Toro 47P22 Service Manual Download

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2-CYCLE GTS 120 ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 1

PREFACE

I. GENERAL INFORMATION

SAFETY INSTRUCTIONS

MAINTENANCE

MODEL AND SERIAL NUMBERS

TWO-CYCLE ENGINE THEORY AND OPERATION

CARBURETOR THEORY AND OPERATION

SPECIAL TOOLS LIST

II. MAINTENANCE

AIR CLEANER

SPARK PLUG

EXHAUST SYSTEM

DECARBONING CYLINDER HEAD

IGNITION TIMING (MODEL 47PZ2 ONLY)

IGNITION TIMING (DIAL INDICATOR)

CONTACT POINTS AND CONDENSER MODEL47PZ2 ONLY

IGNITION COIL

GOVERNOR

GOVERNOR OPERATION

FUEL TANK

CARBURETOR

STORAGE

III. TROUBLESHOOTING AND TEST PROCEDURES

PRELIMINARY TROUBLESHOOTING

ENGINE BRAKE AND IGNITION SWITCH

BBC APPLICATIONS

FUEL TANK

TESTING COMPRESSION

CRANKCASE

ENGINE TROUBLESHOOTING CHART

IV. ENGINE REMOVAL, DISASSEMBLY, ASSEMBLY AND REPAIR INSTRUCTIONS

ENGINE REMOVAL

ENGINE DISASSEMBLY AND REPAIR

RECOIL STARTER REPAIR

CARBURETOR REPAIR

ENGINE ASSEMBLY AND REPAIR

SERVICE DATA SPECIFICATIONS

Summary of Contents for 47P22

Page 1: ...47PZ2 ONLY IGNITION TIMING DIAL INDICATOR CONTACT POINTS AND CONDENSER MODEL47PZ2 ONLY IGNITION COIL GOVERNOR GOVERNOR OPERATION FUEL TANK CARBURETOR STORAGE III TROUBLESHOOTING AND TEST PROCEDURES PRELIMINARY TROUBLESHOOTING ENGINE BRAKE AND IGNITION SWITCH BBC APPLICATIONS FUEL TANK TESTING COMPRESSION CRANKCASE ENGINE TROUBLESHOOTING CHART IV ENGINE REMOVAL DISASSEMBLY ASSEMBLY AND REPAIR INSTR...

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Page 3: ...aintenanceof your TORO Rotary Mower Engine To assure proper and effective performance you are urged to read this manual carefully The purposeof this manual is to provide the Service Dealerwith working guidelines of maintenance troubleshooting test and overhaul procedures The ToroCompany reservesthe right to change product specifications or this manualwithout notice The Toro Company Service Departm...

Page 4: ...l47PZ2 Only 1 1 3 Ignition Coil Model 47P22Only 1 1 3 Governor Operation 1 1 5 Ignition Coil Models47PD3 47PE4 47PF5 11 4 Governor 11 4 FuelTank 1 1 5 Carburetor 1 1 6 Storage 1 1 6 111 TROUBLESHOOTINGAND TEST PROCEDURES 111 1 Spark Intensity 111 1 PreliminaryTroubleshooting 111 1 Engine Brake and Ignition Switch 111 1 BBC Applications 111 2 FuelTank 111 2 Testing Compression 111 2 Crankcase 1 1 1...

Page 5: ...pes do with safety Failure to comply with from side to side but avoid slopes when the the instruction may result in personal grass is wet If possible mowwhen the grass injury is dry for best results 11 Keepface hands and feetawayfromthe Before Operating mower housing and cutter blade while the 1 Operate your mower only after reading the engine is running Stay behind the handle Operators Manual A r...

Page 6: ...r mance and continued safety certification of the mower use genuineTORO replacement parts and accessories Replacement parts andaccessories madebyother manufac turers may result in nonconformance with the safety standards MODEL AND SERIAL NUMBERS The TOROTwo cycle Rotary Mower has two sets of identification numbers There is a model and serial number to identify the engine and a model and serial num...

Page 7: ...case Ata pointapproachingthebottom of thestroke the exhaustportopensand the burnt 1 3 gases begin to beexpelled from the combustion chamber Figure 1 3 __ l _ _ _ _ _ m _ Intake Ports Closed Exhaust Port I Third Port Closed Figure 1 3 At a point of piston travel slightly before bottom dead center BBDC the fuel transfer ports on the sides of the cylinder walls are uncovered and the compressedfuel ai...

Page 8: ...ke plate must be moved to the open position The engine speed is now regulated by the throttle plate In no load condi tions a small portion of the fuel may be drawn from the main discharge tube however the pri mary fuel supply is drawn from the pilot circuit 1 4 Air passingthrough the pilot jet from the pilotair fitting draws fuel outof the pilot jet orificefrom the float bowl This fuel pre mixes w...

Page 9: ... 014in Ignition Coil Air Gap 38 50mm 015 020in Float Height Setting BlackFloat N A 11 16 The black float may be usedon these engines as a replacement Part number 81 0970 N A N A FASTENER TORQUE SPECIFICATIONS Adapter Plate Housing Capscrews 3 8 16UNC 2 9 4 6 Kg m 21 33ft lb BladeCapscrew 6 2 8 3 Kg m 45 60ft lb FlywheelNut M 10 4 0 5 0 Kg m 29 36 ft lb Muffler Nuts M 8 90 120Kg Cm 100 140in lb Air...

Page 10: ...ight 36 4050 Tachometer 42 2730 Ohmmeter Multimeter Feeler Gauges Micrometer Spark PlugGappingTool CompressionGauge Timing Tester 41 7900 Threebond 1104 Loctite 515 505 80 Loctite 242 Threebond 1342 505 76 Timing Dial Indicator Dial Indicator Cylinder GaugeSet Spark PlugSocket Coil Gauge 38 50mm 015 020 in Torque Wrench ft lb Torque Wrench in lb Magnetic V Blocks Dial Indicator Stand ...

Page 11: ...UG Many times an inspectionof the spark plug can determinewhethertheengine isfunctioning properly A spark plug which is functioning normallywill show slightelectrode wear with brown or greyishtan deposits Oilfouledand black carbon fouled plugs are caused by a rich carburetor mixture weak spark or improper gasoline to oil mixture Excessively worn elec trodes ora blistered insulator indicatespark pl...

Page 12: ...OSITS IMPORTANT WHENREMOVINGCARBONDE Before installing the mufflercheck for cracks and leaks Inspect theinletand outlet for carbon buildup Remove excessive deposits with a scraping tool and soak the muffler in solvent to remove wet oil deposits Allow to air dry or dry with compressedair Remove the muffler heat shield and tap the muffler bodywith a plastic hammer to loosen the carbondeposits Blow a...

Page 13: ... cratered or have surface buildupthey should be cleaned or replaced The contacts can be cleaned with an electrical sol vent and contact point sandpaper Ensure that all dust and dirt is removed after sanding Cratering of the points indicates the condenser may be faulty Verify the condition of the condenser through tests with anignition analyzer If an analyzer is not available the condenser must be ...

Page 14: ...ngof thecoilmaybecompletedwithaGraham Lee ignition tester model number31 SMXH In structionsfor testing are includedwith the tester High Tension Wi Figure 2 10 GOVERNOR The governor linkage is factory preset to regu latetheenginespeed at 3000 150 RPM Check theadjustment of the governor if the engine is suspected of improperspeed To gain access to the governor linkage removal of the air cleaner is r...

Page 15: ... will not retrofit Model 47PF5 engines will includeaweldstud on the governor linkagefor ease of reassembly See Figure 2 1 5 Governor Arm Governor Spring Figure 2 14 Figure 2 15 FUEL TANK CAUTION The gasoline in the fuel tank is explosive Always drain or fill tank outdoors away from fire and flame Do not smoke when fuel vapors are present Forthe engineandcarburetortofunction properly the fuel suppl...

Page 16: ... jet part number 81 1050 option Models47PD3 47PE4and47PF5arealso equipped with a heat deflector and insulator as showninFigure2 18 Model 47PZ2 was builtwith out insulators or heat deflectors This model may be fitted with a heat shield kit number 81 221 0to prevent hot restart problems 47PD3 47PE4 47PF5 Engine Model Carburetor Standard Main Jet ToroPart No 81 1940 High Altitude Main Jet Toro Part N...

Page 17: ...ction Replace theplug if damaged burnt or fouled 3 Check for the correct spark plug gap and adjust if necessary to 8 mm 032in by bending the outer electrode Do not pry against the inner electrode or the insulator may be damaged 4 Attach the spark tester as shown and verify the tester gapis set at 4 2 mm 166 in 5 Pull the starter and observe for spark THE SPARK MAY BE DIFFICULT TO SEE IN WELL LIGHT...

Page 18: ...vent which if plugged will prevent fuel from entering the carburetor 1 2 3 Remove the fuel cap and inspect the vent Clean if necessary Visually inspect the bottom of the fuel tank for dirt or other contaminants If dirt water or other contaminants are present the tank shouldbe flushed with a small amount of fresh fuel Thisis most easily accomplished whenthe fuel tank is removed See DisassemblyInstr...

Page 19: ... not replaceable Special factory processes are required to install this liner CRANKCASE The engine relies on a tightly sealed crankcase in order tofunction properly The downward movementof the piston causes the crankcaseto be pressurized This pressure is required to expell the exhaustgasesfrom the combustion chamber and to supply a fresh fuel mixture for the compression stroke The upward movement ...

Page 20: ...fficulty SYMPTOMS Installcorrect spark plug page 1 5 Reset air gap 8mm 032 Replace sparkplug Replace spark plug Empty carb tank refillw fresh Empty carb tank refill w fresh mi Clean or replace cap __ Check linesfor restriction Clean or replacefilter Squeeze excess oil from filter Reseal crankcase and replaceseals Readjust See page 11 4 __ Readjust refer to page 111 2 Replace ignition switch Clean ...

Page 21: ... 1342 or Loctite 242 on the threads of the center capscrew during reassembly and torque to 80 90Kg Cm 70 110in lb On installation there should be sufficient spring pretension to hold the recoil rope taut in the rope pulley RECOIL STARTER REPAIR NOTE Place a small amount of 2grease on the recoil spring to prevent rust and corrosion ASSEMBLYAND iS Center Spring Pawl Spring Pawl Retainer Center Sprin...

Page 22: ...de screwdriver B One end of the float pivot pin is IMPORTANT NOOTHER PARTS ARESERVICE ABLE DISASSEMBLY OF THE THROTTLE AND CHOKE PLATES ISNOTRECOMMENDED THE SCREWS ARE FACTORY TORQUED AND LOCKED IN PLACE IF NOT PROPERLY REAS SEMBLED THE SCREWS MAY LOOSEN AND CAUSE ENGINE DAMAGE D Reassemble the carburetor in reverse order The carburetor and work area should be clean to prevent contamination enteri...

Page 23: ...uds before attempting to push the piston into the cylinder Insert the crankshaft and piston assembly into the cylinder IMP0RTANT ASSURETHEARROWONTOP OF THEPISTONFACESEXHAUSTPORT WHEN ASSEMBLED 4 Lubricate the large end of the crankshaft with two cycleoil and install the sliding governor collar Insert the small locating pin intothe crankshaft andslidethe flywheel collar into position Position the f...

Page 24: ...e ignition switch wire 47PZ2 and zone start models only IMPORTANT CHECK FOR PROPER OPER ATION OF THE IGNITION SWITCH AND BRAKE ASSEMBLY See Troubleshooting Section page 111 1 13 Placethe blower housing onthe engine and attach withone capscrew in the front and another in the rear NOTE USE CAUTION IN ROUTING THE HIGHTENSIONWIRE SO THATITDOES NOT BECOME PINCHED BETWEEN THE BLOWER HOUSING AND THE ENGI...

Page 25: ...learance Replace the cylinder block or the piston if the clearance is excessive Piston Diameter 1mm 004 in or less Wrist Pin Wrist Pin Hole The wrist pin andwrist pin holemust be properly fitted for efficient engine performance Measure the wrist pin and check the diameter of the piston holes to be no morethan the oversize dimension indicated Largest Cylinder Diameter minus Wrist Pin Diameter 11 95...

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