Toro 51643 User 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 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

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

ABOUT THIS MANUAL
This Service Manualwas written expressly for the Tor0 TC3000,TC4000 and
TC5000 Gas Powered Trimmers. The Tor0 Company had made every effort to
makethe information
in this manual completeand correct.
This manual was written with the servicetechnician
in mind. It isorganized so
that information usedmost often is up front. As a result, you will findreference
information on safety,maintenance,specifications, special tools and
troubleshootingall
in the front third of the manual.
Disassembly, inspectionand reassembly proceduresarecovered
in the last
two-thirds ofthe manual and aregroupedbycomponent. We triedtocover each
common repair with itsown section or sub-section. For example, you will find
that air gapadjustment andignition coilreplacement arecalled out separately.
And, because certain componentsare often difficult totroubleshoot without a
good understandingofhow theywork, we haveincludedsomecomponenttheory.
Thisinformationcan be found of thebeginning of most service procedure
sections.
We are hopefulthat you will find thismanual a valuableaddition toyour shop. If
you shouldcome acrossany errorsor ifyou haveany questions regardingthis
manual, pleasecontactusat the following address:
The Tor0Company
81 11 Lyndale AvenueSouth
Bloomington,MN,USA55420
The Tor0 Companyreserves the right tochange product specifications or this
manual withoutnotice.
The Tor0Companygratefully acknowledgesthe assistance of Mitsubishi Heavy
Industries, Ltd.
in the productionof this manual.
COPYRIGHT@ ALL RIGHTS RESERVED
(C) The ToroCompany 1987
MINNEAPOLIS, MN 55420 -USA

TABLE OF CONTENTS
Reference Information
Page
1
Specifications2
SafetyInformation
ToolRequirements
5
Troubleshooting 6
Maintenance 8
Service Procedures
Section
1 CarburetorPage
operation11
removal
14
disassembly 14
reassembly 16
installation 18
adjustment18
Section2 FuelSystem
Fuel Tank
removal 20
installation20
Primer Pump
properuse21
operation
disassembly22
reassembly22
21
inspection22
Fuel Pickup Tube and Filter
service 23
Fuel Cap
operation23
disassembly24
inspection 24
reassembly24

TABLE OF CONTENTS
ServiceProcedures(cont'd)
Page
operation
25
airgapadjustment 27
coilremoval 28
coil installation 29
RecoilStarter
Recoil Mechanism
operation
30
removal 30
disassembly 30
reassembly 31
installation 32
Starter Pulley
removal
33
installation 33
Section 5 Clutchandlsomount
Clutch Shoes and Flywheel
operation
34
disassembly 34
inspection 34
reassembly 35
removal 35
Clutch Drum and Housing
disassembly
35
reassembly 35
lsomount (TC4000 and TC5000 only)
operation
36
disassembly 37
reassembly 37
Section 6 Engine
operation
38
removal from drive tube 40
disassembly 41
cleaning afterdisassembly 42
inspection 43

TABLE OF CONTENTS
ServiceProcedures(cont’d)
Section6Engine(cont’d))Page
reassembly
44
installation on drivetube. 45
Section 7 ControlandGrip
Control
disassembly 46
reassembly
Grip removal
installation
Section
8 Handle
TC3000
removal from drive tube 48
Installation on drivetube. 48
adjustment
TC4000
removal from drive tube 48
installation on drivetube. 48
adjustment. 49
TC5000
removal from drive tube 49
installation on drivetube. 50
adjustment. 50
Section 9 Shield
removal from drive tube
52
installation on drivetube. 52
mounting cutter knife on shield 53
Section 10 Gearbox
removal from drive tube
54
installationondrivetube. 54
sealremoval
sealinstallation

TABLE OF CONTENTS
ServiceProcedures(cont’d)
Drive Shaft
removal 56
installation 56
Drive
Tube
removal 56
installation57
Section
12 Leeco@ManualLineFeedHead
sped
removal 58
linereplacement 58
installation 58
Headdisassembly 59
inspection 59
reassembly 59
Section
13 Kaaz@ManualLineFeedHead
headdisassembly61
linereplacement 61
headreassembly 62
Section14PlasticFixedLineHead
linereplacement
63
headremoval 63
headinstallation 64
Section15 MetalFixedLineHead
linereplacement
65
headremoval 65
headinstallation 66
Section16TapandTrim@Head
Spool
removal 67
linereplacement 67
installation 67

TABLE OF CONTENTS
Service Procedures (cont’d)
Section TapandTrim@Head(cont’d) Page16
Headdisassembly68
inspection 68
reassembly68
Section17
MetalBlades
removal69
installation69
Section18
Harnesses
assembly 70
Section19
SparkArrestorMuffler
removal71
installation71
maintenance71

SAFETY INFORMATION
A
Thismanual is intended as aserviceandrepair
this safety symbol manualonly.Thesafetyinstructionsprovided in this
means WARNING
or manualareforthetroubleshootingandserviceofthe
CAUTIONproductonly.TheindividualOperator’sManualwill
PERSONALSAFETY containsafetyinformationontheoperationofthe
INSTRUCTIONRead the instruction TC3000.
TC4000. orTC5000.
because
it has todo with safety.
Failureto comply with the instruction
mayresult
in personal injury or death. Operator’s Manualswith complete operational safety
instructions are available through:
The Tor0 Company
Publications Department
81 11 Lyndale Avenue South
Minneapolis,
MN 55430 U.S.A.
FOR YOUR SAFE TY...
I----
Avoid possible explosions Avoid unexpectedstarting of the engine
Store fuel in a container designed for gasoline and Alwaysdisconnectthespark plugwirebefore
never smoke while working around gasoline. attempting any cleaning, adjustment or repair.
Avoidfires Avoid contactwith a movingcutter head
Never allow the trimmer engine closer than one meterAlways stay clear of the cutter head when the engine
(three feet)toany combustible material. is running. Theclutch is a mechanical device which
Avoid accidental misuse offuel
Alwaysstorefuel in anapprovedcontainer that is
could fail. Do not rely on
it to keep the cutter head
from turning.
properly labeled.
Avoidfalls
Always wipe up spilled fuel or oil.
Avoid blindness
Alwaysweareyeprotectionwhenrepairingor
running a gas trimmer.
Avoid asphyxiation
Never operate an engine
in a confined area without
Avoid hearing
loss
Wear earprotection when running a gas trimmer.
proper ventilation.
1

SPECIFICATIONS
Engine Specifications
TC3000 and TC4000 Service Specifications
2

SPECIFICATIONS (cont'd)
TC3000andTC4000ServiceSpecifications(Cont'd)
Piston Ring
0.020 to 0.060 mm 0.150 mm
Side Clearance
(0.0008 to 0.0024") (0.0059")
.
TC5000 Service Specifications
3

SPECIFICATIONS (cont'd)
Carburetor Specifications
ItemStandard
Throttle Valve Needle Jet
1.4 to 1.6mm (0.055 to 0.W')
IdleSpeedAdjustingScrewAdjust so idle is (3000 200 rpmonTC3000and TC4000
(2500 200 rpm on TCSOOO)
Fastener Torques
Fastener kgm in Ibs
Crankcase Screws
0.4 to 0.5 35to43

TOOL REQUIREMENTS:
FlywheelPullerTor0partnumber41-7650Dial Indicator
SparkTesterTor0partnumber41-7890
Tachometer
Tor0 partnumber42-2730
FeelerGauge
Compression Gauge
Metric Socket Set
3/8” Drive
Spark Plug Socket
#2 Phillips Screwdriver
12
oz. Ball Peen Hammer
Magnetic
V Blocks & Dial IndicatorStand
Spark Plug Gapping
Tool
Torque Wrench
Threebond#1104Tor0partnumber
505-80
Loctite#242Tor0partnumber 505-76
Micrometer
Snap Ring Plier (inside
& outside type)
Hex. Key Set
5

TROUBLESHOOTING
Engine Does Not Produce Spark
Engine
Floods During Starting
Engine Not Getting Fuel
crankcase leak

TROUBLESHOOTING (cont’d)
EngineLacksPower
Engine Has Low Compression
Remedy I
Engine Backfires (indicated by burnt air cleaner element)
Trimmer Vibrates Excessively
7

Maintenance Air Cleaner
Servicing ofthe air cleaner is recommended after every
25 hoursofoperationormoreoften in verydusty
conditions.
See Figure 1.
1.
2.
3.
4.
5.
6.
7.
AIR
FILTER GRID
FOAM FILTER
FILTER SCREEN
Figure 1
Maintenance Muffler
Decarbonizing the muffler is recommended after every
50 hoursofoperationor if enginespeeddecreases
drastically. See Figure
2.
Remove the two screws securing the air cleaner
cover tothe trimmer
Carefully remove the filter grid, foam filter and filter
screen.
Wash the foam filterina soap and water solution
and dry thoroughly.
If the filter shows any sign of
damage replace
it.
Saturate the foam filter with 5ml (one teaspoon) of
SAE 30 oil, then squeezetodistribute the oil evenly
and to remove excess oil. The element should be
damp but not wet.
Wash the filter screeninaclean solvent and air dry.
If the filter screen shows any signs of damage,
replace
it.
Reinstall the air cleaner components as shown in
Figure
1. Note that the flat side of the filter grid
faces the foam filter.
Tighten the air cleaner screwsto
0.15 to 0.20 kgm
(13 to 17.5 in Ibs)
Figure
2
1. Removethethreescrewssecuringthemuffler
cover tothe trimmer.
2. Removethe two nutssecuringthemuffler to the
engine.
3. Rotate the engine crankshaft until the piston totally
covers the exhaust port. Clean the exhaust port
area byusingacleanflatpieceofhardwood.
Remove all loose particles.
IMPORTANT Use extremecare when cleaning
the exhaust port. Stay clear
of the piston so it
will not be damaged.
4. Inspecttheinsideofthemufflerforexcessive
carbon buildup.
If carbon buildup appears to be
restrictingtheexhaustflow,replacethemuffler.
Otherwise, clean the muffler by holding
it with a
vice grips and heating with a propane torch. Once
hot, break the carbon loose by hitting the muffler
on
a hardsurface.Ensurethatthemuffleris
completelyfree
of allcarbonparticlesbefore
reinstalling.
5. Reinstallmufflerusing a newmufflergasketand
tighten all fasteners securely.
6. Reinstall the mufflercoverasshown inFigure 1.
8

Maintenance Spark Plug
The TC3000,
TC4000 and the TC5000 each use an NGK
BMGA spark plug or the equivalent. Correct gap is 0.6-0.7
mm (0.024-0.028”). Therecommendedservicinginterval
for the spark plug is
25 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 from
the engine usinga 19mm (3/4") socket.
IMPORTANT: Replace
a cracked, fouledordirty
spark plug.
Do not sand blast, scrape or clean
electrodes becauseenginedamage could
result
from grit enteringthe cylinder.
3. Setthepluggap to 0.6-0.7mm (.024-.028”) See
Figure
3.
5. Pushthepickupassemblybackintothetankand
install the gas cap.
I3
.024 .028"
(0.6 0.7 mm)
Figure 3
4.
Reinstall the plug and gasketinthe engine. Tighten
to 1.2 kgm (1 04 inIbs)
Maintenance FuelFilter
Fuel filter replacement is recommended after every
25
hours of operation.
1. Drainthefuelfromthefueltankintoacontainer
designed for gasoline. Start the engine and
let it
run at idlespeeduntil it stopsandallfuelis
expended.
2. Removethe 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
out the
fuel tank opening. See Figure
4.
3. Removethefilter byholdingtheblacktubingand
pulling the filter straight
off.
4. Replacethefilterassembly.
Figure
4
Maintenance CoolingSystem
Before each use, visually inspect thecoolingair inlet, the
cooling fins,andtheopeningsaround themufflerfor
debris.Obstructionoftheseareascouldlead
to
overheating and possible engine damage.
Becarefulnot
to damagethecoolingfinsduring
cleaning.
Maintenance Trimmer Implement
Thetrimmerimplementsrequirenolubrication.
However, cleaning of the implement and the drive shaft
area is recommended after every
25 hours of operation.
More frequent cleaning may be required
if trimming in
very tall grass or
if the implement area gets excessively
hot.
Refer
to the Table of Contents forthelocationof
information on removal and cleaning of your particular
implement.
Maintenance Preparation
for Storage
The followingprocedureisrecommendedtoensure
proper operation of the trimmer before storage of more
than a month.
1. Drain the fuelfromthetankintoacontainer
designed for gasoline. Start the engine and
let it
run atidlespeeduntil it stopsandallfuel is
expended.
2. Remove dirt andgrimefromexternalpartsofthe
trimmer. Ensure that thecoolingfins are clean.
3. Pull thesparkplugwireoffthesparkplug.Clean
around the plug
so that debris will not fall into the
sparkplug hole when the plug is removed. Remove
the spark plug.
9