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2-CYCLE GTS 120 ENGINE SERVICE MANUAL
Table of Contents – Page 1 of 1
PREFACE
I. GENERAL INFORMATION
SAFETY INSTRUCTIONS
MAINTENANCE
MODEL AND SERIAL NUMBERS
TWO-CYCLE ENGINE THEORY AND OPERATION
CARBURETOR THEORY AND OPERATION
SPECIAL TOOLS LIST
II. MAINTENANCE
AIR CLEANER
SPARK PLUG
EXHAUST SYSTEM
DECARBONING CYLINDER HEAD
IGNITION TIMING (MODEL 47PZ2 ONLY)
IGNITION TIMING (DIAL INDICATOR)
CONTACT POINTS AND CONDENSER MODEL47PZ2 ONLY
IGNITION COIL
GOVERNOR
GOVERNOR OPERATION
FUEL TANK
CARBURETOR
STORAGE
III. TROUBLESHOOTING AND TEST PROCEDURES
PRELIMINARY TROUBLESHOOTING
ENGINE BRAKE AND IGNITION SWITCH
BBC APPLICATIONS
FUEL TANK
TESTING COMPRESSION
CRANKCASE
ENGINE TROUBLESHOOTING CHART
IV. ENGINE REMOVAL, DISASSEMBLY, ASSEMBLY AND REPAIR INSTRUCTIONS
ENGINE REMOVAL
ENGINE DISASSEMBLY AND REPAIR
RECOIL STARTER REPAIR
CARBURETOR REPAIR
ENGINE ASSEMBLY AND REPAIR
SERVICE DATA SPECIFICATIONS
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Troubleshooting
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Summary of Contents for Toro GTS 120
- Page 1 2-CYCLE GTS 120 ENGINE SERVICE MANUAL Table of Contents – Page 1 of 1 PREFACE I. GENERAL INFORMATION SAFETY INSTRUCTIONS MAINTENANCE MODEL AND SERIAL NUMBERS TWO-CYCLE ENGINE THEORY AND OPERATION CARBURETOR THEORY AND OPERATION SPECIAL TOOLS LIST II. MAINTENANCE AIR CLEANER...
- Page 3 The Toro Company has made every to make this service manual a useful tool for the service and maintenance of your TORO Rotary Mower Engine. To assure proper and effective performance, you are urged to read this manual carefully.
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Page 4: Table Of Contents
TABLE OF CONTENTS TOPIC PAGE E ..............GENERAL INFORMATION ................Safety Instructions ..................Maintenance ..............Model and Serial Numbers ............Two-cycle Engine Theory and Operation ..............Carburetor Theory and Operation Engine Specifications .............................. -
Page 5: Safety Instructions
Operators Manual. A replacement manual is available by sending the complete model 12. During operation the grass defector or com- and serial number to: The Toro Company, plete bagging assembly must be installed on 81 11 Lyndale Avenue South, Minneapolis, mower. -
Page 6: Maintenance
The TORO Two-cycle Rotary Mower has two sets burn. of identification numbers. There is a model and serial number to identify the engine and a model and serial number to identify the chassis. -
Page 7: Carburetor Theory And Operation
the exhaust ports. The third port design engine gases begin to be expelled from the combustion has the carburetor mounted on the side of the chamber (Figure 1-3). cylinder. The passage from the carburetor into - - l _ _ _ _ _ m _ the crankcase is called the third port. - Page 8 Air passing through the pilot jet from the pilot air carburetor causes atmospheric pressure to push rawfuel from the float bowl into theair stream, where fitting draws fuel out of the pilot jet orifice from the float bowl. This fuel pre-mixes with the breaks into fine...
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Page 9: Engine Specifications
ENGINE SPECIFICATIONS Model 47P22 47PD3 Type cycle, single cylinder piston ported, air cooled Rotation (viewed from output end) Counter-clockwise Displacement (7.38 Bore 58 mm (2.28 Stroke (1.81 46 mm Crankshaft (.98in) 24.9 forged steel Rated Output 3.5 Hp @ 3600 RPM (5.28 kg-m Torque... -
Page 10: Special Tools
SPECIAL TOOLS LIST PART NO. DESCRIPTION ITEM ........Flywheel Puller.. 41-7650 ........ Starter Cup Wrench 45-1 390 ........Timing Tester.. 41 -7900 ........Spark Tester 41 -7890 ........Continuity Light 36-4050 ........Tachometer.. 42-2730 ......Ohmmeter (Multimeter)........Feeler Gauges ........ -
Page 11: Air Cleaner
SPARK PLUG Many times an inspection of the spark plug can CAUTION: To reduce poten- determine whether the engine is functioning tial accidents, never perform properly. A spark plug which is functioning an adjustment or maintenance proce- normally will show slight electrode wear with dure while the engine is running. -
Page 12: Decarboning Cylinder Head
remove the muffler from the engine by removing the loose carbon from the muffler using com- the two retaining nuts and the through bolt (Figure pressed air. Install the muffler using a new gasket and attach it with proper fasteners tightened to 2-3). -
Page 13: Contact Points And Condenser (Model 47Pz2 Only)
installing new or reconditioned contact points IGNITION TIMING (DIAL INDICATOR) ensure that the wiring is routed through the channel The ignition timing may be more accurately in the crankcase housing and under the ignition checked using a dial indicator. Remove the spark coil. -
Page 14: Governor
GOVERNOR The ignition coil contains two separate windings The governor linkage is factory preset to regu- inside the coil casing (Figure 2-9). Use an Ohm- late the engine speed at 3000 150 RPM. meter to check the resistance levels of each wind- Check the adjustment of the governor if the ing. -
Page 15: Governor Operation
The replacementfuel filter linkage assembly. The boss does not exist on is Toro Part Number 56-6360 (Figure 2-1 6). Period- model 47PZ2 engines therefore thevariable throt- ically inspect the vent in the fuel tank cap. Remove tle linkage will not retrofit. -
Page 16: Carburetor
All gas- Standard Main Jet #80 Toro Part No. 8 1 - 1 0 4 0 oline must be removed to prevent gumlike varnish Optional High-altitude deposits from forming in the fuel system. Pull the Main Jet #77.5... -
Page 17: Preliminary Troubleshooting 111-1
111. TROUBLESHOOTING AND TEST PROCEDURES 1. Pull off the spark plug connector and remove Generally all gasoline-powered products require plug. the spark some form of service or repair during their life- time. The amount of time and expense involved 2. Inspect the spark plug for wear, carbon in repairing a product can be greatly impacted deposits and damage. -
Page 18: Bbc Applications
Engines equipped with a Blade Brake Clutch (BBC) line fuel filter found on commercial engines may mechanism, Models 47PD3,47PE4 and 47PF5 replaced using Toro Part Number 56-6360. See with serial numbers that start with are fitted 2 .., Figure 2-1 6. -
Page 19: Crankcase
CRANKCASE 2. Pull the starter rope rapidly several times until the compression reading on the gauge The engine relies on a tightly sealed crankcase stabilizes. in order to function properly. The downward movement of the piston causes the crankcase to 3. -
Page 20: Engine Troubleshooting Chart
The possible causes have been arranged with ENGINE TROUBLESHOOTING CHART the most easily inspected items to be checked The following troubleshooting chart lists the listed first. Utilizing the chart in this manner Will symptoms, causes and remedies of common lessen the amount time required to repair the engine malfunctions. -
Page 21: Engine Removal
IV. ENGINE REMOVAL, DISASSEMBLY ASSEMBLY AND REPAIR INSTRUCTIONS ENGINE REMOVAL To remove the engine from the mower the air cleaner housing, recoil assembly and fuel tank must first be removed to disconnect the control cables. Remove the retaining capscrew, lock- washer, blade, blade adapter and self-propel components below the mower deck from the... -
Page 22: Carburetor Repair
flywheel by hand and remove the three re- IMPORTANT: NO OTHER PARTS ARE SERVICE- ABLE. DISASSEMBLY THE THROTTLE AND maining capscrews retaining the starter cup CHOKE PLATES IS NOT RECOMMENDED. THE to the flywheel. (It may be necessary to insert SCREWS ARE FACTORY TORQUED AND a screwdriver through the starter cup to hold LOCKED IN PLACE. - Page 23 of the two-cycle and install onto either end the crankcase. Use a seal pick to remove the crankshaft. Insert the bearing locating rings governor shaft seal. into the slots of the crankcase housing to NOTE: The cylinder contains a cast iron sleeve, locate the bearings and crankshaft in position.
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Page 24: Service Data Specifications
adapter plate with the dimple facing the spark crankshaft. The blade retaining capscrew plug end. Install the four retaining capscrews should be tightened to 6.2-8.3 Kg-m (45-60 and torque to the proper specification. ft-llb). Install the ignition cam and locating pin to the 12. - Page 25 Exhaust Port Intake Port Cylinder bore The cylinder bore is checked by measuring the cylinder liner at a total of six places using a cylinder gauge. Two measurements, apart, Third Port must be taken at the approximate A, 6 and C elevations as shown.
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