Toro 51643 Service Manual Download Page 2

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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 ADJUSTMENT

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

Summary of Contents for 51643

Page 1: ...ION 1 CARBURETOR CARBURETOR OPERATION CARBURETOR OPERATION THE DIAPHRAGM PUMP CARBURETOR OPERATION FUEL METERING MIXING CARBURETOR OPERATION THE PRIMER SYSTEM CARBURETOR REMOVAL CARBURETOR DISASSEMBLY...

Page 2: ...ENT REASSEMBLY COIL COIL REMOVAL COIL INSTALLATION SECTION 4 RECOIL STARTER RECOIL STARTER OPERATION RECOIL MECHANISM REMOVAL RECOIL MECHANISM DISASSEMBLY RECOIL MECHANISM REASSEMBLY RECOIL MECHANISM...

Page 3: ...TALLATION 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...

Page 4: ...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 LI...

Page 5: ......

Page 6: ...example you will find that air gap adjustment andignition coil replacement arecalled out separately And because certain components are often difficult to troubleshoot without a goodunderstandingof how...

Page 7: ...es Section 1 Carburetor Page operation11 removal 14 disassembly 14 reassembly 16 installation 18 adjustment18 Section 2 Fuel System Fuel Tank removal 20 installation20 Primer Pump properuse21 operatio...

Page 8: ...tion 32 Starter Pulley removal 33 installation 33 Section5 Clutch and lsomount Clutch Shoes and Flywheel operation 34 disassembly 34 inspection 34 reassembly 35 removal 35 Clutch Drum and Housing disa...

Page 9: ...drive tube 48 Installation on drive tube 48 adjustment TC4000 removal from drive tube 48 installation on drive tube 48 adjustment 49 TC5000 removal from drive tube 49 installation on drivetube 50 adju...

Page 10: ...n 58 Head disassembly 59 inspection 59 reassembly 59 Section 13 Kaaz Manual Line Feed Head headdisassembly61 linereplacement 61 headreassembly 62 Section 14 Plastic Fixed Line Head linereplacement 63...

Page 11: ...Section Tap and Trim Head cont d Page 16 Head disassembly 68 inspection 68 reassembly68 Section 17 Metal Blades removal69 installation69 Section 18 Harnesses assembly 70 Section 19 Spark Arrestor Muf...

Page 12: ...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 clean...

Page 13: ...SPECIFICATIONS Engine Specifications TC3000 and TC4000 Service Specifications 2...

Page 14: ...SPECIFICATIONS cont d TC3000andTC4000ServiceSpecifications Cont d Piston Ring 0 020 to 0 060mm 0 150 mm Side Clearance 0 0008to 0 0024 0 0059 TC5000 Service Specifications 3...

Page 15: ...ions Item Standard Throttle Valve Needle Jet 1 4to 1 6mm 0 055to 0 W Idle Speed Adjusting Screw Adjust so idle is 3000 200 rpm on TC3000 and TC4000 2500 200 rpm onTCSOOO Fastener Torques Fastener kgm...

Page 16: ...42 2730 FeelerGauge Compression Gauge Metric Socket Set3 8 Drive Spark Plug Socket 2 Phillips Screwdriver 12 oz Ball Peen Hammer MagneticV Blocks Dial IndicatorStand Spark Plug Gapping Tool Torque Wre...

Page 17: ...TROUBLESHOOTING Engine Does Not Produce Spark Engine Floods During Starting Engine Not Getting Fuel crankcase leak...

Page 18: ...TROUBLESHOOTING cont d Engine Lacks Power Engine Has Low Compression Remedy I Engine Backfires indicated by burnt air cleaner element Trimmer Vibrates Excessively 7...

Page 19: ...r cleaner components as shown in Figure 1 Note that the flat side of the filter grid faces the foam filter Tighten the air cleaner screws to 0 15to 0 20 kgm 13to 17 5 in Ibs Figure2 1 Remove the three...

Page 20: ...gure 4 3 Removethefilter by holding the black tubing and pulling the filter straight off 4 Replace the filter assembly Figure4 Maintenance Cooling System Before each use visually inspect the coolingai...

Page 21: ...r every40hours of operation 1 Remove thecutterimplementfromthetrimmer Referto the Table of Contentsfor the location of information on removal of your particular implement 2 Removethegearcasecapandthes...

Page 22: ...sures are alternately being created bythe upand down movement of the piston Transfer of these pressure pulses is accomplished by a passage which leads from the lower crankcase toa point just below the...

Page 23: ...entersthemaindiaphragmcavity See Figure 10 NOTE Themaindiaphragmservesonlyasa reservoir so thatfuelcanbeproperlymetered beforeenteringtheventuri It doesnot do any pumping of fuel during normal operati...

Page 24: ...er atomize the fuel an air correction jet was added The air correction jet allows filtered airto enter the carburetor throat perpendicular to the normal air flow This action creates turbulence in the...

Page 25: ...secure the carburetor onto the intake flange See Figure17 Figure 17 3 Removetheintakeflange gasketandinsulators 4 Remove the two screws securing the intake assemblyto the cylinder and carefully remove...

Page 26: ...ragmassemblyandthe 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 Figur...

Page 27: ...gure25 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...

Page 28: ...hragm gasket against the carburetor the main diaphragm assembly upon the main diaphragmgasket themaindiaphragmcover upon the main diaphragm assembly When installing the main diaphragm assembly positio...

Page 29: ...the pulse hole is not obstructed Install the carburetor Tighten the screwsto 3 to 45 kg m 26 to 38 in Ibs 18 CORRECT ROUTING Figure 32 4 Attach the fuel feed line and the overflow line tothe carbureto...

Page 30: ...tly may damage the tip Carburetor Adjustment Throttle Valve CAUTION Stay clear of cutter head whenever engine is running 1 Removetwoscrews securing the air cleaner cover to the trimmer and remove the...

Page 31: ...ssary do notforgettoresettheairgap 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 e...

Page 32: ...m on the TC3000 TC4000 and TC5000 is used oncoldstartsonlyandensuresthatfuelis present throughout the entire fuel system It relies on manual pumping action to draw fuel into the primer and to pump it...

Page 33: ...dtwo ballvalves See Figure 44 4 Insertathin non puncturingpunchthroughthe holeinthe bottomof the pump and carefully push outgasket A valve seatA with valve cushion and gasket B 22 Primer Pump Inspecti...

Page 34: ...ements and the fuel strainer located inside the pickup weight Clean or replace as necessary Reassemble the pickup assembly making sure that the pickup tube fits snugly on the top of the fiber filter e...

Page 35: ...asket holder and breather valve out of the tank cap See Figure 49 FuelCap Inspection 1 It is important that the fuel cap properly vents the tank Inspect the gasket to ensure that the hole at the round...

Page 36: ...voltage is much too lowto produce a spark at the spark plug The secondary coil serves to amplify the voltage produced in the primary To accomplish this the secondary coil must have many more windings...

Page 37: ...stor allows a large current 12 to flow from point C to E The magnitude of current l2will varyin proportion to the smaller current l1 Thus the transistor functions as an amplifier in that it allows a s...

Page 38: ...plug function The first is that the electrodes are properly gapped and are clean This ensures that a strong spark willbe present and that it occurs at the proper time Excessivegaporfoulingcandelay fir...

Page 39: ...cylinder Remove the cover wire and grommet are properly positionedin the Figure 62 cylinder cover slot 2 Installthemufflerandmufflercover TC5000 Air Gap Adjustment 3 Install the carburetor as describe...

Page 40: ...r gap by following female connector found beneath the carburetor theprocedurefoundunderheading AIR GAP gasket beneathit See Figure63 5 Positiontheengineassembly so thattherecoil housing is resting on...

Page 41: ...tie the knot from the T handle See Figure6 6 The recoil mechanism shownin Figure64functions as follows The operator pulls the rope which in turn results in the reel spinning As the reel turns itwinds...

Page 42: ...sprung the spring should be replaced side down and rapping iton a hard flat surface Be A CAUTION Do not remove the wire surrounding the spring until the spring is installed in the recoil housing Remov...

Page 43: ...nd pawl onto the recoil reel as an assembly Make su 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 8to 1 O kgm 70to 8...

Page 44: ...rns while trying to remove it place a pieceof wood on one of the starter pulley ratchets 2 Remove the starter pulley nut by turning it andtap to loosen counterclockwise See Figure73 Starter Pulley Ins...

Page 45: ...iods of time near the engagement speed may cause the clutch to slipandoverheat Thiscanresultin peeling of the clutchshoes Clutch Shoes and Flywheel Disassembly 1 Remove the engine from the drive tube...

Page 46: ...t Holdthe flywheelusing astrap wrench and tighten the flywheel nut to 1 O to 1 3kg 2 Inserttheclutchboltsthroughtheclutchshoes making sure that the markings you made note of m 87to 113in Ibs i 35 earl...

Page 47: ...g and may lead to premature failure Install the large snap ring Supporttheinnerrace of theclutchhousing bearing from the drive shaft end with a sleeve or deep well socket and press the clutch drum int...

Page 48: ...the engine from the drive tube See Figure82 Figure82 NOTE It is not necessary to remove the throttle linkage 2 Removethe two allen screws that secure the two halvesofthecushionholderandseparate the h...

Page 49: ...ce the term port to port There are four major components that are involved inthe combustion cycle Piston Intake Port Exhaust Port Scavenger Ports Their relative locations can be seen in Figure8 4 EXHA...

Page 50: ...MIXTURE LOWER CRANKCASE 1 Figure89 6 The spark plug fires before the piston reaches the top of its stroke This sets off combustion of the air fuel mixture sealed inthe combustion chamber Note that the...

Page 51: ...esfromtherearofthe throttle control grip A needle nose plier may help See Figure 94 I Figure94 Figure92 3 Remove the two screws retaining the throttle control housingto the drive tube and remove the 9...

Page 52: ...se until it iscompletely unscrewed Be careful not to lose the washer 7 Removethe two bolts securing the cylinderto the crankshaft See Figure9 6 crankcase Figure96 8 Carefully pull the cylinder and cyl...

Page 53: ...to removethepistonrings from the piston RINGS KNOCK PINS Figure 100 Engine CleaningAfter Disassembly 1 Clean all parts in appropriatesolventsaccording to the solvent manufacturer s recommendations 2 I...

Page 54: ...nkshaft 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 outatthe...

Page 55: ...ury and engine failure 1 Usefingerpressure to installthetwopistonrings onthe piston IMPORTANT The hemispherically notched ends of the rings match the locating pins inthe ring grooves Also note that th...

Page 56: ...l Mechanism Installation page32 15 Install the flywheel clutch shoes tank and coil as described under ClutchShoesandFlywheel Reassembly page36 16 Install the muffler and muffler cover 17 Install the c...

Page 57: ...ht control half as shown above in Figure 108 CAUTION Check to ensure that the switch willkill the engine Use a Volt Ohm Meter or test light to check the switch The switch should be closed in the off p...

Page 58: ...ip Installation 1 2 3 4 5 6 Insert the switch wire terminals inthe grip housing Slip the rubber grip over the control housing Lubricate the tube with a soap and water solution and slide the grip assem...

Page 59: ...3 Install the control and grip as described underGrip 4 Mounttheengineasdescribedunder Engine and secure with the knob Installation on Drive Tube page47 Installation on Drive Tube page 45 TC3000 Handl...

Page 60: ...ge49 machine screws and locknuts TC4000 Handle Adjustment Described below is a suggested nominal setting for the TC4000 handle Onceanominalpositionisset the 1 Loosenthefivemachinescrewsthatsecurethe h...

Page 61: ...the grip and attach the cable to the trigger as shown In Figure 121 Plug thetwo ignition kill wires into the rear of the grip NOTE Itdoes not matter which way the wires are connected since they have t...

Page 62: ...5000 Handle Adjustment cont d 3 Withthehandlemountnutsstillloose rotatethe handles so that they havea slight forward tilt See Figure 123 Figure123 4 Tighten the four lockwashers to secure the Setting...

Page 63: ...emoving the gearbox Remove the gearbox beremovingthelocatingscrew andthe two clamping screws then pulling the gearbox straight off the shaft 6 Remove theshieldbracket by looseningthe two clamping scre...

Page 64: ...rewdriver into the slot in the top of the shield and turning the cutter implement counterclockwise 53 Shield Mounting Cutter Knife on Shield A single or dual line Tap and Trim cutter head may be used...

Page 65: ...e shaft 3 Remove the three screws securing the shield tothe gearbox and on units with serial numbers 6 O O O O O O 1 and up remove the grass wrap shield 4 Removethefourmachinescrewsandnylonlock nuts t...

Page 66: ...ase within the gearbox 1 Remove thecutterimplementbyinsertingaflat bladed screwdriverinto the hole in the top of the shield then rotating the cutter implement clockwise asviewedfromthebottomofthe trim...

Page 67: ...e two shieldbracketscrewsclosest to the drive tube then pull the gearbox and shield n assembly off the drive tube 3 Pull the drive shaft from the tube being careful not to damage the splined end 4 Ins...

Page 68: ...o require replacement Drive Tube Installation 1 Mountthecontrolandgriponthedrivetubeas described underGrip Installation page47 2 Mounttheengineonthedrivetubeasdescribed under Engine Installation on Dr...

Page 69: ...Useof improper line could result in personalinjury Toreplacethetrimmerline firstmeasurethe appropriate length of line n 095 20 feet IMPORTANT TheLeeco R Head cuts with a dual line however DO NOT CUT T...

Page 70: ...ing pressure Remove the knob spring and spool Leeco R ManualFeed Head Inspection 1 Inspect the drum spool and knob for any damage whichmayimpairtheiroperation Replaceas required 2 Inspect the eyelets...

Page 71: ...e knob NOTE Rotate the knob counterclockwise to tighten Reinstall the head assembly onto the drive shaft by turning counterclockwise Insert a medium blade screwdriver into one of the slots shownin Fig...

Page 72: ...ent Replacement trimmer line is available from your local Tor0retailer in eithersinglepiecesor in 1 3Ib bulk packages A CAUTION Do not substitute any type of wire or other string like material as trim...

Page 73: ...the spool above the drum Pushtheeyelets intotheslots inthedrummaking sure that they bottomout Place the spool and drum assembly on the cutter head shaft with the spool facing the shield Secure with th...

Page 74: ...fixedline head uses nylon line 2 5mm 105 i n diameter and40cm 16 in length A CAUTION Do not substitute any type of wire or other string like material as trimmer line Use only Tor0 approved replacemen...

Page 75: ...1 Mount the cutter head on the shaft SeeFigure149 GRASS WRAP SHIELD HEAD Figure 149 2 Looselysecurewiththehexnut NOTE The nut has left hand threadsso it will be necessary to turn it counterclockwise t...

Page 76: ...ft Figure 150 1 Center of line 2 Outerprojections 3 Position in slot IMPORTANTWhile it is possible to use two lineswith the metal fixed linehead best cutting results are obtained by using only one lin...

Page 77: ...er gearbox cover See Figure 153 Figure 153 2 3 4 Mount the cutter head Place the plate washer on the shaft and loosely secure the cutter head assembly with the nut NOTE The cut has left hand threadsso...

Page 78: ...A CAUTION Do not substitute any type of wire or other string like materialastrimmerline Use only Tor0 approved replacement monofilament lineof 080 diameter Use of improper line could result in person...

Page 79: ...ff the drive shaft Tap and Trim Head Inspection 1 Inspectthedrumforanyobviousdamage to the plastic 2 Make sure that the eyeletinthe drum is intact and that the areas that contact the trimmer line are...

Page 80: ...blade Inspectthe blade for damage or cracks and replace if necessary Metal Blade Installation Note If you are installing either the saw blade or the brush blade for the first time you will require the...

Page 81: ...ing assembly onto the tube approximately 15cm 6 inches below the isomount housing Secure with the nut and machine screw See Figure 162 3 Adjust the harness sothat the trimmer line or blade rotatesina...

Page 82: ...or Muffler Removal page 71 2 Remove the two screws securing the spark arrestorto the muffler See Figure 165 2 Removethe two nutssecuringthemuffler to the engine and the Phillips head screw near the fu...

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