927 0006 Onan CCK (spec A F) Genset Instruction Manual (02 1969)
User Manual: 927-0006 Onan CCK (spec A-F) Genset Instruction manual (02-1969)
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GENERAL INfORMATION
THE PURPOSE OF THIS BOOK. This instruction book is.furnished so
that the operator may learn of the charactertsUcsoftheplant. . A thor
ough study of the book wilL help the operator to keeptheplant in.. good
operating condition so that it will give efficient service. An under
standing of the plant will also assist the operator il} determining the
cause of trouble if it occurs.
KEEP THIS BOOK lIANDY. Such. simple mistakes as the use of im
proper oil, improper fuel, or the neglect of routine servicing mayre
sult in failure of the plant at a time when it is urgently needed. It is
suggested that this book be kept near the plant so that it may he refer...
red to when necessary.
'
.
SERVICE. If trouble occurs and th~operato:t:' is unable to determine the
cause after a thorough stuayof tl1isbook, or if he is unable to deter
mine what repair parts are required,needed information will be fur
nished upon request. WHEN ASKING FOR INFORMATION, BESURE TO .
STATETHEMODEl,t,.SPEC.,AND SERIAL NUMBERS OF THE PLANT.
THIS INFORMATION IS ABSOLUTELY NECESSARY AND MAYBE OB
TAINED FROM THE NAMEPLATE ON THE PLANT .
.
MANUFACTURER'S WARRANTY
The Manufacturer warrants each produCt of its manufacture to be
free from·defe.cts in materjal and factory workmanship if ,properly'
installed, serviced and operated under nonnal conditions accord-.
ing to the Manufacturer s instructions,
Manufacturer's obligation under this warranty is limited to oor~
reeting without charge at its factory any part or parts thereof
wllich shan be returned to its factory· or one of· its Authorized
Service Stations, transportation charges prepaid, within ninety
(90) days after being put into .service by theoriglnal user, and
which upon examlnlltioll shall disclose to the ManUfacturer's sat-'
isfaction to have been originally defective. Correction of such de'
fect~ by repair to, or supplying of replacements for defective Parts,
shall constitute fulfillment of all obligations tf) original user.
'
This warranty shall not 'apply to any of the 1.fanufactmer's prod- '.
ucts which must be replaced because. of nonnal wear, which have '.
been mbject to mistlse, negligenCE) or acclde:IjJ or which shall have
been repaired or altered outside of the !I!anufacturer's factory un
less autllorlzed by the Manufacturer"
Manufacturer sh~1J not he liable for loss, damage or e).-pense
directly or indirectly from the usc of it~ product odrom any other
cal1se. The Manufacturer Inakes no "'llrro.ljtY,'~l:>atsoe"er ",.ith re
spect to component parts which are warranted separately by their
respective manufacturers,
.. . .
.
,
TIle above warrant)' supersedes and is in lieu of all other war
ran tics, expressed or implied, and no person, ag~nt or dealer is
lluthorized to give all)' warranties.on hehalfof tile ~!anufactllrer
nOt 10 nssumefor the ~I"nllfncttlrer any' other liability in COIllI€Electric Choke Adjustment ; ........... , .' ....... ; ... ,. . • ....
51
36. Magneto Stator Installation ............. " .......... , . ... . . .
55
37. Coil and Circuit for Magneto Ignition.. .. . . . .. . . . . . . . . . .. . . . •
55
38. Coiha.nd Circuit for Battery Ignition .......•.•. ; .. . . . . . . . . . . . . 5 6
39.- IgnitionTiming •.•.. '. ............"...........................
57
40. Valve Service ...•......•...•. '. ....................... " . . . • .
59
41. Installing the Gear Cover .. . .. . .. . . . . . . . . . . . • • . . . . . . . . . .. ..
60
42. GovernoJ:' Cup .. ' ..•... '.' ... , .. ; ..•........ ',' ................
61
43. Timing Gears .....
o. •
62
44; Fitti~g piston Rings to the Cylinder. . . . . .. . . . . • . . . • . . • . . .. .
64
4.5. RedUCing Connecting Roo Clearance •... . . . . .. ... . .. . .. . . ..•
64
46. Bearing Installation. .. . . . . ... . . .. .. . . . . . . . . . . . . .. .. . • . .. ...
66
47. Oil seal Installation. . .. . •. ... ... . . . .... . . . . • .. . ... . . . . . ...
66
48. Crankshaft End-Play. . . . • . .. . . . . •. . . . . . . . . . • . . . • . . . . . . . . ..
67
49. Oil Pump Removal .•..•... , ......•................. , . . . . . ..
67
50. Brushes and Springs ........ '" .'...... , . . . ... .. ... . . . •. . ..
'69 '
51. "'Commutator Repair .•..... " . . . • . . . . . . . •• . . . . • . . . .. • . . . . ..
70
52, Continuity Test Lamp.......................... ...........
71
53.' Armature Growler •..•........•..'•.....•..•... '. .•...•..' ...
71
54. Generator Assembly ......................... ; .. . . • . • • . .. . ..
73
55. Servicing Readi-pull starter •..•.•..•.•• " ....•••••....
76 '.
56. Installing Readi-pull starter, Un1ts"prlor to spec.D !. , i • " .~.
'•...7'.786.'.'~".'.'"
Readi-Pull
n57. Installing
..
'Starter,
. Units
". beginning spec.' D •. .; •. .•• ~ , '.
0
0
;
•••••••••••••
' •••••••••••••••••••••
"0 •
•
..
~
i
SUBJECT
TABLE OF CONTENTS,
Description
, Introduction ........................ ',' ................ .
General Description •..... , ... , .......•.... , ...... , ' ..
Engine Details' ............ , ................ , , ....... .
Generator Details, Controls ............. , ............ .
Accessories ........... '. ............... '..... ', .. , .... .
Installation
Location,Mobile Installation •.•..... , , .............. , ..
Ventilation, permanent Mounting Base ................. ,
Mounting Cushions, Exhaust ..........................•
Oil Drain Extension , ..... , ...•..'...• , .......•.......•.
Battery .............. ', . ~ ............................. .
Start & Ignition Switches, Magnet Servic,e Plant ••.•.....•
Connecting the Load Wires ..................... , ...... .
Grounding ..•..... , .............................. , . " .. .
Remote Control Switch, Separate Fuel Tank ............ .
Underground Tank," ''0 ay" Tarik, Carrying Frame, DOlly ... '
Readi-pull starter ... '. . '. •.........•. , . '................ .
,Gas Regulator •......... '... ; .......'....... ~ ......... ~ .
Vacu-Flo Cooling ............................... '. .....•
Preparation
Lubrication ; •.. '....•.... '. ........................... .
Air Cleaner,Fuel, Before Initial start .......•.....•....
Operation
starting the pIant • . . . . . . . . . . . . . . • . • . . . . . . . . .. . . . : . . . . .
Applying the Load ...............'...................... '
Charge Rate, Stopping the Plant, Changing Fuel .......... .
Function of the Controls .................... , .•..........
A bnormal Operating, Conditions
'Low Temperatures .. , ..........,.... : ...• ',' ........... .
High, Temperatures •..... " . " .... '. ..................... i ...
Dust and Dirt .... : . ',' .. '. ............... ; ......•.......
Periodic Service
Daily Service •... : .............. ; ......•. , .. '. ..... , ... "
Weekly Service •................'..................•.• '.
Monthly Service, ....... , .........'.................... ..
Adjustments
'
General, Governor and Booster ..•...•.......• : .•.••..•
Voltage Chart; Speed. Chart ............ ,'... , ........... '
Oil Pressure Relief Valve .......................•....•
Carburetor ................. ;. " ..................... .
Electric Choke •..... ; ....• ; ........•... "....••......•
Maintenance and Repair
.
,
General, Table of Clearances ..• '" ......... ".•. ".••.•.
AssemblyTorques, Engine ........... " " ..........••..•
Generator .................................. ~, ...... ," .
Control ..•,.................. ".....•. '. ..... ; ....... '. .•
Starter ....................•..................•.. '•....
Service Diagnosis" ......... : .....•.... ;' .... : ........... ~'
Wiring Diagrams . ; ...... ,. ., .'. . . . . . . . . ........... '," ...... .
PAGE NO.
1
2
4
5
6
7
9
10
11
15
16
16
21
22
23
,24
25
26
28
29
,30 "
31
32
33
,35
36'·'
37
38
39
40,.
43
46
49
50
51
53
54,>
69
74
75
79
87
m
ENGINE SERVICE CHART
FOR DETAILED SERVICE INSTRUCTIONS, SEE PERIODIC SERVICE.
The following recommended Engine Servicing Chart may be used as a
guide to estimating servicing requirements of ONAN Gasoline Engines .
. The chart is based on the Units operating under favorable conditions,
such as: use of recommended fuel and oils, etc.
HOURS OF OPERATION
SERVICE & PARTS.
REQUIRED
0
0
JX
0 0
0
C\l
0
(()
0
~
0 0 0 0 0 0
0 0 0 0 0 0 00 00 0 0 0 0 0 0
0 0 0 0 0 0 10
(() 0 10 0 10 0
10 co r- <0 en 0
~ (\J ('I) ('I) ~ It)
""
lX
IX IXIX
Oil change (Check daHy).
1-. I-
Clean and gap plugs. ___ _
IX rx IX
t><
*A.ir cleaner. __________ _ IXIXIX
t><
Ignition pOints. ________ _ lXIX rx X D<
tClean carbon. ________ _IX
IXXXlX IX
Clean carburetor. ______ _ex IX
Check tappets. ________IXXlX ~
IX
..
Grind valves. _________ _
+--~I--~ LX .tx
Clean oil base. ________
IX
Clean crankcase breather~IX rx]XrxIXIX IXrxlZ~
Clean engine. _________
IX rx
AS REQUIRED
Replace spark plugs. __ _
AS REQUIRED
Replace valves, ______ _
-
AS RE~UIR~~ _ _ _ _
Replace pOints. ______ _
-
AS REQUIRED
.
. Replace piston rings. __ _
~~
I ~I
~Z
--tx
-
l:)
z....
z
0
t:
z
0
0
U
w
0:
w
fw
...J
a.
::E
0
u
* Check the air
cleaner often~ Thoroughly clean and put in fresh oil at
least every 100 hours.
If it is necessary to remove parts for inspection and gaslmts are dis
turbed they should be replaced with new ones.,
Periodic Inspection: For loose or poor connections, fittings, etc.
t Recommended fuel: Use regular gradegasoline of at least 68 octane
.
Do not usepremjurn type. If a high lead content
fuel is used, it will be necessary to remove t.he lend deposits more
frequently..
Keep engine clean.
IV
DESCRIPTION
1
INTRODUCTION. - This instruction manual is supplied to assist in the
proper installation, operation, and servicing of the
CeK series electric generating plants. Unless otherwise stated, these
instructio~s apply to all standard plants of the CCK series.
.
The .plant model and specification, seriaL number, and electrical char
acteristics appear on the nameplate. The manufacturer produces many.
types of generating plants, industrial engines,and separate generators.
Basic differences such as voltage, type ofCQoUng, optional equipment ,
and manufacturing improvements are.'
Typical example:
5CCK~1M/1A
5CCK-1 /1A 5CCK-1R/1A
.
Ignition: ,
. Oil Capacity: (U. S. Quart)
Magneto
. Magneto
4 Q~rt
-
*
4 Quart
*
.
*
5CCK-1RV/1A
Battery
4 Quart
FuelTank(U. S. Gallon)
Separate (5) Mounted (4)
(Mtd. Optional)
Cranking and Choking:
Manual
Manual
Electric
Gasoline Carburetor:
Standard
Standard
Standard
. Gas-GasQJJI1e Carburetor:, Optional
Optional
Optional
Engine RPM (60 cycle):
EngineRl"M (50 cycle): ,
1800 (nominal) 1800(nominal} 1800(nominal
1500(nominal) 1500(nominal) 1500(n.ominal
4" Outlet Box Receptacles
Optionalt
Standard
Optionalt
t
Optional
Optional t
Optional
Housing;
NOTEt
.*
*
Terminals
Optional for
Vacu:-Flo
4
DESCRIPTION
ENGINE DETAILS
The engine is a horizontally opposed 2 cylinder, air cooled, 4 stroke cy
cle, L head internal combustion type. Standard models burn gasoline
fuel.. Some special models are equipped with a combination type carbure
tor for burning either gasoline or gas fuel.
The cylinder bore is 3-1/4 inches, the piston stroke 3 inches, piston
displacement 50 cubic inches, compression ratio 5. 5to L The cast
iron cylinder and crankcase isa single casting.
The engine speed is controlled by aflyball type governor built into the
camshaft gear. The governor is externally adjustable. The governor
function is supplemented by a speed booster. The booster is operated
by manifold vacuum and serves to improve stability under load condi
tions.
Ignition current on manual and portable type plants is supplied by a high
tension, flywheel magneto. Ignition current on remote control type
plants is supplied by the starting battery.
.
The engine is cooled by air forced around the cylinder walls and head.
Plants which are "pressure cooled" have blower fins on the flywheel
which draw air in throughthe opening at the front of the blower housing.
Special models of the remote control type plants may be Vacu-FloCooled
and have blower fins which expel heated air out through the duct at the
front of the blower housing, as desirable for small enclosure installa
tions.The letier"V" appears in the model ofVacu-Flo cooled type
plants. (Example: 5CCK-3RV /lA).
.
The engine has aluminum alloy 3 ring pistons, and full
ton pins .. The counterbalanced crankshaft turns in two
main bearings which are replaceable-precision-sleeve
necting rods are aluminum alloy with integral bearing.
may have forged steel connecting rods and replaceable
floating type pis
unusually large
type. The con
Special models
rod .bearings.
The exhaust valves and seats are Stellite faced. Valve tappets are ad
justable self-locking. A positive rotator for each exhaust yalve provides
long trouble free performance (Rotators not on "Spec A" models).
The gear type oil pump supplieS! pressure lubrication to main and con
nectingrod bearings. Oil pressure is controlled by an externally-ad
justable .spring loaded relief valve.
DEBe RIP T 10 N
j"';
I
GEJil"E.RA'I'OR DETAlLS
.
,I
.
..
".
.,
I
.
· The alternatingcllrrelJ:tgel}.~rator . • isar.eyolytnga¥.~.~~J,lre,self· exdted, .
inher.ently.reg.41ated .type•....•. ~h<7AI.1p:E!~el1t..q~signp~".tJj~;;~~perator. with,
saturated,. 4 pole, . . shuntWO;undf)eld,assureSGJo~~17~g~J~tionof voltage
b~tween no loadalld.f.1.1.1l.·lo~ynieans of the required rheostat. '.
C.ONTROLS .'
Thenianual typePlants.h.avea:mariJ~1 choke on the carburetorand a stop
.
. .
button on theblowerliollstng.·
plantsha'V~.receptacles.and aPHb:light ina~dition to'
· Thepo!';abletype
. a manual chokeana.stopbuu6h>
The ·~9.rembt.e
. . . . ..
tYf>epl~ts.havea~;ele.ctri;.c.~
eonthe .carbUret()r.,a
0.£or m.anual()relec~
tricstart 10catedonthecontrOlbQx.nl()l1nt~()¥~t'·(the· gene r~tor •..;.. 'r'he'..'
contr()Is aredesignedS:o ,thatauxiliar.Y'alltQ~:itiQ;;Q~_linetra:nsf~r~qn:-;
tro1.eqllipri'lentinay be: cOnnected.
. .....
" . .' '<.\ .
start~stop switc.h,···acharge·~!llm~t.~~Lari.q,~r(.
6
DESCRIPTION
SPECIAL ACCESSORIES
The following specIal accessories are not standard equipment but are 3.
vailable at extra cost from your dealer. When ordering any of the fol- .
. lowing special accessories, always be sure to give the Modetand Serial
numbers· of the plant on the order.
GASEOUS FUEL CONVERSION
~TS.
- These kits contain parts and in
structions which permit the use
of Butane, Propane or natural gas as well as gasoline;
AUTOMATIC CONTROLS (ACRen:lote Start Plants Only) .... A separate
control is .
available for either 50 or 60 cyclea. c. units that willautomaUcally
start and stop the plantas the load requires.
LINE TRANSFER CONTROLS (AG Remote Start Plants Only).- Line
transfer
controlsare available for use with either 500r 60 cycle units instandby
service. When regular power service fails, the line transfer control
aritomaticallystarts>the standby plant and takes over the load .. Theplant
stops automatically when regular service is restored.
. ..
.
.
UNDERGROUND FUEL TANKS AND LINES. - 55 gallon and 110 gallon
fuel tanks and 5/16 inch
and 3/8 inch copper fueLlinesin either 25 or 50 foot length are avail
able for installing the fuel tank underground.
REMOTESTART-STOPSWlTCHES .. - Additiollairemote start-stop
switches are available from your
dealer.
a-CONDUCTOR CABLE.
~
This #18-wire3-conductor cable is designed
for remote start-stop station installation and
. is adequate Size for switches within 250 feet wire distance.
TW()..;WHEEL DOLLY. - The dolly makes the plant portable' by one man.
.
The dolly is designed to assemble to the tubu.
larcarryingframeas furnished on the portable type plant. Thedolly
has semi-pneumatic tires and adjustable folding handles with hand grips•
.. FUELRESERVOlR(DAY)TANl{. - This tank with fittings can be mounted
.
on the plant and serves to assure·
. quick starting of standby plants by replenishing by gravity feed, fuel lost
from the carburetor during shut-down periods.
.
COLD WEATHER SHUTTER~ -. FitsVacu-flo plants .. Lirnits air}Iow.
.
.
. EXHAUST GASES FROM INTERNALCOMBPS,;£, . ,
'ARE ,DEAD:LYPOISONQUS. ·.EXCES~lVE~INHA\
. CA"USE SERIOVS' ILLWESSORI):EATH•.•... NEV' ' .
. '. 'rHEPLANTINSIDE A'BUILDINGOR. OTHER'
. SPACEWITH()UTPIP:Ii.!OJiLLEbCHAus'tG1\S ...'
THE ENCLOS,URE. . . "
," '. . '. . ,', ... '. ,', .',
pref¢r~bleamb,ien,tait,Jemp~~aturefOrbestengine.'
LOCATION. ,-TM
,.'..•
. ,",
. performancE! isweUab9yefree~Wg;.and theprefe;rable " '
ambie~t air temperature for. mO$tefficteJ:'lt'ge,neratbr operaUonls ,well
.. under lOOoF • and shouldnotexceedUOoF.if conditions permit con~
·trollingtl}'etemperature.'
.
. .
.
ist9,J~¢installed, ,~
Iftllegeneratingplant'
in permanent location,' choose"
a site'{ormQuntin(!t tile plant that will be more or less centrally located .
in;relati'on,tothe elec~rical load. 'Plan toaYoici runningwiringwhich
carries a heavy e,lectljical, load foralongdisb.U!ce .. The greater Ule
distance,lhe, larger t~ewirell1:ust be> The selected site should be in a.
clean; dry,. wellyelltJlated location,preferably heated in extremely cold
,weather.'
A dustyor'dan:ip'locationwilln~G¢!ilsitate
more frequent ser
vicing,.
....... ,., ".' .", ......
...,.,...... ,
MOBILE INSTALL:A1;'Io.N~,":,'rhegeneratingplantmust be securelybol
.. .'.....
' . ' .' ..ted to thefloor or other r igidmember if it
,lstobe'mQuntedin,~yehiCle. 'D,ql1otJleglect the piping 'of the poisonous
exha~stgases to ,t~~,911tQQO~s.:KeepJlle,eXh~1l(3tPipWg Seyer;ll . inches
.away ironj inf}am,mablemater.ialsMdsupporttlJ.e piping securely so .
tnatU willrem~inp~~l11l\tneiltlYin,pl~ce.
....
.
.
.
. ".
.......... .....
.
.C.i'\lJTJON,>: ...'
........ . . .' ..• ....
.
'. Do. not run theveh,icle.J~s;iq.,~aclos.edbuUdingand operate the gellerating
'set.. ' J:,1e suretl1;:lt lhe eXhau.~t.line~, are ,carefully .extended to theou.tside •.•.
ofJhebuilding. .
.' .
.
.
..
·IftbevehiCleisa.~10sedon:~;pr2pet\~~litilatiOnmust be proVid~d .. Sev
'eral smallopening13iWill:sufnC~;})ut therem.ustbe at least 3..1!2 square>
. feet of inletarea and a SiIllHa¥\1~mount for anoutlet if the plant is the
pressure-cooled type. ':prElY~~~i.recirculanOnolll~,!tted air wherever .' .. '.
possible_ The vactium-c,~oled·type;p.1ant iSl1l()r¢ easily. adapted to small'
enclosure installation,
since h,eatedair" call
[)e(;i~C.ted outside.
....
.
'.- . " ":
.""; "':' ' - - "
.<: ',,:,' ',-,. ,,\,:'-', : ."
' "; .
-
:z.'IG. 1
"7
TYPICAL INSTALLATioN
9
INSTA LLATION
Plahtsl110unted in vehiclesmdstalso.begrounded .. Review the applicable
sections in t he National Electrical Code and localregulations' to ,.deter;..
mine the steps to be takenforgrotindi.n.
g:the set, .
.
"
"
',~-
.
'-
,
'
-
.'
.
~'
.
.YENTILA TION(PIiESSUREJC GOL ED,P LA NT) .-Hrovidf;,\,,-3WIRE 3QUART \19 'iz I B '1,6[IS7/161
1(!J-2 WIRE.
4 QUART 120 ')1,;\ 9 '14-116 5/ ... I
1(!J13
....1-3
o
z
~
~
>
1-3
00
Z
......
t.:I
I-'
t'Il.
'"'
Z
r;
. r:d
I:i:I
~
5
pj
.!:tj
~
"=.i
t::
~l
~
g
»
t'"
.!2:
o
~
.....
iI:i:I
o
'3WIRE
1$-2 WIRE
l(!)t3d>-3W~
GEN. CONN·
1$-2WIRE
:...--.-12----1
NOTE:
i
PIPE PLUG
Y;ITH TAN K TyP E. II\UFFLE.R..
3 FT. F'LEX. EXHAUST TU61l'"
CC K
t
SON5, INC.
LRECEPTACLE EOX
(yflR. SlOE)
OWG. N~
50oA473
MINNEAPOLIS, MINN.
D.W. ONAN
REFERENCE NOTE.:.
SE.E. DR."'WING ",2 410C2.35 FOR DOLLY
,------REA01-PULL S,"'R,ER
PORTABLE
Z
o
H
1-3
>
t-'
t-'
>
1-3
00
Z
H
~
.....
INSTALLATION
15 '
BATTERY, AC REMOTECONTROL PLANT. - A 12~volt battery is re
quired. If two6-volt
batteries are used, the batteries must be connected in series by connect
ing a short cable betw'een the positive posto! one battery and the negative
of the other hn++~~..,
FIG. 10- BATTERY CONNECTION - AC ,REMOTE PLANTS
Connect one of the long battery cables between the positive (+) battery
post and the BATTERY terminal on the start solenoid in the control box.
To avoid internal damage to the start solenoid, use care in tightening
the cable terminal nut. 'Connect the other battery cable between the
negative {-} battery post and the ground terminal (screw, stud, or
solderless type) on the generator.
Connect the 32 volt battery for the dual purpose plant in the same manner 1
using a :fused double pole switch between the plant and the battery. Refer
to the, wiring diagram. Be sure all electrical connections are tighL
'Coat batteryclampsand posts with a light coating of grease or vaseline
, to minimize corrosion.
'
,
BATTERY, MAGNET SERVICEPLANT.':'A 12 volt battery (or tWO" 6 volt"
' " " ", '
, , ' , batteries in series) is required.
Connect the battery positive cable to the engine start solenoid switch term
inal.Connectthebattery negative cable to the ground point on the oil
base as shown.
•
FIG. 11 BATTERY CONNECTION, MAGNET SERVICE PLANT
INSTALLATION
16
START AND IGNITION SWITCHES, MAGNET SERVICE PLANTS ,- The
magnet
service plant is supoUed with separate ignition toggle and start push but
jon switches. These switches can be mounted at any convenient point
where the operator will be able to know when the plant starts. Accidental
closing of the start switchwhile the plant is running may damage the
, starter. Connect the ignition toggle switch across the plant terminals
marked IGN. SW ,Connect the start switch across the plant terminals
marked START SW, Note that the center plant terminal is common to
both Circuits, thus permitting use of only three Wires. Use #18 or larger
"wire.
IGNITION
',,'
~
'I
_ I
. SW'TCH~
..
...
"
~-s~-,~~-~L,-•~I=======~~
FIG.",12 START & IGNITION SWITCHES, MAGNET SERVICEPLANT
WIRING, . - If ~ecessary to install wiring, follow specifications of local
and national electrical codes. If in doubt, consulia licensed
electrician, Use sufficientlyla.rge, insulated wire between the plant and
the load. Install a circuit breaker or a fused main switch in the load line
near to the plant. REFER TO THE APPLICABLE PLANT WIRINGDIA
GRAM.
Where connections are made by joining two wires, always be sure to
tape the connections thoroughly. Apply two layers of half-Iappedelec
. trician's tape and two layers of half-lapped friction tape, extending both
well beyond the ends of the connection.
The wire sizewill depend largely on the distance and permissible volt
age drop between the plant and the load and the amount and kind of load.
Consult a competenteiectrician. Check.national and local codes before
installing.
'
'cONNECTINGTHE LOADWmES, MAGNET SERVICE. - The magnet
service
.
plant has generator leads marked A1, F2, and A2. extending into the
outlet box. Connect the voltage control rheostat between leads F2 and
A2. Connect the magnet (load) wires to generator leads A1 and A2.
AI-TO
~~~~~:_~~A2~~~~~~AT
..
CrAPE:
CONNECTIONS
F'IG. '13 LOAI1WIRES~MAGNET SERVICE
PLANT
J'1
INSTALLATION
"'YVE~i:Ndi~~£'t
·'c·ll?,;VQLT
Ihlit)T PowerFlv:for, . 4~Volt~ieDrQP(2. 3 Voils}
. WIRE SIZ/i;:NO.
Watts
Amps
100
200
1.74
SOO
2:61
'l0!)
500
'750
3:'l8
4.·35'.
1.000
,1\100
2000'
2500
50.00
,87
6.52
14
510
;!51l'
610
40li
170 '.' 270
121). 200.
.•. 10°5',.:
8.6~
6
1?8.0, '. .2040
3.250
5300
840. ..1020
'430.. · 660'
32'0, 510
1625
1080
2650
1770
650
430
i06o'
710
1 0~,0 ·",·.:,." ."'c.,.'.'.'."',".. ·179"
255, 410
275
50
89;\." 125
)3,04
17,38
35
25
5r'
21,n
5P;:
65
65
20
"".:35'
50
43.36
25
SIO
80
325
215
160
"130
40
6(i
205
140
100
1325
6209
4100
2730
20ljO
1640
1090
820
530
350
265
210
550
410
350
105
160
... 4pove fIg)lr~sr~pZ;~!leHt,,~point to point di.~.tance for a 2 wire run. Ii 4%
. voltaged.r?p)g;:~~r'!lihl$l!l~~i double the distance listed. If only 1% volt
... Ilge
isallowilble,
gi;ri.ge
ti:l'!i':Q~Stances Hsteq by 2.
, '
.
. , . .'
. " ",
f··"
..
.
.
;~./.~ .'.~,','
; ·,Single
Pha~e 115YbitA.C.~Use·115 Volt table'above.
'SIngle P/1I!.se 11'\)':239 Volt, A. C. 3 Wire - U~.e 115 Volt table above for
e~h 115 Volhircuit. .
....
.
.\
SIngle Phl1,.~e, 230 VoltA, C. - Do~ple t1).e dIStancel3 listed In the 11(; Yolt
t;J,ble abOVe,' Use Alnps Col~inn.
.
Three P)1alSe 230. Volt circuit ~ MultIply tile qi.stances In the 115 Volt Table.
by 3-1/4 fqr Jj)e 1il!).1ne load. yse the Amps Column.'
.
CONNECTING THE LOAD WIRES, AC REMOTE PLANTS. - The ac
loadter~
minals arejocated.in,Sidetlie.gOl1trol pox andare marked. Th~ same
marklngl?Jtppearon thewi~ing,4iagl;'am. These terminals are oftha
sOldetle$~tY1J(3anq,qQ;I1p;(j)~tioIlsaremade by simply .inserting the end of •.
.the .load Wire: into the~pnne(ltQ:r"AAd-tightening the s(lrew. Thoroughly .
strip 1/26f aninchQf'"ins:!J~ation.:from the end of each wire before msert...
ing lfintbate"minal!~;,;Hoa4w~tii:s.:ent~r the (lontrolbox: throl-lgh a gram".
:meted hole •. ;aa su:re~,c9PMetioIis ar~ clean and tight.
.
.Leave tbelo~q.lines:wttFhj~p:!inllntil the plant Ms been started j;l.nd .
cheCked. Nodamag~;"tR."
. ~nerat()r or Controls
ning.the
plant
with
Do'lQa,
:nnected.
'
' . . '
wm resJ,1ltfrpm run..
",~~:,~,
. 1 Phase, 2 Wir~ ~ ~C;. Remote .
.. On singlephase,iwo Wi,Ta pU:mts., .c,Pllnectthe load wires to the plant I)y'
connecHng the(grQ!lnd;~;(wlt;U§1)..lo,~4:wipet9the cOntrolboz terminal .
mark~d "M2'·. 'Connectthe"'hptt',4ngrpunded(black) load wire to tn(3"
controlboxterroinalJn:arked. 'ilVP:". .
..
.
:-\
18
INST ALLATION
SINGLE PHASE;TWO WI RE CON NECTIONS
t:11'l..~----!ct'.- CONNECT GROUNDED (WHITE> SIDE
OF LOAD CIRCUIT HERE (M2>
REMOTE
PLANTS
ECTUNGROUNDED (BLACK) SIDE
OF LOAD CIRCUIT HERE (Mil
CONNECT GROUNDED (WHITEl
5.1DEOF LOAD CIRCUIT TO
. LEAD MARKED M,;;
MANUAL
PLANTS
240V.
REMOTE
PLANTS
MANUAL
PLANTS
120 V,
240V.
120\1.
240 V.-I PH.
REMOTE
PLANTS
240 V.
lPH.
ifiZl;::.....r-_-+240V.
3PH.
FIG. 14 - AC LOAD WIRE CONNECTIONS
240 v.
I PH.
INSTALLATION,
19
1 Phase, 3 Wire -AC Remote
On single phase, three wire plants, connecttheloqR,.,y-*esto the plant
by connecting the ground (white) load wire to the ,eonlrol box terminal
marked "M2". Connect one of the ';hot" ungroundeci'(bfack) load wires
to the control box terminal marked, "Ml",and conn~d.theremaining
"hot" ungrounded (black) load, wire to the controlbo]i::tEirminal marked
"M3".
' """
Two 120 volt circuits are available. One circuit across "MP' and "M2"
and another circuit across '1M2" and "M3". The load on each i20volt
circuit should not be more than 1/2 th~Sl!pacity of thepiant.
One 240 volt circuit is available. This circuit is across "Ml" and "M31t •
"M2"is ,not used with a 240 volt circuit. If only 240yolt current is used,
the full ratedcaP!lcity of the plant may be used. '
Both 120 volt current and 240 volt current may beused at the same time.
However, the total of either 120 volt load plus 1/2 the 240 volt load
should not exceed 1/2 the capacity of the plant. For example: a total of
2500 watts isavaUable oneach 120 volt circuit of a 5000 watt single' phase
3 wire plant. If2000 watts ofcurrent~s used on eith~r 120 volt circuit,
only 1000 watts of 240 volt current can be used at the s~metime. ,To de
termine the current available on each 120 volt circuitwhenthe 240 volt
load is known, subtract the 246 volt load from the plant: rated capacity
and divide the remainder by two.
3 Phase, 3 Wire,:, AC Remote
For three phase current, connect onEiloadwire to each of the three
generator terminals "M1"j "M2", and "M3".If a testrtin indicates
wrongrotation of 3 phase motors in the load circuit,:reverse the con
nections ',at any two generatorteI'minals.,
<-..
,
'
. .
,
!
Single phase current can be obtained between any two terminals. Three'
.such single phase circultsare th1;tsa.y~ilable: "Mland M2", !1M! and
Msn, !1M3 ,andM2!1.NotmorethanQ.n,~thirdthecapacityof the gen
eratorisavailable on each singlephase:~ircuit.
." ,
If both single and three phase current is used attl1e .same timet use .' ..
care not to over-load any. one ·ofthe single phase cttcllJts. Subtract the·
amount of the three phase load from the. rated capacity of the generator.
Dividetheremaillder :by three, todeterminethe an)ountof single phase
load which may be connected to eachofthel3ingleph~se circuits.
4WirePl~nt
;.. AC.Remote
The four wire plantJs designed toproduc;e.$ingleph;ise cur~entof. one
voltage, and three phase c,urreritotdifrerent'vol,~age. As indicated on
the plant nameplate, thesingle.phasecurrel)t is the lower voltage, and.
20
INSTALLATION
the three phase current is the higher voltage.
F'or single phase current, connect the "hot" load wire to anyone of the
terminals "Ml" ,"M2", or "Ma". Connect the ground (white) load wire
to the terminal marked "MO". Up to one thixd the rated capacity of the
generator is available on each sihgle phase circuit, if no 3 phase load
is connected.
For three phase current, connect the "hot" load :wires to the terminals
marked "Ml'.', "M2", and "M3", one wire to each terminal. Connect
the ground load wire, if used, to the plant terminal marked "MO".
If both Single phase and three phase current is used at the same time,
use care not to over-load .any one of the single phase circuits. Subtract
the amounfof the three phase load from the rated capacity of the gen
erator. Divide the remainder by three to determine the amount of single
phase load which may be connected to any single phase circuit.
CONNECTING THE LOAD WillES, AC MANUAL PLANTS. - Manual
type plants
have generator output leads which extend into an outlet box. Connections
to the output leads.may vary between different installations: The user
should instal! a circuit breaker or a fused switch in the main load line
to provide for automatic disconnecting of the load.
If the application is essentially stationary, the tiser may desire to con
nect the load leads within the outlet box on the plant, using bolts or con
nectors and taping each lead. If the main load lines are to be run in ri
gid condUit, install a short length of flexible conduit between the outlet
·box and the rigid conduit. Flexible conduit may be used entirely if so
desired. If conduit is not used, install a Romex connector, or a simi
lar load conductor securing device, to hold the load wires where they
enter the outlet box.
.
Manuai type pla:ntshave marking ("M!", etc.) on the generator leads
which correspond to the. same markings on the control box output ter
minals of the f8mote type plants. The. instructions for connecting the
load wires are not repeated here. Please refer to the instructions
· CONNECTING THE LOAD WillES, AC RE.MOTE PLANTS and select the
.paragraphs which apply to the model in question.
CONNECTING THE LOAD WillES, AC PORTABLE PLANTS. - The port
able type
plant is designed for applications which require plant operation at var
· ious locations. These plants have outlet receptacles of the grounding
type which serve for easy connection and disconnection of the load·,
Matching electrica,l plugs or caps must be provided on the load wires.
21
FIG. 15 - LOAD RECEPTACLES", PORTABLE
PLANTS
-.
.
.
GROUNDING, ALLFLANTS. :.. If grounding is. called for in localelec~
.
tr\cal codes, or if radio interference
necessitates it, provide a separate ground. Also the operator will de;'
sire to protect himself from possible dangerous electrical shocks by .
grounding the generator plant and branch circuits. Radio interference
may result if the plant is groWlded to a water pipe or to agroWld used by
a radio. Drive.a 1/2" diameter rod or pipe into the ground as near to
the plant as possible. Make certain that the groWld rod will always pen
etrate moist earth. Fasten an approved groUild clamp to the rod. Run
a wire (number 8 or larger) (never smaller than 2. sizes smaller than
the largest wire used in the system) from the clamp to the pla.J?t ground
terminal. If no separate groWlding term,inal is provided on the plant,
connect to the BATTERY NEGATIVE or to the grounded load line wire•.
•The installation must be mechanically secure,and must havelowreslS
tance electric. C
. with national and ·local electrical
GROUNOING ROD
SHOU\.OSE AS
C\.OSE TO P\.ANT
AS PRACTICA\.
ATTACH GROUNDING
WIRE TO ROD. WITH.
. AN IMPROVED TYPE
OF C\.AMP
FIG. 16 - PLANT
DRIVE ROD
INTO MOIST
EARTH
22
. INSTALLATION
REMOTE CONTROL SWITCH, AC PLANTS. - One or more remote con
trol switches may be con
nected to provide remote control of starting and stopping remote plants.
The wire length from the plant to the switch dete.rmines the wire size
necessary. For distances up to 250 feet use #18 wire. Use #16 wire
up to 400 feet, or use -#14 wire up to 630 feet.
.
The four place terminal block, located in the control box, is marked
"REMOTE CONTROL", B+, 1, 2, and 3 appears in the illustration. Ter
. minal number 1 is used as ,a common ground, terminal number 2 con
nects to the stopping circuit of the plant and terminal number 3 connects
to the starting circuit of the plant... The terminal marked B+ , is to be
used only wUhan automatic control installation.
Connections for two styles of momentary contact toggle switches for use
as Remote Start-Stop Stations are illustrated. Connect:aU number "2"
or "OFF" switch terminals to the number "2" terminal on the planttet
minal block. Likewise, connect together all number "3" or ~tON" ter
minalsand also, aU number "I" or "SINGLE"(not marked) terminals.
If the switch is to be mounted vertically, start position should be upward
. to conform with
at the
when a
is used.
(TWO
S7VL£SOF MOM£N7ARY CONTACt
FIG. 17 - REMOTE START-STOP STATIONS
SEPARATE F:UEL TANK. - The separate fuel tank has a capacity of 5
gallon (U. S. Measure).
Install the fuel tank so that the bottom of the tank will be less than 4 feet
below the fuel pump. The top of the tank must not be above the fuel pump.
Refer to the Typical· Installation illustration.
Follow the instructions supplied with the fuel tank and cap, according to·
the installation requirements. Connect the pipe thread end of the fuel
line to the fuel filter and bra.cket elbow.
INSTALLATION
Note that one end of the shorter flexible fuel line has a swivel connecto;
fitting, and the other enq. is solid to the line. Connect the solid end to:
the filter outlet, and the swivel end to the fuel pump inlet. Take caret£>
startthreads straight. Thethreads on the two ends are different and
may be damaged if the ends are reversed.
UNDERGROUND FUEL TANK.- Comply with local codes governing un.;.
derground gasoline tank installations~
If the fuel lift for the fuel pump on the engine is greater than the recom
mended maximum of 4 feet, then an auxiliary electric fuel pump shoulp
.be installed ahead of the engine pump to provide a dependable supply of
fuel.
FUEL RESERVOm (DAY) TANK. - In standby service, the generating
plant may stand unused for many·
days ..In this period of shut-down, .sufficient gasoline may evaporate
from the carburetor to lower its fuel level considerably. Prolonged
cranking may therl be necessary in order to pump enough gasoline into
the carburetor for the engine to start. On installations where automatic,
unattended starting after extended shut-down is necessary,an auxiliary,
gravity feed fuel tank~should be installed, FueI'irom this tank flows by
gravity to the carburetor ,thus replacing any fuel lost through evapora
. Uon andpromotes quick starting after an idle period.
Note: Return line to underground
tank must be larger than supply
line to fuel pump .inlet.
Jl£Nr C>4P -h-iol-F
fiN$i>41.!. AiU>4sr
3 FEEl 7fllOV£ rH£
K'ESERVOIR rANK)
I
VENr1.lAl£ ro £%i£RIOI(
OF Ei'UI'i.l?I·M?,
~"~U'E~
FIG: 18 -
F\lE~ RESERVOIR "DAY"
TANK
r
1
\
'
/
CARRYING FRAME (OPTIONAL ACCESSORY ). - The welded tubular
steel frame is stand
ard equipment on the portable type plants. The frame may be added to .
the manual or the remote type plants but. it does not provide for the se
parate fuel tank or for the remote-starting batteries. Use the existing
. mounting cushions and spacers, Usea bonding strap or other suitable
grounding conductor between the plant and the carrying frame.
..
2-WHEEL DOLLY (OPTIONAL ACCESSORY). - The dolly is designed
t6 assemble to the
carrying frame as furnished on the portable type plant. The dolly has
.i
i
f
24
INSTALLATION
semi-pneumatic tires and adjustable folding handles with hand grips.
READI-PULL STARTER. ,.. Refer to the separate section in this publi
cation for installation, operation and main,..
tena:h~e of the Readi-Pull rope recoil starter. The starter may be
positioned in various directions of rope pull as illustrated under MAIN
TENANCE AND REPAIR.
The air housing on vacuum-coole.RIME FUEL SYSTEM
PRESS START BUTTON OR PULLREADI-PULL STARTER
I
~.•.
FIG. 26 - STEPSTO FOLWW INBTARTING THE PLANT
I
I
ABNORMAL OPERATING CONDITIONS
35
Abnormal operating conditions are those elements and ambient tempera
ture!? to which a generating set may be exposed and which tend to shorten
the lifetime of the component parts of the machine. Subzero tempera
tures, equatorial exposure, and extremely dusty atmosphere are typi
cal examples. The following preventive maintenance should be performed
to help avoid unnecessary breakdown of equipment.
.
LOW TEMPERATURES
LUBRICATION. - Directions for the proper grade of oil to use in cold
weather are given in the PREPARATION section.
When changing oil in cold weather, be sure to drain the oil only' when
the oil is warm from running.
If an unexpected drop inthe temperature causes oil in the crankcase to
become too thick to run freely from the oil drain, do not attempt to
start the plaht. If the plant is started when the oil is congealed, serious
damage may result from improper lubrication. Remove the plant to a
warm location, or. apply heat externally until the oil is sufficiently warm •.
FUEL.... Fresh winter grade, automotive type gasoline is an aid to start
lng in cold weather. Premium highly-leaded gasoline should
not be used. Keep gasoline supplies free of moisture condensatiQr,I-'!~".
Leave room in the fuel tank to compensate forexpanslon. ",',","
AIR CLEANER. ;.. The oil in the air cleaner should be the same ,""~U'l,,,":,.~
that used in the crankcase. If frost forms in
cleaner and reStricts theHow of.air, empty the air cleaner oil
rurlthe plantwlth the air cleaner dry. Refill the cup when temper
conditions again permit the use of oil in the normal manner.
.
IGNITION. - Cold weather starting is aided by a properly servicEld ig..
nitionsystem. See that the ignition breaker pOints are
clean and properly adjusted. Clean and adjust the spark plugs.
.)
BATTERY. - If the plant useS starting batteries, keep the batteries in
.I
.
a well charged condition. A discharged battery may freeze. !
at20 0 F. A fully charged battery will not freeze at -900F. If the plant ':1
is to remain in a cold location during an extended shut,..down period,
.: I
:;-:;,e 3t~~:;!~ery In a w.arm Plac. e....
Givet.h.e battery a freShe. nlng '.ha...rge.•.._..•.•. '.,1
ELECTRIC CHOKE. - It may· be nec.essary to readjust the electric choke .
.
. ' o n remote type plants for easier starting at lower '.
ambient temperatures. Refer to the ADJUSTMENTS s e c t i o n ' l
~.'
COOLING,- The flow of airto'theengiIie maybe partially opstructed .' .. . '."
to keep the engine at operating temperature, if desired.
,
However, use extreme care to avoid overheating.
36
ABNORMAL OPERATING CONDITIONS
HIGH TEMPERATURES
LUBRICATION. - In temperatures above 90 0 (320C.) for continuous
operation use SAE number 50 oil. Keep the oil level
close to the full level, and change the oil at least every 100 operating
hours.
.
COOLING. - The engine and generator of this plant depend upon a con
stant supply of fresh air for proper cooling. See that no
thing obstructs the circulation of air to and around the plant. Keep
cooling fins clean and unobstructed. Make Sure that the blower housing
and cylinder air housings are properly in place and are undamaged.
Keep the ignition timing properly adjusted.
BATTERY PREPARATION FOR REMOTE START AC PLANT. - For a
usual
plant installation, follow the instructions for Batteries under INSTAL
LATION.. However, standard automotive/type batteries will seU-dis- .
charge rapidly when installed where the ambient temperature is con
0
sistently above 90 F~, such as in a boiler room. Battery life is con
siderably shorter under such high temperature conditions. To lengthen
battery life, reducethe electrolyte from a normal 1. 275 specific gravity
reading at full charge, to a 1. 225 reading. Attach a tag to the battery,
noting that the specific gravity has been reduced•.
.:.,.:.','
'
..•. :::.:\;
the cranking power of the battery is somewhat reduced when its electro
lYte is diluted for longer life, but if the temperature is consistently high
the reduced power will not be noticed.
1. Fully chargethe battery. DO NOT BRING AN OPEN FLAME OR
BURNING CIGARETTE NEAR THE BATTERIES ON CHARGE BE
CAUSE THE GAS RELEASED DURING CHARGING IS VERY FLAM
MABLE.
2. While battery is on charge, use a hydrometer or filler bUlb to si
phon off all of the electrolyte above the plates in each cell. Do not
I;lttempt to pour off!! Dispose. of the removed electrolyte. AVOID
SKIN OR CLOTHING CONTACT WITH ELECTROLYTE.
3. Fill each cell with pure distilled water.
4. Recharge the batteries for one hour at a 4 to 6 ampere rate.
5. Use a reliable battery hydrometer, to test each cell. If the speci
fic gravity is above 1.225, repeat steps number 2, 3, and 4 until the
highest specific gravity r.eading ~f the fully charged battery is not
~ver 1.225. Most batteries reqUIre repeating steps 2 3 and 4·t
wo
times.
' ,
ABNORMAL OPERATING CONDITIONS
37'
DUST AND DIRT
CLEANLINESS. - Keep the engine as clean as practicable. Service the
air cleaner as frequently as conditions require. Keep
oil and gasoline supplies in air tight containers. Do not allow cooling
fins of cylinders or cylinder heads to become dirty or obstructed. Keep
the generator commutator, brushes, and brush guides clean.
LUBRICATION, - Change the crankcase oil every 50 operating hours,
.
instead of every 100 operating hours, during sever
ely dusty operating conditions.
"
Important!
,,4~GIVETHESE
NUMBERS
WHEN ORDERING REPAIR PARTS OR
REQUESTING SERVICE INFORMATION
fOR YOUR UNIT!
WRITE IN NUMBERS SHOWN ON PLANT NAMEPLATE
38
PERIODIC SERVICE
Follow a definite schedule of inspection and servicing to assure the best
. performance and long life of the plant. Service periods outlined below
are for average service and normal operating conditions. Under un
usual service or abnormal operating conditions, service the plant more
frequently. Keep a record of the hours the plant is operated each day to
assure servicing at the proper time.
DAILY SERVICE
If the plant is operated more than 8 hours daily, perform
the following .services each 8 hours of operation.
FUEL. - Check the fuel supply often enough to avoid running 'out of fuel.
NEVER FILL THE FUEL TANK WHILE THE PLANT IS RUN
NING. Use clean, fresh,regular automotive type gasoline of at least
68 octane rating. Use of a highly leaded premium grade of gasoline is
not recommended.
CRANKCASE OIL LEVEL. - R-emove the oil fill cap and check the crank
,. ,
case oil level. Add oil as necessary to
keep the oil level at the full mark on the gauge. Recommended grades
ofoil.ar~ "given underPREPAR~TION. Avoid overfilliilg whIch will
allow the connecting rod to strike the oil and cause oil foamlngwhich
interferes with efficient
lubrication.
.
.
"
~
~
The oil fill cap gasket must always be in· good condition and the cap must
always be securely tightened in place. Air leakage into the crankcase
at thigpoint 'Will cause oil carry-over at the breather , excessive oil con
sumptionand possible oil leakage around the seals.
AID CLEANER. - Turn the thumb screw, located at the bottom of the
air cleaner cup, out as far as it will go and remOve
the cup. Add oil as necessary to raise the level to the indicated level
with oUof the same SAE number as used in the engine crankcase, except
as instructed under ABNORMAL OPERATING CONDITIONS.
FIG. 27 - AIR CLEANER SERVICE
PERIODICSERVIC E
39
CLEANING. - A clean plant will give m::Jre satisfactory service. Wipe
off dirt and any spilled oil.
BI-WEEKLY SERVICE
If the plant is operated more than 50 hours weekly, per
form the following services each 100 hours of service.
CRANKCASE. - If using diluted oil, or highly le.aded gasoline, change
.
the crankcase oil each 50 hours of operation. Under
normal conditions and when using oil which is not diluted, change the
crankcase oil each 100 hours of operation. Do hot drain the oil when the
plant has been standing idle. Run the plant until the oil is thoroughly
warmed up, then stop the plant and drain the oil.
AIR CLEANER. - First remove the air cleaner oil cup, then remove
the air cleaner from the engine and thoroughly clean
them in gasoline or other suitable solvent. Allow the element to dry or
dry it with compressed air before reinstalling it. Refill the cup to the
level shown in the cup with oil of the same grade used in the engine
crankcase except as instructed under ABNORM..I\I,. OPERATING CON
DITIONS ..
GOVERNOR LINKAGE. - Put a drop or two of lubricating oil at the point
where the link engages the carburetor throttle
arm.
Lubricate the governor arm ball joint with a dry type lubricant such. as
powdered graphite to assure best performance and longest life of the
ball joint. If graphite is not available, use a light non-gummy oil.
SPARK PLUGS. - Clean the sparkplugs and reset the gap as given in
the Table of Clearances! Test the. plug under com
pression on a plug testing machine, if one .is available. Replace a de
fective plug with a new one.
BATTERY. - If the plant uses a starting battery, keep the connections
tight and clean. Keep the electrolyte at the proper level
above the separators by adding clean water. Distilled water isrecom
mended for use in batteries. If distilled water is not obtainable, use
clean soft water such as filtered rain water. Do not use water which
contains alkali or minerals. Use a hydrom,':?ter to cl1eck the charge con
dition before adding water. In freezing weather, add water only before •.••.. . .
running the plant, to assure mixing the water with the electrolyte.
4:
J
DOLLY WHEELS.- The bearings of some of the doUywheelsare lub
.
ricated through the Zerk fittings on the hubs. Use
an approved wheel bearing lubricant-One or two shots from'a high
pressure gun will usually be sufficient.
.'.
..•.•....
,.. .
40
PERIODIC SERVICE
MONTHLY SERVICE
If the plant is operated more than 200 houts monthly, per
form the following services each 200 hours of operation.
FUEL SYSTEM. - On plants with a separate fuel tank, drain the fuel
tank and remove the shut-off valve and filter assem
bly. Carefully clean the filter screen. Tighten connections well when
reassembling. Empty the fuel filter bowl of any sediment which may
have accumulated;
BREAKER POINTS. - Remove the breaker_box cover and inspect the
breaker points. .If they appear to be too. badly
burned or pitted, discard them and install a new set. Dress the old
. points with a fine stone providing they still appearsel'vlcable.
Adjust the bre.aker point gap tb O. 020 inch at lull separation after dres- .
sing the points or changing them, Place a drop of light lubriCating oil
on the breaker arm pivot after installing new points.
The ignition condenser is faulty and should be replaced if thefollow1rlg
conditions persist: (1) ExceSsive arcing at the breaker points;
(2) Breaker points continually burn over; (3) Yellow colored spark at .
the points,
PLACE A DROP OF" LIGHT OIL
ON BR.EAKER ARM PIVOT
EVERY 1200 OPERATINGr-:,,-,,:,+~====::::--.
SET BREAKER
POINT GAP
WIDTH AT
TO ADJUST GAP
LOOSEN SCREWS
~Ab.TURN CAM-S"
I!ETJGHTEN SCREWS
THESE SCREWS MUST BE LOOS
ENED TO ADJUST POSITION OF"
THE BREAKER EOX WHEN
SPACER IS NOT USED,
"'-----"'---LOOSENTHESE SCREWS TO AD
JUST POSITION OF BREAKER
EOX WHEN SPACER IS USED.
• ADVANCE
RETARD •.
FIG. 28
- SERVICING THE BREAKER POINTS
EXHA UST SYSTEM, - Inspect all exhaust line connections carefully.
Make any necessary repairs or replacements.
PERIODIC SERVICE
41
CARBON REMOVAL. - Regular removal of carbon deposits from the.
comhustion chamber helps to keep engine effi
ciency high. Thefrequency with which it is advisable to remove carbon
will vary considerably with the type of fuel used, the type of oil used,
and operating conditions. Use of highly leaded gasoline necessitates
frequent removal of'carbon and lead deposits from the cylinder head,
top of piston and valves, and top surface of the cylinder block.
VALVE GRINDING. - Valve grinding is a service that should be done if
your plant is to continue running efficiently. When
ever the engine begins to lose power or to use more fuel or oil than it
normally does, check the compression to determine the need of repairs.
Check the compression of each cylinder with a reliable compression
gauge while the engine .is 'still warm and as soon after stopping the en- .
gine as you can. The compression of each cylinde;r in a new engine at
sea level is about 90 lbs~ at hand cranking (105 lbs. elec. cranking)
speed. Compression readings of the cylinders should be within 10 lbs.
of each other and high enough to assure no loss of power. A low com':'
pression reading may point to a poor valve condition, worn or sticking
piston rings, worn piston ring grooves, or worn cylinder walls, An
excessively high compression reading may point to a heavy carbon for
mation within the cylinders.
If readings indicate a compression loss,' remove the spark plugs and
squirt only enough SAE number 50 au into each cylinder to seal the
rings. Take the compression readings again. If the readings remain
about the same, the valves probably need servicing. However, if the
readings have increased quite a bit, the valves are probably in good
condition •
. Loss of compression may be due to worn or sticking piston rings, worn
piston ring grooves, or worn cylinder walls. Follow instructions given
in the Maintenance and Repair sect~on when making repairs.
.
.I
CRANKCASE BREATHER VALVE. - If the engine begins to leak oil,
.
the valve in the breather tube may
besticking .. Lift the rubber cap from the breather tube. Then lift out
the valve and inspect it. Frequently the breather valve (check valve)
.!
will' lift off with and remain inside the rubber cap. Pry it out. First·
soak then wash the valve in kerosene or suitable solvent so thatthe disc
will work freely. Run the engine and hold the valve assembly in place
to prove it opens and closes. Replace a faulty valve with a new one. If
the metal mesh type baffle, used in the breather tube of later engines,
is completely restricted by sludge, etc., lift it out with a hooked wire, "
clean and reinstall it or a new one, leaving only 2-114" of empty space
. ._.••.. J
inthe top of the breather tube. Avoid crushing the baffle or allowing
.
shreds to fall into the crankcase. An internal retainer ring stops the .
baffle from falling through. Reassemble the valve as illustrated.
.1. .·
42
PERIODIC SERVICE
: BE SURE TUBE
NOT MAKE CON
TACT WITH VALVE DISC.
FIG. 29::':SERVICING THE CRANKCASE BREATHER VALVE
GENERATOR. - Check the condition of the commutator (and collector
rings onACplarits). Clean the brush contact surface
with a dry, lint free cloth, If heavily coated, or slightly rough, sand
smooth with4fOO sandpaper. Do not use emery or carborundum cloth
or 'Paper.
Install new commutator brushes and other rectangular brushes when the
old ones are worn t05 /8" or less in length.
.
See that all connections are tight. Remove carbon dust from the gener
ator.
NEUTRAL BRUSHPOSITION.-Brushes will arc excessively and brush
wear will be rapid if the btushrig is
moved from its original "neutral" position as marked at the factory.
CAUTION
If a new armature or brush rig is installed, the "neutral brush position"
mu,st be re-Iocated and re-marked. Neutral brush pOSition is that point
at which the least arCing of the brushes occurs.. Ifa voltmeter is avail
able, the brush rig should be set at the point where highest voltage is
generated. If a voltmeter is not available, set the brush rig at the point
. where the brushes show the least arcing.
GENERATOR BEARING. - The generator bearing is pre-lubricated
and sealed. It requires no periodic ser
vicing during its service life.
ADJUSTMENTS
43
GENERAL. - Generating plant satisfactory performance is dependent
upon correct adjustments. Adjustmehtscan not fully com
pensatefoI' troubles such as low engine power due to engine condition.
GOVERNOR AND BOOSTER ADJUSTMENT. - The governor and booster
controls. the speed of the
engine. A speed fl-djustment includes adjusting both d.evices. Refer to
the Governor and Booster illustrations.
Carefully study the related subj ects in the following paragraphs and
.
check each point in the order given before attempting adjustments on the
governor:
.
'
1.. GENERAL. - Before making final governor adjustments, run the
plant about 15 minutes under light load to reach nor:"
mal operating temperatirie. (If the governor is completely out of adjust
ment, make a preliminary adjustment at no load to first attain a safe
voltage operating range. )
.
On a c generating plants,engine speed determines the output voltage
and .current frequency of the generatqr.. By increasing the engine speed,
generator voltage and frequency is in~reased, and by decreasing the en
gine speed, generator voltage and frequency is decreased. An accurate
voltmeter or frequency meter (prefetably both) should be connected to
the generator output in order to correctly adjust the governor of the a c
plant. A small speed drop not noticable without .instruments will result
in an objectionablevoltagedrop. The engine speed can be checked with
a tachometer.
The governor arm is fastened to a snaft which extends from the gear
cover, and is connected by a ball joint and link to the.carburetor throttle'
arm . .Flyballs behind the cup on the; camshaft gear, actuate the gover
nor arm. If the carburetor has been removed, or the governor disas
sembled, it maybe necessary to readjust the governor.
The'speed booster is a separateauxUiary device which supplements the
function ·of the governor ; The speed booster is adjusted to increase gov
ernoraction as the load on the generator is increased. The booster
serves to maintain or increase the speed at the higher loads. This re
sults iIi more nearly constant output voltage.
'
The booster is mounted on the intake manifold and is operated by engine
'1':'"!
vacuum through a small passage in the manifold. When the plant isop- . i .•.
erating at about half load or less, theenginevacuumissufficiel1t to
...... ',
cause the' diaphragm to overcome the tensiOll of the internal booster'
1
spring. Under these coriditions, there is no tension on the booster e}"1er- . . ~
..i'."!
nal spring and the'boosterdoes not affect· the governor operation.
.~
44
ADJUSTMENTS
As the load on the plant is increased, the engine vacuum becomes less,
and booster internal spring tension overcom~s the pull of the diaphragm,
and tension is put on the booster external sptiIig. The tension on the ex
, ternal spring "helps" the· regular governor spring in its function, thus
causing a slight increase in engine speed as the load is increased.
A binding inthe bearings of the governor shaft, in the ball joint, or in
the carburetor throttle assembly will cause ~rratic governor action or
alternate increase and decrease in speed (huhting). A lean carburetor
adjustment may also cause hunting. Springs, of all kinds have a tendency
to lose their calibrated tension through fatigue after long usage. If all
governor and carburetor adjustments are properly made, and the gover
nor action isstiU erratic, replacing the spring with a new one and reset
ting the adjustments will usually· correct the ,trouble.
2. STEPS TO FOLLOW. - This gives tlie p~ocedure only briefly. Refer
to the details on 'eac.hsubject herein.
.
.
a. Adjust the carburetor main jet for the best fuel mixture while oper
ating the plant with a full rated load connected.
b. Adjust the carburetor idle needle with no load connected.
c.Adjust the length of·the governor linkage.
d, Check the governor linkage and throttle shaft for binding or exces- .
sive looseness.
e, Adjust the governor spring tension for rated speed at no load opera
tion with booster disconnected (or held inoperative).
f.Adjust the governor sensitivity. .
g. Recheck the speed adjustment.
h. Set the carburetor thr6ttle stop screw.
i. Setthe vacuum speed-booster.
3. LINKAGE. - The engine starts at wide open throttle. The length of
the linkage connecting the governor arm to the thr'otUe
shaftand ievertsadjusted by rotating the ball joint. Adjust this length
so that withthe engine stopped and tension on the governor spring, the
stop on the. carburetor throttle shaft just contacts the underside of the.
carburetor bowl, as illustrated. ,This setting allows immediate control
by the governor after starting. It also synchronizes the travel of the .
. governor arm and the throttle shaft.
4. SPEED ADJUSTMENT. - With the warmed-up plant operating at no
load, and with the booster external sprIng
. disconnected (or otherwise held inactive), adjusUhetension of the gov,..
ernor spring. Refer the Voltage Chartand the Speed Chart and select
theeolumn which corresponds to thenaineplate of the plant in question.
Turn the speed adj usting nut to obtain a voltage and speed reading with
in the Hrriitsshown.
.
A D.JU S T M EN 'tS
CARBURETOR THROTTLE PLATE..
.
rn
L.-..J
\.
SCREW~ ....
.s\~
. . ~.C1
THROTTLE STOP
GOVERNOR CUP
GOVERNOR
SHAFrYOl"-E
FIG. 80 - GOVERNOR ADJUSTMENTS
A'6~ACKEl"
E"'SRACKET
S-LJNK.
C-SPRING.
"-$PRING
C" DIAP.HRAGM
F- pIN
ClNCL.Ut>tS H·)
H-l.EVER
.
46 '
·AD JUS TM.E N TS
.
.
VOLTAGE CHART FOR CHECKING GOVERNOR REGULATION
DIRECT CURRENT
TYPES OF PLANTS-·- - -........1
U5
VOLT
DC
250
VOLT
DC
·.MAGNET
SERVICE
. Maximum No Load Volts .
Minimum Full Load Volts Without Booster
Maximum Voltage Drop Froin No, Load to
Full Load
.
.30
..
preferred Voltage Regulation, :No Loa.d.to
Full Load
.
120- no
265-245
Preferred Voltage Spread
20
SPEED CHART FOR CHECKING GOVERNOR REGULATION
DC
250
VOLT
MAGNET
SERVICE
2000*
2000
t
*
1800
t
DIRECT CURRENT .
TYPES OF PLANTS-----~ 115
VOLT
. Mjlximum No Load Speed
··RPM (Revolutions Per Minute)
Minimurn·FullLoad·speed Without Booster
RPM (Revolutions per Minute)
1800
Maximum speed Drop From No Load
Operation to Full Load Operation .
RPM (Revolutions Per Minute)
200
Note
NQte
*
t -
200
For models Prior to Spec "D", speed is 2400-2700 rpm.
For m odelspriortd S.pec "D'\ .speed is 2 500-2750 rpm.
47 '
ADJUSTMENTS
VOLTAGE' CHART
FOR CHECKING GOVERNOR REGULATION 7 '
..
'
ALTERNATING CURRENT
TYPES OF PLANTS
..
NOTE,,: Output rating is at UNITY powerl
factor load
'
,I
I
Maximum No Load Volts
,
120 VOLT,
1 PHASE,
2 WIRE
OR
120/240 V.,
1 PHASE,
3 WIRE
240 VOLT"
1 PHASE, '
2 WIRE
OR
240 VOLT,
3 PHASE,
3 WIRE
126
252
110
' 220
16
32
,
Minim.um Full Load Volts Without Booster
Maximum Voltage Drop From No Load
Operation to Full Load Operation
'Preferred Voltage Regulation, No Load
to Full Load Operation
Preferred Voltage Spread
118-114
4
236-228 '
8
SPEED CHART FOR CHECKING GOVERNORREGULATION-,
ALTERNATIN~
CURRENT
TYPES OF PLANTS
....
I
I~
FOR ALL
60,CYCLE
PLANTS
FOR ALL
50 CYC.LE
PLANTS'
Maximum No LoadSpeed
RPM (Revolutions Per Minute)
Cycles (Curren(Frequency)
1920
64
1710
57
Minimum Full Load SpeedWithQut Booster
RPM (Revolutions Per Minute)
CyCles (Current Frequency)
1710
, 57
1500
50
90
3
90
3
Maximum Speed Drop From'No Load
Operation to Full Load Operation
RPM (Revolutions Per Minute)
CyCles (Current Frequency)
Preferred Speed Regulation, No Load to
Full Load Operation
,1lPM (Revolutions Per Minute)
Cycles (Current Frequency)
Preferred Speed Spread,
RP M(RevolutionsPerMinute)
Cycles (Current Frequency)
1830-1770
61-59
1590..1530'
, 53-51
60
60
'2
2
48
ADJUS TMENT S
5. SENSITIVITY ADJUSTMENT. -Refer to the Govern()rAdjustment
. illustration, 'and to the Voltage and
Speed, Charts. ,Check the voltage and speed, first, with no load conne.cted
and again with, a full load. Adj.ust the sensitivity so as to give the closest
regulation (least speed and voltage difference betweenno load and full
load). without causing a hunting condition.
To increase, sensUivity(Closer regulation),shUt the, adjusting clip to
ward the governor shaft. On earliermodeIs, prior to spec. D, turn
the adjusting'stud,c(>unter(!.lockwise. .An adjustmentiortoo much S4:lrult
tivitywiU. cause· alternate increase and decrease.ofengine speed (hunting) .
.
.
.
, To decreasesensitivity,shift the adjusting clip toward the outer en(iof
the governor arm. On earlier modeIs turn thea.(ijusting stud clockwise.
Too little sensitivity will result in too much difference in. speed between "
no load and full load conditions. '
'
Any change inthesensiti~tyadjUstment usually requires a compensat
ingspeed (spring tension) adjustment.
6. THROTTLE STOP SCREW.- The throttle Jeyerstop Screw should
'.
' b e set at 1/32 inch distance from the
manifold w1j:entheengine is operating with no load connected. Refer to
theillust:ratian,'Throttle Stop Leyer Position.
IOLING'POSITION
'FIG. 32 .:THROTTLE STOP LEVER POSITION
l
7. SPEED-BOOSTER ADJUSTMENT. -After satisfactory perf()rmance
unde.r variou$loadshas been
attained by governor adjustments without the booster, thebo0ste:t.can
be connected. Connect the booster external spring to the brJlcketon
the governor link (rod)•. With the plant operating at no load,i slide the
bracket on the governor link just to the position where there' is no ten-·
sion on the external spring.
;
'APPly a full rated electrical load to the generator. The output voltage "
should stabilize at nearly the same reading for fulUoad as for no load
operation. The speed may remain about the same .or increase 'when the
~
load is applied, resulting in a frequency 1 or 2 cycles HIGHER THAN'
, . the no 'load frequency. (1 cycle is equal to 30 rpm [ora 4 pole genera
tor.) If the rise in frequency is more than2 cycles, lessentheinter~
.l
ADJUSTMENTS
naLsprtng tension. If there isadrop. in the frequency, increase the,
booster Internal spring tension. To increase the tension, pullout on the
spring bracket, and move the pIn to a different hole.
With the ,booster disconnected, a maximum drop of 3. cycles from no load
to,£un load is normal. With the booster in operation a maximum IN...
C~E,ASE of 2 cycles from no load to full load is normal. A drop of 1 '
,cycle at 1/4 load is permissible, giving an over all spread of 3 cycles,
ma:ximum.
'
.
,
The.effectofthe booster is limited by the general condition of the engine.
The booster can not compensate for a loss in engine vacuum caused by
leaky valves, wornpiston rings, etc,
The, . b oosterrequires little maintenance other than using a fine, wire to
clean the small hole in the short Vacuum tube which fits into the hole in .
thetop.of the engine intake manifold. Do not enlarge this hole. If there'
is'tensicm on the' external spring, when the plant is' operating at no load
or light load,it maybe due to improper adjustment; restrictedho},ein
the small vacuum
or a leak in the booster diaphragm or gasket.
'tube,
.
'
'
OILPRESSURERELIEF VALVE ADJUSTMENT. -
.:,\".,.::-,
,'._.'..;,;,
Th~r()UPtessur,e of
the, plalltcallbe .
easily adjusted by means 'of the slotted stud and locknutlonaied just be
low the governor Unkage, as illustrated, Oil pressure reading when the '"
plantlsthoroughlywarmedupisfrom 25 to 40 pounds. To increase' ,
oil pressure;"loosen the locknut and turn the stud in. To decrease oil
pressure, loosen the ,locknut and turn the stud out. Be sure to tighten,
the,Jockmitsecu:re~y after, making art adjustment.
Lo~oiLpres:sure may point to worn or poorly adjusted main or con
neclingrodbearlngs,a weak or broken by-pass spring, a defective
gauge or a poor adjustment. Check the oil pressure gauge before mak-,
ingany other test, it may be defective.
FIG.SS -OIL PRESSURE RELIEF VALVE ADJUSTMENT
ADJUSTMENTS
GARBURETORADJUST:MENTS, GASOLINE... The carbl!.retor has ad
justable main and idle
needle valVes. Refer to the illustration, Carburetor Adjustments. Dur
. ing the test run of a. new generating plant; the factory performs carbure
tor adjustments which under normal circumstances should not be dis
turbed.Thecarburetor is simple in construction and normally needs
little attention other than aperiodic cleaning, as instructed under MAIN
TENANCE AND REPAlR. .
The c.orrect setting for themairi jet needle gives the best stability at
full rated load ()peration~· The main needle setting will be about 1-3/4
.. turns open.
.
f
(
The correct setting for the idle needle gives the best stability at no load
operation. The idle needle setting will be about 1/2to 1 turn open.
Before tampetingwith jet settitlgs, mark the existing adjustment or
countthe number of turns the needle WaS backed out from its seat.
:NEVERfOI'ce the needle against its seat more than fffinger tight l1 betoo 't1o't'I'tl!u
If the carburetor IS entirely out of adjustment, open the main needle
. about 2turns and the idle needle about.1 turn, to permit starting. Make
final adjustments afte.t the plant reaches normal operating temperature.
To make the final adjusbnei:tt, slowly turn the main needle inward (clock-.
Wise) for leanetmixture, until the plant begins to lose speed, or the
voltage eh-ops.· Then turn the needle outward (counterclockwise) slowly
to the pomt where the plant will carry the rated lull load. Checkthe
operation at various loads. It there. is a teildency tu hunt (alternately
mcrease and decteasespeed) at any luad; turn the adjusting needle out
for richer fuel mixture, \illtilthe hunt iseorrecled,. but do not turn the
adjusting heedleoutmoI'e than 1/2 turn beyonq t:hepoint where maximum
generator outp.u.t ISobtaified. Make the flnaladjustmentofthe idle needJe
w~ile!hf:plantis.wal"'i.na.nd operating at no load. SlowlY lotn theld1e
.
a:dJustlngneedle .znward(clockwise) untll.the. plant loses SP~d from .
.'
51
ADJUSTMENTS
lack of fuel. Then turn the needle slowly outward until the plant runs
smoothly •
. A substantial change in a carburetor adjustment requires acompensat
ing adjustment of the governor speed.
.~
.
The throttle idle stop screw should be adjusted to clear the manifold "by
1/32" when theplant.isoperating atdesrredspeedand no load condition•.'
This setting helps prevent hunting during changes in .load.
.
J,;
.
.
CARBURETQR ADJUSTMENTS, GAS FUEL. -Whenoperatingongas .
...
fuel,foUow the procedure.given for gasoline fuel, using the gas fuel adjusting screwS. AI~
. ways be sure theearburetor choke. is locked in its wide open position.' .
.
.
ELEGTRICCHOKE ADJUSTMENT ,,- The a c remote control type plant
.'
.
.
.'.
.....
is equipped .with a thermal action.
electric choke. A thermostatic coil (bi-metal) engages the choke shaft
and is set at the faCtory to give the correct chOking action for average
temperature conditions. .When the plant starts, current from the gen
erator is supplied to a small heating element in thecboke cover. This
heating element causes the thermal coil to wind tighter and turn the
choke shaft, gradually opening the choke as the plant warms up. Wheu
the plant is 'stopped the thermal coil cools off, causing the choke shaft
. to·returnto the correct position for the next start.··
.
.
The thermal coil (bi-metal)is installed in the choke ·tlodyin.acounter
clockwise direction as viewed starting from the insid~ turn. The ther....
mal coil tends :to coil tighter· when heated,~ands in. cooling •. An in
.
spection .hole in the .circumference. of the· choke bracket (bousing)p~r"':
mitsinspection during assembly to see that. the fork of the choke co·V'~··l~;:'~;'Ji;h;il\t;1
straddles and holds the loop in the outer .coil of the bi-metal.
LOOSEN THESE
SCREWS AND
. ROTATE 'tHE
ENtIRE COVER
ASSEMBLY
FIG. 35 - ELECTRIC CHOKE ADJUSTMENT
Extreme temperature may require a slight readjustment of the choke.
setting, To adjlistthe choke, loosen the two screws which retain the
chok~cover to the choke body. For less choking action, turn the cover
al;!sembly sligbtly in a clockwise direction, . looking at the. thermal unit
end.· For more choking action, turn the cover assembly slightly ina
counterclockwise direction.
.
52
ADJUSTMENTS
Approximate settings for the choke are given in the following table.
TEMPERATURE (Degrees Fahrenheit) POSITION OF CHOKE PLATE
58
66
,72
76
82
Closed
1/4 Open
1/2 Open
3/4 Open
Wide Open
Successive trials at various positions are necessary to set the choke
the best pos ition ,at temperatures below 32 0 F.
at
~
Ii the choke does not operate properly, check to see that the heating
element heats- properly. There must be no binding of the chOke shaft
'or thermal coil. Eesure to retighten the lock screws after any adjust
ment.
Alqlohat the oppos iteend of the choke shaft, may beus-ed to manually
, operate the choke in the event the electric element burns out or the choke
does not operate for any reason. Turn the knoblIi the direction shown '
on the knob., If electric choke failure occurs, the choke will remain at
':>.;'U~h~'e~~ine start~;after 15:secorids ofc-:mnking and assuming thatfu"el,
,'ignition, andcomptession ar e adequate, but the engine sputters, 'spits
or stops before if warms up,then the choke is set too lean.
;
:;!
MAINTENANCE AND REPAIR
53
GENERAL.• Refer to the Service Diagnosis section for assistance in
locating and correcting troubles which may occur ~ If a
major repair or overhaul becomes necessary, the engine should be care·
fully checked and necessary repairs made by a competent mechanic.
Major generator repairs should be made by a competent electrician.
Maintain JactoryUmits and clearances as given in the Table of elearances,
replacing worn parts whenrtecessary. Avoid accidental shorts by dis
connecting the battery when servicing controlparts.
'
TABLE OF CLEARANCES
All clearances given at room temperature of 70 0 F .
. MINIMUM
MAXIMUM
Intake Valve Tappet Clearance at 700 F.
0.015"
0.017"
Exhaust Valve Tappet Clearance at 70 0 F.
0.015"
0.017"
Intake Valve Stem Clearance in Guide
0.0025"
0.001"
·0;004"
Exhaust Valve Stem Clearance in Guide
0.0025"
Valve Seat Width
3/64"
.1/32"
. 44 0
ValveFACE Angle
450
Valve SEAT Angle
Valve InterferenceAngle
10
Crankshaft Main Bearing Clearance
0.003"
Aluminum Alloy, Flanged - Prior Spec 'F' 0; 002"
0.0035"
"Bronze"Faced. - Begin model Spec "F" 0.0025"
0.012"
0.006"
Crankshaft End Play
0.Od3"
0.0015"
Camshaft Bearing Clearance
0.003"
Camshaft End Play
Connecting Rod Bearing Clearance .
0.002".
0.00.3"
. (Alum~ Rod)
0.002"
o.ois"
Connecting Rod End Play
0.003"
0.002"
. Tim ing Gear Backlash
0~005"
0.002"
Oil Pump Gear Backlash
. Piston Clearance in Cylinder ,Conformatic
Type (measured at bottom of skirt)
0.0005"
. Interference
0.0015"
Clearance
0
Thumb
Push
Fit
Piston Pin Clearance in piston at 70 F.
0.0001"
0.0006" ,
P iston Pin Clearance in Rod at 700 F.
0.010"
0.023"
Pif.tonring gap in cylinder
0.020"
Breaker Point Gap at Full Separation
0.018"
Spark Plug Gap - For Gaseous Fuel
0.025"
Spark .Plug Gap - 'For Gasoline Fuel
2.000"
Crankshaft Main Bearing J ournal·Std. Size 1,9995"
1.6260"
1.6255"
Crankshaft Rod Bearing Journal·Std.Size
3.249"
.CylinderBore.·Standard Size'
. 3.248"
.\
54
MAINTENANCE AND REPAIR
ASSEMBLY ·TORQUES
Assembly torques as given here require the use of a torque wrench.
,These assembly torques. will assure proper tightness without danger of
stripping the threads. If a torque wrench is not available, you will have
to estimate the degree of tightness necessary for the stud, nut or screw
being installed and tighten accordingly. Be carefut not to strip the
threads. Check all studs, nuts and screws often. Tighten as needed to
prevent them from working loose.
LB. FT. TORQUE
Cyliiider Head Capscrews ....•..............•
Rear Bearing Plate Nuts •...•.............••.
Connecting Rod Bolts ....... , ............•.•.
Flywheel Capscrew .......................... .
Armature thru Stud and Nut ...•............•..
Other 5/16 inch Cylinder Block. Studs and Nuts .•
25 to
18 to
29 to
40 to
45 to
10 to
30
20
:H
45
50
12
ENGINE
CARBURETOR. - CarbUretor maintenance should consist of regular
cleaning. Some types of gasoline have a tendency to
ward formation 01 gum deposits inside the carburetor. This gum for
maHon can usually be removed by soaking in alcohol or acetone. A fine
wire may be used to clean jets.
the float is not damaged. If necessary to reset the f1oan~vel,
a small screw drlv-er to bend the lip of the float, With the,carbure
toi: casting inverted and the float resting llghtly against the needle in its
. seat, clearance between the bowl cover gasket and the free end of the
float should be 5/16"(7/32" ifa "DAY" reservoir tank is used) •
. Carburetor adjustments appear inthe ADJUSTMENT section herein. Be
slire the throttle assembly works freely. When reinstalling adjusting
needles, do not force them into their seats.
MAGNETO STATOR INSTALLATION . .., The magneto stator assembly
is mounted on the gear cover
andtheflywheel must be removed to expose it. ThE? st::tl~r has 2 pairs
of mounting hales. The innermost holes give 19 0 sparkadvance as re
quir~d for engines with speed range of 1500to,2490.rpm.The outer
most holes give 250 spark advance asrequir, '~,?engineswith speed
range of 2500 rpm and above.ConnectJhe 8 r coil lead (ground)
to the stator mounting screw .Connectth~ ~t,C)r larger lead to the
insulated terminal on the blower housingw
oconnectslo the
ignition coil andbreakerpoints.BestJl'(Jthe
er lead is heldin
place to prevent rubbing on the flywheel. .
.
MAINTENANCE AND REPAIR
55
--,-ri~,; USE OUTSIDE MOUNTING
I HOLES FOR
!
25° SPARK
ADVANCE
-I-ii.....:i-iii-r--f--fr---
usE: INSIDE MOUNTING
HOLES FOR 19° SPARK ,
ADVANCE,
, If flywheel rubs on poles
loosen poleshoe mounting
screws, tap poleshoe, and
retighten mounting screws.
FIG. 36 - MAGNETO STATOR INSTALLATION
IGNITION COIL INSTALLATION. - Coil connections differ between mag
,
neto ignition plants and battery igni
tionplants. Refer to the illustration which applies. The ignition coil is
grounded on magneto ignition plants but not grounded with battery ignition.
The spark occurs aUhe build-up of magneto current and at the collapse
of battery current.
WARNING
Use only a 6-volt
coil tester.
HIGH
TENSION,LEAD
BREAKER
MECHANISM
MAGNETO STATOR
ASSEMBLY
SPARK PLUG
HIGH' )
TENSION
LEAD
FIG~
37 -COILINSTALLATION AND ELECTRICAL
CIRCUIT 'FORMA'GNETO IGNITION
.~
~
...
56
MAINTENANCE AND REPAIR
S~ARK~
~LUG~
BREAKER
MECHANISM
WARNING
Use only a 6-volt
coil tester
J
S~ARK ~LUG
HIGH /
TENSION
LEAD
FIG. 38 - COIL INSTALLATION AND ELECTRICAL
CIRCUIT FOR BATTERY IGNITION
TIMING THE IGNITION. - Ignition timing procedure is the same for
manual-start type plants with magneto igni
tion as for remote-start type plants with 12 volt battery ignition.
The spark advance is 190 before top center for all models with engine
speeds ranging from 1500 to 2400 rpm. Models with engine speeds of
2500 rpm and up use the 25 0 spark advance. The correct timing is
stamped on the cylinder block near the breaker box.
Timing procedure follows:
1. Remove the cover from the breaker box. If the timing is very far
off, attain an approximate setting by loosening the mounting screws
and shifting the breaker box (and spacer if used) to align the witness
marks on the cylinder block and breaker box (or spacer).
2. Crank the engine over slowly by hand in the direction of crankshaft
rotation until the witness mark on the flywheel and the "TC-" mark
. on the gear cover ar e exactly in line. See the illustration Ignition Tim
i n g . b
3. Adjust the ignition breaker point gao width to 0.020 inch at full sep
aration.
II II
i
57
MAINTENANCE AND REPAIR
PLACE A DROP OF LIGHT OIL
ON BREAKER.ARM PIVOT
EV"'RY 1200 OPERATING
Ad,:.ance Spark
TERMJ
SETBREAKfR
POINT GAP
WIDTH AT 0,
TO ADJUST GAP
LOOSiH SCRE'I'IS
"A't TURN CAM
RETIGHTEN
"An
..
Retard Spark
THESE SCREWS MUST BE I..DO
. ENED TO'ADJUST POSITION OF
THE BREAKER BOX WHEN
SPACER !S NOT USED.
' - - - - - " ' - LOOSEN THESE SCREWS TO AD
.JUST POSITION OF BREAKER .
<~o.)( .W.He:N..!)P"'C:EB.~S USED
.
.
.
.
4. Turn the flywheel
to the left, against crankshaft rotation, until the
timing mark is about two inches past the 250 mark on the gear cover;
5. Turn the flywheel slowly to the right and note whether the ignition
points just separate when the mark ontheflywheel aligns with the
correct degree mark (19 0 or 25 0 ) on the gear cover. If the marks
align as the points break, timing is correct. If they do not, loosen the
breaker box mounting screws and shift the whole breaker box assembly
slightly toward the air cleaner to retard the timing (points breairing
too soon), or shift it slightly away from the air cleaner to advaricethe,
timing (points not breaking soon enough) .. Tighten the breaker box
mounting screws securely after making an adjustment. Refer toihe
illustration, Ignition Timing.
To accurately check the time at which the spark occurs, an automotive
type timing light may be used when the engine is running.
To accurately check the time at which the spark occurs when not run
ning the engine, connect a continuity test lamp set across the ignition
[I il l
58
. MAINTENANCE AND REPAIR
breaker points. Touch one test prod to the breaker box terminal (to
which the lead to the coil\is connected), and touch the other test prod
to a good ground on the engine. Turn the crankshaft against rotation
(backwards) until the points close. Then slowly turn the crankshaft with
rotation. The lamp should go out just as the points break.
6. Reinstall the breaker box cover.
FLYWHEEL. - To remove the flywheel turn the flywheel mounting screw
outward about 2 turns. Use a screw driver behind the
flywheel to take up the crankshaft end play. Then strike a sharp end
wise blow on the head of the capscrew with a heavy soft faced hammer
to loosen. A suitable puller (with claws or with bolts to agree with fly
wheel) may be used to pull the flywheel.
Do not drop the flywheel. A broken fin will destroy the balance.
A magneto flywheel which has lost its magnetism can be remagetized.
The spark should jump a 3/16 inch gap with ease as tested by holding
the spark plug wire away from a clean metal part of the engine while
cranking.
VALVE SERVICE. - Properly seated valves are essential to good en
gine performance. The aluminum cylinder head
is removable for valve servicing. Do not use a pry to loosen the cy
,linder head, rap sharply on the edge with a soft faced hammer, taking
care not to break any cooling fins. A conventional type valve spring .
lifter may be used when removing the valve spring locks, which are of
the sp'ttt type. Clean all carbon deposits from the cylinder head, piston
top, valves, guides, etc. If a valve face is burned or warped, or the
,stem worn, install a new valve.
Worn valve stem guides may be replaced from inside the valve chamber.
Valve locks are the split, tapered type, the smaller diameter of which
must face toward the valve head. Tappets are also replaceable from
the valve chamber,. after first removing the valve assemblies.
The valve FACE angle is 44 0 • The valve SEAT angle is 45 0 • This 10
interference angle results in a sharp seating surface between the valve
and the top of the valve seat. The interference angle method of grinding
valves minimizes face deposits and lengthens valve life .
.The valves should not be hand lapped, if at all avoidable, since the sharp
contact may be destroyed. This is especially important where stellite
faced valves and seats are used. Valve faces should be finished in a
In.achine to 44 0 , Valve seats should be ground with a 450 stone, and the
wldth of the seat band should be 1/32 to 3/64 of an inch wide, Grind
i
I1II
IIII
i
III
MAINTENANCE
NOTE-USE A STANDARD
AUTOMOT IVE TYPE ,
WRENCH TO ADJ
r.
TH~:r
VALVE
INSE
ND REPAIR
59
NOTE: SEE VALVE TAPPET
LEARANCES IN TEX.T.
I
VALVE SPRING
RETAINER WASHER
rtNTAKE VALVE ONl.Y)
VE SPRING
~~
•.•.P
. •,.•.c
•..: .
VijVE
'I~
A!3&-
SEAT
- Valve
Grinding
only
eno~gh
to assure proper seating.
Remove all grinding' dust from engine parts and install each valve
in its-proper location. Check each valve for a tight seat, using an air
pressure type testing tool. If such a tool is not available; make pen
cil marks at intervals across the valve face and observe if the marks
rub off uniformly when the valve is rotated part of a turn against the
seat.
Lightly oil the valve stems and reassemble aU parts removed. Adjust
the valve clearance.
The positive type exhaust valve rotocaps serve to prolong valve life and
need for valve service. When functioning properly the exhaust valve is,
rotated a fraction of a turn each time it opens. While at open position
the valve can be rotated freely but in only one direction. Try it. If
I
60
MAINTENANCE AND REPAIR
rotocaps are faulty, install new rotocaps.
TAPPET ADJUSTMENT. - These plants are equipped with adjustable
tappets. To make a valve adjustment, re
move the valve covers. Crank the engine over slowly by hand until the
left hand intake valve, when facing the flywheel, opens and closes.
Continue about 1/4 turn until the mark on the flywheel and the "TC"
. mark on the gear cover are in line.. This should place the left hand
piston at the top of its compression stroke, the pOSition it must be in
to get proper valve adjustment for· the left hand cylinder. Clearances
are shown in the Table of Clearances herein. For each valve the thin
ner gauge (minimum) should pass. freely between the valve stem and
valve tappet but the thicker gauge (maximum) should not. Refer to
the illustration, Valve Service,
To correct the valve clearance, simply turn the adjusting screw as
needed to obtain the right clearance. The screw is self-locking and
will stay where set.
If valve clearance can no longer be held within given limits, replace
the valve.
To adjust the valves on the right hand cylinder,
. crank the engine over one complete revolution
and again line up the mark on the flywheel
and the "TC" mark on the gear cover. Then
follow the adjustment given for the valves of
the left hand cylinder.
GEAR COVER.
~
After removing the mounting
.screws, tap the gear caver
with a soft faced hammer to loosen it.
gel1~ly
When installing the gear cover, make sure that
.the pin in the gear cover engages the metal lined
,
l.,.
I;
¥',
=~==:=~--GOVERNOR
~~,.~~~
.~GOVERNOR CUP
II
~'
I
fO:
I
ff ~
:
~:
~N"!;:'- ,
o"
<'\ \
\ \
~
I
IF FEELER WILL
ENTER HOLE
BALL HAS
FALLEN OUT.
,..",.~l1.
ARM
GOVERNOR
SHAFT
ROLL PIN
ROTATE GOVER
NOR CUP SO
1
FITS INTO THE
METAL LINED
HOLE IN THE
CUP
°1
,
...'---';.J' p",-
A3S9a.
FIG.
- INSTALLING THEGEARCOVER
.°
.
(SMOOTH 510E
TOWARD CUP>
GOVERNOR
SHAFT YOKE
;.:,
I'
! '
MAINTENANCE AND REPAIR
61
(smoothest) hole in the governor cup. Turn the governor cup so that the
metal lined hole is at the 3 0' clock position. The smooth side of the gov
ernor yoke must ride againstthe governor cup. Turn the governor arm
and shaft clockwise as far as possible andholdin this position until the
gear cover is installed flush against the crankcase. Be careful not to
damage the gear cover oil seal. Adjust the roll (stop) pin to protrude to
a point 3/4 inch from the cover's mounting surface.
.
GOVERNOR CUP. - With the gear cover removed, the governor cup
can be taken off after removing the snap ring from
the camshaft center pin. Catch the fly balls while sliding the cup off.
Replace with a new part, any fly ball
which is grooved or has a flat spot,
the ball spacer if its arms are worn
or otherwise damaged, and the gov
ernor cup if the race surface is
grooved or rough. The governor
must be a free spinning fit on the
camshaft center pin, but without any
looseness or wobble.
When installing the governor cup,
tilt the engine so the gear tsup, put
the flyballs in place (equally spaced)
and ins tall the cup and snap ring on
the camshaft center pin.
WHEN GOVERNOR IS
PROPERLY ASSEMBLED
THE DIMENSION SHOWN'
ON DRAWING WILL BE
AS INDICATED,
~
CENTER
GOVERNOR FLY
FIG. 42 -GOVERNOR CUP'
The camshaft center pin extends out 3/4" from the end of the camshaft.
This distance provides an in and out travel distance
7/32"for the
governor cup, as illustrated. ' Hold the cup against the flybaUs . whe]).:
measuring. If the distance is less (the engine may race especially at
no load), remove the center pin and press a new. pin in only the required
amount.' Otherwise, grind off the hub of the cup as required. The cam
. shaft center pin can not be pulled outward nor removed without damage.
If the center pin extends out too far, the cup will not hold the fly balls
properly.
of
,-
TIMING GEARS. - If replacement of either the crankshaft.gear or the
camshaft gear becomes-necessary, install both gears
new, never one only. To remove the crankshaft gear; first remove
the snap ring, then insert two long *10-32 steel screws into the tapped
gear holes and tighten the screws alternately. As the screws are tight
ened, the screw ends will seat against the crankshaft shoulder and force
the gear off the end of the crankshaft.
62
MAINTENANCE AND REPAIR
SCREWS PASS THROUGH
\lEAR ANO BEAR
AGAINST CRANK
SH~FT ~nv'"v~"_
THESE MARKS MUST
COINCIOE WHEN IN~
STALLING TIMING
GEARS.
FIG. 43 - TIMING GEARS
The camshaft gear is pressed on and keyed to the camshaft. The cam
shaft and gear must be removed as an assembly, after first removing
the crankshaft gear lock ring and washer. Before removing the cam
shaft and gear assembly, remove the cylinder head and valve assem
blies. Remove the operating plunger for the breaker points. Remove
the fuel pump and tappets. After removing the-governor cup assembly
from the gear, the camshaft may be pressed out of the gear by use of a
hollow tool or pipe which
fit over the camshaft center pin. Do not
press on the center pin or damage it in any way.. The governor ball
spacer is a press fit to the camshaft .gear.
will
When pressing a camshaft gear onto the camshaft, be sure the gear is
. started straight and thaUhe key is properly: in place. Install the gov
. ernor cup assembly before installing the camshaft and gear. in the en
.gine.
.
.
Note that each timing gear is stamped'with "0" mark near the edge. The
gear teeth must mesh so that these marks exactly coincide when the gears
are installed in the engirie. Be sure, when installing the camshaft gear
and shaft assembly,' that the thrust washer is properly in place behind
the camshaft gear. Replace the retaining washer and lock ring to the
crankshaft.
CYLINDER, - The cylinder wears very little in normal service. If
through improper lubrication or accident, the cylinder
wall should become' scored or worn badly, the cylinder may be rebored
and.honed to accomodate a new piston and rings of one of the available
oversizes. Pistons and rings are available in .010",.020", and .030"
oversizes. An engine may have been fitted at the factory with .005"
overSize pistons, and will be so indicated by the letter "E" following
the engine serial number stamped on the cylinder block and on the plant
nameplate. Use standard size rings on a .005 ff oversize piston. If the
MAINTENANCE AND REPAIR
,63
,cylinders are not being reconditioned, but new piston rings are being in
stalled, remove al1yridge which may have become formed at the top of
piston ring travel in the cylinder bore.
PISTONS AND RINGS.-The piston and connecting rod assemblies are
,
, '
, removed through the top of the cylinder • The
pistons are fitted with two compression rings and one oil control ring
with an expander . Inspect each piston. The piston ring grooves should
be cleaned of any carbondeposits, and the oil return slots in the lower
groove must be open.
If the pistons are badly scored, very loose in the cylinders, have ba.dly
worn ring grooves, or otherwise are not in good condition, install new
pistons~ Insta.ll new pistons if the old ones are lOOSe on the piston pins
and 0.002' inch oversize piston pins will not correct it. Handle pistons
carefully to,::\.void nicking the walls, Any raised surface of this type
must be dressed down carefully.
Conformatic type pistons are designed for very close fit in the cylinder
bore. , A slot on opposite sides of the piston behind the oil control ring
permits oil t·eturn and allows lor expansion. The piston is interchange
able as to which side should be nearer the oil base.
Inspect the rings carefully for fit in grooves, for tension, and for seat
ing on cylinder walls. Install new rings where there is any doubt about
the condition of the old rings.
Before installing new ringsonthepistcin, check the ring gap by placing
eachring squarely lnits cylinder at a position correspondlng to the bot
tom of its travel. ,The gap betweeJ;l the ends of therlng should .beas
,
given intl1e Table ofClearances. Rings which are slightly oversize may
be HIed as necessary to obtain the correct gap,butdo not use rings
which require too much filing. Standard size rings may be used on a
.005" oversize piston. • 010", • 020" ,and. 030" oversize rings are to be
used on .010", • 020", and :030" oversize pistons, respectively. Rings
of the tapered type are usually marked "TOP" on one Side, or identified
in some other manner, and the ring must be installed with this mark
toward the closed end of the piston. Space each ring gap one third of
the way around the piston from the preceding one, with no gap directly
in line with the piston pin. The bottom piston ring groove should be fit~
ted with an expander and an oil control ring and the two upper grooves
fitted with compression rings. If a chrome faced ring is used, it will be
in the top groove. The oil control ring is selected for best performance
in regard to the correct unit pressure characteristics.
I
I
,t"',
,
The piston is fitted with a .full floating type piston pin. The pin is kept
~'
in place by two lock rings in the piston, one at each side. Be sure these
'
lock rings are properly in place ,before installing the piston and connect-.
64
MAINTENANCE AND REPAIR
ing rod in the engine. Correct piston to cylinder clearance appears in
the Table of Clearances.
FIG. 44 ... FITTINGPISTON RINGS TO THE CYLINDER
CYLINDER HEAD.-. Models using
gaseous fuelhavea'high com
pression cylinder head. Beginning in 1959 this
cylinder head has a 3/32" radius boss visible on the thick edge near the
spark plug to identify itfrom standard compression. Bothheadsmust
be of tbesamecompression.
CONNECTING EODS . .,. The connecting rods' should he serviced at the
.
same time the pistouso1'. piston ringsaresel'- .
viced. Rods must'Pe removed with the piston. Rods are :waiIablein
standard or 0•. 020 inch· undersize .
.The. connecting rod bearing surface is aluminum aUoy andpr.operclear,,..
ance between the rod bearing surface and the crankshaft bearing surface
is obtamedbprdressingtheconnectingrod cap.. 1'hecorrect clearance
is shown in the Table of Clearances. Use..a s.heet of 320 grit .or finer
abra.sive onasmooth fiatsllrface. Place the ends ofthe connecting rod
caR.on.the.abraaive material and carefully dreSs the ends down asne.ed-'
ed.Besurethecap is heldperiectlystraight.Remove all abrasive
fromihe cap befOl'einstalling it.
. ,
FIG. 45;..REDUCING CONNECTINGRODCtEARANCE
The.connectingroda.n~pistonass.emblymust be properly ljIigl1.etl·befCJre
reas~embly to the engme. Theah{fningshouJd be done onan3 .'. ..t
alignwtJ gauge by a compef.ent operator.'. Misalignme .t.· . ". . ccura e
. .
" ' , ....
n may cause rapid
MAINTENANCE AND REPAIR
65
wear of piston, pin, cylinder and connecting rod.
Install the connecting rods and caps with raised lines (witness marks)
aligned and with the caps facing toward the oil base. The rod and cap
numbered "2" goes on the journal which is farther from timing gears.
Coat the crankshaft journal bearing surfaces with oil before installing
the rods. Crank the engine by. hand to see that the rods are free. If
necessary, rap the connecting rod cap screws sharply with a soft faceci
hammer to set the rod square on the journal..
BEARINGS.
~
Removal of the camshaft or crankshaft bearings'requires
complete disassembly of the engine. Use a press or a
suitable drive plug to remove the bearings. Support the casting to avoid
distortion and avoid damaging the bearing bore during removal and in
stallation. Use oil on bearings to reduce friction when installing and
again lubricate with oil after installing.
New crankshaft mainbearings are precision type which DO NOT re
quire line reaming or line boring after installation. They are available
in standard size or in 0.002 inch or 0.020 inch undersize. Expand the
bearing bore by placing the casting in hot water or in an oven heated to
200 0 F. Be careful, if a torch is used, to apply only a little heat! If
practical, cool the preCision bearing to shrink it. Align the oil hole(s)
in bearing with the oil hole(s) in bearing bore. The oil passage must
be at least 1/2 open. The cold oiled preCision bearing should require
only light taps to position it.. Install the flanged type bearing (used
prior to Spec F) with its notch engaged with the stop pin. Install the
bronze faced bearing (used beginning with Spec F) flush with the inside
end of bore. If head of lock pin is damaged, use side cuttersor "easy
out" tool to remove and install new pin. Apply oil to. thrust washer
(one used with each bearing, begin Spec F) to hold it in place while in
stalling the crankshaft.' Oil grooves in thrust washers must face the
crankshaft, washers must be flat (not bent) and washer's two notches
must fit. over two lock pins
to prevent riding on crankshaft.
.
\
Install the front camshaft bearing with its oil hole aligned with the hole
inthe bore (except bores without oil hole install with bearing groove at
top) . Press it in flush with the outside end of the bore. Install the rear
. camshaft bearing with its plunger. notch faCing out and aligned with the
hole in the bearing bore. Press or drive it in flush with the bottom of
the counterbore which receives the expansion plug.
The camshaft bearings must be line bored or line reamed after being
installed in the cylinder block, to allow a clearance as sholvn in the
Table of Clearances. For· this service, consult a reliable machine
shop, your dealer or factory... Install the expansion plug of th<." rt:ar
bearing.
.~
~
~
!
I
66
MAINTENANCE AND REPAIR
• I
. EXCEPTION: FLANGED BEARING IS
USED PRIOR TO SPEC. F.
INSTALL WITH CUT-OUT TO
TOP AND REAR OF' ENGINE
REAR
CAMSHAFT
BEARING
8
EXCEPTION-EARLIER ENGINES
DO NOT HAVE OIL HOLE IN BORE.
LOC.{'~~NRJNG
PRECISION TYPE- DO NOT
LINE REAM OR BORE.
CRANKSHAFT BEARING
H 7"
-o*$&fj"\..:tJF~M
----ACiGNHOLE'iNBEARING
-WITH HOl..E IN BEARING BORE ~ '-
I
g~D~
,FRONT CAMSHAFT BEARING
FIG. 46 - BEARING INSTALLATION
OIL SEALS. - The gear cover mustbe removed to replace its oil seal.
Drive the old seal. out from the inside of the gear cover.
The bearing plate must be removed to replace its oil seal. Drive the
oil seal out from the inside.
»
When installing the gear cover oil seal, tap the seal inward until it is
3.1/32 of an inch from. the mounting face of the cover.
When installing the bearing plate oil seal, tap the seal into the bearing
plate bore to bottom against the shoulder in the plate bore. After the
sealis in place, it is advisable to apply a thin coating of shellac or
Permatex around the outer surface of the seal at the point where it comes
in contact with the bearing plate hoss,' Use.a seal expander, or place
a piece of shim stock around the end of the crankshaft, when replacing
the bearing plate tb avoid damaging the seal. Remove the shim'Stock .
as soon as the plate is in place.
FIG. 47 - OIL SEAL INSTALLATION
CRANKSHAFT. - Inspect the bearing journals. If they are scored and
can not be smoothed out by dreSSing down, the bear
ing journals should be refinished to use 0.002" or O. 020" underSize .
bearings or a new crankshaft should be installed. If a worn main bear
ing journal can not be fitted with an available precision type underSize
MAINTENANCE ANO REPAI.R
~-;;f,-'MEASlJRE
:::
67
ENDPLAY
HERE
I
(REFER TO TABLE OF
CLEARANCES)
.LI______~~~~~~~~~--~~
FIG. 48 .,. CRANKSHAFT END-PLAY
bear.ing, then refinish it to the next undersize. If a worn connecting
rod bearing journal can not befitted by dressing down the rod cap, then
refinish it to take the undersize rod available.
Whenever making major repairs on the engine, always inspect the
drilled passages of the crankshaft. .If necessary, clean them to assure
proper lubrication of the connecting rods.
When installing the crankshaft, use gaskets'as needed behind the bear ..
ingplate to assure end playas given in the Table of Clearances. herein.
OIL PUMP • - To remove the oil pump, it is necessary to detach the
intake cup assembly, as illustrated.
'e
Check the oil pump thoroughly for worn parts. Oil the pump to prime
it before reinstalling. Except for gaskets, the component parts of the
pump are not available' individually. The suction cup is available seInstall a new
if r",ml1;t"Pti
•••••
~
FIG. 49 - OIL PUMP REMOVAL
68
M A IN TEN AN C E AND REP A IR
FUEL PUMP. - A dlaphragm type fuel pump is usect. If fuel does not
reach the carburetor, check the fu~l pump before dis
.mantling it. The pump can be checked by disconnecting the fuel line at
the carburetor, cranking the'engine slowly by hand, and observing whe
ther fuel comes from the line at the carburetor. If there is enough
fuel in the tank, and the line between the tank and the pump .is open but
,the pump fails, repair or replace it. Failure of the pump is usually
due to a leaking diaphragm, valve or valve gasket, a weak or broken
'spring, or wear in the drive linkage. If the operator chooses to repair
the pump rather than install a new one, the use of a complete repair
kit is recommended.
ALWAYS RETURN THE HAND PRIMING LEVERALL-THE-WAY IN
WARD so that the priming lever does not prevent the normal operation
of the pump. If the fuel pump rocker arm is being lifted by the cam
shaft, the engine must be cranked 1 revolution before the priming lever
will be effective.
Rotating the diaphragm 1/4 turn will dtsengagethe drive link ..
,!Diluted oil indicates a faulty fuel pump.
,GASKETS. - Always use new gaskets when replacing any part that re
quires a gasket. Thoroughly clean the surface that the gas
ket contacts before installing the gas):{et.
TESTING IGNITION COIL. - A 6-volt tester may be used to test the
,
ignition coil. To avoid burning out the coil,
do not use a 12-volt tester and do not leave coil on tester over 15 or 20
minutes.
~."
MAINTENANCE AND REPAIR
69
GENERATOR
The. generator normally needs little care other than a periodic check of
the brushes, ,commutator and collector rings. If a major repair job on
the generator should become necessary, have the equipment checked by
a competent electrician who is thoroughly familiar with the operation of
electric generating equipment. Continuity tests may be performed with
out disassembly of the generator.
GENERATOR DISASSEMBLY. - The procedure is mostly self-evident.
Remove the band and endcover. Re
::lllove constant-pressure-type springs and lift all brushes.
Remove generator through stud nuts.. Hold both the end bell with its
btushrigand the frame assembly, since they are separat~e parts, and
remove them as one assembly from the adapter. Screw driver slots in
the adapter provide for prying the frame loose. Be careful not to iet
the frame assembly restor dragon the armature.
, Turn thearmaturenutoutto the end of the armature through stud. While
pulling outwardwith one hand under the armature, strike a sharp end
wise blow on the nuttoloosenthe ar.mature. Remove the armature and
blower as an assembly. The blower is a keyed and pressed fit on the
armature shaft, and isa keyed and tapered fit to the engine crankshaft.
1f the armature does. not come loose, place a heavy brass rod on the
armature shaft near the ball bearing and strike a sharp downward blow
on the rod with a hammer• Rotate the armature 1/2 turn before repeat
ing. Do not strike the commutator ~ collector rings, or bearing.
BRUSHES AND SPRINGS.. - Inspect brushes periodically. Brushesworn
to 5/8incb should be replaced. Replace
springs if damaged or if p,roper tension is questionable. Rapid brush
INSTALIi..BRUSH"ES
WITH BEVELLED TOP
SLANTlN'G DOWN
,OWARD SPRING
HOLDER
TO REMOVE BRUSH
SPRING PRESS,
SPRING HOLDER
DOWN AND OUT AS
SHOWN IN BROKEN
LINES.
RING
FIG. 50, - BRUSHES AND SPRJNGS
4
•
J
I,
70
wea.r may be 'caused from high'nlica befween.cCln'imutatorbars, rough
c,jrrimutatot or colleCtor rings; or frbma' deviationft'om!!h:eutral"posi
.tioninthe'adjtistment'of the' brush rig. KEVER bend the constant..pres
sure..;.tyt>e·· sprihg over the edge of its' support. .
.
BRUSHRIG POSITION. - Check the witness mark on the brush rig and
. . . . '. . . .'
··if necessary align it w'iththebdss in the end:
bell. If the brush rig is adjusted so that there is,ar'cing oftheb:rushes, .
bttishwear'will be rapid, voitageand cutrentwillnot hoTd steady, and
.
the: generator rnayoverheat .. '
Whenever. ::Ii riewbrllsh rig or armature is:iristaI1ed,' the brush rig must
be adjustedtb thepoin.twhere'the brushes 'do not arc regardless of where
thewithess"matk falls. This 'is! coml'll'oillyknowll ~as the "neutral"brush .'
positibn.~:l.
:i'
' .
i'"
COLLECTOR RINGS (AC Units) - If the collector rings become groov
" " ' e d o r out of round, 'or the brush Sur;;'
face becomes pitteqor rough so that 'goodbtush seating cannot be ,main
tained, ur:em'ove thearmattireamd refiniSh the collectorrihgsin:a lathe..
If the· commutator appearst6:bce rough or· scored, lJefinishit at th~ same·
time. Remove or adequately shield the ballbear,ing 'during refinishiIig.
COMMUTA'I':OR.·.... ' The commutator; bars wear down with usage so that
the mica between them must be undercut. This
shbilldilDe 'doneass6oil' as the m:lca on(anypaTt 0fthe.eomm.utatorteacfies
the brushes. A suitable undercutting tool can be made frOID/a haiek,sawi
bl~e •.:'iAvoid 'injriry;,to:the'BUFfaces;of!the:'cbpp'er bars,~,'Lea:.ve!n:o.burrs
al'Ong'the:iedges cof, the'bars/':The mica musi' also:' be; undercut whenever, .
,i.~·'i·"·'·
!
i
I
t
FIG. 51 - COMMUTATOR REPAIR
MA INT ENA NC E AND R EPA IR
71
TESTING WINDINGS. - A test lamp set and an armature growler are re
.
quired for the various tests. Before making any
tests, lift all brushes into their holders and disconnect the load circuit
wires from the plant. If the armature tests defective, the practical re
pair is to replace it..' If a field coil tests defective, replace the entire
coil assembly unless the trouble is in one of the external leads. Then
it can be repaired as the nature of the trouble requires.
ARMATURE GROUND TEST. - To test the armaturefor a grounded
. condition, liftor remove the brushes
so that. none contact thecomrtlutator or collector rings. Use a cantin&.
uity typetestlamp set.. Place one test prod onthe commutator, .and
the other test prod on a bare,clean part of the armature shaft. The
test prods must make good electrical contact. The test lamp should not
glow. If the test lamp does glow, the dc winding or thecomrtlutator
is grounded. To testthe a c winding, place one test prod on One of
the collector rings and the other test prod on the armature shaft. li the
test lamp glows,the a c windingor a collector ring is grounded. Ite...
ar
,
Ii
TEST LAMP
!
FOR JESTING FOR OPEN
CIRCUITS AND GROUNDS.
-If.
<1$£ 3 OJ? ... CANDL£POW£II
,
BULB.
.
FIG. 52-' CONTINUITY
TEST LAMP
FIG. 53 - ARMATURE
GROWLER
ARMATUREOPEN CIRCUIT TEST. • The armature ac winding may
be tested for an open circuit with
out removal ofthearmatur.e. Testing the de winding requires removal
and the use of an armature growler.
Totest the a c winding, be sure airbrushes are lifted or removed.
Use a test lamp set. Place one test prod oneach of the collector rings.
If the test lamp does not glow, the .a c winding is open circu,ited.
To test the d cwinding, place the armature in a growler. With the
growler current on; pass a smooth steel strip across the commutator
segments. Repeat all around the commutator. At some point around
the commutator, a spark should occur as the strip contacts two adja.
~.\
•
72
MAINTENANCE AND REPAIR
cent segments. Rotate the armature slig'htlyand repeat the test. Con
. Hnue until a spark is obtained between all adjacent segments. If 110
spark is obtained at s.ome point, an open circuit is indicated. (NOTE
A short circuit in the winding might prevent sparking, This condition
may be indicated by the short circuit test described in the next para
graph.) Replace an open circuited armature with a new one.
ARMATURE SHORT CIRCUIT TEST. - To test for a short circuit, place
the armature in a growler. With
the growler current on, hold a steel strip about 1/2 inch above the arm
ature laminations. Pass the strip back andforth over the laminations.
Cover as much of the lamination area as possible. If the strip is mag
netic ally attracted to the armature at any point, a short Circuit is in
dicated. After testing in one position, rotate thearmaturesHghtly in
the growler and repeat the test. Continue until a complete revolution of
the armature in the growler has been made. Replace a short circuited
armature with a new one.
TESTING FIELD WIl\TDINGS. - Use a test lamp set for all tests except
a short circuit. The field ceils .of all
a c plants are saturated shunt weund, the Remote Start plants having
a series field. winding in additien for cranking and battery charging pur
poses. When testing a field coil assembly, disconnect all of its exter
nal leads from their terminals. Tag and mark each lead te assure pro-.
per cennectionswhen reassembling.
TESTING FIELD WINDINGS FOR GROUNDS. - To test a coil assembly
fer a ground, disconnect
its exte:t:nal leads and teuch one test pred te the terminal of .one of its
leads and the ether test prod te the gene rater frame. If the lamp lights,
the ceil assembly ,being tested is grounded. The greund may be in a
coil, ceil cennectien, .or ceil lead. Repair.or replace as needed.
TESTING FIELD WINDINGS FOR OPENCIRCUIT. - To testa coil as
.
.
.
semblyfor an .open
circuit, disconnect its external leads and teuch .one test pred te the ter
. minalof .one ceil winding lead, and the other test pred to the other lead
(.or leads) ·ef that coil winding. If the lamp does net light, the winding
being tested is .open. If the fault lies in a connectien between ceils, or
ina ceil lead, the connection can be repaired. If it is inside the coil, re:
place the entire ceil assembly with a new .one.
BALL BEARLl>{G. - If replacement of the armature ball bearing becomes
necessary,pull the bearing frem the shaft with a
suitable bearing puller. Be careful not to damage the armature shaft
because it must remain true te serve as a turning center when refinish
ingthe c.ommutat.or .or c.ollect.orrings .. Drive the bearing on tothe
sheulder .on the shaft. Useadeuble-sealed pre-lubricated baH bearing.
· MAINTENANCE AND REPAIR
73
GENERATOR ASSEMBLY. - When reassembling the generator, see
that there are no nicks or dirt on the arm
ature blower tapered surface. These .conditions may cause an excessive
run-out (wobble) at the bearing end. Run-outshould be within 0.002".
Ti hten the armat~re through stud nut· securely.
I
FIG. 54- GENERATORABSEMBLY
74
MAINTENANCE AND REPAIR
CONTROLS
equipm~nt fails to function properly, replace the
defective part with a new part of the same kind rather than try to repair
the old part. No attempt should be made to repair such parts as meters,
fuses, switches, relays, or receptacles. Check all electrical connec
tions and contacts whenever servicing control equipment.
If any of the control
Always disconnect the battery whenever servicirig controls to avoid
accidentally starting the plant. When disassembling controls, tag each
lead that has to be removed and mark the connection point
the lead
on the tag to assure correct connections when reassembling.
of
. ,75
MAINTENANCE AND REPAIR
SERVICING THEREAOI-PULL STARTER (FIG. 55)
", CAUTION: The recoil spring may unwind and causeinjury if let
'
,
fly wildly. when starter is disassembled or reassembled.
· The sheave hub bearing (16) has a recess which was, packed full of grease
at the factory ... Normally no additional lubrication is required. How
ever, if the. starter is disassembled for som,e other reason, add grease
tothe bearing and to the spring pawls (11) where they contact the rat
chet arm (13).
.
.
.
.
.
To install a .newrope. or internal parts remove the starter from its
mounting ring by removing the 4 clamping screws.
.
..'
'
.
. . . . . .
'
!I
.
!!
Ii
To install anew rope, rotate the sheave (10) with Crankshaft rotation:
direc:tidntofully tighten the spring (8), back up only as necessary to
. align the hole. in the sheave with theslot.in the cover (5), clamp the
rope to the she~ve;thenwhen released the rope will wind on the sheave.
ii
!i
II'I
I'
To install anew recoilspr,ingremove the Sheave from the coyer. Wind
the spring; with its rivetheads outward, forming a coil small enough
to be .inserted in the recess.' of the starter cover. . It may be necessary
to Uethespringwithapiece of wire to prevent its unwinding during in
stallat:io~unless other help is available. Place the spring in the cover.
recesS in crankshaft rotation direction. Remove the tying wire if used .
. While holdlngthespringto prevent its unwindinginst8.11 the inside end
.'of thespririgontheroll pin (7) in the cover. With the pull rope removed,
. iDstallthe sheave .assembly in the cover so that the tab on the sheave.
enters the outside end loop of the recoil spring. Be sure the thrust
washer (9) is in place. Then install the pull rope,
1
Spring breakageisniuchless common than spring fatigue due to long,
usage; In either case the spring should be replaced. Cleaning andlub- .
ricatingthepawls~'and ratchet arms inthe rope sheave will improve a
sluggish acting recoil. '. To temporarily extend the lifeofa fatigued
spring,try rewiiiding if "inside out" (rivets heads inward).
· To install a ratchet ar.m (13) in the sheave, the pawl (11) must first be
removed~ The ratchet arm will fit .in only the correct pOSition. The
· spring -pawl must be installed with its flat edge against the ratchet arm.
Theanti":back
lash cogwheel (6). is an easy press fit on the. starter cover.
)
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I
76
MAINTENANCE AND REPAIR
I·ROPE AND GRIP
2.ROPE ONLY
3·GllJP ONLY
4·PLUG
5-START'£R COVER
5-COGWHEEL
6A-SPruNG WASHER
7-I\OLL PIN
S·RECOIL SPRING
9-'l'HRUST WASHER
lO·I\OFE SHEAVE
II·PAWL
12·PAWL SPRING
12A-SPlROL PIN
13·HATClIE'l'ARM
14·PIVOT ROLL PIN
I5-RCPE Cl.AMP
16·BEARlNG
17·SCREW
IS' FLEXl..OCK NUT
IS-WASHER
M·MGUN'l'ING RING
21·SPEED GIlIF NU'l'
22·M TCHET WHEEL
23.Sl'ECIAL CAl'SCHEW
FlG.. 55 - SERVICINGTHE READI-PULL STARTER
i
POSI1'ION Cr.-STAR-:
1'ER ASSEM6L"'f
I
MAY BE CHANGEC
BY LOOSENING
CLAMP SCREWS
I
@
I
I
i
SPECIAL NUT
BLOWER
HOUSING
.... fL~T WASHERS
®
il
r4l.
LOCK WASHER
I
ORILLEO.
HEAD SCREWS \
-----~0~----
,.'
\,~-
.RATCHET.WHE.EL
'---------~-~--
I
~
I
-
ALIGNING STARTER ON ENGINE
FlG~ 56 - INSTALLING THE STARTER, UNITS PRIOR TOSPEC.D
MAINT.ENANGEANDRE PAIR
77
INSTALLING STAR'!',ER,UNITSPRIOR TOSPEG. D. -Foruse mtha
Re.adi-PuH start
er, th.e blower housing on theengirle· must be as rigiclas possible ... Ex
amine the. blower housing carefully'. If the.moufltingholes are worn.or
if the blower, housing is otherwise damaged,repiace it with a new one.'
.Proceedas follows to install.t,hecomplete starte.r kit.
.
1. Refer to the h:stallationdrawing.Do notcMnge the Ilywheel mount
ing screw. New screws (iffurnishedj are needed on other. mOdel
'engines.only.
"
.
,
.
"
-
.
t : : : 2 . Install the new ratchet~ wheel. (1 ito the· blower wheel, .using the two
. ..special head screws and lock washers provided. A 318 inch 12 point
socket or closed end wrenchfits these screws. Tighten securely•
3. Four special nuts are supplied for mountingthe starter to th~blower housing•. IUheblower housing is not already fitted with sirnilar
mounting nuts, remove the blower housing and. insta,ll the nuts in the
square holes (2) .in the blower housing. See detail A. Reinstall the
.
blower housing, tightening securely in place.
4; Note thattherearetwo smallholesdrilledthrough the starter cOv
er.See detail G.Pull slowly out on;the starter, rope while sight
ingthrough one, .oUhese holes. When the starter .is turned a partial
turn, •. the open,-centerrQllpins in the. starter,rope sheave wiUalign
with th~se two holes. Wl'ljle ..llOlding inthealigned position, insert a ten
pennYCOmlllon naUthrough eacho! the holes. Push the nails in up to
their heads.
5. Install thesta.rt~~a.ssembly(3) to the blower. housing, making sure.
that the. nail ends.etltel'lllepilot holes in the ratchet wheel mounting
sCJ;ews. It will probably be necessary to turn the flywheel a partial re,
volution to allow proper alignment. While holding in position, mount
'
the starter, using a hex head screw (4), lock washer(5), and two flat
washeTs(6) at each mounting arm as shown in the detaUdrawing A.
Tighten the mounting screws securely. Remove the nails.
6. The ·directibnof pull on the starter rope is adjustable to fit the re
qtlirementsof the individual installation. See detail B. To change
the direction of pull, loosen the four· clamp scre\\,s,(8) and turn the
starter in its mounting ring to the desired position. Tighten the four
clamp screws securely. Try the starter several times, making sure
that the pull rope will not rub against one of the clamp screws.
7. Ocassionally checkthe operation of the starter, making sure the
starter isproperlyc.entered (step 5.aQove). Seethatthe blower
housing mounting screws are tight•. If the blower housing tends to shift,
its mountingfioles may have becomewo~n oversize .• ·If. the blowerhous- .
ingtendsJo'weaye ordistorfdu.rillg starter operation, installation of. a .
newhousingjs recommended. .
.
.I
~
I
i
1
MAINTENANCE AND REPAIR
78
INSTALLINGSTARTER, UNITS BEGINNING SPEC. D. - See that the
engine blower housing
is in good condition. Ii the mounting holes are worn or if the blower
housing is otherwise damaged, replace it'with a new one. See Fig. 57.
Install the. new ratchet wheel (1) against rope sheave (11) using lock
. washer (10) and flywheel mounting screw (9). Discard the large flat
washer from engines so equipped. Engage drive hole with flywheel boss.
L
2. Four special nuts are supplied for mounting'the .starter to the
blower housing. If the blower housing is not already fitted with
similar nuts, remove the. blower housing arid install the nuts as shown
in detaU·A. Reinstall the blower housing, tightening securely in place.
3. Install centering pin (12) instal'ter center screw (14) allowing 3/8"
to pl'otrude. For reinstallations readjust pin depth.
.
.
4~
Center the starter assembly over the ratchet wheel with thecen
tering pin engaging the center hole· of the. flywheel mounting screw.
While holding in position, mount the starter, usingahex head screw,
lock washer,and two flat washers at each mounting arm as shown in
detail A. Tighten the mounting screws securely.
.
5. The direction of pull on the starter rope is adjustable to fit the re
quil'ements of the individual installation. See detail B. Tochange
. the direction of pull,loosen the four clamp SCrews (8) and turn the
stal'terin its mounting .ring to the desired position. Tighten the four
clamp screws securely. Try the.starter several times, making :sure
that the pulll'ope wilLnot rub against oneoft):1e clamp SCrews.
POSI"110N OF STAR
TER ASSEMSl.'r:
MAY 'BE CHANGED
BY LoosENING
CLAMP SCREWS
.
@
,
.•.......;;
"
,.
F'IG. 57 -INSTALLING STARTER, UNITS BEGINNING
SERVICE DIAGNOSIS·;
POSSIBLE CAUSE
.Tobheayy oil
: _
-,
- ,-
_
RJ£MEDY
incI;~l}1q:;~se.
'"" -' --'
- --, _ .>",. _., ' -.
J)rain..l{efill, WUhUghteroil.
~
..Eng;in~setzed .
Disasse-mpleand repair.
Discliargedordefectiv~i'battery ..
Recharge' o!"'replace.
Loose connectiolls.
Ti!glit~n loose connections.
Gorrodedbattery terminals.
C.1ean corroded terminals. Re
place cable if necessary •
BtOcshes w6rn.exC6f>sive1yor
ruakingpoOrcontact.
Replac{3 brushes or cleancommut.,..
:itor. .
StiortCircuit fugeneratoror
load circuit..... .
Repair or replace parts necessary.
Disconnect load.
:Dirty0l' corroded points in
startsolenoid.switch.
Replace switch.
~NGINEWI~LNOT
START.WHEN CRANKED
Faulty ignition.
Clean, adjust, qr replace breaker
points, spar:k plugs, condenser,
etc., orretime ignition. .
Lack of fuel orfaultYcarbure,.: .
tion.
Refill the tank. Check the fuel Sy
stem. Clean, adjust or replace
parts necessary .
Clogged fuel filter.
Clean.
Cylinders flooded.
Ground spark plug ca~les. Crank
,rnginewith spark plurs removed.
',. J)rain. Refill with good fuel.
Tighte;n cylinder' heads. and spark
plugs... If still not corrected, grind
.the,.yalyes. ReplaN' th~'pistol1 ring$.
l$inec~Ssary •
R.e.seLbr.eaker .paints or. retime' ign...
'Uion.
.
t
j
4
II
I
80
SERV1CE DIAGNOSIS
REMEDY
POSSIBLE CAUSE
ENGINE RUNS BUT VOLTAGE DOES NOT BUILD UP
See that brushes seat.weU on ~om;..
mutator and collector rings, are
free in holders, are not worn too
short, and have good spring tension.
Poor brush contact.
Open circuit, short circuit, or
ground in generator.
Refer lothe GENERATOR section of
Maintenance and Repair.
Residual magnetism lost.
Magnetize the field.
VOLTAGE UNSTEADY BUT ENGINE NOT MISFIRING
Speed to low.
Adjust governor to correct speed,
Poor commutation or brush
contact.
Rl3finish commutator or undercut
mica if necessary. See that
brushes seat well on commutator
and collector rings, are free in
holders, are not worn too short,
and have good spring tension.
Loose connections.
Tighten connections.
Fluctuating load.
Correct any abnormal load con
dition causing trouble.
GENERATOR OVERHEATING
Short in load. circuit.
Correct short circuit.
Generator overloaded.
Reduce the load.
Improper brush rig position.
Adjilst.
ENGINE OVERHEATING
Improper lubrication•.
Change to proper oil.
Poor ventilation.
Provide ample ventilation at all
times.
..
. Dirty or oily cooling surfaces ..
Retarded ignition timing•..
. Generator overloaded.
Keepthe engine clean•
. Retimefgnitioll •
Reduce lDad.·
':'
SERVICE DIAGNOSIS
POSSIBLE CAUSE
81
REMEDY
vogrAGE;DRQPSUNPEE JiEAVY LOAD
Engine ·lackspower.
Poor, compression.
Fau~ty
carbuI-E)tion.
.... See r,emedi€ l ')\mder ."Engme.Mis
(it,E)s ~tEeavYLoadl' ..
'I'igbten'cyHnd er heads and spark
,plugs i···· If. stillJ10t corrected grind
the valves; Replace piston rings
,ifhecessary.
Check the fuelsyste:ql.Clean, ad
just or .repair as needed.
'
D irtycarburetorai:r~leaner.
Clean.
ChQke partially closed.
Choke plate must be wide open at
operating· temperattire.
, Carbon incylindersormcar
buretor venturi.
Restricted
exhau~t .line.
Remove carbon.
Clean or increase the size.
ENGINEiMIS.FffiESA T LIGHT LOAD
Carburetor idle' jet clogged
or improperly adjusted.
Clean.
Sparkplug, gaps' too na.r row ~
Adjust to correct gap.
Intak e air leak.
Faulty ignition•..
ENGINEMISFmE~.A'I'
. Tighten. Replace gaskets if nec
essary.
Clean,adjust,or replace breaker
pOints,spark plugs, condenser,
etc.jor retime ignition. '.
ijEAVY 'LOAD
Clean, adjust, or replace br,eaker
,points, spark plugs, condellser,
etc.,. or retime ignition.
Cloggedc~rburetor.
82
S ERYIC E DIAGNOSIS
POSSIBLE CAUSE
REMEDY
ENGINE MISFIRES AT HEAVY LOAD (Cont. )
Clogged fuel·screen.
Clean.
Defective spark plug cable.
Replace.
ENGINE MlSFIRES AT ALL LOADS
Fouled spark plug.
Clean and adjust.
Defective or wrong spark plug.
Replace.
Leaking valves •
Grind valves.
. Broken valve spring.
Replace.
Defective or impropedyad
justed breaker points.
Adjust or replace breaker points.
LOW OIL PRESSURE
Oil too . light or diluted from
leaking fuel pump diaph:ragm.
Drain, refill with proper oil. Re
pair or r.eplace fuel pump.
Oil too low.
Add oil.
Oil relief valve not seating.
Remove and clean, or replace.
Badly worn bearings.
Replace.
Sludge on oil screen.
Remove and clean.
Badly worn oil pump.
Replace.
Defective oil pressure gauge.
Replace.
HIGH OIL PRESSURE
Oil too heavy.
Clogged oil passage.
Oil relief valve stuck.
Defective 011 pressure gauge.
Drain, refill with proper oiL
. Clean aU· lines. and paiilsages.
Remove and cJean.
Replace.
SERVICE DIA GNOSIS
POSSIBLECAUSE
83
REMEDY
ENGI~EBAC:£(FIRES
AT CAE BUEE'!'OR
Lean fuel mixt.ure.
Cleap. carburetor.· Adjust jets.
Clogged fuel filter.
Clean.
Airleakat .intake. manifold or
carburetor flange ..
Tighten mounting screws..~~place
gaskets as necessary.
Poor fuel.
R¢fill with good,freshfuel.
Spark advanced toqfar.
Reset breaker pOints 01' retime ig
nitiOn.
.
Intake valve leaking.
Reseat or replace.
EXCESSIVE. OILCONSUMJ:~TION, LIGHT BL UE..~XHA UST
Poorcompres.sion..~
.......
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iALTERNATING CURRENT, 120VOLT, 1 PHASE, 2 WIRE
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®CONNCcrO'R iii!' 33/ o Z7
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