Service Manual TC-355 UTILITY ENGINE. Date ISM, Inc th Street SW Auburn, WA Phone: (253) Fax: (253)

Transcription

1 UTILITY ENGINE Date ISM, Inc th Street SW Auburn, WA Phne: (253) Fax: (253) custsvc@tanaka-ism.cm

2 Table f Cntents Specificatin Chart & Trque Limits Truble Shting Safety and Shp Practices Rutine Maintenance Diagnstic Tls General Inspectin Engine Repair Warranty Statement custsvc@tanaka-ism.cm

3 Truble Shting Engine Will Nt Start Check Functin f: Page N. Rewind Starter 6, 10, 11 Ignitin System: N Spark...7, 8, 11, 12 Fuel System : Fuel Tank..6, 8, 13 Fuel System : Carburetr..8, 13, 14,15 Air Filter.6 Exhaust System..7, 15 Cmpressin.7 Engine Idles Prly Check Functin f: Page N. Clutch System.9 Ignitin System: Spark Plug.7, 8 Ignitin System: Pr Spark 8, 11, 12 Fuel System : Fuel Tank..6, 8, 13 Fuel System : Carburetr..8, 13, 14,15 Air Filter.6 Exhaust System 7, 14, 15 Cmpressin.7 Engine Lacks Pwer Check Functin f: Page N. Clutch System.9 Ignitin System: Pr Spark...7, 8, 11, 12 Fuel System : Fuel Tank..6, 8, 13 Fuel System : Carburetr..8, 13, 14,15 Air Filter.6 Exhaust System 7, 14, 15 Cmpressin.7 Engine Stps Suddenly Check Functin f: Page N. Ignitin System: N Spark...7, 8, 11, 12 Fuel System : Fuel Tank..6, 8, 13 Fuel System : Carburetr..8, 13, 14,15 Cmpressin custsvc@tanaka-ism.cm

4 Safety & Shp Practices The mst successful and prfitable service shps cnsistently seem t maintain the best habits f safety, cleanliness, and rderly prcedure. The fllwing infrmatin is intended as a guide twards develping habits that are necessary t accmplish satisfactry service wrk. Maintain a clean and rderly wrk area that is well lighted and adequately ventilated. Tls, instruments, and parts needed fr wrk shuld be clean and readily available befre any jb is started. (Special tls available fr servicing TANAKA equipment are listed in this manual.) Equipment shuld be cleaned befre repair wrk starts. Cleaning will ften help reveal a surce f truble. Befre attempting t repair r perate any equipment, read and understand all infrmatin prvided by the instructin manual fr the equipment. Never attempt t service an engine that is running r still heated frm running unless it is specifically required by the manufacturer s instructins. Wipe-up all spilled liquids immediately. Use nn-flammable slvents fr cleaning. Clean all parts befre recnditining r reassembling. Thrughly inspect all parts fr wear r damage. Replace all parts that shw damage r excessive wear. Always recnditin and /r repair equipment strictly accrding t the Manufacturer s specificatins. Be sure all shields and safety devices are crrectly installed befre perfrming any final perating tests. After cmpletin f any service r repair, the equipment shuld be thrughly cleaned. Rutine Maintenance Guide Each Use 20 Hrs. 25 Hrs. 100 Hrs. Air Filter Clean O All Fasteners Check Tightness O Cling Fins Clean O Spark Arrestr Clean O Fuel Filter Clean O Spark Plug Clean O Muffler & Exhaust Prts Clean O 4 custsvc@tanaka-ism.cm

5 Diagnstic Tls Cmpressin Gauge Part N Pressure Tester Part N W-500 Ohmmeter (Digital Type) Engine Tachmeter (Digital Type) Part N Three Pint Spark Tester Disassembly & Assembly Tls Pin Remver Part N Flywheel Remver Set 1. Handle ( ) 2. Center Blt ( ) 3. Flywheel Puller ( ) 4. Blts ( ) 5 custsvc@tanaka-ism.cm

6 General Inspectin Once the engine is remved frm the equipment, this is an ideal time t inspect fr damage as well as ptential areas that may require repair. Sme f the diagnstic evaluatin cannt be effectively perfrmed after disassembly has begun. Cver, Shrud, Fan Case Inspect cvers, shruds, and fan case t identify damage r cracks due t vibratin, grund cntact, etc. All f the shrud cmpnents are designed fr ruting the flw f cling air arund the engine. Any brken r missing cmpnents culd lead t ver heating f the engine during peratin. Order replacements as need. Inspect the rubber spark plug bt fr any damage that may cause a ptential shck hazard. Ensure that the fuel tank is nt damaged in any way due t pssible grund cntact, excessive vibratin, etc. Any ptential fuel leaks may be apparent during this initial inspectin, as the expsed fuel n the engine cmpnents may attract dirt. This prvides a gd visual reference. Recil Starter Ensure that the engine turns freely when the recil starter is pulled, and that the recil starter rpe retracts psitively int the starter husing. Fuel If gasline is present in the fuel tank, take the pprtunity t empty it int a clear cntainer. This may reveal cntaminatin such as water, (as depicted in the pht phase separatin f gasline and water is very bvius), sediment, r the lack f tw-cycle il/fuel mixture. Air Cleaner Remve the air cleaner cver (A), and inspect the air cleaner element (D). Ensure that it is clean and lightly iled. Make sure the inside f the husing that accmmdates the cleaner element is free f dirt and dust. The vented area f the crankcase, visible in the pht between the fuel tank and the air cleaner bdy (B), allws air frm the flywheel fins (C) t be circulated t the exterir f the engine and is critical t prper cling. Ensure that there is n debris within the vent fins that wuld impede the circulatin f air. 6 custsvc@tanaka-ism.cm

7 General Inspectin Cnt. Chke Lever Check t ensure that the chke lever (A) is able t rtate freely within the air cleaner bdy, and that it has nt been bent as t prevent a gd seal when clsing ver the air intake. Spark Plug Remve the spark plug rubber prtectin bt and high-tensin lead, and remve/inspect the spark plug. Picture A depicts a spark plug that has a brken insulatr. Picture B depicts a spark plug that has fuled due t a rich fuel/il mixture. Picture C depicts a plug that has fuled due t carbn build-up. All f these cnditins will prevent the spark plug frm functining prperly, and will require replacement. Picture D depicts a plug characteristic f healthy running cnditins. The electrde shuld have a glden/tan clr, and n damage is present. Whenever the integrity f a spark plug cmes int questin, it shuld be replaced. Whether the plug t be installed is new, used r cleaned, it shuld be checked fr crrect electrde gap, which is.024. Cylinder Cmpressin Insert a cmpressin gauge int the empty spark plug hle and pull the recil starter handle briskly several times, until the needle n the gauge stps climbing. This reading represents the cmpressin in the cylinder, and is a gd gauge f the pistn rings ability t hld pressure. The unit will struggle t run with cmpressin less than apprximately 90 psi. Such lw readings indicate the need fr service t the cylinder, pistn r pistn rings. 7 custsvc@tanaka-ism.cm

8 General Inspectin Cnt. Spark Testing While the rubber spark plug bt / high-tensin lead are remved frm the spark plug, this is an ideal time t test the quality f the current being delivered t the spark plug. Insert a three pint spark tester int the spark plug bt and briskly pull the recil starter. The tester shuld reveal a strng spark with a blue clr. Lack f spark, weak spark, r yellw spark may indicate a prblem with anther electrical cmpnent within the engine. Ignitin Cil Testing Cnnect an hmmeter t the ignitin cil with ne lead inserted int the spark plug bt and the ther making cntact with the cylinder fins f the engine (as shwn). Secndary resistance, when tested this way, shuld indicate 4.2 (+/- 1) KΩ. If the reading is nt within this range, replace with a new cil, (previus tests fr spark using a three pint tester shuld have indicated a weak spark r nne at all). If the reading is within range, and still weak r n spark is evident, replace the ignitin cil. Fasteners Check t ensure that all fasteners are tight prir t disassembly. Lsening f fasteners n the carburetr side may cause erratic running cnditins, r even engine failure. It s always best t knw if fasteners are prperly trqued prir t engine service, as prblematic running cnditins may be the result. Fuel Filter Using a hked wire, reach int the filler neck f the fuel tank, and grasp the fuel line. Gently pull the fuel line, with the fuel filter attached, thrugh the filler neck. The filter shuld be white in clr and shuld be cmpressible between tw fingers. If it appears disclred r hard, replace with a new ne. 8 custsvc@tanaka-ism.cm

9 Engine Repair ENGINE SERVICE Trubleshting shuld alert yu t prblem areas, and these prblem areas can be addressed as majr sub-cmpnents f the engine: Centrifugal Clutch Recil Starter Electrical System Fuel System Cmpnents Exhaust System Crank Case It is imprtant t prperly identify which areas f the engine require service t avid any unnecessary tear dwn f cmpnents nt requiring service. CLUTCH SYSTEM CAUTION: Never attempt t run the engine with the clutch expsed. The clutch is designed t vercme the frce f the spring, thus allwing cntact with the clutch drum, ultimately prviding drive t the PTO side f the equipment. If the clutch is nt cntained within the clutch drum while the engine is running, the clutch cmpnents may cme detached frm the engine and pse a risk f flying bjects. The clutch system is made up f the clutch shes, clutch spring, and the blts and washers (flat and waved) securing them t the flywheel. Using an impact wrench r a sharp blw t a scket wrench, remve the blts securing the clutch t the flywheel (right hand threaded, cunter-clckwise fr remval.) This will enable all f the cmpnents t be inspected. Check fr any signs f damage t clutch shes r excessive wear n the lining f the shes. When new, the shes have apprximately tw millimeters f lining. Order spares as needed. Inspect the wave washers munted between the blt and the clutch shes t ensure that they are nt cracked and still prvide spring tensin. Ensure that the spring is nt cracked r brken. Replace as needed. When re-installing the clutch cmpnents, attach the spring between the shes then add the blts with the wave washers. Hld in place with the flat washers between the backside f the clutch arms and the flywheel, and tighten the stepped blts t 185 in.-lbs. 9 custsvc@tanaka-ism.cm

10 Engine Repair Cnt. RECOIL STARTER CAUTION: The recil spring is wund with significant frce. When remved frm the starter bdy, it will rapidly unwind. It is recmmended that yu wear glves and eye prtectin when remving the starter spring. The recil starter is made up f the rpe, spl and rewind spring. On the engine side is the starter pawl and the nut securing it t the crankshaft. If the recil starter fails t retract the rpe, r if the rpe is brken r frayed, it will be necessary t disassemble the starter. Remve the small screw lcated in the center f the rpe spl that secures the spl t the starter bdy. This will expse all f the starter cmpnents. Inspect the spl fr any sign f warping, cracks r chips. Replace as necessary. Ensure that the rpe is nt frayed and is tightly secured with knts t bth the starter handle and the spl. Inspect the starter bdy fr any cracks r ther damage. Replace as needed. Inspect the starter pawl cup and the spring-laded pawl lcated within the cup. The pawl pivts n a spring, and shuld have cnstant tensin keeping it in place. If the starter pawl spring is brken, it will be necessary t replace the pawl cup. The spring is retained within the starter bdy by the spl as well as clips frmed in bth ends f the spring. Check t ensure that the spring is nt brken, and that the ends are prperly installed in the starter bdy. If the spring shws n signs f breakage, it may nt be necessary t remve it frm the starter bdy. When installing a new spring, use cautin, as it is wund with significant frce. New replacement springs cme pre-wund and wrapped with tie-wire. Carefully grasp the spring with needle nsed pliers and hld it riented in place prir t remval f the tie-wire. With the tie-wire carefully remved, it will be pssible t insert the spring int the starter husing. Ensure that the utside end f the spring (A) is prperly psitined in the recil starter husing, and when the spl is placed ver the tp f the spring, the tab n the inside f the spring (B) is prperly lcated in the prvisin n the spl. Prir t placing the spl ver the rewind spring, apply a small amunt f grease t the inner wall f the center hle n the spl. Wind the rpe n the spl abut three turns cunterclckwise, as viewed frm the starter pawl side. Install the starter spl int the case, making sure that the spl engages with the inner end f the rewind spring. Install washer and screw hlding starter spl in the case. Recil Starter cnt custsvc@tanaka-ism.cm

11 Engine Repair Cnt. Recil Starter cnt. It is necessary t increase the spring tensin in the starter prir t use. Rtate the spl cunterclckwise several times with the rpe hked int ntch (A). Hld the spl t prevent it frm rewinding and pull the starter grip ut t take up the rpe slack. Let the starter rewind slwly. Pull starter several times t check the spring rewind tensin. If the starter is nt rewinding fully, repeat the prcess described abve. ELECTRICAL SYSTEM The electrical system includes the flywheel (1), the cil (2), high tensin lead assembly (3) and the spark plug (4). T remve the flywheel, it is first necessary t effectively stp the pistn frm mving within the cylinder. This is easiest accmplished by rtating the crankshaft until the pistn is n a dwnward strke, then inserting several inches f starter rpe int the spark plug hle. Upn rising in the cylinder, the pistn will cntact the rpe, and will nt be allwed t cmplete its cycle r crankshaft rtatin. This will allw the flywheel-munting nut t be remved. The flywheel nut is right hand threaded. Remval is in the cunter clck-wise directin. Electrical Systems cnt custsvc@tanaka-ism.cm

12 Engine Repair Cnt. Electrical Systems cnt. With the flywheel nut remved, a flywheel puller can be attached t separate it frm its press fit t the crankshaft. Align the center blt f the puller with the indent in the end f the crankshaft, and thread at least tw carrier blts thrugh the puller and int the flywheel. Make sure that at least several threads are utilized in attaching the carrier blts, as they will bear the lad f pulling the flywheel lse. Damage t these threads will require replacing the flywheel itself. With the puller prperly attached t the flywheel, use the T-handle t turn the center pivt pint until the flywheel cmes lse frm the crankshaft. Remve the flywheel (refer t page 11 fr disassembly prcedure), and inspect the integrity f the flywheel keyway, the crankshaft keyway and the key itself. Any defrmatin f the key r keyway will require replacement f thse cmpnents. After identifying the integrity f the cil (refer t page 8 fr cil testing prcedure), r replacing it with a new ne, check the air gap between the cil and flywheel (A). Gap shuld be measured with a feeler gauge and set at custsvc@tanaka-ism.cm

13 Engine Repair Cnt. FUEL SYSTEM The fuel system cnsists f the carburetr (1), fuel tank (2), fuel supply line (3), and fuel filter (4). The carburetr is held in place between the air cleaner bdy and the heat insulatr blck with tw screws that are accessed n the exterir f the cleaner bdy (with the cver and cleaner element remved). After remving the carburetr, inspect the gasket that munts between the carburetr and insulatr blck. Often times a cmprmised gasket will shw signs that it has allwed fuel t escape. Replace all munting gaskets when servicing the carburetr. Using a straight edge such as a metal ruler, check the carburetr insulatr fr any pssible warping. If the insulatr shws sign f warping replace it with a new ne. Using a carburetr pressure tester, test the pressure-hlding ability f the carburetr. Attach the tester line t the intake fitting f the carburetr (nt t be cnfused with the fitting that accmmdates the purge bulb return line). The carburetr shuld hld 7 PSI. Readings less than this indicate a prblem within the carburetr. Fuel Systems cnt custsvc@tanaka-ism.cm

14 Engine Repair Cnt. Fuel Systems cnt. The pump bdy f the carburetr is held tgether with fur screws. With these screws remved, it will be pssible t inspect all f the pump cmpnents f the carburetr. Inspect all gaskets and diaphragms t ensure that they have nt lst their pliability, and shw n signs f cracking r drying. If any f these cmpnents are in questin, replace all f them with a carburetr repair kit ( ). Pay careful attentin t their psitin in the carburetr during re-assembly custsvc@tanaka-ism.cm

15 CARBURETOR SERVICE The main bdy f the carburetr cnsists f the carburetr bdy (A), the thrttle shaft (B) and the thrttle wire receiver (C). Tw screws secure the thrttle wire receiver and the thrttle shaft t the carburetr bdy. While it s nt necessary t remve the thrttle valve fr inspectin, rtate it by hand t ensure that it is able t freely rtate with the carburetr bdy and that it can reach the full range f mtin permitted between the idle adjustment screw and the full RPM stpper n the carburetr bdy. Any binding shuld be addressed by blwing frced air int the thrttle valve/bdy area. If it still des nt rtate freely, the entire carburetr will need t be replaced. Als ensure that the -ring munted t the carburetr bdy n the air cleaner side is nt trn r dried. Replace as necessary. (The -ring is a cmpnent cntained within the carburetr repair kit.) The fuel tank is munted t the crankcase with three screws that extend frm underneath the tank, and thrugh the tank-munting bracket. Additinally, there are three small spacers that fit within the blt hles in the fuel tank itself. Inspect the tank, tank cap, tank vent and fuel lines fr any signs f leakage r damage. Replace as needed. With the fuel supply line discnnected frm the carburetr it is pssible t check the integrity f the fuel filter. With the tank cap securely tightened, gently shake the tank while partially filled with gasline. If the filter is allwing gas t flw, the agitatin f the fuel in the tank will frce fuel up and ut f the fuel line. If the fuel filter is in questin, replace it. EXHAUST SYSTEM The exhaust system cnsists f the muffler / muffler gasket (1), and heat shield (2). The muffler is a sealed, nn-serviceable unit. If the muffler is damaged, the entire unit needs t be replaced. Remve the shrud cvering the muffler and cylinder. Remve the muffler and inspect the exhaust prt and mating prtin f muffler fr any build f carbn. Carbn build up is a nrmal ccurrence in a tw-cycle engine, and remval is a matter f rutine maintenance custsvc@tanaka-ism.cm

16 Engine Repair Cnt. CRANKCASE / ENGINE When re-assembling the muffler cmpnents, be sure that the heat shield is prperly installed with the muffler lcatr tabs prperly inserted. The heat shield is crucial t the cling f the engine, and imprper installatin can lead t verheating f the engine. The engine cmpnents include the crankcase, crankshaft / cnnecting rd, cylinder, pistn and pistn rings. Further, the crankcase als cntains the main crankshaft supprt bearings and the crankshaft seals. The cylinder is attached t the crankcase with fur screws, which are accessed frm the tp f the cylinder. With the screws remved, the cylinder will slide ff f the crankcase and pistn/rings. The pistn is attached t the cnnecting rd with a press-fit wrist pin. Remval f this pin first requires the remval f the pistn pin retaining circlips installed in the side f the pistn, at either end f the pin. These are remved with a pair f needled nse pliers, and are nt re-usable. New spares shuld be installed upn re-assembly. Crankcase / Engine cnt custsvc@tanaka-ism.cm

17 Engine Repair Cnt. Crankcase / Engine cnt. With the engine taken dwn t this level, it is generally accepted that the pistn rings shuld be replaced. They prvide the engine with the prper amunt f cmpressin, and due t their inaccessibility, it s best t re-assemble with new rings. Hwever, if servicing requires the remval f the pistn, fitting f new rings t the pistn shuld nt be dne until the pistn has been re-assembled t the cnnecting rd, as the pistn pin remver tl can cause damage t the rings. Using a pistn pin remver, lp the strap end arund the pistn with the hle aligned t allw the passage f the pistn pin. It may be necessary t insert a small screw between the remver and the pistn pin, as the remver may have a smaller diameter than the inside f the pistn pin. The crankcase halves are jined with fur screws. Remving these screws will allw the entire cntents f the crankcase t be expsed. Inspect the main supprt bearings, if they are in questin replace them. Upn re-assembly, install a new crankcase gasket between the halves. Carefully inspect the crankshaft, paying particular attentin t the amunt f play between the cnnecting rd and the crankshaft pin. Side-t-side play (A) is nrmal. Hwever, any detectable play in an upand-dwn mtin (B) is unacceptable. This indicates the need fr a replacement crankshaft. The cnnecting rd and crankshaft are ne, nn-serviceable part custsvc@tanaka-ism.cm