CTM2 16 18 20 24 HP Onan Engines
User Manual: CTM2 - 16 18 20 24 HP Onan Engines
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16, 18, 20 and 24HP Onan Engines John Deere Horicon Works CTM2 (19APR90) LITHO IN U.S.A. ENGLISH Introduction This component technical manual (CTM) contains necessary instructions to repair the engine. Use this component technical manual in conjunction with the machine technical manual. An engine application listing in the introduction identifies product-model/engine type-model relationship. See the machine technical manual for: N CAUTION: THIS SAFETY-ALERT SYMBOL MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. When you see this symbol on your machine or in your manual, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. • Engine removal and installation. • Theory of operation, diagnostic, and testing procedures. CTM2,IFC CTM2 (19APR90) -19-03FEB87 16, 18, 20 & 24HP Onan Engines 130495 Group 00 Introduction INTRODUCTION 00 1 This manual is part of a total service support program. FOS MANUALS—REFERENCE TECHNICAL MANUALS—MACHINE SERVICE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians. -UN-23AUG88 Technical Manuals are concise service guides for specific machines. Technical manuals are on-the-job guides containing only the vital information needed by an experienced service technician. RW5559 Component Technical Manuals are concise service guides for specific components. Component Technical Manuals are written as stand alone manuals covering multiple machine applications. O53,INTRO2 CTM2 (19APR90) 00-1 -19-03JUL85 16, 18, 20 & 24HP Onan Engines 130495 Introduction/About This Manual FEATURES OF THIS TECHNICAL MANUAL John Deere ILLUSTRUCTION format emphasizing illustrations and concise instructions in easy-to-use modules. Emphasis on diagnosis, analysis, and testing so you can understand the problem and correct it. Diagnostic information presented with the most logical and easiest to isolate problems first to help you identify the majority of routine failures quickly. Step-by-step instructions for teardown and assembly. -UN-23AUG88 Summary listing at the beginning of each group of all applicable specifications, wear tolerances, torque values, essential tools, and materials needed to do the job. An emphasis throughout on safety—so you do the job right without getting hurt. This technical manual was planned and written for you—an experienced service technician. Keep it in a permanent binder in the shop where it is handy. Refer to it when you need to know correct service procedures or specifications. RW5560 00 2 O53,INTRO3 -19-07OCT85 M98,INTR,1 -19-11NOV85 ABOUT THIS MANUAL This Component Technical Manual (CTM-2) covers the recommended repair procedures for all 16, 18, 20, and 24 HP Onan Engines removed from the machine. These engines can be repaired on a clean work bench or put on an engine stand. Some components may be serviced without removing the engine from the machine. You may want to determine the repair procedure before you remove the engine. Refer to the machine technical manual for engine removal and installation procedures. CTM2 (19APR90) 00-2 16, 18, 20 & 24HP Onan Engines 130495 Introduction/Engine Specifications ENGINE SERIAL NUMBER PLATE 00 3 -UN-07SEP88 The engine serial number plate is located under the air cleaner. M34584 Refer to the engine model designation on your engine’s serial number plate to identify repair information covered in the Component Technical Manual. M98,INTR,2 -19-07OCT85 BASIC ENGINE SPECIFICATIONS ENGINE B43E B43G P218G B48G and P220G T260 CYLINDER 2 2 2 2 2 CYCLE 4 4 4 4 4 BORE 82.55 mm (3.25 in.) 82.55 mm (3.25 in.) 82.55 mm (3.25 in.) 82.55 mm (3.25 in.) 90.42 mm (3.56 in.) STROKE 66.55 mm (2.62 in.) 66.55 mm (2.62 in.) 73 mm 2.875 in.) 73 mm (2.87 in.) 76.20 mm (3.00 in.) DISPLACEMENT 710 cm3 (43.3 cu in.) 710 cm3 (43 cu in.) 782 cm3 47.7 cu in.) 782 cm3 (48 cu in.) 983 cm3 (60 cu in.) *HORSEPOWER 12kW (16 hp) 13.5 kW (18 HP) 13.4 kW (18 hp) 15 kW (20 hp) 18 kW (24 hp) *Horsepower rating is established by engine manufacturer in accordance with Standard International Combustion Institute procedure. It is corrected to (60 ˚F) and 29.92 hg barometer. Laboratory test engines are equipped with air cleaner and muffler. CTM2 (19APR90) 00-3 M98,INTR,3 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Introduction/Hardware Torque Specifications ENGINE APPLICATION CHART 00 4 Front Mowers Refer to the engine application chart to identify product-model/engine type-model relationship. Machine No. CONSUMER PRODUCTS F910 F930 Lawn and Garden Tractors Machine No. Engine Model . . . . . . . . . . . . . . . . . . B48G or P220G . . . . . . . . . . . . . . . . . . T260 Engine Model 316 . . . . . . . . . . . . . . . . . . . B43E or P218G 318 . . . . . . . . . . . . . . . . . . . B43G or P218G 420 . . . . . . . . . . . . . . . . . . . B48G or P220G M98,INTR,4 -19-29JAN87 ENGLISH TORQUE SPECIFICATIONS NOTE: Wrench torque tolerance is ± 20%. Bolt Diameter Three Radial Dashes* Plain Head* lb-ft 1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 9/16 in. 5/8 in. 3/4 in. 7/8 in. 1 in. 6 10 20 30 45 70 95 165 170 255 N·m 8 14 27 41 61 95 128 225 230 345 lb-ft N·m 9 18 30 50 75 110 155 270 435 660 12 24 41 68 101 150 210 365 590 895 Six Radial Dashes* lb-ft N·m 12 25 45 70 110 155 215 385 620 930 16 34 61 95 149 210 290 520 840 1260 Torque figures indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap screws unless otherwise specified in this manual. * Torque value for bolts and cap screws are identified by their head markings. CTM2 (19APR90) 00-4 S11,2000,DD -19-11JUL85 16, 18, 20 & 24HP Onan Engines 130495 Introduction/Hardware Torque Specifications METRIC TORQUE SPECIFICATIONS 00 5 NOTE: Wrench torque tolerance is ± 20%. Bolt Diameter M5 M6 M8 M10 M12 M16 M20 M24 Property Class 8.8* lb-ft 5 8 18 37 66 166 321 554 Property Class 10.9* lb-ft N·m 6 10 25 50 90 225 435 750 7 11 26 52 92 229 450 775 N·m 9 15 35 70 125 310 610 1050 Torque figure indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap screws unless otherwise specified in this manual. * Torque value for bolts and cap screws are identified by their head markings. CTM2 (19APR90) 00-5 S11,2000,DE -19-11JUL85 16, 18, 20 & 24HP Onan Engines 130495 Introduction/Hardware Torque Specifications 00 6 CTM2 (19APR90) 00-6 16, 18, 20 & 24HP Onan Engines 130495 Group 05 Air Cleaner and Breather SPECIFICATIONS Item Measurement Specification Breather Valve Cover Bolt Torque 2 ± 1 N·m (18 ± 9 lb-in.) 05 1 M98,2005K,1 -19-07OCT85 M98,2005K,2 -19-07OCT85 M98,2005K,3 -19-07OCT85 M98,2005K,4 -19-07OCT85 REMOVE AIR CLEANER M36995 -UN-25JAN90 1. Remove wing nut and cover. M36996 -UN-25JAN90 2. Remove lock nut and air cleaner element. M31044 -UN-14JUL89 3. Remove precleaner. Wash precleaner as necessary. CTM2 (19APR90) 05-1 16, 18, 20 & 24HP Onan Engines 130495 Air Cleaner and Breather/Air Cleaner -UN-07SEP88 4. Wash precleaner in warm, soapy water. Rinse in clean water. Squeeze precleaner to remove most of water. Let precleaner air dry. M34579 05 2 M98,2005K,5 -19-07OCT85 M98,2005K,6 -19-07OCT85 M98,2005K,7 -19-07OCT85 M34582 -UN-07SEP88 5. Hold a lighted bulb inside air cleaner element. If you can see the light through element and the paper appears clean, the element is still usable. If the element is oily, dirty, bent, torn, crushed or obstructed in any way, install a new element. -UN-25JAN90 IMPORTANT: Close choke and all openings to keep objects from falling into carburetor, flywheel housing, and air intake system. 6. Remove three cap screws and splash plate (A). 7. Remove two base cap screws (B). M36997 8. Push breather hose (C) from air cleaner base. 9. Lift air cleaner base from carburetor. 10. Clean inside of base and cover. 11. Inspect air intake hose for cracks or deterioration; replace if necessary. CTM2 (19APR90) 05-2 16, 18, 20 & 24HP Onan Engines 130495 Air Cleaner and Breather/Air Cleaner INSTALL AIR CLEANER -UN-25JAN90 1. Check carburetor intake to make sure the O-ring is in place. 2. Put air cleaner base on carburetor. M36997 3. Install breather hose (C). Be sure breather hose and intake hose are tightly installed to prevent dirt from entering the system. 4. Install and tighten two cap screws (B). 5. Install and fasten splash plate (A) with three screws. M98,2005K,8 -19-08OCT85 M98,2005K,9 -19-08OCT85 M98,2005K,10 -19-11NOV85 6. Apply 1 oz (30 ml) of clean engine oil to precleaner. M34580 -UN-07SEP88 7. Squeeze precleaner to distribute oil evenly and to remove excess oil. 8. Put precleaner on air cleaner element. Install element and holddown. M36996 -UN-25JAN90 9. Install lock nut. Tighten until snug only. CTM2 (19APR90) 05-3 16, 18, 20 & 24HP Onan Engines 130495 05 3 Air Cleaner and Breather/Breather, Repair -UN-25JAN90 10. Install cover. Fasten with wing nut. M36995 05 4 M98,2005K,11 -19-08OCT85 M98,2005K,12 -19-08OCT85 M98,2005K,13 -19-08OCT85 M98,2005K,14 -19-08OCT85 REPAIR BREATHER—T260 ENGINE -UN-25JAN90 1. Remove air cleaner. (See Remove Air Cleaner in this section.) M36998 2. Loosen clamp to remove breather tube. 3. Remove filter packing. M36999 -UN-25JAN90 4. Wash filter packing in a safe solvent and blow dry with air pressure. If packing comes apart or is deteriorated, replace it. 5. Wash breather valve with solvent. Inspect ball valves to be sure they move freely. -UN-25JAN90 Inspect O-ring for cuts or cracks. Replace if defective. M37002 6. When installing breather tube, be sure filter packing is in breather and that the O-ring is installed on the valve assembly. CTM2 (19APR90) 05-4 16, 18, 20 & 24HP Onan Engines 130495 Air Cleaner and Breather/Breather, Repair REPAIR BREATHER—B43E, B43G, B48G, P218G, AND P220G ENGINES -UN-25JAN90 1. Remove air cleaner. (See Remove Air Cleaner in this group.) M37000 2. Pull breather tube from breather assembly. M98,2005K,15 -19-29JAN87 M98,2005K,16 -19-08OCT85 M98,2005K,17 -19-08OCT85 M98,2005K,18 -19-08OCT85 3. Remove filter packing. M37001 -UN-25JAN90 4. Wash filter packing in a safe solvent and blow dry with air pressure. If packing comes apart or is deteriorated, replace it. M37017 -UN-25JAN90 5. Remove three cap screws to remove manifold cover. 6. Remove cap screw (A). -UN-25JAN90 IMPORTANT: Do not drop small parts into engine opening when removing breather assembly. M37018 7. Remove breather assembly. CTM2 (19APR90) 05-5 16, 18, 20 & 24HP Onan Engines 130495 05 5 Air Cleaner and Breather/Breather, Repair 8. Clean parts with solvent. Inspect reed valve (C). Replace it if cracked or bent. Replace gaskets if broken or deteriorated. -UN-25JAN90 M37024 9. Install in order: A—Gasket B—Deflector C—Reed Valve D—Washer E—Spring F—Gasket G—Valve Cover H—Washer I—Cap Screw M98,2005K,19 -19-08OCT85 M98,2005K,20 -19-11NOV85 M98,2005K,21 -19-11NOV85 -UN-25JAN90 IMPORTANT: Be sure gaskets are in place before tightening cap screw. Breather will not function properly if air leaks are present. M37025 10. Tighten cap screw to 2 ± 1 N·m (18 ± 9 lb-in.). -UN-25JAN90 11. Install manifold cover. Fasten with three cap screws. M37017 05 6 NOTE: When installing the first gasket, be sure it aligns with the flange on the deflector (B). Apply a small amount of clean grease to the gaskets to hold them in place during installation. CTM2 (19APR90) 05-6 16, 18, 20 & 24HP Onan Engines 130495 Air Cleaner and Breather/Breather, Repair M37001 -UN-25JAN90 12. Install filter packing in breather tube. M98,2005K,22 -19-11NOV85 M98,2005K,23 -19-11NOV85 M37000 -UN-25JAN90 13. Push breather tube securely onto valve cover. CTM2 (19APR90) 05-7 16, 18, 20 & 24HP Onan Engines 130495 05 7 Air Cleaner and Breather/Breather, Repair 05 8 CTM2 (19APR90) 05-8 16, 18, 20 & 24HP Onan Engines 130495 Group 10 Intake Manifold and Cylinder Heads SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Feeler Gauge Measure cylinder head flatness 10 1 M98,2010K,1 -19-11NOV85 M98,2010K,2 -19-08OCT85 SERVICE PARTS KITS The following kits are available through your parts catalog: Overhaul Gasket Kit CTM2 (19APR90) 10-1 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Intake Manifold SPECIFICATIONS Item Measurement Specification P218G, P220G, B43E, B43G, B48G Engines Torque 11 ± 3 N·m 97 ± 27 lb-in.) T260 Engine Torque 29 ± 2 N·m (257 ± 18 lb-in.) Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) B43E, B43G, B48G Engines Torque 11 ± 3 N·m (97 ± 27 lb-in.) T260 Engine Torque 29 ± 2 N·m (257 ± 18 lb-in.) P218G, P220G Engines Torque 6 N·m (53 lb-in.) Flatness 0.005—0.10 mm (0.002—0.004 in.) Torque-In Sequence 20 ± 1 N·m (180 ± 12 lb-in.) (Top six nuts with washers) Torque-In Sequence 16 ± 1 N·m (142 ± 12 lb-in) (Bottom four nuts) Torque-In Sequence 20 ± 1 N·m (180 ± 12 lb-in.) Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) MUFFLER AND EXHAUST PIPES Exhaust Pipe Cap Screw INTAKE MANIFOLD Attaching Cap Screw CYLINDER HEAD Cylinder Head Attaching Cap Screws or Nuts P218G, P220G, B43E, B43G, B48G Engines T260 Engine: M98,2010K,3 -19-10FEB87 M98,2010K,4 -19-11NOV85 REMOVE INTAKE MANIFOLD 1. Remove muffler. (See machine technical manual.) -UN-25JAN90 2. Remove four cap screws to remove exhaust pipes and gasket (A). Inspect exhaust pipes for cracks or damage. Replace as necessary. 3. Remove air cleaner base. (See Group 05 in this manual.) M36913 10 2 CTM2 (19APR90) 10-2 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Intake Manifold 4. For T260 engines, remove two cap screws to remove coil bracket. M36920 -UN-25JAN90 5. Remove clip (A) to disconnect throttle rod. M98,2010K,5 -19-11NOV85 M98,2010K,6 -19-10FEB87 6. If engine is in machine, loosen clamp and screw (A) to disconnect choke cable (B). -UN-25JAN90 7. If engine is in machine, slide hose clamp (C) back to disconnect fuel inlet line (D). M36921 A—Screw B—Choke Cable C—Hose Clamp D—Fuel Inlet Line 8. For T260 engine, remove four cap screws to remove intake manifold, carburetor, and gaskets (A). -UN-25JAN90 For B43E, B43G, or B48G engine, remove three cap screws to remove spacer (B), intake manifold, carburetor, and gaskets (C). M36922 For P218G and P220G engine, remove four cap screws to remove intake manifold, carburetor, and gaskets. M36251 -UN-22NOV89 T260 Engine B43E, B43G, B48G Engines M98,2010K,7 CTM2 (19APR90) 10-3 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 10 3 Intake Manifold and Cylinder Heads/Intake Manifold 9. For T260, P218G or P220G engine, remove two cap screws to remove carburetor, gasket (A), spacer (B), and gasket (C). M36923 10. Inspect intake manifold for cracks or holes. Replace as necessary. M36252 -UN-22NOV89 T260, P218G, P220G Engine B43E, B43G, B48G Engines M98,2010K,8 -19-10FEB87 M98,2010K,9 -19-08OCT85 INSTALL INTAKE MANIFOLD -UN-22NOV89 1. Install a new gasket on intake manifold. M36253 10 4 -UN-25JAN90 For B43E, B43G, or B48G engine, remove two cap screws to remove carburetor and gasket (A). CTM2 (19APR90) 10-4 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Intake Manifold 2. For T260, P218G, or P220G engine, install gasket (A) spacer (B), gasket (C), and carburetor on intake manifold. Install and tighten two cap screws. M36924 -UN-25JAN90 For B43E, B43G, or B48G engine, install carburetor on intake manifold and fasten with cap screws. M36254 -UN-22NOV89 T260, P218G, P220G Engine B43E, B43G, B48G Engines M98,2010K,10 -19-30JAN87 M98,2010K,11 -19-30JAN87 NOTE: For T260 engine, go to step 5. -UN-29JAN90 3. Install new gaskets with notch in gasket aligned with notch on intake port. 4. For B43E, B43G, or B48G engine, install intake manifold and tighten cap screws to 11 ± 3 N·m (97 ± 27 lb-in.). Install spacer (A). M36256 -UN-29JAN90 M36255 For P218G or P220G engine, install intake manifold and oil fill tube. Tighten cap screws to 6 N·m (53 lb-in.). CTM2 (19APR90) 10-5 16, 18, 20 & 24HP Onan Engines 130495 10 5 Intake Manifold and Cylinder Heads/Intake Manifold 5. Install new gaskets on intake ports. -UN-25JAN90 6. Install intake manifold and tighten cap screws to 29 ± 2 N·m (257 ± 18 lb-in.). M36926 -UN-25JAN90 M36925 10 6 T260 engine M98,2010K,12 -19-11NOV85 M98,2010K,13 -19-08OCT85 M98,2010K,14 -19-30JAN87 7. If engine is in machine, connect fuel inlet line (D) and fasten with hose clamp (C). -UN-25JAN90 8. If engine is in machine, connect choke cable (B) to choke linkage. Push choke knob down. Hold choke linkage upward (choke plate open). Tighten screw (A) and clamp. M36921 A—Screw B—Choke Cable C—Hose Clamp D—Fuel Inlet Line 9. Connect throttle rod and fasten with clip (A). M36920 -UN-25JAN90 10. For T260 engine, install coil bracket on intake manifold. Install and tighten two cap screws. CTM2 (19APR90) 10-6 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Intake Manifold 11. Install new exhaust pipe gaskets. -UN-25JAN90 12. Install exhaust pipes and fasten with four cap screws. Engine Measurement Specifications T260 Cap Screw Torque 29 ± 2 N·m (257 ± 18 lb-in.) B43E, B43G, B48G, P218G or P220G Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) M36914 EXHAUST PIPE TORQUE SPECIFICATIONS 13. Install manifold covers and fasten with cap screws. M36915 -UN-25JAN90 14. Install air cleaner assembly. (See Group 05 in this manual.) M98,2010K,15 CTM2 (19APR90) 10-7 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 10 7 Intake Manifold and Cylinder Heads/Cylinder Head REMOVE CYLINDER HEAD 1. Park tractor safely. 2. Remove engine. (See machine technical manual.) 3. Disconnect spark plug wire (A). 4. For T260 engine, remove six cap screws to remove lift bracket (B), exhaust pipe shroud (C), and right side shroud (D). For B43E, B43G, or B48G engine, remove four cap screws to remove lift bracket (B) and right side shroud (D). -UN-25JAN90 For P218G or P220G engines, remove air cleaner assembly (See Group 05 in this manual.) Remove four cap screws to remove lift bracket and right side shroud. M36927 A—Spark Plug Wire B—Lift Bracket C—Exhaust Pipe Shroud D—Right Side Shroud -UN-25JAN90 T260 Engine M36928 10 8 B43E, B43G, B48G Engines M98,2010K,17 CTM2 (19APR90) 10-8 -19-30JAN87 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Cylinder Head 5. Disconnect spark plug wire (A). 6. For T260 engine, remove seven cap screws to remove lift bracket (B), exhaust pipe shroud (C), and left side shroud (D). For B43E, B43G, OR B48G engine, disconnect voltage regulator leads (E). Remove five cap screws to remove lift bracket (B) and left side shroud (D). 10 9 For P218G or P220G engines, disconnect voltage regulator leads. Remove four cap screws to remove lift bracket and left side shroud. M36929 -UN-25JAN90 A—Spark Plug Wire B—Lift Bracket C—Exhaust Pipe Shroud D—Left Side Shroud E—Voltage Regulator Leads M36930 -UN-25JAN90 T260 Engine B43E, B43G, B48G Engines M98,2010K,18 CTM2 (19APR90) 10-9 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Cylinder Head -UN-25JAN90 IMPORTANT: Do not remove cylinder heads while they are hot. Cylinder head may warp. A hot gasket will be soft and difficult to remove. 7. Remove spark plug (A). M36931 For P21G, P220G, B43E, B43G, OR B48G engine, remove nine cap screws and washers (E) to remove cylinder head and gasket (D). T260 Engine M36932 -UN-25JAN90 A—Spark Plug B—Compression Washer (20 Used) C—Washer (10 Used) D—Gasket E—Washer (9 Used) P218G, P220G, B43E, B43G,B48G M98,2010K,19 -19-10FEB87 M98,2010K,20 -19-08OCT85 IMPORTANT: Do not damage gasket sealing surface while cleaning carbon deposits. -UN-14JUL89 9. Carefully clean carbon deposits from combustion chamber and gasket surface on heads and cylinder block with a scraper and wire brush. 10. Inspect head for cracks or broken cooling fins. Check gasket sealing surface for burrs or nicks. Replace head if damaged. M30948 10 10 8. For T260 engine, remove 10 nuts, 20 compression washers (B), and 10 washers (C) to remove cylinder head and gasket (D). 11. Measure cylinder head flatness in several locations. CYLINDER HEAD SPECIFICATIONS Item New Part Wear Tolerance Flat Within 0.05 mm (0.002 in.) 0.10 mm (0.004 in.) Replace head if cylinder head is warped more than 0.10 mm (0.004 in.). CTM2 (19APR90) 10-10 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Cylinder Head INSTALL CYLINDER HEAD -UN-25JAN90 NOTE: To install cylinder head on P218G, P220G, B43E, B43G, OR B48G engine, go to step 4. 1. For T260 engine, install a new gasket (A) on cylinder head. M36933 2. Install cylinder head on cylinder block. Install flat washer (B), two compression washers (C) with outside edges contacting each other, and nut (D) on each of the top six longer studs. Install flat washer and nut on each of the bottom four shorter studs. Tighten nuts in several steps in the sequence shown. NUT TORQUE SPECIFICATIONS Top six nuts . . . . . . . . . . . . . . . . . . . . 16 ± 1 N·m (142 ± 12 lb-in.) (with compression washers) Bottom four nuts . . . . . . . . . . . . . . . . . 20 ± 1 N·m (180 ± 12 lb-in.) 3. Install spark plug (E). M36934 -UN-25JAN90 A—Gasket B—Washer (10 Used) C—Compression Washer (20 Used) D—Nut (10 Used) E—Spark Plug M98,2010K,21 CTM2 (19APR90) 10-11 -19-30JAN87 16, 18, 20 & 24HP Onan Engines 130495 10 11 Intake Manifold and Cylinder Heads/Cylinder Head 4. For P218G, P220G, B43E, B43G, or B48G engine, install a new gasket (A) on cylinder head. -UN-25JAN90 5. Install cylinder head on cylinder block with the five longest cap screws in the top holes of cylinder head. Tighten cap screws in several steps in the sequence shown. CAP SCREW TORQUE SPECIFICATION M36935 Attaching Cap Screws . . . . . . . . . . . . . 20 ± 1 N·m (180 ± 12 lb-in.) -UN-25JAN90 6. Install spark plug (B). M36936 10 12 M98,2010K,22 CTM2 (19APR90) 10-12 -19-30JAN87 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Cylinder Head 7. For T260 engine, install left side shroud (D), exhaust pipe shroud (C), lift bracket (B) and fasten with seven cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). For P218G or P220G engines, install left side shroud, lift side shroud, lift bracket, and fasten with four cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). Connect voltage regulator leads. 10 13 For B43E, B43G, OR B48G engine, install left side shroud (D), lift bracket (B), and fasten with five cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). Connect voltage regulator leads (E). Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of the voltage regulator. -UN-25JAN90 8. Connect spark plug wire (A). M36929 A—Spark Plug Wire B—Lift Bracket C—Exhaust Pipe Shroud D—Left Side Shroud E—Voltage Regulator Leads M36930 -UN-25JAN90 T260 Engine B43E, B43G, B48G Engines M98,2010K,23 CTM2 (19APR90) 10-13 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake Manifold and Cylinder Heads/Cylinder Head 9. For T260 engine, install right side shroud (D), exhaust pipe shroud (C), lift bracket (B), and fasten with six cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). For P218G or P220G engines, install right side shroud, lift bracket, and fasten with four cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 10. Connect spark plug wire (A). 11. Install engine. (See machine technical manual.) M36927 -UN-25JAN90 A—Spark Plug Wire B—Lift Bracket C—Exhaust Pipe Shroud D—Right Side Shroud -UN-25JAN90 T260 Engine M36928 10 14 For B43E, B43G, OR B48G engine, install right side shroud (D), lift bracket (B), and fasten with four cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). B43E, B43G, B48G Engines M98,2010K,24 CTM2 (19APR90) 10-14 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Group 15 Intake and Exhaust Valves ESSENTIAL TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Number Name Use JDG 323 Valve Guide Driver Remove valve guides JDE 118 Valve Guide Driver Remove valve guides JDG 569 Valve Guide Installer Install valve guides JDG 507 Valve Seat Cutter Cut seats to 45˚ 15 1 M98,2015K,1 -19-10FEB87 SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Feeler Gauge Measure valve clearance Valve Spring Compressor Remove and install valves Valve Inspection Center Measure valve out-of-round Outside Micrometer Measure valves and tappets Spring Compression Tester Check valve springs Valve Guide Brush Clean valve guides Telescoping Gauge Measure tappet and valve guide bores Valve Seat Cutter Recondition valve seats Vernier Calipers Measure valve seat width Blind Hole Puller Set Remove valve seats Bushing, Bearing, and Seal Driver Set Install valve seats M98,2015K,2 CTM2 (19APR90) 15-1 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Service Parts Kits SERVICE PARTS KITS The following kits are available through your parts catalog: Valve Gasket Kit Tappet Kit Overhaul Gasket Kit M98,2015K,3 15 2 CTM2 (19APR90) 15-2 -19-08OCT85 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Specifications SPECIFICATIONS Intake and Exhaust Valves (B43E, B43G, B48G, AND T260 Engines) Item New Specification Wear Tolerance 1. Exhaust Valve Stem O.D. 8.66—8.67 mm (0.341—0.3414 in.) 8.64 mm (0.340 in.) 2. Intake Valve Stem O.D. 8.70—8.71 mm (0.3425—0.3429 in.) 8.66 mm (0.341 in.) 3. Valve Face Angle 44˚ 15 3 4. Valve Face Margin 5. Valve Spring Free length (approx.) Test length 6. Valve Cover Cap Screw Torque 0.787 mm (0.031 in.) 42.21 mm (1.662 in.) 34.92 mm (1.375 in.) at 169—187 N (38—42 lb force) 2.1 ± 0.7 N·m (18 ± 6 lb-in.) Intake and Exhaust Valves (P218G and P220G Engines) Item New Specification Wear Tolerance 1. Exhaust Valve Stem O.D. 7.061—7.074 mm (0.2780—0.2785 in.) 7.05 mm (0.2775 in.) 2. Intake Valve Stem O.D. 7.099—7.112 mm (0.2795—0.2800 in.) 7.07 mm (0.2783 in.). 3. Valve Face Angle 44˚ 4. Valve Face Margin 5. Valve Spring Free length (approx.) Test length 6. Valve Cover Cap Screw Torque 0.787 mm (0.031 in.) 40.64 mm (1.60 in.) 26.67 mm (1.05 in.) at 245N (55 lb force) 2.1 ± 0.7 N·m (18 ± 6 lb-in.) M98,2015K,4 CTM2 (19APR90) 15-3 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Specifications TAPPETS Item New Specification Wear Tolerance Tapped O.D. 18.99—19 mm (0.747—0.748 in.) 2. Tappet Bore I.D. 19.06—19.09 mm (0.750—0.751 in.) 19.15 mm (0.754 in.) 3. Tappet-To-Bore Clearance 0.04—0.08 mm (0.0015—0.003 in.) 0.15 mm (0.006 in.) 18.90 mm (0.744 in.) 2. Tappet Bore Valve Seats 15 4 Item New Specification Wear Tolerance 1. Valve Seat Angle 45˚ 2. Valve Seat Width 0.8—1.2 mm (0.031—0.047 in.) Valve Guides Item New Specification Wear Tolerance Valve Guide I.D. (B43E, B43G, B48G, T260 Engines) 8.74—8.79 mm (0.344—0.346 in.) 8.84 mm (0.348 in.) Valve Guide I.D. (P218G, and P220G Engines) 7.14—7.16 mm (0.281—0.282 in.) 7.19 mm (0.283 in.) 2. Intake Valve Stem Clearance 0.03—0.06 mm (0.001—0.002 in.) 0.13 mm (0.005 in.) 3. Exhaust Valve Stem Clearance 0.06—0.10 mm (0.002—0.004 in.) 0.15 mm (0.006 in.) Item New Specification Wear Tolerance 1. Intake Valve 0.13 mm (0.005 in.) 2. Exhaust Valve 0.33 mm (0.013 in.) Valve Clearance M98,2015K,5 CTM2 (19APR90) 15-4 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves REMOVE INTAKE AND EXHAUST VALVES -UN-29JAN90 1. Remove engine if these components cannot be removed with engine in unit. (See machine technical manual.) 2. Remove exhaust pipes with muffler (A). M36473 3. Remove intake manifold (B). (See Remove Intake Manifold, Group 10 in this manual.) 4. Remove cylinder head (C). (See Remove Cylinder Head, Group 10 in this manual.) 15 5 M98,2015K,6 -19-08OCT85 NOTE: Be careful not to lose breather assembly when removing cover. -UN-29JAN90 5. For P218G, P220G, B43E, B43G, OR B48G engines, carefully remove cap screw to remove breather manifold cover. M36262 For T260 engine, remove cap screw to remove valve cover and gasket (A). M36263 -UN-29JAN90 B43E, B43G, B48G Engines T260 Engine M98,2015K,7 CTM2 (19APR90) 15-5 -19-17FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 6. Remove parts (A—F) if equipped and inspect for wear or damage. M36264 -UN-29JAN90 A—Spring B—Washer C—Valve D—Gasket E—Breather Base F—Gasket 15 6 M98,2015K,8 -19-08OCT85 M98,2015K,9 -19-11NOV85 M98,2015K,10 -19-08OCT85 M98,2015K,11 -19-08OCT85 7. Close oil drain hole with a shop towel to prevent retainers from falling into gear case. -UN-29JAN90 IMPORTANT: Identify valve assembly during removal so they can be installed in original ports. M36265 8. Compress valve springs using a valve spring compressor to remove retainers. Release spring pressure and remove compressor. M36266 -UN-29JAN90 9. Remove exhaust and intake valves. 10. Clean carbon from valve face, head, and stem using a wire brush. -UN-29AUG88 11. Remove scratches from valve stems using steel wool or crocus cloth. 12. Inspect valve for damage, corrosion, pitting, or burned face. CTM2 (19APR90) M35307 13. Check valve for out-of-round, bent or warped condition using a valve inspection center. 15-6 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 14. Measure valve stem outside diameter. New Parts Wear Tolerance Exhaust Valve 8.66—8.67 mm (0.341—0.3414 in.) 8.64 mm (0.340 in.) Intake Valve 8.70—8.71 mm (0.3425—0.3429 in.) 8.66 mm (0.341 in.) M35308 Item -UN-29AUG88 B43E, B43G, B48G, AND T260 VALVE STEM SPECIFICATION P21G AND P220G VALVE STEM SPECIFICATIONS Item New Parts Wear Tolerance Exhaust Valve 7.061—7.074 mm (0.2780—0.2785 in.) 7.05 mm (0.2775 in.) Intake Valve 7.099—7.112 mm (0.2795—0.2800 in.) 7.07 mm (0.2783 in.) 15 7 15. If diameter is less than wear tolerance specification, replace valve. M98,2015K,12 -19-10FEB87 M98,2015K,13 -19-08OCT85 -UN-29AUG88 IMPORTANT: Do not lap valves. The sharp seating surface between the valve and seat will be removed resulting in shorter valve life. M36267 16. If valve faces are worn, burned or pitted, grind valves to a 44 degree face angle (A) following manufacturers instructions. If valve face margin (B) is less than 0.787 mm (0.031 in.) after grinding, replace valve. CTM2 (19APR90) 15-7 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 17. Remove rotators (A) and springs (B) using a screwdriver. Rotator must turn freely. -UN-29JAN90 18. Check spring using a spring compression tester. B43E, B43G, B48G AND T260 SPRING SPECIFICATIONS Free length (approximate) . . . . . . . . . . . . . . . . 42.21 mm (1.662 in.) M36268 Test length at 169—187 N . . . . . . . . . . . . . . . . . . . . . . . 34.92 mm (38—42 lb force . . . . . . . . . . . . . . . . . . . 1.375 in.) 15 8 P218G AND P220G SPRING SPECIFICATIONS Free Length (approximate) . . . . . . . . . . . . . . . . 40.64 mm (1.60 in.) Test length at 245N . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.67 mm (55 lb force . . . . . . . . . . . . . . . . . . . . . . . 1.05 in.) M98,2015K,14 -19-10FEB87 M98,2015K,15 -19-08OCT85 M98,2015K,16 -19-08OCT85 IMPORTANT: Never reuse intake valve seal. The seal must be replaced each time the valve is removed. M36269 -UN-29JAN90 19. Remove intake valve seal if equipped. M36270 -UN-29JAN90 20. Remove tappets. Inspect tappets for wear or damage. CTM2 (19APR90) 15-8 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 21. Measure tappet outside diameter. Item New Parts Wear Tolerance Tappet Diameter 18.99—19 mm (0.747—0.748 in.) 18.90 mm (0.744 in.) -UN-29JAN90 TAPPET SPECIFICATIONS M36272 If tappet diameter is less than 18.90 mm (0.744 in.), replace tappet. M98,2015K,17 -19-08OCT85 M98,2015K,18 -19-08OCT85 M98,2015K,19 -19-08OCT85 15 9 22. Measure tappet bore inside diameter and determine tappet clearance (tappet bore I.D. minus tappet O.D.). Tappet Bore Diameter Tappet Clearance New Parts Wear Tolerance 19.06—19.09 mm (0.750—0.751 in.) 19.15 mm (0.754 in.) 0.04—0.08 mm (0.0015—0.003 in.) 0.15 mm (0.006 in.) M36273 Item -UN-29JAN90 TAPPET BORE SPECIFICATIONS If tappet bore diameter exceeds 19.15 mm (0.754 in.), install over-sized tappet or replace cylinder block. If tappet clearance exceeds 0.15 mm (0.006 in.), install over-sized tappet, replace tappet or replace cylinder block. NOTE: The over-sized tappets available are 0.05 mm (0.002 in.) and 0.13 mm (0.005 in.). 23. Clean valve seats using a wire brush. -UN-29JAN90 24. Inspect valve seats for damage, corrosion, pitting or warped condition. M36274 25. If necessary, cut seats to a 45 degree seat angle using a seat cutter such as JDG507. CTM2 (19APR90) 15-9 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 26. Measure valve seat width after cutting. Valve seat width must be 0.8—1.2 mm (0.031—0.047 in.). -UN-29JAN90 27. If seat is too wide after cutting, use a 30 degree valve seat cutter to narrow seat to specifications. IMPORTANT: Do not lap valve seat. Doing so will result in shorter valve life. 15 10 M36275 28. Clean the valve seats, valve guides, and valves with solvent or a vacuum. M98,2015K,20 -19-08OCT85 M98,2015K,21 -19-08OCT85 M98,2015K,22 -19-08OCT85 29. After valve grinding or seat cutting, check valves for a tight and uniform seat. -UN-29JAN90 Apply dye to valve face. Install and hold valve against seat and turn slightly. M36276 Remove valve and look for a fine clean line on valve face. The line must be at the center of valve face and have no open spots. If necessary, cut valve seat again or replace valve seat. M36952 -UN-25JAN90 30. Remove valve seats using a blind-hole puller. CTM2 (19APR90) 15-10 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 31. Clean valve guides using a valve guide brush. -UN-29JAN90 32. Measure valve guide inside diameter and determine valve stem clearance (valve guide I.D. minus valve stem O.D.). Item New Part Wear Tolerance Valve Guide Diameter (B43E, B43G,B48G,T260 8.74—8.79 mm (0.344—0.346 in.) 8.84 mm (0.348 in.) Valve Guide Diameter P218G and P220G) Intake Valve Stem Clearance 7.14—7.16 mm (0.281—0.282 in.) 7.19 mm (0.283 in.) 0.03—0.06 mm (0.001—0.002 in.) 0.13 mm (0.005 in.) Exhaust Valve Stem Clearance 0.06—0.10 mm (0.002—0.004 in.) 0.15 mm (0.006 in.) M36277 VALVE GUIDE SPECIFICATIONS 15 11 If valve guide diameter exceeds specifications, replace valve guide. If valve stem clearance exceeds wear tolerance specification, replace valve guide, valve, or both. M98,2015K,23 CTM2 (19APR90) 15-11 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves IMPORTANT: Failure to lean top surface of valve guide can damage valve guide bore during removal. 33. Remove carbon from top surface of valve guide using a wire brush. 34. For B43E, B43G, B48G or T260 engine, remove valve guides using JDG 323 Valve Guide Driver. For P218G or P220G engine, remove valve guides using JDE 118 Valve Guide Driver. M36278 -UN-29JAN90 35. Remove gasket (A). M98,2015K,24 -19-30JAN87 M98,2015K,25 -19-30JAN87 INSTALL INTAKE AND EXHAUST VALVES 1. Clean and dry all parts. Apply clean engine oil to all internal parts. Use a valve gasket kit when assembling the engine. 2. Install a new gasket (A) on intake valve guide. -UN-25JAN90 3. Install valve guides using JDG 569 Valve Guide Installer (B) and a large washer (C). Pull valve guides until shoulder is tight against cylinder block. M36953 15 12 CTM2 (19APR90) 15-12 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 4. Install valve seats with chamfer away from driver disk. Push valve seats to bottom of cylinder block bore. Valve Size B43E, B43G, B48G B43E, B43G, B48G Intake Exhaust 1-3/16 and 1-7/16 in. 15/16 and 1-3/16 in. T260 T260 Intake Exhaust 1-1/8 and 1-1/2 in. 1 and 1-5/16 in. P218G, P220G P218G, P220G Intake Exhaust 1-7/16 in. 1-3/16 in. M36883 Engine -UN-25JAN90 DISKS FOR VALVE SEAT INSTALLATION 15 13 M98,2015K,26 -19-30JAN87 M98,2015K,27 -19-08OCT85 M98,2015K,28 -19-08OCT85 IMPORTANT: Valve assemblies must be installed in original bores for maximum valve performance. M36270 -UN-29JAN90 5. Install tappets in original bores. IMPORTANT: Never reuse intake valve seal. The seal must be replaced each time the valve is removed. M36279 -UN-29JAN90 6. Install intake valve seal, if equipped, with lip of seal toward tappet. CTM2 (19APR90) 15-13 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves M36280 -UN-29JAN90 7. Install springs (A) and rotators (B). 15 14 M98,2015K,29 -19-08OCT85 M98,2015K,30 -19-08OCT85 M98,2015K,31 -19-08OCT85 8. Put clean engine oil on valve stems. M36266 -UN-29JAN90 9. Install intake and exhaust valves. 10. Close oil drain hole with a shop towel to prevent retainers from falling into gear case. -UN-29JAN90 11. Compress valve springs using a valve spring compressor. CTM2 (19APR90) 15-14 M36281 12. Apply petroleum jelly or retainers to help hold retainers on valve stem. Install retainers on valve stem with taper toward rotator. Be sure retainers are seated in valve stem slot. Slowly release spring pressure to remove compressor. 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves MEASURE AND ADJUST VALVE CLEARANCE -UN-29JAN90 1. Turn the flywheel clockwise until the intake valve opens and then closes. Continue turning flywheel until the TDC (top-dead-center) mark (A) on the flywheel is upward. M36282 Both valves (B) must be closed and the piston (C) must be at the top of its compression stroke. If the valves are open, the piston is on the exhaust stroke and the flywheel must be turned one revolution. M36283 -UN-29JAN90 15 15 M98,2015K,32 -19-08OCT85 M98,2015K,33 -19-08OCT85 M98,2015K,34 -19-08OCT85 2. Measure valve clearance using a feeler gauge. VALVE CLEARANCE SPECIFICATION Specification -UN-29JAN90 Item Intake Valve (A) . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) M36284 Exhaust Valve (B) . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.013 in.) M36285 -UN-29JAN90 3. If necessary, hold tappet and turn tappet screw to adjust valve clearance. CTM2 (19APR90) 15-15 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves CONTINUTE TO INSTALL AND EXHAUST VALVES -UN-29JAN90 1. Install parts (A—F) if equipped. Be sure washer (B) is on top of valve (C). M36264 A—Spring B—Washer C—Valve D—Gasket E—Breather Base F—Gasket M98,2015K,35 15 16 -19-11NOV85 NOTE: For T260 engine, go to Step 3. M36287 -UN-29JAN90 M36286 -UN-29JAN90 2. Install breather manifold cover and cap screw. Check that cap screw is installed through spring, washer, and valve. Tighten cap screw to 2.1 ± 0.7 N·m (18 ± 6 lb-in.). P218G, P220G, B43E, B43G, AND B48G M98,2015K,36 -19-10FEB87 M98,2015K,37 -19-11NOV85 M36288 -UN-29JAN90 3. Install new gasket (A). Install valve cover (B) and cap screw. Tighten cap screw 2.1 ± 0.7 N·m (18 ± 6 lb-in.) T260 Engine CTM2 (19APR90) 15-16 16, 18, 20 & 24HP Onan Engines 130495 Intake and Exhaust Valves/Intake and Exhaust Valves 4. Install cylinder head (C). (See Install cylinder Head, Group 10 in this manual.) -UN-29JAN90 5. Install intake manifold (B). (See Install Intake Manifold, Group 10 in this manual.) 6. Install exhaust pipes with muffler (A). (See Intake Manifold, Group 10 in this manual.) M36473 7. Install engine if removed. (See machine technical manual.) M98,2015K,38 CTM2 (19APR90) 15-17 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 15 17 Intake and Exhaust Valves/Intake and Exhaust Valves 15 18 CTM2 (19APR90) 15-18 16, 18, 20 & 24HP Onan Engines 130495 Group 20 Flywheel SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use 13-Ton Puller Set Remove flywheel M98,2020K,1 -19-08OCT85 OTHER MATERIAL 20 1 Number Name Use TY9375 John Deere LOCTITE® Pipe Sealant with TEFLON® Apply to threads of flywheel cap screw LOCTITE is a trademark of the Loctite Corp. TEFLON is a trademark of the DuPont Co. M98,2020K,1A -19-08OCT85 SPECIFICATIONS Item Measurement Specification Flywheel Cap Screw Torque 51 ± 3 N·m (38 ± 2 lb-ft) P218G and P220G Engine: Flywheel Cap Screw Torque 67—75 N·m (50—55 lb-ft) Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) B43E, B43G, B48G, and T260 Engine: M98,2020K,2 CTM2 (19APR90) 20-1 -19-10FEB85 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel REMOVE FLYWHEEL 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire (A) and voltage regulator leads (B). 3. Remove five cap screws (C) to remove lift bracket (D) and right side shroud (E). A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M36289 -UN-29JAN90 20 2 M98,2020K,3 -19-24OCT85 M98,2020K,4 -19-08OCT85 M36290 -UN-29JAN90 4. Loosen hose clamp (A) to disconnect fuel pump impulse line (B). CTM2 (19APR90) 20-2 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel 5. Disconnect governor spring (A). 6. Remove two screws to remove fuel pump (B). 7. For P218 or P220G engines, remove air clean assembly. Remove two cap screws to disconnect ignition coil from flywheel shroud. 8. Disconnect fuel line. 9. Remove five cap screws to remove flywheel shroud (C). M36291 -UN-29JAN90 20 3 M98,2020K,5 -19-30JAN87 M98,2020K,6 -19-30JAN87 IMPORTANT: Do not use a pry bar in fins to keep flywheel from turning. Doing so can damage fins. CAUTION: Loosen flywheel cap screw only two turns. Do not remove cap screw. If cap screw is removed, flywheel may cause injury when it comes loose. M36292 N -UN-29JAN90 10. Fasten locking pliers to ring gear to prevent flywheel from turning. 11. Loosen cap screw two turns only. CTM2 (19APR90) 20-3 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel 12. For P218G or P220G engines, remove two cap screws from flywheel. -UN-29JAN90 IMPORTANT: Do not pry on flywheel with a screwdriver. Ceramic magnets on gear case cover can be damaged. 13. Loosen flywheel using a puller. M36293 14. Remove puller, cap screw, washer, and flywheel. -19-30JAN87 M98,2020K,8 -19-30JAN87 M98,2020K,9 -19-10FEB87 M98,2020K,10 -19-30JAN87 NOTE: P218G or P220G engine, flywheel and shield are not shown. -UN-29JAN90 15. If necessary, remove five cap screws to remove flywheel shield. M36294 16. Inspect flywheel for cracks, broken fins, or broken magnets. Inspect flywheel ring gear for chipped or broken teeth. Replace flywheel if damaged. NOTE: Different engine models have different shaped keys. M36295 -UN-29JAN90 17. Remove key. INSTALL FLYWHEEL 1. Install key in crankshaft. -UN-29JAN90 For P218G or P220G engines, align slot in magnetic ring with slot in crankshaft and install key. M36296 20 4 M98,2020K,7 CTM2 (19APR90) 20-4 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel NOTE: P218G or P220G engine, flywheel and shield are not shown. M36294 -UN-29JAN90 2. Install flywheel shield, if removed, and fasten with five cap screws. M98,2020K,11 -19-30JAN87 IMPORTANT: Do not lubricate crankshaft taper. The crankshaft taper must be dry to hold the flywheel tight. 20 5 -UN-29JAN90 3. Clean crankshaft taper before installing flywheel. 4. Apply pipe sealant on threads of flywheel cap screw. M36297 5. Align keyway (A) in flywheel with key (B) in crankshaft. Install flywheel. 6. Install washer and cap screw. 7. Fasten locking pliers to ring gear to prevent flywheel from turning. -UN-29JAN90 8. On B43E, B43G, B48G, and T260 Engines: Tighten cap screw to 51 ± 3 N·m (38 ± 2 lb-ft). M36298 On P218G and P220G Engines: tighten cap screw to 67—75 N·m (50—55 lb-ft). M98,2020K,12 CTM2 (19APR90) 20-5 -19-10FEB85 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel 9. Install flywheel shroud (C) and fasten with five cap screws. 10. For P218G or P220G engine, connect ignition coil to flywheel shroud and fasten with two cap screws. Install air cleaner assembly. 11. Connect fuel line to carburetor. 12. Install fuel pump (B) and fasten with two screws. 13. Connect governor spring (A) in top hole of arm. M36291 -UN-29JAN90 20 6 M98,2020K,13 -19-30JAN87 M98,2020K,14 -19-30JAN87 M36290 -UN-29JAN90 14. Connect fuel pump impulse line (B) and fasten with hose clamp (A). CTM2 (19APR90) 20-6 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel 15. Install right side shroud (E), lift bracket (D) and fasten with five cap screws (C). Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 16. Connect spark plug wire (A) and voltage regulator leads (B). Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of the voltage regulator. 17. Install engine. (See machine technical manual.) A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M36289 -UN-29JAN90 20 7 M98,2020K,15 CTM2 (19APR90) 20-7 -19-30JAN87 16, 18, 20 & 24HP Onan Engines 130495 Flywheel/Flywheel 20 8 CTM2 (19APR90) 20-8 16, 18, 20 & 24HP Onan Engines 130495 Group 25 Camshaft ESSENTIAL TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Number Name Use JDG 325 Crankshaft Seal Installer Install gear cover oil seal M98,2025K,1 -19-09OCT85 SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Bushing, Bearing, and Seal Driver Set Remove and install oil seal, bearings, and camshaft gear Dial Indicator Measure camshaft gear end play and backlash Outside Micrometer Measure camshaft Telescoping Gauge Measure camshaft bearings Press Remove and install camshaft gear M98,2025K,2 25 1 -19-11NOV85 OTHER MATERIAL Number Name Use TY6304 John Deere LOCTITE® Flexible Sealant Apply to camshaft plug surface of cylinder block. TY9375 John Deere LOCTITE Pipe Sealant with TEFLON® Apply to threads of clutch adapter plate screws, gear cover cap screws, and breaker point assembly screw. LOCTITE is a trademark of the Loctite Corp. TEFLON is a trademark of the DuPont Co. CTM2 (19APR90) M98,2025K,2A 25-1 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Service Parts Kits SERVICE PARTS KITS The following kits are available through your parts catalog: Overhaul Gasket Kit M98,2025K,2B -19-09OCT85 25 2 CTM2 (19APR90) 25-2 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Specifications SPECIFICATION Item New Specification Wear Tolerance 1. End Play: B43E, B43G, B48G, and T260 Engine 0.08—0.3 mm (0.003—0.012 in.) 0.4 mm (0.018 in.) End Play: P218G, P220G Engine0.280—1.22 mm (0.0110—0.0480 in.) 2. Gear Backlash: B43E, B43G, B48G Engine 1.65 mm (0.065 in.) 0.03—0.15 mm (0.001—0.006 in.) 0.23 mm (0.009 in.) T260 Engine 0.05—0.08 mm (0.002—0.003 in.) 0.15 mm (0.006 in.) P218G, P220 Engine 0.025—0.127 mm (0.001—0.005 in.) 0.20 mm (0.008 in.) 25 3 3. Governor Cup Travel 5.6 mm (0.22 in.) 4. Journal O.D. 34.90—34.91 mm (1.374—1.375 in.) 34.80 mm (1.370 in.) 28.37—28.47 mm (1.117—1.121 in.) 27.99 mm (1.102 in.) Intake, B43G, B48G 29.57—29.72 mm (1.164—1.170 in.) 29.18 mm (1.149 in.) Exhaust, B43G, B48G 29.44—29.59 mm (1.159—1.165 in.) 29.06 mm (1.144 in.) Intake and Exhaust, T260 29.57—29.72 mm (1.164—1.170 in.) 29 mm (1.142 in.) 29.5 mm (1.162 in.) 29.7 mm (1.171 in.) 29.5 mm (1.162 in.) 29.18 mm (1.149 in.) 6. Bearing I.D. 34.95—34.98 mm (1.376—1.377 in.) 35.03 mm (1.379 in.) 7. Camshaft Clearance 0.038—0.076 mm (0.0015—0.003 in.) 0.125 mm (0.005 in.) 8. Clutch Adapter Plate Screw Torque 35 ± 1 N·m (310 ± 9 lb-in.) 9. Gear Cover Cap Screws and Nut Torque 12 ± 1 N·m (106 ± 9 lb-in.) 5. Lobe Height: Intake and Exhaust, B43E Intake, P218G Exhaust, P218G Intake, P220G Exhaust, P220G 28.49 28.98 29.18 28.98 mm mm mm mm (1.122 (1.141 (1.149 (1.141 in.) in.) in.) in.) M98,2025K,3 CTM2 (19APR90) 25-3 -19-10FEB87 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft REMOVE CAMSHAFT 1. Remove engine. (See machine technical manual.) 2. Remove muffler and exhaust pipes (A). 3. Remove intake manifold (B). (See Remove Intake Manifold, Group 10 in this manual.) 4. Remove cylinder heads (C). (See Remove Cylinder Heads, Group 10 in this manual.) 5. Remove intake and exhaust valves (D). (See Remove Intake and Exhaust Valves, Group 15 in this manual.) 6. Remove flywheel (E). (See Remove Flywheel, Group 20 in this manual.) -UN-29JAN90 M36474 M98,2025K,4 -19-11NOV85 M98,2025K,5 -19-10FEB87 M98,2025K,6 -19-10FEB87 M36299 -UN-29JAN90 7. Remove Allen screw to remove breaker point cover, if equipped. NOTE: Be careful not to lose the plunger during breaker point assembly removal. -UN-29JAN90 8. Remove two screws to remove breaker point assembly and gasket (A), if equipped. M36300 25 4 A—Muffler and Exhaust Pipes B—Intake Manifold C—Cylinder Heads D—Intake and Exhaust Valves E—Flywheel CTM2 (19APR90) 25-4 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft -UN-29JAN90 IMPORTANT: Do not hit gear cover with a metal hammer or remove cover with a screwdriver. Doing so may damage gear cover. 9. Remove four cap screws and nut to remove clip (A), gear cover, and gasket (B). M36301 For P218G or P220G engine, disconnect wire leads from ignition coil. Remove crankshaft key and magnetic ring. 10. If gear cover is tight, hit cover lightly with a soft-faced hammer to loosen it. M98,2025K,7 -19-10FEB87 25 5 M36302 -UN-29JAN90 11. Remove oil seal using a 2 in. driver disk. M98,2025K,8 -19-09OCT85 M98,2025K,9 -19-02FEB87 12. Measure camshaft end play. New Parts Wear Tolerance B43E, B43G, B48G and T260 0.08—0.3 mm (0.003—0.012 in.) 0.4 mm (0.018 in.) P218G and P220G 0.280—1.22 mm (0.0110—0.0480 in.) 1.65 mm (0.065 in.) M36303 Engine -UN-29JAN90 CAMSHAFT END PLAY SPECIFICATION If end play exceeds wear tolerance, replace camshaft thrust washer. CTM2 (19APR90) 25-5 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft 13. Measure camshaft gear backlash. CAMSHAFT GEAR SPECIFICATIONS New Part Wear Tolerance -UN-29JAN90 Item B43E, B43G, B48G Engine 0.03—0.15 mm (0.001—0.006 in.) 0.23 mm (0.009 in.) 0.05—0.08 mm (0.002—0.003 in.) 0.15 mm (0.006 in.) 0.025—0.127 mm (0.001—0.005 in.) 0.20 mm (0.008 in.) M36304 Camshaft Gear Backlash T260 Engine Camshaft Gear Backlash P218G, P220G Engine Camshaft Gear Backlash If backlash exceeds wear tolerance, replace camshaft gear and crankshaft gear. M98,2025K,10 -19-10FEB87 M98,2025K,11 -19-09OCT85 M98,2025K,12 -19-09OCT85 M36305 -UN-29JAN90 14. Remove snap ring to remove thrust washer. -UN-29JAN90 IMPORTANT: Do not allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces may be damaged. 15. Carefully remove camshaft until rear lobe is even with camshaft bearing. Turn camshaft until lobe (A) fits into camshaft bearing notch (B). Remove camshaft. M36307 25 6 CTM2 (19APR90) 25-6 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft M36306 -UN-29JAN90 16. Remove thrust washer. M98,2025K,13 -19-09OCT85 DISASSEMBLE AND INSPECT CAMSHAFT -UN-29JAN90 1. Hold cup against flyballs. Measure distance from snap ring to surface of hub. The distance must be 5.6 mm (0.22 in.). If the distance is not correct, replace camshaft assembly. M36308 NOTE: The camshaft and pin are only serviced as an assembly. 2. The cup (A) must spin freely on the camshaft pin without excessive play. Replace parts as necessary. M98,2025K,14 -19-09OCT85 M98,2025K,15 -19-09OCT85 3. Remove snap ring to remove hub (A) and cup (B). M36309 -UN-29JAN90 4. Inspect cup race for grooved or rough surface. Replace cup if necessary. CTM2 (19APR90) 25-7 16, 18, 20 & 24HP Onan Engines 130495 25 7 Camshaft/Camshaft 5. Remove flyballs. Inspect flyballs for grooved or flat spots, replace if necessary. -UN-29JAN90 6. Inspect flyball spacer (A) for wear or damage. Replace camshaft gear if necessary. NOTE: The flyball spacer, plate, and camshaft gear are serviced as an assembly only. M36310 IMPORTANT: If camshaft gear is replaced, always replace crankshaft gear also. 7. Inspect camshaft gear for chipped or broken teeth. Replace camshaft gear if necessary. M98,2025K,16 -19-09OCT85 M98,2025K,17 -19-11NOV85 M98,2025K,18 -19-11NOV85 IMPORTANT: Be sure to hold camshaft while removing camshaft gear. -UN-14JUL89 8. Remove gear using a 1 in. deep-well socket, 1 in. driver disk, and a press. M30688 9. Remove key. 10. Measure camshaft journal outside diameter. Item New Part Wear Tolerance Journal Diameter 34.90—34.91 mm (1.374—1.3745 in.) 34.80 mm (1.370 in.) -UN-29JAN90 CAMSHAFT JOURNAL SPECIFICATIONS If journal diameter is less than 34.80 mm (1.370 in.), replace camshaft. CTM2 (19APR90) M36311 25 8 25-8 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft 11. Measure camshaft lobe height. New Specification Wear Tolerance Lobe Height: B43E Intake and Exhaust 28.37—28.47 mm (1.117—1.121 in.) 27.99 mm (1.102 in.) B43G, B48G Intake 29.57—29.72 mm (1.164—1.170 in.) 29.18 mm (1.149 in.) B43G, B48G Exhaust 29.44—29.59 mm (1.159—1.165 in.) 29.06 mm (1.144 in.) T260 Intake and Exhaust 29.57—29.72 mm (1.164—1.170 in.) 29.18 mm (1.149 in.) P218G Intake 29 mm (1.142 in.) P218G Exhaust 29.5 mm (1.162 in.) 28.49 mm (1.122 in.) 28.98 mm (1.141 in.) P220G Intake 29.7 mm (1.171 in.) P220G Exhaust 29.5 mm (1.162 in.) M36312 Item -UN-29JAN90 CAMSHAFT LOBE SPECIFICATIONS 25 9 29.18 mm (1.149 in.) 28.98 mm (1.141 in.) If lobe height is less than wear tolerance, replace camshaft. M98,2025K,19 -19-02FEB87 M98,2025K,20 -19-09OCT85 M36313 -UN-29JAN90 12. If equipped, remove two screws to remove clutch adapter plate. CTM2 (19APR90) 25-9 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft M36314 -UN-29JAN90 13. Remove plug (A) using a wooden dowel. M98,2025K,21 -19-09OCT85 M98,2025K,22 -19-11NOV85 14. Measure camshaft bearing inside diameter and determine camshaft clearance (camshaft bearing I.D. minus camshaft journal O.D.). Item New Part Wear Tolerance Camshaft Bearing Diameter 34.95—34.98 mm (1.376—1.377 in.) 35.03 mm (1.379 in.) 0.038—0.076 mm (0.0015—0.003 in.) 0.125 mm (0.005 in.) Camshaft Clearance M36315 25 10 -UN-29JAN90 CAMSHAFT BEARING SPECIFICATIONS If camshaft bearing diameter exceeds 35.03 mm (1.379 in.) replace bearing. If camshaft clearance exceeds 0.125 mm (0.005 in.), replace camshaft bearing, camshaft, or both. CTM2 (19APR90) 25-10 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft M36317 -UN-29JAN90 M36316 -UN-29JAN90 15. Remove camshaft bearing using a soft steel rod or chisel to bend bearing away from side of bore. M98,2025K,23 -19-09OCT85 M98,2025K,24 -19-09OCT85 ASSEMBLE CAMSHAFT 1. Install key in camshaft. -UN-14JUL89 2. Install gear with timing mark “0” away from camshaft. 3. Align slot in gear with key in shaft. CTM2 (19APR90) 25-11 M30756 4. Push camshaft into gear using a 1-3/8 in. driver disk and a press until camshaft is even with bottom of gear surface. 16, 18, 20 & 24HP Onan Engines 130495 25 11 Camshaft/Camshaft 5. Apply clean engine oil on camshaft parts before assembly. M36310 -UN-29JAN90 6. Install flyballs in flyball spacer (A) notches. M98,2025K,25 -19-09OCT85 M98,2025K,26 -19-09OCT85 M98,2025K,27 -19-09OCT85 -UN-29JAN90 7. Install cup (A), hub (B), and fasten with snap ring. M36318 25 12 M36306 -UN-29JAN90 8. Install thrust washer. CTM2 (19APR90) 25-12 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft INSTALL CAMSHAFT -UN-29JAN90 1. Clean and dry all parts. Apply clean engine oil on all internal parts before assembly. NOTE: The service camshaft bearing is half the width of the original bearing, but the camshaft bearing surface is the same. M36319 2. Align oil hole (A) in bearing with oil hole (B) in cylinder block. Install rear bearing using a 1-3/8 in. driver disk (C) and 1-1/2 in. driver disk (D). Push bearing even with surface of cylinder block. A—Bearing Oil Hole B—Cylinder Block Oil Hole C—1-3/8 in. Driver Disk D—1-1/2 in. Driver Disk M98,2025K,28 -19-09OCT85 25 13 M36320 -UN-29JAN90 3. Install front bearing using a 1-3/8 in. driver disk (A) and 1-1/2 driver disk (B). Push bearing even with bottom of bore. Be sure bearing is past breaker point plunger hole (C) in cylinder block. M98,2025K,29 -19-09OCT85 M98,2025K,30 -19-09OCT85 4. Apply flexible sealant on plug surface of cylinder block. M36321 -UN-29JAN90 5. Install plug tight against bottom of cylinder block counterbore. CTM2 (19APR90) 25-13 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft 6. If equipped, apply pipe sealant on threads of clutch adapter plate screws. M36322 -UN-29JAN90 7. Install clutch adapter plate and two screws. Tighten screws to 35 ± 1 N·m (310 ± 9 lb-in.). M98,2025K,31 -19-09OCT85 M98,2025K,32 -19-09OCT85 8. Put clean engine oil on camshaft bearing journals. -UN-29JAN90 M36307 9. Install flywheel cap screw in crankshaft to aid in turning crankshaft for timing mark alignment. 10. Turn camshaft until lobe (A) fits into camshaft bearing notch (B) and carefully install camshaft. -UN-29JAN90 11. Align timing marks (C) on camshaft and crankshaft gears and continue to install camshaft. M36323 25 14 IMPORTANT: Do not allow camshaft lobe to hit bearing surfaces while installing camshaft. Machined surfaces may be damaged. CTM2 (19APR90) 25-14 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft 12. Align slot (A) in thrust washer with key (B) in crankshaft. M36305 -UN-29JAN90 M36324 -UN-29JAN90 13. Install thrust washer and snap ring. M98,2025K,33 -19-09OCT85 M98,2025K,34 -19-09OCT85 M98,2025K,35 -19-11NOV85 M36325 -UN-29JAN90 14. Install oil seal (A) with lip of seal downward, in gear cover using JDG 325 Crankshaft Seal Installer (B). 15. Turn cup until the plastic bushing (A) is in the 3 o’clock position. M36326 -UN-29JAN90 16. Apply multipurpose grease between cup and camshaft gear to hold cup in position. CTM2 (19APR90) 25-15 16, 18, 20 & 24HP Onan Engines 130495 25 15 Camshaft/Camshaft 17. Install new gasket on cylinder block. 18. Be sure plastic bushing (A) and pin (B) are aligned. -UN-29JAN90 IMPORTANT: Do not hit gear cover with a metal hammer during installation. Gear cover may be damaged. M36327 19. Hold governor arm away from camshaft and carefully install gear cover. M36328 -UN-29JAN90 25 16 M98,2025K,36 -19-09OCT85 M98,2025K,37 -19-09OCT85 M36329 -UN-29JAN90 20. Pull engine forward and move governor arm back and forth. Governor cup should be felt moving in and out. If no movement is felt, the pin is not in plastic bushing. Remove gear cover and repeat steps 18—20. CTM2 (19APR90) 25-16 16, 18, 20 & 24HP Onan Engines 130495 Camshaft/Camshaft 21. Apply pipe sealant on cap screw (A) threads. -UN-29JAN90 22. Install clip (B), four cap screws and nut. Tighten cap screws and nut to 12 ± 1 N·m (106 ± 9 lb-in.). 23. Install stator wiring (C) in clip. M36330 24. For P218G or P220G engine, connect wires leads to ignition coil. Install crankshaft key and magnetic ring. M98,2025K,38 -19-10FEB87 25. Install new gasket (A) on cylinder block. -UN-29JAN90 NOTE: Be careful not to lose the plunger during breaker point assembly installation. 26. Apply clean engine oil on plunger. Remove excess oil after installation. M36331 27. Apply pipe sealant on Allen screw threads. M36300 -UN-29JAN90 28. Install breaker point assembly and fasten with two Allen screws, if equipped. M98,2025K,39 -19-10FEB87 M98,2025K,40 -19-10FEB85 29. Install breaker point wire in breaker point assembly groove. M36299 -UN-29JAN90 20. Install breaker point cover and tighten Allen screw. CTM2 (19APR90) 25-17 16, 18, 20 & 24HP Onan Engines 130495 25 17 Camshaft/Camshaft 31. Install flywheel (E). (See Group 20 in this manual.) 32. Install intake and exhaust valves (D). (See Install intake and Exhaust Valves, Group 15 in this manual.) 33. Install cylinder heads (C). (See Install Cylinder Heads, Group 10 in this manual.) 34. Install intake manifold (B). (See Install Intake Manifold, Group 10 in this manual.) 35. Install engine. (See machine technical manual.) -UN-29JAN90 A—Muffler and Exhaust Pipes B—Intake Manifold C—Cylinder Heads D—Intake and Exhaust Valves E—Flywheel M36474 25 18 M98,2025K,41 CTM2 (19APR90) 25-18 -19-10FEB85 16, 18, 20 & 24HP Onan Engines 130495 Group 30 Connecting Rods and Pistons SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Feeler Gauge Measure connecting rod end play and piston ring end gap. Ridge Reamer Remove ridge from top of cylinder bore. Outside Micrometer Measure engine components. Telescoping Gauge Measure connecting rod bores and piston pin bore. Piston Ring Expander Remove and install piston rings. Vernier Calipers Measure piston ring groove width and piston O.D. Inside Micrometer Measure piston bore. Flex Hone To deglaze cylinder bores Piston Ring Compressor Install pistons in cylinder block. 30 1 M98,2030K,1 -19-11NOV85 OTHER MATERIAL Number Name Use PLASTIGAGE® Measure connecting rod bearing clearance PLASTIGAGE is a trademark of the TRW Corp. M98,2030K,2 -19-09OCT85 M98,2030K,2A -19-11NOV85 SERVICE PARTS KITS The following kits are available through your parts catalog: Overhaul Gasket Kit CTM2 (19APR90) 30-1 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Specifications SPECIFICATIONS Connecting Rods Item New Specification Wear Tolerance 1. Side Clearance 0.05—0.41 mm (0.002—0.016 in.) 0.8 mm (0.03 in.) 2. Connecting Rod Cap Nut Torque: B43E, B43G, B48G, 18 ± 1 N·m P218G, P220G Engine (159 ± 9 lb-in.) 3. Connecting Rod Cap Nut Torque: T260 20 ± 1 N·m (177 ± 9 lb-in.) 4. Piston Pin Clearance: B43E, B43G, B48G Engine T260 Engine P218G and P220G Engine 30 2 5. Piston O.D.: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 6. Cylinder Bore I.D.: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 7. Piston-To-Bore Clearance: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 0.005—0.010 mm (0.0002—0.004 in.) 0.003—0.013 mm (0.001—0.005 in.) 0.001—0.0162 mm (0.00004—0.00064 in.) 82.42—82.44 mm (3.245—3.246 in.) 90.42—90.45 mm (3.560—3.561 in.) 82.32 mm (3.241 in.) 90.32 mm (3.556 in.) 82.53—82.55 mm (3.249—3.250 in.) 90.488—90.512 mm (3.5625—3.5635 in.) 82.68 mm (3.255 in.) 90.632 mm (3.5682 in.) 0.076—0.127 mm (0.003—0.005 in.) 0.178—0.229 mm (0.007—0.009 in.) 0.28 mm (0.011 in.) 0.38 mm (0.015 in.) 8. Cylinder Bore Taper: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 0.13 mm (0.005 in.) 0.08 mm (0.003 in.) 9. Cylinder Bore Out-of-Round 0.08 mm (0.003 in.) M98,2030K,3 CTM2 (19APR90) 30-2 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Specifications PISTON Item 1. Ring Groove Width: Top Ring Second Ring Oil Ring 2. Ring End Gap 3. Piston Pin Bore I.D.: B43E, B43G, B48G, P218G, P220G Engine T260 Engine New Specification Wear Tolerance 2.032—2.057 mm (0.080—0.081 in.) 2.032—2.057 mm (0.080—0.081 in.) 4.775—4.801 mm (0.188—0.189 in.) 2.21 mm (0.087 in.) 2.21 mm (0.087 in.) 4.95 mm (0.195 in.) 0.25—0.51 mm (0.010—0.020 in.) 1.52 mm (0.060 in.) 17.468—17.478 mm (0.6877—0.6881 in.) 19.055—19.065 mm (0.7502—0.7506 in.) 4. Rod-to-Crankshaft Bearing Clearance 0.051—0.084 mm (0.002—0.0033 in.) 0.13 mm (0.0053 in.) 5. Crankshaft Connecting Rod Journal O.D. 41.28—41.30 mm (1.6252—1.6260 in.) 41.25 mm (1.6242 in.) 41.35—41.36 mm (1.6280—1.6285 in.) 44.46—44.48 mm (1.7505—1.7510 in.) 41.39 mm (1.6295 in.) 44.50 mm (1.7520 in.) 17.463—17.468 mm (0.6875—0.6877 in.) 19.050—19.055 mm (0.7500—0.7502 in.) 17.371 mm (0.6839 in.) 18.959 mm (0.7464 in.) 6. Connecting Rod Crankshaft Bore I.D.: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 7. Piston Pin O.D.: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 8. Connecting Rod Piston Pin Bore I.D.: B43E, B43G, B48G, P218G, P220G Engine T260 9. Piston Pin Clearance: B43E, B43G, B48G, P218G, P220G Engine T260 Engine 30 3 17.470—17.480 mm (0.6878—0.6882 in.) 19.06—19.07 mm (0.7504—0.7508 in.) 0.005—0.018 mm (0.0002—0.00007 in.) 0.005—0.020 mm (0.0002—0.0008 in.) M98,2030K,4 CTM2 (19APR90) 30-3 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Connecting Rod PISTON—CONTINUED Item New Specification Wear Tolerance 10. Bores Out-of-Round 0.05 mm (0.002 in.) Cylinder Head Item New Specification 1. Attaching Cap Screw Torque: B43E Engine B43G, B48G, P218G, P220G Engine 23 ± 1 N·m (204 ± 12 lb-in.) 20 ± 1 N·m (180 ± 12 lb-in.) 2. Attaching Nut Torque (T260 Engine): Top Six Nuts (with compression washers) Bottom Four Nuts 16 ± 1 N·m (142 ± 12 lb-in.) 20 ± 1 N·m (180 ± 12 lb-in.) 3. Oil Base Cap Screw Torque 27 ± 3 N·m (239 ± 27 lb-in.) 4. Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) 30 4 M98,2030K,5 -19-02FEB87 M98,2030K,6 -19-09OCT85 MEASURE CONNECTING ROD END PLAY 1. Remove engine. (See machine technical manual.) -UN-29JAN90 2. Disconnect spark plug wire (A). 3. Remove six cap screws to remove lift bracket (B), oil fill tube bracket (C), and left side shroud (D). CTM2 (19APR90) M36472 A—Spark Plug Wire B—Lift Bracket C—Oil Fill Tube Bracket D—Left Side Shroud 30-4 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Connecting Rod 4. Disconnect spark plug wire (A) and voltage regulator leads (B). 5. Remove five cap screws (C) to remove lift bracket (D), and right side shroud (E). M36289 -UN-29JAN90 A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M98,2030K,7 -19-09OCT85 M98,2030K,8 -19-09OCT85 M36290 -UN-29JAN90 6. Loosen hose clamp (A) to disconnect fuel pump impulse line (B). CTM2 (19APR90) 30-5 16, 18, 20 & 24HP Onan Engines 130495 30 5 Connecting Rods and Pistons/Connecting Rod 7. Disconnect governor spring (A). 8. Remove two screws to remove fuel pump (B). -UN-29JAN90 9. Remove three cap screws to remove flywheel shroud (C). M36291 30 6 M98,2030K,9 -19-09OCT85 M98,2030K,10 -19-09OCT85 M98,2030K,11 -19-02FEB87 M36374 -UN-29JAN90 10. Remove four cap screws to remove oil base and gasket (A). 11. Measure connecting rod side clearance. New side clearance specification is 0.05—0.41 mm (0.002—0.016 in.). M36380 -UN-29JAN90 If clearance exceeds 0.8 mm (0.03 in.), replace connecting rod and connecting rod cap. CTM2 (19APR90) 30-6 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Connecting Rod MEASURE CONNECTING ROD BEARING CLEARANCE -UN-29JAN90 Measure each connecting rod bearing clearance using the following PLASTIGAGE method or by measuring after the pistons have been removed. M36381 IMPORTANT: Connecting rod end caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. 1. Put identification marks on connecting rods, rod caps, and cylinder block. -UN-29JAN90 2. Remove nuts to remove connecting rod caps (B43E, B43G, B48G, P218G and P220G Engines—top photo). M36388 Remove cap screws to remove connecting rod caps (T260 Engine—bottom photo). M98,2030K,12 -19-02FEB87 M98,2030K,13 -19-09OCT85 3. Wipe oil from connecting rod bearing surface and crankshaft journal. M36382 -UN-29JAN90 4. Put a piece of PLASTIGAGE or an equivalent on the full length of the bearing surface about 6 mm (1/4 in.) off center. CTM2 (19APR90) 30-7 16, 18, 20 & 24HP Onan Engines 130495 30 7 Connecting Rods and Pistons/Connecting Rod 5. Turn crankshaft about 30˚ from bottom of oil pan and install connecting rod cap. Install and tighten nuts or cap screws evenly to specifications. Measurement Specifications B43E, B43G, B48G, P218G, P220G Cap Nut Torque 18 ± 1 N·m (159 ± 9 lb-in.) T260 Cap Screw Torque 20 ± 1 N·m (177 ± 9 lb-in.) M36383 Engine -UN-29JAN90 CONNECTING ROD SPECIFICATIONS M98,2030K,14 -19-02FEB87 M98,2030K,15 -19-09OCT85 6. Remove nuts or cap screws and connecting rod cap. -UN-29JAN90 7. The flattened PLASTIGAGE will be found on either the bearing surface or crankshaft journal. 8. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its WIDEST point. Remove PLASTIGAGE. The number within the graduation marks indicates the bearing clearance in thousandths of an inch or in millimeters depending on which side of the envelope is used. M36384 30 8 9. New bearing clearance is 0.051—0.084 mm (0.002—0.0033 in.). If clearance exceeds 0.13 mm (0.0053 in.), remove pistons. If clearance is correct, install connecting rod caps and tighten nuts or cap screws to specifications. CTM2 (19APR90) 30-8 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods REMOVE PISTONS AND CONNECTING RODS -UN-29JAN90 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire (A). M36472 3. Remove six cap screws to remove lift bracket (B), oil fill tube (C), and left side shroud (D). A—Spark Plug Wire B—Lift Bracket C—Oil Fill Tube Bracket D—Left Side Shroud M98,2030K,16 -19-09OCT85 4. Disconnect spark plug wire (A) and voltage regulator leads (B). 30 9 5. Remove five cap screws (C) to remove lift bracket (D), and right side shroud (E). M36289 -UN-29JAN90 A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M98,2030K,7 CTM2 (19APR90) 30-9 -19-09OCT85 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods M36290 -UN-29JAN90 6. Loosen hose clamp (A) to disconnect fuel pump impulse line (B). M98,2030K,8 -19-09OCT85 M98,2030K,9 -19-09OCT85 M98,2030K,10 -19-09OCT85 7. Disconnect governor spring (A). 8. Remove two screws to remove fuel pump (B). 9. Remove three cap screws to remove flywheel shroud (C). M36291 -UN-29JAN90 30 10 M36374 -UN-29JAN90 10. Remove four cap screws to remove oil base and gasket (A). CTM2 (19APR90) 30-10 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods -UN-29JAN90 IMPORTANT: Do not remove cylinder heads while they are hot. Cylinder head may warp. A hot gasket will be soft and difficult to remove. 11. Remove nine cap screws to remove cylinder head and gasket (A). M36385 Remove 10 nuts, 20 compression washers (A), and ten washers (B) to remove cylinder head and gasket (C). M36386 -UN-29JAN90 B43E,B43G,B48G,P21G and P220G T260 Engine M98,2030K,17 -19-02FEB87 M98,2030K,18 -19-09OCT85 12. Clean carbon from cylinder bore using a wire brush. -UN-29JAN90 13. Before piston removal, check cylinder bore for ridges. The ridges can cause damage to piston or rings if ridge is not removed. M36387 14. If necessary, remove ridge from top of cylinder bore using a ridge reamer. CTM2 (19APR90) 30-11 16, 18, 20 & 24HP Onan Engines 130495 30 11 Connecting Rods and Pistons/Pistons and Connecting Rods -UN-29JAN90 IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. 15. Put identification marks on connecting rods, rod caps, and cylinder block. M36381 16. Remove nuts to remove connecting rod caps. (B43E, B43G, B48G, P218G and P220G Engines—top photo.) M36388 -UN-29JAN90 Remove cap screws to remove connecting rod caps. (T260 Engine-bottom photo) 30 12 M98,2030K,19 -19-02FEB87 M98,2030K,20 -19-09OCT85 M36389 -UN-29JAN90 17. Push piston and connecting rod out of cylinder bore using a wooden dowel. CTM2 (19APR90) 30-12 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods INSPECT PISTONS AND CONNECTING RODS -UN-29JAN90 1. Measure crankshaft connecting rod journal diameter. Measure several places around each journal and each side of journal. M36390 NOTE: If engine has had previous major overhaul, crankshaft journals may have been ground and undersize connecting rods installed. CONNECTING ROD JOURNAL SPECIFICATIONS Item New Parts Wear Tolerance Journal O.D. 41.28—41.30 mm (1.6252—1.6260 in.) 41.25 mm (1.6242 in.) If journal diameter is less than 41.25 mm (1.6242 in.), replace crankshaft or have journals ground by a qualified machine shop. The following undersize connecting rods are available: 0.25 mm (0.010 in.) 0.50 mm (0.020 in.) 0.76 mm (0.030 in.) 30 13 M98,2030K,21 CTM2 (19APR90) 30-13 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 2. Measure connecting rod bore diameter and connecting rod clearance (bore I.D. minus journal O.D.). -UN-29JAN90 3. Install connecting rod cap on connecting rod. Install and tighten nuts or cap screws evenly to specifications. 18 ± 1 N·m (159 ± 9 lb-in.) Cap Screw Torque T260 Engine 20 ± 1 N·m (177 ± 9 lb-in.) Item New Parts Wear Tolerance Bore I.D.: B43E,B43G,B48G, P218G, P220G Engines 41.35—41.36 mm (1.6280—1.6285 in.) 41.39 mm (1.6295 in.) T260 Engine 44.46—44.48 mm (1.7505—1.7510 in.) 44.50 mm (1.7520 in.) Clearance 0.051—0.084 mm (0.0020—0.0033 in.) 0.135 mm (0.0053 in.) If bore diameter exceeds wear tolerance, replace connecting rod. If connecting rod clearance exceeds 0.135 mm (0.0053 in.), replace connecting rod or grind crankshaft connecting rod journals and install undersize connecting rods. M98,2030K,22 -19-02FEB87 M98,2030K,23 -19-09OCT85 4. Remove piston rings using a piston ring expander. -UN-29JAN90 IMPORTANT: Do not use a caustic cleaning solvent to remove carbon from pistons; piston may be damaged. 5. Clean carbon from piston surfaces using a wire brush. Clean piston ring grooves with a piston ring groove cleaner or the end of a piston ring filed to a sharp point. M36392 30 14 Cap Nut Torque B43E, B43G, B48G, P218G, P220G Engines M36391 CONNECTING ROD SPECIFICATIONS CTM2 (19APR90) 30-14 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 6. Measure piston ring groove width. Measure several places around each piston. New Part Wear Tolerance Top Ring 2.032—02.057 mm (0.080—0.081 in.) 2.21 mm (0.087 in.) Second Ring 2.032—2.057 mm (0.080—0.081 in.) 2.21 mm (0.087 in.) Oil Ring 4.775—4.801 mm (0.188—0.189 in.) 4.95 mm (0.195 in.) M36393 Item -UN-29JAN90 PISTON RING GROOVE SPECIFICATIONS If ring groove width exceeds wear tolerance, replace piston. M98,2030K,24 -19-11NOV85 7. Inspect piston for worn or cracked ring lands. Excessive piston wear near the edge of the top ring land indicated preignition. 30 15 M36394 -UN-29JAN90 8. Clean and inspect oil holes in oil ring groove for a plugged condition. Replace parts as necessary. M98,2030K,25 CTM2 (19APR90) 30-15 -19-09OCT85 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 9. Measure piston ring end gap. Push rings into cylinder bore approximately halfway using piston. Item New Part Wear Tolerance All Rings 0.25—0.51 mm (0.010—0.020 in.) 1.52 mm (0.060 in.) -UN-29JAN90 PISTON RING END GAP SPECIFICATIONS M36396 -UN-29JAN90 M36395 If end gap exceeds 1.52 mm (0.060 in.), replace rings. Deglaze cylinder bore before installing new rings. 30 16 M98,2030K,26 -19-12NOV85 M98,2030K,27 -19-09OCT85 IMPORTANT: Pistons must be installed in the same direction and on the same connecting rod they were removed from. -UN-29JAN90 10. Put a mark on each piston and connecting rod for proper identification to aid in assembly. 11. Remove two snap rings. M36397 12. Remove piston pin using a wooden dowel. CTM2 (19APR90) 30-16 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 13. Measure diameter of piston pin at six places; two measurements 90˚ apart at each end and two measurements 90˚ at center. New Part Wear Tolerance Pin O.D. B43E,B43G,B48G, P218G, P220G Engine 17.463—17.468 mm (0.6875—0.6877 in.) 17.371 mm (0.6839 in.) 19.050—19.055 mm (0.7500—0.7502 in.) 18.959 mm (0.7464 in.) T260 Engine M35365 Item -UN-29AUG88 PISTON PIN SPECIFICATIONS If pin diameter is less than wear tolerance, install a new piston pin. M98,2030K,28 -19-02FEB87 14. Measure piston pin bore in connecting rod and piston pin clearance (bore I.D. minus pin O.D.). 30 17 Item New Part B43E, B43G, B48G, P218G, P220G Bore I.D. 17.470—17.480 mm (0.6878—0.6882 in.) B43E, B43G, B48G, P218G, P220G Pin Clearance 0.005—0.018 mm (0.0002—0.0007 in.) T260 Bore I.D. 19.06—19.07 mm (0.7504—0.7508 in.) T260 Pin Clearance 0.005—0.020 mm (0.0002—0.0008 in.) M36398 Engine -UN-29JAN90 PISTON PIN BORE SPECIFICATIONS If piston pin bore diameter exceeds specifications, replace connecting rod. If pin clearance exceeds specifications, replace connecting rod, piston pin, or both. 15. Inspect connecting rod cap screws and nuts for damaged threads. Inspect connecting rods for nicks, cracks, scored bores, or bores out-of-round more than 0.05 mm (0.002 in.). M98,2030K,29 CTM2 (19APR90) 30-17 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 16. Measure piston pin bore in piston and piston pin clearance (bore I.D. minus pin O.D.). Item New Part B43E, B43G, B48G, P218G, P220G Bore I.D. 17.468—17.478 mm (0.6877—0.6881 in.) B43E, B43G, B48G Pin Clearance 0.005—0.010 mm (0.002—0.0004 in.) P218G, P220G M36399 Engine -UN-29JAN90 PISTON PIN BORE SPECIFICATIONS 0.001—0.0162 mm (0.00004—0.00064 in.) T260 Bore I.D. 19.005—19.065 mm (0.7502—0.7506 in.) T260 Pin Clearance 0.003—0.013 mm (0.0001—0.0005 in.) If piston pin bore diameter exceeds specifications, replace piston. 30 18 If piston pin clearance exceeds specifications; replace piston, piston pin, or both. M98,2030K,30 CTM2 (19APR90) 30-18 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 17. Measure piston O.D. perpendicular to piston bore at a point approximately 30 mm (1.2 in.) from top of piston or 2.5 mm (0.1 in.) below oil ring groove. -UN-29JAN90 NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Item New Part Wear Tolerance Piston O.D. B43E, B43G, B48G, P218G, P220G Engine 82.42—82.44 mm (3.245—3.246 in.) 82.32 mm (3.241 in.) 90.42—90.45 mm (3.560—3.561 in.) 90.32 mm (3.556 in.) T260 Engine M36400 PISTON SPECIFICATIONS If piston diameter is less than wear tolerance, install a new piston. 18. Inspect piston for cracks at ring lands, skirts, and pin bores. Inspect piston for scuffing or scoring; replace as necessary. 30 19 M98,2030K,31 -19-02FEB87 M98,2030K,32 -19-09OCT85 -UN-29JAN90 19. Inspect cylinder bores for scuffing, scoring, scratches, cracks, and wear. If cylinder bores are damaged, replace cylinder block or rebore and hone cylinder for next oversize piston. M36401 20. If the cylinder bore is not damaged, check cylinder bore for wear. CTM2 (19APR90) 30-19 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 21. Measure piston bore I.D. at four places; two measurements 90˚ apart at top of ring travel and two measurements 90˚ apart at bottom of ring travel. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. 22. Measure piston clearance (piston bore I.D. minus piston O.D.). 23. Measure cylinder bore taper (A—C, B—D). 24. Measure cylinder bore out-of round (A—B, C—D). CYLINDER BORE SPECIFICATIONS 30 20 Wear Tolerance 82.53—82.55 mm (3.249—3.250 in.) 90.488—90.512 mm (3.5625—3.5635 in.) 82.68 mm (3.255 in.) 90.632 mm (3.5682 in.) Piston Clearance B43E, B43G, B48G, P218G, P220G 0.076—0.127 mm Engine (0.003—0.005 in.) T260 Engine 0.178—0.229 mm (0.007—0.009 in.) Taper B43E, B43G, B48G, P218G, P220G Engine T260 Engine Out-of-Round -UN-29JAN90 New Part M36402 Item Bore I.D. B43E,B43G, B48G, P218G, P220G Engine T260 Engine 0.28 mm (0.011 in.) 0.38 mm (0.015 in.) 0.13 mm (0.005 in.) 0.08 mm (0.003 in.) 0.08 mm (0.003 in.) If cylinder bore exceeds wear tolerance, replace cylinder block or have cylinder rebored by a qualified machine shop. If cylinder is rebored, oversize piston and rings must be installed. The following oversize pistons and rings are available: 0.25 mm (0.010 in.) 0.50 mm (0.020 in.) 0.76 mm (0.030 in.) If piston clearance exceeds wear tolerance, replace cylinder block, piston or both, or rebore cylinder. Install oversize piston and rings. If taper or out-of-round exceed wear tolerance, replace cylinder block, or rebore cylinder. Install oversize piston and rings. M98,2030K,33 CTM2 (19APR90) 30-20 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods DEGLAZE CYLINDER BORES -UN-29JAN90 NOTE: It is recommended that crankshaft be removed. If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. M36403 1. Deglaze cylinder bores using a flex-hone. M98,2030K,34 -19-10OCT85 NOTE: A cutaway of a cylinder bore is shown for clarity of photograph. -UN-02DEC88 2. Use flex-hone as instructed by manufacturer to obtain 45˚ crosshatch pattern as shown. RW619 IMPORTANT: Do not use gasoline, kerosene, or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 3. Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean cylinder walls using clean white rags and water. Continue to clean cylinder until white rags show no discoloration. M98,2025R,29 -19-31JUL84 ASSEMBLE PISTONS AND CONNECTING RODS -UN-29JAN90 IMPORTANT: Pistons must be installed on connecting rods from which they were removed. M36397 1. Identification marks on piston must be to the same side as marks on connecting rod. 2. Put clean engine oil on piston pin. Install pin through piston and connecting rod. 3. Install snap rings. Be sure snap rings are fastened in groove all around. M98,2030K,35 CTM2 (19APR90) 30-21 -19-10OCT85 16, 18, 20 & 24HP Onan Engines 130495 30 21 Connecting Rods and Pistons/Pistons and Connecting Rods 4. Install oil ring expander in bottom piston ring groove. Turn expander so ends are above either end of the piston pin. M36392 -UN-29JAN90 5. Install oil ring over expander with a piston ring expander. Turn oil ring so ends are on opposite side of piston from the expander ends. M98,2030K,36 -19-10OCT85 M98,2030K,37 -19-10OCT85 6. Install second ring in middle groove, with chamfer (A) toward bottom of piston, or with dot (B) toward top of piston (T260 only). -UN-29JAN90 7. Install compression ring in top groove, with dot (B) toward top of piston. M36404 -UN-29JAN90 M36406 30 22 CTM2 (19APR90) 30-22 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods INSTALL PISTONS AND CONNECTING RODS -UN-29JAN90 IMPORTANT: Pistons must be installed in the same cylinder they were removed from and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. M36363 1. Apply clean engine oil on piston,s connecting rod bearing surface, and cylinder bore. 2. Turn crankshaft until rod journal is at bottom of its stroke. M36407 -UN-29JAN90 M36364 -UN-29JAN90 3. Install piston with notch (A) or oil hole (B) toward camshaft using a ring compressor. Push piston down until connecting rod is seated on crankshaft rod journal. M98,2030K,38 CTM2 (19APR90) 30-23 -19-10OCT85 16, 18, 20 & 24HP Onan Engines 130495 30 23 Connecting Rods and Pistons/Pistons and Connecting Rods -UN-29JAN90 IMPORTANT: Connecting rod caps must be installed on the same connecting rod they were removed from and in the same direction. 4. Apply clean engine oil on connecting rod cap. M36408 5. Install connecting rod cap with this side (A) outward on connecting rod. Install connecting rod cap with large tang (B) away from camshaft on connecting rod. -UN-29JAN90 B43E, B43G, B48G, P218G, and P220G M36409 30 24 T260 Engine M98,2030K,39 -19-02FEB87 M98,2030K,40 -19-02FEB87 6. Install and tighten nuts or cap screws evenly to specifications. Hit connecting rod cap LIGHTLY with a soft-faced hammer to align it with connecting rod. Specification B43E, B43G, B48G, P218G, P220G Cap Nut Torque 18 ± 1 N·m (159 ± 9 lb-in.) T260 Cap Screw Torque 20 ± 1 N·m (177 ± 9 lb-in.) M36383 Measurement M36410 -UN-29JAN90 Engine -UN-29JAN90 CONNECTING ROD SPECIFICATIONS CTM2 (19APR90) 30-24 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods NOTE: To install cylinder head on T260 engine, go to Step 9. -UN-29JAN90 7. Install a new gasket on cylinder head. M36411 8. Install cylinder head on cylinder block with the five longest cap screws in the top holes of cylinder head. Tighten cap screws in several steps in the sequence shown. CAP SCREW TORQUE SPECIFICATIONS B43E, B48G, P218G, P220G Engine . . . . . . . . . . . . . . . 20 ± 1 N·m (180 ± 12 lb-in.) M36412 -UN-29JAN90 B43E Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ± 1 N·m (204 ± 12 lb-in.) M98,2030K,41 -19-11FEB87 M98,2030K,42 -19-10OCT85 9. Install a new gasket on cylinder head. -UN-29JAN90 10. Install cylinder head on cylnder block. Install flat washer (A), two compression washers (B) with outside edges contacting each other, and nut (C) on each of the top six longer studs. Install flat washer and nut on each of the bottom four shorter studs. Tighten nuts in several steps in sequence shown. T260 Engine Top Six Nuts (with compression washers) M36413 NUT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 16 ± 1 N·m (142 ± 12 lb-in.) M36414 -UN-29JAN90 Bottom Four Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 1 N·m (180 ± 12 lb-in.) CTM2 (19APR90) 30-25 16, 18, 20 & 24HP Onan Engines 130495 30 25 Connecting Rods and Pistons/Pistons and Connecting Rods 11. Install a new gasket (A) on oil base. M36416 -UN-29JAN90 M36415 -UN-29JAN90 12. Install oil base. Install and tighten four cap screws to 27 ± 3 N·m (239 ± 27 lb-in.). 30 26 M98,2030K,43 -19-10OCT85 M98,2030K,44 -19-10OCT85 13. Install flywheel shroud (C) and fasten with three cap screws. 14. Install fuel pump (B) and fasten with two screws. M36291 -UN-29JAN90 15. Connect governor spring (A) in top hole of arm. CTM2 (19APR90) 30-26 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods M36290 -UN-29JAN90 16. Connect fuel pump impulse line (B) and fasten with hose clamp (A). M98,2030K,45 -19-10OCT85 17. Install right side shroud (E), lift bracket (D), and fasten with five cap screws (C). Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 18. Connect spark plug wire (A) and voltage regulator leads (B). Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of the voltage regulator. 30 27 M36289 -UN-29JAN90 A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M98,2030K,46 -19-10OCT85 M98,2030K,47 -19-10OCT85 19. Install left side shroud (D), oil fill tube bracket (C), lift bracket (B), and fasten with six cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). -UN-29JAN90 20. Connect spark plug wire (A). 21. Install engine. (See machine technical manual.) CTM2 (19APR90) M36472 A—Spark Plug Wire B—Lift Bracket C—Oil Fill Tube Bracket D—Left Side Shroud 30-27 16, 18, 20 & 24HP Onan Engines 130495 Connecting Rods and Pistons/Pistons and Connecting Rods 30 28 CTM2 (19APR90) 30-28 16, 18, 20 & 24HP Onan Engines 130495 Group 35 Crankshaft and Main Bearings ESSENTIAL TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Number Name Use JDG327 Puller Legs Remove crankshaft gear and bearing plate. JDG 329 Seal Expander Protect and install oil seal on JDG 328. JDG 328 Crankshaft Seal Installer Install oil seal in bearing plate. M98,2035K,1 -19-10OCT85 SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use 13-Ton Puller Set Remove crankshaft gear and bearing plate. Bushing, Bearing, and Seal Driver Set Remove crankshaft gear, oil seal, main bearings. Ridge Reamer Remove ridge from top of cylinder bore. Outside Micrometer Measure crankshaft main bearing journals. Telescoping Gauge Measure crankshaft main bearing. Feeler Gauge Measure crankshaft end play. Piston Ring Compressor Install pistons. M98,2035K,2 35 1 -19-10OCT85 OTHER MATERIAL Number Name Use T43515 John Deere LOCTITE® Retaining Compound Apply to outside surface of main bearing LOCTITE is a trademark of the Loctite Corp. CTM2 (19APR90) M98,2035K,3 35-1 -19-12NOV85 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Specifications SERVICE PARTS KITS The following kits are available through your parts catalog: Overhaul Gasket Kit Crankshaft Bearing Kit Oil Pump Gasket Kit M98,2035K,4 -19-10OCT85 SPECIFICATIONS 35 2 Item Measurement Specification 1. Main Bearing Journal O.D. 50.78—50.80 mm (1.9992—2.0000 in.) 50.72 mm (1.997 in.) 2. Main Bearing I.D.—B43E, B43G, B48G, T260 Engines 50.838—50.902 mm (2.0015—2.0040 in.) 50.930 mm (2.0051 in.) 3. Main Bearing I.D. P218G, P220G Engine 50.06—50.88 mm (2.0024—2.0034 in.) 50.94 mm (2.0055 in.) 4. Bearing Clearance —B43E, B43G, B48G, T260 Engines 0.064—0.097 mm (0.0025—0.0038 in.) 0.145 mm (0.0057 in.) 5. Bearing Clearance—P218G, P220G Engines 0.061—0.106 mm (0.0024—0.0042 in.) 0.156 mm (0.006 in.) 6. Bearing Plate Cap Screws Torque 35 ± 1 N·m (310 ± 9 lb-in.) 7. End Play: B43E, B43G, B48G, P218G, P220G Engines 0.15—0.30 mm (0.006—0.012 in.) T260 Engine 0.13—0.23 mm (0.005—0.009 in.) 8. Connecting Rod Cap Nut Torque B43E, B43G, B48G, P218G, P220G Engines 18 ± 1 N·m (159 ± 9 lb-in.) 9. Connecting Rod Cap Screw Torque T260 Engine 20 ± 1 N·m (177 ± 9 lb-in.) M98,2035K,5 CTM2 (19APR90) 35-2 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings REMOVE CRANKSHAFT AND MAIN BEARINGS -UN-29JAN90 1. Remove engine. (See machine technical manual.) 2. Remove muffler and exhaust pipes. M36332 3. Remove intake manifold. (See Remove Intake Manifold, Group 10 in this manual.) 4. Remove cylinder heads. (See Remove Cylinder Heads, Group 10 in this manual.) 5. Remove intake and exhaust valves. (See Remove Intake and Exhaust Valves, Group 15 in this manual.) 6. Remove flywheel. (See Remove Flywheel, Group 20 in this manual.) 7. Remove camshaft. (See Remove Camshaft, Group 25 in this manual.) 8. Remove oil pump and oil base. (See Remove Oil Pump and Remove Oil Base, Group 40 in this manual.) 9. Remove crankshaft gear using JDG 327 Puller Legs (A), 1 in. driver disk (B), and a puller. 35 3 IMPORTANT: If crankshaft gear is replaced, always replace camshaft gear also. 10. Inspect crankshaft gear for chipped or broken teeth. Replace crankshaft gear if necessary. M98,2035K,6 -19-10OCT85 M98,2035K,7 -19-10OCT85 M36333 -UN-29JAN90 11. Remove key if necessary. CTM2 (19APR90) 35-3 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings M36334 -UN-29JAN90 12. If necessary, remove ridge from top of cylinder bore using a ridge reamer. M98,2035K,8 -19-10OCT85 IMPORTANT: Connecting rod caps must be installed in the same connecting rod they were removed from. -UN-29JAN90 13. Put identification marks on connecting rods, rod caps, and cylinder block to aid in assembly. Remove nuts to remove connecting rod caps. M36335 Remove cap screws to remove connecting rod caps. B43E, B43G, B48G, P218G and P220G M36336 -UN-29JAN90 35 4 T260 Engine M98,2035K,9 -19-02FEB87 M98,2035K,10 -19-10OCT85 M36337 -UN-29JAN90 14. Push piston and connecting rod out of cylinder bore using a wooden dowel. CTM2 (19APR90) 35-4 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings IMPORTANT: Do not remove bearing plate using screwdrivers. Cylinder block or bearing plate sealing surface may be damaged. -UN-29JAN90 15. Remove five cap screws to remove bearing plate and gasket. M36339 -UN-29JAN90 M36338 16. If bearing plate is tight, remove bearing plate using JDG 327 Puller Legs (B) and a puller. M98,2035K,11 -19-10OCT85 35 5 17. If equipped, remove thrust washer (A) and shim (B). -UN-29JAN90 IMPORTANT: Do not allow crankshaft lobes to hit cylinder block while removing crankshaft. Machined surfaces may be damaged. M36340 18. Turn crankshaft until lobe (C) fits into cylinder block notch (D). Carefully remove crankshaft. A—Thrust Washer B—Shim C—Crankshaft Lobe D—Cylinder Block Notch M98,2035K,12 CTM2 (19APR90) 35-5 -19-10OCT85 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings -UN-29JAN90 NOTE: Original rear bearing uses a separate thrust washer. Replacement rear bearing is a one piece assembly with the thrust washer part of the bearing. M36341 19. If equipped, remove thrust washer and shim. M98,2035K,13 -19-10OCT85 M98,2035K,14 -19-12NOV85 INSPECT CRANKSHAFT AND MAIN BEARINGS -UN-29JAN90 1. Measure crankshaft main bearing journal outside diameter. M36342 NOTE: If engine has had previous major overhaul, crankshaft journals may have been ground and undersize bearings installed. 2. Measure several places around each journal and each side of both journals. 35 6 NOTE: For connecting rod journal specifications, see Piston and Connecting Rods in Group 30 in this section. MAIN BEARING JOURNAL SPECIFICATIONS Item New Parts Wear Tolerance Journal O.D. 50.78—50.80 mm (1.9992—2.0000 in.) 50.72 mm (1.997 in.) If journal diameter is less than 50.72 mm (1.997 in.), replace crankshaft or have journals ground by a qualified machine shop. The following undersize main bearings are available: 0.05 0.25 0.50 0.76 mm mm mm mm (0.002 (0.010 (0.020 (0.030 CTM2 (19APR90) in.) in.) in.) in.) 35-6 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings 3. Measure main bearing diameter and main bearing clearance (bearing I.D. minus journal O.D.). New Part Wear Tolerance Bearing I.D. B43E,B43G,B48G, T260 Engines 50.838—50.902 mm (2.0015—2.0040 in.) 50.930 mm (2.0051 in.) Bearing Clearance B43E,B43G,B48G, T260 Engines 0.064—0.097 mm (0.0025—0.0038 in.) 0.145 mm (0.0057 in.) Bearing I.D.— P218G and P220G Engine 50.06—50.88 mm (2.0024—2.0034 in.) 50.94 mm (2.0055 in.) Bearing Clearance P218G and P220G Engine 0.061—0.106 mm (0.0024—l0.0042 in.) 0.156 mm (0.006 in.) -UN-29JAN90 M36343 Item -UN-29JAN90 MAIN BEARING SPECIFICATIONS M36344 If bearing diameter exceeds 50.930 mm (2.0051 in.), replace bearing. If bearing clearance exceeds 0.145 mm (0.0057 in.), replace bearing or grind crankshaft journals. Install undersize bearings. 35 7 If bearing diameter and clearance are within specifications and bearings are not damaged, bearings can be reused. M98,2035K,15 -19-12FEB87 M98,2035K,16 -19-10OCT85 M36345 -UN-29JAN90 4. Remove oil seal (A) using a 2 in. driver disk. CTM2 (19APR90) 35-7 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings M36346 -UN-29JAN90 5. Carefully remove crankshaft bearing (A) using a 2 in. driver disk (B) and 2-1/8 in. disk (C). M98,2035K,17 -19-10OCT85 M98,2035K,18 -19-10OCT85 M98,2035K,19 -19-10OCT85 M98,2035K,20 -19-10OCT85 IMPORTANT: Support cylinder block to avoid distortion and damage to bearing bore during removal. -UN-29JAN90 6. Carefully remove crankshaft bearing (A) using 2 in. driver disk (B), 2-1/8 in. driver disk (C), and a pipe (D). M36348 -UN-29JAN90 7. Clean and inspect oil passages in main bearing journals, connecting rod journals, main bearing bore in cylinder block, and main bearing bore in bearing plate. -UN-29JAN90 8. Inspect lock pins (A) in bearing plate and cylinder block for wear or damage. If necessary, remove lock pins using an Easy-Out tool. M36349 35 8 M36347 A—Crankshaft Bearing B—2 in. Driver Disk C—2-1/8 in. Driver Disk D—Pipe CTM2 (19APR90) 35-8 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings INSTALL CRANKSHAFT AND MAIN BEARINGS -UN-29JAN90 1. Clean and dry all parts. Apply clean engine oil on all internal parts before assembly. M36349 2. If necessary, install new lock pins (A) in bearing plate and cylinder block. M98,2035K,21 -19-10OCT85 3. Clean bearing O.D. and bearing bore in cylinder block with primer. NOTE: Replacement bearing has a flange which is used as the thrust washer. -UN-29JAN90 5. Align oil holes (A) in bearing with oil holes (B) in cylinder block. Align notches (C) in bearing with lock pins (D) in cylinder block. M36350 4. Apply retaining compound supplies with bearing on bearing O.D. and bearing bore in cylinder block. 35 9 -UN-29JAN90 6. Install bearing using a 2 in. driver disk and 2-3/8 in. disk. Push bearing tight against cylinder block. Be sure bearing notch is around lock pin. Remove excess retaining compound from bearing I.D. and flange. M36351 A—Bearing Oil Holes B—Cylinder Block Oil Holes C—Bearing Notches D—Lock Pins M98,2035K,22 -19-10OCT85 M98,2035K,23 -19-10OCT85 NOTE: Bearing can be put in a freezer to aid installation. 7. Apply clean engine oil on outside surface of bearing. M36352 -UN-29JAN90 8. Align oil hole (A) in bearing with oil hole (B) in bearing plate. Install bearing using a 2 in. driver disk and 2-3/8 in. disk. Push bearing flush with surface of bearing plate. CTM2 (19APR90) 35-9 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings M36353 -UN-29JAN90 9. Apply multipurpose grease between lips of oil seal. M98,2035K,24 -19-10OCT85 M98,2035K,25 -19-10OCT85 M98,2035K,26 -19-10OCT85 10. Install JDG 329 Seal Expander (A) in JDG 328 Crankshaft Seal Installer (B). M36354 -UN-29JAN90 11. Install oil seal with lips toward crankshaft seal installer. Push oil seal tight against shoulder of crankshaft seal installer. Remove seal expander ONLY. 12. Remove old seal material from oil seal bore in bearing plate. -UN-29JAN90 13. Install oil seal (A) using JDG 328 Crankshaft Seal Installer (B) and 2-3/16 in. driver disk (C). Push oil seal to bottom of bearing plate bore. DO NOT remove crankshaft seal installer at this time. M36355 35 10 CTM2 (19APR90) 35-10 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings -UN-29JAN90 IMPORTANT: Original rear bearing uses a separate thrust washer. Replacement rear bearing is a one piece assembly with the thrust washer part of the bearing. Do not install thrust washer or shim when replacement bearing is used. M36356 14. Apply multipurpose grease on plain side of thrust washer. 15. Install thrust washer with oil grooves (A) toward crankshaft and notches (B) between lock pins (C). DO NOT install shim on this side of crankshaft. M98,2035K,27 -19-12NOV85 16. Apply clean engine oil on main bearings and crankshaft main bearing journals. -UN-29JAN90 IMPORTANT: Do not allow crankshaft lobes to hit cylinder block while installing crankshaft. Machined surfaces may be damaged. M36357 17. Turn crankshaft until lobe (A) fits into cylinder block notch (B). Carefully install crankshaft. M98,2035K,28 -19-10OCT85 M98,2035K,29 -19-12NOV85 18. Align notch (A) in new gasket with notch (B) in bearing plate and install gasket. -UN-29JAN90 19. Apply multipurpose grease on plain side of washer. 20. Install thrust washer with oil grooves (C) toward crankshaft and notches (D) between lock pins (E). DO NOT install shim at this time. CTM2 (19APR90) M36358 A—Gasket Notch B—Bearing Plate Notch C—Oil Grooves D—Thrust Washer Notches E—Lock Pins 35-11 16, 18, 20 & 24HP Onan Engines 130495 35 11 Crankshaft and Main Bearings/Crankshaft and Main Bearings -UN-29JAN90 IMPORTANT: Bearing plate will fit tight against cylinder block only if lock pins are in thrust washer notches. Do not pull bearing plate inward using cap screws as lock pins, thrust washer or crankshaft may be damaged. M36359 21. Align notch (A) in bearing plate with plug (B). Carefully install bearing plate. If bearing plate will not fit tight against cylinder block, remove bearing plate and check thrust washer position. Remove JDG 328 Crankshaft Seal Installer (C). M36360 -UN-29JAN90 22. Install and tighten five cap screws to 35 ± 1 N·m (310 ± 9 lb-in.). M98,2035K,30 -19-10OCT85 M98,2035K,31 -19-11FEB87 23. Measure crankshaft end play using a feeler gauge. Engine Measurement Specification B43E, B43G, B48G, P218G, P220G T260 End Play 0.15—0.30 mm (0.006—0.012 in.) 0.13—0.23 mm (0.005—l0.009 in.) End Play -UN-29JAN90 CRANKSHAFT SPECIFICATIONS M36361 35 12 If end play exceeds specifications, remove bearing plate and add shim(s). CTM2 (19APR90) 35-12 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings 24. Install shim or shims between bearing plate and thrust washer. Be sure shim and thrust washer notches (A) are between lock pins (B). Repeat steps 21—23. M36362 -UN-29JAN90 NOTE: Shims are available in 0.13 mm (0.005 in.) thickness only. Use shims as required. M98,2035K,32 -19-10OCT85 IMPORTANT: Pistons must be installed in the same cylinder they were removed from and in the same direction. -UN-29JAN90 25. Apply clean engine oil on pistons, connecting rod bearing, and cylinder bore. M36363 26. Turn crankshaft until rod bearing journal is at bottom of its stroke. IMPORTANT: Be careful not to damage crankshaft rod journal while installing piston. 35 13 M36365 -UN-29JAN90 M36364 -UN-29JAN90 27. Install pistons with notch (A) or oil hole (B) toward camshaft using a ring compressor and wooden dowel. Push piston down until connecting rod is seated on crankshaft rod journal. M98,2035K,33 CTM2 (19APR90) 35-13 -19-10OCT85 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings -UN-29JAN90 IMPORTANT: Connecting rod caps must be installed on the same connecting rod they were removed from and in the same direction. 28. Apply clean engine oil on connecting rod cap. M36366 29. Install connecting rod cap with this side (A) outward on connecting rod. Install connecting rod cap with large tang (B) away from camshaft on connecting rod. M36367 -UN-29JAN90 B43E, B43G, B48G, P218G, and P220G T260 Engine Shown M98,2035K,34 -19-02FEB87 M98,2035K,35 -19-02FEB87 30. Install and tighten nuts or cap screws evenly to specifications. Hit connecting rod cap LIGHTLY with a soft-faced hammer to align it with connecting rod. Specification B43E, B43G, B48G, P218G, P220G Cap Nut Torque 18 ± 1 N·m (159 ± 9 lb-in.) T260 Cap Screw Torque 20 ± 1 N·m (177 ± 9 lb-in.) M36368 Measurement -UN-29JAN90 Engine -UN-29JAN90 CONNECTING ROD SPECIFICATIONS M36369 35 14 CTM2 (19APR90) 35-14 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings M36370 -UN-29JAN90 31. Install key if removed. M98,2035K,36 -19-10OCT85 32. Install crankshaft gear using the following heat method or by driver method. The heat method is recommended. -UN-29JAN90 NOTE: For driver method, go to Step 33. HEAT METHOD N M36371 a. Heat crankshaft gear to 232˚ C (450˚F) for 1/2 hour using a bearing oven. CAUTION: Gear is hot. Be careful not to burn hands while installing gear. 35 15 b. Align slot (A) in gear with key (B) in crankshaft. c. Install gear with holes (C) outward on crankshaft. Push gear tight against crankshaft shoulder. M98,2035K,37 CTM2 (19APR90) 35-15 -19-12NOV85 16, 18, 20 & 24HP Onan Engines 130495 Crankshaft and Main Bearings/Crankshaft and Main Bearings 33. Install crankshaft gear using the following driver method. -UN-29JAN90 DRIVER METHOD a. Align slot (A) in gear with key (B) in crankshaft. M36372 IMPORTANT: Support engine on crankshaft only. Do not support engine on cylinder block. Block may be damaged. b. Install gear with holes (C) outward on crankshaft using a 1-5/8 in. I.D. pipe (D), 1-9/16 in. driver disk (E), and 1-15/16 in. driver disk (F). Push gear tight against crankshaft shoulder. M36373 -UN-29JAN90 A—Slot B—Key C—Holes D—1-5/8 in. I.D. Pipe E—1-9/16 in. Driver Disk F—1-15/16 in. Driver Disk M98,2035K,37A -19-12NOV85 35 16 34. Install oil pump and oil base. (See Install Oil Pump and Install Oil Base, Group 40 in this manual.) 35. Install camshaft. (See Install Camshaft, Group 25 in this manual.) 36. Install flywheel. (See Install Flywheel, Group 20 in this manual.) 37. Install intake and exhaust valves. (See Install Intake and Exhaust Valves, Group 15 in this manual.) 38. Install cylinder heads. (See Install Cylinder Heads, Group 10 in this manual.) 39. Install intake manifold. (See Install Intake manifold, Group 10 in this manual.) 40. Install muffler and exhaust pipes. (See Install Intake Manifold, Group 10 in this manual.) 41. Install engine. (See machine technical manual.) M98,2035K,38 CTM2 (19APR90) 35-16 -19-12NOV85 16, 18, 20 & 24HP Onan Engines 130495 Group 40 Lubrication System ESSENTIAL TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Number Name Use JDG 325 Crankshaft Seal Installer Install gear cover oil seal. JDG 333 Crowsfoot Wrench Tighten oil filter adapter cap screws. M98,2040K,1 -19-11NOV85 SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Bushing, Bearing, and Seal Driver Set Remove gear cover oil seal. Dial Indicator Measure oil pump gear backlash and starter pinion gear backlash. 13-Ton Puller Set Remove flywheel 40 1 M98,2040K,2 -19-11NOV85 OTHER MATERIAL Number Name Use TY 9375 John Deere LOCTITE® Pipe Sealant with TEFLON® Apply to threads of gear cover, flywheel, and oil filter adapter cap screws. LOCTITE is a trademark of the Loctite Corp. TEFLON is a trademark of the DuPont Co. CTM2 (19APR90) M98,2040K,3 40-1 -19-11OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Service Parts Kits SERVICE PARTS KITS The following kits are available through your parts catalog: Oil Pump Gasket Kit Overhaul Gasket Kit M98,2040K,4 -19-11OCT85 40 2 CTM2 (19APR90) 40-2 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Specifications SPECIFICATIONS Oil Pump Item New Specification Wear Tolerance 1. Gear Backlash: B43E, B43G, B48G, T260 Engines 0.05—0.13 mm (0.002—0.005 in.) 0.23 mm (0.009 in.) Gear Backlash: P218G, P220G Engines 0.025—0.203 mm (0.001—0.008 in.) 0.36 mm (0.014 in.) 2. Gear Housing Cap Screw Torque: B43E, B43G, B48G, T260 Engines 19 ± 2 N·m (168 ± 18 lb-in.) Gear Housing Cap Screw Torque: P218G, P220G Engines 10 N·m (88 lb-in.) 3. Oil Pump-to-Cylinder Block Cap Screw Torque 11 ± 1 N·m (97 ± 9 lb-in.) 4. Gear Cover Cap Screw Torque 12 ± 1 N·m (106 ± 9 lb-in.) Oil Pressure Regulating Valve 1. Spring Free Length (approx) Spring Test Length 25 mm (1.0 in.) 13 mm (0.5 in.) at 12 N (2.6 lb force 2. Oil Pressure Regulating Valve Cap Screw Torque 28 ± 3 N·m (248 ± 27 lb-in.) Oil Base 1. Starter-to-Oil Base Cap Screw Torque 34 ± 1 N·m (301 ± 9 lb-in.) 2. Oil Base-to-Oil Base Block Cap Screw Torque 27 ± 3 N·m (239 ± 27 lb-in.) 3. Starter Pinion Gear Backlash (Adjustable Starter Bracket Only) 318 S.N. ( 420 S.N. ( 40 3 —231,857) —224, 882) 4. B43E, B43G, B48G, T260 Engine: Flywheel Cap Screw Torque 51 ± 3 N·m (38 ± 2 lb-ft) 5. Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) ) 0.51 ± 0.38 mm (0.020 ± 0.015 in.) Oil Filter Adapter Item 1. Attaching Cap Screw 2. Lift Bracket Cap Screw 3. Oil Filter Bypass Valve Cap Screw (910 and 930 Front Mowers) Measurement Torque Torque Torque Specification 12 ± 1 N·m (106 ± 9 lb-in.) 11 ± 3 N·m (97 ± 27 lb-in.) 28 ± 3 N·m (248 ± 27 lb-in.) M98,2040K,5 CTM2 (19APR90) 40-3 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pump REMOVE OIL PUMP 1. Remove engine. (See machine technical manual.) -UN-29JAN90 2. Remove flywheel. (See Group 20 in this manual.) M36417 3. Remove clip (A) to disconnect governor rod (B) from governor arm (C). M98,2040K,7 -19-11OCT85 M98,2040K,8 -19-11OCT85 M98,2040K,9 -19-11OCT85 -UN-29JAN90 IMPORTANT: Do not hit gear cover with a metal hammer or remove cover with a screwdriver. Doing so can damage gear cover. 4. Remove four cap screws and nut to remove clip (A), gear cover, and gasket (B). M36418 If gear cover is tight, LIGHTLY hit gear cover with a soft-hammer to loosen it. 5. Remove oil seal using a 2 in. driver disk. M36302 -UN-29JAN90 40 4 CTM2 (19APR90) 40-4 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pump 6. Measure oil pump gear backlash. New Part Wear Tolerance Backlash—B43E, B43G, B48G, T260 Engine 0.05—0.13 mm (0.002—0.005 in.) 0.23 mm (0.009 in.) Backlash—P218G, P220G Engine 0.025—0.203 mm (0.001—0.008 in.) 0.36 mm (0.014 in.) M36419 Item -UN-29JAN90 OIL PUMP GEAR SPECIFICATIONS If backlash exceeds specification replace oil pump. M98,2040K,10 -19-02FEB87 M36421 -UN-29JAN90 M36420 -UN-29JAN90 7. Remove two cap screws to remove oil pump assembly. If suction tube hits crankshaft lobe, install flywheel cap screw in crankshaft. Turn crankshaft until suction tube can be removed. M98,2040K,11 CTM2 (19APR90) 40-5 -19-11OCT85 16, 18, 20 & 24HP Onan Engines 130495 40 5 Lubrication System/Oil Pump DISASSEMBLE AND INSPECT OIL PUMP -UN-29JAN90 1. Inspect oil pump gear (A) for chipped or broken teeth. If gear is damaged, replace oil pump assembly. M36422 2. Inspect suction tube (B) for cracks, plugged suction screen, or damage. If necessary, remove suction tube using locking pliers. M98,2040K,12 -19-11OCT85 M98,2040K,13 -19-11OCT85 M98,2040K,14 -19-11OCT85 3. Remove two cap screws to remove oil pump housing and gasket (A). M36423 -UN-29JAN90 4. Measure original gasket thickness. New gasket must be the same thickness as original gasket. 5. Inspect gears (A) for chipped or broken teeth, scoring, and wear. -UN-29JAN90 6. Inspect housing (B) for cracks, wear or damage. If gears or housing are damaged, replace oil pump assembly. M36424 40 6 CTM2 (19APR90) 40-6 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pump ASSEMBLE OIL PUMP -UN-29JAN90 1. Thoroughly clean and dry parts. Put clean engine oil on all internal parts. 2. Install suction tube (A), if removed, using locking pliers. M36425 3. Install a new gasket (B), the same thickness as original gasket, on housing. 4. Install housing and two cap screws. For B43E, B43G, B48G, and T260 Engines: tighten cap screws to 19 ± 2 N·m (168 ± 18 lb-in.). -UN-29JAN90 For P218G and P220G Engines: tighten cap screws to 10 N·m (88 lb-in.). M36426 5. Fill oil pump housing with clean engine oil through pump outlet port (C). M98,2040K,15 -19-11FEB87 INSTALL OIL PUMP 1. Turn crankshaft until suction tube does not hit crankshaft lobe. -UN-29JAN90 40 7 M36427 -UN-29JAN90 M36421 2. Install oil pump assembly. Install and tighten two cap screws to 11 ± 1 N·m (97 ± 9 lb-in.). M98,2040K,16 CTM2 (19APR90) 40-7 -19-11OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pump M36325 -UN-29JAN90 3. Install oil seal (A), with lip of seal downward, in gear cover suing JDG 325 Crankshaft Seal Installer (B). M98,2040K,17 -19-11OCT85 M98,2040K,18 -19-11OCT85 4. Turn cup until the plastic bushing (A) is in the 3 o’clock position. M36428 -UN-29JAN90 5. Apply multipurpose grease between cup and camshaft gear to hold cup in position. 40 8 CTM2 (19APR90) 40-8 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pump 6. Install new gasket on cylinder block. 7. Be sure plastic bushing (A) and pin (B) are aligned. -UN-29JAN90 IMPORTANT: Do not hit gear cover with a metal hammer during installation. Gear cover can be damaged. M36430 -UN-29JAN90 M36429 8. Hold governor arm away from camshaft and carefully install gear cover. M98,2040K,19 -19-11OCT85 M98,2040K,20 -19-11OCT85 M36431 -UN-29JAN90 9. Tip engine forward and move governor arm back and forth. Governor cup should be felt moving in and out. If no movement is felt, the pin is not in plastic bushing. Remove gear cover and repeat Steps 7—9. CTM2 (19APR90) 40-9 16, 18, 20 & 24HP Onan Engines 130495 40 9 Lubrication System/Oil Pressure Regulating Valve 10. Apply pipe sealant on cap screw (A) threads. -UN-29JAN90 11. Install clip (B), four cap screws, and nut. Tighten cap screws and nut to 12 ± 1 N·m (106 ± 9 lb-in.). M36432 12. Install stator wiring (C) in clip. M98,2040K,21 -19-11OCT85 M98,2040K,22 -19-11OCT85 M98,2040K,23 -19-11OCT85 13. Install clip (A) on governor arm (B). Push governor rod (C) and governor arm toward carburetor until they bottom out. -UN-29JAN90 14. Install governor rod in closest governor arm hole. If governor rod is between two holes, install governor rod in next hole toward flywheel. Push clip on governor rod. M36433 15. Install flywheel. (See Group 20 in this manual.) 16. Install engine. (See machine technical manual.) 40 10 REMOVE OIL PRESSURE REGULATING VALVE -UN-22NOV89 1. Park tractor safely. 2. Disconnect negative (-) battery cable. NOTE: For T260 engine, go to Step 8. M36217 3. Remove wing nut to remove air cleaner cover. CTM2 (19APR90) 40-10 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pressure Regulating Valve M36447 -UN-29JAN90 4. Remove lock nut to remove plate and element (A). M98,2040K,24 -19-14OCT85 M98,2040K,25 -19-14OCT85 5. Remove three cap screws to remove splash plate. M36448 -UN-29JAN90 6. Remove two cap screws (A) to remove air cleaner base (B). Pull breather hose (C) out of air cleaner base. 7. Loosen nut to remove air cleaner bracket. M36449 -UN-29JAN90 40 11 M98,2040K,26 -19-14OCT85 M98,2040K,27 -19-14OCT85 M36450 -UN-29JAN90 8. Remove cap screw and washer (A). CTM2 (19APR90) 40-11 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pressure Regulating Valve 9. Remove spring (A) and valve (B). -UN-29JAN90 10. Inspect spring, valve, and valve bore for wear or damage. 11. Check spring using a spring compression tester. SPRING SPECIFICATIONS M36451 Free length (approx.) . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1.0 in.) Test length at 12 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (2.6 lb force . . . . . . . . . . . . . . 0.5 in.) M98,2040K,28 -19-26NOV85 M98,2040K,29 -19-14OCT85 M98,2040K,30 -19-14OCT85 M98,2040K,31 -19-14OCT85 INSTALL OIL PRESSURE REGULATING VALVE -UN-29JAN90 1. Thoroughly clean and dry parts. 2. Put clean engine oil on all internal parts. M36451 3. Install valve (B) and spring (A). 4. Install washer (A) and cap screw. Tighten cap screw to 28 ± 3 N·m (248 ± 27 lb-in.). M36452 -UN-29JAN90 NOTE: For T260 engine, stop here. -UN-29JAN90 5. Install air cleaner bracket. Be sure air cleaner bracket is level and tighten nut. M36449 40 12 CTM2 (19APR90) 40-12 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Pressure Regulating Valve 6. Install breather hose (C) in air cleaner base (B). -UN-29JAN90 7. Install air cleaner base on carburetor. Install air intake hose in flywheel shroud hole. 8. Install and tighten two air cleaner base cap screws (A). M36448 9. Install splash plate and fasten with three cap screws. M98,2040K,32 -19-14OCT85 M98,2040K,33 -19-14OCT85 M36447 -UN-29JAN90 10. Install element (A) and plate. Install and tighten lock nut. 11. Install air cleaner cover and tighten wing nut. 12. Connect negative (-) battery cable. M36217 -UN-22NOV89 40 13 M98,2040K,34 CTM2 (19APR90) 40-13 -19-14OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base REMOVE AND INSPECT OIL BASE 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire (A) and voltage regulator leads (B). 3. Remove five cap screws (C) to remove lift bracket (D) and right side shroud (E). M36289 -UN-29JAN90 A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M98,2040K,35 -19-14OCT85 M98,2040K,36 -19-14OCT85 4. Loosen hose clamp (A) to disconnect fuel pump impulse line (B). M36290 -UN-29JAN90 40 14 CTM2 (19APR90) 40-14 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base 5. Disconnect governor spring (A). 6. Remove two screws to remove fuel pump (B). M36291 -UN-29JAN90 7. Remove five cap screws to remove flywheel shroud (C). M98,2040K,37 -19-14OCT85 8. Remove screw to disconnect oil fill tube bracket. M36434 -UN-29JAN90 40 15 M98,2040K,38 -19-14OCT85 M98,2040K,39 -19-14OCT85 M36374 -UN-29JAN90 9. Remove four cap screws to remove oil base and gasket (A). CTM2 (19APR90) 40-15 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base NOTE: On P218G and P220G Engines the starter is not attached to the oil base. -UN-29JAN90 10. Remove two cap screws to remove starter. M36435 11. Inspect oil base for cracks, broken fins, or damage; replace if necessary. M98,2040K,40 -19-02FEB87 M98,2040K,41 -19-02FEB87 M98,2040K,42 -19-26NOV85 INSTALL OIL BASE -UN-29JAN90 NOTE: On P218G and P22G Engines the starter is not attached to the oil base. M36436 1. Install starter and two cap screws. Tighten cap screws to 34 ± 1 N·m (301 ± 9 lb-in.) 2. Install a new gasket (A) on oil base. -UN-29JAN90 M36415 -UN-29JAN90 3. Install oil base. Install and tighten four cap screws to 27 ± 3 N·m (320 ± 27 lb-in.). M36416 40 16 CTM2 (19APR90) 40-16 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base M36434 -UN-29JAN90 4. Install oil fill tube bracket and fasten with screw. M98,2040K,43 -19-14OCT85 5. Pull starter pinion gear outward until teeth contact flywheel ring gear. Measure starter pinion gear backlash. Backlash specification is 0.51 ± 0.38 mm (0.020 ± 0.015 in.). -UN-29JAN90 6. If backlash is not correct, loosen starter cap screws (A) and move starter bracket (B) to obtain correct backlash. M36437 NOTE: For engines with adjustable starter bracket, measure starter pinion gear backlash using the following procedure. For all other units with non-adjustable starter bracket, go to Step 18. M36438 -UN-29JAN90 Tighten starter cap screws to hold bracket in position. Check backlash again. M98,2040K,44 CTM2 (19APR90) 40-17 -19-14OCT85 16, 18, 20 & 24HP Onan Engines 130495 40 17 Lubrication System/Oil Base IMPORTANT: Do not hold flywheel from turning with a pry bar. Doing so can damage fins. CAUTION: Loosen flywheel cap screw only two turns. Do not remove cap screw. If cap screw is removed, flywheel may cause injury when it comes loose. M36292 N -UN-29JAN90 7. Fasten locking pliers to ring gear to prevent flywheel from turning. 8. Loosen cap screw two turns only. M98,2040K,45 -19-21OCT85 M98,2040K,46 -19-21OCT85 M98,2040K,47 -19-21OCT85 IMPORTANT: Do not pry on flywheel with a screwdriver. Ceramic magnets or gear case cover can be damaged. -UN-29JAN90 9. Loosen flywheel using a puller. 10. Remove puller, cap screw, washer, and flywheel. M36293 40 18 M36439 -UN-29JAN90 11. Tighten starter cap screws to 34 ± 1 N·m (301 ± 9 lb-in.). CTM2 (19APR90) 40-18 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base IMPORTANT: Do not lubricate crankshaft taper. The crankshaft taper must able dry to hold the flywheel tight. -UN-29JAN90 12. Clean crankshaft taper before installing flywheel. 13. Apply pipe sealant on threads of flywheel cap screw. M36297 14. Align keyway (A) in flywheel with key (B) in crankshaft. Install flywheel. 15. Install washer and cap screw. 16. Fasten locking pliers to ring gear to prevent flywheel from turning. M36298 -UN-29JAN90 17. On B43E, B43G, B48G, T260 Engines: tighten cap screw to 51 ± 3 N·m (38 ± 2 lb-ft). M98,2040K,48 -19-11FEB87 18. Install flywheel shroud (C) and fasten with five cap screws. 40 19 19. Install fuel pump (B) and fasten with two screws. M36291 -UN-29JAN90 20. Connect governor spring (A) in top hole of arm. M98,2040K,49 CTM2 (19APR90) 40-19 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Base M36290 -UN-29JAN90 21. Connect fuel pump impulse line (B) and fasten with hose clamp (A). M98,2040K,50 -19-21OCT85 M98,2040K,51 -19-21OCT85 22. Install right side shroud (E), lift bracket (D), and fasten with five cap screws (C). Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 23. Connect spark plug wire (A) and voltage regulator leads (B). Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of the voltage regulator. 24. Install engine. (See machine technical manual.) A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M36289 -UN-29JAN90 40 20 CTM2 (19APR90) 40-20 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Filter Adapter REMOVE OIL FILTER ADAPTER 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire (A) and voltage regulator leads (B). 3. Remove five cap screws (C) to remove lift bracket (D), and right side shroud (E). M36289 -UN-29JAN90 A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M98,2040K,52 -19-21OCT85 4. Remove oil filter (A). 5. Disconnect engine oil pressure sender wiring lead (B). M36440 -UN-29JAN90 40 21 M98,2040K,53 -19-21OCT85 M98,2040K,54 -19-21OCT85 M36441 -UN-29JAN90 6. Remove two cap screws to remove oil filter adapter and gasket (A). CTM2 (19APR90) 40-21 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Filter Adapter 7. Remove two cap screws to remove drain pan. 8. Remove engine oil pressure sender (A). M36442 -UN-29JAN90 9. Inspect oil filter adapter for thread damage, cracks or damage; replace as necessary. M98,2040K,55 -19-21OCT85 M98,2040K,56 -19-21OCT85 M98,2040K,57 -19-21OCT85 INSTALL OIL FILTER ADAPTER 1. Install engine oil pressure sender (A). M36442 -UN-29JAN90 2. Install drain pan and fasten with two cap screws. 3. Install new gasket (A) on oil filter adapter. 4. Apply pipe sealant on top cap screw threads. -UN-29JAN90 M36443 -UN-29JAN90 5. Install oil filter adapter and two cap screws. Tighten cap screws to 12 ± 1 N·m (106 ± 9 lb-in.) using JDG 333 Crowsfoot Wrench (B) or a 1/2 in crowsfoot wrench. M36444 40 22 CTM2 (19APR90) 40-22 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Filter Adapter 6. Connect engine oil pressure sender wiring lead (B). M36440 -UN-29JAN90 7. Install oil filter (A). M98,2040K,58 -19-21OCT85 8. Install right side shroud (E), lift bracket (D), and fasten with five cap screws (C). Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 26 lb-in.). 9. Connect spark plug wire (A) and voltage regulator leads (B). Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of the voltage regulator. 10. Install engine. (See machine technical manual.) A—Spark Plug Wire B—Voltage Regulator Leads C—Cap Screw (5 used) D—Lift Bracket E—Right Side Shroud M36289 -UN-29JAN90 40 23 M98,2040K,59 CTM2 (19APR90) 40-23 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Line Adapter REMOVE OIL LINE ADAPTER 1. Remove engine. (See machine technical manual.) 2. Remove three cap screws to remove lift bracket (A) and exhaust shroud (B). M36445 -UN-29JAN90 3. Remove four cap screws to remove left side shroud (C). M98,2040K,60 -19-21OCT85 M98,2040K,61 -19-21OCT85 M98,2040K,62 -19-21OCT85 4. Disconnect engine oil pressure sender wiring lead (A). M36446 -UN-29JAN90 40 24 M36453 -UN-29JAN90 5. Remove two special screw to remove oil adapter and gasket (A). CTM2 (19APR90) 40-24 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Line Adapter 6. Remove oil adapter hoses. M36454 -UN-29JAN90 7. Remove engine oil pressure sender (A) and elbow (B). M98,2040K,63 -19-21OCT85 M98,2040K,64 -19-21OCT85 8. Remove cap screw (A), washer (B), spring (C), and valve (D). -UN-29JAN90 9. Inspect spring, valve, and valve bore for wear or damage. M36455 A—Cap Screw B—Washer C—Spring D—Valve INSTALL OIL LINE ADAPTER 1. Thoroughly clean and dry parts. 40 25 -UN-29JAN90 2. Put clean engine oil on all internal parts. 3. Install valve(D), spring (C), washer (B), and cap screw (A). Tighten cap screw to 28 ± 3 N·m (248 ± 27 lb-in.). M36455 A—Cap Screw B—Washer C—Spring D—Valve M98,2040K,65 CTM2 (19APR90) 40-25 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Line Adapter 4. Apply pipe sealant on threads of elbow, engine oil pressure sender and oil adapter hoses. -UN-29JAN90 5. Install elbow (B) and engine oil pressure sender (A). M36454 6. Install oil adapter hoses. M98,2040K,66 -19-21OCT85 M98,2040K,67 -19-21OCT85 M98,2040K,68 -19-21OCT85 7. Install new gasket on oil adapter. 8. Apply pipe sealant on top special screw threads. M36456 -UN-29JAN90 9. Install oil adapter and two special screws. Tighten special screws to 12 ± 1 N·m (106 ± 9 lb-in.). M36457 -UN-29JAN90 40 26 M36446 -UN-29JAN90 10. Connect engine oil pressure sender wiring lead (A). CTM2 (19APR90) 40-26 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Line Adapter 11. Install left side shroud (C) and fasten with four cap screws. 12. Install exhaust shroud (B), lift bracket (A), and three cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). M36445 -UN-29JAN90 13. Install engine. (See machine technical manual.) M98,2040K,69 -19-21OCT85 40 27 CTM2 (19APR90) 40-27 16, 18, 20 & 24HP Onan Engines 130495 Lubrication System/Oil Line Adapter 40 28 CTM2 (19APR90) 40-28 16, 18, 20 & 24HP Onan Engines 130495 Group 45 Governor SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Press Remove and install camshaft gear. Bushing, Bearing, and Seal Driver Set Remove and install gear cover bushing and oil seal M98,2045K,1 -19-21OCT85 OTHER MATERIAL Number Name Use T43512 John Deere LOCTITE Thread Lock and Sealer (Medium Strength) Apply to threads of governor fork screws LOCTITE is a trademark of the Loctite Corp. M98,2045K,2 -19-21OCT85 SERVICE PARTS KITS The following kits are available through your parts catalog: Overhaul Gasket Kit 45 1 M98,2045K,2A -19-11NOV85 M98,2045K,3 -19-21OCT85 SPECIFICATIONS Item Measurement Specification Governor Cup Travel 5.6 mm (0.22 in.) Gear cover surface-to-pin Distance 19 mm (0.75 in.) CTM2 (19APR90) 45-1 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Assembly REMOVE GOVERNOR ASSEMBLY AND GOVERNOR LINKAGE 1. Remove engine. (See machine technical manual.) 2. Remove muffler and exhaust pipes (A). 3. Remove intake manifold (B). (See Remove Intake Manifold, Group 10 in this manual.) 4. Remove cylinder heads (C). (See Remove Cylinder Heads, Group 10 in this manual.) 5. Remove intake and exhaust valves (D). (See Remove Intake and Exhaust Valves, Group 15 in this manual.) 6. Remove flywheel (E). (See Remove Flywheel, Group 20 in this manual.) -UN-29JAN90 7. Remove camshaft. (See Remove Camshaft, Group 25 in this manual.) M36474 A—Muffler and Exhaust Pipes B—Intake Manifold C—Cylinder Heads D—Intake and Exhaust Valves E—Flywheel M98,2045K,4 -19-21OCT85 M98,2045K,5 -19-21OCT85 45 2 DISASSEMBLE AND INSPECT GOVERNOR ASSEMBLY -UN-29JAN90 1. Hold cup against flyballs. Measure distance from snap ring to surface of hub. The distance must be 5.6 mm (0.22 in.). If the distance is not correct, replace camshaft assembly. M36308 NOTE: The camshaft and pin are only serviced as an assembly. 2. The cup (A) must spin freely on the camshaft pin without excessive play. Replace parts as necessary. CTM2 (19APR90) 45-2 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Assembly 3. Remove snap ring to remove hub (A) and cup (B). M36309 -UN-29JAN90 4. Inspect cup race for grooved or rough surface. Replace cup if necessary. M98,2025K,15 -19-09OCT85 M98,2025K,16 -19-09OCT85 5. Remove flyballs. Inspect flyballs for grooved or flat spots, replace if necessary. -UN-29JAN90 6. Inspect flyball spacer (A) for wear or damage. Replace camshaft gear if necessary. NOTE: The flyball spacer, plate, and camshaft gear are serviced as an assembly only. M36310 IMPORTANT: If camshaft gear is replaced, always replace crankshaft gear also. 7. Inspect camshaft gear for chipped or broken teeth. Replace camshaft gear if necessary. 45 3 IMPORTANT: Be sure to hold camshaft while removing camshaft gear. -UN-14JUL89 8. Remove gear using a 1 in. deep-well socket, 1 in. driver disk, and a press. M30688 9. Remove key. M98,2025K,17 CTM2 (19APR90) 45-3 -19-11NOV85 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Linkage DISASSEMBLE AND INSPECT GOVERNOR LINKAGE -UN-29JAN90 1. Move governor arm. The governor arm must move freely without excessive play. M36475 2. Inspect fork (A) and governor arm shaft (B) for wear or bent condition. Replace parts as necessary. M98,2045K,6 -19-21OCT85 M98,2045K,7 -19-21OCT85 M98,2045K,8 -19-02FEB87 M98,2045K,9 -19-21OCT85 3. Pull governor arm shaft outward. M36476 -UN-29JAN90 4. Remove ball bearing from governor arm shaft hole using a magnet. -UN-29JAN90 5. If necessary, remove staked ends of fork screws using a small grinder. M36477 45 4 6. Remove two screws to remove fork. If screws are tight, support governor arm shaft (A) and loosen screws using an impact driver. M36478 -UN-29JAN90 7. Remove governor arm shaft. CTM2 (19APR90) 45-4 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Linkage M36479 -UN-29JAN90 8. Remove seal. M98,2045K,10 -19-21OCT85 M98,2045K,11 -19-21OCT85 M36884 -UN-25JAN90 9. Remove bushing using a 1/2 in. driver disk and 9/16 in. disk. 10. Measure distance from surface of gear cover to pin. The distance must be 19 mm (0.75 in.). Inspect pin for damage. M36886 -UN-25JAN90 M36885 -UN-25JAN90 11. If the distance is not correct or pin is damaged, remove pin. M98,2045K,12 CTM2 (19APR90) 45-5 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 45 5 Governor/Governor Linkage ASSEMBLE GOVERNOR LINKAGE M36885 -UN-25JAN90 M36887 -UN-25JAN90 1. Install new pin in gear cover until pin is 19 mm (0.75 in.) from surface of gear cover. M98,2045K,13 -19-21OCT85 M98,2045K,14 -19-21OCT85 M98,2045K,15 -19-21OCT85 -UN-25JAN90 2. Install new bushing using a 1/2 in. driver disk and 9/16 in. disk. Push bushing even with bottom of oil seal bore. M36884 45 6 M36480 -UN-29JAN90 3. Install new seal, with lips of seal toward driver, using a 1 in. driver disk. Push seal even with surface of gear cover. CTM2 (19APR90) 45-6 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Linkage 4. Install governor arm shaft (A). -UN-29JAN90 5. Apply thread lock and sealer (medium strength) on threads of fork screws. M36478 6. Install fork with bent ends upward. Install and tighten two screws. M98,2045K,16 -19-21OCT85 M98,2045K,17 -19-21OCT85 M36888 -UN-25JAN90 7. Support governor arm shaft. Hit end of fork screws using a punch so screws cannot be removed. IMPORTANT: Ball bearing must be installed for proper governor shaft operation. -UN-25JAN90 8. Install ball bearing in governor arm shaft hole. M36889 9. Install governor arm shaft (A) in governor arm shaft hole. M98,2045K,18 CTM2 (19APR90) 45-7 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 45 7 Governor/Governor Assembly ASSEMBLE GOVERNOR ASSEMBLY 1. Install key in camshaft. -UN-14JUL89 2. Install gear with timing mark “O” away from camshaft. 3. Align slot in gear with key in shaft. M30756 4. Push camshaft into gear using a 1-3/8 in. driver disk and a press until camshaft is even with bottom of gear surface. M98,2045K,19 -19-21OCT85 M98,2025K,25 -19-09OCT85 M98,2025K,26 -19-09OCT85 5. Apply clean engine oil on camshaft parts before assembly. M36310 -UN-29JAN90 6. Install flyballs in flyball spacer (A) notches. -UN-29JAN90 7. Install cup (A), hub (B), and fasten with snap ring. M36318 45 8 CTM2 (19APR90) 45-8 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Assembly and Linkage INSTALL GOVERNOR ASSEMBLY AND GOVERNOR LINKAGE 1. Install camshaft. (See Install Camshaft, Group 25 in this manual.) 2. Install flywheel (E). (See Install Flywheel, Group 20 in this manual.) 3. Install intake and exhaust valves (D). (See Install Intake and Exhaust Valves, Group 15 in this manual.) 4. Install cylinder heads (C). (See Install Cylinder Heads, Group 10 in this manual.) 5. Install intake manifold (B). (See Install Intake Manifold, Group 10 in this manual.) -UN-29JAN90 6. Install muffler and exhaust pipes (A). (See Install Intake Manifold, Group 10 in this manual.) 7. Install engine. (See machine technical manual.) M36474 A—Muffler and Exhaust Pipes B—Intake Manifold C—Cylinder Heads D—Intake and Exhaust Valves E—Flywheel M98,2045K,20 -19-21OCT85 45 9 CTM2 (19APR90) 45-9 16, 18, 20 & 24HP Onan Engines 130495 Governor/Governor Assembly and Linkage 45 10 CTM2 (19APR90) 45-10 16, 18, 20 & 24HP Onan Engines 130495 Group 50 Carburetor SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use 1/2 in. Crowsfoot Wrench To remove carburetor M98,2050K,1 -19-21OCT85 M98,2050K,2 -19-21OCT85 SERVICE PARTS KITS The following kits are available through your parts catalog: Choke Shaft Kit Gasket Kit Carburetor Float Kit Float Valve And Seat Kit Idle Needle Kit Idle Speed Adjusting Screw Kit Throttle Shaft Kit Carburetor Repair Kit SPECIFICATIONS 50 1 Item Measurement Specification Carburetor Float Level Height from edge of bowl 0 to 1 mm (0.0 to 0.04 in.) Carburetor Float Drop Depth below edge of bowl 5 mm (0.20 in.) Minimum Breaker Point Gap Opening 0.41 mm (0.016 in.) M98,2050K,3 CTM2 (19APR90) 50-1 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor REMOVE CARBURETOR NOTE: The carburetor removal includes procedures for all carburetors. The differences are noted. The carburetor can be removed with engine in machine. 1. If equipped, turn reserve fuel lever to OFF position. 2. Remove air cleaner assembly. (See Remove Air Cleaner in Group 05 of this manual.) M98,2050K,4 -19-21OCT85 M98,2050K,5 -19-21OCT85 3. If engine is in machine, disconnect fuel line from carburetor. M36985 -UN-25JAN90 4. If engine is in machine, loosen choke cable clamp screws (A). Disconnect cable from carburetor. 5. If engine is in machine, remove clip (A) to disconnect governor control linkage. -UN-25JAN90 6. Loosen set screw. Remove breaker point cover, if equipped. M36986 50 2 M36987 -UN-25JAN90 T260 Engine B43E, B43G, or E48G Engine M98,2050K,6 CTM2 (19APR90) 50-2 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor IMPORTANT: Be careful not to lose the point plunger or to allow dirt to enter the exposed plunger hole. M36988 -UN-25JAN90 7. Loosen two set screws. Move point assembly, if equipped, out of the way for access to carburetor mounting bolts. M36989 -UN-25JAN90 T260 Engine (Early point assembly) B43E, B43G, OR B48G Engine (Early M98,2050K,7 -19-11FEB87 M36990 -UN-25JAN90 8. Loosen two cap screws with JDG-333 Crowsfoot Wrench or short handled 1/2 in. open-end wrench. Remove carburetor. M36991 -UN-25JAN90 T260 Engine B43E, B43G, or B48G Engine M98,2050K,8 CTM2 (19APR90) 50-3 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 50 3 Carburetor/Carburetor 9. Remove gasket. M36992 -UN-25JAN90 NOTE: If it is necessary to replace the mounting cap screws on the T260 engine, the intake manifold must be removed. (See Remove Intake Manifold, Group 10 in this manual.) T260 Engine M98,2050K,9 -19-21OCT85 M98,2050K,10 -19-21OCT85 M98,2050K,11 -19-21OCT85 M98,2050K,12 -19-21OCT85 DISASSEMBLE CARBURETOR -UN-25JAN90 NOTE: Carburetor disassembly includes procedures for all carburetors. The differences are noted. M36954 1. Remove two cap screws. Remove choke control bracket. -UN-25JAN90 2. Remove two screws and choke valve. M36955 50 4 3. Remove choke valve shaft. 4. Remove foam seal (A) from shaft. M36956 -UN-25JAN90 Inspect choke shaft. Replace shaft if it shows excessive wear or is bent. CTM2 (19APR90) 50-4 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor M36957 -UN-25JAN90 5. Remove two screws and throttle valve. M98,2050K,13 -19-21OCT85 M98,2050K,14 -19-21OCT85 6. Remove throttle valve shaft. 7. Remove foam seal (A) from shaft. M36958 -UN-25JAN90 Inspect throttle shaft. Replace shaft if it shows excessive wear or is bent. M36959 -UN-25JAN90 8. Remove four screws to remove air intake. M98,2050K,15 CTM2 (19APR90) 50-5 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 50 5 Carburetor/Carburetor M36961 -UN-25JAN90 9. Remove and discard gasket. M36968 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G or P220G M98,2050K,16 -19-02FEB87 M98,2050K,17 -19-21OCT85 M98,2050K,18 -19-21OCT85 -UN-25JAN90 10. Remove O-ring. M36960 50 6 M36964 -UN-25JAN90 11. For T260 engine, remove float retaining screw. CTM2 (19APR90) 50-6 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor 12. Remove float, pivot pin, and needle valve. -UN-25JAN90 Inspect needle valve. Replace valve if it is grooved or pitted. M36965 Check float for dents or leaks. Replace if defective or loaded with fuel. M36970 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,19 -19-02FEB87 13. Remove seat. Remove washer (A). M36966 -UN-25JAN90 Inspect needle seat area for wear or damage. Replace seat if defective. M36971 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,20 CTM2 (19APR90) 50-7 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 50 7 Carburetor/Carburetor M36972 -UN-25JAN90 14. For B43E, B43G, B48G, P218G, or P220G engine, remove slow idle jet. M98,2050K,21 -19-02FEB87 M36962 -UN-25JAN90 15. Remove reservoir plug and gasket. M36969 -UN-25JAN90 T260 Engine 50 8 B43E, B43G, B48G, P218G, OR P220G M98,2050K,22 CTM2 (19APR90) 50-8 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor 16. Remove main jet. M36963 -UN-25JAN90 Inspect main jet. Replace if damaged. M36973 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,23 -19-02FEB87 17. For P218G or P220G engines, remove plastic cap from idle mixture screw. -UN-25JAN90 18. Remove idle mixture screw and spring. Inspect seating surface of mixture screw. Replace if worn or damaged. M36967 19. Remove idle speed screw (A) and spring. Replace springs if weak or broken. M98,2050K,24 CTM2 (19APR90) 50-9 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 50 9 Carburetor/Carburetor CLEAN CARBURETOR IMPORTANT: Never clean holes or passages with small drill bits or wire because a slight enlargement or burring of these holes will change the performance of the carburetor. No other method of cleaning other than solvent should be used. 1. Soak all metal components not replaced in carburetor cleaner. Do not soak non-metal floats or other non-metal parts. 2. Clean all carbon from carburetor bore. Be careful not to plug the idle or main fuel ports. 3. Dry out all passages with low pressure air 240 kPa (2.4 bar) (35 psi). Make sure all holes and passages are open. Do not use rags or paper to dry parts. M98,2050K,25 -19-21OCT85 M98,2050K,26 -19-11FEB87 ASSEMBLE CARBURETOR -UN-25JAN90 NOTE: Carburetor assembly includes procedures for all carburetors. The differences are noted. Use new seals, gaskets, and O-ring when assembling carburetor. 50 10 M36967 1. Install idle speed screw (A) and spring. 2. Install idle mixture screw and spring. Turn idle mixture screw in until lightly seated, then back it out 1-1/4 turns. For P218G and P220G engines, install plastic cap on idle mixture screw. CTM2 (19APR90) 50-10 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor M36963 -UN-25JAN90 3. Install main jet. M36973 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,27 -19-02FEB87 M36962 -UN-25JAN90 4. Install reservoir plug and gasket. M36969 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,28 CTM2 (19APR90) 50-11 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 50 11 Carburetor/Carburetor M36972 -UN-25JAN90 5. For B43E, G43G, B48G, P218G, or P220G engine, install slow idle jet. M98,2050K,29 -19-02FEB87 M36966 -UN-25JAN90 6. Install seat and washer (A). M36971 -UN-25JAN90 T260 Engine 50 12 B43E, B43G, B48G, P218G, or P220G M98,2050K,30 CTM2 (19APR90) 50-12 -19-01JAN87 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor 7. Install float, pivot pin, and valve. Be sure wire on valve is hooked over tab on float. M36965 -UN-25JAN90 Install float, pivot pin, and valve. Be sure valve is hooked on float tab. M36970 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,31 -19-02FEB87 M36964 -UN-25JAN90 8. For T260 engine, fasten float assembly with retaining screw. Make sure pivot pin is in the groove and that the float moves freely without binding. M98,2050K,32 CTM2 (19APR90) 50-13 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 50 13 Carburetor/Carburetor When checking float level and float drop, measure to float body, not seam. -UN-25JAN90 9. Turn carburetor and check float setting using straightedge. Adjust floats so that they are even with edge of bowl or no more than 1 mm (0.04 in.) beyond edge. Bend float tab (A) to adjust. M36974 Turn carburetor and hold pivot pin in place. Check float setting using a straightedge. Adjust floats so that they are even with the edge of bowl or no more than 1 mm (0.04 in.) beyond edge. Bend float tang (A) to adjust. M36975 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, or P220G M98,2050K,33 -19-11FEB87 -UN-25JAN90 10. Turn carburetor right side up and measure float drop. The distance from top of carburetor body to top of float must be at least 5 mm (0.20 in.). Bend float arm (A) to adjust. If float drop is adjusted, check float level again. M36983 50 14 M36984 -UN-25JAN90 T260 Engine B43,E, B43G, B48G, P218G, or P220G M98,2050K,34 CTM2 (19APR90) 50-14 -19-02FEB87 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor M36960 -UN-25JAN90 11. Install O-ring on carburetor intake. M98,2050K,35 -19-21OCT85 M36961 -UN-25JAN90 12. Install gasket. M36968 -UN-25JAN90 T260 Engine B43E, B43G, B48G, P218G, OR P220G M98,2050K,36 -19-02FEB87 M98,2050K,37 -19-21OCT85 M36959 -UN-25JAN90 13. Install air intake. Fasten with four screws. CTM2 (19APR90) 50-15 16, 18, 20 & 24HP Onan Engines 130495 50 15 Carburetor/Carburetor M36958 -UN-25JAN90 14. Apply a small amount of oil to the foam seal (A). Install foam seal and throttle valve shaft. M98,2050K,38 -19-21OCT85 M98,2050K,39 -19-21OCT85 M98,2050K,40 -19-21OCT85 M98,2050K,41 -19-21OCT85 M36957 -UN-25JAN90 15. Install throttle valve. Adjust valve plate so that it is centered in the bore before tightening the two screws. To center the plate, back off the throttle stop screw and completely close the throttle lever. Seat the valve plate by tapping with a small screwdriver, the tighten screws. -UN-25JAN90 16. Apply a small amount of oil to the foam seal (A). Install foam seal and choke valve shaft. M36956 50 16 M36955 -UN-25JAN90 17. Install choke valve. Adjust valve plate so that it is centered in the bore before tightening two screws. CTM2 (19APR90) 50-16 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor M36954 -UN-25JAN90 18. Connect choke shaft wire and install choke control bracket. Fasten with two cap screws. M98,2050K,42 -19-21OCT85 M98,2050K,43 -19-21OCT85 INSTALL CARBURETOR M36992 -UN-25JAN90 1. Put new gasket on intake manifold. Install carburetor. T260 Engine M36990 -UN-25JAN90 2. Fasten carburetor with two cap screws. Tighten with JDG-333 Crowsfoot Wrench or short handled 1/2 in. open-end wrench. M36991 -UN-25JAN90 T260 Engine B43E, B43G, or B48G Engine M98,2050K,44 CTM2 (19APR90) 50-17 -19-21OCT85 16, 18, 20 & 24HP Onan Engines 130495 50 17 Carburetor/Carburetor 3. Be sure point plunger (A) and gasket (B) are in place. Be sure plunger hole (C) is uncovered. M36993 -UN-25JAN90 4. Apply thread sealant on threads of set screws and install breaker point assembly, if equipped. T260 Engine M98,2050K,45 -19-11FEB87 5. Fasten point assembly, if equipped, with two set screws. M36988 -UN-25JAN90 6. Check point gap. Set gap to 0.41 mm (0.016 in.). M36989 -UN-25JAN90 T260 Engine (Early point assembly) 50 18 B43E, B43G, or B48G Engine (Early M98,2050K,46 CTM2 (19APR90) 50-18 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor -UN-25JAN90 IMPORTANT: Be sure to position breaker point lead so cover does not pinch it. Engine will not run if cover and wire make a short circuit. 7. Install breaker point cover and tighten screw, if equipped. M36986 8. If engine is in unit, install clip (A) and connect governor control linkage. M36987 -UN-25JAN90 T260 Engine B43E, B43G, or B48G Engine M98,2050K,47 -19-11FEB87 50 19 CTM2 (19APR90) 50-19 16, 18, 20 & 24HP Onan Engines 130495 Carburetor/Carburetor 9. If engine is in machine, connect and fasten fuel line to carburetor with clamp (A). -UN-25JAN90 NOTE: Adjust choke properly for satisfactory engine starting and operation. The following adjustment can only be made with engine installed in machine. M36994 10. Install choke cable in bracket and fasten with screw (B). 11. Push choke control knob (on instrument panel) in all the way. 12. Hold choke valve (C) straight up and tighten screw (D). 13. Pull choke control knob out. Choke valve must be closed. Push knob in. Valve must be completely open. Adjust if needed. 14. Check that choke and throttle linkages operate freely. 15. Install air cleaner assembly. (See Install Air Cleaner in Group 05 of this manual.) 16. Adjust engine speed. (See machine technical manual.) M98,2050K,48 -19-26NOV85 50 20 CTM2 (19APR90) 50-20 16, 18, 20 & 24HP Onan Engines 130495 Group 55 Stator and Rectifier—Regulator SPECIFICATIONS Item Measurement Specification Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) B43E, B43G, B48G, T260 Engine: Flywheel Cap Screw Torque 51 ± 3 N·m (38 ± 2 lb-ft) P218G and P220G Engine: Flywheel Cap Screw Torque 67—75 N·m (50—55 lb-ft) M98,2055K,1 -19-11FEB87 M98,2055K,2 -19-02FEB87 REMOVE STATOR 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire and voltage regulator leads. 3. Remove cap screws to remove lift bracket (A) and manifold cover (B). M36445 -UN-29JAN90 4. Remove four cap screws on T260, P218G, or P220G engine; five cap screws on B43E, B43G, B48G engine to remove side shroud (C). 55 1 M36290 -UN-29JAN90 5. Loosen hose clamp (A) to disconnect fuel impulse line (B). M98,2060K,6 CTM2 (19APR90) 55-1 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Stator 6. Disconnect governor spring (A). 7. Remove two screws to remove fuel pump (B). M36291 -UN-29JAN90 8. Remove five cap screws to remove flywheel shroud (C). M98,2060K,7 -19-05NOV85 M98,2055K,3 -19-22OCT85 IMPORTANT: Do not hold flywheel from turning with a pry bar. Doing so can damage the fins. CAUTION: Loosen flywheel cap screw only two turns. Do not remove cap screw. If cap screw is removed, flywheel may cause injury when it comes loose. M36292 N -UN-29JAN90 9. Fasten locking pliers to ring gear to prevent flywheel from turning. 10. Loosen cap screw two turns only. 55 2 CTM2 (19APR90) 55-2 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Stator IMPORTANT: Do not pry on flywheel with a screwdriver. Ceramic magnets and gear case cover can be damaged. -UN-29JAN90 11. Loosen flywheel using a puller. M36293 12. Remove puller, cap screw, washer, and flywheel. M98,2055K,4 -19-22OCT85 M98,2055K,5 -19-22OCT85 M98,2055K,6 -19-22OCT85 13. Disconnect stator lead from retaining clip (A). M37155 -UN-25JAN90 14. Remove three cap screws. Gently pull stator off mounting posts. INSTALL STATOR -UN-25JAN90 1. Put stator on mounting posts and fasten with three cap screws. Tighten cap screws evenly so that stator is held flat against posts. M37155 Connect stator lead in retaining clip (A). 55 3 CTM2 (19APR90) 55-3 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Stator IMPORTANT: Do not lubricate crankshaft taper. The crankshaft taper must be dry to hold the flywheel tight. -UN-29JAN90 2. Clean crankshaft taper before installing flywheel. 3. Apply pipe sealant on threads of flywheel cap screw. M36297 4. Align keyway (A) in flywheel with key (B) in crankshaft and install flywheel. 5. Install washer and cap screw. IMPORTANT: Do not hold flywheel from turning with a pry bar in the fins. Doing so may damage the fins. -UN-29JAN90 6. Fasten locking pliers to ring gear to prevent flywheel from turning. M36298 7. On B43E, B43G, B48G, T260 engines, tighten cap screw to 51 ± 3 N·m (38 ± 2 lb-ft). On P218G and P220G engine, tighten cap screw to 67—75 N·m (50—55 lb-ft). M98,2060K,73 -19-11FEB87 55 4 CTM2 (19APR90) 55-4 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Stator 8. Install flywheel shroud (C). Fasten with five cap screws. 9. Install fuel pump (B). Fasten with two screws. M36291 -UN-29JAN90 10. Connect governor spring (A) in top hole of arm. M98,2055K,7 -19-26NOV85 M98,2055K,8 -19-22OCT85 M36290 -UN-29JAN90 11. Connect fuel pump impulse line (B) and fasten with hose clamp (A). 55 5 CTM2 (19APR90) 55-5 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Replace 12. Install side shroud (C). Fasten with four cap screws on T260, P218G, and P220G engine; five cap screws on B43E, B43G, or B48G engine. 13. Install manifold cover (B) and lift bracket (A). Fasten with three cap screws on T260 engine; two cap screws on B43E, or B48G engine. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 14. Connect spark plug wire and voltage regulator leads. Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of voltage regulator. M36445 -UN-29JAN90 15. Install engine. (See machine technical manual.) T260 Engine Shown M98,2055K,9 -19-02FEB87 M98,2055K,10 -19-22OCT85 REPLACE RECTIFIER-REGULATOR M37239 -UN-25JAN90 1. For T260 engine only, remove three cap screw (A) to remove manifold cover. 55 6 CTM2 (19APR90) 55-6 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Replace 2. Disconnect battery lead (A). 3. Disconnect two stator leads (B). -UN-25JAN90 4. Remove cap screw (C). 5. Push regulator toward cap screw; then lift from shroud. M37240 6. Install new regulator and fasten with cap screw (C). 7. Connect two stator leads (B) to “AC” terminals. T260 Engine (Top Photo) 8. Connect battery lead (A) to “B+” terminal. M37241 -UN-25JAN90 9. For T260 engine only, install manifold cover and fasten with three cap screws. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). B43E, B43G, B48G, P21G, or P220G M98,2055K,11 -19-02FEB87 55 7 CTM2 (19APR90) 55-7 16, 18, 20 & 24HP Onan Engines 130495 Stator and Rectifier—Regulator/Replace 55 8 CTM2 (19APR90) 55-8 16, 18, 20 & 24HP Onan Engines 130495 Group 60 Starter SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICE-GARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. Name Use Volt-Ohm-Amp Meter Check continuity Armature Growler Check starter armature 13-Ton Puller Set Remove flywheel Blind Hole Puller Set Pull bushings Dial Indicator Check armature shaft thrust gap M98,2060K,1 -19-05NOV85 60 1 CTM2 (19APR90) 60-1 16, 18, 20 & 24HP Onan Engines 130495 Starter/Specifications SPECIFICATIONS Item Measurement Specification Starter Pinion Backlash 0.13—0.89 mm (0.005—0.035) Brushes Wear Length 6.35 mm (0.25 in.) minimum Armature Lock Nut Torque 30 ± 3 N·m (265 ± 27 lb-in.) Battery Terminal Nut Torque 6 ± 1 N·m (53 ± 9 lb-in.) Negative Brush Cap Screw Torque 4.5 ± 0.5 N·m (40 ± 4.5 lb-in.) End Cap Thru-Bolts Torque 7 ± 1 N·m (62 ± 9 lb-in.) Brushes Wear Length 11.5 mm (0.45 in.) minimum End Cap Thru-Bolts Torque 5.7 ± 1.1 N·m (50 ± 10 lb-in.) Solenoid Screws Torque 6 ± 1 N·m (53 ± 9 lb-in.) Armature Shaft Thrust Gap Clearance 0.1 to 0.5 mm (0.004 to 0.020 in.) Pinion-to-Stop Ring Gap Clearance 0.5 to 2.0 mm (0.020 to 0.079 in.) Starter Mounting Cap Screws Torque 34 ± 1 N·m (300 ± 9 lb-in.) B43E, B43G, B48G, T260 Engines: Flywheel Mounting Cap Screw Torque 51 ± 3 N·m (38 ± 2 lb-ft) Lift Bracket Cap Screw Torque 11 ± 3 N·m (97 ± 27 lb-in.) BENDIX DRIVE STARTER SOLENOID DRIVE STARTER M98,2060K,2 -19-11FEB87 60 2 CTM2 (19APR90) 60-2 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter SERVICE PARTS KITS The following kits are available through your parts catalog: Solenoid Kit Bushing Kit Brush Kit Hardware Kit Clutch Kit Shift Lever Kit M98,2060K,3 -19-26NOV85 REMOVE STARTER—B43E, B43G, B48G, AND T260 ENGINES NOTE: See Starting Circuit Diagnosis in machine technical manual before removing starter. 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire and voltage regulator leads. 3. Remove cap screw to remove lift bracket (A) and manifold cover (B). M36445 -UN-29JAN90 4. Remove four cap screws on T260 engine; five cap screws on B43E, B43G, or B48G engine, to remove side shroud (C). T260 Engine Shown M98,2060K,4 CTM2 (19APR90) 60-3 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 60 3 Starter/Starter M36290 -UN-29JAN90 5. Loosen hose clamp (A) to disconnect fuel impulse line (B). M98,2060K,6 -19-05NOV85 M98,2060K,7 -19-05NOV85 6. Disconnect governor spring (A). 7. Remove two screws to remove fuel pump (B). M36291 -UN-29JAN90 8. Remove five cap screws to remove flywheel shroud (C). 60 4 CTM2 (19APR90) 60-4 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter NOTE: Measure starter pinion gear backlash to check for wear. -UN-29JAN90 9. Pull starter pinion gear outward until teeth contact flywheel ring gear. Measure starter pinion gear backlash. Item New Part Backlash 0.13—0.89 (0.005—0.035 in.) M36437 STARTER PINION SPECIFICATIONS If backlash exceeds 0.89 mm (0.035 in.), replace starter pinion. M98,2060K,8 -19-05NOV85 M98,2060K,9 -19-05NOV85 IMPORTANT: Do not hold flywheel from turning with a pry bar. Doing so can damage the fins. CAUTION: Loosen flywheel cap screw only two turns. Do not remove cap screw. If cap screw is removed, flywheel may cause injury when it comes loose. M36292 N -UN-29JAN90 10. Fasten locking pliers to ring gear to prevent flywheel from turning. 11. Loosen cap screw two turns only. IMPORTANT: Do not pry on flywheel with a screwdriver. Ceramic magnets and gear case cover can be damaged. 60 5 -UN-29JAN90 12. Loosen flywheel using a puller. M36293 13. Remove puller, cap screw, washer, and flywheel. M98,2060K,10 CTM2 (19APR90) 60-5 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter M37102 -UN-25JAN90 14. Remove two cap screws. Remove starter. Bendix Drive Starter Shown M98,2060K,11 -19-05NOV85 REMOVE STARTER—P218G AND P220G ENGINES NOTE: See Starting Circuit Diagnosis in machine technical manual before removing starter. 1. Remove engine. (See machine technical manual.) 2. Disconnect spark plug wire. 3. Remove cap screw to remove lift bracket and manifold cover. 4. Remove cap screws to remove side shroud. 5. Remove cap screws from flywheel shroud. Move flywheel shroud just far enough to remove starter. M46014 -UN-08JAN90 6. Remove two cap screws (A) to remove starter. M98,2060K,11E -19-11FEB87 DISASSEMBLE BENDIX DRIVE STARTER -UN-25JAN90 1. Remove rubber dust cover. M37104 60 6 M98,2060K,12 CTM2 (19APR90) 60-6 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter M37105 -UN-25JAN90 2. Remove two thru-bolts. M98,2060K,13 -19-05NOV85 M98,2060K,14 -19-05NOV85 M98,2060K,15 -19-05NOV85 NOTE: Brush springs may snap out of the end cap when it is removed. Be careful not to lose springs. M37106 -UN-25JAN90 3. Remove end cap. M37107 -UN-25JAN90 4. Remove two cap screws to remove negative brushes. 5. Remove nut to remove positive side brushes. Check all brushes for cracks or excessive wear. Replace brushes if they are worn shorter than 6.35 mm (0.25 in.). -UN-25JAN90 60 7 Inspect springs. Replace springs if they are weak or broken. M37108 Always replace springs and brushes as a set if any are defective. M98,2060K,16 CTM2 (19APR90) 60-7 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 6. Pull armature assembly out of housing. -UN-25JAN90 Clean housing and magnets. Magnets must be securely glued to inside of housing and must be free of cracks. M37109 Replace housing if magnets are loose or cracked. M98,2060K,17 -19-05NOV85 M98,2060K,18 -19-05NOV85 7. Hold armature in soft-jaw vise. 8. Remove lock nut and disassemble parts (I—A). -UN-25JAN90 Clean and check starter drive components for wear or damage. Inspect bushing in cap (C) for wear. Replace damaged or worn parts. M37111 -UN-25JAN90 M37110 A—Armature B—Thrust Washer C—Cap D—Seal E—Drive Pinion F—Spacer G—Spring H—Washer I—Lock Nut 60 8 CTM2 (19APR90) 60-8 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter -UN-25JAN90 IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. M37112 9. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 grit sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. 10. Test for grounded windings using an ohmmeter or test light. Touch probes on commutator and armature core. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. M98,2060K,19 -19-05NOV85 M98,2060K,20 -19-05NOV85 11. Test for open circuited windings using an ohmmeter or test light. M37113 -UN-25JAN90 Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. 60 9 CTM2 (19APR90) 60-9 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 12. Test for short circuited windings using a growler. Put armature in growler and hold a hacksaw blade above each slot while slowly rotating armature. -UN-24APR89 If coil is shorted, the blade will vibrate on the slot. M17166 NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 13. If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. M98,2060K,21 -19-05NOV85 M98,2060K,22 -19-05NOV85 ASSEMBLE BENDIX DRIVE STARTER -UN-25JAN90 1. Apply a generous film of silicone base grease, such as GE Versilube 322-L or equivalent, to the worm gear. M37114 2. Apply a thin film of grease to bearing surfaces (A). 60 10 CTM2 (19APR90) 60-10 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 3. Assemble parts (A-I) in sequence order. -UN-25JAN90 4. Hold armature in a soft-jaw vise. Tighten lock nut to 30 ± 3 N·m (265 ± 27 lb-in.). M37115 -UN-25JAN90 M37111 A—Armature B—Thrust Washer C—Cap D—Seal E—Drive Pinion F—Spacer G—Spring H—Washer I—Lock Nut M98,2060K,23 -19-05NOV85 M98,2060K,24 -19-05NOV85 M37109 -UN-25JAN90 5. Put armature assembly in housing. Align notch in cap with mark on housing. 60 11 CTM2 (19APR90) 60-11 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 6. Install positive side brushes. Fasten with fiber washer, flat washer, lock washer, and nut. -UN-25JAN90 Tighten nut to 6 ± 1 N·m (53 ± 9 lb-in.). 7. Install negative brushes. Fasten with cap screws and tighten to 4.5 ± 0.5 N·m (40 ± 4.5 lb-in.). M37107 -UN-25JAN90 M37108 8. Install springs. M98,2060K,25 -19-05NOV85 M98,2060K,26 -19-05NOV85 M98,2060K,27 -19-05NOV85 9. To make temporary brush holders, cut steel banding into four pieces, 76mm (3 in.) long. Bend flanges 25 mm (1 in.) long as shown. M37116 -UN-25JAN90 10. Push brushes down on the springs and hold them in place with the four brush holders. Make sure that chamfered side of brush is up and that the wires do not rub against the commutator or end cap. 11. Apply a light film of grease to bushing (A). -UN-25JAN90 12. Align tab and notch (B); then install end cap on starter. M37117 60 12 CTM2 (19APR90) 60-12 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 13. Hold end cap in place and remove four temporary brush holding clips. M37118 -UN-25JAN90 14. Be sure notches on both end caps are aligned with tabs on housing; then fasten with two thru-bolts. Tighten bolts to 7 ± 1 N·m (62 ± 9 lb-in.). M98,2060K,28 -19-05NOV85 M98,2060K,29 -19-05NOV85 M37104 -UN-25JAN90 15. Install rubber dust cover. 60 13 CTM2 (19APR90) 60-13 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter BENCH TEST SOLENOID DRIVE STARTER NOTE: Perform bench test before disassembling the starter motor to determine the cause of the problem. IMPORTANT: Never operate motor longer than 20 seconds. Allow at least two minutes for cooling and battery recovery before operating again. Overheating, caused by excessive operation, will seriously damage starting motor. 1. Connect a 12-volt battery (A) to starter battery terminal (B) and starter frame (C). Use heavy duty cables. -UN-29AUG88 2. Connect a remote start switch (D) between switch terminal (E) and battery terminal (B). NOTE: A short piece of wire with a small clip on the end will allow a more positive connection at the switch terminal. M37149 A—12-Volt Battery B—Battery Terminal C—Starter Frame D—Remote Start Switch E—Switch Terminal M98,2060K,30 -19-05NOV85 M98,2060K,31 -19-26NOV85 When switch is activated, starter should engage and run. IF SOLENOID CHATTERS; hold-in winding is open-circuited. IF NOTHING HAPPENS; either the solenoid pull-in winding is open-circuited or mechanical parts are sticking. 60 14 IF SOLENOID ENGAGES, BUT MOTOR DOES NOT RUN; check solenoid switch continuity, brushes, armature, and field windings. Solenoid cannot be repaired, replace it. CTM2 (19APR90) 60-14 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter DISASSEMBLE SOLENOID DRIVE STARTER 1. Remove nut (A) to disconnect field coil lead. M37150 -UN-25JAN90 2. Remove two screws (B). M98,2060K,32 -19-05NOV85 M98,2060K,33 -19-05NOV85 M98,2060K,34 -19-05NOV85 3. Remove solenoid switch (A), spring (B), and plunger (C). M37129 -UN-25JAN90 Clean and inspect parts. Replace solenoid assembly if spring is weak or broken or if other parts are defective. NOTE: If bench test indicated solenoid problems, use an ohmmeter or test light to check switch. M37151 -UN-25JAN90 4. Touch one probe of tester to field coil terminal and other probe to battery terminal. There should be no continuity. 5. With tester probes still on field coil terminal and battery terminal, push spring loaded switch button (A). There should be continuity when button is pushed in all the way. M37152 -UN-25JAN90 60 15 M98,2060K,35 CTM2 (19APR90) 60-15 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter M37153 -UN-25JAN90 6. Test for open circuits by touching probes to switch terminal (A) and to field coil terminal (B). There should be continuity. M98,2060K,36 -19-05NOV85 M98,2060K,37 -19-05NOV85 M98,2060K,38 -19-05NOV85 M98,2060K,39 -19-05NOV85 7. Touch probes to switch terminal (A) and to solenoid body (C). There should be continuity. M37154 -UN-25JAN90 If the solenoid fails any of the tests, it is defective and must be replaced. M37121 -UN-25JAN90 8. Remove two screws (A) and two thru-bolts (B). NOTE: Make a mark across front bracket, field coil, and end cap to align parts in assembly. -UN-25JAN90 9. Remove end cap. Remove thrust washers (A) which may stick on end cap or around armature shaft. Inspect bushing in end cap for excessive wear. Replace end cap assembly if cap is bent or deformed, or if bushing is worn. M37122 60 16 CTM2 (19APR90) 60-16 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter M37123 -UN-25JAN90 10. Pull springs back to remove two field coil brushes from brush holder. Remove brush holder. M98,2060K,40 -19-05NOV85 M98,2060K,41 -19-05NOV85 M37139 -UN-29JAN90 11. Use an ohmmeter or test light to check for continuity. Touch one probe of tester to brush mounting plate and other probe to each of the field coil brush holders (A). If there is continuity, replace the brush holder assembly. 12. Pull spring back to remove negative brush. M37125 -UN-25JAN90 M37124 -UN-25JAN90 Measure brush length. Replace brush if worn below minimum length of 11.5 mm (0.45 in.). M98,2060K,42 CTM2 (19APR90) 60-17 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 60 17 Starter/Starter M37140 -UN-29AUG88 13. To replace negative brush, cut off worn brush and install new one using a soldering gun and 60-40 rosin core solder. Newly installed wire should be approximately same length as the original. M98,2060K,43 -19-05NOV85 M98,2060K,44 -19-05NOV85 M98,2060K,45 -19-05NOV85 M98,2060K,46 -19-05NOV85 14. Remove field coil. -UN-25JAN90 IMPORTANT: Do not clean starter parts with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush or wipe clean with a cloth. M37126 Clean and inspect field coil. Check for bare wires or broken insulation that may cause grounding. M36757 -UN-29AUG88 15. Test for grounded field winding using an ohmmeter or test light. Touch one probe of tester to field coil brush and other probe to field frame. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field frame assembly must be replaced. -UN-29AUG88 M36758 60 18 16. Test for open field coil by touching a probe to each field coil brush. If there is no continuity, the field coil is open and the field frame assembly must be replaced. CTM2 (19APR90) 60-18 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 17. Check brushes for cracks or excessive wear. M37127 -UN-25JAN90 Replace brushes if they are worn shorter than 11.5 mm (0.45 in.). M98,2060K,47 -19-05NOV85 M98,2060K,48 -19-05NOV85 M98,2060K,49 -19-05NOV85 M37141 -UN-25JAN90 18. To replace brushes, melt solder from brush lead connection and install new brush. If additional solder is needed, use only 60-40 rosin core solder. M37130 -UN-25JAN90 19. Remove rubber seal (A) and steel plug (B). 60 19 CTM2 (19APR90) 60-19 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 20. Remove armature (A) and lever (B). -UN-25JAN90 Inspect armature for signs of dragging against pole shoes. Inspect lever for cracks or excessive wear. Replace if defective. M37131 Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. Never use emery cloth. Clean all dust from armature when finished. M98,2060K,50 -19-05NOV85 M98,2060K,51 -19-05NOV85 M98,2060K,52 -19-05NOV85 21. Test for grounded windings using an ohmmeter or test light. -UN-25JAN90 Touch probes on armature core and commutator bar. Armature windings are connected in series, so only one commutator bar needs to be checked. M37132 If test shows continuity, a winding is grounded and the armature is defective. 22. Test for open circuited windings using an ohmmeter or test light. -UN-25JAN90 Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature is defective. M37133 60 20 CTM2 (19APR90) 60-20 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 23. Test for short circuited windings using a growler. Put armature in growler and hold a hacksaw blade above each slot while slowly rotating armature. -UN-24APR89 If coil is shorted, the blade will vibrate on the slot. M17166 NOTE: A short circuit most often occurs because of copper dust or filing between two commutator segments. 24. If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, the armature is defective. The armature is not serviceable. If any of the tests indicate grounded, shorted, or open circuited windings, replace the entire starter. M98,2060K,53 -19-05NOV85 IMPORTANT: Do not clean overrunning clutch in solvent. The clutch contains grease which would be removed. -UN-25JAN90 NOTE: Check overrunning clutch before removing it from armature. M37134 25. Turn clutch drive counterclockwise by hand. Pinion should turn freely. 26. Turn pinion clockwise. A definite resistance should be felt. If clutch is free-wheeling in both directions, or if it shows resistance when turned counterclockwise, it is defective. Replace overrunning clutch if it is defective or if pinion gear shows excessive wear or damage. 60 21 M98,2060K,54 CTM2 (19APR90) 60-21 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 27. Hold armature assembly in a soft-jawed vise. Slide stop ring (A) down using a piece of pipe. M37136 -UN-25JAN90 M37135 -UN-25JAN90 28. Push snap ring (B) from groove. M98,2060K,55 -19-05NOV85 M98,2060K,56 -19-05NOV85 29. Remove snap ring (A), stop ring (B), overrunning clutch (C), and baffle plate (D). M37137 -UN-25JAN90 A—Snap Ring B—Stop Ring C—Overrunning Clutch D—Baffle Plate 60 22 CTM2 (19APR90) 60-22 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 30. Check bushing in front frame for excessive wear. If it is necessary to remove bushing (A), use a 3/8 in. blind-hole puller and slide hammer. M37138 -UN-25JAN90 NOTE: Thrust washer will be pulled along with bushing. M98,2060K,57 -19-05NOV85 M98,2060K,58 -19-05NOV85 ASSEMBLE SOLENOID DRIVE STARTER M37142 -UN-25JAN90 1. If front frame bushing is being replaced, press new bushing (A) and thrust washer (B) into front frame. Use a 5/8 in. driver to install washer tight against shoulder of counterbore. 60 23 CTM2 (19APR90) 60-23 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 2. Install baffle plate (A), overrunning clutch (B), stop ring (C), and snap ring (D). Be sure flange of baffle plate (A) is pointing upward. 3. Put snap ring (D) in groove. Pull stop ring (C) over the snap ring. M37143 -UN-25JAN90 A—Baffle Plate B—Overrunning Clutch D—Stop Ring E—Snap Ring M98,2060K,59 -19-05NOV85 M98,2060K,60 -19-05NOV85 M98,2060K,61 -19-05NOV85 4. Apply Multemp PS No. 2 grease or equivalent to both ends of armature shaft and to the lever (B). Apply light oil to the overrunning clutch splines. M37131 -UN-25JAN90 5. Install armature assembly (A) and lever (B) into front frame. Note the position of the lever. 6. Install steel plug (B) and rubber seal (A). M37130 -UN-25JAN90 60 24 CTM2 (19APR90) 60-24 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter M37126 -UN-25JAN90 7. Install field coil. Be sure notch in field coil flange aligns with rubber seal. M98,2060K,62 -19-05NOV85 M98,2060K,63 -19-05NOV85 M98,2060K,64 -19-05NOV85 M37124 -UN-25JAN90 8. Install negative brush and hold it in place with the spring. M37123 -UN-25JAN90 9. Put brush holder assembly on commutator and install field coil brushes. Pull springs back and push all three brushes against commutator, then release springs to hold brushes. NOTE: Install same number of thrust washers as was removed when disassembling starter. 60 25 -UN-25JAN90 10. Apply grease to thrust washers (A) to hold them to end cap. M37122 11. Install end cap. Be sure slot in end cap aligns with rubber seal. M98,2060K,65 CTM2 (19APR90) 60-25 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 12. Install two screws (A). M37121 -UN-25JAN90 13. Install two thru-bolts (B) and tighten to 5.7 ± 1.1 N·m (50 ± 10 lb-in.). M98,2060K,66 -19-05NOV85 M98,2060K,67 -19-05NOV85 M98,2060K,68 -19-05NOV85 14. Apply grease to the lever fork and apply light oil to the plunger (C). M37129 -UN-25JAN90 15. Connect plunger (C) to lever fork and install spring (B) and solenoid switch (A). Note position of switch terminal on solenoid. 16. Fasten solenoid with two screws. Tighten screws to 6 ± 1 N·m (53 ± 9 lb-in.). M37144 -UN-25JAN90 17. Connect field coil lead and fasten with nut (A). 60 26 CTM2 (19APR90) 60-26 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 18. Check armature shaft thrust gap. Set dial indicator on pinion then raise the armature shaft to determine thrust gap. Nominal Value Armature Shaft Thrust Gap 0.1 to 0.5 mm (0.004 to 0.020 in.) M37145 Item -UN-25JAN90 SPECIFICATION M37146 -UN-25JAN90 If the thrust gap is not within the nominal value limits, add or remove thrust washers shown in Step 10. M98,2060K,69 -19-05NOV85 NOTE: Normally the pinion clearance will not be affected by servicing the starter unless the solenoid is replaced. -UN-26APR89 19. To check pinion clearance, connect a 12-volt battery (A) to starter frame (B). Connect a remote switch (C) between solenoid terminal (D) and battery (A). Use heavy duty cables. M37147 A—12-Volt Battery B—Starter Frame C—Remote Start Switch D—Solenoid Switch Terminal 60 27 M98,2060K,70 CTM2 (19APR90) 60-27 -19-05NOV85 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter IMPORTANT: To avoid solenoid overheating, do not leave solenoid activated longer than necessary to measure clearance. 20. Close the switch to activate solenoid which will shift the pinion into cranking position. Measure clearance between the pinion and stop ring. SPECIFICATION Item Nominal Value Pinion-to-Stop Ring Clearance 0.5 to 2.0 mm (0.020 to 0.079 in.) If clearance is not within the nominal value limits, add or remove shims between solenoid and front frame. See Step 15. -UN-25JAN90 Adding shims provided with Solenoid Repair Kit, decreases the amount of clearance. M37148 21. After assembly, perform bench test. (See “Bench Test Solenoid Drive Starter” in this group.) M98,2060K,71 -19-05NOV85 INSTALL STARTER—P218G AND P220G ENGINES 1. Install starter. Tighten cap screws (A) to 26 N·m (230 lb-in.). 2. Align flywheel shroud and install cap screws. 3. Install side shroud and cap screws. 4. Install manifold and lift bracket. Tighten cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 5. Connect spark plug wire. 6. Install engine. (See machine technical manual.) M46014 -UN-08JAN90 60 28 M98,2060K,72A -19-02FEB87 CTM2 (19APR90) 60-28 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter INSTALL STARTER—B43E, B43G, B48G, AND T260 ENGINES M36439 -UN-29JAN90 1. Install starter. Tighten two cap screws to 34 ± 1 N·m (300 ± 9 lb-in.). Bendix Drive Starter Shown M98,2060K,72 -19-11FEB87 IMPORTANT: Do not lubricate crankshaft taper. The crankshaft taper must be dry to hold the flywheel tight. -UN-29JAN90 2. Clean crankshaft taper before installing flywheel. 3. Apply pipe sealant on threads of flywheel cap screw. M36297 4. Align keyway (A) in flywheel with key (B) in crankshaft and install flywheel. 5. Install washer and cap screw. IMPORTANT: Do not hold flywheel from turning with a pry bar in the fins. Doing so may damage the fins. -UN-29JAN90 6. Fasten locking pliers to ring gear to prevent flywheel from turning. M36298 7. On B43E, B43G, B48G, T260 engines, tighten cap screw to 51 ± 3 N·m (38 ± 2 lb-ft). On P218G and P220G engine, tighten cap screw to 67—75 N·m (50—55 lb-ft). 60 29 M98,2060K,73 CTM2 (19APR90) 60-29 -19-11FEB87 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter -UN-29JAN90 NOTE: For engines with adjustable starter bracket, measure starter pinion gear backlash using the following procedure. For all other units with non-adjustable starter bracket, go to Step 21. M36437 8. Pull starter pinion gear outward until teeth contact flywheel ring gear. Measure starter pinion gear backlash. Backlash specification is 0.51 ± 0.38 mm (0.020 ± 0.15 in.). If backlash is correct, go to Step 21. 9. If backlash is not correct, loosen starter cap screws (A) and move starter bracket (B) to obtain correct backlash. M36438 -UN-29JAN90 Tighten starter cap screws to hold bracket in position. Check backlash again. M98,2060K,78 -19-26NOV85 M98,2060K,9 -19-05NOV85 IMPORTANT: Do not hold flywheel from turning with a pry bar. Doing so can damage the fins. CAUTION: Loosen flywheel cap screw only two turns. Do not remove cap screw. If cap screw is removed, flywheel may cause injury when it comes loose. M36292 N -UN-29JAN90 10. Fasten locking pliers to ring gear to prevent flywheel from turning. 11. Loosen cap screw two turns only. 60 30 CTM2 (19APR90) 60-30 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter IMPORTANT: Do not pry on flywheel with a screwdriver. Ceramic magnets and gear case cover can be damaged. -UN-29JAN90 12. Loosen flywheel using a puller. M36293 13. Remove puller, cap screw, washer, and flywheel. M98,2060K,10 -19-05NOV85 M98,2060K,79 -19-26NOV85 M36439 -UN-29JAN90 14. Tighten starter cap screws to 34 ± 1 N·m (300 ± 9 lb-in.). IMPORTANT: Do not lubricate crankshaft taper. The crankshaft taper must be dry to hold the flywheel tight. -UN-29JAN90 15. Clean crankshaft taper before installing flywheel. 16. Apply pipe sealant on threads of flywheel cap screw. M36297 17. Align keyway (A) in flywheel with key (B) in crankshaft and install flywheel. 18. Install washer and cap screw. IMPORTANT: Do not hold flywheel from turning with a prybar in the fins. Doing so may damage the fins. -UN-29JAN90 19. Fasten locking pliers to ring gear to prevent flywheel from turning. M36298 20. Tighten cap screw to 51 ± 3 N·m (38 ± 2 lb-ft). M98,2060K,80 CTM2 (19APR90) 60-31 -19-26NOV85 16, 18, 20 & 24HP Onan Engines 130495 60 31 Starter/Starter 21. Install flywheel shroud (C). Fasten with five cap screws. 22. Install fuel pump (B). Fasten with two screws. M36291 -UN-29JAN90 23. Connect governor spring (A) in top hole of arm. M98,2060K,75 -19-26NOV85 M98,2060K,76 -19-26NOV85 M36290 -UN-29JAN90 24. Connect fuel pump impulse line (B) and fasten with hose clamp (A). 60 32 CTM2 (19APR90) 60-32 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 25. Install side shroud (C). Fasten with four cap screws on T260 engine; five cap screws on B43E, B43G, or B48G engine. 26. Install manifold cover (B) and lift bracket (A). Fasten with three cap screws on T260 engine; two cap screws on B43E, B43G, or B48G engine. Tighten lift bracket cap screw to 11 ± 3 N·m (97 ± 27 lb-in.). 27. Connect spark plug wire and voltage regulator leads. Install the two stator leads on “AC” terminals and the battery lead on “B+” terminal of voltage regulator. M36445 -UN-29JAN90 28. Install engine. (See machine technical manual.) T260 Engine Shown M98,2060K,77 -19-26NOV85 60 33 CTM2 (19APR90) 60-33 16, 18, 20 & 24HP Onan Engines 130495 Starter/Starter 60 34 CTM2 (19APR90) 60-34 16, 18, 20 & 24HP Onan Engines 130495 Group 65 Ignition System REPLACE BREAKER POINTS AND CONDENSER—B43E, B43G, B48G, AND T260 ENGINES -UN-25JAN90 NOTE: On later engines, the condenser is located on side of air filter bracket. M37242 1. Remove air cleaner assembly. (See Remove Air Cleaner in Group 05 in this manual.) 2. Remove breaker point cover. M98,2065K,1 -19-02FEB87 3. Remove two set screws to remove breaker points. -UN-25JAN90 4. Loosen screw (A) to disconnect coil and condenser leads. 5. Remove screw (B) to remove condenser. M37243 6. Install new condenser and point assembly. Apply thread sealant on threads of set screws and fasten breaker points. Early Point Assembly Shown M98,2065K,2 -19-05NOV85 M98,2065K,3 -19-05NOV85 M37244 -UN-25JAN90 7. Check breaker point gap. Turn engine flywheel until points are at their widest gap. Adjust gap to 0.41 mm (0.016 in.) using a flat feeler gauge. 65 1 CTM2 (19APR90) 65-1 16, 18, 20 & 24HP Onan Engines 130495 Ignition System/Ignition Coil 8. Be sure coil lead wire is in notch in the base; then install breaker point cover. Tighten cover set screw snug only so cover is not crushed or deformed. M37242 -UN-25JAN90 9. Install air cleaner assembly. (See Install Air Cleaner in Group 05 in this manual.) M98,2065K,4 -19-05NOV85 REPLACE IGNITION COIL—B43E, B43G, B48G, AND T260 ENGINES -UN-25JAN90 1. Remove air cleaner assembly. (See Remove Air Cleaner in Group 05 in this manual.) 2. Disconnect spark plug wires (A). M37156 3. Loosen screw (B) to remove coil. 4. Remove wires (C) and (D). 5. To install coil, fasten breaker point lead to negative (-) terminal (D) and ignition switch lead to positive (+) terminal (C). T260 Engine (Top Photo) 6. Install coil and fasten with screw clamp (B). -UN-25JAN90 7. Connect spark plug wires (A). M37157 8. Install air cleaner assembly. (See Install Air Cleaner in Group 05 in this manual.) B43E, B43G, B48G Engine (Bottom M98,2065K,5 -19-11FEB87 65 2 CTM2 (19APR90) 65-2 16, 18, 20 & 24HP Onan Engines 130495 Ignition System/Ignition Coil REPLACE IGNITION COIL—P218G AND P220G ENGINES -UN-08JAN90 1. Remove air cleaner assembly. (See Remove Air Cleaner in Group 05 in this manual.) 2. Disconnect wire leads (A—F). M46015 3. Remove two cap screws to remove ignition coil. 4. Install ignition coil and two cap screws. 5. Connect wire leads and install air cleaner assembly. (See Install Air Cleaner in Group 05 in this manual.) A—Spark Plug Wire B—Spark Plug Wire C—Condenser Wire D—Wiring Harness (Key Switch) E—Orange Wire (Ignition Coil) F—Black Wire (Ignition Coil) M98,2065K,6 -19-11FEB87 M98,2065K,7 -19-11FEB87 REPLACE IGNITION MODULE AND MAGNETIC RING—P218G AND P220G ENGINES -UN-08JAN90 1. Remove air cleaner assembly. (See Group 05 in this manual.) 2. Remove flywheel. (See Group 20 in this manual.) M46016 3. Remove three cap screws. Gently pull stator (A) off mounting posts. 65 3 CTM2 (19APR90) 65-3 16, 18, 20 & 24HP Onan Engines 130495 Ignition System/Ignition Coil 4. Remove key (A) and magnetic ring (B). 5. Remove two cap screws to remove ignition coil (C). -UN-08JAN90 6. Install coil (C), magnetic ring (B)—marked “FLYWHEEL SIDE”, and key (A). 7. Install starter and cap screws. M46017 8. Install flywheel. (See Group 20 in this manual.) 9. Install air cleaner. (See Group 05 in this manual.) M98,2065K,8 -19-02FEB87 65 4 CTM2 (19APR90) 65-4 16, 18, 20 & 24HP Onan Engines 130495 Contents Page Page 00 Group 00— . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . About This Manual . . . . . . . . . Engine Serial Number Plate . . . Engine Specifications . . . . . . . Engine Application Chart . . . . . Hardware Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 05—Air Cleaner and Breather Specifications . . . . . . . . . . . . . . . . . Air Cleaner Remove . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . Breather, Repair T260 Engine . . . . . . . . . . . . . . . . B43E, B43G, or B48G, Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 00-1 00-2 00-3 00-3 00-4 00-4 Specifications . . . . . . . . . . . . . . . . . . . . . . 20-1 Flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 Group 25—Camshaft Essential Tools . . . . . . . . . Service Equipment and Tools Other Material . . . . . . . . . . Service Parts Kits . . . . . . . Specifications . . . . . . . . . . Camshaft Remove . . . . . . . . . . . . Disassemble and Inspect . Assemble . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . 05-1 . . . . . 05-1 . . . . . 05-3 . . . . . 05-4 . . . . . 05-5 Group 10—Intake Manifold and Cylinder Service Equipment and Tools . . . . . . . . . Service Parts Kits . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . Intake Manifold Remove . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Remove . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . Group 15—Intake and Exhaust Valves Essential Tools . . . . . . . . . . . . . . . . . Service Equipment and Tools . . . . . . . . Service Parts Kits . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . Intake and Exhaust Valves Remove . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Measure and Adjust Valve Clearance . . . . . Heads . . . 10-1 . . . 10-1 . . . 10-2 . . . 10-8 . . 10-11 . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4 . 25-7 25-11 25-13 Pistons ...... ...... ...... ...... . . . . . . . . Group 30—Connecting Rods and Service Equipment and Tools . . . . Other Material . . . . . . . . . . . . . . Service Parts Kits . . . . . . . . . . . Specifications . . . . . . . . . . . . . . Connecting Rod Measure End Play . . . . . . . . . . Measure Bearing Clearance . . . Pistons and Connecting Rods Remove . . . . . . . . . . . . . . . . Inspect . . . . . . . . . . . . . . . . . Deglaze Cylinder Bores . . . . . . Assemble . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 10-4 15-1 15-1 15-2 15-3 . . . . 15-5 . . . 15-12 . . . 15-15 Group 20—Flywheel Service Equipment and Tools . . . . . . . . . . . . 20-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 20-1 25-1 25-1 25-1 25-2 25-3 30-1 30-1 30-1 30-2 . . . . . . . . 30-4 . . . . . . . . 30-7 15 20 25 30 35 . . . . . . . . . . . 30-9 30-13 30-21 30-21 30-23 40 Group 35—Crankshaft and Main Bearings Essential Tools . . . . . . . . . . . . . . . . . . . Service Equipment and Tools . . . . . . . . . . Other Material . . . . . . . . . . . . . . . . . . . . Service Parts Kits . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 35-1 35-1 35-2 35-2 45 55 Continued on next page 60 All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. 65 CTM2-19-19APR90 COPYRIGHT© 1989 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION™ Manual CTM2 (19APR90) 05 i 16, 18, 20 & 24HP Onan Engines 130495 Contents Page Page 00 05 10 15 20 25 30 35 40 45 50 55 60 65 Crankshaft and Main Remove . . . . . . Inspect . . . . . . . Install . . . . . . . . Carburetor Remove . . Disassemble Clean . . . . Assemble . Install . . . . Bearings . . . . . . . . . . . . . . . . . . 35-3 . . . . . . . . . . . . . . . . . . 35-6 . . . . . . . . . . . . . . . . . . 35-9 Group 40—Lubrication System Essential Tools . . . . . . . . . . . . Service Equipment and Tools . . . Other Material . . . . . . . . . . . . . Service Parts Kits . . . . . . . . . . Specifications . . . . . . . . . . . . . Oil Pump Remove . . . . . . . . . . . . . . . Disassemble and Inspect . . . . Assemble . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . Oil Pressure Regulating Valve Remove . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . Oil Base Remove and Inspect . . . . . . . Install . . . . . . . . . . . . . . . . . Oil Filter Adapter Remove . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . Oil Line Adapter Remove . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . Group 45—Governor Service Equipment and Tools . . Other Material . . . . . . . . . . . . Service Parts Kits . . . . . . . . . Specifications . . . . . . . . . . . . Governor Assembly and Linkage Remove . . . . . . . . . . . . . . Governor Assembly Disassemble and Inspect . . . Governor Linkage Disassemble and Inspect . . . Assemble . . . . . . . . . . . . . Governor Assembly Assemble . . . . . . . . . . . . . Governor Assembly and Linkage Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 40-1 40-1 40-2 40-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 40-6 40-7 40-7 . . . . . . . . 40-21 . . . . . . . . 40-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2 . 50-4 50-10 50-10 50-17 . 55-1 . 55-1 . 55-3 . 55-6 . . . . . . . . . . 60-1 . . . . . . . . . . 60-2 . . . . . . . . . . 60-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 . 60-6 60-15 60-28 Group 65—Ignition System Breaker Points and Condenser Replace . . . . . . . . . . . . . . . . . . . . . . . . . 65-1 Ignition Coil Replace . . . . . . . . . . . . . . . . . . . . . . . . . 65-2 . . . . . . . . 40-24 . . . . . . . . 40-25 . . . . . . . . . Group 60—Starter Service Equipment and Tools . . Specifications . . . . . . . . . . . . Service Parts Kits . . . . . . . . . Starter Remove . . . . . . . . . . . . . . Repair Bendix Drive Starter . Repair Solenoid Drive Starter Install . . . . . . . . . . . . . . . . . . . . . . . . 40-14 . . . . . . . . 40-16 . . . . . . . . . Group 55—Stator and Rectifier—Regulator Specifications . . . . . . . . . . . . . . . . . . . . . Stator Remove . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier-Regulator Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10 . . . . . . . . 40-12 . . . . .. . .. .. .. 45-1 45-1 45-1 45-1 . . . . . . . . . . 45-2 . . . . . . . . . . 45-2 . . . . . . . . . . 45-4 . . . . . . . . . . 45-6 . . . . . . . . . . 45-8 . . . . . . . . . . 45-9 Group 50—Carburetor Service Equipment and Tools . . . . . . . . . . . . 50-1 Service Parts Kits . . . . . . . . . . . . . . . . . . . 50-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 50-1 CTM2 (19APR90) ii 16, 18, 20 & 24HP Onan Engines 130495
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