Toro 20211, 20219, 20320, 20522C, 20526C Service Manual

OHV GTS 140 ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 3

PREFACE

1. GENE RAL INFORMATION

SAFETY INSTRUCTIONS GENERAL SERVICE SAFETY INSTRUCTIONS MODEL AND SERIAL NUMBERS SPECIFICATIONS SERVICE DATA CARBURETOR FASTENER TORQUE SPECIFICATION SPECIAL TOOLS

2. MAINTENANCE

AIR CLEANER CHANGING OIL SPARK PLUG VALVE LASH GOVERNOR AND THROTTLE LINKAGE IGNITION FUEL SYSTEM CARBURETOR STORAGE

3. TROUBLESHOOTING AND TEST PROCEDURES

TROUBLESHOOTING CHART CARBURETOR REMOVAL--CARBURETOR SERVICE--CARBURETOR REASSEMBLY--CARBURETOR

GAS CAP

DISASSEMBLY SERVICE REASSEMBLY FUEL TANK AND FILTER DISASSEMBLY SERVICE REASSEMBLY IGNITION TESTING SPARK INTENSITY TESTING KILL SWITCH OPERATION BBC AND COMMERCIAL KILL SYSTE MS ZONE START APPLICATIONS REMOVAL--IGNITION INSTALLATION--IGNITION ELECTRIC STARTER AND ALTERN ATOR

OHV GTS 140 ENGINE SERVICE MANUAL

Table of Contents – Page 2 of 3

3. TROUBLESHOOTING AND TEST PROCEDURES - Continued

TESTING--ELECTRIC STARTER IF THE MOTOR TURNS: IF THE MOTOR DOES NOT TURN: TESTING--ALTERNATOR REMOVAL--ELECTRIC STARTER INSTALLATION--ELECTRIC STARTER REMOVAL--ALTERNATOR INSTALLATION--ALTERNATOR RECOIL STARTER REMOVAL AND DISASSEMBLY--RECOIL START ER REPAIR--RECOIL STARTER ROPE REPLACEMENT SPRING REPLACEMENT REASSEMBLY

4. ENGINE DISASSEMBLY, INSPECTION AND REASSEMBLY

DISASSEMBLY RECOIL STARTER FUEL TANK AIR CLEANER COOLING SHROUDS MUFFLER ELECTRIC STARTER ALTERNATOR IGNITION COIL OIL FILL TUBE THROTTLE CONTROL AND CARBURETOR FLYWHEEL BREATHER CYLINDER HEAD ASSEMBLY VALVES OIL PUMP CRANKCASE GOVERNOR ASSEMBLY CAMSHAFT COMPRESSION RELEASE PISTON AND CONNECTING ROD INSPECTION AND RECONDITIONING CRANKSHAFT CONNECTING ROD PISTON CYLINDER PISTON RINGS VALVES

OHV GTS 140 ENGINE SERVICE MANUAL

Table of Contents – Page 3 of 3

4. ENGINE DISASSEMBLY, INSPECTION AND REASSEMBLY - Continued

REASSEMBLY PISTON, RINGS AND CONNECTING ROD CAMSHAFT AND FOLLOWERS GOVERNOR ASSEMBLY CRANKCASE OIL PUMP VALVES CYLINDER HEAD ASSEMBLY BREATHER FLYWHEEL THROTTLE CONTROL AND CARBURETOR OIL FILL TUBE IGNITION COIL ALTERNATOR COIL AND STARTER MOTOR MUFFLER MUFFLER AND COOLING SHROUD AIR CLEANER FUEL TANK RECOIL STARTER

PREFACE

This Service and Overhaul Manual was written expressly for the TOR0 model VMFS and VMG6 Overhead Valve Engine.

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 Tor0 Company reserves the right to change product specifications or

this manual without notice.

The Toro Company gratefully acknowledges the assistance of the Suzuki Motor Company in the production of this manual.

COPYRIGHT

The

MINNEAPOLIS, MN

Toro

ALL

RIGHTS

Company

55420

RESERVED

1986

-

U.S.A.

TABLE

1

GENERAL INFORMATION PAGE

Safety Instructions 1 General Service Safety Instructions 1

Model and Serial Numbers Specifications 2 Service Data 3 Special Tools

2

MAINTENANCE

Air Cleaner

Consumer Air Cleaner Maintenance Commercial Air Cleaner Maintenance

Changing Oil 7 Spark Plug 7 ValveLash 7 Governor and Throttle Linkage 7 Ignition 8 Fuel System 8

Carburetor 9

Storage 9

3

TROUBLESHOOTING AND TEST PROCEDURES

Preliminary Troubleshooting 10 Troubleshooting Chart 11 Carburetor 12

Removal 12 Service 13 Reassembly 13

Gas Cap 14

Disassembly 14 Service 14 Reassembly 14

Fuel Tank

Disassembly 14

Service 14 Reassembly 15

Ignition 15

Testing 15 Removal 16 Installation 17

Electric Starter

Testing Starter 17 Testing Alternator 18 Removal Starter 18 Installation Starter 18 Removal Alternator 19 Installation Alternator 19

Recoil Starter 19

Removal and Disassembly 19 Repair 21

Reassembly 21

&

Filter 14

&

Alternator 17

OF

CONTENTS

1

5

6 6

6

4

ENGINE DISASSEMBLY. INSPECTION AND REASSEMBLY

Disassembly 22

Recoil Starter 22

Fuel Tank 22 Aircleaner 22 Cooling Shrouds 22

L--

Muffler Electric Starter

Alternator

Ignition Coil

Oil Fill Tube 22 Throttle Control and Carburetor 23 Flywheel 23 Breather 23 Cylinder Head Assembly 24

Valves 25 Oil Pump 25

Crankcase 26 Governor Assembly 26

Camshaft 26 Compression Release 27

Piston and Connecting Rod 27

Inspection and Reconditioning 28

Crankshaft 28 Connecting Rod 28 Piston 29 Cylinder 29 Piston Rings 29

Valves 29

Reassembly 31

Piston. Rings and Connecting Rod 31 Camshaft and Followers 32

Governor Assembly 32 Crankcase 32

Oil Pump 32 Valves 33

Cylinder Head Assembly 33 Breather 34

Flywheel 34 Throttle Control and Carburetor 34 Oil Fill Tube 35

Ignition Coil 35 Alternator Coil and Starter Motor 35 Muffler 35

Muffler and Cooling Shroud 36 Air Cleaner 36

Fuel Tank 36 Recoil Starter 36

SAFETY INSTRUCTIONS

A

PERSONALSAFETY INSTRUCTION Read the instruction because do with safety. Failure to comply with the instruction may result in personal injury.

This manual is intended to be a service and

repair manual only. The safety instructions provided in this manual are for the trouble-

shooting and service of the product only.

Individual owners manuals will contain safety information for the operation of products that

are fitted with the engine described in this

manual.

Operators manuals with complete operational safety instructions are available through:

The Toro Company

Publications Department 81 11 Lyndale Avenue South

Minneapolis, MN 55420 U.S.A.

Be sure to include the model and serial number

of your machine.

If

you have any questions concerning this

Repair Manual, please contact:

The Tor0 Company Service Department 81 11 Lyndale Avenue South

Minneapolis,

GENERAL SERVICE SAFETY INSTRUCTIONS

1.

Use extreme care when handling any gasoline and oil that may be in the engine. Gasoline and oil are flammable and should not be exposed to flame or spark. Do not smoke while handling any fuel or oil.

2. Drain and/or store gasoline and oil only in approved containers.

3.

Wipe up any spilled gasoline or oil.

4. Do not run an engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

5.

Disconnect and ground the spark plug high tension wire before performing any engine service. This will prevent accidental starting of the engine.

6.

If the engine must be kept running to perform maintenance

This safety symbol means WARNING or CAUTION-

it

has to

MN

55420 U.S.A.

or

making adjust-

ments, keep clear of the PTO shaft, cutting blades and other moving parts.

7.

Do

not overspeed the engine by changing the governor settings. Maximum engine speed with no load is listed in the engine specifications on page

8. The engine must be stopped before checking the oil or adding oil to the crankcase.

9.

Do

not touch the engine muffler or guard while the engine is running or soon after it has stopped. These areas could be hot enough to cause a burn.

MODEL AND SERIAL NUMBERS

Each Toro OHV engine is equipped with two numbers: a four digit model number and a six digit serial number. The numbers are located on the muffler side of the blower housing. See Fig. 1-1. On units with the model number VMF5, the serial number 1 indicates zone start application, the number electric BBC.

On units with the model number VMG6 the serial numbers will start with 1, The number.1 indicates zone start, the number 2 indicates BBC, the number electric BBC, the number 4 indicates international key electric, the number

commercial application and the number

indicates zone start commercial.

The mower that these engines are mounted on also have model and serial numbers that are located on a decal on the back of the mower housing between the rear wheels.

In any correspondence concerning the mower or engine, supply the model and serial numbers to assure that the correct information and replacement parts are obtained. Genuine TORO replacement parts may be ordered

through your local TORO Authorized Service Dealer.

2,

Figure 1-1

2.

BBC and number

2,

3,

3

indicates key

5

3,

key

4, 5 or 6.

indicates

6

1

SPECIFICATIONS

Engine type Air cooled 4 cycle, gasoline, Bore and stroke .64 mm

x

44 mm (2.52 in x 1.73 in)

OHV

Displacement 141 cc (8.7 cu. in) Maximum output 4 HP/3600 rpm Maximum torque 0.83 kg-m (6.00 ft-lb)/2700 rpm Spark plug NGK BPR6ES Spark plug gap .0.7 mm 0.8 mm (0.028 in 0.032 in) Ignition coil air gap.. .38-50 mm (.015-,020) Fuel Unleaded regular Fuel tank capacity .1.2 Oil.. Oil capacity

30

weight or low-30 multi-viscosity

L

550

ml (18.59

(.26 gallon)

0Z)

Ignition system Electronic transistorized ignition

Ignition timing degree 25 BTDC rpm Starting system. .Recoil starter/Electric (12 volt) Governor Centrifugal mechanical Pump system.. Trochoid oil pump Carburetor Butterfly valve Air cleaner Polyurethane foam element Dry weight 12.0 kg (26.5 Ibs)

(KW)

HP

3

2

0

2000

2500

Figure 1-2

3000

3600

RPM)

TORQUE (Nm)

kgrn

2

SERVICE

DATA

ITEM

Crankshaft diameter

Crankshaft deflection Limit Wear limit on cylinder bore

Piston diameter

Piston-to-cylinder clearance

Piston pin hole diameter

Piston pin diameter Piston pin clearance in connecting rod Limit Piston ring groove width (Top and 2nd)

Piston ring thickness

(Top) STD

_____-

Piston ring clearance

in groove

Piston ring end gap

Connecting rod big end side

clearance

Crank pin diameter Connecting rod big end inside diameter

Crankpin oil clearance in connecting rod Limit

__-

Cylinder head distortion limit Cylinder distortion limit

Valve head thickness

Width of valve seat contact

Valve Lash

Valve stem diameter

Valve guide inside diameter

(Top) Limit

(2nd) STD

(2nd) Limit

(Top) STD

(Top) Limit

(2nd) STD

(2nd) Limit

I

Intake

_-

Exhaust

Intake

Exhaust-

STD Limit STD Limit

(TOP) (2nd)

ST D

STD

___-

STD

UNIT

mm (in!

____-

mm (in) mm (in) mm (in)

____-

mm (in)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

~-

mm (in) mm (in)

mm (in) mm (in) mm (in) mm (in)

~-

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

____-

mm (in) mm (in) mm (in)

mm

(in)

DATA

Upper crankshaft: 21.960 -21.980 (0.8646 0.8654) Lower crankshaft: 24.959 24.980 (0.9826 0.9835)

0.05

(0.0020)

0.100 (0.0039)

63.960 63.975 (2.5181 2.5187)

63.915 (2.5163)

0.055

0.025

0.120 (0.0047)

15.006 15.014 (0.5904 0.591 1)

14.995 15.000 (0.5904 0.5906)

0.006 0.019 (0.0002

0.05

(0.0020)

1.52 1.54 (0.0598 0.0606)

1.47 1.49 (0.0579 0.0587)

0.03 0.07 (0.0012 0.0028)

0.10 (0.0039)

0.03 0.07 (0.0012 0.0028)

0.10 (0.0039)

0.2 0.4 (0.0079 0.0158)

0.70 (0.0276)

0.2 0.4 (0.0079

0.70 (0.0276)

24.00 24.20 (0.945 0.953)

25.99 26.00 (1.023 1.024)

26.015 26.025 (1.024 1.025)

0.01

5

0.080 (0.0031)

0.03 (0.0012)

0.03

0.07

0.20 (0.0079)

0.900 1.1 .13 (.001

5.460 5.475 (0.2150 0.2156)

5.440 5.455 (0.2142 0.2148)

5.500

(0.0010 0.0022)

0.0007)

0.0158)

0.035 (0.0006 0.0014)

(0.001 2 0.0028)

00

(0.0354 0.0433)

,005)

5.512 (0.2165 0.2170)

5.51 2 (0.21 65 0.21 70)

3

SERVICE DATA (Continued)

ITEM

Intake (STD)

Intake

Valve guide clearance Exhaust

Valve guide oversize

Valve spring free length

to

valve stem

(Limit)

(STD)

Exhaust

(Limit)

Limit

CARBURETOR

ITEM

TYPE Main jet (High altitude) Main air jet

Pilot jet

Throttle valve

UNIT

mm(in)

mm (in)

mm (in) mm (in) mm (in) mm (in)

0.025 0.052 (0.0010 0.0020)

0.080 (0.0032)

0.045 0.072 (0.0018 0.0028)

0.100 (0.0039)

0.3

(0.01 18)

32.0 34.0 (1.2598 1.3386)

.O

(1.2205)

31

30.51 7 30.577 (1.201

UNIT

#

mm (in)

#

mm (in) Pilot air jet

#

MlKUNl BV

82.5 (80

part number

1.8 (0.0709)

40

1

.O

(0.0394)

130

DATA

5

18-13

1.2038)

DATA

81-1040)

Pilot outlet

Valve seat

Air screw turns open

FASTENER TORQUE SPECIFICATION

ITEM

Cylinder head bolt

Flywheel nut Connecting Conventional bolts

5

6

8

10

"#7"

marked bolts

5

6

8

10

mm mm

mm

mm mm mm

mm

rod

nut

kg-m (ft-lb: kg-m (ft-lb: kg-m (ft-lb:

kg-m (ft-lb) kg-m (ft-lb) kg-m (ft-lb)

kg-m (ft-lb)

kg-m (ft-lb) kg-m (ft-lb) kg-m (ft-lb)

mm (in)

(rotation)

UNIT

0.7

(0.0276)l

1.5 (0.0591)

1

.o

DATA

1.8 2.8 (13.0 20.0)

5.6 6.4

0.6 1

0.2 0.4 (1.5

0.4 0.7 (3.0 1

.O

2.2

(40.5

.O

(4.5

1.6

(7.0

3.5

(16.0 25.5)

46.5)

7.0)

3.0)

5.0)

11.5)

0.3 0.6 (2.0 4.5)

0.8 1.2 (6.0

8.5)

1.8 2.8 (13.0 20.0)

4.0 6.0 (29.0 43.5)

I I

4

SPECIAL TOOLS

@

Adaptor T-handle wrench

50-9410* 50-9480*

Valve guide remover

installer

81 -4880

Expandable pilot

Cutter

&

50-9500*

head

60"

81 -4830

Figure

Valve guide reamer

Reamer handle

A

81-4840 81-4850

81-4860

Rotor remover

41 -7650

1-3

Cutter

head

81

-4870

*These tools are also

used on the edger and generator engines.

I

All

fasteners on the

standard set

3/8

in. drive ratchet with short extension

10

mm socket

12

mm socket

14

mm socket

19

mm socket

10

mm open end

14

mm open end

OHV

engine are metric. The

of

tools will require the following:

Torque wrench Ring compressor Pliers Feeler gauge Compression tester

Inside and outside micrometer measuring

tools Screwdrivers, standard and phillips Tachometer

5

2.

MAINTENANCE

AIR CLEANER

The consumer air cleaner should be serviced every air cleaner is of a two part design: the foam pre-cleaner should be serviced every 25 hours and the paper element every

frequent service for both air cleaners may be

required in dusty or dirty conditions.

Consumer Air Cleaner Maintenance

1.

2. Clean loose debris from the air cleaner

3.

25

hours of engine use. The commercial

50

hours. More

Stop the engine and pull the high tension wire off the spark plug.

body. Push

in

the locking tabs and lift off the air

2-1.

cleaner cover. See Fig.

Clean the cover.

Figure 2-2

PAPER ELEMENT

Figure 2-1

4.

Remove the foam element. See Fig.

5.

Wash the element in soap and water. Squeeze element may tear.

6.

Dry the element and saturate it with teaspoons of SAE the element

7. Reinstall the air cleaner element and cover.

Commercial Air Cleaner Maintenance

1.

Follow steps Cleaner Maintenance.

2. Loosen and remove the two cover knobs. See Fig. 2-2.

3.

Lift the cover away from the body.

4.

Remove the air cleaner elements (paper and foam). See Fig. 2-3.

to

remove dirt, do not twist as the

30

engine oil. Squeeze

to

remove excess oil.

1

and 2

in

Consumer Air

2-1.

5

Figure

5.

Clean the foam element with soap and

DO

water.

6.

Clean the paper element with Air Filter Element Cleaner, Toro part number 27-

7220. CAUTION: This compound contains sodium metasilicate which may cause burns and is harmful

chemical

Follow the manufacturers instructions.

7.

Light accumulations moved by blowing compressed air from the inside CAUTION: Always wear safety glasses when working with compressed air. This procedure should be used if the element must be immediately put back in service because a

washed element must be dried before use.

Make sure the compressed air is at 280 kPa

8.

(40 psi) or less. Hold the air nozzle at least inch away from the element.

After cleaning examine the paper element

9.

for holes or leaks by holding a light behind the element. Slowly turn the element and

look through the paper for defects.

NOT

out

of the reach

to

the outside of the dry element.

2-3

OIL

THIS

if

swallowed. Keep this

ELEMENT.

of

dust may be re-

of

children.

1

6