Onan P216, P218, P220, P224 Performer Series Full Service & Repair Manual

P216, P218 P220, P224 Performer Series Printed in U.S.A. 965-0762 12-96

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. 1 This symbol refers io a hazard or LAWARNING unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in personal injury or product or properfy damage. Fuels, electrical equipment, batteries, exhaust gases and moving parts present potential hazards that 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- IeWARNiNG’ fendedforuseinanytype ofaircraft. Use of this engine in aircraft can result in engine failure and causes serious personal injury or death. General 0 Provide appropriate fire extinguishersand install them in convenient locations. Use an extinguisher rated ABC by NFPA. 0 Make sure that all fasteners on the engine are secure and accurately torqued. Keep guards in position over fans, driving belts, etc. 0 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 0 Do not wear loose clothing in the vicinity of moving parts. such as PTO shafts. flywheels, blowers, couplings, fans, belts, etc. 0 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 while servicing batteries. Lead acid 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, and free from leaks. Piping at the engine should be 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. ” d Exhaust System 0 Exhaust products of any internal combustion engine are toxic and can cause injury, or death if inhaled. All engine applications, especially those within a confined area, should be equipped with an exhaust system to discharge gases to the outside atmosphere. 0 Do not use exhaust gases to heat a compattment. 0 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: 0 Dizziness 0 Vomiting Headache 0 Muscular Twitching 0 Weakness and Sleepiness 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 exhaust system, shut the unit down immediatelyand have it inspected and repaired at once by a competent mechanic. 0 Throbbing in Temples Cooling System . 0 Coolants under pressure havea higher boiling point than water. DO NOT open a radiator pressure cap when coolant temperature is above 212OF (100°C) or while engine is running. Keep the Unit and Surrounding Area Clean 0 Make sure that oily rags are not left on or near the enginc 0 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 ................................................... .I-1 Specifications ........................................................ .2-I Dimensions and Clearances ........................................... .3-1 Assembly Torques and Special Tools ................................... .4-1 Engine Troubleshooting ............................................... .5-1 Oil System ........................................................... .6-1 Fuel System .......................................................... .7-1 Ignition and Battery Charging .......................................... .8-1 Engine Wiring Diagram ................................................ .8-7 Starting System.. ..................................................... .9-1 Engine Disassembly, ................................................. 10-1 ~AWARNING I EXHAUST GAS IS DEADLY! Exhaust gases from all fuels (including diesel, gasoline, 1iqu.J propane, natura gas) contain carbon monoxide, an odorless and colorless gas. Carbonmonoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: 0 Dizziness 0 Nausea 0 Muscular Twitching 0 Headache 0 Vomiting 0 Weakness and Sleepiness 0 Throbbing in Temples 0 Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCEANY OF THESESYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. 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, ventilation and regular, frequent visual and audible inspections of the complete exhaust system. i

General Information INTRODUCTION This manual deals with specific mechanical and electrical information needed by engine mechanics for troubleshooting, servicing, repairing, or overhaulingthe engine. Usethe separatePARTS MANUALfor parts identification and for establishingtheir proper location on assemblies. The PARTS MANUALcontains detailedexploded 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 sidesaredeterminedby viewing theengine 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. See the Operator’s Manualfor fuel and engine oil recom- mendations and the Periodic Maintenance Schedule. Use only Genuine Onan replacement parts to 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. P 2 16 G - I / 10464 A 1. 2. 3. 4. 5. 6. 7. 1 2 3 4 5 6 7 I AWARNING I Factory code for general identification of basic engine series. Number of cylinders. BHP rating. Fuel required (G = horizontal shaft, V = vertical shaft). Engine duty cycle. Factory code for designated optional equipment, if any. Specification (spec letter) which advances with factory production modifications. 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 US. customary units of measure. UNIT OF SERIES 4 SPECIFICATION MEASURE P216 P218 P220 P224 Number of Cylinders 2 2 2 2 Bore in 3.250 3.250 3.250 3.560 (mm) (82.55) (82.55) (82.55) (90.42) Stroke in 2.625 2.875 2.875 3.000 (mm) (66.68) (73.03) (73.03) (76.20) (cm3) (71 0) (782) (782) (983) Compression Ratio 6.5 to 1 7.0 to 1 7.0 to 1 7.0 to 1 Rated Speed (Maximum) RPM 3600 3600 3600 3600 Power at BHP 16 18 20 24 Oil Capacity* Displacement cu in 43.3 47.7 47.7 59.7 Rated Speed (kW) (1 1.9) (13.4) (1 4.9) (1 7.9) Without Filter (litre) (1.4) (1.4) (1.4) (1.4) Medium Capacity Base Qts 2.2 2.2 2.2 2.2 Without Filter (litre) (2.1) (2.1) (2.1) (2.1) Standard Base Qts 1.5 1.5 1.5 1.5 High Capacity Base Qts 2.7 2.7 2.7 2.7 Without Filter (litre) (2.6) (2.6) (2.6) (2.6) Oil Filter Capacity Qts .3 .3 .3 .3 (litre) (.3) (.3) (.3) (.3) Crankshaft Rotation Valve Clearance (Cold) (viewed from flywheel) Clockwise Clockwise Clockwise Clockwise Intake in ,005 ,005 .005 ,005 Exhaust in .013 .013 .013 .013 Spark Plug Gap in ,025 .025 .025 .025 (mm) (64) (.64) (.64) (.64) . (mm) (.13) (.13) (.13) (.13) (mm) (.33) (.33) (.33) (.33) Ignition Timing BTC 20" 20" 20" 20" Cylinder Compression psi 75 to 115 75 to 115 75 to 115 75 to 115 * - Refer to MAlNTENANCE section. (kPa) (517 to 793) (51 7 to 793) (517 to 793) (517 to 793) 2- 1

Dimensions and Clearances I P216, P218, P220 All clearancesgiven at room temperature of 70°F. (21OC).All dimensionsin inches (approximatemillimeter dimensions in parentheses) unless otherwise specified. DESCRIPTION MINIMUM MAXIMUM Inches (mm) Inches (mm) CYLINDER BLOCK Cylinder Bore Honed Diameter ............................ 3.2490 (82.52) 3.2500 (82.55) Maximum Allowable Out-of-Round ......................................... 0.003 (0.08) Main Bearing Inside Diameter (Without bearing) ............. 2.1 870 (55.55) 2.1 880 (55.58) Main Bearing Inside Diameter (Installed service bearing) ..... 2.0015 (50.84) 2.0040 (50.90) Camshaft Bearing Bore (Installed service bearing) ........... 1.3757 (34.94) 1.3787 (35.02) CRANKSHAFT Main Bearing Journal Diameter ............................ 1.9992 (50.78) 2.0000 (50.80) Main Bearing Clearance .................................. 0.0024 (0.061) 0.0042 (0.1 07) Connecting Rod Journal Diameter ......................... 1.6252 (41.28) 1.6260 (41.30) Crankshaft End Play.. .................................... 0.0060 (0.152) 0.01 20 (0.305) Taper ................................................. 0.005 (0.13) CONNECTING ROD Large Bore Diameter (Rod bolts properly torqued) ........... 1.6280 (41.35) 1.6285 (41.36) End Play ................................................ 0.0020 (0.051) 0.01 60 (0.406) Piston Pin Bushing Bore (Finished bore) .................... 0.6879 (17.47) 0.6882 (1 7.48) Bearing to Crankshaft Clearance.. ......................... 0.0020 (0.051) 0.0033 (0.084) CAMSHAFT Bearing Journal Diameter ................................. 1.3740 (34.90) 1.3745 (34.91) Bearing Clearance ....................................... 0.0015 (0.038) 0.0030 (0.076) 0.0480 (1.219) Lobe Height End Play ................................................ 0.0110 (0.279) P216, P218 Intake.. .................................... 1.1 370 (28.88) P216, P218 Exhaust .................................... 1.1 570 (29.39) P220 Intake.. .......................................... 1.1670 (29.64) P220 Exhaust.. ........................................ 1.1 570 (29.39) PISTON Clearance in Cylinder Measure 90° to pin 1.187 inch below top of piston ......... 0.0033 (0.084) 0.0053 (0.1 35) Piston Pin Bore 0.6877 (17.47) 0.6882 (1 7.48) Ring Groove Width .......................................... Top Compression Ring ................................. 0.0800 (2.032) 0.081 0 (2.057) Bottom Oil Control Ring. ................................ 0.1 880 (4.775) 0.1 890 (4.800) * Middle Compression Ring., ............................. 0.0800 (2.032) 0.081 0 (2.057) C 3-1

P216. P218. P220 DESCRIPTION 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 (Stem to 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) ......................... GEAR BACKLASH Timing Gear ............................................. Oil Pump Gear ........................................... MINIMUM MAXIMUM Inches (mm) Inches (mm) 0.00004 (0.001) 0.00064 (0.01 6) 0.0002 (0.005) 0.0007 (0.01 8) 0.6875 (17.46) 0.6877 (1 7.47) 0.0030 (0.076) 0.0080 (0.203) 0.01 00 (0.254) 0.0200 (0.508) 0.2795 (7.099) 0.2800 (7.1 12) 0.001 0 (0.025) 0.0025 (0.064) 44O 1.4395 (36.56) 1.4405 (36.59) 1.443 (36.65) 1.444 (36.68) 0.031 0 (0.787) 0.0470 (1.1 94) 45O 0.2780 (7.061) 0.2785 (7.074) 0.0020 (0.051) 0.0035 (0.089) 44" 1.1 890 (30.20) 1.1 900 (30.23) 1.1 920 (30.28) 1 . 1930 (30.30) 0.031 0 (0.787) 0.0470 (1.1 94) 45O 0.281 0 (7.137) 0.2820 (7.163) 0.2805 (7.1 25) 0.281 5 (7.150) 0.7475 (18.99) 0.7480 (1 9.00) 0.7500 (19.05) 0.751 5 (1 9-09) 0.0020 (0.051) 0.0040 (0.102) 1.600 (40.64) 1.055 (26.80) 1.346 (34.1 9) 55 Ib . (25 kg) 25 Ib . (11 kg) 0.001 0 (0.025) 0.0050 (0.1 27) 0.001 0 (0.025) 0.0080 (0.203) 3-2

Onan P216, P218, P220, P224 Performer Series Full Service & Repair Manual

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