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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
The Toro Company has made every effort 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 areurged to read this manual
carefully.
i
TABLE OF CONTENTS
TOPIC PAGEE
.
1 GENERAL INFORMATION ....................................................................
Safety Instructions ................................................................................
1-1
1-1
Maintenance ....................................................................................... 1-2
Model and Serial Numbers ................................... .,.................................... 1-2
Two-cycle Engine Theory and Operation .......................................................... 1-2
Carburetor Theory and Operation ................................................................. 1-4
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fastener Torque Specifications ................................................................... 1-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
II.>MAINTENANCE .............................................................................. 11-1
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Exhaust System .................................................................................. 11-1
Decarboning Cylinder Head ...................................................................... 11-2
Ignition Timing (Model 47PZ2 Only) .............................................................. 11-2
Ignition Timing (Dial Indicator) .................................................................... 11-3
Contact Points and Condenser (Model 47PZ2 Only) .............................................. 11-3
Ignition Coil (Model 47P22Only) ................................................................. 11-3
Ignition Coil(Models 47PD3.47PE4. 47PF5) .................. .................................. 11-4
Governor .................................................................. ...................... 11-4
Governor Operation .............................................................................. 11-5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Carburetor ....................................................................................... 11-6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
111.TROUBLESHOOTING AND TEST PROCEDURES .......................................... 111-1
Preliminary Troubleshooting ..................................................................... 111-1
Spark Intensity .................................................................................. 111-1
Engine Brake and Ignition Switch ................................................................ 111-1
BBC Applications ................................................................................ 111-2
Fuel Tank ..................................................... .................................. 111-2
Testing Compression ............................................................................ 111-2
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111-3
Engine Troubleshooting Chart ................................................................... 111-4
IV. ENGINE REMOVAL, DISASSEMBLY, ASSEMBLY AND REPAIR INSTRUCTIONS ........ 1v-1
Engine ................................................................................. Removal 1v-1
Engine Disassembly and Repair ................................................................ 1v-1
Recoil Starter Repair ............................................................................ 1v-1
Carburetor Repair ............................................................................... 1v-2
Service Data Specifications ...................................................................... 1v-4
Maintenance Record ............................................................................ 1v-6
Maintenance Record ............................................................................ 1v-7
SAFETY INSTRUCTIONS 6. Wear long pants and substantial shoes. Do
Your rotary mower at the time of its manufacture, notoperatethemowerwhile
wearing
meets the blade safety requirements of the Con- sandals, tennis shoes,sneakersorshorts.
sumer Product Safety Commissions Safety Stan- Do not wear loose fitting clothingthat could
dard for Walk Behind Power Lawn Mowers. A get caught in moving parts.
representative sample was testedand verified by 7. If long grass will be cut, setthe height-of-cut
an independent laboratory for compliance with in the highest position. After mowing, rein-
the B71.1-1980 Specifications of the American spect the area and remove all debris. Then
National Standards Institute. However, improper lower the height-of-cut and mow the grass
use or maintenance by the operator or owner again.
can still result in injury. To reduce the potential 8. Since gasoline ishighly flammable, handle it
for injury follow these safety instructions.
carefully
This machine is equipped with abladebrake A. Use an approved gasoline container.
which is designed to stop the blade within 3 B. Do not fill the fuel tank when the engine is
seconds when the control lever is released. hot or running.
Check to be sure the control and brakefunction C. Do not smoke while handling gasoline.
correctly before each use of the mower. Repair D. Fill the fuel tank outdoors and up to about
any defective or damaged safety components one-half inch from the top of the tank, not
beforeoperationiscommenced.To further the filler neck.
reduce the possibility of injury, always stop the E. Wipeup any spilled gasoline.
engine before leaving the operator’s position.
While Operating
9. Cutting the grass with a rotary mower de-
This
safety
symbol
means mands attention.
Always maintain secure
WARNING or CAUTION - footing, balance
and control.
PERSONAL SAFETY INSTRUCTION - 10. Cut the grass during the daytime or when
Read the instruction becauseit has to there is adequate artificial light. Cut slopes
do with safety. Failure to comply with from side to side, but avoid slopeswhen the
the instruction may result in personal grass is wet. If possible, mowwhen the grass
injury. is dry for best results.
11.Keepface,hands and feetawayfromthe
Operating
Before mowerand housing cutter blade while the
1. Operate your mower only after reading the engineis running. Stay behind the handle
Operators Manual. A replacement manual is until the engine andall moving parts stop.
available by sending the completemodel 12. During operation thegrass defector or com-
and serial number to:The Toro Company, plete bagging assemblymust be installed on
8111 Lyndale Avenue South, Minneapolis, the
mower.
Minnesota 55420. Attn: Publications. 13. Stop the engineand wait for allmoving parts
2. Never allow children to operate the mower to stop before removing the bag, bagging
or adults tooperate mower without assembly, oruncloggingthedischarge
proper instructions. chute. If the chute must be unclogged, pull
3. Become familiar with the controls and know the high tension wire from the spark plug to
how to stop the engine quickly. prevent the possibility of accidental starting.
Use a stick to remove theobstruction.
4. Keep everyone,especially children and pets,
away from the areaof operation. Remove 14. If a solid object is hit by the blade or if the
-
sticks, stones, wire and anyother debris that mower vibrates abnormally, stop the engine
might be picked up and thrown by the blade. immediately. Disconnect the high tension
wire from the spark plugtoprevent the
5. TAMPERING WITH OR DEFEATING A possibility of accidental starting. Then check
SAFETY DEVICE OR COMPONENT WHICH the mower for possible damage, bent blade,
RESULTS IN NONCONFORMANCE WITH A an obstruction or loose parts. Repair the
SAFETY STANDARD, MAY RESULTIN PER- mower before using it again.
SONAL INJURY. Eachtime before operating
the mower, check for damage or abnormal 15. Stoptheenginebeforeadjustingthe
wear. If a safety device, shield, or decal is height-of-cut.
defective ordamaged, repair or replace it 16. If a gravel driveway, road orpathmust be
before operation is commenced. crossed, stop the engine so loose sand and
1-1
rocks are not thrown. rotary mowers. To assure optimum perfor-
17. Before leaving the operator’s position behind mance and continued safety certification of
the handle, stop the engine and wait for all the mower, use genuineTORO replacement
moving parts to stop. Do not walk in front of parts and accessories. Replacement parts
the mower while the engine is running. Dis- andaccessories madebyother manufac-
connect the high tension wire from the spark turers may result in nonconformance with
plug if the mower will be unattended. the safety standards.
18. Do not touch any part ofthe engine while it is
running or shortly after it is stopped
because MODEL AND SERIAL NUMBERS
the engine will be hot enough to cause a The TOROTwo-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. The
I
engine identification numbers are stamped into
Muffler is extremely hot.Keep the blower housing behindthe air cleaner.Model
children and pets away. 47PF5 engines built for 1986 have the engine
identification numbers stamped in the blower
housing above the spark plug. Engine models
MAINTENANCE 47PE4 and 47PF5 have serial numbers that start
with the number 1,2 or3.The number 1 indicatesa
19. Before the mower is serviced or adjusted, zone start application. The number 2 indicates
stop the engine andremove the key fromthe BBC application and the number 3 indicates
switch. Disconnectthe high tension wire from commercial application.
the spark plug to prevent the possibility of
accidental starting. The chassisidentification numbers are located on
20. Toassurethe mower is in safe operating a decal on the ofbackthe mower housing, between
condition, keep all nuts, bolts andscrews the rear wheels.
tight. Assurethe blade capscrew is tightened In any correspondence concerning the mower,
to the proper torque. supply the model and serial numbers to assure
21. If major repairs are ever needed or if assis- that thecorrect information and replacementparts
tanceis desired, contact an Authorized are obtained. Genuine TORO replacement parts
TORO Service Dealer. may be ordered throughyour local TORO Autho-
22. If the mower must be tipped when it is rized Service Dealer.
serviced or adjusted,drain the gasoline from
the fuel tank. TWO-CYCLE ENGINE THEORY AND
OPERATION
23. If a guard, safety device or safety decal is
damaged, replace the defective part(s) be- Theory
fore operating the mower. Two-cycleengines have special advantages
24. To reduce potential fire hazards, assure the which make their use more practical in certain
mower is free of excessive grease,grass, applications. Two-cycle engines arelightweight
leaves and accumulationsof dirt. with an excellent power to weightratio and can
25. The grass bag must always be in good con- beoperated in any position. They are also
dition; therefore, check it before each use to notably easy to maintain and service because of
assure the bag is not torn or deteriorated. their uncomplicated design.
Always replace a defective grass bag. The TOROTwo-cycle Engine usedon the TORO
26. Allow the engine to cool before storing the Rotary Mowers is a third-port, loop scavenged
mower in any enclosure suchas a garageor design. This design name describes the path of
storage shed. Do not store the mower near the fuel / air mixture into the crankcase and com-
any open flameorwhere gasoline fumes bustion chamber, and the exhausting of spent
may be ignited by a spark. gases.
27. Do not overspeed the engine by changing In a loop-scavengeengine, a high pressure area
the governor settings. Recommended speed is created in the crankcase by the downward
of the engine is 3000 rpm. To assure safety movement of the piston. Pressurizedfuel-air
andaccuracy, have anAuthorized TORO mixture rushesinto the combustionchamber
Service Dealer check the engine speed with through the intake ports and is directed toward
a tachometer. the cylinder head. This fresh mixture then strikes
28. At the time of manufacture the mower con- the cylinder head and loops down forcing burnt
formed to the safety standards in effect for gases in the combustion chamber out through
1-2
the exhaust ports. The third port design engine gases begin to beexpelled 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. All ports Intake Ports Closed
within the engine areopened and closed by the
piston skirt as the piston moves up and down Exhaust Port
within the cylinder.
Operation
The piston closes all engine ports as it moves
toward the combustion chamber(Figure 1-1). The
moving piston creates ahigh pressure in the com-
bustion chamber and a partial vacuum in the
crankcase.
Figure 1-3
At a point of piston travel slightly before bottom
dead center (BBDC) the fuel transfer ports, on the
sides of the cylinder walls, are uncovered and
the compressed fuel/air mixture in the crankcase
Co
-is allowed to enter the combustionchamber
wherethey help expel theburnt gases and
charge the chamber for the followingpiston
stroke (Figure 1-4).
\
__-__
Figure 1-4
Figure 1-5
Operation
When starting the engine, an extra rich mixture is
required. The choke plate is closed by the opera-
tor to provide an approximate 8:1 ratio of fuel to
air for this rich mixture. Closing the choke plate
further reducesthe air pressurearea inthe
venturi to increase the fuel drawn into the car-
buretor bore. In this condition fuel is drawnfrom NO LOAD
the float bowl through the pilot system ports as Figure 1-7
well as the main discharge tube to achieve the
proper starting mixture (Figure 1-6). As the throttle plate opened
is to compensate for
loads the engine is being placed under, the main
discharge tubebecomes the main source of fuel.
Pilot System
Pilot Jet Opening the throttle plate increases the flowof
Pilot Air Fitting air through the venturi and strengthens the low
pressure area at the main discharge tube. Fuel
discharge increases at the main discharge tube
as it decreasesfrom thepilot system. Air is
drawn from the air correction jet through holes
along the length of the main discharge tube. This
pre-mixes air with the fuel before it enters the
carburetor bore for more efficient atomizing of
:he fuel (Figure 1-8).
/pilot System
COLD START
Figure 1-6
Fuel atomization becomes more efficient, due to
heat, oncetheengine has reachednormal
operating temperature. As a result, the engine
doesnotrequirethe rich mixtureit did for
starting and the choke plate must be moved to
the open position. The engine speed is now
regulated by the throttleplate. In no load condi-
tions a small portion of the fuel may be drawn Float Bowl
UNDER LOAD
from the main discharge tube, however the pri-
mary fuel supply is drawn from the pilot circuit. Figure 1-8
1-4
ENGINE SPECIFICATIONS ~ - - -
Model 47P22 47PD3
Type cycle, 2 single cylinder piston
ported, aircooled
Rotation (viewed
from output end) Counter-clockwise
Displacement cc121in) cu.
(7.38 ~-
Bore 58
(2.28
mm in)
Stroke in) (1.81 46 mm
Crankshaft (.98in)
mm24.9 forged steel
Rated Output 3.5 Hp @ 3600 RPM
(5.28
kg-mTorque
.73 ft-lb) @ 3000 RPM
Compression Ratio 6: 1
Compression 8.4kps/cm2 20 psi) to
10.5 kps/cm (1 50 psi)
Gas-Oil Ratio 50:1
Gasoline Unleaded Regular
T
Oil T O
2 cycle oil
Fuel Tank Capacity 1.89 I (2 qt)
Air Cleaner Two stage foam element
Carburetor Mikuni BV-15std. main jet #80 #76.3
High Altitude Jet #77.5 --
#72.5
Governor
-~ Mechanical Flyweight
Spark NGK-
BPMR4A
*The black float may be used on these engines as a replacement. Part number
81-0970.
(.032in)
Figure 2-1
Figure 2-4
Condenser I
Cam Follower
Figure 2-7
IGNITION COIL
Whenever the flywheel is exposed the ignition
coil condition and air gap should be checked.
Inspect the ignitioncoil foracracked casing, loose
laminations,damaged wires and over heating.The
Figure 2-6 ignition coil air gap.38-50is mm (.015-.020 in). A
non-metallic flexible gauge suchas shown in the
CONTACT POINTS AND CONDENSER Special Tools Section should be used. Toadjust,
MODEL 47P22 ONLY rotate the flywheel magnets away from the igni-
tion coiland loosenthe two ignition coil retaining
The contact points and condenser do wear out
capscrews. Insert the gauge between the coil
through use and their performance level is
laminations and the flywheel (Figure 2-8).Tighten
affected by dust, moisture and
corrosion. Inspec-
the retaining capscrews to hold the adjustment.
tion of these components requires removal of the
flywheel.
(See Disassembly Instructions.) With the flywheel
removed, inspect for wear of the cam follower
and burning or pitting of the contact points. The
surface of the contact points should have a grey,
frosted appearance if wearing normally. If the
contact points are cratered orhave surface
buildup they should be cleaned or replaced. The
contacts can be cleaned with an electrical sol-
vent and contact point sandpaper. Ensure thatall
dust and dirt is removed after sanding. Cratering
of the points indicates the condenser may be
faulty.Verify the condition ofthe condenser
through tests with anignition analyzer. If an
analyzer is not available the condenser must be
considered faulty and shouldbe replaced. When Figure 2-8
11-3
The ignition coil contains two separate windings GOVERNOR
inside the coil casing (Figure 2-9). Use an Ohm- The governor linkage is factory preset to regu-
meter to check the resistance levels of each wind- latetheenginespeed at 3000 150 RPM.
ing. Tocheck theprimary winding,disconnect the Check the adjustment of the governor if the
ignition switch wire and connectthe positive lead engine is suspectedof improper speed. To gain
of the Ohmmeter to the ignition coil lead. Connect access to the governor linkage removal of the
the negative lead to the engine frame (ground).The air cleaner is recommended. (See Disassembly
primary winding resistance is ohms (Rxl Instructions.) Beforeadjusting the governor,
scale). To check the secondary winding, disconnect inspect the control linkage forbent, broken and
the high tension wire at the spark plug. Connect worn parts. Loosen the governor arm clamping
the positive lead of the Ohmmeter to the high ten- bolt and use ascrewdriver to spread the gover-
sion wire. Connect the negative lead to the engine nor arm clamp (Figure 2-1 1).
frame (ground). The secondary coil resistance
should be 5800-7940 ohms ( R x l 000 scale). The
ignition coil must be replaced if the resistance
levels areincorrect.
Primary Coil
ohms Secondary Coil
5800-7940 ohms
(R x 1000 scale)
Figure 2-11
Ground Model 4 7 P 2 2
High Tension
Wi
Figure 2-12
CAUTION: Thegasolinein
thefueltankisexplosive.
Alwaysdrain or fill tankoutdoors,
awayfromfireandflame. Do not
smoke when fuel vapors are present.
Fuel Cap
Governor
Spring
PilotJet
Engine Model
47PD3,47PE4,47PF5
Carburetor
Standard Main Jet
ToroPart No. 81-1940
High Altitude Main Jet
Toro Part No. 81-2340
Needle Valve
Float Pivot Pin
Figure 2- 18
Kill Switch
Bracket
111-3
ENGINE TROUBLESHOOTING CHART The possible causes have been arranged with
The following troubleshooting chart lists the the most easily inspected items to be checked
symptoms,causes and remedies of common listed first. Utilizing the chart in this manner Will
engine malfunctions. Once the symptom lessen the amount Of time required torepair the
beendetermined, systematically eliminate the engineandlimitthepossibility Of incorrectly
possible causes until the actual cause is found. diagnosing the cause of the difficulty.
SYMPTOMS
_Check
_ - lines for restriction
Clean or replace filter
Squeeze oil from filter
excess
Reseal crankcase andreplace seals
Readjust See page 11-4
Replace needle____-._-
Repair or replace _-
Replace ignition coil
Replace flywheel
111-4
IV. ENGINE REMOVAL, DISASSEMBLY ASSEMBLY AND
REPAIR INSTRUCTIONS iS
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
componentsbelow the mower deck fromthe
engine crankshaft. Remove the four capscrews
that retain the engine to the mower chassis and
remove the engine from the mower. The engine
can then be placedin a supportfixture for repair.
Most common repairs, however, can be accom-
plished with the engine in place on the mower
chassis.Use the following procedures to dis-
assemble the engineon the mower chassis:Spring Center Pawl Spring
/-
Pawl Retainer-
ENGINE DISASSEMBLY AND REPAIR
1. Remove the high tension wire from the spark
plug and drain the fuel from the fuel tank.
Figure 4-1
A CAUTION:Thegasoline
the fuel tank is explosive.
Alwaysdrain
awayfrom
or fill tankoutdoors,
fire andflame.Donot
in 3. Disconnect the fuel line from the carburetor.
Remove the fuel tank by lifting it from the
mounting tabs of the blower housing.
4. Remove the capscrew,two nuts and lock
r -
smoke when fuel vapors are present. washers which retain the muffler and remove
the muffler from the engine. The heat shield
may also be removed from the muffler. Dis-
card the mufflergasket and removeany
2. Remove the four retaining capscrews from gasket material remaining on the engine or
the recoil starter and lift the starter from the muffler.
engine. Disconnect the recoil rope from the 5. Lift the retaining tabs ofthe air cleaner cover
rope handlestop for ease ofhandling. andremove the coverand filter element.
RECOIL STARTER REPAIR Remove the capscrew,andtwo locknuts
A. Remove the center capscrew from the retaining the air cleaner housing and liftthe
recoil assembly and lift off the pawl re-. housing fromthe engine.
tainer.Remove the centerspring, pawl 6. Remove the remaining three capscrews from
andpawl spring. Lift the rope pulley the blower housing andlift the blower hous-
assembly from the recoilhousingand ing from the engine.
remove the recoil spring and retainer 7. Cage the spring activated engine brake by
(Figure 4-1). compressing and retaining the control bar
B. Replace all worn ordamaged parts before against the operating handle.Removethe
reassembling.Reassemble therecoil capscrew holding the ignition switch and
starter in reverse order. Use Threebond brake assembly in place. Disconnect the
#1342 or Loctite #242 on the threads of ignition switch from the electrical lead and
the center capscrew during reassembly remove the switch fromthe brake assembly.
and torqueto 80-90Kg-Cm(70-1 10 in-lb). Slowly lower the control bar to disengage
On installation there should be sufficient the brake. The brake assembly may now be
spring pretension to hold the recoil rope disconnectedfrom the controlcable for
taut in the rope pulley. repair.
8. Use a starter cup wrench as shown in the
NOTE: Place asmall amount of #2 grease onthe Special Tools List to hold the starter cup
recoil spring to prevent rust and corrosion. while loosening the flywheel nut. Hold the
IV- 1
flywheel by hand and remove the three re- IMPORTANT:NO OTHER PARTSARESERVICE-
maining capscrews retaining the starter cup ABLE. DISASSEMBLYOF THE THROTTLE AND
to the flywheel. (Itmay be necessary to insert CHOKE PLATESIS NOTRECOMMENDED.THE
a screwdriver through the starter cup to hold SCREWS AREFACTORYTORQUED AND
the flywheel should the capscrews be ex- LOCKED IN PLACE.IF NOT PROPERLY REAS-
tremely tight.) SEMBLED THE SCREWS MAY LOOSEN AND
CAUSE ENGINE DAMAGE.
IMPORTANT: DO NOT DEFORM THE
STARTER CUP ORSTARTER ENGAGE- D. Reassemble the carburetor in reverse
MENT DIFFICULTY MAY RESULT. order.The carburetor and work area
9. Use the flywheel Duller listed in the Special should be clean to prevent contamination
Tools Section to pull the flywheel from the entering the small orifices in the carbu-
crankshaft. retor body.
IMPORTANT:DONOT PRY ONTHEFLY- 14. Remove theretaining capscrew, lockwasher,
WHEEL CASTING OR STRIKE THE CRANK- anti-scalp cup if applicable, blade, blade
SHAFT OR DAMAGE WILL RESULT. adapter, and self-propel components from
10 Remove the capscrews retaining the contact the crankshaft. Remove the four capscrews
point cover and liftthe cover from the engine. retaining the engine to the mower chassis
Remove the small nut retaining the electrical and liftthe engine from the mower.
wires to the contact point assembly. Remove 15. To gain access to the components inside the
the two ignition coil hold down screws and crankcase remove the four capscrews re-
lift the ignition coil and wire harness from the taining the engine tothe mower adapter
engine. plate and remove the adapter plate from the
11 Remove the two screws holding the points engine. Removethe six retaining capscrews
and condenser in place and lift the points holding the two halves of the crankcase
and condenser from the engine. Removethe together and separatethecrankcase.
flywheel key from the crankshaft and slide 16. Remove the crankshaft and piston as an
the timing cam from the engine. There is a assembly. Remove the seals, bearing locat-
small locating pin for the cam. Take care so ing rings, and bearings from each end of the
that this pin isnot lost. crankshaft. Slidethegovernor assembly
12. Loosen the clamping bolt on the governor from the crankshaft taking care not to lose
lever and pry the clamping section of the the small locating pin for the governor fly-
lever apart with a screwdriver. Remove the weight collar.
lever, controlrodandsprings from the 17. To remove the piston from the connecting
engine. rod use a needle nose pliers and remove one
13. Disconnect the choke cable from the car- of the wrist pin retainers. Slide the wrist pin
buretor and slide the carburetor, spacer and out of the piston far enough to allow the
gaskets fromthe mounting studs. piston to be removed from the connecting
rod. The needle bearing may be removed
IMP0RTANT: DO NOTREMOVETHECHOKE from the connecting rod, however, there are
SHAFT SCREW OR THE THREADS MAY
BE- no further serviceable parts on the crank-
COME STRIPPED. shaft assembly.
IMPORTANT: THE THREEPIECE CRANK-
CARBURETOR REPAIR SHAFT IS ASSEMBLED AT THE FACTORY
A. Drain the fuel from the carburetor bowl TOPRECISIONTOLERANCES. ATTEMPT-
by removing the bowl nut, washer and ING TO DISASSEMBLE THE CRANKSHAFT
bowl. The bowl seal may be replaced FURTHER WILL RESULT IN CRANKSHAFT
using a seal pick if fuel leakage is noted DAMAGE.
on the carburetor bowl. 18. The wrist pin and piston rings may be re-
B. One end of the float pivot pin is moved from the piston for replacement. The
purposely deformed to lock the pin into top ring is made of cast iron with a chrome
the casting legs. Visually determine plating on the outside diameter.
which end is deformed and drive the pin
IMPORTANT:USECAUTIONWHENRE-
from the opposite end. Removethe pivot
MOVINGTHERINGS. OVER-STRETCHING
pin, float, needle valveand spring
THERINGSWILLRESULT IN DIFFICULTY
retainer from the assembly.
DURING ENGINE REASSEMBLY.
C. The main jet and the pilot circuitjet can
be removed for inspection using a flat 19. Remove the governor shaft E-ring and flat
blade screwdriver. washer and slide the governor shaft out of
IV-2
the crankcase. Usea seal pick toremove the two-cycle oil and install onto either end
of the
governor shaft seal. crankshaft. Insert the bearing locating rings
NOTE: The cylinder contains a cast iron sleeve, into the slots of the crankcase housing to
however, this sleeve is not replaceable. The locate the bearings and crankshaft in position. n
purpose of the sleeve retainer ring is to assist the Removeburrsfromeitherendofthecrankshaft
manufacturing process and hold the cast iron and slide seals into position. To prevent seal
sleeve in place to limit engine damage should damage on installation use a small amount of
the sleeve loosen during operation. #2 grease onthe inside diameter of the seal.
Both seals should be installed with thelipfac-
Engine Assembly And Repair ing into thecrankcase assembly.
NOTE: Before attemptingto reassemblethe engine
refer to the
Service Data Specifications (page IV-4)
and replace all parts which are outside the recom-
mended values.
r-
1. Ensure there are no burrs on the governor
shaft which could cause seal damage and
position thegovernor shaft through the hole
in thecrankcase casting. Use aliberal
amount of#2 grease andinstall the governor
shaft seal with the lip towards the inside of
the crankcase. Position the flat washer on
the governorshaft against the shaft seal and
install the E-ring.
2. Install the two piston rings onto the piston.
The chrome surfaced ring should be posi- Figure 4-2
tioned at the top of the piston. There is a
small letter ‘R” stamped on the top side of 5. Assure both halves ofthe crankcase are clean
each piston ring. This letter should face the and free of grease andold sealant. Applya thin
top of the piston. If the piston ring is put in uniformamount of Threebond #1104 or Loc- P
upside down it will not seat properly in the tite #515 sealant to the mating surfaces and
ring groove. Lubricate the wrist pin needle position of the crankcase halvestogether.
bearing with two-cycle oil and insert into the
6. There are three different size capscrews on
connecting rod. Position the pistonover the
the model 47PZ2to hold the crankcase halves
connectingrodand insert the wrist pin
together.(Thecapscrewsonthe47PD3,47PE4
through the piston, needle bearing and pis-
and 47PF5 are all the same length). Starting on
ton rod. Insert the spring retainers to lockthe
the governor control shaft side install the two
wrist pin in place.
medium sized capscrews ateither end. Install
IMPORTANT: THE ARROW CAST INTO THE one short capscrew and governor spring
TOP OF THEPISTON MUST FACETHE bracket in thecenter hole. Install the other two
EXHAUST PORT WHEN ASSEMBLED. remaining short capscrews into theother side
3. Lubricate the moving parts and friction sur- in the center hole and the hole nearest the
faces of the crankshaft and piston with two- large end of the crankshaft. Install the long
cycle oil.Rotate the piston rings until the ring capscrew in the remaininghole. Torque all
gap aligns with the locating studs before capscrews evenly80-95 Kg-Cm(70-110 in-lb).
attemptingtopushthepistonintothe See Figure 4-3. Position the engine mower
cylinder. Insert the crankshaft and piston
assembly into the cylinder.
IMP0RTANT:ASSURETHEARROWONTOP
OF THE PISTON FACES EXHAUST PORT
WHEN ASSEMBLED.
4. Lubricate the large end of the crankshaft
with two-cycleoil andinstallthesliding
governor collar. Insert the small locating pin
into the crankshaft and slide the flywheel
collar into position. Position the fly weights
on the lip of the governor collar and locate
47P22 Only
the control shaft between the collar and the Torque Capscrews to 80-95 K a C m (70-1 10 in-lb).
crankshaft assembly(See Figure 2-13 and
4-2). Lubricate the crankshaft bearings with Figure 4-3
IV-3
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).
7. Install the ignition cam and locating pin to the 12. Cage the engine brake spring by lifting the
flywheel end of the crankshaft. Install the con- control bar intothe handle andretaining it in
denser andpointsin position. Rotate thecrank- place. Install the ignition switch, brake assem-
shaft until thecam followeris on the high point bly and brake padon theengine. Releasethe
of the cam. Adjustthe point gap using a feeler control bar and connect the ignition switch
gauge of the appropriate size to set the air gap wire. (47PZ2 and zone start models only.)
at .35mm (.014 in). (47PZ2engine only.)
IMPORTANT: CHECK FOR PROPER OPER-
8. Install the ignition coil loosely on the mount- ATION OF THEIGNITIONSWITCH AND
ing posts.Connect the double lead to the BRAKEASSEMBLY(See Troubleshooting
contact point assembly (47PZ2 engine only), Section page 111-1).
making sure the wires are routed between
the ignition coil mounting posts. The single 13. Place the blower housing onthe engine and
lead should be routed along side of the attach with one capscrew in the front and
crankcase housing through the hole in the another in the rear.
casting. The ignition coil air gap setting will NOTE:USECAUTION IN ROUTINGTHE
be adjusted later. HIGHTENSIONWIRE SO THATITDOES
NOTBECOMEPINCHEDBETWEENTHE
9. Place the gasket, spacerand the second gas- BLOWER HOUSING AND THE ENGINE.
ket overthe mounting studs of the carburetor.
See Figure 2-18for correct gasket and spacer 14. Place the mufflerand muffler gasket overthe
placement. Slide the carburetor onto the engine studs. Install the through-bolt, nuts
mounting studs. Assemblethe governor con- and lock washers on the muffler and tighten
trol lever, linkage and springs to the governor to the recommended torque.
shaft and the carburetor throttle plate. Move
the governor shaft to the right and rotate the 15. Connect the choke cable to the carburetor
governor shaftto theright. Tighten theclamp and camp the cable in place on the blower
bolt to hold the adjustment. housing. Install the air cleaner housingto the
carburetor mounting studs using the ap-
10. Install the contact point cover (47PZ2engine propriate nuts. Install the through-bolt and
only), flywheel key and flywheel to thecrank-
tighten the boltand nuts to the recom-
shaft. Installthestartercupwith thecapscrews
mended torque. Position the filter element in
and torque 80-90to Kg-Cm (70-1 10 in-lb). Use place and install the air cleaner cover. En-
the starter cup wrench to hold the flywheel
sure the cover snaps firmly in place.
from turning and tighten the’retaining nut on
the end of crankshaft to 4-5 Kg-m(29-36f3-lb). 16. Slide the fuel tank into position and connect
Use the air gap gauge listed in the Special the fuel line to the carburetor. Attach the
Tools Section and adjust the air gapbetween recoil assembly using the four capscrews
the flywheel and ignition coil laminations to .5 required and route the starter rope through
mm (.020 in) maximum. the handle stop on the mower handle.
11. Attach the engine to the mower chassis and 17. Install thespark plug and attach the high
install the blade components to the engine tension wire.
IV-4
Exhaust Port
Intake Port
Cylinder bore
The cylinder bore is checked by measuring the
cylinderliner at a total ofsix places using a
cylinder gauge. Two measurements, apart, Third Port
must be taken at the approximate A, 6 and C
elevations as shown. Readings larger than the
listedspecificationsindicatean excessively
worn bore and the cylinder block must be re-
placed. The cylinder liner is not a serviceable
Cylinder Bore Diameter
part of the engine. 58.000-58.115mm
(2.284-2.288 in)
-
Wrist Pin Wrist Pin Hole /--
The wrist pin andwrist pin holemust be properly
fitted for efficient engine performance. Measure
the wrist pin and check the diameter of the piston
holes to be no more than the oversize dimension
indicated.
Wrist Pin Diameter Maximum Hole Diameter
11.955-12.005mm (.472-.473 in) .050mm (.002 in) Oversize