Toro GTS 150 Service Manual Download

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OHV GTS 150 ENGINE SERVICE MANUAL

Table Of Contents – Page 1 of 4

PREFACE

SAFETY INFORMATION

SAFETY TIPS

SPECIFICATIONS

GTS 150 ENGINE SPECIFICATION

GTS 150 CARBURETOR SPECIFICATIONS

GTS 150 FASTENER TORQUES

TOOL REQUIREMENTS

TROUBLESHOOTING

ENGINE DOES NOT START WHEN "COLD"

ENGINE WILL START "COLD", BUT WILL NOT START "HOT"

ENGINE DOES NOT PRODUCE SPARK

ENGINE HAS LOW COMPRESSION

ENGINE FLOODED WITH FUEL

ENGINE VIBRATES EXCESSIVELY

ENGINE CRANKSHAFT WILL NOT TURN

ENGINE PRODUCES MECHANICAL KNOCKING SOUND

PRE-IGNITION

ENGINE SMOKES EXCESSIVELY

ENGINE STALLS

SPARK PLUG FOULED

GTS 150 MAINTENANCE

SERVICING AIR CLEANER

REPLACING THE SPARK PLUG

REMOVING GASOLINE FROM THE FUEL TANK

CHANGING CRANKCASE OIL

CARBURETOR - ADJUSTMENT

COMPRESSION - MEASUREMENT

THROTTLE - ADJUSTMENT

CLEAN THE ENGINE AND RECOIL STARTER

CLEAN THE COOLING SYSTEM

PREPARING THE ENGINE FOR STORAGE

Summary of Contents for GTS 150

Page 1: ...E FLOODED WITH FUEL ENGINE LACKS POWER BENT PUSH ROD ENGINE SURGING ENGINE BACK FIRES ENGINE AFTER FIRES ENGINE OVERHEATS ENGINE VIBRATES EXCESSIVELY ENGINE CRANKSHAFT WILL NOT TURN ENGINE PRODUCES MECHANICAL KNOCKING SOUND PRE IGNITION ENGINE SMOKES EXCESSIVELY ENGINE STALLS SPARK PLUG FOULED GTS 150 MAINTENANCE SERVICING AIR CLEANER REPLACING THE SPARK PLUG REMOVING GASOLINE FROM THE FUEL TANK C...

Page 2: ...UEL TANK REMOVAL FUEL TANK AND FILTER CLEANING FUEL CAP OPERATION FUEL CAP SERVICE FUEL HOSE REMOVAL FUEL HOSE INSTALLATION SECTION 3 IGNITION OPERATION IGNITION OPERATION FLYWHEEL IGNITION OPERATION IGNITION ARMATURE COIL IGNITION OPERATION SPARK PLUG ARMATURE COIL WIRING OPERATION AIR GAP ADJUSTMENT IGNITION ARMATURE COIL REMOVAL IGNITION ARMATURE COIL TESTING IGNITION ARMATURE COIL INSTALLATION...

Page 3: ...E REMOVAL CARBURETOR OPERATION CARBURETOR REMOVAL IGNITION COIL OPERATION IGNITION COIL REMOVAL THROTTLE BRACKET REMOVAL ALTERNATOR OPERATION ALTERNATOR REMOVAL IF INSTALLED FLYWHEEL REMOVAL ELECTRIC STARTER OPERATION ELECTRIC STARTER REMOVAL IF INSTALLED THROTTLE CONTROL LEVER AND LINK ROD REMOVAL VALVE COVER REMOVAL HEAD ASSEMBLY REMOVAL HEAD DISASSEMBLY VALVES AND SEATS RECONDITIONING BREATHER ...

Page 4: ...STALLATION BREATHER INSTALLATION HEAD ASSEMBLY PUSH RODS INSTALLATION HEAD INSTALLATION VALVE CLEARANCE ADJUSTMENT VALVE COVER INSTALLATION THROTTLE BRACKET INSTALLATION GOVERNOR CONTROL LEVER AND LINK ROD INSTALLATION CARBURETOR INSTALLATION GOVERNOR ADJUSTMENT ELECTRIC STARTER INSTALLATION FLYWHEEL INSTALLATION ALTERNATOR INSTALLATION IGNITION ARMATURE COIL INSTALLATION FLYWHEEL BRAKE INSTALLATI...

Page 5: ......

Page 6: ...rmance for the life of the engine you are read this manual carefully Itisnot the purpose ofthis manual toteachcomponent theory but rather to provide the mechanic with a working guideli of maintenance troubleshooting test repair and overhaul procedures The ToroCompany reserves the right to change product specifications or this manual without notice The Toro Company gratefully acknowledges the assis...

Page 7: ...uretor description operation removal pressure testing disassembly cleaning and service assembly adjustment Section 2 FuelSystem fuel tank operation removal cleaning fuel cap operation service fuel hose removal installation Section 3 IgnitionSystem Ignition operation flywheel armature coil 19 19 20 21 21 21 22 22 23 23 23 23 23 23 23 25 25 25 Table of Contents 2 GTS 150 ...

Page 8: ...ion Section5 Engine operation disassembly air cleaner rewind starter blower shroud muffler shroud flywheel brake fuel tank muffler oil fill tube carburetor ignition coil throttle bracket alternator flywheel electric starter throttle control lever head components valves and seats reconditioning breather 25 26 26 26 26 26 27 27 28 28 29 30 30 30 30 30 3 1 3 1 3 1 3 1 32 32 32 33 33 33 34 34 35 36 GT...

Page 9: ...m assembly piston pin and rings piston crankshaft governor shaft cam followers camshaft governor and splasher sump oil pump breather head push rods valves valve clearance adjustment throttle bracket governor control lever carburetor governor adjustment electric starter flywheel alternator ignition armature coil 36 37 37 37 38 38 39 39 40 40 40 41 41 41 41 41 42 42 42 42 43 43 43 43 44 44 44 45 45 ...

Page 10: ...TABLE OF CONTENTS ServiceProcedures cont d flywheelbrake Page45 muffler 45 dipsticktube 46 fuel tank 46 blowershroud 46 rewindstarter 46 air cleaner 47 sparkplug 47 GTS 150 5 Table of Contents ...

Page 11: ... engine while running or shortly after running Avoid fails Do not operate the mower on slippery surfaces or if footing is questionable Avoid fires and falls Wipe up any spilled fuel or oil Avoid asphyxiation Never operatean engine in a confined area without proper ventilation Avoid eye injuries Wear eye protection when working with springs or cables and when running engine Avoid unexpected startin...

Page 12: ...r 44 ounces 1 3 liters solid state magneto type 22 degrees BTDC primary 2 4 Ohms secondary2400 5000 Ohms Champion RC12YC gap 030 76 mm rewind 1 2 volt on some models _ I RecommendedOil detergent SAE1OW 30 or 30 SF SG two stage foam type with optional paper element manual snap over design intank washable 75 micron Piston aluminum alloy nent I Piston Rings two compression one 3 piece oil control GTS...

Page 13: ...SPECIFICATIONS cont d GTS 150Carburetor Specifications GTS 150 Fastener Torques Specifications a GTS 150 ...

Page 14: ...ve adjustingj a m screw Nutdriver acceptable _ I _ __ I _ _ _ _ _ r m Y _ _ _ I I p deep well for spark plug _ _ _s_ B S part number 19372 B S part number 19069 6 S part number19334 6 S part number19070 B S part number19340 _ ____I_____ _______I p _ I I _ _ _ t i 1 1 _ 1 _ _ _ _ Specifications ...

Page 15: ...TROUBLESHOOTING Engine Does Not Start When Cold Engine Will Start Cold but will Not Start Hot inadequatevalve clearance readjust valves to 005 007 12 17 mm measured Engine Does Not Produce Spark GTS 150 ...

Page 16: ...Engine has Low Compression incorrect valve clearance readjust valvesto 005 007 15 17 mm measured with engine cold Engine Flooded with Fuel c a r b u r e t o r replacefailed parts Engine Lacks Power GTS 150 11 Troubleshooting ...

Page 17: ...TROUBLESHOOTING cont d Bent PushRod Engine Surging Engine Back Fires Engine After Fires Engine Overheats Engine Vibrates Excessively out of balance blade Trouble shooting 12 GTS 150 ...

Page 18: ...LESHOOTING cont d Engine Crankshaft Will Not Turn Engine Produces Mechanical Knocking Sound Pre Ignition _ w i t hfresh unleaded regular fuel with no more Engine Smokes Excessively GTS 150 13 Troubleshooting ...

Page 19: ...TROUBLESHOOTING cont d Engine Stalls Spark Plug Fouled ...

Page 20: ...nd to distribute theoil thor oughly A damp elementis desirable 4 Reinstall the foam element and air cleaner cover Do not operate the engine without the air cleaner element as extreme engine wear and damage will likely result A Paper elements are available for use inextremely dirty conditions Toropart number 77 901 0 Replacingthe Spark Plug Use a Champion RC12YC spark plug or equivalent Th correct ...

Page 21: ...ained return the mower toitsupright positionandaddfreshoil to theengine Refer to Filling the Crankcase with Oil onpagexx The crank case capacity is25oz 74 liters When changing oil the crankcase may retain a small amount of oil reduc ing the amount required to bring the oil level back to normal Carburetor Adjustment 1 Turn the idle mixturescrew clockwise until itseats DO NOT FORCE 2 Turntheidlemixt...

Page 22: ...value Throttle Adjustment Throttle control adjustment may berequiredifthe engine does not start stop or run at the correct speed Whenever a new throttle control cable isinstalled the throttle must be adjusted 1 Stop the engine allow it to cool and disconnectthe sparkplugwire Removethekeyonelectric start models 2 Move the throttle control to the Fast position 3 Loosen the cable clamp screw untilthe...

Page 23: ...med and the engine stops Repeat the starting procedure twomore times to assure allthe gaso lineisremoved from the engine If gasoline isnot removed fromthecarburetor in this manner gum likevarnish deposits will form and cause starting problems and or poor engine operation 18 Fuel can be left inthe fuel tank only if afuel additive such as Toro s Stabilizer Conditioneris added to the gasoline and run...

Page 24: ...y or becomes atomized and mixes with the air stream See Figure 10 VENTURI CARBURETOR BORE FLOAT BOWL TO ENGINE When starting the engine an extra rich mixture is required The choke plateis closed by the operator to provide an approximate 8 l approximatelysixtimesricherthan normal ratio of fuelto air for this rich mixture Closing the choke plate further reduces the air pressure area in the venturito...

Page 25: ...Remove the three 5 16 hex washer head shoulder screws retaining the air cleaner to thecarburetor Takecarenot to losethecorkgasketthatseals between the air cleaner body and the carburetor See Figure 14 Figure 14 3 Disconnect the chokeover centerspring Notethe position of thespringforcorrectassembly See Figure 15 Figure 15 4 Remove thetwo 3 8 hex washer head screws that retain the carburetor the ins...

Page 26: ...body of the carburetor 7 Ifthe carburetor vent passage isopen it is not neces sary to remove the welch plug that covers the vent opening inthe bowlof the carburetor Thisis a vent areathatdoesnothaveafilterscreenorother cleanabledevice 8 Removethe pilot circuit welch plug from the side ofthe carburetor Piercetheplugwithasmallchiselor pointed device and pry the plug out of the body of the carburetor...

Page 27: ...r center spring slot toward the right side of the carburetor 6 Insert the choke plate so the plateis capturedinthe slot of the choke shaft The choke should fully close with a90 degree clockwise turn of the shaft 7 Install the idle stop screw Adjustment of the screw should be performed when the engine isrunning Idle speed should besetto1700RPM See page 16for the carburetor adjustment procedure 8 In...

Page 28: ...c thatisventedto a baffle assembly inthe body of the cap The baffle assembly actsto allow expansionin the tank without lossof fuel Atmospheric pressure isallowed GTS150 23 into the tank from an opening inthe capto allow gravity to feed fuel to the carburetor FuelCap Service 1 The fuel cap may not be disassembled however the vent opening on the cap and inner sealing disc sh be kept free of debris 2...

Page 29: ...t 5 Make sure the cork gasket is between the air cleaner body and the carburetor Installthe three5 16 hex washer head shoulder screws 6 Make sure the air cleaner element isproperly cleaned and oiled see Maintenance Section on page 15 and install the element 7 Install the air cleaner cover and tighten the thumb screw GTS150 ...

Page 30: ... current to flow through resistor R tothe base of transistor TR1 This small ba currentwillcause the transistor to turn on creating a low resistance path through the collector emitter circuit ofthe transistor as shown by the dotted line As the magnets continue to cut throughthe coils of the primary winding the primary voltage will increase This voltage also develops across the voltage divider netwo...

Page 31: ...ap and replace the blower shroud The blower shroud fasteners are tightened to 50inIbs 5 6Nm 7 Install the gas cap Ignition Armature Coil Removal 1 Removethegascap CAUTION extreme care ifthere isfuel inthe gas tank Do not smoke or allow open flames around gasoline Gasoline fumes are explosive 2 Remove the four3 8 hex washer head screws that retain the blower housing on the fueltank 3 Remove the blo...

Page 32: ...ly to the engine 2 RemovethealignmentpinfromthePhillipshead screw in the center of the rewind mechanism See Figure24 Figure 24 3 RemovethePhillips head screw from the center of the rewind mechanism and lift the friction plate from the starter See Figure 25 4 Remove the two ratchet dogs and springs Take note of the positioning of the springsfor correct instal See Figure26 Figure 26 5 Completely ext...

Page 33: ...all the dog springs and the brake spring as shown in Figure29 Figure 29 Rewind Starter 28 4 Install the friction disc retainer and retainingscrew See Figure30 SCREW Figure 30 5 Drive the aligning roll pininto the center of the retain ing screw and slide the plastic sleeve over the pin Figure31 Figure 31 Rewind Starter Installation 1 Install the rewind starter on the blower housing cen tering the a...

Page 34: ...C See Figure 32 Figure 32 Compression Stroke The second stroke compression begins as the piston leaves BDC and moves toward TDC Both the intake and exhaustvalvesareclosedatthistime Asthepiston moves the air fuel mixture is compressedinthe cylinder See Figure 33 Figure33 GTS 150 29 Power Stroke When the piston comes close toTDC the mixture is ignite by the spark plug and the third stroke begins The...

Page 35: ...6 2 Remove the foam filter element See Figure 36 3 Remove the three 5 16 hex washer head shoulder screws retaining the air cleaner body tothe carburetor and throttle bracket 4 Pull the air cleaner body away from the engine and at the same time pullthe breather hose off the breather vent tube Donot lose the cork gasket between the air cleaner body and the carburetor See Figure 37 AIR RETAININGSCREW...

Page 36: ...fuel ina container designed for gasoline and never smoke while working around gasoline 3 Releasethe clamping pliers and drain the fuel into a container designed to receive gasoline 4 Remove the two 3 8 hex washerheadscrews 1 1 4 long retaining the fuel tank to the engine 5 The75micron fuel filter screen isan integral part ofthe fuel tank and is not removable GTS 150 31 Muffler Operation The muffle...

Page 37: ...t may now be removed Ignition Coil Operation See Section3 Ignition page25 lgnltionC o i l Removal 1 Note the routingof the ignition ground kill wire this will make reinstallation easier Disconnect the ignition groundwirefrom the terminal on the back of the throttle bracket See Figure 45 2 Disconnect the ignition coil high tension wire from the spark plug 3 Remove the two5 16 hex head screws retain...

Page 38: ...15 16 hex nut retainingtheflywheel starter cup See Figure 50 Figure 50 2 Remove the starter cup andreinstall the flywheel nut to protect the threads on the end of the crankshaft 3 Install Briggs and Stratton flywheel puller 19203 as shown in Figure 51 and remove the flywheel The holes in the flywheel are not tapped and require the useoftheselftappingscrewsincluded with the flywheel puller Alternat...

Page 39: ... 53 2 Use a screwdriverto open the split end of the throttle control lever governor arm and slip the lever off the governor shaft Valve Cover Removal 1 Remove the four 5 16 washer head cap screws that 2 Removethe cover and gasket See Figure 54 retain the valve cover 34 Figure 54 Head Assembly Removal 1 Remove the four 1 2 hex flange head cap screws that retain the head Itisnot necessary to remove ...

Page 40: ...lng The intake and exhaust valve seats on the GTS 150 are factory cutto 44 degrees The intake and exhaust valves are factory ground to 44 75 degrees When reconditio the seats should be cut to 45 degrees and the valves should be ground to 45degrees Thevalvesarethen lapped into the seat for a proper seal 1 Use Briggs Stratton valve lapping tool 19258 and lappingcompound 94150forlappingvalvesand seat...

Page 41: ...pump The pumpis driven by a cross pin inthe end of the cam shaft Oil is drawn into the expanding cavities in the gerotor pump set and issqueezed outthrough collaps ing cavities opposite the intake opening Oilisdischarged through the centerof the camshaft to a drilled passage from the upper camshaft bearing to the upper crankshaft bearing The oilisthen discharged through another drilled passage in ...

Page 42: ...t See Figure65 Figure 65 2 The governor splasheris serviceable only as an assembly Camshaft Operation The camshaft is made of a composite material and driven by the crankshaft The camshaft istimed with the crank shaftto cause the intake and exhaust valves to open and close at the correct time The camshaft isalso responsible for driving the oil pump and ishollowto accommodate the flow of lubricatin...

Page 43: ...h the piston and connecting rod out of the way ofthe crankshaft See Figure 70 Figure 70 3 Thecrankshaftmaynowbewithdrawnfromthe engine Place a sleeve or tape over the crankshaft to prevent the crankshaft keyway from cutting the seal 4 The camshaft drive gear is keyed to the crankshaft and may be removed Take care to note the side of the gear with the timing mark for correct installation See Figure...

Page 44: ...op ring has no top or bottom orientation how ever if it is to be reused install the ring using the original positioning to maintain the established wear patterns 4 The second ring has a step that must face the bott of the piston 5 The three piece oilcontrol ring assembly uses scraper rings above and below a ring expander Piston Pin Removal 1 Notetherelationship of the connectingrodtothe piston for...

Page 45: ...of the engine 2 Lubricate the cylinder walls with SAE30engine oil 3 Push the piston outofthe ring compressor and into the require a piston ring expander below theoil scraper ring expander cylinder SeeFigure 76 Figure76 4 Make surethe pistonis inthe cylinder with the arrow onthe faceof the piston toward the push rod side of the engine The word MAG on the connecting rod should face the magneto side ...

Page 46: ... See Figure80 Figure 80 GTS150 41 Camshaft lnstallatlon 1 Match the timing markonthecamshaftwiththe timing mark on the camshaft drive gear on the crankshaft See Figure81 I Figure81 2 Lubricate the end of the camshaft with SAE30engine oil and install the camshaft Governor Splasher Installation 1 Install the governor asshowninFigure82 Make sure the governor plunger ispositioned against the gover nor...

Page 47: ... the washer and valve seal on the stem of the intake valve See Figure 86 Figure 86 4 Install the springs and valve keepers on each valve The springs are identical and can be used on either valve 5 Install the cap on the stem of each valve The rocker arms and adjusting nuts may now be installed PushRods Installation 1 Standtheengine up and install the two pushrods against the cam followers Itiseasi...

Page 48: ...re88 Figure 88 Valve Cover Installation 1 Mount a new valve cover gasket 2 Install the valve cover See Figure 89 3 Tightenthevalvecoverscrews in adiagonalse quence to 45 in Ibs 5 N m Throttle Bracket Installation 1 Installthe two 3 8 hex washerheadscrewsthat retain the throttle bracket tothe engine block Torque the screwsto 85 in Ibs 9 5 N m SeeFigure 90 Figure 90 2 Install the front blower shroud...

Page 49: ... See Figure 94 Figure 94 4 Install the choke over center spring See Figure 95 Governor Adjustment 1 Toadjust the governorthefollowingsequenceof component installation must be followed a Installthelinkrod on thegovernorarmand b Install thegovernor lever onthe governor shaft carburetor leave it loose c Install the carburetor onthe engine d Attach the link rod spring position 3 Rotate the governor sh...

Page 50: ... its mounting bosses 2 Route the ignition kill wire behind the throttle bracket and connect the killwire to the grounding terminal on the bottomof the throttle bracket See Figure 98 Figure 98 GTS150 45 3 Set the ignition coil air gap the space between the flywheel and ignition coil to 008 012 2 0 30mm 4 Torque the ignition coil screws to 45 in Ibs 5 N m 5 Route the spark plug wire through the slot...

Page 51: ...8 hex washer head cap screws Torque the screws to 35 in Ibs 4 N m See Figure 102and 103 Figure 102 Engine Figure 103 FuelTank lnstallatlon 1 Mount the fuel tank withtwo 3 8 hex washer head cap screws Torque the screws to 45 in Ibs 5 N m 2 Install the fuel hose With electric start models route the fuel hose around the electric starter 3 Installa hose clamp on the fuel tank and carburetor ends of th...

Page 52: ...to connect this hose properly will resultin engine failure due to dirt ingestion 3 Mounttheaircleanerbodytotheenginemaking certain the breather hose is installed on the breather tube 4 Securetheaircleanerbodywiththree 5 16 hex washer head shoulder screws See Figure107 Torque the screwsto 35 in Ibs 4 N m V41 396 GTS150 5 Make surethefoamelement has been properly cleaned and oiled See Maintenance Se...

Page 53: ...apids Michigan The students identified in the photograph completed 93 of the illustrations used in this service manual Students left to right in photograph Top row Karen Becker ScottCooley Kevin Lubien Amada Lopez Dan Backus Second row Scott Thomas Dave Dekarske Ben Beltman Roger Scholz Rich Tyndall Steve Stewart MattVink Front row Jim Pleshokov Scott Geyer Sandi Hutchinson Wendy Skaja Rachel Wisn...

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