Toro CCR 2500 Snowthrower User manual

R-TEK/DURAFORCE (E) ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 1

PREFACE

SAFETY

SPECIFICATIONS

SPECIAL TOOLS

TROUBLESHOOTING

MAINTENANCE

CARBURETOR

FUEL SYSTEM

IGNITION SYSTEM

REWIND STARTER

ENGINE

PIVOTING ZONE START BRAKE

ELECTRIC START SYSTEM (120 VOLT)

ELECTRIC START SYSTEM (12 VOLT)

PREFACE

ABOUT THIS MANUAL

This manual was written expressly for the E series en

g

ines. There are two en

g

ines in this series. One is piston

ported (R tek) and the other is a reed valve (DuraForce). As these en

g

ines are of the same family, they will both be

covered here. Where there are differences between the two versions, a headin

g

will state which en

g

ine is bein

g

discussed. We have made every effort to make this information complete and correct.

We hope that you find this manual a valuable addition to your service shop. If you have questions or comments

re

g

ardin

g

this manual, please contact us at the followin

g

address:

The Toro Company

Consumer Service Department

8111 Lyndale Ave. So.

Minneapolis, MN 55420-1196

The Toro Company reserves the ri

g

ht to chan

g

e product specifications or this manual without notice.

i

TABLE OF CONTENTS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

En

g

ine Specifications (All dimensions are for a new en

g

ine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

En

g

ine Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Carburetor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SPECIAL TOOL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

En

g

ine Will Not Start When “Cold” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

En

g

ine Will Start When “Cold”, But Not When “Hot” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

En

g

ine Will Not Produce Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

En

g

ine Flooded With Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

En

g

ine Has Low Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

En

g

ine Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

En

g

ine Sur

g

es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

En

g

ine Backfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

En

g

ine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

En

g

ine Vibrates Excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

En

g

ine Crankshaft Will Not Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

En

g

ine Produces Mechanical Knockin

g

Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

En

g

ine Pre-I

g

nites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

En

g

ine Smokes Excessively (Smoke is li

g

ht colored, en

g

ine runs well) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

En

g

ine Smokes Excessively (Smoke is dark, en

g

ine runs poorly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

En

g

ine Stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Spark Plu

g

Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Air Filter (Mower Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Spark Plu

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Cleanin

g

the Exhaust System (Lawn Mower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Cleanin

g

the Exhaust System (Snowthrower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Reassemblin

g

Exhaust System (Mower Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

TABLE OF CONTENTS

ii

CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Troubleshootin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Removal of DuraForce Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Removal of R tek Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Cleanin

g

and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Governor Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Reed Valve En

g

ine (DuraForce En

g

ines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Piston Ported En

g

ine (R tek En

g

ines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Presettin

g

the Governor (DuraForce En

g

ines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Servicin

g

the Air Filter (DuraForce En

g

ines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Fuel Cap Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Cleanin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Troubleshootin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Testin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Spark Plu

g

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Spark Plu

g

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

CD Pack Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

CD Pack Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

CD Pack Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Flywheel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

iii

TABLE OF CONTENTS

REWIND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Reed Valve En

g

ine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Piston Ported En

g

ine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Both Piston Ported and Reed Valve En

g

ines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Reed Valve Service (DuraForce En

g

ines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

PIVOTING ZONE START BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

ELECTRIC START SYSTEM (120 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Troubleshootin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Reinstalling External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

TABLE OF CONTENTS

iv

ELECTRIC START SYSTEM (12 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Troubleshootin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Starter Testin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Alternator Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Alternator Output Testin

g

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Alternator Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Alternator Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cup Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

1

SAFETY

SAFETY INFORMATION

General

This safety symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction

because it has to do with your safety. Failure to comply with the instruction may result in personal

injury or even death.

This manual is intended as a service and repair manual only. The safety instructions provided herein are for

troubleshootin

g

, service, and repair of the en

g

ine only. The individual Operator’s manual will contain safety

information on the complete product powered by the E series en

g

ine. Operator’s manuals with complete

instructions are available throu

g

h:

Lawn-Boy Corporation / The Toro Company

Parts Department

8111 Lyndale Avenue South

Bloomin

g

ton, MN 55420 U.S.A.

Avoid unexpected startin

g

of en

g

ine...

Always turn off the powered product and disconnect the

spark plu

g

wire before attemptin

g

cleanin

g

, adjustment,

or repair.

Avoid lacerations and amputations...

Stay clear of all movin

g

parts whenever the en

g

ine is

runnin

g

. Treat all normally movin

g

parts as if they were

movin

g

whenever the en

g

ine is runnin

g

or has the

potential to start.

Avoid burns...

.Do not touch the en

g

ine while it is runnin

g

or shortly

after it has been runnin

g

.

Avoid Falls...

Do not operate the powered product on slippery

surfaces or if footin

g

is questionable.

Avoid fires...

Wipe up any spilled fuel or oil immediately.

Avoid asphyxiation...

Never operate an en

g

ine in a confined area without

proper ventilation.

Avoid fires and explosions...

Use a container desi

g

ned for

g

asoline. Avoid spillin

g

fuel and never smoke while workin

g

with any type of

fuel.

Safety Tips

Avoid accidental misuse of fuel...

Always store fuel in a properly labeled container

desi

g

ned for

g

asoline.

Avoid injury due to inferior parts...

Use only Toro/Lawn-Boy ori

g

inal parts to ensure that

important safety criteria are met.

Avoid injury to bystanders...

Always clear the area of bystanders before startin

g

or

testin

g

powered equipment.

Avoid injury due to projectiles...

Always clear the area of sticks, rocks, or any other

debris that could be picked up and thrown by the

powered equipment. Keep all safety shields in place.

Avoid modifications...

Never alter or modify any part unless it is a factory

approved procedure.

Avoid unsafe operation...

Always test the safety systems after makin

g

adjustments or repairs on the machine.

SPECIFICATIONS

2

Specifications

Engine Specifications (All dimensions are for a new engine)

Item DuraForce R tek

Type Reed valve 2-cycle Piston ported 2-cycle

Bore

Stroke

Wrist pin diameter

Crankpin diameter

End play (crankshaft)

.

0 - .017" (0 - .431mm) Walk mower

.

0 - .017" (0 - .431mm) 1998 Snow

0 - .0215" (0 - .533mm) 1999 and

later Snow

Side play (crankshaft) near lower main

Piston cyl. Clearance (tightest loc.)

Wrist pin hole diameter

Bottom ring thickness, new

End gap, new (both rings)

Displacement

Horsepower 6.5HP 4 or 5HP

Compression ratio

Compression

Carburetor

Dual-circuit Lawn-Boy with fixed jets, float type with primer and choke

Fuel required

Mix ratio 32:1 50:1

Recommended Oil

.

Lawn-Boy Generation II 2-cycle

oil or NMMA TCW3 Toro 2-cycle oil or NMMA TCW3

Fuel tank capacity

Ignition type

CD Pack air gap

Spark plug / air gap

Start system Rope rewind or 12 VDC Rope rewind or 120 VAC

Governor

Governed Engine Speed

.

2900 +

300 rpm

.

4HP runs at 3700 +

300

CCR 2400 - 3700

5HP runs at 3800 +

300 rpm

CCR 2450 & 2500 - 3800 rpm

CCR 3600 - 3900 rpm

CCR 3650 - 4000 rpm

Snow Commander - 4000 rpm

All snow engines are +

300 rpm

Idle Speed 2200 - 2800 rpm N/A

A

ir Cleaner

.

Oiled foam type with Centrifugal

pre-cleaner N/A

Air vane

Unleaded regular (87 octane R+M/2):2-cycle oil

Varies with product

Solid-state CD Pack, magneto type

NGK projected nose / NGK BPMR4A .030" (.76mm)

.010" (.25mm)

.016/.008 in. (.40/.20mm)

8.6 cu in. (141cc)

5.8:1

Approximately 115 psi. Service limit 80 psi.

.0006" + .0003 - .0006 (.015mm + .008 - .015)

.0035" to .0059" (.089 to .150mm)

.500"/.5005" (12.705mm / 12.712mm)

.0600 +

.0005 (1.52mm + .013)

2.5000" +

.0005 (63.5mm + .0127)

1.75" (44.45mm)

.5000" + .0000 - .0002 (12.70mm + .000 - .005)

.7427" + .0003 - .0002 (18.85mm + .008 - .005)

3

SPECIFICATIONS

Engine Fastener Torque Requirements

Choke Manual, butterfly type

Fuel filter In-tank and in-carburetor

Piston rin

g

s Cast iron, semi-keystone top rin

g

. Second rin

g

is rectan

g

ular.

Anti-rotation pin in piston.

Piston Permanent mold, hi

g

h silicon aluminum

Item DuraForce R tek

Bolt, Head 140 - 200 in. lbs. (16 - 22 Nm) 140 - 200 in. lbs. (16 - 22 Nm)

Jet, Main 4 - 6 in. lbs. (.44 - .66 Nm) 4 - 6 in. lbs. (.44 - .66 Nm)

Jet, Pilot* 10 - 12 in. lbs. (1.1 - 1.3 Nm) 6 - 8 in. lbs. (.66 - .88 Nm)*

Nozzle, Carburetor* 16 - 28 in. lbs. (1.7- 4.0 Nm) 20 - 30 in. lbs. (2.2 - 3.4 Nm)

Nut, Blade 45 - 50 ft. in. (60 - 67 Nm) NA

Nut, Flywheel 375 - 425 in. lbs. (42 - 47 Nm) 375 - 425 in. lbs. (42 - 47 Nm)

Seat, Float Valve* 16 - 28 in. lbs. (1.7 - 4.0 Nm) 22-32 in. lbs. (2.4 - 3.5 Nm)

Screw, Brake Plate Assembly 60 - 70 in. lbs. (6.7 - 7.8 Nm) NA

Screw, Carburetor Mountin

g 20 - 30 in. lbs. (2.2 - 3.4 Nm) 20 - 30 in. lbs. (2.2 - 3.4 Nm)

Screw, CD I

gnition Pack 90 - 110 in. lbs. (10 - 12 Nm) 90 - 110 in. lbs. (10 - 12 Nm)

Screw, Cylinder to Crankcase 55 - 90 in. lbs. (6.2 - 10.0 Nm) 55 - 90 in. lbs. (6.2 - 10.0 Nm)

Screws, En

gine Mounting 170 - 220 in. lbs. (19 - 25 Nm) 170 - 220 in. lbs. (19 - 25 Nm)

Screw, Float Bowl 10 - 13 in. lbs. (1.1 - 1.5 Nm) 10 - 13 in. lbs. (1.1 - 1.5 Nm)

Screw, Muffler (611228) 55 - 90 in. lbs. (6.2 - 10.0 Nm) 55 - 90 in. lbs. (6.2 - 10.0 Nm)

Screw, Muffler Cover 55 - 90 in. lbs. (6.2 - 10.0 Nm) NA

Screw, Muffler Plate 140 - 200 in. lbs. (16 - 22 Nm) NA

Screw, Reed 10 - 13 in. lbs. (1.1 - 1.5 Nm) NA

Screw, Rod Cap to Rod 65 - 75 in. lbs. (7.3 - 8.4 Nm) 65 - 75 in. lbs. (7.3 - 8.4 Nm)

Screw, Shroud 58 - 70 in. lbs. (6.5 - 7.8 Nm) 58 - 70 in. lbs. (6.5 - 7.8 Nm)

Screw, Shroud Base 58 - 70 in. lbs. (6.5 - 7.8 Nm) 58 - 70 in. lbs. (6.5 - 7.8 Nm)

Spark Plu

g 150 - 200 in. lbs. (17 - 23 Nm) 150 - 200 in. lbs. (17 - 23 Nm)

Rewind Starter to blower housing NA 20-30 in. lbs. (2.2 - 3.4 Nm)

Screw, Manifold NA 55 - 70 in. lbs. (6.2 - 7.8 Nm)

Screw, Muffler NA 100 - 130 in. lbs.

* Overtorquin

g will crack the carb body and cause the engine to run rich page rev 8/06

Item DuraForce R tek

SPECIFICATIONS

4

Standard Torques

Carburetor Specifications

Nut, Shroud 100 - 130 in. lbs. (10 - 14 Nm) 140 - 170 in. lbs. (16 - 19 Nm)

Screw, Starter Bracket to Recoil NA 30 - 35 in. lbs. (3.4 - 3.8 Nm)

Screw, Gov Pivot Block to Cyl. NA 30 - 35 in. lbs. (3.4 - 3.8 Nm)

Screw, Elect Start to Crankcase 140 - 200 in. lbs. (16 - 22 Nm) 75 - 100 in. lbs. (8.2 - 11 Nm)

Size US (Metric)

#10 - 24 20 - 30 in. lbs. (5.1 - 6.21 Nm)

1/4 - 20 55 - 90 in. lbs. (6.2 - 10.0 Nm)

5/16 - 18 140 - 200 in. lbs. (16 - 22 Nm)

Item DuraForce R tek

Type Lawn-Boy, float type, dual-circuit, with primer and choke

Body Material Minlon

Seat material Brass with Viton tipped needle. Both are replaceable.

Inlet Needle “Pop-Off” Pressure 5 psi (.7 k

g

/cm2) (Wet)

Main Jet 77.5 73.8

Main Nozzle Brass

Pilot Jet 37.5 42.5

Hi

g

h Altitude NA

Float Adjustment Float hei

g

ht .500 ± .030" bowl flan

g

e (no

g

asket) to top of float

Item DuraForce R tek

5

SPECIAL TOOLS

SPECIAL TOOL REQUIREMENTS

Listing

Description Order From Part Number Comments/Use

Air Gap Gau

g

e Toro 604659 Sets .010” (.25 mm)

g

ap between flywheel

and coil

Piston Ring CompressorOTCTOR 4089Compresses piston rin

g

s to allow installation

into the cylinder

Wrist Pin Knockout Tool Toro 602884 Used to drive wrist pin out of piston

OTC Tool & Equipment Division

SPX Corporation

Industrial Park

2013 4th Street NW

Owatonna, MN 55060

Telephone: 800-533-0492

Fax: 507-455-7011

TROUBLESHOOTING

6

TROUBLESHOOTING

Engine Will Not Start When “Cold”

Engine Will Start When “Cold”, But Not When “Hot”

Possible Causes Remedies

Fuel tank is empty Fill with clean, fresh, properly-mixed, unleaded fuel

Bad fuel Drain tank and float bowl. Fill the tank with clean, fresh,

unleaded, properly-mixed fuel.

Fuel filter plu

gg

ed Replace fuel tank

Air cleaner plu

gg

ed Wash and re-oil air cleaner element (DuraForce only)

Fouled spark plu

g

Remove and replace the spark plu

g

No spark at spark plu

g

See “En

g

ine Will Not Produce Spark” table

Insufficient momentum Check for loose blade, mower only

Incorrect i

g

nition timin

g

Check for sheared flywheel key

Low compression See “En

g

ine Has Low Compression” table

En

g

ine flooded with fuel See “En

g

ine Flooded With Fuel” table

Reed valves not closed Replace reed valves (DuraForce only)

Reed valves stuck closed Free up and run en

g

ine to clean (DuraForce only)

Primer or choke not operatin

g

Fix or replace

Possible Causes Remedies

En

g

ine is flooded See “En

g

ine Flooded With Fuel” table

Excessive alcohol in fuel Use no more than 10% ethanol blend. Avoid methanol

En

g

ine is overheated See “En

g

ine Overheats” table

Clo

gg

ed bowl vent Clean bowl vent

Fuel percolation (vapor lock) Use current season

g

as for fuel mixture

7

TROUBLESHOOTING

Engine Will Not Produce Spark

Engine Flooded With Fuel

Engine Has Low Compression

Possible Causes Remedies

Spark plu

g

wire disconnected Reconnect spark plu

g

wire

Spark plu

g

fouled or dama

g

ed Replace spark plu

g

Spark plu

g

wire dama

g

ed Replace CD pack

Coil kill wire

g

rounded Locate and eliminate the unwanted

g

round

I

g

nition coil failed Replace CD pack

Flywheel ma

g

nets weak Replace flywheel

Possible Causes Remedies

Overuse of choke position Take throttle off choke

Throttle cable misadjusted Adjust throttle cable, if present

Air cleaner plu

gg

ed Wash and re-oil air cleaner element (DuraForce only)

Fouled spark plu

g

Replace spark plu

g

Carburetor inlet needle stuck open or leakin

g

Clean carburetor, replace failed parts, and pressure test

Carburetor Air Vent Clean Air Vent

Possible Causes Remedies

Worn piston rin

g

s Replace piston rin

g

s or short block

Piston rin

g

(s) stuck in

g

roove Replace piston and rin

g

s

Cylinder worn Remove and replace short block

TROUBLESHOOTING

8

Engine Lacks Power

Engine Surges

Engine Backfires

Possible Causes Remedies

Dull blade Sharpen or replace blade, mower only

Housin

g

choked with

g

rass and debris Clean housin

g

thorou

g

hly, mower only

Plu

gg

ed exhaust system Clean exhaust ports

Muffler plu

gg

ed Clean or replace muffler

Flywheel key sheared Replace flywheel key

Carburetor dirty Clean carburetor

Intake air leak Repair or replace failed components(s)

Low compression See “En

g

ine Has Low Compression” table

Possible Causes Remedies

Fouled idle circuit Clean idle circuit

Air leak Check sealin

g

surfaces, oil seals,

g

askets, and port plu

g

s

Restricted fuel flow Check filters and fuel line

En

g

ine RPM low Adjust to proper specification. Note: A sli

g

ht sur

g

e at no

load is normal.

Governor link misadjusted (R tek) Adjust

Air vane stickin

g

Clean or replace

Possible Causes Remedies

Flywheel key sheared Replace key

Muffler filled with carbon Clean muffler

Exhaust ports plu

gg

ed Clean ports

Air leak to crankcase Replace seals or re-seal crankcase to cylinder

Spark plu

g

partly fouled Clean or replace

9

TROUBLESHOOTING

Engine Overheats

Engine Vibrates Excessively

Engine Crankshaft Will Not Turn

Engine Produces Mechanical Knocking Sound

Possible Causes Remedies

Cylinder head coolin

g

fins clo

gg

ed Clean fins thorou

g

hly

Restricted carburetor jets Clean carburetor and jet

Improper

g

as to oil mix ratio Ensure mixture is correct

Coolin

g

air intake plu

gg

ed Remove forei

g

n material and clean

Possible Causes Remedies

Blade out of balance Balance blade or replace if dama

g

ed

Bent blade Replace blade

Loose en

g

ine mountin

g

screws Ti

g

hten en

g

ine mountin

g

screws (en

g

ine to plate, plate

to mower housin

g

)

Bent crankshaft Replace crankshaft

Flywheel out of balance (dama

g

ed) Replace flywheel

Possible Causes Remedies

En

g

ine brake incorrectly en

g

a

g

ed Disen

g

a

g

e brake and inspect and repair as necessary,

mower only

Blade jammed in housin

g

Inspect and repair or replace, mower only

Piston seized in its cylinder Inspect and repair or replace

Starter jammed Repair starter

Possible Causes Remedies

Loose blade Inspect and ti

g

hten blade nut to correct torque, mower

only

Loose flywheel Inspect and ti

g

hten flywheel nut to correct torque

Pre-i

g

nition is occurrin

g

See “En

g

ine Pre-I

g

nites” table

Loose rod cap Replace rod and bearin

g

s

Loose en

g

ine mountin

g

bolts Ti

g

hten bolts

TROUBLESHOOTING

10

Engine Pre-Ignites

Engine Smokes Excessively (Smoke is light colored, engine runs well)

Engine Smokes Excessively (Smoke is dark, engine runs poorly)

Possible Causes Remedies

Wron

g

spark plu

g

- too hot Install the correct type of spark plu

g

Low quality fuel (old or stale) Replace with fresh, unleaded re

g

ular fuel

Carbon buildup in en

g

ine Decarbon en

g

ine and muffler

Excessive alcohol in fuel Replace with fresh unleaded fuel havin

g

no more than

10% ethanol

Sheared flywheel key Inspect and repair

Possible Causes Remedies

Sli

g

ht oil accumulation in crankcase None; normal on start-up

Air cleaner element clo

gg

ed Clean and re-oil or replace air cleaner element, mower

only

Fuel/oil mixture too rich Drain fuel tank and fill with fuel of correct mixture

Choke is in “On” position Move to hi

g

h speed or “Off” position

Possible Causes Remedies

Carburetor runnin

g

too rich Clean and check carburetor

Choke is in “On” position Move to hi

g

h speed or “Off” position

11

TROUBLESHOOTING

Engine Stalls

Spark Plug Fouled

Possible Causes Remedies

En

g

ine out of fuel Refill with fresh fuel of the correct mixture

En

g

ine overloaded Unload en

g

ine and restart

Fuel filter plu

gg

ed Clean fuel filter/tank

Spark plu

g

fouled See “Spark Plu

g

Fouled” table

Fuel cap vent plu

gg

ed Replace fuel cap

I

g

nition inadvertently

g

rounded Inspect and repair to remove unwanted

g

round

Carburetor vent plu

gg

ed Clear vent of obstruction

En

g

ine overheated Clear debris from fins or cause of overheatin

g

Improper lubrication Tear down and inspect for dama

g

e

Possible Causes Remedies

Incorrect spark plu

g

Use correct spark plu

g

Carburetor runnin

g

too rich Clean/rebuild carburetor

Clo

gg

ed air cleaner element Clean and re-oil element or replace, mower only

Overuse of “choke” position Move control off “choke” position and check throttle

cable adjustment

Weak i

g

nition system Replace CD i

g

nition pack

Worn rin

g

s and/or cylinder Rebuild en

g

ine or short block

Use of poor fuel Drain fuel tank and replace with fresh, unleaded re

g

ular

fuel havin

g

the correct oil mixture

Fuel/oil mixture too rich Drain fuel tank and fill with fuel of correct mixture

Wron

g

Oil Use Toro 2-cycle oil, Lawn-Boy DuraForce oil, or

NMMA TCW3 approved oil

12

THIS PAGE INTENTIONALLY LEFT BLANK

13

MAINTENANCE

Recommended Maintenance Schedule

Frequency Item Comments

5 Hours Fasteners Check blade and en

g

ine mountin

g

fasteners

frequently. Keep all nuts, bolts, and screws

ti

g

ht to ensure safe operation.

25 Hours Housin

g

(Mower only.) Remove the buildup of

g

rass

clippin

g

s and dirt.

(Self-propelled mower only.) Clean

g

rass

clippin

g

s and debris under drive belt

mechanism cover and drive belt.

Spark Plu

g

Clean, inspect, and re

g

ap; replace if

necessary.

50 Hours Air Filter (Mower only.) Remove and clean each

mowin

g

season or every 50 hours; more

frequently if operatin

g

conditions are dusty.

Blade

Blade Brake

(Mower only.) Sharpen or replace; maintain

more frequently if ed

g

e is dulled quickly in

rou

g

h or sandy conditions.

Check stoppin

g

time every 50 hours or at start

of each mowin

g

season. Blade must stop

within 3 seconds of releasin

g

bail. If not,

repair or replace.

Lubrication (Self-propelled mowers only.) Grease rear

hei

g

ht adjuster brackets.

Exhaust Ports Clean every 50 hours or at least once each

season.

Fuel System Check for leaka

g

e and/or deterioration of fuel

hose. Replace if necessary.

100 Hours Coolin

g

System Clean

g

rass clippin

g

s, debris, or dirt that clo

g

en

g

ine air coolin

g

fins; clean more frequently

under dirty or hi

g

h chaff conditions.

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Toro CCR 2500 Snowthrower User manual

Toro CCR 2500 Snowthrower User manual

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