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WISCONSIN

MODELS V465D
V41NID, V461D

REPAIR

WISCONSIN
~ MOTORS, LLC

FOREWORD
Goodoperation and a plannedmaintenance programas outlined in this manualare vital in
obtaining maximumengineperformanceandlong enginelife. Theinstructions on the following
pageshavebeenwritten with this in mind,to give the operatora better understandingof the
various problemswhichmayarise, andthe mannerin whichtheseproblemscanbest be solved
or avoided.

Theoperatoris cautionedagainst the use of anyparts, other than genuineWisconsinparts,
for replacementor repair. Theseparts havebeenengineeredandtested for their particular
job, andthe use of anyother parts mayresult in unsatisfactoryperformance andshort engine
life. Wisconsin
distributors anddealers, because of their close factory relations, canrender
the best andmostefficient service.

THE LIFE OF YOURENGINEDEPENDS
ON THE CAREIT RECEIVES.

The MODEL,SPECIFICATION and SERIALNUMBER of your engine must be given when
ordering parts. The MODEL and SPECIFICATION numberare on the nameplate. The SERIAL
NUMBER is stampedeither on the crankcaseor the engine’s identification tag.

Copy the MODEL,SPECIFICATION and SERIALNUMBER
in the spaces provided below so
that it will be availablewhenorderingparts.

MODEL SPECIFICATION

SERIAL NUMBER

To insure promptandaccurateservice, the following informationmustalso be given:

1. State EXACTLY
the quantity of eachpart andpart number.

2. State definitely whetherparts are to be shippedby express,freight or parcel post.

3. State the exact mailing address.

IMPORTANT
READTHESE INSTRUCTIONSCAREFULLY

All pointsof operationandmaintenance havebeencoveredas carefully as possible,but if further
informationis required,sendinquiries to the factory for promptattention.

Whenwriting to the factory, ALWAYS
GIVE THEMODEL,SPECIFICATION
ANDSERIAL
NUMBER
of the enginereferred to.

Starting and OperatinqNewEngines

Carefulbreaking-inof a newenginewill greatlyincreaseits life andresult in troublefreeoperation.
A factory test is not sufficient to establishthe polishedbearingsurfaces,whichare so necessary
to the properperformance andlong life of an engine.Thesecanonly be obtainedby runninga
newenginecarefully andunderreducedloads for a short time.

¯ Besurethe engineis filled to the properlevel with a goodquality engineoil.

¯ For properprocedures
to follow whenbreaking-ina newengine,see’Testing Rebuilt Engine’.

Thevariousbearingsurfacesin a newenginehavenot beenglazed,as they will be with continued
operation,andit is in this periodof "runningin" that specialcaremustbe exercised,otherwise
the highly desired glaze will never be obtained. A newbearing surface that has oncebeen
damaged by carelessnesswill be ruined forever.

IMPORTANT SAFETY NOTICE
Properrepair is importantto the safe andreliable operationof an engine.This RepairManual
outlines basic recommendedprocedures,someof whichrequire special tools, devicesor work
methods.

Improperrepair procedures
can be dangerous
andcould result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE

Warninglabels havealso beenput on the enginesto provideinstructions andidentify specific
hazardswhich,if not heeded,couldcausebodily injury or deathto youor other persons.These
labels identify hazardswhich maynot be apparentto a trained mechanic.Thereare many
potential hazardsfor an untrainedmechanic
andthere is no wayto label the engineagainstall
suchhazards.Thesewarningsin the RepairManualandon the engineare indentified by this
symbol:

z WARNING

Operationsthat mayresult only in enginedamage
are identified in the RepairManualby this
symbol:

,&CAUTION
WisconsinMotors, LLCcannotanticipate every possible circumstancethat might involve a
potential hazard;therefore, the warningsin this manual
are not all inclusive. If a procedure,
tool, device or workmethodnot specifically recommended by WisconsinMotors, LLC,is used,
youmustsatisfy yourself that it is safe for youandothers. Youshouldalso ensurethat the
engine will not be damaged or madeunsafe by the proceduresyou choose.

IMPORTANT: Theinformation,specificationsandillustrations in this manualare based
on informationthat wasavailable at the time it waspublished.The specifications,
torques, pressuresof operation, measurements, adjustments,illustrations and other
items can changeat any time. Thesechangescan affect the service given to the
product. Get the completeand mostcurrent informationbefore starting any job. For
parts, service, or information, contact WisconsinMotors,LLC, Memphis, Tennessee.

these items are provided by the manufacturerof the end item in which the engine is used. rings. iii . ties. hydraulic pumpsand generators. or near. movingparts. Useor service of the engine(including the useof modifiedparts or materials) not in accordance with manufacturer’sspecifications could damage your engine or causepersonal injury. to avoid any hazardsinherent to these sub-systems. Injuries maybe causedby lack of care whenworking with. LLC. solvents.or fuel systems. fuel lines or other fuel system components. Alwaysobservesafety precautions. hot parts. LLC. WARNING Someequipment and materials used in the overhaul or maintenanceof an engine such as machinetools. Readandobserveall individual safety warningsas you use this manualto operate. WARNING Most sub-systems used in conjunction with Wisconsin Motors.clutches.however. electrical equipment. electrical connections or other electrical components.fans. gasoline or other fuels maybe dangerousand can causeinjury. are not supplied by WisconsinMotors. pressurizedsystems. Improperattire suchas looseclothing. hoses. service or repair your engine.batteries. Always wear eye and hearing protection whenworking on or near engines. fuel tanks. soft shoesor bare feet couldbe hazardous and should be avoided whenservicing engines. Someof the dangers associated ’with servicing such items are generally mentionedin this manual. transmissions. Alwaysexercise caution wheneve="working with an engine or any associated system.the appropriate handbooksand safety instructions provided by the manufac- turer of the enditem should alwaysbe consulted prior to the undertakingof any work on sub- systemsattached to the engine.compressed air. industrial engines including (but not limited to) radiators.electrical equipment.

without first removingthe ¯ Do not spin handcrank whenstarting. whichif breathedcausesserious ¯ When starting engine. Turningthe machineryover by hand during adjusting or crankingcomponents clean andfree from conditions cleaningmight start the engineand machinerywith which might causethe crank jaw to bind and not it. Displacement Models V461 D. invisible gas. a poisonous. Model V465D 3-3/4" Bore m 4" Stroke 177 cu.M. Keep ignition cable fromthe spark plug. in. odorless and ¯ Alwaysrefuel slowly to avoid spillage.P. Displacement 2 . Nevermakeadjustmentson machinerywhile it is ¯ Donot start enginewith clutch engaged. releaseproperly. SAFETY PRECAUTIONS ¯ Neverfill fuel tank while engneis runningor hot. the exhaustis pipedoutside. ¯ Neverrun engine with governordisconnected. familiarize yourself with the operating instructions. Keep this book handy at all times. This exhaustcontains carbon monoxide. accidents.load. from movingparts of equipment.4" Stroke 154 cu. V460D 3-1/2" Bore.Oil periodically to preventrust. causingseriousinjury to the operator. maintain a safe distance illness andpossible death. Donot operateenginein a closed building unless avoidthe possibility of spilled fuel causinga fire. connected to the engine.or Precaution is the best insurance against operate at speedsin excessof 2400R. in.

.................................................................. 30 Rotation ........................................ 10 Carburetor andManifold ........................................................................................................... 24 TestingRebuilt Engine ........ 15 Knocking ............ 34 Missing .....................30 FuelMixture ................................................. 16 Lubrication System ................................................................................................................................................................................................ 13 OilPressure ReliefValve ..................................................................................................... 29 Engine Stops.......... 12 Surging or Galloping .......................................................................................... 25 Stopping Engine -.............................................................................. i FuelPump ........... 18 Take-off View ................. 12........................................... 14 Overheating .. 19 Sectional Views .... 21 Generator ................... ShellType....................................................................................................................... 12 .....................................................12 GeneralInformation andDesign .......... 18 FanEndView . 17 Crankshaft andMain BearingPlate........................................................................................................................................................................ 26 Storageof Engine for Winter .................................................................................. 21 Electrical Wiring Diagrams Lowor NoOilPressure ...................................................... 38 Camshaft Gear........................................................................................................................................................................................................... 26 Neon Lamp Timing ............................................................................................................................................................................... 15 StartingDifficulties-... 10 Gasoline Strainer ................... Pre-Cleaner .............. 13 PistonRingandRodClearance Chart......... 2 Cylinder Head.................................................................. 21 Distributor IgnitionwithAlternator ........ 9 Gear Cover....................................Gradeof andServiceClassification .................... 16 EngineSupports andOilPan........................... 25 Oil -................... 27 Safety Precautions ..................................................................... 8 Alternator-........................ 20 Piston Rings .......................Roller Type(Older Models).................... 25 StartingProcedure .. 15 Bearing -.......................... 20 Valves ................................................................ 23 MagnetoService Camshaft ......................................................................................Overspeeding ........................FuelMixture ................................................................................................... ii-iii Cylinder Barrel...BeltDriven .............................................................................................................Electric.................... 31 Magneto Timing .................................... 25 SolidStateIgnition Distributors .......................................................................................... 11 Cooling .... 11 GovernorAdjustment andOperation ............................................................................................................................. 12 OilPressure Reducing Valve ............................................................ 30 Compression............................................................................. 23 Starting andOperating Instructions ........................................................................................ 12 Ignition Spark................................................... 28 Timing Marks ................. 9 Warm-Up Period-................................................ 31 Safety Notice ................................................................. Engine Clutch Adjustment ............................... 8 Connecting RodandPiston.................................................................. 17 Breather Cap..................................................................................................................................................................................... 24 StartingandOperating New Engines ........................................... 27 SafetySwitch-.............. 20 Valve Tappet Adjustment ..............................................Restoring .... 32 OilPressure andAdjustment ................................... 10 Gear Train................... 8 CarburetorAdjustment ............................. 10 Horsepower ............... 12 ZenithModel 87A8 ......................... 15 OilPump ........................ 31 Timing Instructions ...... 21 ValveGuides andSeatInserts........ 8 Flywheel Shroud .......................................................................... 21 Magneto Ignition .. 19 Cylinder Shrouding ........... 21 Fuel.............................. 28 Rocker Arm Covers .......................................................................................................................... 16 Carburetor Service Ignition System ...................................................................................... 9 CenterMainBearing........................................................................................................................ 21 RockerArm Assembly ...................... 24 Spark Plugs ............................................................................................ 16 FuelPump andPriming ..................................................................................................................... 29 Troubles -.....................11 Accessories ............. 23 Governor ........................................................... 20 ElectricWiringCircuits ....Center Main ........ 9 Flywheel ....................... 13 Piston ...................HighTemperature ............................... 20 Distributor Ignition withGenerator(OlderModels)....................................... 10 Lubrication ...................................................Anti-Diesel Valve .............................................. 3 Dieseling.......... 30 OilFilter................ 8.......................................................................................................................................................................................................Vapor Lock.......................Causes andRemedies ..... 10 CenterMainBearing............................... CONTENTS AirCleaner.............................................................................................................................. 11......................................... 35-37 Illustrations....................................... 14 IdlerGearandShaft... 23 LubricationSystem .... 34 Generator (OlderModels) ................................. 5 Clutch Reduction Unit...................................................... 26 StartingMotor -...................... 3940 DistributorandAccessory Drive................................................................................................ 8 KeepEngine Clean .............................................................................................. 20 FiringOrder ...... 25 Timing ............ 9 Valves -............................................................................................................................................................................... 29........................................7 Compression-........................................ 8 Disassembly andReassembly ...................... 30 Fairbanks-Morse TypeFM-X4B7D ................................................................................... 5 Clutch Power Take-off ................................................................................................................................................................... 30 High OilPressure ................................ 32 Distributor Timing ................................................................................................................................................................................................................................... 21 Distributor Maintenance ................................................. 14 Ignition ................................................................................................................... 28 Backfiring Through Carburetor ............Grinding......... 6................................................................

8. See Page 12. change. Pages 8 and 9. If dirt and chaff are allowed to accumu- 5. 1. 3. ditions. Keep space between cylinder banks clean. to full mark on oil gauge saber. The screen deflects foreign materials away 7. accumulated dirt frequently. B. Keep filled tween fins of cylinders and heads. Every 4 to 8 hours. See Oil Filter baffle plates to insure uniform cooling of both banks instructions. 4. Cylinder head covers can be removed by releasing snap clips and unscrewing wing nut. conditions. will restrict the intake of cooling air enough to bring about an overheating condition. The air is divided and directed by ducts and replace cartridge every oil change. If operating conditions are extremely dusty ing. Every 8 hours check crankcase oil level. 2. cleaning and maintenance instructions to insure trou. which 6. Accumulated late in the cylinder shrouding or in the V between dirt caked on screen will restrict cooling. creating an overheating condition. Do not allow shrouding to become damaged or bad- ly dented as this will retard air flow. cylinder banks. Read instructions on air cleaner regarding its care. vent to clean out dirt gathered in the back fire mended for engines operating in dusty and dirty con. The collector type pre-cleaner must be emptied of from the air intake opening and helps maintain maxi. and washed in a sol- The rotating screen. follow these few Never operate engine with air shrouding removed. Clean out all dirt and chaff from interior of shroud and from be.’ ble free and satisfactory engine performance. Even a small section of screen clogged up with dirt this must be kept dry. of cylinders. Every 50 hours drain crankcase and refill with fresh oil. illustrated in Fig. KEEP EN( INE CLEAN PREVENT OVERHEATING This engine is cooled by a flow of air from a combi. the flow of cooling air will be re- stricted. Page 10. trap and filter element. depending on dust conditions. could result in costly repairs. but no more. B . depending on dust mum cooling efficiency. Removedirt an. Rotating screen must be kept clean. Replace this oil filter cartridge every other oil nation fan-flywheel. A Fig. is recom. Keep rotating screen clean.~ chaff from cylinder heat deflectors See Lubrication. encased in a sheet metal shroud. check air cleaner and change oil. The entire air cleaner should be removed from the engine at least once a year. at manifold ports. With reference to Figures A and B. 6 4 Fig. Do not use oil or water in pre-cleaner.

STARTER SWITCH CYLINDER NU VOLT AGE IGNIT ION fWHEEL SHROUD GENE DISTRIBUTOR PREoCLEANE FUEL PUMP HEAT SHIELD OIL BATH ~ AIR CLEANER GASOLINE STRAINER PUMP L GAUGE SABER STARTING SO STARTING MOTOR~ OIL FILTER OIL DRAIN PLUG -OPTIONAL- OIL GAUGE AND FILLER LOCATION Fig. MUFFLER ANTI-DIESE LING SOLENOID ROCKER ARM COVERS BUTTON VARIABLE SPEED OIL FILLER AND ~IOR CONTROL BREATHER CAP PRESSURE GAUGE . 1 .

GENERATOR DISTRIBUTOR VOLTAGE REGULATOR .CESSORY DRIVE ASSEMBLY CARBURETOR~ GOVERNOR: ADJUSTING SCREW ~LEVER ~ GOVERNOR ASSEMB~ /SPRING LOCKNUT~ ANTI-DIESELING~ SOLENOID FLYWHEEL AIR SHROUD I t. IGNITION COl.~.~_~ CAMSHAFT THRUSTPLUNGI OIL UEL PUMP MAINBEAI: --CAMSHAFT IDLER ~-MAIN BEARING HAND CRANK DIL PUMP FAN-FLYWHEEL SECTIONALVIEWS OF ENGINE 6 .

CLEANER\ / GASOLINE STRAINER EXHAUST // ~-OIL FILLER AND / ROTATOR BREATHER CAP . V-461D AND V-465D .~TTAPPET ADJUSTING SPARK PLUG- SCREW \\ / / HI. ~OIL PRESSURE REDUCING VALVE rOlL BATH AIR CLEANER EXHAUST MUFFLER / PRE.TEMP SAFETY L DIP STICK SHAFT LOCK-SCREWS STARTING SOLENOID STARTING MOTOR OIL PRESSURE j RELIEF VALVE~ ~ OIL DRAIN PLUG ~CENTER OIL FILTER MAIN BEARING MODELS V-460D.

2 64.this will retard the air 2400 56. and the of the crankshaft. All engines The standard oil gauge saber is located on the left are equipped with either fixed speed governors. but butor.8 60. and check level by meansof the oil gauge saber.5 Never operate an engine with any part of the 2000 50. IGNITION For each 10° higher temperature. as specified in "Grade element. altitude above sea level. LUBRICATION All of the circulated oil passes thru a full. and at a Barometric pressure of 29. cover.0 2800 60. The flywheel gives one power stroke per cylinder for each two revolutions end of the engine is designated the front end. the opposite side. in which viewing the flywheel or cranking end of the engine. Electric starter and alternator are furnished with be a reduction in horsepower of distributor ignition.4 63.2 52. This the power take-off end of the engine. or an idle control. as a safety factor. The friction in new engines cannot be reduced to the Magnetoignition can be furnished in place of distri.9 41.0 cooling. deduct 3~/2% from above horsepower. -.ex. when specified. tap. For each inch lower Barometer reading. GENERALINFORMATION AND DESIGN ROTATION The rotation of the crankshaft is clockwise when Wisconsin engines are of the four cycle type. 1800 45. V-465D combination fan-flywheel encased in a sheet metal V-461D shroud. 1.9 Impropercirculation of cooling air will cause engine to overheat. an addi- tional | quart of oil is required. engines will develop at least 85 per cent of maximum is fitted with an impulse coupling that provides a power when shipped from the factory. each of the four operations of intake. COOLING Cooling is accomplished by a flow of air. is furnished by a balanced carburetor. limit to 80% of horsepower pets.5 65.M. The air is divided and directed by ducts and 1600 40. For continuous operation. thereby minimizing friction and reducing of Oil" chart.6 baffle plates to insure uniform cooling of all parts. behind the starting motor. A gear type pump provides pressurized lubrication to the connecting rod bearings. the rear end of the engine. GOVERNOR For run-in of new engines. Fill through the breather tube opening wear to critical moving parts of the engine.7 shrouding removed. there will be a re- The spark for ignition of the fuel mixture is directed from duction in horsepower of 1%. Crankcaseimpurities are collected in the filter correct grade of lubricating oil.5 Keep cylinder and head fins free from dirt and chaff. compression. HORSEPOWER The horsepower given in the above chart is for an CARBURETOR atmospheric temperature of 60 ° Fahrenheit.4 2200 53.P. giving correct fuel to air ratios for all speeds and loads. by a distribu- For each 1000 ft. The engine will develop approximately 95% LUBRICATIONSYSTEM of power shown on chart when friction is reduced to a minimum. by a V-460D R. circulated HORSEPOWER CHART over the cylinders and heads of the engine. ultimate minimum during the regular block test. valve train and to an oil spray nozzle in the gear shown. fill crankcase with the filter. When replacing oil filter. power take-off end. See variable speed regulator to control the governed Fig. When specified. at the proper time.flow oil Before starting a new engine. The spray nozzle lubricates the governor and gear train.92 inches The proper combustible mixture of gasoline and air. STARTING AND OPERATING friction crankshaft bearings. The power will powerful spark for easy starting. the engine speed by varying the throttle opening to suit the load imposed upon the engine. This gives counter-clockwise rotation when viewing pansion and exhaust requires a complete stroke. 2600 58. below the oil filler-breather tube. The oil expelled from these areas form a INSTRUCTIONS FOR mist which lubricates the cylinder walls and the anti. increase as friction is reduced during a few days of operation. use same oil as recom- A governor of the centrifugal flyball type controls mendedin Grade of Oil Chart. a saber can be furnished on speed of the engine. of mercury. camshaft bearings.8 56. . a hand side. The high tension magneto used. the coil to the spark plugs. 3000 60. at sea level.6 47. there will tor. with 6 quarts of oil.

Oil should be drained while engine is hot. Viscosity grades. Release choke but- this condiUon. 2 SERVICE CLASSIFICATION OF OIL pistons and bearings will be damaged. Disengage clutch. the bowl. primer lever will move more easily. or when engine has been out of operation for a period of time. causing serious trouble 3. free from dirt and water. Some: of the poorer fuel valve. well known brands of ernor control is furnished. valve stems. These types ofoil are for engines performing FUEL PUMPand PRIMING (Fig. The gasoline should have an octane rating of at least 5. yet it is the cheapest item of operating cost. carburetor bowl. tional view of engine. ton to open position after engine starts. SGor CC which prevents movement of the pump rocker arm.A. start in full load position. as it and if necessary. Select your oil solely on quality and suitability . Assuming the gasoline strainer is empty. and in fact might prevent the engine from operating at all. constant starting and stopping. Aftef strainer bowl is full. will then flow more freely. Summer or Fall SAE30 electric start engines do not require hand priming. If this does not occur. or knock. the engine should "I" 15°Fto 0°F SAE 10W be turned over one revolution so that the fuel pump Below Zero SAE 5W-20 drive cam will be rotated from its upper position UseOils classified as Service SE. To drain oil. Viscosity Numbers listed in Grade of Oil Chart will prove economical and assure long engine life. use same oil as recom. Follow summer recommendations in winter if engine is housed in warm building.for no one thing is so sure to bring about unsaUsfactory performance and unnecessary expense as incorrect lubrication. A. SF.High grade oil of the body suited to the requirements of your engine is the most important single item in the economical operation of the unit. In addition to the S. + 120°F to + 40°F Whenpriming. FUEL STARTING PROCEDURE The fuel tank should be filled with a good quality 1.never o~ price . operating in centric on the camshaft. Keep screw threads clean side. cylinders will score. if furnished. and if operation is continued under sufficient to start the engine. E. remove drain plug in oil pan at oil filter Do not oil Bendix drive. Fig.this classified according to severity of engine service. but re- . Use oils would impede the flow of fuel to the carburetor. page 6. Open gasoline. Hand Primer for hand crank engine is furnished as an GRADE OF OIL option. Crankcase Capacity 6 Qts. classified by the Americal Petroleum Institute as Service SE. New engines require priming. Set throttle about 1/2 open if variable speed gov- Use only reputable. unless otherwise specified. Gravity feed and Spring.ves will bum. trol. See Fig. SFor SG. Check crankcase oil level and fuel supply. refer to "Fuel Pump" paragraph for instructions. High-grade highly refined oils. and in the various small passages in the carburetor. 2. 2) under unfavorable or severe operating conditions such as: The diaghragm type fuel pump is actuated by an ec- high speeds. a distinct resistance of the fuel pump Winter diaghragm should be felt when moving the hand lever + 40°F to + 15°F SAE20-20W up and down. grades of gasoline contain gum which will deposit on 2. as illustrated in cross sec- extreme high or low temperatures and excessive idling. corres- ponding in body to the S. STARTING Checkoil level every 8 hours of operation. lubricate with powdered graphite. approximate- ly 25 strokes of the primer lever are required to fill Additional for Oil Filter I Qt. ELECTRIC STARTING MOTOR The old oil should be drained and fresh oil added A 12 volt starting motor with an attached starting after every 50 hours of operation. When carburetor is full the hand mendedin Grade of Oil Chart. with a two-speed con- REGULAR GRADE gasoline. solenoid is provided as standard equipment on this model engine.E. va~. oils are also Be sure that air vent in tank cap is not plugged. Turn ignition-starting switch to ’start’ position 90. and is a necessary function when starting a SEASONOR TEMPERATURE GRADEOF OIL new engine for the first time. piston rings. in operating. etc. 4. and at the same time pull out choke button only tonate. an additional 5 to 10 strokes are required to fill the For run-in of new engines. Low octane gasoline will cause the engine to de.

As a Racing an engine by disconnecting the governor. as prescribed in ’Warm-Up To rectify this condition.M. That meansthat if the speedis doubled. If operating conditions are speed to suit the load applied. bearings. snug fit. minimize valve necessary.the parts list for correct service part number. but which might its mounting pad on the side of the crankcase. The stub end One of the main troubles caused by the abrupt shut. When the ignition is turned off. Readjustment. rings. but with choke open (choke button in). replace filter after every oil change. This will reduce the internal tem. should be de-energized and releases a valve that shuts off the "run-in" gradually to insure trouble-free service and fuel supply in the carburetor. or by result. to hurry the warm-up period. at 40 to 4S P. is controlled by a pressure relief valve. of the rubber gasket at the base . replacing oil filter. stresseswill be nine timesas great. This is especially important on new passes the filter material by means of a relief valve engines and in cool weather. CAUTION:Engine will not operate if ignition New Engine" instructions. A full-flow oil filter is furnished on this model of en- is very destructive to the polished wearing surfaces gine as standard equipment. is extremely dangerous. in hard starting. as illustrated life will result as a reword for these easily applied in Fig. depending on how hot the P. continue cranking with the ANTI-DIESEL VALVE starting motor. STOPPING ENGINE To stop engine. BREATHER CAP Strict adherenceto the preceding instructions cannot The crankcase is ventilated thru a breather cap he too strongly urged. Refer cause wrecking of the engine and possible injury to to "Oil Filter" in disassembly instructions. and temperature before load is applied. an anti-dieseling solenoid Period’ paragraphs. a few minutes of running at moderate speed. then. valve is provided to assure immediate stopping. See Fig. it is recommended recommendations. and also as a safety extremelydusty. If the engine has been running hard and is hot.I. 3. The governor placement. Do not over-tighten. bearings. At every oil change. etc. use a new fibre washer in reassembly. This requires only tighten to 80 inch pounds torque. for correct running-in procedure. thus stopping the en- long engine life. 3. Use only a Wisconsin oil filter. started for the first time. it is very important that proper oil film on these various surfaces cannot be it be serviced regularly in order to function properly. When the engine when cranking or waiting until the engine engine starts release switch to ’run’ position. Since all of the circulat- on pistons. do not HIGH PRESSURE SYSTEM stop it abruptly from full load.. cylinders.I. When re- bystanders° assembling a new filter. add a film of oil to the face All partsof the engineare designedto safelywith. warping. ting off of a hot engine is vapor lock. cl~oke if ~t tends to stop. pro- engine has been.the stresses specially designed for this model of engine. which The oil filter is easily removed by unscrewing it from not only overstrain all working parts. in. This will result move plug from the end of the valve. The oil filter should be replaced after is provided as a means for controlling the engine every other oil change.P. gauge pressure (was SO for three to five minutes. established until the oil has warmed up and become When the filter element becomes clogged. the solenoid becomes New engines. must be made while engine is running. located in the top of the oil filter. Refer to "Starting and Operation of gine. Even a hot engine re. turn ignition-starting switch to ’off OIL PRESSUREAND ADJUSTMENT position. Refer to will be quadrupled.turn filter to a stand any speedswhich might normallybe required. which can be overcome by choking quires a momentarychoking when starting. Refer to Fig. and greatly increased engine mounted to the top of the oil filler tube. 3 and the following instructions: cluding the manifold and carburetor will also reduce faster. as the ed oil passes thru the filter. allow it to warm up a few minutes sionallydiesel. but it must be rememberedthat the stressesset up in Pour 1 additional quart of oil into crankcase when rotatingpartsincreasewith the squareof the speed. WARM-UP PERIOD If solenoid is removed from carburetor for some rea- The engine should be allowed to warm up to operating son. disconnected. then ½ turn more.).S. measure to guard against excessive speeds. the oil by- sufficiently fluid. on the inside front cover wire from anti-diesel solenoid to starting switch is of this manual. before applying load. If flooding should occur. has cooled off sufficiently to overcome the vapor lock.S. and of course the external temperature. High compressionengineshave a tendencyto occa- After engine starts.and if the speedsare trebled. perly adjusted at the factory. Re. due to air circulation from the flywheel° The oil pressure relief valve is located beneath the starting motor and next to the oil filter. Racing OIL FILTER an engine or gunning it. of the valve is closed off by an expansion plug. with a .afterthe ignitionhas beenshut off. there is no variation in oil pressure to indi- doing anything to interfere with the governed control cate that the oil filter is clogged and requires re- engine speed. that the cap be cleaned by washing in kerosene. but remove the load Oil supplied to the center main and connecting rod and allow engine to run idle at 1000 to 1200 R. when perature of the engine much faster.

valve train and gover. Caution: Do not clean with gasoline. LUBRICATION SYSTEM 3/16 Allen wrench.I. air cleaner from engine and soak in solvent to clean placed with a completely new unit. If valve becomes faulty it should be re. and result in costly repairs. 4904657.) DRAIN HOLES For PushRodTubes OIL S CENTERMAIN BEARING HIGH PRESSUR OIL HEADER LINDER WALLSANDMAIN BEARINGSARE LUBRICATED ADJUSTING BY OIL MIST ANDSPRAY THROWN OFF THE CONNECT- OIL PRESSURE RELIEF ING RODSANDCRANKSHAFT. EXHAUSTROCKERARM ROCKERARM LOW PRESSURE OIL HEADER OIL PRESSURE GAUGE DRAINLINE OIL SPRAYNOZZLE.3. and engine follows: Oil pressure to the rods is channeled thru oil hot.S. or low pressure oil header. nor-gear train nozzle at 3 to 4 P..~I.M.i. to the level line indicated on the oil cup. adjust oil pressure 40 to 45 P. Once each week.p. and if oil pressure falls below 15 the center main bearing instead of thru a collet on the P. remove iustable). remove the outer lock screw. rings and bearings in The pressure reducing valve. Add the same grade of oil as used in the header. when making this check. tt~.. See Fig. 2 cylinder beneath the air duct of No. HIGH OIL PRESSURE OIL PL LOWOIL PRESSURE STRAINERSCREEN STILLOIL or OIL FILM / OIL DRAINPLUG Fig. must seal off any oil which may by-pass the screw threads. crankshaft gear. ~/. be serviced frequently. mount outer lock screw AIR CLEANER firmly in place. turn clockwise to increase gauge ter main bearing replaces the roller bearing. Use a new 3/4 inch expansion plug to The oil bath air cleaner. tappets.S. case in front of No.P. crankcase. bear.s..P.turer (not ad. tively clean conditions.I. out accumulated dirt from element. After adjustment is made. supplies oil to very dusty conditions. mounted on the crank- a few days time. and lub- pressure. but can be checked by connecting a low pressure Detailed instructions are printed on the air cleaner. LubricatesGovernor andGearTrain FILLERAND BREATHER CAP GAUGE SABER (Dip Stick) PRESSU REDUCINGVALVE INCH PIPE PLUG For LowPressure For CheckingLowOil Oil Header Pressure Line(3 to 4 p. illustrated in Fig. adjust spring tension by means of Beginning with serial No. 11 . LOCKSCREW OIL FILTER EXPANSION PLUG(3/4 dio. out oil in the air cleaner or with dirty oil. With CENTER MAIN BEARING (V. gauge to the 1/8" pipe tap located at the take-off end of the engine above the camshaft plug. Idle engine the crankshaft by means of an oil line connection to at 1000 R.ru a pressure Remove oil cup from bottom of air cleaner and clean reducing valve from the main or high pressure oil thoroughly. in compara- the camshaft bearings. Operate the Operating the engine under dusty conditions with- engine at 1800 R. may wear out cylinders.M. This pressure is not registered[ on a gauge. 3. check for irregularities in the oil pump. ings and oil connections. pistons. Oncea year. 2-4 bank. is pre-set by the manufac. oftener if conditions are severe.465D) the same wrench. depending on the dust condi- tions in which the engine is operated.I. rication to the connecting rod bearings is modified as NO’rE: With engine running at 1800 Ft. LOW PRESSURE SYSTEM Service daily or twice a day if engine is operating in The upper. counter-clockwise to reduce pressure. a shell type cen- the adjusting screw..S. naptha or benzine.

4 is the other cylinder in this bank. flywheel in the left bank of cylinders.Cleanbowl and screen thoroughly. matic advance type and it is driven off an engine Clean bowl regularlyof accumulateddust and dirt. that is.Repair kits are availablefor The firing order of the cylinders is 1-3-4-2. refer to partslist in rear of battery type distributor rotates at one-half engine manual. it requires no adjustment. this must be thus driving the distributor rotor at one half engine kept dry. No. speed in a counter-clockwise direction when viewed from above. The 12 .dirt and waterfrom enteringthe carburetor SOLID STATE IGNITION DISTRIBUTORS and causingtroubleor even completestoppageof the ManyWisconsin engines are now being equipped with a solid engine. 5 Fig. There will be less dangerof breakingthe gasketif the bowl is TIMING givena twistas it is beingremoved. PRE-CLEANER The collector type pre-cleaner. speed shaft through a pair of two to one ratio gears.Replacegasket if it has become FIRING ORDER damagedor hardened. 1 cylinder is the one nearest to the The main metering jet in the carburetor is of the fix. manual. 4 Manufacturer’s Instruction Bulletin in the back of this manual.P. when GASOLINE STRAINER checking or adjusting spark advance. The idle from the flywheel end of the engine. removesthe A battery ignition system is standard equipment on largerdirt and dust particlesbeforethe air reaches this model of engine. repair and inspectedfrequently. To remove sedimentbowl. Do not use oil or water in pre-cleaner. 5. 2 cylinder is the tion. the distributor is fully advanced at 2000 R. 3 cylinder is needle should be adjusted for best low speed opera. mountedto the top of IGNITION SYSTEM the air cleaneras i11ustratedin Fig. loosen nut below bowl and swing wire bail to one side. and the servicereplacement. The gasolinestraineris very necessaryto prevent sediment. speed.and cleanedif dirt or waterare parts information can be found in the rear section of this present. No. Detailed troubleshooting. see Fig. 4. Daily attention to the air cleaner and pre-cleaner is one of the most important considerations in prolong. For one nearest to the flywheel in the right bank of cylin- illustrations and more information. COLLECTOR TYPE PRE-CLEANER----~ iE CONNECTIONS OIL BATH AIR CLEANER OIL LEVEL Fig.P. or over. the other cylinder in this bank. see Carburetor ders and No.M.This strainerhas a glassbowl and shouldbe state ignition distributor. as is the case with conventional ’in line’ en- gines. Engine must be running at 2000 R. The intervals between the firing of the cylin- CARBURETOR ADJUSTMENT ders is 180°.M. The running spark advance of the engine is 23° and ing engine life. The distributor is of the auto- the main air cleaner. when viewed ed type. while carburetor throttle is closed by hand. No.

7 breaker points are firmly closed. Continue turning the engine over until the leading edge of the ’X’ marked vane on the flywheel is in e. Mount distributor clump to drive housing.o’clock posi. ing wilI affect the ignition advance. cylinder-banks. With the clamp screw loose. or tributor body is set and locked in place. before dis- o’clock position as illustrated in Fig. AR[ JUST 8[G~NNtNG TO OPEN ADVANCE ARM TIMING INSTRUCTIONS: The No. The No.NG SCREW~ taking out the screws holding screen in place. Assemble distributor to housing.020 of an inch should be til the rotor contact points in an approximate 2 checked and adjusted per paragraph (e). ready to fire in the retarded position. Fig. ROCKER ARMASSEMBLY Inlet RockerArm Movement\ FORNO./~ppRROTOR CONTACT head covers. is located a.DJUST. g. graphs (f) and (g).~ A~von~. 1 and opening. and mount distributor as foiiows: er points are just beginning to open. Before mounting distributor to housing. o~N̄ [ CYUNOCR ~XH. 7. 3. Fig. 1 cylinder is now b. 1 piston must be ~-CLAMP SCREW on top dead center of the compression stroke before distributor can be mounted. 1. Fig. PRESTOLITE DISTRIBUTOR this can be accomplished as follows: or stud in an approximate 12 o’clock position. Remove rocker arm cover from No. Adjust breaker point gap to 0. This ROTOR will expose the timing marks on flywheel shroud.USTVALVE~ TOR ROTATE BODY CLOCKWISE UNTIL BREAKER POINTSARE JST BEGINNINGTO OPEN R~n~in~Sp~. distributor cap. remove rotor and dust cover. 7A. turn distributor body 4. 2. as per valve opens and then closes. Mount rotor on shaft and turn uno The breaker point gap of 0. 1 CYLINDER duringCrankingCyclejust\ Jboth Valves Closed when beforeCompressionStroke. f. tributorbody in a clockwise rotation until break- for Prestolite. With reference to Fig. OX. refer to Fig. away and in a 12 . 13 . 7. properly mesh. At this point a slight resistance can be felt as the a. Then turn dis° for the revised Delco-Remy distributor or Fig. shown ROCKERARM .020 inch maximum line with the centerline mark of the No. 6. tion as shown. Tighten clamp screw. 7o DELCO-REMY DISTRIBUTOR Fig.4. t O’CLOCK POSITION ADVANCE ARM TIMING MARKS (Refer to Fig. 6 cylinders are numbered from i to 4 on the cylinder ~. If applicable. take off breaker point cam strikes the breaker arm.4.~ ¯ ~/" "X= MarkedFlywheelVane ~/~. 1 piston now slightly in a counter-clockwise rotation so that on TDC of the compression stroke. Hold distributor with face up and terminal wire or terminal stud. 1 cylinder bank. 7. 6) Remove screen over flywheel air intake opening by BREAKER POINT . as per para- o’clock position as in Fig. Ho~.~ / /~ ~ ~ ADJUSTING SLOT {or Timing Lig. Turn engine over with hand crank until the inlet but do not tighten screw.~.t ~ ~ "~ LOCKSCREW Fig. see ’Distributor Maintenance’. Mount dust cover ing the gears while retaining the terminal wire and distributor cap. DISTRIBUTOR TIMING: With the No. 7. also the vane on flywheel marked by an ’X’ and the letters LOCKSCREW~~~ ~ ~ NOTE: On engines equipped with a rotating screen COUNT-EN-CLOCKWlSE attached to the flywheel. tighten advance arm mounting screw to the drive housing. thereby not requiring removal of the rotating screen when timing the engine. d. because any change in gap open- c. the leading edge of the ’X’ marked vane is identified by an ’l’ stamped on the ~’-CONDENSER outer rim of the screen.

points. 20Woil.htened. with the center terminal until the white flywheel vane matches up with the advance tower connected to the ignition coil.~RUN DISCHARGE fo. 8. Seal plug in reassembly. very slightly and insert a feeler gauge between the nected to the battery. when tim- for spark plug identification.. spark plugs of like numbers.P. Every 50 hours of operation. to the felt in the top of the cam sleeve. The engine shouldbe timed to the 23°advanced posi- DISTRIBUTOR MAINTENANCE tion at not less than 2000 R. however. 8) would not be accurate.WIRING DIAGRAM If care is exercised in the preceding instructions. If it does not. Turn engine over by means of the starting crank until the distri- Connect the red terminal clip. At the time of the flash. open or CYLINDER close points as required until a slight drag is felt No. white.P. the automatic advance in the distributor will not be in the "full advance position" and thus the timing NEONLAMP TIMING (Fig.SPARKPLUGS ~ ~ 4 ~ROTATION CARBURETOR VOLTAGE REGULATOR Hf-TEMPERATURE ’PRESTOLITE ’ REGULATOR~ I ~ Fig. RUNNING SPARK Every 100 hours. to the metal portion of the screw the cam. with reference to Fig’s. | terminal tower for the Delco-Remydistribu. Fig.. since it is self-lubricated by oil RED TERMINAL CLIP in the accessory drive housing. The new style Delco. Then with the engine operating at 2000 R. By means of a screw driver inserted into the adjusting slotof the Delco-Remy distributor or by the CENTERL~NEOF No.P. Check timing with a neon lamp as shown in Fig. Fig. The No. ing. Tighten lockscrew and recheck gap. STARTINGSOLENOID ~E~TER ’~’’~ O~. 9. gram. Loosen the stationary contact Iockscrew driver. 14 . DELCO-REMY DISTRIBUTOR MOUNT|FIG . or over.020 inch at full driver into the No. timing hole. as illustrated in Fig. Every 200 hours of operation. Be sure clampscrewis then carefully tig. apply 3 to 5 drops of light engine ADVANCETIMING HOLE oil (10W). (DISTRIBUTORIGNmON -. The terminal sequence is 1-3-4-2 in a clamp screw should be loosened and the distributor body counter-clockwise direction. 8. 1 and adjusting screw of the Prestolite distributor. 7B. The old style Delco-Remy distributor has a built-in oil reservoir. from a conventional butor breaker arm rubbing black is on a high point of type timing lamp. the WITH GENERATOR spark timing should be accurate enough for satis. ] SPARK when sliding feeler gauge between the points. Fig. 7 or 7A.td. checking spark advance SeePage34) with a neon lamp. 9 DISTRIBUTORIGNITION -. making contact with the spark plug wire terminal.~ C/ Cl ARGE ~~ ~ BAT TER~ IGNITIONCOiL -. and in should line up with the running spark advancetiming hole an approximate 1 o’clock location for the Prestolite on theflywheelshroud. 7B. allow the flash from the neon lamp to illuminate the whitened tor is located in an approximate 2 o’clock position on vane. 8 and 1 or 2 drops to the breaker arm pivot. the leading edge of the vane the distributor cap. See ~/iring Dia. One of the other two timing lamp wires is con. and the other to ground. as described in ’Neon Lamp Tim- Chalk or paint the end of the ’X’markedvane on the flywheel.WIRINGDIAGRAM WITHALTERNATOR factory starting. ing’ is necessary.seeFig. ner.. as required. Mount ignition cables to turned slightly clockwise or counter-clockwise. the distributor distributor.M. 1 terminal tower on the distributor separation and can be adjusted in the following man- cap.Remy distributor does not have an external oil plug.M. insert a small screw The normal breaker point gap is 0. The cylinder shroud covers are marked If the engine is running below 2000 R. the oiler on the side of the Prestolite distributor base should have 3 to 5 drops of medium engine oil added. remove oil plug in base and refill with No..

the gear tooth marked with an "X" will Fig. Remove inspection hole plug. 1 and 3 cylinders. line with the vertical centerline mark on the Battery shroud. 1 ter- minal.~ ¢~O ~ 111. Leading Edge of ’X’ Marked Avoid excessive lubrication. Fig. See Magneto Timing Diagram. 39798()7. meshing the gears so that when magneto is Safety Switch assembled. ground circuit. 1 Terminal Indicated on point grease to breaker arm rubbing block. 1 piston on compression st:rake turn en. Leave. ]0. flywheel in this position (flywheel keyway will be on top). until the leading on the flywheel shroud. 1. Assuming the magneto is removed from the engine.WIRING DIAGRAM 15 . 23° before centerline of the edge of the ’X’ marked vane on the fl. add 3 to 5 drops of medium engine oil into the oil cap at both ends of Mag - the generator. with a neon light. unless otherwise speci- fied. Expose timing marks on flywheel and :shroud. generator was furnished as standard NI2 equipment. Then turn the magneto gear in a clockwise rotation. see Firing Order paragraph page 12 and gliring Diagram. Polarity leads from the magneto should be connected to spark does not affect starting motor. 5. The a negative ground circuit. gine. illustrates. 11. 2. ELECTRICAL WIRING CIRCUITS ~. Position No. I0. coil and battery. 10.Every 200 hours. the ammeter. generator and regulator is knownwhenre-wiring. Fig. Every 50 hours of operation. dard wiring circuits for all electrical equipment is for negative ground polarity. 1 piston on compression stroke. shown. 1 terminal is identified on the magneto cap. See Fig. reverse terminal connections at mounting magneto. Clockwise Rotation. Spark Plugs Starting Motor set magneto for spark discharge to the No. instead of the pre. the advance is indicated by a hole gine over past top dead center. a m. GENERATOR A 12 volt. Magneto Anti-Diesel 6. Place gasket on flange and mount magneto to en. which in- following manner: dicates the centerline of the No.’. 4. until a spark is observed between the wire and frame. Fig. Re- tain gear in this position. ly by hand. MAGNETO TIMING DIAGRAM The wiring diagram. i I ~-’~-Marked Gear Tooth Visible in ~’~JCJ [¢l~zO ~I~-~ Lower HQIfof lnspection Hole Beginning with engine serial No. 17 amp.. To wire equipment that has a posi. Refer This can be checked by turning crankshaft over slow- to ’Timing Marks’ paragraphs on Page 13. or oil the End Cap. The impulse will also snap every 180° of flywheel rotation thereafter. Other Terminals Follow Firing Order in a Vertical Centerline Mark cam wick. Fig.gative hole in gear cover. 1 terminal socket and bent to within 1/8 inch of the magneto frame. timing is accomplished in the wheel iines up with the mark on flywheel. Be sure polarity of The No.ywheel is in No. MAGNETO TIMING Ighen magneto is properly timed the impulse coupling For engines furnished with magneto ignition in place will snap when the ’DC’ . coil and distributor. or vice versa. This is accomplished by use of a short stiff length of wire placed into the No. Oil that mayget on the contact points will cause them to burn. the stan. Solenoid Hi-Temperatur. as per ’Timing Instructions’ paragraphs on Page 13. The running spark advance is 23° . plugs of corresponding numbers. With No. 1 and 3 cylinders. Thegenerator is manufacturedby either the. as shown in Fig. 10 viously furnished positive ground. located in gear cover at magneto mounting flange. tripping the impulse coupling. 11 be visible through the lower half of ’~he inspection MAGNETO IGNITION . Dolco-Rerny Running Spark Advance Company or Prestolite Company.a clockwise direction viewing the cap end.’X’marked vane of the fly- of distributor ignition. on older model engines. The terminals follow the proper firing order of 1-3-4-2 Do not use positive ground generator and regulator in in . To check timing 3. 9. add a small amount of high melting No. Securely tighten nut and capscrew for tive ground polarity.

030 of an inch. If there is a weak spark. No. remove the spark plugs and squirt about a fluid ounce of crankcase oil through the spark plug hole into each cylinder. the exboust rocker orm necessary to install a new condenser.014 inch nate the ignition coil and distributor as the source of trouble. 12. Approximately every 350 hours of operation. Exhaust . or none at all. IGNITION SPARK(Fig. Then reassemble spark plugs and compression should be satisfactory. VALVE TAPPET ADJUSTMENT (Fig. the strength of the ignition spark may be tested as follows: Disconnect the cables Fig. Insert a stiff piece of wire or metal tighten plug until it begins to seat on the gasket. the breaker points may have to be readjusted or replaced. because incorrect settings will have an adverse af- fect on engine operation.The magneto is driven at crankshaft speed in clock* wise direction when viewing gear end of magneto. This may cause difficulty in starting. 12) If difficulty is experienced in starting the engine or if engine misses firing. Check spark plug gap with a wire type gauge and regap as shown in Fig. replace spark plugs with new plugs of correct heat range. 13 from all towers on the distributor cap. Fig. If the ignition spark becomes weak after continued operation. with the tappet in its lowest position (valve complete- ly closed) and the engine cold: Fig. A good spark at each of the towers will elimi. Spark plug gap . Tighten spark plugs to 22 foot pounds torque.020 inch gap. It may be facing the side of the engine. check The rocker arms can be identified as follows: When breaker point opening for 0. Hold the terminal for this then turn 1/2 to 3/4 of a turn more. or the ignition coil may be faulty. like Champion 14 ram. 12 Repeat this check with each of the other ignition Inlet . Turn engine over slowly. To remedy this con- dition. Refer to Magneto Service Instructions in rear of manual for service and adjustment of breaker points. 13. The SET GAP magneto distributor rotor turns at half engine speed. RESTORING COMPRESSION tions with the hand crank and watch for a spark to On a new engine or on one which has been out of op- discharge during the cranking cycle. 14 16 . 14) The clearance between the valve and rocker arm. Magneto breaker point gap is 0.015 inch at full separa- tion. as shown in Fig. 13) The spark plugs should be removed periodically. the oil may have drained off the cylinder so that compression will be weak. two complete revolu. SPARKPLUGS (Fig. N-12Y or equal. Use a new gasket when mounting either old or new plugs and thoroughly clean threads in cylinder head before installation. rod into one of the sockets.008 inch cables. If torque wrench is not available. INLET ARM The width of the gap between the points of the two electrodes must be very carefully and precisely set. except the center coil tower. cleaned and re-gapped. tower 1/8 inch from the wire or rod.0. Turn the engine over several times with the starting crank to distribute the oil over the cylinder walls.0. eration for some time.0.

4 CHECK GASKET SURFACE bank of cylinders.’. and the control 1. carefully replace the cover The governor rod connection to the carburetor must be gaskets to prevent oil leaks. 15 completed. A spring connected to the gover- nor lever tends to hold the govern~r flyweights to their inner position. as illustrated in Fig. This will prevent governor lever should then be moved as far as pos- gasket slippage or deformation when mounting sible in the same direction. The extra turn will shorten GOVERNOR SWIVEL BLOCK CARBURETORTHROTTLE ] LEVER (WIDE OPEN) OPERATION CONTROL ROD The centrifugal flyball governor rotates on a station- ary pin pressed into the upper part of the timing gear cover. 17) valve tappet adjustment. see Fig. then screw rod in one more turn. Old gaskets harden. throttle wide open at that point. Use new gaskets. 1 inlet valve clearance first. at rod must be of such length as to hold the carburetor the rounded end. push the rod toward arm covers. very carefully adjusted for length. FORPAINT ACCUMULATION Mark each rocker arm with chalk as adjustment is Fig. turning crankshaft is made easier. suit conditions by adjusting the governor spring tension. Flyweights are hinged to lugs on the drive gear.peed. until the bent and will very likely leak. 3 inlet can be adjusted. 16. 16 17 . Start by adjust- ing No. 1 cylinder and adjusl: the exhaust clearance. the carburetor as far as it will go. This speed can be varied to Fig. As the engine speed increases. centri- fugal force in the flyweights acts against the spring and closes the throttle to a point where the engine speed will be maintained practically constant under varying load conditions. Smooth scraped area with emery cloth or steel wool. the governor spring will keep the flyweights in. 4 inlet valve. The motion of the sleeve is transmitted through a ball thrust bearing to the gov- ernor lever. Fig. 2 and No. Scrape off any paint that forms a hump. With spark plugs re- moved. the rocker arm carburetor throttle lever in a wide open position. to prevent repetition. ROCKERARM COVERS(Fig. the rod should be screwed in or out 4. Clean gasket faces on the cylinder head and rocker lever. which in turn is connected to the carba- retor throttle lever. 3 exhaust. The cover. also to hold the carburetor throttle open. By means of a ½ inch tappet wrench.is to the right in the cylinder head and the inlet rocker arm to the left. otherwise the gov- If oil does appear around the rocker arm covers. The governor is driven off the camshaft gear and turns 1/8 faster than crankshaft . 15. Holding both parts in the cover to cylinder head. ~ Th~ same procedure applies to the No. for paint accumulation.ainst a flanged sliding sleeve. The sequence in which the tappets are adjusted is determined by the 1-3-4-2 firingorder. Measure the clearance between the top of the valve and the nose of the rocker arm with a feeler gauge. as shown in Fig. after timing or GOVERNOR ADJUSTMENT(Fig. re. starting with No. Spread a thin coat of perma-tex intc. Return to No. turn the tappet adjusting screw clockwise to decrease valve clearance and counteroclockwise to increase the clearance. No. then adjust the No. above position. This will put the 3. end of the rod will register with hole in lever. to hold gasket in place. 14. then by just a short turn of the crank. With the engine at rest. With the control rod disconnected from the governor 2. Check gasket face surface of rocker arm cover. moving it back and forth as the fly- weights move in or out. 15) When reassembling rocker arm covers. Hard- ened pins on the flyweights bear a~. ernor will not function properly and cause the engine assemble in the following manner: to surge badly. take a =set" of the swivel block on the carburetor. 16.

or equal. iS OF but grease gun fittings are provided for periodic bear. First. For the Rockford clutch. Obs olet e PTAo4819 units have a pilot bearing grease fitting at Fig. 2800 2935 1(~’ ~. tion. is furnished with 12 the clutch operating lever. 19. TURNADJUSTING DRIFT PUNCHOR ing lubrication. Insert a screw driver in one of the notches and the no load speed and this must be taken into consi. if the engine is to be operated at 2000 revolu. Fig. A tachometer or revolution counter should be used against the crankshaft to check speed while adjust- ing the governor spring tension. see Fig. Loosen screw holding the adjustment lock m governor. until a very firm pressure is ample.M. while loosening the locknut will lower the spring tension and reduce the R. a vari* convenient method of keeping the take-off shaft from able speed or two speed (over-center idle control) turning. either by means of a and no load speeds of the engine and the hole cor. swivel block. opening in the clutch housing.nt lock is visible thru the inspection to suit the speed at which the engine is to be opera.P.M. RoP. The Governor Lever Chart shows the full load clutch must be held stationary.M. turn the adjusting ring in a counter-clockwise direc- deration when readjusting the governor. 18) The clutch available on this engine is of the dry disc FROM type. by means of the adjusting screw. Sinclair AF-1 grease.M. R. the spring should be Tighten adjusting lock screw and mount inspection hooked into the 6th hole in the governor lever and the cover. As an ex. The housing bearing should be greased COUNTER-CLOCK WlSE SIMILARTOOL every fifty hours of operation and the clutch throwout Fig. 18 2600 2745 9 bearing greased every day before starting. holes for attaching the governor spring.P. No oil should be put into the clutch housing. 19 ROCKFORD CLUTCHADJUSTMENT 18 . to run 2200 R. required to engage the clutch with the operating lever. when a load is suddenly ap. CLUTCHADJUSTMENT(Fig. remove the clutch inspection plate and release The governor lever. 1500 1685 3 HOLE NO. LOAD LOAD NO. otherwise it will become overheated and damaged. This will eliminate exces- sive wear on the threads in the carburetor throttle If the clutch begins to slip it should be readjusted. 1600 1825 4 1700 1855 4 1800 2000 5’ 12 1900 2055 5 2000’ 2oo 6 2100 2230 6 2200 2375 7 2300 2440 7 HOUSING RING 2400 2545 8 GREASE FITTING 2500 2695 9 Fig. 19 or Fig. under no load. Use Mobil ’2700 L 2810 9 Gargoyle grease BRB No. spring tension adjusted. 2900 3065 1 Rockford PTA-4856 units have a sealed pilot bearing 3000 3175 12 and require no external lubrication. 17. The ted. one notch at a time. 3. CLUTCH AND REDUCTION UNITS CLUTCH POWERTAKE-OFF (Fig. Tightening the ad- justing screw locknut will give higher speeds. The speed at full load will then be approximately 2000 revolu- tions per minute. 17 the end of the drive shaft and are lubricated same as the linkage slightly and will enable the carburetor the housing bearing. turn engine over by means of the hand crank until the portant that the spring is hooked into the proper hole clutch adjustme. or by some responding thereto. for either a fixed speed.P. It is very im. tions per minute under load. 20) plied to an idling engine. throttle lever to bounce back from the stop pin rather than jam against the pin. drift punch wedged in place as shown. Note that the full load speed is less than place.

or wedge a screw A new clutch generally requires several adjustments driver into the adjusting yoke and against the side until the friction surfaces are worn in. 21. ER CAP DIL SABER / BEARING GREASEFITTING Fig. to The high temperature safety switch is mounted on the allow lockpin to snap into hole in floating plate. The cause of the over- The throwout bearing should be lubricated once a day heating condition will have to be remedied before the before starting. 21 .AF ETY SWITCH ROCKFORD CLUTCHREDUCTIONUNIT Fig. 22) lever requires a distinct pressure to er~gage. or operating lever jumps out. units. Remove wire from lockpin and turn adjusting yoke slightly.haft counter- clockwise. while unit is warm. if external oil fittings are provided for this purpose. also warp pistons and valves. 90 to No. Therefore. 22 19 . 20 the clutch must be adjusted. as illustrated in Fig.. the same as is used in the power take-off off sufficiently to allow the engine to be re-started.E. same type grease as used in the clutch power take- off units. temperatures become critically high. Turn the adjusfing yoke in a the Twin Disc and Rockford clutch reduction units. Twin Disc units have an external grease fitting for the throwout bearing. no oil should be pul~ in the clutch An overheated engine will score the cylinder walls. The reduction unit is operated in oil and the gear case oil level must be maintained to the oil saber gauge mark or plug opening. use No. 110 Viscosity must be used. 30 S. If clutch slips. See Fig. Refer to "Clutch Ad- hole on the side of the lockpin to keep pin in outer justment" paragraph for adjustment of the clutch in position. of the inspection hole opening to keep yoke from turning. clockwise direction as shown. heats. using the in Troa~les. burn out connecting rod and crankshaft bearings. Tighten yoke enough so tha~: the operating HIGH TEMPERATURESAFETY SWITCH (Fig. The shifter shaft should be lubricated periodically. Causes and Remedies section. 4 spark plug. tion surfaces are worn in. this may ruin the friction surfaces.A. This safety switch will automatically stop the engine when head A new clutch requires several adjustments until fric. Release clutch operat- TWIN DISC CLUTCHADJUSTMENT ing lever and remove hand hole plate. a waiting period of about 5 The clutch in the clutch reduction units is of the dry nutes will be required before the switch has cooled disc type. 21) and stop the engine. pull adjusting [ockpin out the clutch reduction units is the same as is used in and insert a piece of 1/16" diameter wire into the the clutch power take-off units. In Twin Disc units.A. 2]. housing. crankcase oil. No. and then turn the take-off s. cylinder head near the No. Change oil every 2000 hours of service. 20. The clutch in For the Twin Disc clutch. Add grease to fitting thru opening on engine is re-started. For Rockford units.E. Do not let a new clutch slip. See Engine Overheats paragraph side of housing. If an extreme cylinder head temperature causes the switch to automatically short out the ignition system CLUTCH REDUCTION UNIT (Fig. see Fig. high grade transmission oil S. Fig.

nues to drip from carburetor with engine standing idle. to ignite the mixture. Scoredcylinders. Check plunger for spring tension. or position. This will require reboring of the cylinders and Water.Test startingswitchand starting motor and replace or repair if necessary. Breaker points pitted or fused. worn or incorrect If due to flooding. the problem. No fuel in tank. Breaker arm sticking.shut-offclosedor cap ventplugged. Worn and leaking ignition cables. too much fuel entered the cylinder gap.If a remedy mixture on compression stroke. IGNITION Check operation of valve: A solenoid ’click’ should No sparkmay be attributed to the following: be heard when ignition switch is turned to start Ignitioncabledisconnected from coil. Anti-diesel solenoid valve. Valves adjusted with insufficient clearance under valve stems. Poor grade or stale gasoline that will not vaporize Distributor condensor leaking or grounded. See ’Distributor Timing: in attempting to start the engine. is apparent. In that case.the followingcausesare listedunderthe three See ’Restoring Compression’. a 10%variance betweencylinders would mean the engineis improperlyadjusted. See ’Compression: buretor choke open. ENGINE MISSES Spark plug gap incorrect.no remedyis suggested. maintaining satisfactory operation of gasoline en- gines. plete cylinder barrels.CAUSESAND REMEDIES To test for cloggedfuel line. sparkplugs. If line is open. indicate leaking rings. headings:Fuel Mixture. TTP does not consider it practical to publish a PSI compressionfigure for the engineto turn over at a low startingspeed. Often tapping the float chamber of the carburetor very lightly will remedy this trouble. Brokenignitioncables. arise. Do not strike carbu.etc. inoperative. dirt. See "Valve Tappet Adjustment: Fuel pump diaphragmworn out or punctured. Replace solenoid valve if the above doesnot rectify Condensation on spark plug electrodes. Check for disconnected. and Ignition.such as too heavya load can showwhether or not an engine has faulty compression. Goodspark. Damagedcylinder head gasket or loose cylinder head. See "Spark Plugs’. In this case a hissing noise will be heard whencranking engine. See "Timing: Carburetor flooded. or replacement of com- flow of fuel to carburetor. Piston rings stuck in piston due to carbon accumulation. Distributor breaker points pitted. They are: If the starteris ’dead’or is unableto turnthe engine over. Our recommendationis that whatever conditions may affectstarting. properly timed. retor with any metal tool.the causesof troubleare givenin the Loosespark plugs or broken spark plug. or gum in gasoline interfering with free fitting with oversize pistons and rings.a because of the variables involved: engine condition.the en- gine cannotbe started. TROUBLES.fuelshoulddrip Three prime requisites are essential to starting and out at loosenednut. Poor compression. Compression. In each case. This will likewise cause hissing noise on compressionstroke. leaking valves or any of the following: As a guide to locatingany difficultieswhich might Cylinder dry due to engine having been out of use for sometime. See ’Starting Procedure’. A proper fu I mixture in the cylinder. eapecially if en.also check Goodcompressionin the cylinder.and startingswitch. Dirt or gum holding float needle valve in carburetor open.clean plunger Sparkpluginsulators broken. tery. Spark timing wrong.startingmotor. for brokenor frayedcables.Thereare otherfactorswhich Compression check with a commercial compression test gauge contribute to hard starting. These testing. See ’Starting Procedure’. but do not necessarily gauge test is performed.Plugswet or dirty. loose or broken wire. STARTINGDIFFICULTIES FUEL MIXTURE Valve stuck open due to carbon or gumon valve stem.causingshortcircuits. due to escaping gas orderin whichthey are most apt to occur. starting may be accomplished by continued cranking with the car. 3. 2O . and RPMof test. Spark plug point gap wrong. methodof long exhaustpipe with high back pressure. Carburetor not chokedsufficiently. at carburetor. due to excessive choking. the mixture will most Water in gasoline. sufficiently to form the proper fuel mixture.checkbatteryand cableconnections at the bat- 1. COMPRESSION If all threeof theseconditions do not exist. See ’Spark Plugs’. Loose connection at ignition cable.loosenfuel line nut at carburetorslightly.Cableswet. Stickyvalv s. Remove solenoid from carburetor .distributor. If not. This condition will be indicated if fuel conti. and seat with solvent. Weak spark or no spark in one of the cylinders. likely be too rich to burn. gine is cold.

HIGH OIL PRESSURE Oil pressure gauge defective. Engine overloaded. Ignition troubles.il. on the intake manifold while the engine is warm and running at moderate speed.Engine scored or stuck due to lack of oil. Engine operated in confined space where cooling air is continually recirculated. Restricted cooling air circulation. Governor spring hooked into wrong hole in lever. Hot carbon particles in engine. or heavy load at low speed. is necessary. (the ENGINE KNOCKS same kind of oil as used in the crankcase of the en- Poor grade of gasoline or of low octane rating. Wire from anti-diesel solenoid to starting switch dis. Gears worn or broken. The ignition switch should then be shut off and the engine stopped. ENGINE STOPS Overheated valves. See gine). protecting them from the atmosphere.ad. See ’Neon LampTiming’. See "Neon Lamp 77ming’. ’. jus trnen t ’.ENGINE SURGES OR GALLOPS ENGINE BACKFIRES THROUGH CARBURETOR Carburetor flooded. dirt or gum in gasoline. INSTRUCTIONSFOR PROTECTING ENGINES FOR WINTEROR SHORTSTORAGE PERIODS Engine operated while detonating due to low octane gasoline. fuel pump and tank of all Worn or loose piston pin. Drain crankcase oil while the engine is warm. consequently becoming Faulty relief valve. Oil too heavy. See ’Spark Plugs’. shonld be injected into the pipe tap opening ’Fuel’. immediately. Clogged pressure line. Drain fuel lines. ENGINE OVERHEATS Clogged or leaky oil line connections. Crankcase oil supply low. Gasoline vaporized in fuel lines. or enough so that a heavy bluish smoke Carbon or lead deposits in cylinder head. Low grade of gasoline. Oil too thin dueto dilution or too light of grade used. to prevent lead and gum sediment from in- 21 . Faulty oil pump. Strainer screen clogged up. rings and valves and keep them from rusting and sticking. Loose cover or body. Fuel tank empty. heading. operation will leave a coating of oil on the above mentioned parts. will appear at the exhaust. Dirty or incorrect grade of crankcase c. Cover worn. See ’Stopping En. carburetor. Ignition spark timed wrong. Part of air shroud removed from engine. Water or dirt in gasoline. Spark plugs too hot. Worn rod bearings. LOW or NO OIL PRESSURE gine’. Gasket damaged. To protect the cylinders. See "Governor Ad- Poor grade of gasoline. Air vent hole in fuel tank cap plugged. Restricted exhaust. Governor rod incorrectly adjusted. gasoline. Loose or burnt out connecting rod bearing. Dirt between cooling fins on cylinder or he. Vapor lock in fuel lines or carburetor due to using Oil line to gauge clogged up. due to excessive heat around engine (Vapor Lock). Sticky inlet valves. Water. Oil pressure gauge defective. connected or damaged. Replenisl~. a half and half mixture of kerosene and good engine oil. Crankcase oil supply low. pistons. Faulty relief valve. About a quarter of a pint Engine operating under heavy load at low speed. too hot. See ’Ignition’. Engine cold. Carbon in engine. winter gas (too volatile) in hot weather. This fogging Spark advanced too far. as the Engine overheated due to causes under p r e v i o u s oil will flow more freely than when cold.

gine from the weather by a proper covering. (Refer to Lubrication and Air Cleaner. scrubbed of all sediment which may have collected there. for the duration of the storage period. All exposed unpainted metal parts should be coated with grease or heavy oil. If this is not possible.terfering with future operation. It is suggestedthat machinesbe stored inside a tion which may have collected may be drained before building.) The outside of the engine. Also be sure to put oil to the proper ings. full mark on the saber. Do not use any oil heavier tor intake. should be thoroughly It is advisable to use new spark plugs at the begin- cleaned of all dirt and other deposits. 30. especially if the en- gine has given considerable service. It is highly recommend. Fill crankcase with the correct grade of oil to the Tape or otherwise seal off the air cleaner or carbure. than $AENo. and the sediment removed from the oil cup at the bottom of the cleaner. level in the air cleaner. 22 . Before starting the engine after the storage period. ning of the operating interval. Refuel engine and follow the starting instructions as shown on preceding pages of this manual. remove crankcase drain plug so that any condensa. including the cooling fins on the cylinders and heads. oil and accumulated dust. as well as the exhaust and breather open. a new The air cleaner should be thoroughly cleaned of all gasket should be used. Gasoline fumes from ed that the crankcase bottom cover be removed and gradual evaporation is a dangerous fire hazard. protect the en- new crankcase oil is added. When reassembling the bottom cover.

but disconnect: ignition wires from anti-diesel sole- noid. pull outward and at the same time strike the end of the crankshaft An engine that has been rebuilt with new connecting several times with a babbitt hammer. hose at oil pressure gauge. Note: cylinder barrels. and fitted with new pistons. ACCESSORIES Remove clutch or clutch reduction unit if engine is equipped with either of these accessories. Page 10. nition wires at solenoid and taking out the three cap- cylinder heads. with a mallet to break the seal. starting solenoid. crankshaft. CONTROLPANEL can remain on :Flywheel shroud. As disassembly progresses. should go through a thorough "run-in" period crankshaft and bearings. be sure the Woodruff key is in position about one-half hour at about 1200 ~o 1400 R. should t hen be increased to engine operating speed.P. DISASSEMBLY AND REASSEMBLY OF ENGINE Engine repairs should be made only by a mechanic OIL FILTER is removed by tapping side of cartridge who has had experience in such work. Do not use an open end. screws holding starter to flange on gear cover. relative to these parts. Use all new After the flywheel screen has been removed. as The following procedure is for complete disassembly shown in Fig. drive out gaskets and ’O’ rings in reassembly. the order handle of the wrench a sharp blow with a soft hammer may be altered somewhat.M. Fig. remove flywheel nut. Refer to =Oil Filter". the paragraphs of reassembly. 23 23 . monkey or the mechanic. Do not use a hard hammer as it may ruin the valves. Reassembly of the engine should be pipe wrench. used in the proper place. Fig. Remove Woodruff key from before any load is applied to it. 23. as will be self-evident to to loosen nut. on the shaft and that the keyway in the flywheel is without load. 24. ignition wires at coil and voltage regulator (battery terminal). gear cover. Strike the of an engine. rod shell bearings and having cylinders rebored or The flywheel will slide off the taper of the crank- replaced. 23. The R. By means of a 2¼" socket power wrench or 2¼" offset box wrench. and lubricate the starting crank pin in the crankshaft and straighten all bearing surfaces. connecting rods. main bearing plate and the spark The rubber Bendix cover will drop off when flywheel plugs to the specified torque readings indicated in shroud is removed. made in the reverse order. all of the parts should be thoroughly cleaned. for an additional three and one-half to four hours. see Fig. When disassem. STARTINGMOTORis removed by disconnecting ig- Tighten the capscrews and nuts of the manifolds. still without load. Then pierce can with bling the engine. FLYWHEEL (Fig. oil pan. The engine should be started and allowed to run for In reassembly. AIR CLEANER can be removed as a complete unit when flywheel shroud is removed. for replace- exercised in reassembly so the right screw will be meat instructions. 24) While the engine is partly or fully dismantled. choke wire at carburetor. out the bent tabs on lockwasher. rings and shaft. Disconnect tubing and elbow connection from carburetor to air cleaner. therefore great care must be moved.M. Place a pan can be kept together. The flywheel is mounted to a taper on the crankshaft. Capscrews of ’various lengths under the filter to catch oil leakage when filter is re- are used in the engine.P. it is advisable to have several boxes screw driver or similar pointed tool to serve as a available so that parts belonging to certain groups handle for unscr ewing filter from case. TESTING REBUILT ENGINE Take a firm hold on the flywheel fins. variable speed control. The proper =running-in" of the engine will help to establish polished bearing surfaces and proper clear- ances between the various moving parts and thus add years of trouble free service to the life of your engine.

2 and No. 4 spark plug wires and hi. insert rubber Bendix cover between a sharp blow with a hammer. 26) Disconnect ignition wires from field and armature Remove cylinder head covers by dis-engaging 3 clips and taking out the thumb screw. 25) GENERATORm Older Models (Fig. seat flywheel shroud. 27) DIX COVER Disconnect ignition wire at distributor and take off distributor cap. leaving high tension cables in place. 27. FLYWHEEL CYLINDER SHROUD DISTRIBUTOR ACCESSORY COVERCLIPS SHROUD DRIVE HOUSING CAPSCREWHOLES Fig. and striking the end of the pipe In reassembly. 26 Take out the following capscrews: 4 from flywheel Fig. Take out the capscrew holding the adjust- ing strap to generator. FLYWHEEL SHROUD(Fig. shroud. 24 shroud to cylinder shrouds. 25 Fig. HEAT DEFLECTOR CAP SCREWHOLES STARTER DISTRIBUTOR AND ACCESSORYDRIVE (Fig. The lined up accurately with the key. terminals. As illustrated in Fig. By taking out the 2 capscrews Disconnect No. the distributor and accessory drive housing can be withdrawn from the gear cover as a complete unit.ENERATOR SLOTTED HOLES ADJUSTING STRAP IN GENERATORBRACKET FOR I~ELT ALIGNMENT Fig. air cleaner and control panel assem- flywheel on crankshaft taper by slipping a piece of bly can be removed as illustrated in Fig. 26. Slip wires thru grommet in generator can be removed as shown in Fig. 27 . 4 from heat deflectors and 6 from inside flywheel shroud to gear cover. the temperature switch wire. . 25. After mounting. pipe over the end of the crankshaft and against the hub of the flywheel. flywheel shroud and starter pad on gear cover. Note that the holes in the generator bracket are slot- ted for belt alignment in reassembly. Remove 2 capscrews holding the accessory drive housing to the gear cover. which hold the bracket to the engine supports.

These notches are to match up with a similar notch on the inlet port of the cylin- der heads in reassembly. Tap gear cover es. HEAT DEFLECTORS ~ARBUR ETOR STARTER FLANGE ANTI-DIESEL SOI_ENOID ALIGNMENT NOTCH )ORTS SPACER PLATE GEAR COVER DOWELPIN Fig. To prevent restriction in ports because of misalign- ment between the manifold and cylinder heads. 30 25 . MANIFOLD AND CARBURETOR(Fig. Take out the Remove the 2 bottom screws holding the governor 2 capscrews which attach the cylinder shroud to the housing to the gear cover and spacer plate. there is a cast notch on top of the No. 30) governor lever. Remove capscrews from front face of gear cover and fold to the cylinder heads. Disconnect No. 29) Disconnect fuel line at carburetor and control rod at GEARCOVER(Fig. Right hand cylinder shroud is re- moved in like manner. the The left hand cylinder shroud with voltage regulator gear and flyweight assembly can be slipped off shaft and spark plug wires attached can be removed as in gear cover. The two manifold branch. torque and the anti-diesel solenoid mounted to the carburetor is tightened to |00 inch pounds torque. CYLINDER SHROUDING(Fig. LEFT HAND Note that the exhaust manifold gaskets and inserts SHROUDTO HEAT DEFLECTOR MOUNTING HOLES CYLINDER will remain in the cylinder head ports. refer to "GovernorAdjustment". 3 in- let ports of the manifold. were taken off. 1 and No. SHROUDTO CRANKCASE VOLTAGE REGULATOR MOUNTING HOLES FUEL PUMP Fig. 2 and the No. from left hand side of engine. 29 Fig. 28. Top 2 heat deflector at the take-off end of the engine and screws were removed when spark plug wire clamps the 2 screws mounting the shroud to the crankcase. Tighten manifold to cylin- der head nuts to 25 foot pounds torque. carburetor and speed control bracket assembly can be lifted off as a complete unit. In reassembly. for setting engine operating speed. whereas the inlet gaskets will stay in the manifold ports. 29. 28) Swing heat deflector bracket to one side and remove Remove ignition coil and generator adjusting strap complete pump adapter and strainer assembly. 28 Loosen screw on heat deflector at fuel pump. The upper to lower manifold screws are tightened to 15 It. 2 cylinder. shown in Fig. 2 screws from rear at No. New gaskets should be mounted accordingly in reassembly. Remove 2 capscrews holding pump adapter to crankcase.pages 17 &18. Unhook governor spring and remove the 4 nuts and clamp washers which secure the mani. /bs. After removing governor housing. See Fig. 3 wires at spark plugs and remove spark plug GOVERNOR wire clamps at top of governor housing.

If pump fits too tight to remove by hand. as illustrated in Fig. illustrated in Fig. and with a 5/32 inch Allen wrench. Cylin- der heat deflectors can now be removed. 31 when assem. 33 In reassembly. 30. 31 alternately. with hammer and brass rod. 33) Remove locknut and driver gear from shaft. 32. gine supports and oil pan. 33. Take out slotted pipe plug from bottom of crankcase. and remove as illustrated in Fig. In reossembly. Use Perma-tex on capscrews for both engine supports and oil pan.or. Withdraw the oil pump from in- side the crankcase. SPACER PLATE ANGE FOR IVE HOUSING GOVERNORGEAR CAMSHAFT THRUST LOCKSCREWHOLE PLUNGERAND SPRING CAMSHAFT GEAR LOCKSCREWSEAT TIMING MARKS CRANKSHAFT GEAR ACCESSORY DRIVE GEAF IDLER GEAR OIL PUMPGEAR Fig. ALLEN HEAD SLOTTED PIPE PLUG Mount engine supports with machined flats toward LOCKSCREW flange side of spacer plate where accessory drive housing is mounted. Tighten capscrews for engine supports to 40 foot pounds torque. tighten gear cover capscrews to |8 foot pounds torque. be sure lockscrew seat in pump hous- ing lines up with lockscrew hole in crankcase. from starter flange to accessory drive housing opening. Make the box about 16 inches square x 8 inches high with a 2¼ inch clearance hole Future reference can be made to Fig. bling crankshaft and camshaft. 33) Use a work bench with a clearance hole of at least GEAR TRAIN (Fig. Remove main bearing plate . 33. Fig. and tip the engine over to rest on the train will be exposed as shown in Fig. 31) 2¼ inches in diameter for the engine crankshaft to With the removal of gear cover and oil sling. use a pulley. Fig. 31. remove lockscrew as shown in Fig. as accurate location of the timing marks is essential for proper engine With engine tipped over on take-off end. use a new gasket underneath oil pan. remove en- operation. the gear extend thru. 26 . and open at the bottom. Note that dowel pins will remain in cover. in the top. OIL PUMP(Fig. and tighten capscrews to 18 foot poundstorque. if convenient. construct an camshaft thrust plunger and spring to prevent their engine fixture by making a box from 2 x 6 lumber as being lost. 32 In reassembly. mount with oil drain to- SPACERPLA" ward side opposite flange on spacer plate for acces- FOR ACCESSORYDF HOUSING sory drive housing. hammering on end of shaft t o loosen gear will damage pump. ENGINE SUPPORTSAND OIL PAN (Fig. If gear is too tight to remove by hand. tap front of pump housing (not shaft). 32. Fig.

Pull rings in order to slip the cylinder over the piston. Note: When reassembling cylinder heads on a com. See Fig. wedgedunder the bail wire. V-460D cess in cylinder head. The oil der barrel. Fig. Fig. SPECIAL FEATURE Rocker arm assembly can be left bolted to the cylin- der head. Use new ’O’ ring for push rod housing to re. Take off the 4 nuts and washers from cylinder barrel studs. See Fig. barrel that is to be replaced.by meansof a special piston sleeve. ~t will be necessary to square up the inlet and exhaust port flanges with those of the mani- fold. Lift cylinder In reassembly. The sleeve is In reassembly. 37 27 . pistons and rings can be removed for replacement without a major en. A piston sleeve can be made from the lower portion of a scrap cylinder. is at the top of its stroke. 37) gine disassembly. 35 Fig. Place a parallel steel bar across the ports and tap the heads lightly with a rubber mal- let to rotate them until they are square. place a new gasket at bottom of cylin- head and rocker arm assembly off cylinder. Place new ’O’ ring on oil drain tuh~. barrels. ROCKER ARM PUSH ROD PUSH ROD ASSEMBLY CYLINDER CONNECTING Fig.or hold downclip as used on ModelV-465D.000 for V-465D hammer.750 for V-461D. Torque cylinder head nuts alternately and in 3 steps. Remove. 34. 36. 35) CYLINDER V-461D. 37 and Turn crankshaft over until piston. . 3. Turn cylinder head nuts to a snug fit and re-check alignment. Cylinder Barrel paragraphs. 36 SLOT FOR CLEARING CYLINDER BARREL CONNECTINGROD RING OPENING IN LINE WITH SLOT Fig° 34 PARALLEl_STEEL BAR Fig. in the cylinder Cylinder Head. 34. It will be necessary to compress the piston drain line will slip out of adapter in crankcase. then 20. Spread a light film of grease on cylinder head gasket so it will stick in place dur- ing reassembly. place a new ’O’ ring under collar of 2¼ inches long with a 7/8 inch wide slot. 36.500" to 3. shown in Fig. pet hole by hand. The remaining studs can be disassembled after cylin- Remove rocker arm cover by means of a screw driver der is taken off. CYLINDERBARREL plete overhaul.750" to 4. Individual cylinder heads. The inside push rod housing.37. Refer to Fig’s. 34. Press collar end of tube into tap- diameter is tapered from the middle to the bottom. CYLINDERBARREL(Fig. do not drive tubes in place with a 3. First 10. top cylinder stud (flanged) on Model HEAD(Fig. unless head or rocker arms need replacing. 35. as out push rods and rod housings. and finally 30 {oot pounds torque.

When bottom ring of as illustrated in Fig.005 inch over- shown in Fig. size. Clean all dirt and come loosened and damaged when rotating the crank. Refer to Chart. shaft. Assemble bottom ring first and work upward. PISTON AND CONNECTINGROD ASSEMBLY. Use a brass rod so as not to up- mounting cylinder. 42. as If the cylinders are worn more than . 40. 2 and 4 cylinder bank. Use a down both banks of cylinder barrels. These numbers must be on the s~me side of the connecting rod in reassem- CYLINDER. use Wisconsin TriCrome DRIFT PUNCH"" piston ring set. loosen If in the opinion of the service station attendant. with its corresponding cap. See Fig. lest they be. 37. 43) The piston skirt is cam-ground to an elliptical con- tour. Fig. PISTON and CONNECTING ROD bly. Lubricate cylinder bore and press set bolt threads. 41. and then do like- until it is snug against crankcase. PISTON(Fig. Force piston into bore by tapping cylinder barrel with a rubber withdraw cylinder barrel. being care- ful not to distort ring. 38. otherwise oil pumping and excessive oil consumption will re- sult. Mount scraper ring with scraper edge down. 39. 39 Fig. PARALLEL FLAT ON CYLINDER If a ring expander tool is not available. 1 CYLINDER. Place cap on rod immediate- piston is securely in cylinder. This can be accomplished by means of a steel retainer bar and the cylinder hold down studs. Fig.Slip sleeve over and slightly below top of piston. 3 cylinder assembly. The thrust face on the piston skirt is 90° from the axis of the piston pin hole. new gasket at bottom of barrel. Remove cylinder retainer bar and barrel on to piston and against sleeve. mallet. 40. 40 28 . lower sleeve and re. Fig. 38. The outer dia- meter of the top compression ring is chrome plated. 42) RETAINER OD BEARING. move thru slot. it is advisable to hold in the same location they were removed from. studs and remainder of parts per ’Cylinder Head’ Identical numbers are stamped on the side of the rod paragraphs of reassembly. chaff from between fins and bottom of flange. 38. P LACE O~ENENDOF RING ON PISTON THRUST FACE Fig. as illustrated in Fig. Clearance between the piston and cylinder must Fig. V-461D and V-465D. 41 for correct placement of rings for the V-460D. a chrome re-ring is necessary. for proper clearance. ly so that it will not be mismatched in reassembly. Ex- tension of piston out of sleeve will act as a pilot for and remove connecting rod cap by tapping hghtly on the end of the bolts. installing top ring last. Mount cylinder wise with the No. turn shaft over so that the nuts for the No. Install new nuts on connecting rod (Fig. and an authorized service station. 1 connect- ing rod cap are accessible. This work should be done by Insert a drift punch in crankshaft crank pin hole. piston and connecting rod. as shown in Fig. Take off the 2 nuts. After removing cylinder heads and before attempting Cylinder barrels should be put back on the crankcase to loosen connecting rod caps. Refer to Fig. Spread ring only far enough to slip over piston and into correct groove. they should be reground and fitted with over- size pistons and rings. install rings by placing the open end of the ring on piston first. Continue to press barrel over piston Remove No. 42. CYLINDER PISTONRINGS(Fig’s. No. 38 be measured at the bottom of the piston skirt thrust face. 39) bolts and torque to 32 foot pounds.

.0011 in Fig.’RANK PINS Volve grinding should be done by an authorized ser- -.--.748 to 3. Gently tap piston into cylinder and to bottom of PISTON PIN TO bore. V-461D V-465D PISTON CHROMEFACED PISTON COMPRESSION RING RING WIT EXPANDER RING COMPRESSOR PISTON AND . and remove spring seat locks.E. GRIND 2. 41 FLAT ON Models Model CYLINDER BARREL CYLINDER V-460D. and thereby prevents the build up of foreign deposits on the valve face and stem.1233 ALL . 42. 1 355 1. within the first few hours of operation. . To remove valves. 43 PISTON RINGS . Release 2. use a standard automotive valve lifter as illustrated I_ 2. Refer to Illustrated Parts Catalog for mounting..0013 to .SIDE CLEARANCE . The valve rotates slightly each time it opens..3005 valve lifter and take out valve. and insert rod end CONNECTINGROD TO CRANK into cylinder from cylinder head end.002 to ..008 to ing should be parallel to flats at base of cylinder CONNECTINGROD SHELL BEAR.498 to 3. cylinder barrel and the complete unit is mounted to valves and inserts should be lapped with a suitable the crankcase.062 m The exhaust valves are furnished with positive type rota- tors. RING AND RODCLEARANCE CRANKPIN AND CENTER BEARING DIMENSIONS The valve face is ground at 45 o to the vertical center line of the valve stem and the valve seat insert Piston and connecting rod is sub-assembled to the should also be ground at a 45 ° angle.A.0008" PISTON PIN TO PISTON tight CENTERMAIN SHELL BEARING VALVES (Fig. as shown CONNECTINGROD BUSHING . Lubricate the piston assembly and lapping compound or they will leak due to improper cylinder walls with No. and stagger seating.072 engine slowly by hand.0038" Replace valves that are burned or pitted. Use the wooden handle end of hammer.-. While the ring gaps 90 ° around the piston.3025 CENTERMAIN ’SHELL’ BEARING and experience to do a good job.008 = to . PISTON.0005 to . 1.~ CONNECTING ROD Fig.."350 WIDTH in the exhaust or intake manifold when cranking the ~ 1.024 Fig. occasionally lift the valves and reset them 29 . barrel for correct assembly to crankshaft. V-461D V-465D BORE 3. 44. since he has the necessary equipment 2. 43.3020 DIA. Clean and inspect operation of rotators -- replace if faulty. After grinding. ING TO CRANKPIN . Use a standard lapping.0018" 38.499" :3.749" PISTON TO CYLINDER AT PISTON SKIRT THRUST FACES . GRIND vice dealer.3000 FOR OBSOLETE’ROLLER’ BEARING in Fig.e.003" PISTON RING COMPRESSED GAP .2. A leaky STANDARD CRANK PIN DIMENSIONS valve can usually be determined by a "hissing’ noise ¯.1238 DIA. oil. spring and exhaust rotator or spring seat. 44) TO CRANKSHAFT JOURNAL .004" automotive type ring compressor.0025 to . 30 S. V-460D. Note: Rod bear- PIN .0000 to . __ 2. see Fig..SIDE CLEARANCE IN GROOVES .0005 to . Fig..

clean. the guide should be driven out and a new guide line up with tapped hole in bracket. a VALVE TAPPETS shell type center main bearing replaces the split rol- (Pull Outward) ler bearing. CAMSHAFT (Fig. In re- than the valve face. lubricate tappets and insert thrust plunger and spring into end of camshaft.006 ~.004 ~ in the guide.D. replace cylinder head. Fig. apply heat (400 o F) to setscrew. Take out shaft setscrew from bottom of bracket with a 1/8" Allen ROCKER ARM VALVE LIFTER ASSEMBLY / SPRING SEAT LOCKS Fig. assembly. When clearance becomes In reassembly. Allow 1/32" to 1/64 ~ clearance be. ROCKERARM ASSEMBLY(Fig. tween valve guide boss and bottom of valve guide Lubricate shaft so that rocker arm bearings will not shoulder. Apply # 271 Loctite pressed in place. 45. The valve stem has a clearance of for removal. 3O . # 271 Loctite in place of staking. Caution: Do not attempt to remove crankshaft from en- gine without first removing center bearing hanger. to setscrew threads and securely tighten in place. 4904657. pressing in place.002" to . due to method of installing. The bearing and hanger assemblies are not interchangeable for service replacement unless the complete crankshaft assembly is changed and the crankcase modified. Re- move hanger to case screws and washers. by using a 1/2 inch hex tubing nut wrench. 44) The camshaft gear has offset mounting holes to pro- Very little wear will occur to the rocker arms as long vide accurate assembly for valve timing. flat surface on shaft fo~ setscrew must . Check guide for . To loosen setscrew VALVE GUIDES.EAR Fig. wrench. setscrew is secured in place with thoroughly with kerosene and re-assemble. See Fig. remove the complete rocker arm bracket ing mark with that of the crankshaft. 46 CENTERMAIN BEARING(Fig. If seat inserts become worn and Pull tappets outward to clear lobes for camshaft re- ground down to the extent that the seats are wider moval. assembly. 46. Fig. and tap shaft out toward setscrew end of ly around the valves.3440/. Fig. remove and wash both valves and head serial # 5634850. Refer to Page 32 for overhaul procedures relative to the now obsolete roller type center main bearing and crank- shaft oil collet. . 48) V-465D CAMSHAFTASSEMBLY Note: Beginning with engine serial No. 44 .in a different position to insure a uniform seat entire. After valves have been lapped bracket. 45 mer to break cap away from hanger body. 46. disconnect oil pressure line at center bearing hanger and at oil header behind fil- ter. With reference to Fig. Tap screw heads lightly and alternately with a ham- Fig. The gear can as they are adequately lubricated. 46) VALVESEAT INSERTS are not replaceable. The following instructions apply to the current pro- duction engines with shell center main. after operate dry when starting engine.bearing. 44. Withdraw tappets from inside crankcase. Then loosen and back out cap to hanger screws about 1/2 inch.3445" I. NOTE: Beginning with in evenly. 47. from cylinder head. If replacement is only be put on the correct way for matching up the tim- necessary. using a brass rod. 47. Ream if necessary. See Fig.

49. 3. Removalof crankshaft with center bearing hanger assembled to it applies only to the obsoletesplit roller bearing. Donot use torque specification.’I ~’i’--~j IDLER GEAR to the bearing surfaces. 48 Do not pry cap and body apart. Also. 50) torque of the two bolts which fasten the center main bearing assembly to the crankcase of the V465Dhas been increased to If it becomesnecessary to removethe oil pressure relief 74-76 LB-FT. Connectoil line from header to bearing hanger. Slip a length of pipe over the gear end of the crankshaft and with the assistance of another person. Disassemble shaft and gear from case by oil line elbow is facing toward oil header side of case as illustrated in Fig. 52) A tappedhole in the side of the crankcasecontains 2 setscrews for locking idler shaft in place. LUGS Fig. 3.The tightening OIL PRESSURE RELIEF VALVE(Fig. gas- kets and shims. 42. withdraw the shaft thru the mainbearingplate opening. Assemblemain bearing plate. In reassembly: Clean thoroughly and apply a film of oil . See Fig. 49) Removemainbearing plate. Remove screws with a Center main bearing hanger. °Assemblehanger so that 45 5/32" Allen wrench. See Fig. 49. illustrated in Fig. use new ’O’ ring in valve body and socket head) and can then also use the new higher torque apply sealer to threads of hex adapter. will F~g. play is set. gaskets and shims from take-off end of engine.005 inch movement. Caution:It will be necessary to rotate the crankshaft so that counterweights clear the center main bearing hanger lugs in crankcase. meansof the 3/8"-16 tappedpuller hole in end of idler shaft.003 to . Fig. Torque screws 32 to 35foot pounds. Check end play and add or remove gaskets to give the necessary . Mount center main bearing after COUNTERWEIGHT/ 2 SETSCREWS crankshaft is assembled to crankcase and ~’ndplay is set.Applicable to obsolete split ~ Ii roller bearingonly. Fig. If clearance approaches . Sepztrate and remove hanger and cap with shell bearing from cra~nkcase. alter- tain a . This change takes advantage of the fin-st unscrew hex adapter and remove expansion plug from greater available strength of the grade 8 socket head adapter. 47. Be sure oil fitting passages are clean. Install capscrews and washers. Note: Older engines were fitted with To XD130 7/16-14 x 2 114" hex head grade 5 capscrew which were torqued to 60 foot pounds. Drawcap to hanger screws finger tight until the two Drive shaft into crankcase with soft metal hammerand main- dowels are just entering holes. lockscrew. be sure oil groove in shaft is facing up.with engine cold. 48. see Fig. engines after SN 6089641 can use the new valve body and turn counter-clockwise for removal. engines built prior to that can use a pipe wrenchor pliers to removevalve body. Assemble ex- 31 . With a hand wrench. Fig. either for cleaning or replacement.002 to . 50.004 inch clearance between idler gear and nately turn each screw 1/2 to 3/4 turns to evenly pull cap tight shoulder of shaft. IDLER GEARAND SHAFT(Fig. Lock shaft in place with to hanger body. Insert a 1/4 inch rod into the cross hole in For service. Fig.removeouter adjustment capscrews PN XB120.005 inch. Secure bearing hanger to crankcase after crankshaft end the 2 Allen set screws. Witha 3/16 inch Allen wrench. the newer style grade 8 capscrew (PN XB120.as illustratedinFig. 52.49 be on the same side. 47 In reassembly: Holes for the main bearing plate are off- set for correct mounting. Check bearing and crankshaft journal for visible wear-- see Clearance Chart. In reassembly. Tu~ Fittin Sli~ specifications. Engines built after SN 6279801 will have the valve. 7/16-14 x 2 1/2 In reassembly.see Fig. 49. MAIN BEARING PLATE and CRANKSHAFT(Fig. replace shell bearing with suitable undersize. greater torque applied. the locating lug on both bearing halves. and torque capscrews to 32 foot pounds. CLEARANCE SLOT FOR IDLER SHAFT Dowelpins in cap are off-center so theft whenhanger is mountedto cap.

With reference to son. bly. Tip case back on en- gine supports and remove main beating plate. and the lugs on the center bearinghangerwill have to line In reassembly. mounting screws and spacers. Take out the adapter mounting ing hanger capscrews approximately 1/2 inch. Mount main bearing plate. (Engines previous to serial No. TUBING NUT OIL COUPLING MOUNTING SCREW TO COLLET OIL PRESSURE REDUCING VALVE COUPLtNG ADAPTER CRANK SHAFT OIL COLL ET Gearoil culler - for engineswith obsolete~lit roller bearing. 54. In reassem. use new ’O’ ring seals at both ends of the coupl. as illustrated in F~g.002 to . gas- ASSEMBLY and DISASSEMBLY PROCEDURE kets and shims. press 16 rollers into the grease of each of main bearing plate opening. Slip a length of pipe over the gear end of low melting point grease or petroleum jelly. the bearing halves. Check end play and add or remove gaskets ROLLER type CENTER MAIN BEARING to give the necessary . not mount. as illustrated in Fig. hold valve in proper location but do up with the clearance slots in the crankcaseface. capscrews and separate hanger and cap from bearing. coat inside of bearing halves with a and shims. 50 pansion plug after adjusting pressure as per "Oil Pressure and Adiustraent". Remove Lubricate ’O’ rings for ease in assembly. use a standard lubricating grease. The oil shaft so that counterweightsclear the lugs in the lines will become unseated without being deformed. crankcase for the center main bearing. capsctew heads lightly and alternately with a hammer. ’Tap screw and slip oil coupling out of culler. OIL PRESSURE REDUCING VALVE (Fig. 52 4 oil line nuts at the valve and at the fittings on top and side of crankcase. Take off retaining ring from outer bearing race and re- Remove the center main bearing hanger to crankcase move bearing halves and rollers from crankshaft. Secure valve in place with In reassembly. Caution: It will be necessaryto rotate the crank. $3. 4904657) Center main bearing (roller type) can be disassembled With reference to Fig. pages 10 & 11. 52. 51 OIL PRESSURE RELIEF VALVE (HEX ADAPTER) EXPANSION PLUG Fig. Place oil lines in position and engage tubing nuts 2 to 3 turns. Do not the crankshaft and with the assistance of another per. and torque capscrews to 32 foot with obsolete pounds. 51. to break cap away from ing and on the shoulder extending into the crankcase. Do not pry cap and body apart. screw and lift valve away from crankcase. Remove valve mounting cap. assemble to crankshaft and clip 32 . hanger body. slot engages with tab on bearing retainer plate. gaskets In . withdraw crankshaft with center bearing thru the Fig. loosen the Fig. Fig. rotate crankshaft oil collet so that capscrew and then tighten tubing nuts.reassembly. 49.004 inch movement. as illustrated in Fig. remove oil coupling from in the following manner: Loosen and back out bear- crankshaft oil culler. 50) To replace the oil pressure reducing valve.

dowel slips into the dowel pin hole. 56. alternately turn each screw 1~ to ¾ turns to evenly draw cap tight to hanger body. Fig. see Fig. 4052826. 56 BEARING HANGER CLEARANCE tion and draw the capscrews finger tight until the 2 (For obsolete center main roller bearing) dowels are just entering holes. HANGER TO together with retaining ring. the capscrews for mounting the bearing hanger to crankcase were lengthened to 3 inches. CHECK WITH 040" SHIMS. 30 and 40 ft/lbs.040 inch clearance between the sides of the bearing han- HANGER CAP ger and crankshaft cheeks. with spacers. Insert shouldered ~.~. Note: Beginning with engine ALT E RNAT ELY serial No. and a spacer added under the screw heads. finger tight and position bearing hanger so that there is a minimum of . With a hand wrench. 15. Secure bearing hanger to crankcase after crankshaft TAP CAPSCREWS CENTER BEARING end play is adjusted. 54 ~ ~FINGER TIGHTEN. place cap in posi. Thus all 4 screws for the center main bearing hanger assembly are the same. /--. Fi 9. 60 foot pounds torque. FOR both mating edges of the bearing. 55 33 . Torque capscrews to 40 foot pounds. Tighten hanger to crank- case capscrews. see Fig. minimizing the possibility of improper assembly. alternately in 3 stages. CLEARANCE 040" BOTH place the hanger body against the bearing so the SIDES. A few squirts of oil in the hanger cap oil hole will help to dissolve the bearing grease. HANGER BODY DOWELPIN HOLE DOWELPIN RETAINING RING CENTER BEARING Fig. Install hanger capscrews. Hold hanger body against bearing. The ring must overlap i I CRANKCASE CAPSCREWS. 55..~_ SETTING CLEARANCE dowel pin into either hole of the bearing race and "~--MINIMU. 53 ----CENTER MAIN BEARING HANGER _JCRANKCASE HANGER BOSS LOWMELTINGPOINT GREASE SPLIT BEARING (FRACTURED) BEARING ROLLERS RETAINING RING GROOVE Fig.

12 VENTILATED . disconnect ground battery damageto the regulator mayoccur. or dis- battery terminal must be grounded. Caution: Output wires from Alternator to Ammeter. terminal when charging battery in vehicle.and from Ammeterto battery terminal on starting soleno{d must be Do Not.S. negative Do Not. becausethe large voltage transient that Do Not.37 Amperes BRUSHES. Reverse polarity will connect the alternator output lead while the alternator is destroy the rectifier diodesin alternator.(+ )OL~TPU~ TERMINAL CARBURETOR ALTERNATOR NO. short the field terminal occurs when disconnection takes place may damage the of the alternator to ground.I. 2 PLUG REDWIRE BLACKWIRE DISTRIBUTOR (S. 10 ga. operate engine with battery disconnected.Voltage Regulator ROTATION. the rectifier diodes in the Do Not. The voltage will rise to an extreme value and permanent As a precautionary measure. regulator may occur. under any circumstances. 10 GAGEMINIMUM (THIS WIREOMITTEDWHEN AMMETER IS SHIPPEDLOOSE ORSUPPLIEDBY CUSTOMER) BATTERYANDCABLES GAUGEMINIMU~ FURNISHEDBY CUSTOMER DISCHARGE~ CHARGE STARTER AMMETER REGULATOR EXCITATION LEAD ANTbDIESELING SOLENOID POS. 3 PLUG IGNITION/STARTING SWITCH NO.Bearings are pre-lubricated.) IGNITION OIL PRESSURE COIL SWITCH HI-TEMPERATURE (WHEN SPECIFIED) SAFTETYSWITCH 34 .2 CONTROL. YB-85A ALTERNATOR REPLACED YB-69 BEGINNING WITH ENGINE S/N 6070163 WI$CON~NEngine Model V-465D SERVICE INSTRUCTIONS SPECIFICATI ONS VOLTS . 4 PLUG NO. P R ECAU TIONS: Observeproper polarity wheninstalling battery. stranded wire. Yes RATED OUTPUT . tor is operating. as dampingeffect of the battery will be lost. No additional lubrication necessary. operating. Connecting charger in reverse will destroy. as permanent damageto the regulator. Use No. disconnect the voltage regulator while the alterna- alternator.Clockwise at drive end LUBRICATION . removethe alternator from the vehicle without first of sufficient size for charging 37 omps.c disconnecting the groundedbattery cable. or larger.

which is part of the throttle body casting. closes the needle valve when Fig. the needle in (clockwise) cuts off the amount of the emul- sion reaching the air stream and makes the mixture leaner. ~ ~:~. to form the idling mixture. and the size of the well vent. discharged into the an" stream. moving on its axle. clockwise (out) permits more of the emulsion to reach the struction permits extremely high angle operation in any air stream and make the idling mixture richer while turning direction. The flow FUEL characteristics of the discharge jet are influenced by the VALVE size. measures the volume of air that passes through the car- HIGH .~c NEEDLE starts.~ FUEL LOAT INLET MA. Air cleaner through a calibrated orifice in the channel from the inside restrictions have a minimum influence on the fuel-air ratio of the air intake to form an emulsion. centric fuel bowl. The mai.~:~:~______________~__~[~e’~~_//_~ ID[E ADJUSTING METERING ~ 1-~t111~ suction. idling and part throttle operation is supplied through the IDLE AIR CHOKE SYSTEM (Fig. or metering orifice. The choke should be fully closed until the engine ~. Moving the choke lever to close the choke plate restricts the air entering the carburetor (except at the pitot tube. As the throttle is opened. to the bowl vent) and increases the suction on the idling system which makes the mixture richer. ]) Fuel under normal pressure entering the float chamber through the fuel valve seat is controlled by the twin float which. and number of holes in the sides of that SEAT part of the jet which is in the metering well.77 CARBURETOR Series SERVICE INSTRUCTIONS DESCRIPTION main jet. This emulsion is when a carburetor is thus ~balanced". 1. N% Fig. 2 IDLE SYSTEM and out (counter-clockwise) to decrease engine speed.U~IL~. 1 FUEL SUPPLY SYSTEM OPERATION FUEL SUPPLY SYSTEM (Fig.~A~LI-I~ ~ over-ch’oked. Turning the adjusting needle counter- jet is in the center of the fuel bowl assembly.. 3) buretor. the carburetor throttle should be opened a little to expose both idle discharge holes to . Fuel from the float chamber flows through the main jet into the metering well. .SPEED SYSTEM (Fig. The through two holes one of which is controlled by the idle metering well which completely surrounds the discharge adjusting needle.~ IDLE FUEL ~ ~ MAIN JET ----. location. All fuel for of main jet opening. Fuel for idling is drawn The Zenith 87-Series is a horizontal carburetor with a con- from this well through the calibration. 3 HIGH SPEED SYSTEM the fuel reaches the proper level in the bowl.JET choke can be returned to wide open position and the throttle closed to the idling position. The very high suction exists at the edge of the throttle plate flow of fuel through the main jet is controlled by the size where the idle discharge holes are located. The venturi. then opened a little to prevent stalling from being WELL ~ . thus a metering well around the outside of the discharge jet. because in the center of the idling jet.n jet and discharge jet are centrally located. t he smallest size that will permit full power development should be used. PICKUP PASSAGE ADJUSTMENTS Adjust the throttle speed by turning stop screw to obtain screw in (clockwise) the desired to increase idling speed Fig. This con.. Fig. 35 .. as well as by FUEL VALVE NEEDLE WELL VENT \~. The well vent is located in the air intake and permits air to enter the top of the At idling speeds the throttle plate is almost closed. IDLE DISCHARGE STARTING THE ENGINE Before cranking the engine. then when the engine is fully warmed up the -IDLE. 4. L. It is a ’~balanced ’~ carburetor. In selecting the venturi size.57. but the increased volume of air entering the engine through the venturi creates sufficient vacuum PITOT TUBE BOWL VENT (suction) on the discharge jet to draw an emulsion of fuel PASSAGE and air from the metering well which receives its fuel from the main jet and its air from the well vent. As the fuel reaches the all air for fuel chamber and metering well ventilation and idling channel it is mixed with air which is admitted idling must come through the air cleaner. the suction on the idling system diminishes. L. the size of the maiu IDLE SYSTEM (Fig. 2) jet. the sizes of the discharge jet orifice. Page 37) IDLE AIR ~ Starting a cold engine requires a much richer mixture of BLE~x ~ THROTTLE ~ PASSAGE fuel and air.

L-57.L-77 Series ZENITH MODEL87A8 CARBURETOR 36 .

(42). In- spect float lever for wear at point of contact with fuel valve needle. Numbers w/ll be found on the parts. using Zenith Tool No.Replace if loaded with gasoline. float body. 4. LY 4. EXPLODEDVIEW (Page 36) 4. REASSEMBLE FUEL BOWL 3. Remove the fuel valve seat (31) and fibre washer (30). using a small 2. using Zenith Tool No. Replace if wear is excessive.the floatbodymust be centeredand at right anglesto the machinedsur- DISASSEMBLY face. Check Specifications. L-57. using the fingers. using 4. 2. maged or if float axle bearing is worn excessively. NOTE: Replace with new float if position using a 9/16" open end wrench. separate fuel bowl (39) from throttle body (26). Installthe fuel valveseat (31) and fibrewasher(30).Jet. C161o85 Fuel Valve Seat Wrench. b. Bending Float Lever. 37 . Install throttle body to fuel bowl assembly gasket (37) 3. 46) and be 31/32=.followedby float numberis the Zenithassemblynumber. 6. This measurementshould Remove the three bowl assembly screws (145. disassemblyand assemblyoperations. NOTE: Inserttapered end of letter"L" pre-fixedto it is TeledyneWiscunsinMotor’s floataxle (35) into floatbracketon side oppositeslot part numberfor the completeassembly. Remove the bowl drain plug (44). Idling ~et and Fuel Valve. Remove the float axle (35) by pressing against the end liminaryidleadjustment. Blowout all pas. sages in throttle body and fuel bowl with reduced air pres- sure. Float Axle -. ~wist.Inspect tapered end of the CLOSED needle to make sure it is smooth and free of grooves. Installidleadjusting needle(17)and spring(18).Replace all gaskets. with the blade of a screwdriver. Use the key numbers on the exploded using a depth gage. 7.Turn the needleout (counter- clockwise)to make the mixturericher.Replace as THROTTLE complete unit. firmlyand evenly. Remove the fuel valve needle (31). 4 CHOKESYSTEM REASSEMBLY ASSEMBLY OF THROTTLE BODY I. 2. C161o85. is off more than 1/16". i. Installthe maindischarge jet (32). Remove the main jet plug (43) and fibre washer (42). Remove the main discharge jet (32).The floatsettingis measuredfrom the machined SEPARATE CARBURETOR BODIES surface(no gasket)of floatbowlcoverto top side float body at highest point. Pressfloat axle (35) intoslottedsideuntilthe axleis centered in bracket. c. Remove the Idle Jet (38). S. using a small screwdriver. CHOKEPLATE VENTURI 2. C161-83 main jet wrench. To increase or decrease dis- DISASSEMBLE FUEL BOWL tance between float body (36)and machined surface (26) use long nosed pliers and bend lever close 1. The plain 3. Remove the idle adjusting needle (17) and spring (18). Fuel Level. NEVER USE A DRILL OR WIRE TO CLEAN 1. 5. 3. L-77 ZENITH MODEL 87A8 CARBURETOR Series Adjustthe idle adjustingneedleto obtainsmoothidlingof INSPECTION OF PARTS the engineat idlingspeed. Gaskets. Remove the fuel bowl to throttle body gasket (37). Remove the float (36). Install the bowl drain plug (44). 4. viewedfromfreeend of float(36). OUT JETS OR IDLE HOLES. 6. Reverse the flow of compressed air through all passages to insure the removal The special tools recommended are: of all dirt. da- to makeit leaner.usinga smallscrew- CheGkthe numberson the metal identification disc pinned driver. Idle Adjusting Needle. Install the idle jet (38). throttle shaft seal and retainer each time the carburetor is overhauled. partsof the carburetorand showstheirrelationship to the for correct measurement to obtain proper fuel level by completeassembly. on machined surface of throttle body (26). Fuel Valve (Needle & Seat) Assembly -. C161-83 Main Jet Wrench. NOTE: Do not bend. Wear of any of these parts can seriously PLATE affect the operation of the float. 6. 3.Screw needleIN (clockwise) untilit seatslightlyagainstthe DISASSEMBLE THROTTLE BODY idledischargehole. or view to identifyand locatepartswhen performing both the apply pressure on the float body. using a 9/16 ~ open end wrench. REASSEMBLE CARBURETOR BODIES CLEANING Install the three bowl assemblyscrews (45.then backit out |~ turnsas a pre- 1. to th~ top of the throttlebodyor indentedin it. Zenith Tool No. Install the main jet (41) and fibre washer (40). Withbowl coverassembly(26)inan invertedposition. Be sure all carbon deposits have been removed from SPECIAL TOOLS throttle bore and idle discharge holes. Remove the main jet (41) and fibre washer (40).Replace if any wear has occurred on the (CLOSEDPOSITION) bearing surface. C161-85. 46) through Thoroughly clean all metal parts in Bendix Metalclene or the fuel bowl and into the throttlebody and draw down Speedclene and rinse in cleaning solvent. C161-83 main jet wrench. IDENTIFY CARBURETOR 2.the numberwith the (36) and float axle (35). plus or minus 1/32". and push throughthe other side. Main . Install the main jet hex plug (43) and fibre washer screwdriver. Seal and Retainer . 2. Check position of float assembly (36). SERVICE AND REPAIR PROCEDURE using ZenithTool No. Installfuel valveneedlein seat(31). using a small screwdriver. 5. Verify the correctness of the following parts. Float Assembly -. POSITION) Replace if pitted or grooved. Fig. FLOAT SETTING The exploded view identifiesthe serviceablecomponent a.and in (clockwise) 1.

with relation to terminal screw releasing the breaker arm spring. as illustrated in Fig. should be replaced with a new factory impregnated wick.015 inch at high point of cam.FAIRBANKS-MORSEType FM-X4B7D For Engine Models V-461D and V-465D GENERAL DESCRIPTION be replaced only during the overhaul of the magneto Fairbanks-Morse Type FM-X4B7D Magneto is de. Then POSITIONFORj No. If the magneto has been removed from the engine Then test the ignition spark while the engine is for servicing. After the points have been installed. away ufacturer’s instructions for timing the magneto to the from the engine block. The magneto lubricant should Fig. Other than this the Type FM-X4B7D Magneto does not require field lubrication. A. -THEN- N~OUNTGEAR WITH RICK PUNCHi~ARK FIELD SERVICE NOT RECOMMENDED OCATED AS SHOWN The cam wick. The first step in magneto field servicing is to exa- mine the magneto for corroded high tension towers. Hold the ignition wire 1/4 in. Then inspect the breaker points for pit. PLACEDISTRIBUTOR vot it between the two small bosses on the bearing ROTOR IN FIRING support until the desired clearance is obtained. the operator must follow the engine man- being cranked. manual. the contact support. TIMING THE MAGNETO TO THE ENGINE broken wires. When installing the magneto on the engine. Retain rotor in this position and fit the drive gear to The installation of new points is the reverse of the impulse coupling lugs so that the prickpunch mark the removal. SERVICING BREAKER POINTS SPECIAL DRIVE GEAR Remove the end cap cover. A. It is possible To remove the point set. or high tension wires not pushed far enough into the magneto tower to make good contact. DRIVEGEARMARKING ANDASSEMBLY 38 . If it is ne- ting. Remove the fulcrum pin snap Assemble gear as follows: Remove magneto end ring and slide the breaker arm off the fulcrum pin. Refer to ’Magneto Timing’ in engine instruction the magneto is not the cause of the engine malfunc. If no spark is seen. Yo128Series Magnet Service Instrucli ns WISCONSIN No. Be sure the points are clean and bright before adjusting them. Insert a EAR PDRIVE ~L screwdriver in the slot of the support bracket and pi. If a strong spark is observed. Y-128-$1 . If points are worn or cessary at any time to remove the drive gear. tion. special shorted. take out the breaker arm to be off 180° in mounting the gear. lead and condenser lead. housing to engine gasket is in good condition. The compact alnico magnetic rotor assures not recommended unless adequate test equipment is an intensely hot spark under most operating conditions. on front of gear is located as shown. No attempt should be made to oil or grease the magneto bearings.I CYLINDER--~ clean the points again before sealing the magneto. Under no circumstances should any attempt be made to remove the magnetic rotor from the housing SERVICE PROCEDURE unless specific instructions for releasing the shaft are available. and maximum dependability of operation with minimum Coil and condenser replacement while simple are service. mounted directly on the impulse coupling. if dry or hard. cap cover and turn distributor rotor until it is in firing Remove the contact support locking screws and lift off position for No. proceed with servicing the be sure the magneto is properly attached and that the magneto. available. they should be adjusted to the correct clearance of 0. coil the correct location of the timing mark on the gear. 1 cylinder. engine. by a Fairbanks-Morse authorized service station using signed and engineered to provide quick easy starting recommended lubricant and factory engineered parts. they should be replaced. oxidation and shorting. distributor rotor and The magneto is equipped with a special drive gear the end cap. care must be exercised in reassembly.

Insure all electrical connec- volts on at least a 15 volt scale. The test light should flicker as the engineis cranked. If the voltmetershowsa constantvoltage in the 1. Visuallyinspectplugwires. If the light doesnot flicker thenthe dislributor electronic If the aboveitems have been checkedand found to be proper moduleis faulty. 12 VOLT TEST LIGHT 1.Withthe ignition switchin leads whichattach to the ignition coil. if not the ignition coil primarywindingis systemappears to be not operating properly: open and the coil should be replaced. Replaceany componentsthat showdeterioration. ignition coil negative(-) terminaland the distributor. negativeto negative. distributor cap and groundto the engine. grease and moisture. major differences are: c. 39 . NOTE: A HIGH AMPERAGE BOOSTCHARGERCAN DAM- 5. the test light again to the negativeterminal of the 2. Disconnectthe high voltage wire fromthe center of the nections. there is an equippedwith a solid state ignition distributor.) NOTE: On somevoltmeters the needle will appear to bouncebetween1 and 12 volts.the test light Thefollowingsteps shouldbe performedif the e. Ignition points have been replaced with a "Hall effect type" electronic module.nd loose con. of the coil. VOLT METER TESTING Someearly production distributors have a blue lead 1. connectsthe negative(-) terminal of the ignition coil whilethe NOTE: If there is no voltage present at the positive side red lead connectsto the positive (+) side of the ignition coil. Checkbattery voltage with engine off. 2. one of the following AGETHESOLID STATECOMPONENTS WITHIN THE DIS- problemsexist: TRIBUTOR. Disconnectthe ground(negative) cable whencharging chassis. NOTES To avoid damageto the distributor componentsthe following NOTE: Ignition timing adjustment specifications and proce. Thevoltmeter should fluctuate from a range of l to 2 for jumpstarting . If the voltmetershowsa constant voltage equal to the 1. 1. newsolid state ignition distributors are similar in appearance b. and the engine’s distributor is believed to be faulty. the electronic modulehas an open replaced with a magnetassembly. conditions must be avoided: dures for the solid state ignition systemsare the sameas the correspondingpoint ignition distributor. negative(-) side of the ignition coil.Do not reverse the battery tim ing light shouldbe usedto checkand adjust ignition tim ing. ignition coil. Reconnectthe black primarylead of the distributor to It is especiallyimportantthat the capand]plugwiresbe in the negative(-) terminal of the ignition coil. Connect goodcondition.be sure battery polarity is correct volts to a rangeof 10to 12 volts as the engineis cranked. SOLID STATEIGNITION DISTRIBUTORS Manynew Wisconsin multi-cylinder engines are nowbeing a. 5. recheckthe circuit fromthe battery through the ignition switchto the coil. Set the voltmeterto the battery disconnected. It should be 12 4. Distributor camwhich opens ignition points has been battery voltage. NOTE: The sameWisconsincoil is used on the: solid state and 2. Externallythe opencircuit somewhere in the primaryignition circuit. 6. Checkbattery terminals for corrosion a. 3. circuit and requires replacement. the distributor should be tested. distributor cap and groundit to the engine block or 3. If the voltmetershowsa constant0 reading. If the voltmeterdoes not fluctuate. REVERSE POLARITY . Crank the engine. Connectthe positive (+) lead of a voltmeter to the instead of a black lead for the negativecoil lead. JUMPSTARTING . 2.5 volt range. Groundthe nega.ngines ignition shouldlight.(this distributor is for negativegroundsystems only) or the ignition coil wires.Only use another 12 volt battery 4. terminalof the coil. (positive to positive. Checkfor loose or poor connectionsin ignition circuit.0 to to a conventional point ignition distributor. Disconnectthe high voltage wire fromthe center of the engine which cause excessive arcing.Do notoperate the engine with tive (-) lead of the voltmeter. cables . 3. the battery. Connectthe test light betweenthe positive (+) side This solid state ignition distributor uses two primary wire the ignition coil and ground. Connectthe test light to the negative(-) terminalof the TROUBLESHOOTING ignition coil. distributor capand rotor. Internally the 3. Disconnect the black primary lead going betweenthe point ignition systems. 4. 3. Anautomotivetype 1. The black or blue lead the "on" position the light shouldlight. VOLTAGE SURGES . coil wire. Turnthe ignition switchon . Avoidusing switches on the 2. Crank engine. free of oil. to 15 volts. the electronic moduleis shorted out. red lead to positive Testingcanbe doneeither witha voltmeteror a 12volt test light. tions are madeproperly. Blackcoil lead to TESTING negativeterminal of the coil.

...... 1 4 Thrustwasher set .................... 1 8 20120005 Elect.... 1 6 Gear ....VG4D.......... 1 5 Spacer(YF50AS1) ............................... YF50A (incl.............. 1 12 20120003 Dustcover.............................. 1 11 9 20120004 Magnet assembly ... 6......... extension(not illus) ......... 7) ........... 1 -.. V465D and W4-1770 ITEM PARTNO..... 1 10 20121006 Rotor and spacer (includesitems10-13)....V465D.......... 4O ............... QTY DISTRIBUTION APPLICATION -..... 1 GF99S1 Gear kit for YF50BS1..... includes 4....... VG4D...... YF50AS1........................... YF50S1............ 1 YF50BS1 VG4D..... DESCRIPTION .............015" 1" Alsosoldseperately o Notservicedseparately...... 1 7 PA367 Rollpin..YF50BS1Ignition Distributor USE WITH MODELVH4D.............. 1 YL394-18 Wire.......... 20121001 Gear kit for YF50.................. 11).. 1 10 20120011 Rotorspacer ...... 20121003 Distributor cap & gasket YF50S1 VH4D............ screws) ................ 1 YL396Ao18 Wire..................... 1 13 Rotor ..001" ..... extension(not illus) .. 1 11 20120010 Distributor capgasket. 1 SHAFT END PLAY:.W4-1770(top mounted) (includes 1...................... 1 2 20120015 Advance weightsset ...... 4-7)..... 1 3 20120012 Advance Springsset ..........W4-1770 (side mnted) YFSOAS1 VH4D....V465D(top mounted) O 1 Venteddistibutor cap........ module(incl..............

~_.S.E__£ W~R__~ GNITIONS co..g SWITCH ! /~CHARGE AMMETERI / ~ STARTING MOTOR s OB D C ~ .L I\\ Io~II .O~.EO ..Typical Wiring Diagram for engine with 30 ampFlywheel Alternator 10 GAGEMINIMUM BATTERY AND CABLES i FOR.I..~CO~. RECTIFIER/ REGULATOR STATOR 41 ..S.o~ ANTI-DIESELING HI-TEMPERATURE DISTRIBUTOR SOLENOID SAFETYSWITCH S.

Tennessee38133 Phone:(901) 371-0353¯ Toll Free: 800-932-2858 January 2002 WM2025C . LLC Service Center ~ WISCONSIN MOTORS. LLC SALESOFFICE: 2020Fletcher CreekDrive ¯ Memphis. SERVICE AND PARTS Available from your Authorized WISCONSIN MOTORS.