Toro CCR 2500 Snowthrower User manual

Category
Lawnmowers
Type
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
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
ned for
asoline.
Avoid injury due to inferior parts...
Use only Toro/Lawn-Boy ori
inal parts to ensure that
important safety criteria are met.
Avoid injury to bystanders...
Always clear the area of bystanders before startin
or
testin
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
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

Category
Lawnmowers
Type
User manual

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