Toro Power Plus P216V Service Manual Download Page 2

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ONAN TORO POWER PLUS P216V, 18V, 20V ENGINE - VERTICAL

Table of Contents – Page 2 of 2

IGNITION AND BATTERY CHARGING

IGNITION SYSTEM DESCRIPTION

BATTERY JUMP STARTING

FLYWHEEL ALTERNATOR

ALTERNATOR OUTPUT TEST

STARTING SYSTEM

INSPECTION AND TESTING

ENGINE DISASSEMBLY

VALVE FACE AND SEAT GRINDING

PISTONS AND CONNECTING RODS

CHECKING CONNECTING ROD BEARING CLEARANCE

OIL SEALS

PISTON ASSEMBLY

INSTALLATION OF PISTON IN CYLINDER

CYLINDER HEADS

Summary of Contents for Power Plus P216V

Page 1: ...TION INTRODUCTION ENGINE MODEL REFERENCE SPECIFICATIONS DIMENSIONS AND CLEARANCES ASSEMBLY TORQUES SPECIAL TOOLS ENGINE TROUBLESHOOTING OIL SYSTEM CRANKCASE OIL OIL FILTER CHANGE CRANKCASE BREATHER PR...

Page 2: ...TEST STARTING SYSTEM ELECTRIC STARTER SERVICE STARTER REMOVAL STARTER DISASSEMBLY STARTER ASSEMBLY INSPECTION AND TESTING STARTER MOUNTING ENGINE DISASSEMBLY DISASSEMBLY ASSEMBLY VALVE SYSTEM TAPPETS...

Page 3: ...Service Manual 1710 P216V 18V 2OV Toro Power Plus Engine Tractors Riding Mowers...

Page 4: ...T smoke or use an open flame inthe vicinity of the engine or fuel tank Internal combustion engine fuels are highly flammable Fuel lines must be of steel piping adequately secured andfreefromleaks Pipi...

Page 5: ...nd colorlessgas Carbonmonoxide is poisonous and can cause unconsciousness and death Symptomsof carbon monoxidepoisoning can include Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vo...

Page 6: ...ide is provided as aquick reference forlocating and correcting enginetrouble The wiring diagram shows how the electrical compo nents are interconnected Thedisassembly sectioncontains major overhaul pr...

Page 7: ...875 2 875 Displacement CUin 43 3 47 7 47 7 Compression Ratio 6 5to 1 7 0to 1 7 0to 1 Power at BHP 16 18 20 Rated Speed 3600rpm kW 1 1 9 1 3 4 14 9 Oil Capacity 1 7 1 7 1 7 Without ter 1 6 1 1 6 Oil Fi...

Page 8: ...NNECTING ROD Large Bore InsideDiameter rod bolts torqued Large Bore Clearance Piston Pin Bore Piston Pin Clearance EndPlay CAMSHAFT Journal Diameter Lobe Height P216V P218V Intake P216V P218V Exhaust...

Page 9: ...1 1 94 Seat ngle 45 Outside Diameter 1 4700 37 34 1 471 0 37 36 VALVE Stem Diameter 0 2780 7 061 0 2785 7 074 Face Angle 44 EXHAUST VALVE SEAT OutsideDiameter Seat Width Seat Angle VALVE GUIDE Intake...

Page 10: ...Bolts Flywheel Capscrews Valve Cover TORQUE SPECIFICATION Ft Lb Nm 10 12 14 16 27 29 36 39 19 21 25 28 9 11 12 15 20 24 27 33 7 9 10 12 7 9 10 12 19 21 25 28 12 14 16 19 50 55 67 75 3 4 4 5 DESCRIPTI...

Page 11: ...Engine Troubleshooting M 1686 5 1...

Page 12: ...oils arerecommended for severe duty use and at temperaturesabove32 F 0 C forminimumoil consumption Crankcasepressure canblow out hot oil which can cause severepersonal injury Do not check oil while t...

Page 13: ...the front camshaft bearing rear cambearing is splash lubricated Normaloil pressureshould be8 psi 55kPa or higherat 1500 rpm whenthe engine is at normal operating temperature If pressure at 1500 rpm dr...

Page 14: ...he plastic stopapproximately centered HIGH SPEED STOP FS 1000 1 GOVERNOR ASSEMBLY FIGURE 1 GOVERNOR SPEED ADJUSTMENT Carburetor Speed Settings 1 Startthe engine and allow it to warm up thoroughly at l...

Page 15: ...inning for a better understanding of the procedures involved Carburetor componentsare shown in Figure 3 lgnition of fuel can result in severe smoke orallow any spark pilot light or arcing eguip ment n...

Page 16: ...loat if loadedwith fuel or damaged 5 Check the choke and throttle shafts for excessive play in their bore This condition may necessitate replacement of the carburetor Reassembly and Installation 1 Ins...

Page 17: ...stfive seconds Record vacuum gauge reading Move throttle control to high idle position Wait at least five seconds and record vacuum gauge reading Shut engine off and remove vacuum gauge hose from fuel...

Page 18: ...vice and replacement intervals Service by gently tapping element on a flat surface If engine is equipped with an element wrapper refer to Periodic Maintenance Schedule for service intervals ELEMENT CO...

Page 19: ...tion to be erratic Work thegovernorarm back and forth several times by handwhiletheengineisidling to check forabove conditions Thegovernor linkageshould be set up as follows Figure 7 1 The governor sp...

Page 20: ...ark plug wires and ground them away from spark plughole Turn keyon and crank engine over for 5 seconds while watching for spark If a spark occurs regularly the problem is not in the ignition system If...

Page 21: ...e clockwise direction until the voltmeterreading switches from approximately 1 volt tobattery voltage At this point one of the chaff screen bolts should liebetweenthe two timingmarksonthe blower housi...

Page 22: ...osion Poor contactat the battery cable connections is often a source of trouble Makesure batterycables are ingood condition and that contacting surfaces are clean and tightly connected Do not reverseb...

Page 23: ...ith a permanent magnet flywheel alternator and solid state voltage regulator rectifier Figure 6 As with all solid state electrical units pre cautionsare necessary when servicing _ Reversingpositive an...

Page 24: ...tteryterminal voltage regulator output using a DCvoltmeter Voltage output should be within the values specified in Table 1 If voltage is greater than specified replace regulator rectifier assembly If...

Page 25: ...AMP r TABLE 1 TESTING 20 AND 35 AMPERE SYSTEMS BASICTEST BATTERY REGULATOR Refer to Alternator 12to 13 VDC 13 6 to 14 7 VD 12to 13VDC STATOR RESISTANCE Refer to Alternator Output Test 0 10 to 0 19 Ohm...

Page 26: ...GNITION SWITCH CONTROL CONDENSER WITH OIL PRESSURESWITCH FOR SHUTDOWN ES 1667 These typical wiring diagrams show the basic wiring necessary for operation of the engine Your engine may differ in circui...

Page 27: ...start circuit components Failureto crank is normally caused by low batterycharge defectivebatterycables corroded or poor connections or low temperatures Ifafter checking these variables starter contin...

Page 28: ...he following points Recom mended grade MultempPS No 2 Armature shaft spline Both bushings Both ends of armature Stopper on armature shaft Piniongear Sliding portion of lever CLUTCH ES 1194 FIGURE 3 IN...

Page 29: ...CE ES 1623 FIGURE 4 PINION CLEARANCE ADJUSTMENT Inspection and Testing Inspect the starter components for mechanical defects before testingfor grounds or shorts Testing Armature for Grounds Touch arma...

Page 30: ...e Do not cleanoverrunning clutch in liquid cleaning solutions Solenoid Push solenoid plunger in and release it The plunger should return toitsoriginal position While holding plunger all theway in chec...

Page 31: ...batterycableand wires to starter Connect battery cablesto battery Connectground cable last STILL ATTACHED TO FIELDCOIL approx CLEAN 1 4to 3 8 inch SOLDERMUST NOT EXTENDBEYOND BRUSHSURFACE SMALL CHAMFE...

Page 32: ...ngine parts are assem bled the engine should turn over by hand freely Use only genuine Onan parts and special tools when reassemblingyour engine 1 Use proper bearing driver to installtop main bearing...

Page 33: ...revolution and again line up the flywheel timing mark with the governor shafton the gearcover Then follow adjustment procedure given for right hand cylinder 8 Replace all parts removed in Step 2 Tigh...

Page 34: ...uidescan bereplacedfrominsidethe valvechamber a seal is provided behind theintake valve guides only The smaller diameter of the tapered valve guides must face toward the valve head Tappets are also re...

Page 35: ...ts from valve seat Select proper puller size determined by inside diameter of valve seat On some pullers usea new seat asa guide to adjust puller depth Figure 4 Pullerjaws must expand into cylinder bl...

Page 36: ...nife edge will be ground Figure 7 on part or all of the head due to the large amount of metal that must be removedto completely refacevalve Heavy valve heads are required for strength and good heat di...

Page 37: ...haft Take care not to drop the wheel A bentor brokenfin will destroythe balance GEAR COVER After removingthe mountingscrews tap the gear cover gently with a soft faced hammerto loosen it When installi...

Page 38: ...rnor cup as illustrated Hold the cup against the flyballs when measuring The camshaft center pin cannot be pulled outward or removedwithout damage Ifthe centerpinextendsouttoo far the cup will not hol...

Page 39: ...mer handle Donot scratchthe crankpin and cylinder wall when removing the piston and rod 5 Mark each piston and rod assembly so they can be returnedtotheir respectivecylinders afteroverhaul Keep connec...

Page 40: ...15 Replacethepistonwhen the side clearance of the top compression ring reaches that specified in DIMENSIONSAND CLEARANCES 2 Replace pistons showing signs of scuffing scoring worn ring lands fractures...

Page 41: ...st be made afterall parts have been removed and block has been thoroughly cleaned and dried 1 Make a thorough check for cracks Minute cracks may bedetectedbycoating the suspectedarea with a mixture of...

Page 42: ...r or not cylinder is out of round I f out of round exceeds that specified in DIMENSIONS ANDCLEARANCES thecylinders mustbe rebored and honed to the next oversize Reboring the Cylinder Rebore andhoneeng...

Page 43: ...x places in bore measure twice at top middle and bottom at90 degreeangles 6 Crosshatch formed by the stones should form an included angle of 23degrees This can be achieved by moving the rotatinghone 2...

Page 44: ...which do not require line reaming or line boring after installation Use a press or a suitable driver to remove bearings Support casting to avoid distortion and to avoid damaging the bearing bore durin...

Page 45: ...ings Use a combination driver and lubricate the outsideof the bearings with SAE 30 oil before installingthem to the dimension shown Figure 21 Oil holes in the bearings must line up with those drilled...

Page 46: ...n Plastigauge envelope to determine clearance The numberwithin the matching graduation on the envelope indicatestotal clearancein millimeters or thousandths of an inch The gear cover and oil base have...

Page 47: ...s stroke 2 Lubricate the number one piston assembly and inside of the cylinder Compress the rings with a ring compressor Figure 27 3 Position the piston and rod assembly in the cylinder block Oil squi...

Page 48: ...ing heads cleanoutall carbondeposits Be careful not to damage the outer sealing edges where gasketsfit The headsare made of aluminum and can be damaged by carelesshandling NO 1 CYLINDER Placea headgas...

Page 49: ...tions are Wheel HorseProducts Inc reserves the shown herein asofthetime of printing designsand standard equipment without rightt ochange product specifications noticeandwithout incurring obligation Ri...

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