or TC5000 the metalfixed line head on a TC3000, for the first time: Part Part Number Plate Washer 41-4430 Nut 41-5410 Cotter Pin 3272-1 2. Mount the cutter head. 3. Place the plate washer on the shaft and loosely secure the cutter head assembly with the nut. NOTE: The cut has left hand threadsso it will be necessary to it counterclockwise to get it started. 4.
SECTION 16 TAP AND TRIM@HEAD 1.Towindreplacementlineonthespool,firsthook one end ofthe line into the keyhole slot in the top flange of the spool. See Fig. 156. CAUTION: Never attempt any service of the trimmer without first head shutting off theengine and allowing the implement to come to a complete stop. A 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.
Tap and Trim Spool Installation (cont'd) 2. With the trimmer line still in the slotin the top of the spool flange, thread the line through the eyelet in the drum. 3. Align thetwo screwdriver slots with the keysin the spool partially onto the core. core and push the 4. Pull on the line to release it from the spool; flange then push the spool firmly onto the core until it "snaps" into place. 2. Center the springon the drive shaft and then place the washer, driver and core onto the shaft as an assembly.
SECTION Blade Adapter Kit for Gas Trimmer, Tor0 part number 41-4440. Tor0 offers two 20 cm (8 inches) blades that fit the straightshafttrimmerline.Theeighttoothbladeis designed for cutting brush and heavy weeds to about up 1.3 cm (1/2 inches). The eighty tooth blade should be used in heavy brush and if scrub trees greater than 2 cm (3/4") are present. 1. Mount the blade on the cutter head shaft. There should bea perfectfit between the lower gearbox cover flange and the hub on the blade.
SECTION 18 HARNESSES Standard and Deluxe Harness Assembly n 1. (TC3000 and TC4000) Slip the ring into the throttle control.See Figure 161. I Figure 162 Figure 161 (TC5000)Mount the clamp and ring assembly onto the tube approximately 15 cm (6 inches) below the nut and isomounthousing.Securewiththe machine screw. See Figure 162. 3. Adjust the harness so that the trimmer line or blade rotates in a nearly level plane with a slight forward tilt. 4.
SECTION 19 Spark Arrestor Muffler Spark arrestor mufflers are available for the straight shaft 3. InstallthenewmufflercoverwiththreePhillips trimmers.Thesemufflersuseametalscreenatthe head screws. muffler to preventsparksfromexiting the muffler chamber. Spark ArrestorMuffler Maintenance They are recommended when trimming in dry areas and After every 50 hours of use, the arrestor screen and may be required by state or local laws.
