Toro 20107, 20210, 20325, 20324, 20328B Service Manual
...
OHV GTS 150 ENGINE SERVICE MANUAL
Table Of Contents – Page 1 of 4
PREFACE
SAFETY INFORMATION
SAFETY TIPS
SPECIFICATIONS
GTS 150 ENGINE SPECIFICATION
GTS 150 CARBURETOR SPECIFICATIONS
GTS 150 FASTENER TORQUES
TOOL REQUIREMENTS
TROUBLESHOOTING
ENGINE DOES NOT START WHEN "COLD"
ENGINE WILL START "COLD", BUT WILL NOT START "HOT"
ENGINE DOES NOT PRODUCE SPARK
ENGINE HAS LOW COMPRESSION
ENGINE FLOODED WITH FUEL
ENGINE LACKS POWER
BENT PUSH ROD
ENGINE SURGING
ENGINE BACK FIRES
ENGINE AFTER FIRES
ENGINE OVERHEATS
ENGINE VIBRATES EXCESSIVELY
ENGINE CRANKSHAFT WILL NOT TURN
ENGINE PRODUCES MECHANICAL KNOCKING SOUND
PRE-IGNITION
ENGINE SMOKES EXCE SSI VE L Y
ENGINE STALLS
SPARK PLUG FOULED
GTS 150 MAINTENANCE
SERVICING AIR CLEANER
REPLACING THE SPARK PLUG
REMOVING GASOLINE FROM THE FUEL TANK
CHANGING CRANKCASE OIL
CARBURETOR - ADJUSTMENT
COMPRESSION - MEASUREMENT
THROTTLE - ADJUSTMENT
CLEAN THE ENGINE AND RECOIL STARTER
CLEAN THE COOLING SYSTEM
PREPARING THE ENGINE FOR STORAGE
OHV GTS 150 ENGINE SERVICE MANUAL
Table Of Contents – Page 2 of 4
SECTION I CARBURETOR
CARBURETOR DESCRIPTION
CARBURETOR THEORY AND OPERATION
CARBURETOR - REMOVAL
CARBURETOR - PRESSURE TESTING
CARBURETOR - DISASSEMBLY
CARBURETOR - CLEANING AND SERVICE
CARBURETOR - ASSEMBLY
CARBURETOR - ADJUSTMENT
SECTION 2 FUEL SYSTEM
FUEL TANK - OPERATION
FUEL TANK - REMOVAL
FUEL TANK AND FILTER - CLEANING
FUEL CAP - OPERATION
FUEL CAP - SERVICE
FUEL HOSE - REMOVAL
FUEL HOSE - INSTALLATION
SECTION 3 IGNITION
OPERATION
IGNITION OPERATION - FLYWHEEL
IGNITION OPERATION - IGNITION ARMATURE COIL
IGNITION OPERATION - SPARK PLUG
ARMATURE COIL WIRING - OPERATION
AIR GAP - ADJUSTMENT
IGNITION ARMATURE COIL - REMOVAL
IGNITION ARMATURE COIL - TESTING
IGNITION ARMATURE COIL - INSTALLATION
SECTION 4 REWIND STARTER
REWIND STARTER - OPERATION
REWIND STARTER- DISASSEMBLY
REWIND STARTER - ASSEMBLY
REWIND STARTER - INSTALLATION
OHV GTS 150 ENGINE SERVICE MANUAL
Table Of Contents – Page 3 of 4
SECTION 5 ENGINE
ENGINE - OPERATION
INTAKE STROKE
COMPRESSION STROKE
POWER STROKE
EXHAUST STROKE
ENGINE DISASSEMBLY
AIR CLEANER - OPERATION
AIR CLEANER - REMOVAL
REWIND STARTER. OPERATION
REWIND STARTER - REMOVAL
BLOWER SHROUD - REMOVAL
MUFFLER SHROUD - REMOVAL
FLYWHEEL BRAKE - OPERATION (IF INSTALLED)
FLYWHEEL BRAKE - REMOVAL (IF INSTALLED)
FUEL TANK - OPERATION
FUEL TANK - REMOVAL
MUFFLER - OPERATION
MUFFLER - REMOVAL
DIPSTICK AND OIL FILL TUBE - REMOVAL
CARBURETOR - OPERATION
CARBURETOR - REMOVAL
IGNITION COIL - OPERATION
IGNITION COIL - REMOVAL
THROTTLE BRACKET - REMOVAL
ALTERNATOR - OPERATION
ALTERNATOR - REMOVAL (IF INSTALLED)
FLYWHEEL - REMOVAL
ELECTRIC STARTER - OPERATION
ELECTRIC STARTER. REMOVAL (IF INSTALLED)
THROTTLE CONTROL LEVER AND LINK ROD - REMOVAL
VALVE COVER- REMOVAL
HEAD ASSEMBLY - REMOVAL
HEAD - DISASSEMBLY
VALVES AND SEATS - RECONDITIONING
BREATHER - OPERATION
BREATHER - REMOVAL
OIL PUMP - OPERATION
OIL PUMP - REMOVAL
SUMP - REMOVAL
GOVERNOR AND SPLASHER - OPER ATION
GOVERNOR AND SPLASHER - REMOVAL
CAMSHAFT - OPERATION
CAMSHAFT- REMOVAL
COMPRESSION RELEASE - OPERATION
COMPRESSION RELEASE - REMOVAL
CRANKSHAFT- REMOVAL
PISTON AND CONNECTING ROD - OPERATION
OHV GTS 150 ENGINE SERVICE MANUAL
Table Of Contents – Page 4 of 4
SECTION 5 ENGINE - continued
PISTON AND CONNECTING ROD - REMOVAL
PISTON RINGS - REMOVAL
PISTON PIN - REMOVAL
GOVERNOR ARM - REMOVAL
ENGINE ASSEMBLY
PISTON PIN - INSTALLATION
PISTON RING - INSTALLATION
PISTON - INSTALLATION
CRANKSHAFT - INSTALLATION
GOVERNOR SHAFT - INSTALLATION
CAM FOLLOWERS - INSTALLATION
CAMSHAFT - INSTALLATION
GOVERNOR/SPLASHER- INSTALLAT ION
SUMP - INSTALLATION
0IL PUMP - INSTALLATION
BREATHER - INSTALLATION
HEAD - ASSEMBLY
PUSH RODS - INSTALLATION
HEAD - INSTALLATION
VALVE CLEARANCE - ADJU ST MENT
VALVE COVER - INSTALLATION
THROTTLE BRACKET - INSTALLATION
GOVERNOR CONTROL LEVER AND LINK ROD - INSTALLATION
CARBURETOR - INSTALLATION
GOVERNOR - ADJUSTMENT
ELECTRIC STARTER - INSTALLATION
FLYWHEEL - INSTALLATION
ALTERNATOR - INSTALLATION
IGNITION ARMATURE COIL - INSTALLATION
FLYWHEEL BRAKE - INSTALLATION (IF REQUIRED)
MUFFLER - INSTALLATION
MUFFLER SHROUD - INSTALLATION
DIPSTICK TUBE - INSTALLATION
FUEL TANK - INSTALLATION
BLOWER SHROUD - INSTALLATION
REWIND STARTER- INSTALLATION
AIR CLEANER - INSTALLATION
SPARK PLUG - INSTALLATION
ACKNOWLEDGEMENT
PREFACE
This Service and Overhaul Manual was written expressly for the following GTS
Model 97777 Type
Model 97772 Type
Model 97777 Type
MODEL & SERIAL NUMBER
01
01
31
11
-01
10-01
10-01
150
Overhead Valve Engines:
The Toro Company has made every effort to make this service manual a useful and lasting addition to every service facility.
To assure proper and effective service, and to provide optimum performance for the life of the engine, you are urged to
read this manual carefully.
It is not the purpose of this manual to teach component theory, but rather to provide the mechanic with a working guideline
of maintenance, troubleshooting, test, repair and overhaul procedures.
The Toro Company reserves the right to change product specifications or this manual without notice.
&
The Toro Company gratefully acknowledges the assistance of the Briggs
University in the production of this manual.
I
COPYRIGHT - ALL RIGHTS RESERVED
Minneapolis,
The Toro Company
MN
55420
-
1991
-
U.S.A.
Stratton Corporation and Ferris State
Reference Information
TABLE
OF
CONTENTS
Service Procedures
Section
1
Carburetor
Safety Information
Specifications
Tool Requirements
Troubleshooting.,
Maintenance
description
operation
removal
pressure testing
disassembly
cleaning and service
assembly
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Page
10
15
19
19
20
21
21
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21
22
6
7
9
adjustment
Section 2 Fuel System
fuel tank
fuel cap
fuel hose
Section 3 Ignition System
Ignition operation
..................................................................................................................
operation
removal
cleaning
operation
service
removal
installation
flywheel
armature coil
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22
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23
23
23
23
23
23
25
25
25
Table of Contents
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-.
GTS
2
...
150
Service Procedures (cont’d)
TABLE
OF
CONTENTS
Section
Section
Section
3
Ignition System (cont’d)
spark plug
armature coil wiring
air gap adjustment
removal
testing
installation
4
Rewind Starter
operation
disassembly
assembly
installation
5 Engine
operation
disassembly
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25
26
26
26
26
26
27
27
28
28
29
30
air cleaner
rewind starter
blower shroud
muffler shroud
flywheel brake
fuel tank
muffler
oil fill tube
carburetor
ignition coil
throttle bracket
alternator
flywheel
electric starter
throttle control lever
head components
valves and seats reconditioning
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30
30
30
30
31
31
31
31
32
32
32
33
33
33
34
34
35
GTS
150
breather
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36
..
3
Table
of
Contents
Service Procedures (cont’d)
TABLE
OF
CONTENTS
Section
5 Engine (cont’d)
oil pump
sump
governor and splasher
cam shaft and cam followers
compression release
crankshaft
piston and connecting rod
piston rings and pin
governor arm
assembly
piston pin and rings
piston
crankshaft
governor shaft
cam followers
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36
36
37
37
37
38
38
39
39
40
40
40
41
41
cam
shaft
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governor and splasher
sump
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oil pump
breather
head
push rods
valves
valve clearance adjustment
throttle bracket
governor control lever
carburetor
governor adjustment
electric starter
flywheel
alternator
ignition armature coil
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43
43
43
44
44
44
45
45
45
.....
Table
of
Contents
~
4
GTS
150
TABLE
OF
CONTENTS
Service Procedures
(cont'd)
flywheel brake
muffler
dipstick tube
fuel tank
blower shroud
rewind starter
air cleaner
spark plug
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45
46
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47
47
GTS
150
5
Table
of
Contents
SAFETY INFORMATION
This safety symbol means
WARNING or CAUTION,
PERSONAL
TION Read the instruction
because
Failure to comply with the
instruction may result in personal injury or
death.
SAFETY
it
has to do wlth safety.
INSTRUC-
SAFETY
This manual is intended as a service and repair
manual only. The safety instructions provided in
this manual are for the troubleshooting and service
of the engine only. The individual Operator's
will contain safety information on the operation of
the complete product powered by the
engine. Operator's manuals with complete operational safety instructions are available through:
The Toro Company
Publications Department
8111
Lyndale Avenue South
MN
Minneapolis,
55430
U.S.A.
Manual
GTS
150
TIPS
Avoid lacerations and amputations ...
Stay clear of all moving parts whenever the engine is
running. Treat
were moving whenever the engine is running or has
the potential to start.
Avoid burns...
Do
not touch the engine while running or shortly after
running.
Avoid fails. ...
Do
not operate the mower on slippery surfaces or
footing is questionable.
Avoid fires and falls...
Wipe up any spilled fuel or
Avoid asphyxiation
Never operate
proper ventilation.
Avoid eye injuries
Wear eye protection when working with springs or
cables and when running engine.
Avoid unexpected starting of engine
Always turn
before attempting any cleaning, adjustment or repair.
all
normally moving parts as
oil.
....
an
engine in a confined area without
....
...
off
key and disconnect spark plug wire
if
they
if
Avoid fires and explosions
Use a container designed for gasoline. Avoid spilling gasoline and never smoke while working around
gasoline.
Avoid accidental misuse of fuel.
Always store fuel
that is designed for gasoline.
Avoid injury due to inferior parts
Use only Toro original parts to insure that important
safety criteria are met.
Avoid injury to bystanders
Always clear the area of bystanders before starting
a
or testing
Avoid injury due to projectiles
Always clear the area to be mowed of sticks, rocks
and other debris that could be picked up and thrown
by the mower.
lawn mower.
in
a properly labeled container
...
..
...
...
...
Safety information
6
GTS
150
SPECIFICATIONS
GTS
I
150
Engine Specification
Engine Rotation
Carburetor float type with fixed main jet
Fuel
led, llstroke overhead valve
Measurement on page 37
counterclockwise as viewed from PTO
unleaded regular
I
Recommended Oil
44
ounces (1.3 liters)
solid state magneto type
22 degrees BTDC
primary .2
Champion RC12YC, gap .030" (.76 mm)
rewind (1 2
detergent SAE 1OW-30 or 30, SF,
two
stage foam type with optional paper element
manual, snap over design
in
tank, washable, 75 micron
.4
Ohms, secondary
_-
volt
on some models)
2400
SG
-
5000
Ohms
GTS
Piston aluminum alloy, permanent mold
Piston Rings
150
I
two
compression,
7
one, 3 piece oil control
Specifications
SPECIFICATIONS
(cont'd)
GTS
GTS
150
Carburetor Specifications
150
Fastener Torques
Specifications
-
a
GTS
150
TOOL REQUIREMENTS
Comments
--
_-
----_.I
connecting rod, flywheel puller
valve adjusting
-
valve adjusting
(Nut
driver acceptable)
I-p
deep well for spark plug
_-_s_
B
&
B
6
6
B
&
&
&
&
S
S
S
S
S
-___ti--
11_1--____---
_.____I_____..^_______I-
I
I
nut
_--__
jam
I_--^
____~rmY___
screw
-.
----
part number 19372
part number 19069
part number 19334
part number 19070
part number 19340
~._-
.-
-~
-p_-
-~
--
.I
-
GTS
150
9
Specifications
TROUBLESHOOTING
Engine Does Not Start When
Engine Will Start “Cold”, but will Not Start
“Cold”
“Hot”
inadequate valve clearance readjust valves
Engine Does Not Produce Spark
to
.005
-
.007” (.12
-
17 mm), measured
GTS
150
Engine has Low Compression
TROUBLESHOOTING
(cont'd)
incorrect valve clearance readjust valves
Engine Flooded with Fuel
with engine cold
carburetor replace failed parts
to
.005
-
.007" (.15-.17 mm) measured
--
Engine Lacks Power
GTS
150
11
Troubleshooting
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