Toro 30620, 30798, 31-16O803, 31-16O804, 41-20OE02 Service Manual
...
ONAN TORO POWER PLUS P216, 18, 20, 24 ENGINES - HORIZONTAL
Table of Contents – Page 1 of 2
SAFETY PRECAUT I O NS
GENERAL
PROTECT AGAINST MOVING PARTS
BATTERIES
FUEL SYSTEM
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY!
COOLING SYSTEM
KEEP THE UNIT AND SURROUNDING AREA CLEAN
CAUTION
GENERAL INFORMATION
INTRODUCTION
ENGINE MODEL REFERENCE
SPECIFICATIONS
DIMENSIONS AND CLEARANCES
P216, P218, P220
P216,P218,P220
P224
P224
ASSEMBLY TORQUES
SPECIAL TOOLS
ENGINE TROUBLESHOOTING
OIL SYSTEM
CRANKCASE OIL
OIL FILTER CHANGE
CRANKCASE BREAT HER
CRANKCASE BREAT HER SE RVICE
P216, P218, P220
P224
PRESSURE LUBRICAT IO N
OIL PUMP
OIL BYPASS VALVE
FUEL SYSTEM
CARBURETOR
CARBURETOR SPEED SETTINGS
CARBURETOR OVERHAUL
REMOVAL
DISASSEMBLY
CLEANING AND REPAIR
REASSEMBLY AN D INSTALLATION
PULSATING-DIAPHRAGM FUEL PUMP
FUEL PUMP TEST PROCEDURE
PURPOSE
CARBURETOR (BEGINNING SPEC G)
CARBURETOR HIGH-ALTITUDE JET (OPTIONAL)
AIR CLEANER
GOVERNOR SENSITIVIT Y
ONAN TORO POWER PLUS P216, 18, 20, 24 ENGINES - HORIZONTAL
Table of Contents – Page 2 of 2
IGNITION AND BATTERY CHARGING
IGNITION SYSTEM DESCRIPTION
IGNITION TIMING
CONTINUITY TEST
IGNITION COIL
SPARK PLUGS
BATTERY INSPECTION
BATTERY JUMP STARTING
FLYWHEEL ALTERNAT OR
ALTERNATOR OUTPUT TEST
TYPICAL WIRING DIAGRAM
STARTING SYSYTEM
ELECTRIC STARTER
SERVICE
STARTER REMOVAL
STARTER DISASSEMBLY
STARTER ASSEMBLY
INSPECTION AND TESTING
STARTER MOUNTING
ENGINE DISASSEMBLY
DISASSEMBLY/ASSEMBLY
SUGGESTED DISASSEMBLY ORDER
SUGGESTED ASSEMBLY PROCEDURE
OPERATION
TESTING COMPRESSION
TAPPET ADJUSTMENT
VALVE SYSTEM
INSPECTION
TAPPETS
VALVE FACE AND SEAT GRINDING
FLYWHEEL
GEAR COVER
GOVERNOR CUP
TIMING GEARS
PISTONS AND CONNECTING RODS
CYLINDER BLOCK
CLEANING
INSPECTION
REBORING THE CYLINDER
HONING CYLINDERS (USING PRECISION HONES)
DEGLAZING CYLINDER BORE S
CRANKSHAFT
BEARINGS
CRANKSHAFT ENDPLAY
CHECKING CONNECTING ROD BEARING CLEARANCE WITH PLASTIGAUGE
OIL SEALS
PISTON ASSEMBLY
INSTALLATION OF PISTON IN CYLINDER
CYLINDER HEADS
P216, P218, P220 INSTALLATION
224 INSTALLATION
Service
Manual
P216,18,20,24
TORO
Engine
Power
Plus
1709
Tractors & Riding Mowers
Safety
It
is recommended that you read your engine manual and
become thoroughly acquainted with your equipment before
you start the engine.
severe personal injury or death.
severe
personal injury or death.
Precautions
This symbol if used warns of imme-
diate hazards which will result in
This symbol refers to a hazard or
unsafe practice which can result In
Fuel System
DO
NOT
fill
fuel tanks while engine
DO
NOT
smoke
or
use an open flame in the vicinity
or
fuel
tank.
engine
highly flammable.
Fuel lines must be
and free from leaks. Piping at the engine should be
approved flexible line.,
flexible lines as copper
brittle enough
Internal combustion engine fuels are
of
steel piping, adequately secured,
Do
will
to
break.
is
not use copper piping for
work harden and become
running.
of
the
This symbol refers to
unsafe practice which can
personal injury or product or property damage.
Fuels, electrical equipment batteries, exhaust gases and
moving parts present potential hazards that
serious, personal injury. Take care
mended procedures. All local. state and federal codes should
be consulted and complied with.
This engine is not designed
tended for
Use
of
this engine in aircraft can result in engine failure
and causes serious personal injury
General
Provide appropriate fire extinguishers and install them in
convenient locations. Use an extinguisher rated
NFPA.
Make sure that all fasteners
accurately torqued. Keep guards in position over fans,
driving belts, etc.
If
it is necessary
running, use extreme caution when close
moving parts. etc.
Protect Against Moving Parts
Do
not wear loose clothing
such as PTO shafts, flywheels, blowers, couplings, fans,
belts, etc.
to
make adjustments while the engine is
in
following these recom-
use
in
any type of aircraft.
on
the engine are secure and
in
the vicinity of moving parts.
or
death.
to
a
hazard
can
hot exhausts,
result
result in
or
In-
ABC
or
in
by
Be sure all fuel supplies have a positive shutoff valve.
Exhaust
Exhaust
Exhaust gases contain carbon monoxide, a poisonous gas
that can cause unconsciousness and death.
and colorless gas formed during combustion
fuels.
If
you experience any
immediately, shut down the unit and do not use until it has
been inspected.
The best protection against carbon monoxide inhalation is
proper installation and regular, frequent inspections
complete exhaust system.
or
immediately and have
competent mechanic.
System
Exhaust products
toxic and can cause injury,
applications, especially those within a confined area,
should be equipped with an exhaust system
to
gases
Do
Make' sure that your exhaust system
Ensure that exhaust manifolds are secure and are
warped by
Symptoms
Dizziness
Headache
Weakness and Sleepiness
appearance
the outside atmosphere.
not
use exhaust gases
Gas
is
of
any internal combustion engine are
or
death
if
inhaled.
to
heat a compartment
is
free
bolts
unevenly torqued.
Deadly!
It
is an odorless
of
carbon monoxide poisoning are:
Vomiting
Muscular Twitching
Throbbing in Temples
of
these symptoms. get out into fresh air
If
you notice a change in the sound
of
exhaust system, shut the unit down
it
inspected and repaired at once by a
of
to
hydrocarbon
All
engine
discharge
of
leaks.
not
of
the
Keep your hands away from moving parts.
Batteries
on
Before starting work
to
prevent inadvertent starting
DO
NOT
SMOKE
batteries give
can be ignited by flame, electrical arcing
Verify battery polarity before connecting battery cables.
Connect negative cable last.
off
the engine. disconnect batteries
of
the engine.
while servicing batteries. Lead acid
a highly explosive hydrogen gas which
or
by smoking.
Cooling
Keep
System
Coolants under pressure have a higher boiling point than
water., DO NOT open a radiator pressure cap when
coolant temperature is above
engine is running.
the
Unit and Surrounding Area Clean
Make sure that oily rags are not left
Remove all unnecessary grease and
Accumulated grease and oil can cause overheating and
subsequent engine damage and present a potential fire
hazard.
212ºF
on or
(100ºC)
near the engine,
oil
or
from the unit
while
~-
E-6
Table
of
Contents
TITLE
General
Specifications
Dimensions and Clearances
Assembly
Engine Troubleshooting
Oil
Fuel
Ignition
Engine
Starting
Englne
Information
Torques and Special Tools
System
System
...........................................................
...........................................................
and
Battery
Wiring
System.
Disassembly...
...................................................
........................................................
...............................................
Charging
Diagram
................................................
......................................................
...............................................
.............................................
....................................
...........................................
PAGE
.1-1
.2-1
.3-1
.4-1
.5-1
.6-1
.7-1
.8-1
.8-7
.9-1
10-1
EXHAUST GAS
Exhaust gases
gas) contain
is poisonous and can cause unconsciousness and
monoxide poisoning can include:
Dizziness
Nausea
Headache
Weakness and Sleepiness
IF
YOU OR ANYONE ELSE EXPERIENCE, ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR lMMEDlATELY.
attention. Shut down the unit and do not operate until
repaired.
Protection against carbon monoxide inhalation includes proper installation,
ventilation and regular, frequent visual and audible inspections
exhaust system.
from
carbon
all fuels (Including diesel, gasoline, liquid
monoxide, an odorless and colorless
IS
DEADLY!
gas.
death.
Throbbing in Temples
Muscular Twitching
vomiting
Inability
If
symptoms persist,
Symptoms of
to
Think Coherently
it
has been inspected and
propane,
Carbon
seek
of
the complete
natural
monoxide
carbon
medical
General
Information
This manual deals with specific mechanical and electrical information needed by engine mechanics for
or
troubleshooting, servicing, repairing,
engine.
Use
the separate PARTS MANUAL for parts identification
and for establishing their proper location on assemblies.
The PARTS MANUAL contains detailed exploded views
of each assembly and the individual piece part numbers
and their proper names for ordering replacement parts.
The illustrations and procedures presented in each
section apply to the engines listed on the cover.
flywheel-blower end of
right and left sides are determined by viewing the engine
from the front. The No.
cylinder is on the right.
If
a major repair
-mechanic should either do the job
check the
ensure that all dimensions, clearances and torque
values are within the specified tolerances.
or
work
of the mechanic assigned to the job to
the
engine is the front end
1
cylinder is on the left, No.
an overhaul is necessary, a competent
overhauling the
or
supervise and
The
so
2
Use only Genuine
ensure quality
results. When ordering parts,
model and
shown
on
the nameplate.
Tom
and
the best
spec
number as well
Plower Plus
possible
always
as
replacement
repair and overhaul
use the complete
the
serial
parts to
number
ENGINE MODEL REFERENCE
Identify your model by referring to the model and
(spec
specification
plate. Always use these numbers and the engine serial
number when making reference
How to interpret
letter) as shown on the unit name-
to
your engine.
MODEL
3
and
SPEC
NO.
6
7
Use
the table of contents for a quick reference to the
separate engine system sections.
The troubleshooting guide is provided as a quick
reference for
The wiring diagram shows how the electrical compo-
nents are interconnected.
The disassembly section contains major overhaul
procedures for step by step removal, disassembly,
inspection, repair, and assembly of the engine
components.
locating
See
the Operator's Manual
and
correcting
INCORRECT SERVICE
SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. SERVICE
PERSONNEL
MECHANICAL SERVICE.
engine trouble.
for
fuel and oil recommendations and
OR
REPLACEMENT OF PARTS CAN RESULT IN
MUST
BE QUALIFIED
1.
Factory code for general identification of basic
engine series.
2.
Number
3.
BHP rating.
4.
Fuel required
5.
Engine duty cycle.
6.
Factory code for designated optional equipment,
any.
7.
Specification
factory production modifications.
TO
PERFORM ELECTRICAL AND/OR
of
cylinders.
(G
=
gasoline).
(spec
letter) which advances with
the
Periodic Maintenance Schedule.
if
1-1
Specifications
This manual contains
SI
metric equivalents that follow immediately
after the
U.S.
customary units of measure.
in
parentheses
2-
1
Dimensions
and
Clearances
P216. P218. P220
All
clearances given at room temperature of
in parentheses) unless otherwise specified
DESCRIPTION
CYLINDER BLOCK
Cylinder Bore Honed Diameter
Maximum Allowable
Taper
.................................................
Out-of-Round
Main Bearing Inside Diameter (Without bearing)
Main Bearing Inside Diameter (Installed service bearing)
Camshaft Bearing
CRANKSHAFT
Main Bearing Journal Diameter
Main Bearing Clearance
Connecting
Crankshaft End Play
.........................................
Bore
(Installed service bearing)
Rod
Journal Diameter
......................................
............................
............................
..................................
.........................
70°F
.
(21 °C) . All dimensions in inches (approximate millimeter dimensions
.
.............
...........
.....
3.2490 (82.52)
2.1870
2.001
5
1.3757
1.9992
0.0024
1.6252
0.0060
(55.55)
(50.84)
(34.94)
(50.78)
(0.061)
(41.28)
(0.1 52)
3.2500 (82.55)
0.005
0.003
2.1
880
2.0040
1.3787
2.0000
0.0042
1.6260
0.01
20
(0.1 3)
(0.08)
(55.58)
(50.90)
(35.02)
(50.80)
(0.1
07)
(41
30)
(0.305)
CONNECTING
Large Bore Diameter
Connecting
Piston Pin Bushing
Bearing to Crankshaft Clearance
CAMSHAFT
Bearing Journal Diameter
Bearing Clearance
End Play
Lobe Height
P216. P218 Intake
P216. P218 Exhaust
P220
Intake
P220 Exhaust
PISTON
Clearance
Measure
Piston Pin Bore
Ring Groove Width
Top
Compression Ring
Middle Compression Ring
Bottom Oil Control Ring
ROD
(Rod
bolts
properly torqued)
Rod
Side Clearance
Bore
(Finished bore)
.................................
.......................................
................................................
......................................
....................................
............................................
..........................................
in
Cylinder
90°
to pin 1.187 inch
...........................................
.................................
...............................
.................................
...........
...........................
....................
...........................
below
top
of
piston
.........
1.6280
0.0020
0.6879
0.0020
1.3740
0.001 5
0.01 10 (0.279)
0.0033
0.6877 (1 7.47)
0.0800
0.0800
0.1 880
(41.35)
(0.051)
(1 7.47)
(0.051)
(34.90)
(0.038)
1.1
370
1.1 570
1.1
670
1.1
570
(0.084)
(2.032)
(2.032)
(4.775)
1.6285 (41
0.0160
0.6882
0.0033
1.3745
0.0030
0.0480
(28.88)
(29.39)
(29.64)
(29.39)
0.0053
0.6882
0
0.081
0
0.081
0.1 890
36)
(0.406)
(1 7.48)
(0.084)
(34.91)
(0.076)
(1.219)
35)
(0.1
(1 7.48)
(2.057)
(2.057)
(4.800)
3-1
P216. P218. P220
PISTON PIN
Clearance in Piston
Clearance in Connecting
Diameter
PISTON RINGS
Clearance
Top Groove
Ring End Gap in Cylinder
INTAKE VALVE
Stem Diameter
Clearance (Stem to Guide)
Valve Face Angle
INTAKE VALVE SEAT
Seat Bore Diameter
Seat Outside Diameter
Valve Seat Width
Valve
EXHAUST
Stem
Clearance (Stem to Guide)
Valve
................................................
seat
Angle
VALVE
Diameter
Face
Angle
......................................
...........................................
...........................................
........................................
in
Block
.....................................
.........................................
.........................................
...........................................
........................................
Rod
..............................
.................................
................................
...............................
................................
MINIMUM
Inches
0.00004
0.0002
0.6875
0.0030
0.01 00
0.2795
0
0.001
1.4395
1.4700
0
0.031
0.2780
0.0020
MAXIMUM
(mm)
(0.001)
(0.005)
(1 7.46)
(0.076)
(0.254)
(7.099
(0.025) 0.0025
(36.56)
(37.34)
(0.787)
(7.061) 02785
(0.051)
Inches
0.00064
0.0007
0.6877
0.0080
0.0200
02800
44º
1.4405
1.471
0.0470
45º
0.0035
44º
0
(mm)
(0.016)
(0.01 8)
(1 7.47)
(0.203)
(0.508)
(36.59)
(37.36)
94)
(1.1
EXHAUST VALVE
Seat
Bore Diameter in
Seat Outside Diameter
Valve Seat
Valve Seat Angle
VALVE
Intake Inside Diameter
Exhaust Inside Diameter
TAPPET
Body Diameter
Bore Diameter
Clearance in Bore
VALVE SPRINGS INTAKE AND EXHAUST
Valve Spring
Valve Spring Length
Valve Open
Valve Closed
Spring Load (Valve Open Length)
Spring Load (Valve Closed Length)
GEAR
Timing Gear
Oil
Pump Gear
Width
GUIDE
BACKLASH
SEAT
Block
...............................
....................................
.........................................
.........................................
....................................
..................................
...........................................
............................................
........................................
Free
Length (Approx.)
........................
............................................
..........................................
..........................
.........................
.............................................
...........................................
1.1890
1.1 920
0.0310
0.281
0
0.2805
0.7475
0.7500
0.0020
0.0010
0.0010 (0.025) 0.0080 (0.203)
(30.20)
(30.28)
(0.787)
(7.1 37)
(7.1 25)
(1
8.99)
(1
9.05)
(0.051)
1
600
1.055
1.346
55
Ib
25
Ib
(0.025)
45º
1.1900
1.1930
0.0470
0.2820
5
0.281
0.7480
0.751
5
0.0040
(4.64
(26.80)
(34.1
9)
(25
kg)
(11
kg)
0.0050 (0.1 27)
(30.23)
(30.30)
(1.194)
(1 9.00)
(1 9.09)
(0.1 02)
3-2
P224
DESCRIPTION
CYLINDER BLOCK
Cylinder Bore Honed Diameter
Maximum Allowable
Taper
Out-of-Round
Main Bearing Inside Diameter (Without bearing)
Main Bearing Inside Diameter (Installed)
Camshaft Bearing Bore (Bearing Installed)
CRANKSHAFT
Main Bearing Journal Diameter
Main Bearing Clearance
Connecting
Crankshaft End Play
CONNECTING ROD
Large Bore Diameter (Without bearing installed and rod bolts
properly torqued)
Connecting
Piston Pin Bushing
Piston Pin Bushing
Bearing to Crankshaft Clearance
CAMSHAFT
Bearing Journal Diameter
Bearing Clearance
End Play
Lobe Height
Intake
Exhaust
...............
..........................................
..................................
Rod
Journal Diameter
......................................
........................................
Rod
Side Clearance
Bore
(Without bushing)
Bore
(Finished
.......................................
................................................
..................................................
................................................
............................
.................................
.............
....................
..................
............................
.........................
...........................
..................
bore)
....................
...........................
.................................
MINIMUM
Inches
3.5625
2.1 870
2.001 5
1.3757
1.9992
0.0024
1.6252
0.0060
1.7505
0.0020
0.81 15
0.7504
0.0020
1.3740
0.001 5
0.01 10
(mm)
(90.49)
(55.55)
(50.84
(34.94)
(50.78)
(0.061)
(41.28)
(0.1 52)
(44.46)
(0.051
)
(20.61)
(1 9.06)
(0.051)
(34.90)
(0.038)
(0.279)
1
.
1670
1.1 570
Inches
3.5635
0.003
0.003
2.1 880
2.0040
1.3787
2.0000
0.0042
1.6260
0.01
20
1.751
0
0.01
60
0.81 25
0.7508
0.0033
1.3745
0.0030
0.0480
(29.64)
(29.39)
(90.51)
(0.08)
(0.08)
(55.58)
(50.90)
(35.02)
(50.80)
(0.1 07)
(41
.
30)
(0.305)
(44.48)
(0.406)
(20.64)
(1 9.07)
(0.084)
(34.91)
(0.076)
(1
PISTON
Clearance in Cylinder
90°
to pin
Measure
Piston Pin
Ring Groove
Top
Middle Compression Ring
Bottom Oil Control Ring
PISTON PIN
Clearance in Piston
Clearance in Connecting
Diameter
PISTON RINGS
Clearance
Top
Ring End Gap in Cylinder
Bore
Width
Compression Ring
................................................
Groove
...........................................
1.187
..........................................
.......................................
inch
below
top
of piston
.........
.................................
...............................
.................................
Rod
.............................
.................................
0.0070
0.7502
0.0800
0.0800
0.1
880
0.00004
0.0002
0.7500
0.0020
0.01 00
(0.1 78)
(1 9.06)
(2.032)
(2.032)
(4.775)
(0.001)
(0.005)
(1 9.05)
(0.051)
(0.254)
0.0090
0.7506
0.081
0
0.081
0
0.1 890
0.00064
0.0008
0.7502
0.0080
0.0200
(0.229)
(1 9.07)
(2.057)
(2.057)
(4.801)
(0.01 6)
(0.020)
(1 9.06)
(0.203)
(0.508)
DESCRIPTlON
INTAKE VALVE
Stem Diameter
Clearance (Stem to Guide)
Valve Face Angle
...........................................
........................................
P224
................................
0.3425 (8.700)
0.001
0
(0.025) 0.0025
44º
0.3430
(8.71 2)
(0.064)
INTAKE VALVE
Seat Cylinder Head Bore Diameter
Seat Outside Diameter
Valve
Seat
Valve
Seat
EXHAUST VALVE
Stem Diameter
Clearance (Stem to Guide)
Value Face Angle
EXHAUST VALVE
Seat Cylinder Head Bore Diameter
Seat Outside Diameter
Valve Seat Width
Valve
Seat
VALVE
Intake Inside Diameter
Exhaust
TAPPET
Body
Bore
Clearance in
VALVE SPRINGS
Valve Spring
Valve Spring Length
Spring Load (Valve Open
Spring Load (Valve
GUDE
Inside
Diameter
Diameter
.Valve Open
Valve Closed
SEAT
.....................................
Width
.........................................
Angle
.........................................
...........................................
................................
.........................................
SEAT
....................................
.........................................
Angle
.........................................
....................................
Diameter
...................................
...........................................
...........................................
Bore
........................................
INTAKE
Free
Length (Approx.)
AND
EXHAUST
............................................
..........................................
Length)
Closed
Length)
..........................
.........................
........................
..........................
..........................
1.5645 (39.74) 1
1.5690 (39.85) 1 .5700 (39.88)
0
0.031
0.341
0
0.0025
1.251
0
1.2550
0.031
0
0.3440
0.3440
'0.7475
0.7500
0.0020
(0.787) 0.0470 (1.194)
(8.661) 0.3420 (8.687)
(0.064)
(31.78)
(31.88)
(0.787)
(8.738)
(8.738)
(18.99)
(1
9.05)
(0.051)
1.662 (42.21)
1.125
1.375
Ib
.
71
38
Ib
.
45º
44º
45º
.
.5655
0.0040
1.2520
1.2560
0.0470
0.3460
0.3460
0.7480
0.751
5
0.0040
(28.58)
(34.93)
(32
kg)
(1 7
kg)
(39.76)
(0.1 02)
80)
(31.
(31.90)
(1.1
94)
(8.788)
(8.788)
(19.00)
(1
9.09)
(0.102)
GEAR BACKLASH
Timing Gear
Oil Pump Gear
.............................................
...........................................
3-4
0.001
0.001
0
0
(0.025)
(0.025)
0.0050
0.0080
(0.1 27)
(0.203)
Assembly
The torque values given in Table 1 have been deter- Tighten all studs, nuts, and capscrews as required to
mined for specific applications. Standard torque values keep them from working loose. Refer to the
must not be used where those listed in Table 1 apply.
The engine assembly torques given here will assure
proper tightness without danger of stripping threads.
threads must
oil before torquing.
be
clean and lubricated with new engine
Torques
All
MANUAL
for
the
location
of
washers and capscrews.
PARTS
P216, P218, P220 TORQUE P216, P218, P220 TORQUE
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION
Gearcase Cover
Rear Bearing Plate Screws
Starter Mounting
Connecting
Flywheel Capscrews
Base
Oil
Oil Pump
Valve Cover.
Cylinder Head
Asbestos Gasket
Graphoil Gasket
Gearcase Cover
Rear Bearing Plate Screws
Starter Mounting
Connecting
Flywheel Capscrews
Oil Base
Oil Pump
Valve Cover..
Cylinder Head Nuts (Cold) Other
(w/Compression
(w/o Compression
Rod
......................
.....................
...................
P224 TORQUE P224 TORQUE
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION
Rod
......................
.....................
................
.....
Bolts
.........
Bolts.
.........
...........
Bolts
(Cold) Other
............
.............
...............
.....
Bolts
.........
Bolts..
........
...........
.................
Washers)
Washers)
....
.
Ft.-Lb. Nm
8-1
0
25-27 34-37
19-21 25-28
12-14 16-19
50-55
18-23 24-31
7-9 10-12
1-2 1-3
16-1 8 22-24
14-1 6 19-22
Ft.-Lb. Nm
8-10 11 -14
25-27 34-37
19-21 25-28
27-29 37-39
50-55
18-23 24-31
7-9 10-12
4-8 5-1 1
14 19
.
17
11-14
67-75
67-75
23
TABLE
1.
Intake Manifold
Mounting Screws..
Exhaust Manifold
Mounting Screws..
Other
1/4"
Stud and Nuts..
Other
5/16"
Stud and Nuts
3/8"
Stud and Nuts
Intake Manifold
Mounting Screws..
Exhaust Manifold
Mounting Screws..
Other
1
/4"
Stud and Nuts..
Other
5/16"
Stud and Nuts.
3/8”
Stud
and Nuts
Cylinder Block
.............
Cylinder Block
...............
Cylinder Block
...............
Cylinder Block
..............
Cylinder Block
..............
Cylinder Block
...............
..........
..........
..........
..........
Ft.-Lb.
6-10 8-1 4
9-1 1 12-15
7-9 10-12
8-10 11-14
18-23 24-31
Ft.-Lb.
20-23 27-31
9-1 1 12-1
7-9 10-12
8-10 11-14
18-23 24-31
Nm
Nm
5
Special
The following special tools are available from
Onan. For further information
900-0019.
Valve Seat Driver
Valve Guide Driver
Oil Seal Guide and Driver
Combination Bearing Remover (Main and Cam)
Combination Bearing Driver (Main and Cam)
Flywheel Puller
Tools
see
TOOL CATALOG
Engine
Troubleshooting
ASOLINE ENGINE
FUEL
SYSTEM
INTERNAL ENGINE
LUBRICATION SYSTEM
THROTTLE AND GOVERNOR
M-1686
Oil
System
CRANKCASE
OIL
Refer to Periodic Maintenance Schedule (located in the
If
Operator's Manual) for oil change interval.
operating
in extremely dusty, high ambient, or low ambient
conditions, change oil more often.
Hot crankcase
His
spilled or splashed on skin. Keep
fingers and hands clear when removing
plug
and wear protective clothing.
Do
not overfill crankcase. Excess oil
oil
can cause burns
the
dl
if
drain
causes higher operating tempera-
tures and may cause foaming.
Run engine until thoroughly warm before draining oil.
Stop the engine, place a pan under the drain outlet and
is
remove the oil drain plug. After the oil
completely
drained, clean and replace the drain plug. Fill crankcase
with correct amount of oil. Refer to SPEClFlCATlONS for
Use
crankcase capacity.
SF,
fication
SF/CC, or SF/CD. Refer
oils meeting the
the proper viscosity grade of oil
to
to
use. Straight weight
API
classi-
chart to determine
oils are recommended for severe duty use and at
temperatures above 32ºF (0ºC) for minimum oil
consumption.
Crankcasepressure can blow
oil and cause
check dl while
Oil level should be to the
the
engine
FULL
is
serious
burns.
Operating.
mark of the dipstick. Start
out
Do
hot
NOT
engine and run for a short time to check for oil leaks
around the drain plug.
TORO
POWER
PLUS
Engine
FIGURE
FULL
ADD - REFER
1.
CRANKCASE
-
ALWAYS
LEAKAGE
TO
AMOUNT
OIL
FILL
REPLACE
OR
MAY
OCCUR
NOT
OVERFILL
ON
OIL
DIPSTICK
C-1000
I
COOLING
FIGURE
FINS
2.
OIL
FILTER
OIL FILTER CHANGE
Refer to
the Operator’s Manual) for oil filter change interval.
operating in extremely dusty, high ambient,
ambient conditions, change oil filter more often.
Spin off oil filter element and discard
clean filter mounting surfaceand make sure new gasket
is inserted in the element. Apply a thin film of clean oil to
the gasket. Spin element down by hand until gasket just
touches mounting pad and then turn down an additional
1
1/2-3/4
With oil in crankcase, start engine and check for leaks
around filter element. Retighten only as much as
necessary to eliminate leaks; do not overtighten.
Periodic Maintenenace Schedule
it.
turn. Do not overtighten.
(located in
or
low
Thoroughly
If
CRANKCASE BREATHER
The crankcase breather prevents pressure from building
up in the crankcase. It also prevents oil contamination
or
by removing moisture
harmful blow-by materials from the crankcase. These
vapors are routed to the carburetor where they are
mixed with incoming air and burned in the combustion
chamber. A sticky breather valve can cause oil leaks,
high oil consumption, rough idle, reduced engine power,
and a rapid formation of sludge and varnish within the
engine.
gasoline vapors and other
BREATHER
Crankcase
Breather
Service
If the crankcase becomes pressurized as evidenced by
or
oil leaks at the seals
excessive oil in the air cleaner
housing, use the following procedure to service.
Most parts cleaning solvents
are
flammable and could cause serious
personal injury
facturer’s recommendations
if
used
improperly. Follow the manu-
when
cleaning
parts.
P216, P218, P220
Remove the breather
ure
3A).
Remove capscrew, flatwashers, valve cover,
pack, spring, washer,
tube
from the valve cover (Fig-
reed
valve, and breather baffle.
Discard gasket and clean all parts in part cleaning
solvent
Over tightening the valve cover can
cause an air leak and allow dirt to
to
enter the engine. Be careful not
distort the valve
cover when tightening.
The reed valve must be flat with no sign of a crease.
Assemble using a new gasket. Do not overtighten valve
cover capscrew.
P224
Remove the breather hose from cap and valve assembly.
Remove cap and valve assembly and wash in a suitable
if
solvent. Replace cap and valve
freely. Puli pack out and wash in solvent.
of
operation
shown in Figure
the valve, screens must be positioned as
38.
balls do not move
To
allow free
FIGURE
FIGURE
3A.
CRANKCASE
3B.
BREATHER
CRANKCASE
-
P216,
BREATHER
P218,
HOSE
CLAMP
-
P224
P220
CLAMP
PACK
6-2
PRESSURE
All
engines use an oil pump to provide a constant flow of
oil to the engine parts. The oil supply collects in the oil
base where it is picked up by the oil pump pick-up cup.
A
by-pass valve is used to control oil pressure. Drain oil
before removing oil base and always use a new gasket
when replacing the oil base.
Oil
Pump
The
oil
pump (Figure 4) is mounted behind the gear
cover and is driven by the crankshaft gear. Inlet pipe and
screen assembly are attached directly to the pump
A
body.
a drilled passage in the crankcase. Parallel passages
distribute oil to the front and rear main bearing and the
oil bypass valve.
discharge passage in pump cover registers with
LUBRICATION
OIL PUMP PICK-UP CUP
Check oil pump thoroughly for worn
prime it before reinstalling. Except for gaskets and pickup cup, component parts of the pump are not available
individually. Install a new pump assembly
are worn,.
Oil
By-Pass
The by-pass valve (located to the right and behind gear
cover) controls oil pressure by allowing excess oil to
the
flow directly back to
a
pressure to
P216, P218, and P220, and about
the P224 at normal operating temperature.
The valve is non-adjustable and normally does not need
maintenance. Determine if valve is operating correctly
by inspecting plunger action as follows:
1.
Remove the cap screw located behind gear cover
and under governor arm.
2. Remove spring and plunger with a magnetic tool.
3.
Determine proper valve operation by checking the
spring and plunger according to the following
measurements:
maximum of about 20 psi (1
crankcase. The valve limits oil
Valve
30
parts.
Oil pump to
if
any parts,
38
kPa) on the
psi (207 kPa) on
OIL
PUMP ASSEMBLY
CRANKCASE TURNED
LEFT SIDE
ON
FIGURE
Circumferential grooves in the main bearings supply oil
to connecting rod bearings through drilled passages
from each main journal.
front main bearing oil supply to the front camshaft
bearing; rear cam bearing is splash lubricated.
Normal oil pressure should be
1500 rpm when the engine is at normal operating
temperature.
value, inspect oil system for faulty components.
If
4.
OIL
PUMP
ASSEMBLY
A
drilled passage connects the
8
psi
(55
kPa) or higher at
pressure at 1500 rpm drops below this
Plunger Diameter
Spring
Free Length
Load
4.
Check the valve seat and clean away any accumu-
lation, of metal particles which could cause erratic
valve, action. Verify that the valve seat is not
damaged.
Clean plunger and spring in parts cleaning solvent
5.
and install.
.....
when compressed to
..........
..............
.;.
....
.2.6 ± 0.2 Ibs (11.6 ± 0.9
0.3105 to 0.3125 in.
(7.89 to 7.94 mm)
1.00 inch
(25.4
mm)
N)
0.5
inch (12.7 mm)
Fuel
System
CARBURETOR
Note: See pages
All
carburetors have a fixed main jet An optional fixed
main jet is available for altitude compensation above
5,000
feet.
The carburetor idle mixture was set for maximum
efficiency at the factory and should normally not
disturbed.
the ignition system is working properly and governor
sensitivity is properly adjusted.
The carburetor has a limited adjustment range between
stops of
within these limits; in to lean the mixture, out to richen.
seat.
If
replacing idle mixture screw, turn in until lightly
seated, then turn screw
P216, P218,
P224
the
stop approximately centered.
If
adjustments seem necessary, first
±
1/8
Turn
in
only
and
carburetor. Replace limiter cap with the plastic
7-4-1,
74-2
for
Spec G
turn. The screw should only
forcing
tight
P220
the
mixture
will
damage
until
light
tension
back
carburetors, and
adjustment
out
1-1
be
screw
the needle
can
be
/4
turns
1
-1
Engines.
be
adjusted
felt
for the
/2
turns for
be
sure
and
Carburetor
1.
Start
(at least
Some equipment manufacturers may require higher
throttle stop
settings. Refer to equipment manufacturer's Operator's Manual for the correct rpm settings. When
rpm settings are not specified by the equipment
manu-factum, use the rpm settings listed
and
2.
Move the engine
Bend
the throttle stop screw on the carburetor controls
engine speed. Adjust the throttle stop screw for
1000
3.
Adjust the governor low speed stop for
idle.
4.
Move the engine
Bend the high
engine runs at
recommended
speed
the
engine and allow it to warm up thoroughly
10
Settings
minutes).
speed
and governor low
speed
in
3.
speed
control
or
turn the low
rpm idle (Figures 1 and
speed
to
the slow position.
stop on the governor
2).
1100
speed
speed
control to the fast position.
stop on
the
equipment manufacturer's
the
governor
speed.
Steps
so
rpm
2
so
rpm
the
ADJUSTMENT
SCREW
I
LOW
SPEED
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