ONAN TORO POWER PLUS P216V, 18V, 20V ENGINE - VERTICAL Table of Contents – Page 1 of 2 SAFETY PRECAUTIONS 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 ASSEMBLY TORQUES SPECIAL TOOLS ENGINE TROUBLESHOOTING OIL SYSTEM CRANKCASE OIL OIL FILTER CHANGE CRANKCASE BREATHER PRESSURE LUBRICATION OIL PUMP OI
ONAN TORO POWER PLUS P216V, 18V, 20V ENGINE - VERTICAL 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 ALTERNATOR ALTERNATOR OUTPUT TEST STARTING SYSTEM ELECTRIC STARTER SERVICE STARTER REMOVAL STARTER DISASSEMBLY STARTER ASSEMBLY INSPECTION AND TESTING STARTER MOUNTING ENGINE DISASSEMBLY DISASSEMBLY/ASSEMBLY VALVE SYSTEM TAPPETS VALVE FACE AND SEAT GRINDING F
Service Manual 1710 P216V,18V,2OV Toro Power Plus Engine Tractors & Riding Mowers
Safety Precautions It is recommended that you read your engine manual and become thoroughly acquainted with your equipment before you start the engine. This symbol if used warns of immediatehazards which will result in severe personal injury or death. This symbol refers lo a hazard or unsafe practice which can result In severe personal injury or death. Fuel System DO NOT fill fuel tanks while engineis running. in the vicinityof the DO NOT smoke or use an open flame engine or fuel tank.
Table of Contents TITLE PAGE . l-1 General Information .................................................. Specifications ............................... ....................... .2-1 .3-1 Dimensions and Clearances .......................................... .4-1 Assembly Torques and Special Tools .5-1 Engine Troubleshooting .............................................. Oil System .......................................................... .6-1 Fuel System. ................................... .
General Information INTRODUCTION This manual dealswith specific mechanicaland electrical informationneededbyenginemechanicsfor troubleshooting, servicing, repairing, or overhauling the engine. Use the separate PARTS MANUAL parts for 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.
ter Specifications . This manual contains SI metric equivalents thatfollow immediately in parentheses after the U.S. customary units of measure. OF SPECIFICATION UNIT MEASURE Number of Cylinders 3.250 Bore 3.250 in (mm) in (mm) CU in (cm³) Stroke Displacement Compression Ratio 20 Power at Speed Rated (3600rpm) Oil Capacity 1.7 Without Oil.3 Filter Capacity 18 . (.3) Valve Clearance (Cold) Intake Spark Plug Gap BHP (kW) 1.7. .3 Qts (litre) (.3) in 2 3.250 (82.55) 2.625 (66.68) 43.3 (710) 6.
Dimensions and Clearances All measurements given at room temperature of 70°F (21°C). All measurements are given in inches with approximate millimeter measurementsin parentheses. Measurements are for standard size parts. DESCRIPTION MAXIMUM (mm) Inches CYLINDER BLOCK Cylinder Bore Diameter .................................... Piston Clearance .......................................... Maximum Allowable Taper ................................................. Out-of-Round ....................................
ngle Angle DESCRIPTION (standard size) Measure 90° from pin bore 1.187 below top of piston. ................................ Ring Groove Width Top Groove ..................................... ....... Middle Groove. ........................................ Bottom Groove. ......................................... Top Groove Clearance. ................................... Pin Bore ................................................ Pin Clearance ............................................ PISTON Diameter ....
Assembly Torques The torque values given in Table 1 havebeen determinedfor specific applications.Standard torque values must not be usedwherethose listed in Table 1 apply. The engine assembly torques given here will assure proper tightness without danger of stripping threads. All threads must be clean and lubricated with new engine oil before torquing. Tighten all studs,nuts, andcapscrews as required to keep themfrom working loose.Refer to the PARTS MANUAL for the location ofwashers and capscrews.
Engine Troubleshooting M-1686 5- 1
Oil System CRANKCASE OIL Refer to Periodic Maintenance Schedule (located in the Operator's Manual) for oil change interval. If operating in extremely'-dusty, high ambient, 'or low ambient conditions, change oil more often. Hotcrankcase oil can cause burns if it comes in contact with skin.. Wear protective clothing and keep fingers and hands clear when draining oil. Crankcase pressure can blow out hot oil, which can cause severe personal injury. Do not check oil while the engine is running.
CRANKCASEBREATHER Oil Bypass Check Ball The crankcase breather prevents pressurefrom building up the crankcase It also prevents oil contamination by removing moistureor gasoline vapors and other 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.
F’uelSystem . . . .. . _ . i . CARBURETOR Carburetor Speed Settings All carburetors have a fixed’main jet. An’optional fixed main jet is avai1abI.e for altitude compensation above 5,000 feet. The carburetor idle mixture wasset for maximum efficiency at the factory and should normally not be disfurbed. If adjustments seem necessary, first be sure the ignition system is working properly and governor sensitivity is properly adjusted.
CARBURETOR OVERHAUL Carburetion problems that are notcorrected by mixture adjustments are usually a result of gummed-up fuel passagesor worn internal parts.Themosteffective solution is a carburetor overhaul. In general, overhauling a carburetor consists of disassembly, a thorough cleaning, and replacement of worn parts. Carburetoroverhaul kits are available. General instructions for overhauling a carburetor are given below.
NEEDLE AND SEAT DJUST BEND FLOAT TANG HERE TO HERE TO ADJUST FLOAT LEVEL ADJUSTMENT WITH FUEL NOFUEL When checking (loaflevel and floatdrop, measure lo float body, not seam. FIGURE 4. CARBURETORFLOATLEVELADJUSTMENTS Cleaning and Repair Reassembly and Installation 1. Soak all metalcomponentsnot 1. Install needle valve, main jet, 2. Clean all carbon from the carburetor bore, especially where the throttle andchoke plates seat. Be careful not to plug the idle or main fuel ports. 2.
PULSATING-DIAPHRAGM FUELPUMP Ignitionfuelcanresult severe personal injury or Thoroughly clean up any spilled fuel. Pulsating-diaphragmfuel pumps, or pulse pumps, rely on changesin crankcasevacuum to create a pulsating movementofthe pump diaphragm. As the engine's pistons moveoutward,avacuum is created.This vacuum is transmitted to the pump diaphragm causing it to pull back and suck fuel into the pump.
AIR CLEANER A dirty air cleaner element can cause engine damage. Ensure air cleaner element is kept clean and free of excess debris. Running engine without air cleaner element will result in engine damage. Do not run engine without air cleaner element installed. Engine is equipped with a paperelement.Refer to Periodic Maintenance Schedule (located in the Operator's Manual) for service and replacement intervals. Service by gently tapping element on a flat surface.
GOVERNOR SENSITIVITY These engines are adapted foruse where a wide range of speed settingsis desired. Engine speedis controlled between minimum and maximum by moving the throttle lever until the desired speedis reached. Check Governor arm, spring,linkage, and throttle shaft for abinding conditionor excessive wear at connecting points. A binding condition will cause the governor to act slowly and regulation to be poor. Excessive wearwill cause a hunting condition and regulation to-be erratic.
Ignition and Battery Charging IGNITION SYSTEM DESCRIPTION This engine is equipped 'with 'an electronic battery ignition system. Both spark plugs fire, simultaneously, thus the needfor a distributor is eliminated.The electronic ignition module is locatedon the enginegear cover belowthe flywheel. The module receives a timing signal from magnetswithin the triggerring which rotates with the enginecrankshaft (Figure 1). If the electronic.
IGNITION TIMING 4. Rotate theflywheel slowly by hand in the clockwise direction until the voltmeter reading switches from approximately 1 volt tobattery voltage.At this point, one of the chaff screen bolts should lie between the two timing marks on the blower housing. To recheck timing,theflywheel must berotated another complete revolution in the clockwise direction. Moving the flywheel back and forth across the referencetiming mark will not activate the electronic ignition control.
SPARK PLUGS Check or replace spark plugs as recommended in the Periodic MaintenanceSchedule (located in Operator's Manual). Replace spark plugs that showsigns of fouling or electrodeerosion. terminals Keep the battery clean and tight. Push the cable terminal down flush with orslightly below the top of the battery post (Figure 5).After making connections, coat the terminals with a light application of petroleum jelly or greaseto retard corrosion.
FLYWHEEL ALTERNATOR 5. Jump starting in any other manner may result in damage to-the battery orthe electrical system. This unit is equipped with a permanent magnet flywheel alternator and solid-state voltage regulator-rectifier (Figure 6). As with all solid-state electrical units, precautions are necessary when servicing. Overcranking the engine can cause starter damage. Allow 5 minutes tor starter to cool i f engaged for longer than 30 seconds.
Keep thesepointsin mind when testing orservicing the flywheel alternator: 1. Be sure engine is being run longenough and fast ALTERNATOR OUTPUT TEST Use a volt-ohmmeter,suchas the Simpson 270, when testing thecharging system. enough to recharge battery after each start. Charging 1. Check battery voltage with unit not running. If not system tests requirefullacharged battery. Alternator within specifications (Table 1) charge battery before output is reduced in direct proportiontoengine rpm.
TABLE 1. TESTING 20 AND 35 AMPERE SYSTEMS r BASIC TEST BATTERY STATOR RESISTANCE REGULATOR PROCEDURE Refer to Alternator 20 AMP 12 to 13 VDC 13.6 35 AMP 12 to 13 VDC to 14.7 VD Refer to Alternator Output Test 0.10 to 0.19 Ohms 0.06 to 0.
TYPICAL WIRING DIAGRAM B+ : ACCESSORIES START OIL PRESSURE SWITCH N SWITCH FOR OIL PRESSURE BYPASS IGNITION SWITCH CONTROL CONDENSER WITH OIL PRESSURE SWITCH FOR SHUTDOWN ES-1667 These typical wiring diagrams show the basic wiring necessary for operation of the engine.
Starting System ELECTRIC STARTER 1. Remove both battery cables from battery. Discon- nect ground cablefirst. Normally the starter will require little or no serviceother than possible brush replacement. However, if through accident ormisuse, the starter requiresserviceor overhaul,the followingwillprovide the information necessary to perform this service. Service \ 2. Disconnect battery cable and electrical lead wires from starter. 3. Remove starter motor.
8. Push stopper toward pinion andremove snap ring (Figure 2). 9. Removestopper and overrunning clutch armature shaft. from CLUTCH ES-1194 FIGURE 3. INSTALLING STOPPER ES-1622 FIGURE 2. REMOVINGOVERRUNNINGCLUTCH 5. Fit overrunning clutch into lever, and install with armature in the front bracket. 10 Inspect starter for damagedor worn parts. 6. Install leverretainer and spacer. Position frame assembly over armature onthe front bracket. 11. Repair or replace all damaged or worn parts as needed. 7.
10. Install and tighten the two through capscrews. 11. Install solenoid plunger in lever. Securesolenoid to front bracket with two machinescrews. COMMUTATOR BARS 12. Install wire lead to the terminal “M” on solenoid. 13.Afterassembly,adjust pinion clearance. Pinion 0.08 clearance should be 0.02 to inch (0.5to 2.0 mm); if not, check as follows (Figure 4): A. Connect starter to a battery. Closeswitch. This will shift pinion into cranking position. B. Push pinion back by hand and measure pinion clearance.
Commutator Inspection: If commutator is dirty or discolored, clean with number 00 to 000 commutator paper. Blow grit out of armature after cleaning. Overrunning Clutch:lnspect pinion and spline teeth for wear or damage. If commutator is scored, rough, or worn,turn itdown in a lathe. If pinion gear is worn or damaged, inspect flywheel ring gear also. Rotatepinion. It should turn free when turned in one direction, and lock when turned inthe opposite direction.
Starter Mounting Brush Replacement: Cut old positive brush from pigtail at the brush. Be Careful not to damage field coil. Clean 1 / 4 to 3/8 inch (6.5 to 9.5 mm) of brush end of pigtail with sandpaperemery or cloth. (Figure 9). Before installing starter motor, make sure the starter mounting surfaceon the enginebase is cleanand free of oil. To install starter use thefollowing procedure. The starter pinion gear lash does not require adjustment. 1.
Engine Disassembly DISASSEMBLY/ASSEMBLY When complete engine disassembly is necessary, first remove all complete assemblies. Individual assemblies such as fuel pump and carburetor can be disassembled and repaired at another time. Suggested Disassembly Order 1. Drain engine oil. 2. Disconnect all exhaust and electrical lines. 3. Removeengine fromits mountingsand place upright in a suitable workarea.
VALVE SYSTEM Tappet Adjustment The engine is equipped with adjustable valve tappets. The valve tappet clearance should be checked and as specified in the Periodic Maintenance Schedule (located in the Operator’s Manual). Adjust the valve clearance only whenengine is at ambient temperature. Proceed as follows: 1. Remove ignition key to prevent accidental starting. 2. Remove all parts necessary to gain access to valve tappets. 3. Remove sparkplugs to ease the task of turning the engine over by hand. 4.
Warpage occurs chiefly in the upper stem due to its exposure to intense heat. Out-of-round wear follows when the seatis pounded by a valve whosehead is not in linewith the stem and guide. Ifa valve face is burned or warped, orif the stem is worn, install a new valve. Driving out old valve guides can cause guide and tappet bore damage. Do not strike guide or tappet bores with driver during removal.
Valve Spring: Check valve springs for cracks, worn ends, distortion; and tension. If spring ends are worn, check valve spring retainer for wear. Check for spring distortion by placing spring on a flat surface next to a square. Measure height of spring and rotate it against square edge to measuredistortion. If distortion exceeds 0.06 inch (1.5 mm) replace spring. Check spring tension at the installed height for both the valveopen and closed position using an accurate valve spring tester.
TAPPETS Very little wear takes place on tappet diameters or in tappet bores.If the clearance between tappet and bore in cylinder block exceeds specifications, replace the tappet. Oversize tappetsare available. Inspect the tappet faceswhich contact camshaft lobes for roughness, scuffing,or concave wear. Replace any worn tappets. If tappets are worn, inspect camshaft for wear. VALVE FACE AND SEATGRINDING around the whole valve face, keep grinding until complete face is ground clean.
FLYWHEEL GEAR COVER Removing theflywheel is a relatively simple process, but the following procedure mustbe followed to avoid damage to the gear case and possible injury to the After removing the mounting screws, tap the gear cover gently with a soft faced hammer to loosen it. 1. Turn the flywheel mounting screw outward about two turns. Incorrect flywheel removal can result in severe personal injury. Do not remove flywheel screw completely when using flywheel puller. 2.
IS PROPERLY ASSEMBLED THE DIMENSION SHOWN ON DRAWING WILL BE AS INDICATED 5 BALL GOVERNOR 10 BALL GOVERNOR GOVERNOR CUP GOVERNOR FLYBALL FLYBALL LOCATIONS CS-1238 FIGURE 10. GOVERNOR CUPDETAILS GOVERNOR CUP TIMING GEARS With the gearcover removed, thegovernor cup canbe taken off after removingthe snap ring from the camshaft center pin. Catch the flyballs while sliding the cup off (Figure 10).
4. Turn the crankshaft until the piston is at the bottom of its stroke and remove theconnecting rod nuts. Lift the rod bearing cap from the rod and pushthe rod and piston assembly out through the top of the cylinder using a hammer handle.Do not scratch the crankpin and cylinder wall when removing the piston and rod.. CRANKSHAFT 'GEAR 5. Mark each piston and rod assembly so they can be returned to their respective cylinders afteroverhaul. Keep connectingrodbearingcapswith their respective rods. 6.
FIGURE 15. CHECKINGRINGSIDECLEARANCE Measuring Pistons: Refer' to DIMENSIONSANDCLEARANCES to determine where to measure piston to be sure the total clearance follows specifications. FIGURE 14. PISTON GROOVE CLEANING Inspection Follow the procedures given below when inspecting pistons and connecting rods. Piston Inspection: 1. Inspect the pistons for fractures at the ring lands, skirts and pin bosses. Check for wear at the ring lands using a new ring and feeler gauge (Figure 15).
Measuring Piston Rings: 1. Install thepiston ring in the cylinder bore. Invert the piston and push the ring to the end of ring travel, about halfway into thebore, which trues the ring end gap. Check the gap with a feeler gauge (Figure 16). CYLINDER BLOCK The cylinder block isthe main support for all other basic engine parts. Crankshaft and camshaft are supported by the block, assuring alignment of the crankshaft and cylinder bores. Cleaning 2.
D. Measureandrecordas “D” cylinderbore diameter (perpendicular to crankshaft) at the bottom of piston travel. 2. Record measurements taken a? top and bottom of piston travel as follows: A. Measure and record as “A” the cylinder bore diameter (parallel to crankshaft) near the topof cylinder bore. E. Reading “A” subtracted from reading “B”and reading “C”subtracted from reading “D” indicates cylinder taper. B.
3. Cleanbaseof boring bar beforebar is set up. Deposits under boringbar will causeit to tilt and the cylinder will be distorted after boring. 4. Make an initial roughcut, followed by a finish cut. Then hone cylinder boreto the specified oversize. Honing Cylinders (Using PrecisionHones) Refer to hone manufacturer's recommendedgrit site to produce specified surfacefinish of 20 to 40 RMS. Too rough of a finish will wear out therings and toosmooth of a finish can retard piston ring seating: 1.
ALIGN HOLE IN BEARING CRANKSHAFT Clean crankshaft thoroughly and inspect journalsfor scoring, chipping, cracking, or signs of overheating. .If crankshaft has overheated, is scored, or excessively worn, reconditioning or replacement will be required. Examine bearing journalsfor cracks if overheating has occurred. WITH HOLE OUTSIDE IN BORE BEARING OF BLOCK Measure crankshaft mainbearing and connecting rod journals at severalplaces ontheir diameter to check for roundness and taper.
TOP MAIN BEARING BORE The bottom main bearing consists of two bearings. Use a combination driver and lubricate the outside of the bearings with SAE 30 oil before installing them to the dimension shown (Figure 21). Oil holes in the bearings must line upwith those drilled in the engine blockso a 1/8" diameter pin can beinserted into hole. Lubricate main bearings lightly with oil after installation.
CHECKING CONNECTING ROD BEARING CLEARANCE WITH PLASTIGAUGE 1. Make certain that all parts are markedor identified so they areinstalled in their original positions. Using a clean dry cloth, thoroughlycleanalloil from crankshaft journal and connectingrod. 2. Place a piece of correct size Plastigauge in the bearing capthe full width of the journal surface and about 1/4 inch (6.35 mm) off center (Figure 24). OIL SEALS The gear cover and oil base have to be removed to replace the oil seals.
PISTON ASSEMBLY 1. Lubricate all parts with engine oil. b 2. Position piston on its respective rod and install the pin. 3. Install the rings on the pistons starting with the oil control ring (Figure 26). Use a piston ring spreader to prevent twisting or excessive expansion of the ring Compression rings have a dot or the word “top” on one side of the ring to indicate which side faces the top of the piston. Unmarked piston rings can be installed either way.
CYLINDER HEADS 3. Use new head gaskets and clean both :he heads and the cylinder block thoroughly where the gaskets rest. Removethe cylinder headsfor carbon cleaning and gasket change at intervals specified in the Periodic MaintenanceSchedule(located in theOperator's Manual). Cylinder Head Installation 1. Place a head gasket on the cylinder block and align the holes in the gasketwith the holes in the cylinder block.
Product information and specifications are shown hereinas ofthe time of printing. Wheel Horse Products,Inc. reserves the right to change product specifications, designsand standard equipment without notice and without incurringobligation. Right at home. PRINTED IN U.S.A.
