Tecumseh TC Series Technician's Handbook
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Tecumseh TC Series Technician's Handbook

Tecumseh TC Series Technician's Handbook

Tc series 2-cycle engine
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TECUMSEH
T E C H N I C I A N ' S
H A N D B O O K
This manual covers all TC, TCH 200 & 300 models.
Other illustrated Tecumseh 2-Cycle Engine, 4-Cycle Engine
and Transmission manuals; booklets; and wall charts are
available through Tecumseh.
For complete listing write or call
TC SERIES
2-Cycle
Engines
Not For Resale
www.SmallEngineDiscount.com

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Summary of Contents for Tecumseh TC Series

  • Page 1 T E C H N I C I A N ' S H A N D B O O K This manual covers all TC, TCH 200 & 300 models. Other illustrated Tecumseh 2-Cycle Engine, 4-Cycle Engine and Transmission manuals; booklets; and wall charts are available through Tecumseh.

  • Page 2: Table Of Contents

    OPERATION ............................. 6 FUEL PRIMERS ............................7 COMPONENTS ............................7 TILLOTSON CARBURETOR ........................8 TROUBLESHOOTING ..........................9 TROUBLESHOOTING CARBURETION - TC SERIES ..............10-11 TESTING ..............................12 SERVICE ..............................12 CARBURETOR PRE-SET AND ADJUSTMENT ..................12 FUEL TANK SERVICE ........................... 13 CARBURETOR DISASSEMBLY ......................
  • Page 3 CHAPTER 6 IGNITION ....................... 21 GENERAL INFORMATION ........................21 OPERATION ............................21 COMPONENTS ............................21 TROUBLESHOOTING ........................... 22 TESTING ..............................23 SERVICE ..............................23 AIR GAP SETTING ..........................23 SPARK PLUG SERVICE ........................23 CHAPTER 7 INTERNAL ENGINE AND CYLINDER ............24 GENERAL INFORMATION ........................

  • Page 4: Chapter 1 General Information

    INSTRUCTIONS. OIL REQUIREMENTS TECUMSEH RECOMMENDS USING TWO CYCLE OIL PART #730227, which is a premium blend that ensures cylinder wall lubrication, mixes easy, does not separate and is specially formulated for use in air or water cooled two cycle engines.

  • Page 5: Fuel Requirements

    FUEL ADDITIVES Only fuel additives such as Tecumseh's fuel stabilizer part number 730245 or liquid varieties can be used when mixed properly. For winter applications, Isopropyl alcohol fuel dryers may be used in the fuel system but must be mixed at the proper ratio recommended by the manufacturer.

  • Page 6: Storage

    To prevent deposits from forming, all gasoline must be removed from the fuel tank and the carburetor. An acceptable alternative to removing all gasoline is adding a fuel stabilizer to the gasoline such as Tecumseh part number 730245. A fuel stabilizer is added to the fuel tank or storage container. Always follow the mix ratio and mixing procedure found on the stabilizer container.

  • Page 7: Chapter 2 Air Cleaners

    Tecumseh engines use either a polyurethane or a paper type air filter system. A polyurethane pre-filter or a flocked screen may be used in conjunction with the main filter. Extremely dirty operating conditions may require frequent filter cleaning or replacement.

  • Page 8: Paper Filter Removal And Replacement

    Paper Filter Removal and Replacement 1. Remove the polyurethane pre-filter (if equipped) from the air filter. Poly Pre-Filter 2. Inspect the filter(s) for discoloration or dirt accumulation. (For the polyurethane pre-cleaner service see step # 5 under "Polyurethane Filter Removal and Service"). If either condition is present, replace the paper type filter using the following steps.

  • Page 9: Chapter 3 Carburetors And Fuel Systems

    (maintaining the proper fuel level in the carburetor) as the float. A limited number of TC engines were produced as outboards using a Tecumseh Series II float style carburetor. Consult the Two Cycle Technician's Handbook (part # 692508) if service is required on this series of carburetor.

  • Page 10: Fuel Primers

    At high speed operation, the throttle shutter is in a full open position. The air velocity through the venturi increases Fuel which further lowers the air pressure at the main fuel Impulse discharge port. All discharge ports are supplying fuel as Intake Air the adjustment orifices will allow (diag.

  • Page 11: Tillotson Carburetor

    TILLOTSON CARBURETOR 1. Diaphragm Cover Screw 2. Metering Diaphragm Cover 3. Diaphragm 4. Diaphragm Gasket 5. Metering Lever 6. Metering Lever Screw 7. Metering Lever Pin 8. Metering Lever Spring 9. Inlet Valve Needle 10. Air Vane 11. Air Vane Screw 12.

  • Page 12: Troubleshooting

    ENGINE TROUBLESHOOTING Engine Will Not Start See Chapter 6 Check For Spark under "Troubleshooting" Check If Spark Plug Is Wet or Dry Check Fuel Supply and Fuel Cap Defective Spark Plug Vent Restriction in Fuel System Restricted Air Filter (filter, screen) Carburetion Problem Improper or Stale Fuel Carburetion Problems Due to...

  • Page 13: Troubleshooting Carburetion - Tc Series

    TROUBLESHOOTING CARBURETION - TC SERIES ADJUSTMENTS High FUEL SYSTEM Plugged Tank Filter or Vent Restricted Fuel Line Dirt in Fuel Passage Loose, Damaged Fuel Line Leak in Pulse System Restricted Pulse Channel Loose Pump Cover Screws Defective Pump Diaphragm AIR SYSTEM...

  • Page 14: Troubleshooting Carburetion - Tc Series

    TROUBLESHOOTING CARBURETION - TC SERIES (CONTINUED) METERING SYSTEM LEVER Worn Lever Set Too High Set Too Low Not Free SPRING Distorted Improperly Installed DIAPHRAGM Leaking (Air/Fuel) Worn Button Improper Assembly Defective Gasket Loose Diaphragm Rivet Hole in Diaphragm Loose Cover Screws INLET NEEDLE &...

  • Page 15: Testing

    TESTING 1. After repeated efforts to start the engine using the procedure listed in the operator's manual fail, check for spark by removing the high tension lead and removing the spark plug. Install a commercially available spark plug tester and check for spark.

  • Page 16: Fuel Tank Service

    FUEL TANK SERVICE TC type II engines have fuel tanks with an integral fuel screen and integral outlet fuel fitting. Some TC type I engine models use a pressed in fuel filter or a weighted filter and a flexible fuel line in the tank. Integral screens or fittings are not serviceable.

  • Page 17: Carburetor Inspection

    8. Clean all metallic parts in carburetor cleaner. Do not Note: Punch should be of the exceed 30 minutes soak time. Blow out all fuel same or larger diameter than passages with compressed air. Do not use tag wire to the welch plug.

  • Page 18: Emissions Carburetor Idle Mixture Adjustment Procedures

    11. If applicable, attach the air vane and torque the mounting screw to 3-5 inch pounds (.34 - .57 Nm) (diag. 3-14). 12. Newer style TC series engines use an insulator / spacer between the carburetor and cylinder. That spacer MUST be installed, as shown, for the fuel pump to operate.

  • Page 19: Chapter 4 Governors And Linkage

    GENERAL INFORMATION TC series engines are equipped with pneumatic (air vane) governors. The governor's function is to maintain a R.P .M. setting when engine loads are added or taken away. Air vane governors are controlled by the air velocity created by fins on the flywheel.

  • Page 20: Troubleshooting

    TROUBLESHOOTING ENGINE OVERSPEEDING 1. If the engine runs wide open (faster than normal), shut the engine off or slow it down immediately. 2. Visually inspect the air vane, linkage, carburetor throttle shaft, and speed control for debris blockage, binding, breakage, or incorrect hook-up. Check the governor spring for a stretched or distorted condition. Remove the recoil assembly and / or fuel tank if necessary.
  • Page 21 TYPE II ADJUST GOVERNED HIGH SPEED WITH SPEED CONTROL PLUNGER PULLED BACK AGAINST SPEED ADJUSTMENT SCREW DECREASE INCREASE SPEED ADJUST SCREW AIR VANE MUST ROTATE FREELY AFTER CLIP IS INSTALLED ITEM DESCRIPTION ITEM DESCRIPTION Base - Housing Spring - Governor Body Assy.

  • Page 22: Chapter 5 Rewind Starters

    GENERAL INFORMATION TC series engines have the recoil assembly as a part of the engine's blower housing. Two different styles of recoil starters are used along with different starter rope locations. Use the engine model and specification number to identify the recoil style and correct replacement parts.

  • Page 23: Assembly Procedure

    2. Release the recoil spring tension on the rope by removing the staple or knot in the starter handle and slowly release the rope into the recoil housing (diag. 5-2). 3. Remove the 5/16" retainer screw. On TC Type I starters, remove the pawl retainer, brake spring, and pawl.

  • Page 24: Chapter 6 Ignition

    CHAPTER 6 IGNITION GENERAL INFORMATION All TC engines are equipped with a solid state ignition module mounted outside the flywheel. The solid state ignition system consists of a flywheel magnet, charge coil, capacitor, a silicon controlled rectifier, a pulse transformer, trigger coil, high tension lead, and a spark plug.

  • Page 25: Troubleshooting

    IGNITION TROUBLESHOOTING Engine Runs Erratically Engine Will Not Start Or Shuts Off, Restarts Check For Spark SPARK NO SPARK Check flywheel for damaged Replace spark plug or sheared key Isolate engine and repeat test Set proper air gap on solid NO SPARK SPARK state module...

  • Page 26: Testing

    TESTING 1. Check for spark using a commercially available spark tester and following the tester's recommended procedure. 2. Check the spark plug for cracks in the porcelain, pitted or burned electrodes, excessive carbon build-up and proper air gap setting. Replace if questionable. 3.

  • Page 27: Chapter 7 Internal Engine And Cylinder

    GENERAL INFORMATION TC series engines use two cycle operation. Two cycle engines provide a higher horsepower to weight ratio than the same size four cycle engines. Two cycle engines use two piston strokes for a complete cycle that occurs every crankshaft revolution, while four cycle engines use four piston strokes and two crankshaft revolutions for a complete cycle.

  • Page 28: Troubleshooting

    TROUBLESHOOTING ENGINE OPERATION PROBLEMS ENGINE MISFIRES ENGINE VIBRATES LACKS POWER EXCESSIVELY Wrong or fouled spark plug Air intake obstructed Bent crankshaft Lack of lubrication or improper Attached equipment out of Carburetor improperly adjusted lubrication balance Ignition timing Loose mounting bolts Carburetor improperly adjusted Exhaust Obstructed Excessive carbon build up...

  • Page 29: Troubleshooting

    TROUBLESHOOTING ENGINE OPERATION PROBLEMS ENGINE KNOCKS OVERHEATS SURGES OR RUNS UNEVENLY Excessive engine loading Associated equipment loose or Fuel cap vent obstructed improperly adjusted Check for excessive carbon in Dirty carburetor or air filter Lack or proper lubrication combustion chamber Cooling air flow obstructed or Carburetor improperly adjusted clogged cooling fins...

  • Page 30: Testing

    TESTING ENGINE KNOCKS 1. Check the blade hub, adapter, crankshaft coupler or associated equipment for loose fit, loose bolts, or crankshaft key or adapter damage. Re-install and re-torque the bolts to the proper torque. 2. Check the flywheel key and the flywheel and crankshaft keyway for wear or partial shearing. Replace if any damage is evident.

  • Page 31: Engine Vibrates Excessively

    Engines requiring replacement of the cylinder, cylinder cover, crankcase, or piston and rod assembly may require the replacement of the short block or a complete engine. Consult the Tecumseh Master Technician's Parts Manual using the engine model and specification number for replacement part information.
  • Page 32 5. Remove the fuel tank on TC type I engines by unhooking the tank spring. For TC type II engines, remove the self-locking nut and washer on the blower housing stud and remove the fuel tank. 6. Remove the rewind starter assembly by removing three machine screws (diag.

  • Page 33: Bearing And Seal Service

    17. Turn the crankshaft to the 90° past the top dead center (T.D.C.) position and remove the crankshaft out of the crankcase opening while sliding the connecting rod Needle Bearing Cover off the crankpin and crankshaft. TC type II engines use a pressed in mechanically retained needle bearing in the connecting rod.

  • Page 34: Assembly

    4. Install either a new crankcase cover "O" ring and lightly 7-14 oil if one was originally used, or apply Loctite # 515 gasket sealant eliminator (Tecumseh part # 510334) to the crankcase surface to seal the crankcase cover. Apply a continuous bead of Loctite (.062" [1.57 mm] bead width) on the crankcase surface.
  • Page 35 are staggered and the cylinder is in the correct position. Use fingers to compress the piston rings and push the cylinder onto the piston. Do not rotate or twist the cylinder (diag. 7-16). 11. Install Torx bolts and alternately torque the bolts to 80-95 inch pounds (9.04 Nm - 10.7 Nm), or on engines with studs instead of bolts: push the cylinder down to a depth where the nuts can be started on the studs.

  • Page 36: Assembly

    17. Attach the ignition module, use the proper air gap gauge between the flywheel magnets and the module laminations (TC300 rotary mower applications and all TC 200 models use air gap .0125" (.317 mm) part # 670291. All other TC 300 engine applications use a 030"...

  • Page 37: Chapter 8 Engine Specification And Sears Craftsman Cross-Reference

    CHAPTER 8 ENGINE SPECIFICATIONS AND SEARS CRAFTSMAN CROSS-REFERENCE TC TORQUE SPECIFICATIONS The torque specifications listed in this chart are to be used for replacing components after disassembly, not for checking an existing engine bolt torque. Checking a torque value on a new or used engine may be lower due to torque relaxation that occurs on all engines from thermal expansion and contraction.

  • Page 38: Engine Specifications

    ENGINE SPECIFICATIONS All Dimensions are in inches TC200 TC300 Metric Metric HP (Approx.) 1.19 Kw 1.49 Kw Bore 1.4370 36.49 1.7495 44.43 1.4380 36.52 1.7505 44.46 Stroke 1.25 31.7 1.25 31.7 Displacement (in ) (cc) 32.78 cc 49.17 cc Spark Plug Gap .030 .762 .030...

  • Page 39: Sears Craftsman Cross Reference

    SEARS CRAFTSMAN CROSS REFERENCE 143.681001 TC300 3010A 143.681021 TC300 3013A 143.941600 TC200 2103C 143.961670 TC200 2124D 143.961672 TC200 2103D 143.971670 TC200 2103E 143.971674 TC200 2124E 143.972070 TC300 3153E 143.982070 TC300 3176F 143.982072 TC300 3173F 143.992070 TC300 3187F 200.651001 TC200 2019C 200.681001 TC300 3010A...

  • Page 40: Chapter 9 Educational Materials And Tools

    Except the TC Engine and TVS840. for troubleshooting electrical systems on outdoor power 692509 equipment. Covers the diagnosis and repair of the Tecumseh 4-cycle 695285 An in-depth look at the 800 series transaxles. Detailing light/medium frame engines. the teardown and reassembly procedures for the 800, 801 691462A and 820 transaxles.
  • Page 41 TOOLS FLYWHEEL PULLER 670299 STRAP WRENCH 670305 1/4" HEAVY GAUGE WIRE HOOK FOR REMOVING (6.35 mm) MUFFLER SPRINGS 12" LONG (309 mm) PISTON AND ROD HOLDER A piece of 3/8" (9.5 mm) wood, 1-1/2" (38.1 mm) wide by 4" (101 mm) long with a slot 3/8" (9.5 mm) wide by 2" (50 mm) long cut out of the center will hold the piston and rod.
  • Page 42 ENGINE HOLDER 670300 To assist in reassembly of the engine block and it's components an Engine Holder, part number 670300, has been developed. Attach to the crankcase of the engine with the blower housing base screws and insert the other end into a bench vise to hold crankcase while inserting engine components.
  • Page 43 Torx 25 670319 Torx 30 670320 SPECIAL PART 510334 Loctite Gasket Sealant Eliminator No. 515 will be sold by Tecumseh under the part number 510334. VIBRATION TACHOMETER 670156 METERING LEVER GAGE 670325 Used to set carburetor metering lever. Not For Resale...

This manual is also suitable for:

Tc 200Tc 300Tch200 -Tch300 -

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