ONAN TORO POWER PLUS P216 18 20 24 EngineS Workshop Manual

ONAN TORO POWER PLUS P216, 18, 20, 24 ENGINES - HORIZONTAL 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 P216, P218, P220 P216,P218,P220 P224 P224 ASSEMBLY TORQUES SPECIAL TOOLS ENGINE TROUBLESHOOTING OIL SYSTEM CRANKCASE OIL OIL FILTER CHANGE CRANKCASE BREATHER CRANKCASE BREATHER SERVICE P216, P218, P220 P224 PRESSURE LUBRICATION OIL PUMP OIL BYPASS VALVE FUEL SYSTEM CARBURETOR CARBURETOR SPEED SETTINGS CARBURETOR OVERHAUL REMOVAL DISASSEMBLY CLEANING AND REPAIR REASSEMBLY AND INSTALLATION PULSATING-DIAPHRAGM FUEL PUMP FUEL PUMP TEST PROCEDURE PURPOSE CARBURETOR (BEGINNING SPEC G) CARBURETOR HIGH-ALTITUDE JET (OPTIONAL) AIR CLEANER GOVERNOR SENSITIVITY

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 ALTERNATOR 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 BORES 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 1709 P216,18,20,24 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 imme- diate hazards which will result in severe personal injury or death. Thissymbolreferstoahazardor unsafe practice which can result In severe personal injury or death. Thissymbolrefersto a hazard or unsafe practice which can result in personal injury or product or property damage. Fuels, electrical equipment batteries, exhaust gases and movingpartspresentpotentialhazardsthat can result in serious, personal injury. Take care in following these recommended procedures. All local. state and federal codes should be consulted and complied with. This engine is not designed or In- tended for use in any type of aircraft. Use of this engine in aircraft can result in engine failure and causes serious personal injury or death. General Provide appropriate fire extinguishers and install them in convenient locations. Use an extinguisher rated ABC by NFPA. Make sure that all fasteners on the engine are secure and accurately torqued. Keep guards in position over fans, driving belts, etc. If it is necessary to make adjustments while the engine is running, use extreme caution when close to hot exhausts, moving parts. etc. Protect Against Moving Parts Do not wear loose clothing in the vicinity of moving parts. such as PTO shafts, flywheels, blowers, couplings, fans, belts, etc. Keep your hands away from moving parts. Batteries Before starting work on the engine. disconnect batteries to prevent inadvertent starting of the engine. DO NOT SMOKE whileservicingbatteries.Leadacid batteries give off a highly explosive hydrogen gas which can be ignited by flame, electrical arcing or by smoking. Verify battery polarity before connecting battery cables. Connect negative cable last. Fuel System DO NOT fill fuel tanks while engine is running. DO NOT smoke or use an open flame in the vicinity of the engine or fuel tank. Internal combustion engine fuels are highly flammable. Fuel lines must be of steel piping, adequately secured, andfreefromleaks.Pipingattheengineshouldbe approved flexible line., Do not use copper piping for flexible lines as copper will work harden and become brittle enough to break. Be sure all fuel supplies have a positive shutoff valve. Exhaust System Exhaust products of any internal combustion engine are toxic and can cause injury, or death if inhaled. All engine applications,especiallythosewithinaconfinedarea, should be equipped with an exhaust system to discharge gases to the outside atmosphere. Do not use exhaust gases to heat a compartment Make' sure that your exhaust system is free of leaks. Ensure that exhaust manifolds are secure and are not warped by bolts unevenly torqued. Exhaust Gas is Deadly! Exhaust gases contain carbon monoxide, a poisonous gas that can cause unconsciousness and death. It is an odorless and colorless gas formed during combustion of hydrocarbon fuels. Symptoms of carbon monoxide poisoning are: Dizziness Vomiting Headache Muscular Twitching Weakness and Sleepiness Throbbing in Temples If you experience any of these symptoms. get out into fresh air 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 of the complete exhaust system. If you notice a change in the sound or appearance of exhaustsystem,shutthe unitdown immediately and have it inspected and repaired at once by a competent mechanic. Cooling System Coolants under pressure have a higher boiling point than water., DO NOT open a radiator pressure cap when coolant temperature is above 212ºF (100ºC) or while engine is running. Keep the Unit and Surrounding Area Clean Make sure that oily rags are not left on or near the engine, Remove all unnecessary grease and oil from the unit ~- Accumulated grease and oil can cause overheating and subsequent engine damage and present a potential fire hazard. E-6

Table of Contents TITLE PAGE General Information ................................................... .1-1 Specifications ........................................................ .2-1 Dimensions and Clearances ............................................. .3-1 Assembly Torques and Special Tools .................................... .4-1 Engine Troubleshooting ............................................... .5-1 Fuel System ........................................................... .7-1 Ignition and Battery Charging ........................................... .8-1 Oil System ........................................................... .6-1 Engine Wiring Diagram ................................................ .8-7 Starting System. ...................................................... .9-1 Englne Disassembly... ............................................... 10-1 EXHAUST GAS IS DEADLY! Exhaust gases from all fuels (Including diesel, gasoline, liquid propane, natural gas) contain carbon monoxide, an odorless andcolorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: Dizziness Throbbing in Temples Nausea Muscular Twitching Headache vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE, ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR lMMEDlATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. Protection against carbon monoxide inhalation includes proper installation, ventilationand regular, frequent visual and audible inspections of the complete exhaust system.

General Information This manual deals with specific mechanical and electrical information needed by engine mechanics for troubleshooting, servicing, repairing, or overhauling the 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. The flywheel-blower end of the engine is the front end so right and left sides are determined by viewing the engine from the front. The No. 1 cylinder is on the left, No. 2 cylinder is on the right. If a major repair or an overhaul is necessary, a competent -mechanic should either do the job or supervise and check the work of the mechanic assigned to the job to ensure that all dimensions, clearances and torque values are within the specified tolerances. 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 locating and correcting engine trouble. The wiring diagram shows how the electrical components are interconnected. The disassembly section contains major overhaul procedures for step by step removal, disassembly, inspection, repair, and assembly of the engine components. Use only Genuine Tom Plower Plus replacement partsto ensure quality and the best possible repair and overhaul results. When ordering parts, always use the complete model and spec number as well as the serial number shown on the nameplate. ENGINE MODEL REFERENCE Identify your model by referring to the model and specification (spec letter) as shown on the unit nameplate. Always use these numbers and the engine serial number when making reference to your engine. How to interpret MODEL and SPEC NO. 3 6 7 1. Factory codeforgeneralidentificationofbasic 2. Number of cylinders. 4. Fuel required (G = gasoline). 5. Engine duty cycle. 6. Factory code for designated optional equipment, if 7. Specification (spec letter) which advances with engine series. 3. BHP rating. any. factory production modifications. See the Operator's Manual for fuel and oil recommendations and the Periodic Maintenance Schedule. INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. 1-1

Specifications This manual contains SI metric equivalents that follow immediately in parentheses after the U.S. customary units of measure. 2- 1

Dimensions and Clearances P216. P218. P220 All clearances given at room temperature of 70°F . (21°C) . All dimensions in inches (approximate millimeter dimensions 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 Bore (Installed service bearing) ........... CRANKSHAFT Main Bearing Journal Diameter ............................ Main Bearing Clearance .................................. Connecting Rod Journal Diameter ......................... Crankshaft End Play ...................................... CONNECTING ROD Connecting Rod Side Clearance ........................... Piston Pin Bushing Bore (Finished bore) .................... Bearing to Crankshaft Clearance ........................... CAMSHAFT Bearing Journal Diameter ................................. Bearing Clearance ....................................... End Play ................................................ Lobe Height P216. P218 Intake ...................................... P216. P218 Exhaust .................................... P220 Intake ............................................ P220 Exhaust .......................................... Large Bore Diameter (Rod bolts properly torqued) ........... PISTON Clearance in Cylinder Measure 90° to pin 1.187 inch below top of piston ......... Piston Pin Bore ........................................... Ring Groove Width Top Compression Ring ................................. Middle Compression Ring ............................... Bottom Oil Control Ring ................................. 3.2490 (82.52) 2.1870 (55.55) 2.001 5 (50.84) 1.3757 (34.94) 1.9992 (50.78) 0.0024 (0.061) 1.6252 (41.28) 0.0060 (0.1 52) 1.6280 (41.35) 0.0020 (0.051) 0.6879 (1 7.47) 0.0020 (0.051) 1.3740 (34.90) 0.01 10 (0.279) 1.1 370 1.1 570 1.1 670 1.1 570 0.001 5 (0.038) 0.0033 (0.084) 0.6877 (1 7.47) 0.0800 (2.032) 0.0800 (2.032) 0.1 880 (4.775) 3.2500 (82.55) 0.005 (0.1 3) 0.003 (0.08) 2.1 880 (55.58) 2.0040 (50.90) 1.3787 (35.02) 2.0000 (50.80) 0.0042 (0.1 07) 1.6260 (41 30) 0.01 20 (0.305) 1.6285 (41 36) 0.0160 (0.406) 0.6882 (1 7.48) 0.0033 (0.084) 1.3745 (34.91) 0.0030 (0.076) 0.0480 (1.219) (28.88) (29.39) (29.64) (29.39) 0.0053 (0.1 35) 0.6882 (1 7.48) 0.081 0 (2.057) 0.081 0 (2.057) 0.1 890 (4.800) 3-1

P216. P218. P220 PISTON PIN Clearance in Piston ...................................... Clearance in Connecting Rod .............................. 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 in Block ............................... Seat Outside Diameter ..................................... Valve Seat Width ......................................... Valve seat Angle ......................................... EXHAUST VALVE Stem Diameter ........................................... Clearance (Stemto Guide) ................................ Valve Face Angle ........................................ EXHAUST VALVE SEAT Seat Bore Diameter in Block ............................... Seat Outside Diameter .................................... Valve Seat Width ......................................... Valve Seat Angle ......................................... VALVE GUIDE Intake Inside Diameter .................................... Exhaust Inside Diameter .................................. TAPPET Body Diameter ........................................... Bore Diameter ............................................ Clearance in Bore ........................................ VALVE SPRINGS INTAKE AND EXHAUST Valve Spring Free Length (Approx.) ........................ Valve Spring Length Valve Open ............................................ Valve Closed .......................................... Spring Load (Valve Open Length) .......................... Spring Load (Valve Closed Length) ......................... MINIMUM MAXIMUM Inches (mm) Inches (mm) 0.00004 (0.001) 0.00064 (0.016) 0.0002 (0.005) 0.0007 (0.01 8) 0.6875 (1 7.46) 0.6877 (1 7.47) 0.0030 0.01 00 0.2795 0.001 0 1.4395 1.4700 0.031 0 0.2780 0.0020 1.1890 1.1 920 0.0310 (0.076) 0.0080 (0.254) 0.0200 (7.099 02800 (0.025) 0.0025 44º (36.56) 1.4405 (37.34) 1.471 0 (0.787) 0.0470 45º (7.061) 02785 (0.051) 0.0035 44º (30.20) 1.1900 (30.28) 1.1930 (0.787) 0.0470 45º 0.281 0 (7.1 37) 0.2820 0.2805 (7.1 25) 0.281 5 0.7475 (1 8.99) 0.7480 0.7500 (1 9.05) 0.751 5 0.0020 (0.051) 0.0040 1 600 (4.64 1.055 (26.80) 1.346 (34.1 9) 55 Ib (25 kg) 25 Ib (11 kg) (0.203) (0.508) (36.59) (37.36) (1.1 94) (30.23) (30.30) (1.194) (1 9.00) (1 9.09) (0.1 02) GEAR BACKLASH Timing Gear ............................................. 0.0010 (0.025) 0.0050 (0.1 27) Oil Pump Gear ........................................... 0.0010 (0.025) 0.0080 (0.203) 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 Rod Journal Diameter ......................... Crankshaft End Play ...................................... CONNECTING ROD Large Bore Diameter (Without bearing installed and rod bolts properly torqued) ........................................ Connecting Rod Side Clearance ........................... Piston Pin Bushing Bore (Without bushing) .................. Piston Pin Bushing Bore (Finished bore) .................... Bearing to Crankshaft Clearance ........................... CAMSHAFT Bearing Journal Diameter ................................. Bearing Clearance ....................................... End Play ................................................ Lobe Height Intake .................................................. Exhaust ................................................ PISTON Clearance in Cylinder Measure 90° to pin 1.187 inch below top of piston ......... Piston Pin Bore .......................................... Ring Groove Width Top Compression Ring ................................. Middle Compression Ring ............................... Bottom Oil Control Ring ................................. PISTON PIN Clearance in Piston ....................................... Diameter ................................................ Clearance in Connecting Rod ............................. PISTON RINGS Clearance Top Groove ........................................... Ring End Gap in Cylinder ................................. MINIMUM Inches 3.5625 2.1 870 2.0015 1.3757 1.9992 0.0024 1.6252 0.0060 1.7505 0.0020 0.81 15 0.7504 0.0020 1.3740 0.0015 0.01 10 0.0070 0.7502 0.0800 0.0800 0.1 880 0.00004 0.0002 0.7500 0.0020 0.01 00 (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 (0.1 78) (1 9.06) (2.032) (2.032) (4.775) (0.001) (0.005) (1 9.05) (0.051) (0.254) 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) 0.0090 0.7506 0.081 0 0.081 0 0.1 890 0.00064 0.0008 0.7502 0.0080 0.0200 (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 (0.229) (1 9.07) (2.057) (2.057) (4.801) (0.01 6) (0.020) (1 9.06) (0.203) (0.508)

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ONAN TORO POWER PLUS P216 18 20 24 EngineS Workshop Manual

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