GENERATOR SET
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GS-107-AC
INSTRUCTION MANUAL
OPERATION MAINTENANCE OVERHAUL
PARTS LIST
GENERATOR SET
GASOLINE ENGINE DRIVEN, 10KW, 12.5 KVA, 0.8 PF, 60 CYCLES,
AIR COOLED, PORTABLE, SELF-CONTAINED SKID & SHIPPING BOX,
Seek PLC Are „025 ~~ SHOCK MOUNTED AN EC
СЁ уг lody PF 015 A 9 рут
CO E 7. [(HOL-GAR MODEL Gs-107-AC) °° /
°C 775 STOCK NO. 6115-000-0006)
AUToL 72 VIE pas . - -
SERIAL NOS. 11-1503
Manufactured for —_
PUBLIC HEALTH SERVICE
Specification PHS-CC-G-202
(27-JULY-1962)
HOL-GAR
MANUFACTURING CORPORATION
Sycamore & Mill Streets
CLIFTON HEIGHTS
Pennsytvania
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November 1963
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SAFETY NOTICE
Do not attempt to operate or maintain the engine generator set until you
have familiarized yourself completely with the equipment by reading the
instructions in the manual,
This equipment contains and generates voliages which are dangerous and
may be fatal if contacted. Exercise cautionanddiscretion in the operation and
maintenance of the equipment. Avoid contacting terminals, binding posts and
other exposed connections. Use extra care when control cabinet panel is open.
Stop the engine generator set immediately if there is any doubt in the
operating condition and maintenance procedure.
Take no unnecessary chances.
TABLE OF CONTENTS
Paragraph Page
INTRODUCTION
General ..... 2.21 4444211 4144 4 4 44 4 4 4 1 ea 11 LA 1 5
Description. .. . 1. 4424 4 4 144 4 4 4 4 4 4 4 4 4 A 4 4 4 4 e nono 2 5
Data ... 11204214 4 8 4 4 4 4 4 44 4 4 4 4 4 4 3 4 8 8 4 4 4 4 4440 3 8
INSTALLATION
Packaging. . oo. iv ch ee ee eee ee eee eee e 4 10
MOVING . ©. RR nr о 10
Site Considerations 2... , 2... 5... кк кк. 6 10
Mounting .... 2.212041 1 2 4 4 1 4 4 4 8212 1 41 4 44 2 42 4 4 0 7 10
Electrical Connections ... 1.214424 42 4 4 4 4 482 4 44 4 4 4 8 10
Mechanical Commections ............. cv... 9 13
Delivery Services .. 1.221212 4 4 11 4 LL LL 414 111120 10 13
OPÉRATION
Control Components .. . 1 1 124142141111 4 4 411 4e ee 21 11 15
Operation ... 2.112112 44 44 4 4 44 4 4 4 4 4 4 4 a naa ora, 12 16
Starting - Stopping . 1. 11144244 44 4 4 4 4 4 4 4 4 4 4 4 ee ea 13 16
MAINTENANCE
General Maintenance ....,., ...................... 14 18
Lubrication. . . . . . Lee. 15 20
Engine Group . ..oxxrredca mee aa oa nda mao nea un a ua 16 20
Generator Group .....1042 21124 84 4 2 8 4 o naa de ro aa 17 20
Control Group .. ... 2224110 421214 4 411112 4 11 40 18 23
Exhaust Group... . 11244441 424 4 412 44 114414 44 426 19 29
Cooling System Group. . «vo vv vit ee ie et eae 20 29
Fuel System Group. . . «vt vit i tr tr er eee a a 21 29
Ignition Group .. o. rre rear 1 440 22 29
Electrical Systern Group . . . .. .. . riera rare 23 29
Housing Group. .... 2214111124 411 2111111111 1220 24 30
Structural Group .. 1.224122 1 4 4 4 4 1 4 4 4 4 A A 4 4 ea 1140 25 30
Accessories .. 21424 4 4 4 4 4 8 4 81 4 2 4 4 8 5 4 0 a 5410 26 30
Trouble Shooting . .. 2.224402 4 4110 0 1 1 4 ee a ee 004» 27 33
PARTS LIST
Part Orders ,, , . ..ocrxexrrevrrevrra nee radar ran 28 36
APPENDIX Key Page
Engine Section. .. 1... 1.022021 14 141 1 4 1 added aaa ra, A Al
Test Equipment Section. . . . ...................... B B.1
Figure
LIST OF [ILLUSTRATIONS
HOL-GAR Model GS-107- AC Engine Generator Set-
3/4 Right Front View ......... error
HOL-GAR Model GS-107- AC Engine Generator Set -
3/4 Left Rear View .. 11.11.1101 4 4 14 4 4 4 14 4 111 11 144
Unit Operational Accessories And On Equipment Spares. .......
HOL-GAR Model GS-107- AC Engine Generator Set
with Container Right Side , , .........................
A Typical Installation of a Generator Set , ..................
Connection Diagram (19227) ..,. .. ...... «cin...
Typical Exhaust Line Connections . . .....................
HOL-GAR Model GS-107- AC Generator Set Controls €
Instruments ... 1.121224 4 404 442 4 4 4 4 4 4 4 2 4 4 4 anar aroma
Commutator (19334) and Collector (19335)
Brush Holder Assemblies .. 1... 1.124444 4 4 4 0 4 4 4 4 4 44000
HOL-GAR Model 19180 AC Generator (GS-107-AC)............
Bearing Bracket (19340) and Exciter Field Frame (19339)
Assemblies , .. LL eee a ae
Rotor Fan and Bearing (19385) and Stator (19384) Assemblies . . . ..
Support Structure Assembly (19355) . ....... 1 1 14121110
Control Panel Assembly (19356)... ...., rre.
Voltage Regulator (19181) .. 1... 11112211 4 14 4 24 4 4 4 4 44 44 7,
Schematic of Engine Ignition System . ... ..................
AC Generator Schematic Diagrams . . .....................
HOL-GAR Model GS-107-AC Wiring & Schematic Diagram
(Plate 19235). , . o.oo tt ee ee daa dono
Page
INTRODUCTION
1. GENERAL
a, This manual contains information for the
operation and maintenance of the HOL-GAR Model
GS-107-AC, 10 KW, 12,5 KVA, 0.8 PF, Air Cooled,
Gasoline Engine Driven, Portable, Self-Contained
Skid and Shipping Box, Shock Mounted, Electric
Generator Set and a listing of parts.
b. The unit is designed in accordance with Public
Health Service Specification PHS-CC-G-202 (27 July
1962),
c. It can provide primary or emergency electric
power within its rated capacity (para. 3) for communi-
cations, lighting or testing equipment and for other
electrically powered equipment,
.CONTROL PANEL AIR CLEANER-
— ASSY (19356) DOOR!
/
SUPPORT ЕЛЕ
STRUCTURE 2
ASSEMBLY | = es
(19355)
FUEL STRAINER BOWL
ENGINE FUEL PUMP:
PRIMER LEVER
LUBE OIL DRAIN
LUBE OIL FILL GAGE
2. DESCRIPTION
a. Engine Generator Set.
The engine generator set is a self-contained,
electric power unit equipped for manual hand crank
starting, The unit and its accessoreis are preserved,
complete and ready for operation, on the skid-base
of the bolted wooden shipping and storage box. Pro-
vision for moving and lifting by forklift fruck is
provided on the skid-base of the shipping and storage
box. Access to all components of the generator set is
readily made when the outer box is removed, An
inspection door in the box provides means of checking
condition of preservation of the inter packing barrier
and access to one instruction manual,
PE HAND! — ENGINE
CRANK! / (JI20-8/967F)
MAGNETO STOP
BUTTON
¡ENGINE
CHOKE
OIL PRESSURE SWITCH |
© LUBE OIL FILTER
OIL PRESSURE GAGE MIES ma
Figure 1. HOL-GAR Model GS-107-AC Engine Generator Set - 3/4 Right Front View
=== слюна
“ENGINE (JI20-S/967F)
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CONTAINER —SKID (81184)?
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FUEL TANK САР
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ss 4195 -) GENERATOR (19180)
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Figure 2. HOL-GAR Model GS-107-AC Engine Generator Set - 3/4 Left Rear View
The engine and generator are rigidly coupiedas a unit
and suitably shock-mounted on the skid-base portion
of the shipping box, for continuous set operation.
Operational controls, instruments and external load
terminals for the set are contained in the control box
and on the engine. The fuel tank inlet is at the top of
the tank, An auxiliary fuel valve is provided to allow
for 2 large external fuel Supply, A ground terminal
for grounding is provided on the unit. The eyeboit
assembly on the engine provides means for lifting
the unit. Accessories (para. 1. € m.) are provided to
facilitate operation.
The complete set consists of the following major
component groups which are described in paragraphs
D. thru m. below.
Engine Exhaust Ignition Housing
Generator Cooling Electrical Structural
Control System System Accessories
Fuel System
b. Engine,
The engine is an ONAN Model J120-S/960F,
air-cooled industrial type, which has four cylinders,
a 3-1/4" vore witha 3 - 5/8 stroke anda displacernent
6
of 120 cubic inches, It develops approximately 30.5
HP at 1800 RPM. It is capable of driving the generator
to 125 percent of the 3 phase rated output at sea level
elevation and 60 degree F. It is of in-line configuration
and designed to conform to SpecificationMIL-E-11275
as amended by the pertinent generator set design
specification (para. 3). Military standard high-mortal-
ity replacement parts are utilized in the engine. It is
equipped with suitable accessories required for proper
engine operation and safety. (paral & Appendix A).
с. Generator Group.
The HOL-GAR Model 19180 AC Generator
is a single bearing, revolving field, 1800 RPM,
synchronous type, utilizing a conventional rotating
exciter with hermetically sealed, plug-in rheo-
static voltage regulator. It has 12 leads reconnec-
table at the connection board, to provide any of the
voltages listed in paragraph 3. The leads are brought
out of the frame through a bushing, which is secured
to the frame, that has a clamping action to eliminate
strain on the leads, Drip proof construction is used
throughout the unit, Its integral air impeller secured
to the rotor shaft hub insures self-ventilation. The
generator rotor is directly connected to the tappered
engine crankshaft extension and key fixed in the bore
of the rotor shaft. The rotor shaftishollow to receive
a stud rod which passes through to the engine crank-
shaft to further secure the rotor to the engine and
provide means of securing the exciter armature.
The exciter armature fits to the tappered end of the
rotor shaft and is secured with a long nut, another
long stud which connects to the rotor stud rod and
external mounting hardware. The rotor is electrically
and mechanically balanced. The brushes, brush rig-
ging, collector ring and commutator are readily
accessible by removal of the end cover. The AC
generator housing is mounted to the engine block and
shockaounted on two feet to the skid-base, Facilities
are provided for lifting the complete AC generator,
d. Control Group.
The drip proof control group is mounted at
the side of the engine generator set over the generator.
This group consists of a control cabinet, engine con-
trols and the connection change board. The control
cabinet assembly is shock-mounted to a supporting
frame. It contains controls, instruments and com-
ponents (para, 11) required for the operational in-
spection, adjustment, safety, regulation and operation
of the engine generator set Power receptacles are
also contained on the control panel. The engine con-
trols and instruments required for the operation and
operational inspection of the engine are on the engine.
The load connection board provides for output change
and load connection.
e. Exhaust Group.
The exhaust group components provide muf-
fling and conduction for the engine combustion noises
and exhaust gases. It consists of the muffler (part
of the engine generator set) and parts integral to the
engine {refer Appendix A).
f. Cooling System Group.
This component group is integral to the engine
which 1s equipped with an air impeller and various
shrouds that move and direct the flow of air through
the engine to maintain it at efficient operating
temperatures.
g. Fuel System Group.
This group contains those components thaï
store and deliver fuel to the engine, Fuel may be
supplied from the integral fuel tank or from an outside
source and either of these two sources may be placed
into the fuel system by means of the auxiliary fuel
valve, The fuel supply is moved from the sources
through the strainer and sediment bowl, by the engine
fuel pump, to the carburetor and then to the engine.
A primer handle on the engine fuel pump is provided
to supply starting fuel to the engine intake manifold.
h. Ignition Group.
This group generates and transmits the ignition
spark for firing of the fuel in the engine (refer
Appendix A).
i. Electrical System Group.
This component group consists of the wiring,
wiring harnesses, cables and other electrical parts
such ав resistors, capacitors, etc., which are line
items of the engine generator set
j. Housing Group.
This consists of the wood shipping and storage
box used to cover and protect the engine generator
set. It is bolted to its skid-base.
k. Structural Group.
This group supports and secures the opera-
tional components of the generator set. It consists
primarily of the skid-base with its support members
and hardware,
1. Engine Accessories.
For details of engine accessories refer to
Appendix A,
(1) Magneto. The magneto furnishes the
electricity to the spark plugs for ignition of the
air-fuel mixture in the engine.
(2) Fuel Pump. The fuel pump is attached
to the side of the engine. It forces the fuel from the
fuel tank through the filter to the carburetor.
(3) Carburetor. The carburetor provides an
atomized mixture of fuel and air so that complete
burning occurs in the combustion chamber of the
engine under various speed and load conditions.
(4) Air Cleaner. One dry foam type cleaner
maintains clean air for the carburetor,
(5) Lube Oil Filter. One cartridge type lube
oil filter maintains clean lubrication oil.
(6) Fuel Filter. A sediment bowl with screen
removes foreign matter from the fuel.
(7) Governor. The governor maintains a con-
stant engine speed as the generator load changes.
(8) Hand Crank. A hand crank for cranking
the engine is included with the unit.
(9) Eye Bolt Assembly. Used for lifting unit
when installed at rear of engine and for engine when
installed at front of engine.
(10) Safety Devices. A low oil pressure
switch is provided on the engine to shut it down in the
event of low oil pressure,
m. Unit Operational Accessories.
These accessories facilitate operation of the
complete unit (para. 3 d & e).
(1) Auxiliary Fuel Hose, This hose is used
for connecting an external fuel source to the engine
generator set
Model .............. GS-107-AC
6115-000-0006
Specification, Design ... PHS-CC-G-202 (27
July 62)
(2) Fuel Drum Adapter. This 1s used to ob- Contract. . ........... GS-005-46353
tain fuel from fuel drums. Order .............. FNW-43774(3)/CD3
Duty ............... Continuous
(3) Amprobe. This test instrument is a Mounting . .... 2... .... Shock-Mounted, Wood-
clamp-on type ac volt-ammeter used for checking Skid Base
ac voltage and current. Weight (Packed Weight). . . 1000 lbs.
Length. .,........... 62 inches
(4) Line Voltage Indicator. This instrument Width. . ............. 28 inches
is used for determining various electrical activity Height . . . ........... 37 inches
in ac-dc elecfrical circuits.
( b. Engine,
5) Hand Tools. These are provided to aid Manufacturer ONAN. Division of Stude-
in maintenance of the unit (para. 3 d). baker Corporation
(8) Ground Rod and Lead. Used to ground pode! NT J120-5/987F
я etails. . ............ Refer Appendix A
unit by driving rod into ground and connecting it to Starti Ma \ Напа Crank
ground terminal with lead. FUME tree na MOT
(7) Fire Extinguisher. This is a 51bcapacity ¢. Generator.
CO-2 Hand type unit provided with nozzle, It is a Manufacturer ......... HOL-GAR Manufacturing
government furnished item. Corporation
Model ,............. 19180
(8) On Equipment Spares. Consist of parts Rated KW, 1 Phase* ..... 10
subject to wear. (para. 3 e) and routine maintenance. Rpm ............... 1800
Frequency ........... 60 Cps
3. DATA Power Factor ......... 0.8
Temperature Rise 2 hrs
a. General at 125%load......... 75°C
Manufacturer ......... HOL-GAR Manufacturing Duty ............... Continuous
Corporation Electrical Ratings
Exc, Gen Fd
Phase Conn, Wire KVA Volts Amps Volts Current
1 Delta 2 12.5 120 104 34 9,4
1 Delta-Delta 3 12.5 120/240 52 34 9.4
3 WYE 4 18,75 120/208 52 38 10.6
3 WYE 4 18.75 240/416 26 38 10.6
3 Delta 3 18.75 240 45 38 10.8
*Note:- The equivalent 3-phase rated output is 15 KW, 18,75 KVA in a wye or delta connection, only
when within the horsepower capability of the engine at low altitudes and moderate temperatures.
d. Unit Operational Accessories (Specify).
Hose, Auxiliary Fuel
(Hol-Gar, 19306)... . 10 ft.
Adapter (Hol-Gar, 19279), . Fuel Drum
Amprobe (RS-1)........ Volt-Ammeter
Indicator, Line Voltage
(FSN 6625-284-0264) . . . AC-DC Voltage &
Electrical Activity
Pliers (1 each) ........ { Linemans
Long Nose
Screw drivers (1 each) ... {6 inch
8 inch
Wrenches (1 set) ....... Allen
Rod (Hol-Gar, H-14053-2) .
Lead (Hol-Gar, 19390) ...
Fire Extinguisher (G.F.E.
4210-595-1777). . . . . ..
Ground (58 '' 1g)
Ground (72''1£)
CO-2,51b capacity
e. On Equipment Spares (Specify).
Brush, AC . .......... 4
Brush, Exciter ........ 4
Fuse . .............. 2
Element, Oil Filter . .. .. 3
Plugs, Spark . . . ....... 8
f. Operating Supplies,
Fuel Tank Capacity
(approx.). . ......... 5.3 gals.
Fuel ............... Regular Gasoline
Fuel Consumption (approx.
at full load) ......... { 2-1/2 gals. /hr,
20 gals,/8 hr. period
Lubrication Oil Capacity . . 6 ats,
Lubrication Oil Consump-
tion (as req'd) ....... 1 pt to 1 qt./8 hr,
period
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Amprobe Volt-Ammeter (1) (Amprobe RS-1)
Fire Extinguisher (1) (G. F. E. 4210-595-1777)
Muffler (1) (#T-8800)
Eye Bolt Assembly
Manuals (2) (GS-107- AC)
Oil Filter Elements (3)
Line Voltage Indicator (1) (FSN 6625-284-0264)
Engine Hand Crank
Auxiliary Fuel Hose (1) (19306)
Fuel Drum Adapter (1) (19279)
Adapter Fuel Strainer (1) (#900)
12 - Brush (4) (18773)
18 - Brush (4) (18383)
14 - Spark Plug (8) (Champion, H-8 or Equal)
15 - Fuse (2)
16 - Ground Rod (1) (H-14053-2)
17 - Ground Rod Lead (1) (19390)
18 - Long Nose Plier
19 - Line Mans Plier
20 - Screwdriver, 6" x 5/16" Tip
21 - Screwdriver, 8' x 3/8" Tip
22 - Wrench Set (Allen), 1/18, 5/64, 3/32, 1/8, 5/32,
3/18, 7/32, 1/4, 5/16, 3/8, 7/16, 1/2.
Figure 3. Unit Operational Accessories And On Equipment Spares
INSTALLATION
4. PACKAGING
a. The unit and accessory parts are preserved
and packed within a moisture barrier envelope, and
covered with the reuseable wooden shipping and
storage box which is secured to the wood skid-base
with bolts to allow for frequent removal and installa-
tion. The moisture barrier envelope contains desiccant
and a humidity indicator which is visible through the
inspection door in the box
Note
Open the interior moisture barrier envelope
only when unit is to be used, or when in
storage if humidity indicator shows excess
moisture, then open for represervation and
sealing as condition may warrant,
b. It is advisable to unpack the equipment as
close to the installation site as practicable to minimize
any possible handling damage. When unpacking the
equipment, be sure to remove all securing straps,
wires, blocks, padding and protective tape. Be aware
of and follow instructions on any special packing or
caution notices that may be attached to the set. Inspect
the equipment for damage; especially take extra care
in inspection tf packaging shows shipping damage,
Use packing list to check for missing components.
Do not operate controls or attempt to start
the engine generator set until you have be-
come familiar with the controls and serviced
the set for operation.
5. MOVING
a, It is recommended that a crane or forklift
truck capable of supporting the engine generator set
be used when lifting or moving the set.
b. When 2 crane is utilized, use cable or heavy
rope slings evenly spaced under the skid-base to
balance the weight. Use a spreader to keep slings away
from the box or unit. Attach guide ropes to the unit to
keep it steady while lifting or moving. I using the
eyebolt assembly be sure it is installed at rear of
engine.
c. When using a forklift truck, be sure that the
lift arms are spaced to support equally the weight
of the engine generator set
6. SITE CONSIDERATIONS
Consider the following when selecting and pre-
paring the installation site for the engine generator
set.
10
a. Proximity of Load.
To reduce transmission line voltage losses
place the engine generator set as close as possible
to the load
b. Shelter.
To protect the engine generator set from cli-
matic and local conditions, if is recommended that
the unit be placed in an adequate shelter. This
shelter must be ventilated to admit suificient air for
engine combustion and to allow heated air (0 escape,
Also, be sure to provide outlets for exhaust gases
using pipe, metal tubing or other suitable material.
Make the exhaust extensions as short and as straight
as practicable allowing it to siope down andaway from
the engine to prevent accumulation of condensate.
¢. Clearances,
Provide working clearances around the engine
generator set, to facilitate operational and mainte-
nance activities,
d. Fuel Supply.
To insure an adequate fuel supply, install a
fuel tank or tanks of sufficient capacity to meet
operating conditions. Consider placing the tanks (55
gallon drums) as close to the engine generator set as
practicable, Be sure that the bottom of the tank is not
lower than 8 feet from the inlet to the fuel pump.
e. Foundation
Check firmness of ground to see that it will
support the unit. See that ground will have proper
drainage to allow area around unit to be as dry as
possible. If the engine generator set is installed in an
existing shelter, be sure that the bearing surface can
support its weight and operational vibrations. If neces-
sary, secure skid to bearing surface,
Note
A typical installation of a generator set is
shown in Figure 5. It does not show the
GS-107-AC unit which is ready for operation
on its integral skid-base,
7. MOUNTING
It is recommended that the engme generator set
be level in both planes of the skid-base and that the
weight of the complete unit be distributed equally
on the skid base.
8. ELECTRICAL CONNECTIONS
a. General.
All internal connections, with the output volt-
age change connection plates connected and the unit
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“NOTE: IF REVOLVING FIEL
IS INSTALLED IN SMALLER
IMATELY 384 CU.FT.COMP
GENERATOR HEATED AIR T
DO NOT JOIN WITH DUCT
HEATED AIR.
12
CONCRETE BASE ©
4 FUEL TANK
MUFFLER
TTO REMOVE
TED ENGINE AIR
20
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Figure 5, A Typical Installation of a Generator Set
tagged to specified 120/208 3 phase 4 wire operation,
are made at the factory. Always check the chaoge
plates to see that they are properly connected for
intended use and that change plates are secure, Refer
to connection diagram when making phase and voltage
change.
b, Output Voltage Change Plates.
Output voltage changes of the generator setare
made by installing the three connection plates provided
with the unit. These are mounted in place on the con-
nection board or stored on the connection board cover.
Refer to the connection board diagram and use the
following procedure to make change.
(1) Select the plate or plates for the desired
output and secure to the connection board as indicated
on the diagram.
(2) Make load connections at the load termi-
nals as indicated on the connection diagram.
(3) Store plate or plates not used onthe studs
of the connection board cover. Replace cover.
c. Power Transmission Cables.
Use the following minimum cable sizes for
specified voltage ratings. It is recommended that
larger cables or wire sizes be used if load cables
are larger than 25 feet.
Current Cable Size
Voltage Phase Wire (amps) (AWG)
120 1 2 104 0
120/240 1 3 52 4
120/208 3 4 52 4
240/416 3 4 26 8
240 3 3 45 4
d. Power Output Connections.
All output power connections are made at the
connection change board terminal studs and load ter-
minals (refer to Figure 6). When making connections
be sure to check connection board diagram for proper
voltage connections. Be sure that the load lines from
the engine generator set mate (or phase in) with
respective load terminals at the load distribution point.
Balance load for generator set as equally as practical
between circuifs that are being utilized.
e. Ground Connection
Use ground rod and lead. Install the ground
lead (J6AWG bare copper wire) from the ground
terminal on the control box support to earth driven
ground rod. Do rot use fuel lines for grounding
purposes.
9. MECHANICAL CONNECTIONS
a. Fuel Line.
The generator set is supplied with one aux-
iliary fuel hose and fuel drum adapter. The hose is
used to connect the engine generator set to an
external fuel source when used. The hose is connected
at the auxiliary fuel inlet port which has a 1/2
inch SAE 20 flared fitting for the hose connection. The
fuel drum adapter is placed in and screwed in the
fuel drum opening to make a fuel hose connection
point to the external supply.
b. Muffler & Exhaust
Install muffler on engine at exhaust manifold.
If unit is used in a shelter connect a suitable exhaust
tube from unit to exterior of the shelter, positioning
muffler at any suitable place in the exhaust line
preferably outside. (Refer to Figs. 5 and 7)
¢. Air Ducts.
If unit is used ina shelter and it is practicable,
construct an air duct from the engine to remove the
heated engine air from the shelter (refer to Fig. 5).
10. DELIVERY SERVICES
2. General,
The engine generator set equipment is in-
spected for completeness and adjusted to specific
operational requirements prior to shipment, Note that
after operational inspection is completedat the factory,
the fuel and lubrication oil are drained from the
respective systems. Perform the following services
and any special services given on attached tags or
notices, before placing the engine generator set into
operation
bh. Visual.
Check the engine generator set equipment for
completeness and damage or loose parts. Correctany
deficiencies.
с. Lubrication
See that the unit is lubricated (refer to
Appendix A). Using the engine dipstick, check the
level of the lubrication oil. There may be an indi-
cation of oil because of drainage from the engine,
filters and oil lines. Drain this residual oil and discard
it. Fill the crankcase to the full mark on the dipstick.
The capacity is 12 pints, Check for and correct any
leaks,
d. Fuel.
Fill internal fuel tank with clean gasoline. Be
sure that fuel is clean and free of moisture.
13
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'" SINGLE THIMBLE DIAMETER 12”
LARGER OR DOUBLE
VENTILATED THIMBLE
HI\DIAMETER 6'' LARGER
—= THAN EXHAUST LINE
HOLES IN END
INNER SLEEVE
ti
| -— <) `'
|,
EXHAUST LINE PASSING THROUGH
|! WALL OR PARTITION
fc EXHAUST LINE MUST BE PITCHED UPWARD
Y! CONSTRUCT A TRAP OF PIPE FITTINGS AT
1 POINT Of RISE
»
VD Avor0 sHARP BENOS |
Figure 7. Typical Exhaust Line Connections
e, Air Cleaner.
See that openings are clear. Saturate foam
type element with SAE 20W motor oll and squeeze
as dry as possible.
f. Controls.
Check all controls and instrurnents to see that
they are present and are in normal off position
(para. 11).
g. Electrical Connections.
Check all electrical connections (para. 8).
h. Mechanical Connections.
Check all mechanical connections (para. 9).
i. Operational Check
Start the engine generator set and ascertain
that it is operating properly (paras. 11 to 13).
OPERATION
11. CONTROL COMPONENTS
The controls, instruments and components utilized
in the operation, regulation and safety of the engine
generator set are listed below with their function
(Fig. 8).
Note
Do not operate the controls or start the
engine generator set until you have become
familiar with the controls and serviced the
unit for operation
ITEM
A-C Ammeters (3) (Fig. 8)
FUNCTION
Indicates per cent rated load and output line current. Meters
are indicated as Phase 1, Phase 2and Phase 3. Meter has 0-50
scale, color coded for single phase and 3 phase, Single phase:
green, 0-17.3 (100%); yellow, 17.3-21.6 (125%); red, 21.8-50
(above 125%). Three phase: green, 0-26 (100%): yellow, 26-32. 5
(125%): red, 32.5-50 (above 125%). To obtain line current use
multiplier in following tabulation
AC-Voltmeter (Fig. 8)
Indicates output voltage. Has 0-150 scale. To obtain voltage
between lines use multiplier in following tabulation.
MULTIPLIERS FOR AMMETERS AND VOLTMETER
CONNECTION
120V-10-2 Wire
120/240 V-16-3 Wire
120/208 V-30-4 Wire Y
240/416 V-30-4 Wire Y
240 V-30-3 Wire A
AMMETER VOLTMETER
MULTIPLIER MULTIPLIER
*6.00 1.00
*3, 00 2.00
2.00 1.73
1.00 3.47
1.73 2,00
*NOTE:- For these two connections disregard ammeter in Phase 2.
Frequency Meter (Fig. 8)
Indicates frequency of ac output in cps. Normal reading is 60
cycles. Calibrated to read from 58 to 62 cycles.
15
ITEM
Load Switch & Circuit Breaker (Fig. 8)
(ON-LOAD-OFF)
Adjust Volts Knob (Fig. 8)
Receptacles - 120V A.C. (Dupiex) (Fig. 8)
Fuse (Fig. 8)
Voltage Change Plates (3) (Fig, 8)
Engine-Run-Start-Stop-Switeh (Fig. 8)
Fuel Valve Off-Tank-Aux (Fig. 8)
Ground Terminal Stud (Fig. 8)
Voltape Regulator (Fig, 14 € 15)
Engine Hand Crank (Fig. 1)
Hand Primer (Fig. 1)
Choke (Fig. 1)
Engine Governor Control (Fig. 1)
Lube Oil Pressure Gauge (Fig. 1)
Low Oil Pressure Switch (Fig. 1)
Lube Oil Dip Gauge (Fig. 1)
Magneto Stop Button (Fig. 1)
Air Cleaner Door (Fig. 1)
FUNCTION
Used to apply or remove load. In the event of overload above
125% of rated load or short circuit, the circuit breaker trips
and stops ac generator from producing power, Itmust be reset
manually; however reset only after load is checkedand adjusted
or condition corrected to prevent tripping.
To adjust voltage output of engine generator set. It controls the
voltage regulator by varying the resistance of the rheostat.
To accommodate external plug-in type utility lines. Two ground-
ing type (3-pole).
To protect 120V A.C. receptacle circuit. Located on connection
board.
For changing unit over to one of the rated voltages, phase and
current operations.
To open and close magneto circuit for run-start-stop of unit.
Start is center position; run-up; stop-down,
Used to connect the external or internal fuel supply to the
engine and to shut fuel supply completely.
On control panel support to ground complete unit to rod with
lead.
Controls electrical output of main generator so thatload varia-
tions caused by load changes are stabilized.
Used to manually start engine.
At engine fuel pump. Used to pump fuel into engine for initial
starting.
Used to reduce amount of air entering carburetor. Pulling
choke out reduces air in fuel-air mixture. Pushing in provides
a balanced fuel-air mixture for normal operation. Adjust as
may be required by operating conditions.
Controls engine speed. See engine operator 's manual for details,
Indicate lube oil pressure 0-15-30-45-60 scale. Oil pressure
should be at least 20 psi, and average 30-35 psi after stabiliza-
tion of engine heat and load. Pressure may be higher at initial
starting and warming.
To ground the magneto and stop engine if lubricating oil drops
too low indicating lube system trouble.
Indicates level of lube oilin crankcase, Has full and low marks,
Use t0 ground magneto and stop engine.
Open in extreme hot weather, when starting engine.
12. OPERATION
The engine generator set normally operates auto-
matically in that the engine speed is governed and
controlled to compensate and correct for frequency
and load variations caused by load changes.
16
13. STARTING-STOPPING
a. Preliminary Action,
Perform the following checks and adjustments
to make sure that the engine generator set is ready
for use.
1 ~ Adjust Volts Knob
2 - Duplex Receptacle (120v)
3 - Engine Run-Start-Stop Switch
4 - Load Switch - Circuit Breaker
5 - AC-Ammeters (Phase 1 - 2 - 3)
6 - Multiplier Plate (Top) (19230)
7 - Wiring - Schematic Diagram Plate {Inside Top)
(19235)
8 - AC - Voltmeter
9 - Frequency Meter
10 - Control Panel Assy (19356)
11 - Fuel Valve Off- Tank- Aux
12 - Auxiliary Fuel Port
13 - 120-Volt Terminals
14 - Load Terminals (L1, L2, L3, LO)
15 - Change Board Diagram Plate (Behind Cover)
16 - Change Board Cover (19226)
10-32 x 3/8-Screw, RD-HD, Cap-Ext-Lock-
washer
Patch Panel (1 - 3 wire - 120/240 v only) (19358)
1/4 - 20 - Nut, Hex, Brass
1/4 - Int - Lockwasher, Phos - Braz.
18 - Ground Stud
19 - Fuse (15 amp)
20 - Patch Panels (2) (19348)
17
Figure 8. HOL-GAR Model GS-107-AC Generator Set Controls € Instruments
17
(1) Ascertain that the unit is serviced for
operation (para. 10).
(2) Check lubrication oil level and fuel level
in internal fuel tank or external supply. Fill as
required.
(3) See that auxiliary fuel valve is in position,
as required, for internal or auxiliary fuel supply.
(4) Check electrical (para. 8) and mechanical
(para. 9) connections.
(5) Always check change board for proper
connections of intended use.
(6) See that shelter (if used) ventilation
facilities are in order.
(7) Check outgoing load cables and external
load circuits to make sure that no short circuit pos-
sibility exists. Be sure load is not connected before
starting generator set External main load switch
should be off. Be sure generator set load switch is
in OFF position.
b. Starting.
During initial start heavy exhaust smoking
from burnout of preservative oils is normal. If engine
fails to start at initial start preservative oils may
have fouled spark plugs. If this occurs remove spark
plugs, clean in gasoline, dry and replace. Use follow-
ing procedure to start
(1) Prime carburetor by working fuel pump
priming lever at pump about 15 strokes and return
inward (down and disengaged).
(2) Set engine switch in START position
(3) Set hand choke as required by local
temperature. Pull choke out for richer mixture,
push in for normal mixture,
(4) Engage hand crank to engine with handle
at 7:00 o’clock position. Pull crank up to 12 o’clock,
with sharp steady pull, Remove crank as soon as
engine starts.
(5) Place engine switch in RUN position.
(6) Check oil pressure, it should be at least
20 psi. If pressure doesn't build up, remedy cause,
(7) Readjust choke as engine warms.
с. Load Application
If practicable, allow unit to warm thoroughly
before connecting electrical load. Apply load in steps,
when practical, instead of 2 full load at once. Most
installations use a line switch, which is closed to
connect the load. For initial operation of a new unit,
try to apply quarter loads (1/4-1/2-3/4-Fuil) at 30
minute intervals to stabilize the unit.
(1) Place load switch {circuit breaker) in ON
position to provide power at the generator set load
terminals.
(2) After unit is stabilized and load is as-
certained, check voltage and adjust with voltage
adjustment knob, Once set this should require in-
frequent attention
(3) Check meters for proper readings. If
overload exists, stop unit and adjust load.
d. Stopping.
Use the following procedure,
(1) Disconnect as much load as possible.
(2) Place load switch (circuit breaker) in OFF
position.
(3) Allow engine to idle a short time.
(4) Place engine switch in STOP position
Note
A stop button is also located at the engine
magneto. This can also be pressed against
the engine to ground the magneto. If this
method is used be sure to return engine
switch on control panel to STOP position.
(5) Place fuel valve in OFF position.
MAINTENANCE
14. GENERAL MAINTENANCE
a. Procedure.
Set up a maintenance procedure for the engine
generator set based on the type of operation (i.e.
continuous, standby or intermittent). The main items
to remember are cleanness, lubrication, proper ad-
justments, leaks, loose parts and improper operation
18
indicated by observation of instruments and control
response. If inspections reveal erratic operation that
may increase and cause complete failure of the unit,
check, order and replace indicated faulty partsbefore
actual breakdown occurs. Use the following minimum
servicing and adjustment tabulation as a guide to
establish a maintenance procedure. Refer also the
engine section (Appendix A) for detail schedules for
the engine.
INTERVAL (Hrs)
= = = = = x= = вр mw = Яя #3 +
+ "= # + #4 4 = ww = = = = =
= e я дни #2 м
SERVICE
Before Operation:- Visually
inspect to see that controls
and instruments are in order
and that there are no loose
connections. Check fuel lines
for secure fits. See that there
are noleaxs, Check fuel supply
and replenish as required. In-
spect for secure engine and
generator mountings. See that
engine exhaust and ventilation
openings are inorder, See that
openings inac generator cover
are free to allow flow of air.
Checkengine lube oil, add oil as
required (refer Appendix A).
During Operation:- See that
instruments are functioning
properly with normal read-
ings. Check fuel tine joints for
leaks, correct any. Bealert to
unusual noises from the en-
gine, and from the generator
that may indicate rubbing or
excessive brush sparking.
After Operation:- Check for
loose parts and secure. Check
fuel lines and supply for
proper stowage, See that fuel
valve is off.
Check lubricating oil allowing
short interval to drain from
filter and lines, Add oil as
required. Checking oil before
and after operation provides
a basis for determining rate of
Oil consumption and possible
trouble in engine operation
Tighten head bolts and adjust
valve clearance on a new or
overhauled engine. {refer Ap-
pendix A),
Clean air filter. Clean and
set spark plug gap. Change
lubricating oil. Clean crank-
case breather,
Check valve tappet clearance
and reset as necessary. Clean
and adjust carburetor. Adjust
and dress breaker points. Ad-
just timing. Remove end cover
of generator to check condi-
tion of brushes, slip rings and
commutator. Remove exces-
sive dust and dirt. Be careful
not to disturb brush settings if
they appear in good shape. See
that mounting hardware is Se-
cure,
INTERVAL (Hrs) SERVICE
500 . . . .......... Replace spark plugs. Clean
combustion chamber and
manifold. Adjust governor and
throttle linkage. Change lubri-
cating oil filter.
750... ,..,...... Clean slip rings and commu-
tator with a lintfree dry cloth.
Use a fine sandpaper (#00) to
smooth or cleanheavily coated
rings or commutator; do not
use emery or conductive abra-
sive c¢loth. Check and replace
brushes, if required. See that
mounting hardware is secure.
ии Check magneto. Replace
breaker points and condenser.
Replace magneto if worn be-
yond econornical repair,
As Required ......, Clean fuel system. Include
draining and flushing tank,
sediment bowl, fuel lines and
fuel pump. Operating condi-
tions and condition of fuel may
increase or decrease this in-
terval. Inspection of sediment
bowl provides an indication of
fuel condition.
b, Tools.
Only standard mechanics and electricians
tools are required for the maintenance of the engine
generator sef,
(1) Operator’s. Refer to paragraph 3 d. for
tools provided with unit.
(2) Instruments. Refer to paragraph 3 d,
11 and Appendix B for instruments utilized in the
operation and maintenance of the unit
(3) Engine Maintenance Tools. Refer to en-
gine section, Appendix A.
с, Painting.
For appearance and protection, clean and
retouch scratched or work painted surfaces.
d. Removal Procedures.
No special techniques are required for the
removal of components of the engine generator set.
However, special notice for parts requiring peculiar
procedures are contained within the particular com-
ponent group. When removing a component, take into
consideration the position of the component, its size
for any required blocking, electrical connections and
mechanical connections. Do not use undue force in
freeing any component.
19
15. LUBRICATION
a. Engine,
The engine lubrication system has a capacity
of 6 quarts. Change crankcase oil every 100 hours
with oil at operating temperature to allow for com-
plete drainage. Change lubricating oil filter every
300 hours. For complete details refer to engine
section (Appendix A).
b. Generator Group.
No lubrication is required as a sealed lubri-
cated bearing is used. During inspection of generator,
examine area around bearing for possible lubricate
seepage that may indicate a broken bearing seal and
foretell a possible breakdown of the bearing. If this
occurs, replace bearing.
c. Linkage Friction Points.
Check all moving linkage friction points and
control cables for free movement. Lubricate as may
be required with powdered graphite or light machine
or engine oil.
d. Housing & Structural Group.
Place light film of oil or light grease on
shipping box mounting bolts and shock mount secur -
ing bolts to prevent rust and corrosion
16. ENGINE GROUP
a. This engine is designed to accommodate mil-
itary standard interchangeable high mortality service
parts. Replacements for these parts should conform
to applicable military standards. When working on
the engine, use standard automotive repair procedures
and practices, For lifting engine alone place eyebolt
assembly at front of engine.
b, Refer to engine section for service and main-
tenance information (Appendix A).
17. GENERATOR GROUP
a. Mounting
Check mounting of generator periodically to
see that it is secure,
Note
Perform the following inspection and mainte-
nance (Pars. b. thru e.) every 250 hours of
operation and as indicated, If unit has been
performing properly, limit service to careful
cleaning by blowing out loose dirt and parti-
cles, so that brush rigging and brushes are
not disturbed.
b. Output Current and Voltage.
Check the output current and voltage with
external meters. If current or voltage is not proper,
20
inspect brushes for signs of wear, proper spring
pressure and freedom of action in holder, Examine
brush holders and see if they are clean.
¢. Slip Rings (=) € Commutator (///).
Surface condition of rings and commutator
Should appear smooth and clean. Scored, rough or
blackened surfaces may be caused by grit Or abra-
sive in brushes, accumulations of dirt around unit
and presence of oil or grease. Use a dry lint free
textured cloth to remove grease scum accumulations.
Moderately rough or scored surfaces canbe smoothed
by using a fine sandpaper (#00). (Do not use conduc-
tive abrasives.) Blow out dirt and grit with clean
compressed air.
d. Brush Springs.
A negator type spring is used, which has a
rated pressure of approximately 5-8 lbs/sq. inch
The spring pressure should present no problem.
Check spring for even set against brush and fit in
slot. See that rivet securing spring to its bracket is
secure.
e. Brushes.
Check brushes for cracks, chips and uneven
wear, At 750 hours, check length of brushes. The
collector ring brush has: a total effective lengib of
3/4 inch from lower edge of brush level at lead end
to center of arc; 2 minimum limit of 3/8 inch from
lower edge of brush bevel at lead end to center of arc.
The commutator brush has: a total effective length
of 11/18 inch from lower edge of brush bevel at lead
end to top of bevel at face; a minimum limit of 3/8
inch from lower edge of brush bevel at lead end to
top bevel at face. Replace brushes that are worn to
the minimum limits or to a point where the lead is
exposed on the brush face.
When replacing brushes, it is important that they are
carefully fitted to the contact surface. To {it brushes,
slip a piece of grade 00 flint paper between contact
surface with flint surface facing the brush, being sure
that the paper is the same width as the contact sur-
face, Move the paper in one direction only, lift and
return until the proper brush surface is obtained.
Repeat process until all brushes have been seated.
New brushes that have not been seated may spark.
If sparking occurs, operate the generator setata light
load to wear brushes. Sparking should diminish as
brush acquires full surface contact
f. Removal.
The ac generator is disassembled into its
parts and subassemblies as it is removed from the
unit.
(1) Release the end cover by removing the
securing hardware. This exposes the bearing bracket
assembly,
(2) The exciter field frame may then be re-
leased from the bearing bracket assembly or the com-
plete bearing bracket assembly may be removed and
100 =-2 -8 :10-6
102-4-8-10 19732 00-8750: ©
102 -6- PH -10 102-a-B
19267
18 469
100-2-8-10-6
104 -6-PH-10
102 -4-3-10 100-2-8 -10- 6
102-4-B-10
164 -G-PH YO
100-2-B-10-6 - Screw, RD-HD, Br, 10-32 18384 - Brush Holder
x 3/8 18427 - Brush Holder Plate
100-2-B-10-8 - Screw, RD-HD, Br, 10-32 18469 - Brush Holder Box
x 1/2 18773 - Brush
100-2-B-10-10 - Screw, RD-HD, Br, 10-32 18782 - Spring
x 5/8 19005 - Back Plate
102-4-B-10 - Nut, Hex, Br, #10-32 19007 - Tab
104-6- PH-10 - Washer, Lock, Phos-Brz, #10 19266 - Insulator
18383 - Brush 19267 - Insulator
Figure 9. Commutator (19334) and Collector (19335) Brush Holder Assemblies
21
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disassembled at a more convenient working area, Be
sure to locate and identify inter-connecting wires
before disconnecting. Before releasing the bearing
bracket assembly it is best to place blocking under
the stator housing and to remove the brushes so that
they may not be damaged when the assembly is drawn
off the rotating parts. Release the bearing bracket
assembly by removing the nuts and washers securing
it to the stator housing at the long studs that pass
through the housing to the adapter frame. Note that
this also releases the stator housing which rests on
the long studs and blocking.
(3) The exciter armature is now exposed and
can be released by removing the nut and washer
securing it to the stud-shaft extension.
(4) At this point if further disassembly is
required, it is necessary to release the generator
leads at the connection board, the fuel line and
electrical connections to the engine and the support
structure for the control box and fuel tank from the
generator housing. The support structure can then be
removed as a complete assembly to expose the re-
maining parts of the generator.
(5) Disengage the stator housing from the
adapter frame, keeping it from dropping and to main-
tain alignment to the rotor and thru-studs, by placing
blocking under it as it is moved from the frame.
Remove the stator studs from the adapter frame.
(6) Place blocking under the rotor assembly.
Release the rotor by removing the long nut and washer
securing it to the stud-shaft extension which passes
through the hollow shaft to the engine crankshaft
extension. Disengage the rotor from the crankshaft
extension and remove, See that key is fixed. The long
stud can now be removed from the crankshaft.
(7) Release the adapter frame from the
engine by removing the securing screws and lock-
washers attaching it to the engine and to the shock
mounts.
g. AC Generator Subassemblies.
(1) The bearing bracket assembly requires
no special procedure for disassembly. However, note
how brush rigging is arranged so that assembly may
be facilitated.
(2) The bearing, fan and key may be readily
removed from the rotor assembly for replacement,
The bearing may be removed with a bearing puller
and a new one installed by careful tapping at inner
race with soft metal pipe with rod or pressing. Dress
slip rings carefully by machine turning or by hand as
conditions warrant. If major repair has occurred to
disturb balance, ¢heck balance and correct.
(3) The stator winding may be separated from
the housing by pressing (normal) or hammering out
using wood block at outside metal edge. Be sure wiring
is released from clamp.
18. CONTROL GROUP
a. General.
Keep the control cabinet assembly free of
dust, dirt and other foreign matter that may cause
electrical malfunctions. See that control mobs are
secure and that switches have proper action. Be sure
voltage change plates are clean and in good condition.
b. Current Transformer.
Used in conjunction with the ammeters. Each
opening has one turn of lead wire. Check mounting.
c. Meters.
Keep meters clean and observe for proper
action and function, Check readings periodically with
external meters.
d. Repair, Removal, Installation.
Limit repair to cleaning and replacement of
parts. The voltage regulator is the only part that is
serviceable (Para. e. below). Depending upon the
amount of repair that may be required, consider
removing the complete control box from the unit for
work at a more convenient location. No special tech-
niques are required as all components are secured
with standard hardware. However, observe how parts
are installed before removal. When installing parts
be sure that the wiring connections are correct; check
against wiring diagram (Fig. 17).
e. Voltage Regulator.
The regohm voltage regulator isused to main-
tain constant output voltage. It functions as an auto-
matic rehostat. The regulating equipment consists of
the controlling element, the regohm, in a separate
housing which plugs into a chassis on which are
mounted a set of control resistors. In addition, an
external voltage adjusting rheostat ls supplied. The
control resistors are designed to meet the require-
ments of this generator set. In general, the resistance
taper used for one application may not be used for
others unless the characteristics are similar. The
regohm voltage regulator consists of three elements;
a voltage sensitive solenoid, a contact finger assembly
and a set of control resistors. The voltage sensitive
solenoid consists of a magnetic coil and a magnet
circuit closed through a moving armature, which is
connected to a push bar. The lower edge of the push
bar is biased so that the fingers, which are set ap-
proximately parallel to the base, are pushed off their
contacts one at a time in sequence. These fingers,
in turn, are connected to pins which plug into corre-
sponding socket terminals on the chassis assembly.
(1) Principles of Operation. As generally
used, the regulator acts as an automatic field rheostat
which adjusts field current in order to maintain
constant output voltage of the generator. In this type
of application the contact fingers of the plug-in unit
(Regohm) rest on the shorting contact bar when the
coil is not energized, reducing the resistance in the
field circuit to a minimum.
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6-32 x 3/4 - Screw, RD-HD, BR
6-32 - Nut, Hex, BR
#6 - Lockwasher, INT, Phos-BR
SSS-1 - Ground Stud
H 11138 - Plate, Indent (GRD)
H 15423-2 - Plate, Ident (3-Way Valve)
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OT15 - Fuse, 15 AMP
#10 - Lockwasher, INT, S
10-32 - Nut, Hex, 5
10-32 x 1/2 - Screw, RD-HD, S
110C-5 - 3-Way Valve
#1/4 - Lockwasher, INT, Phos-BRZ
#1/4 - Lockwasher, INT, S
#1/4 - Lockwasher, INT-EXT, S
1/4-20 - Nut, Hex, BR
1/4-20 - Nut, Hex, S
1/4-20 x 1/2 - Screw, RD-HD, S
1/4-20 x 1 - Screw, RD-HD, BR
153 - Fuel Tank
19154 - Stud
19198 - Current Transformer
19220 - Support Structure
5/18 - 18 x 3/4 - Bolt, Hex-HD, $
5/16 - Lockwasher, Split
19229 - Strap, Fuel Tank
19228 - Bracket, 3-Way Valve
18283 - Board
19278 - Connection Board Assy
19307 - Fuel, Hose
48 x 4 - Connector (1) (Hose To Strainer)
19356 - Control Panel Assy
19368 - Silk Screen (Front)
19369 - Silk Screen (Rear)
19414 - Cover Assy, Control Panel
3302 - Connector, Cable
49 x 4 - Elbow, 90°
49 x 5 - Elbow, 90°
#5/16 - Loekwasher, INT, Phos-BRZ
5/16 - 18 - Nut, Hex, BR
5/16 - 18 x 1 - Screw, Hex-HD, BR
Figure 13. Support Structure Assembly (19355)
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H15457 - Shock Mounts
MD428BS - Rivet
MS35058-21 - Switch, Engine
1214 - Receptacle, Duplex
#1/4 - Washer, Lock, INT-EXT
1/4-20 - Nut, Hex, 8
18387 - Plate, Ident, Load-Switch
13388 - Plate, Ident, 120 VAC
18463 - Plate, Ident, Volts Adjust
19181 - Voltage Regulator Complete W/Rheostat
and Knob
18181-3 - Rheostat & Knob
19231 - Body, Control Panel
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19270-1 - Plate, Ident, Phase 1
19270-2 - Plate, Ident, Phase 2
19270-3 - Plate, Ident, Phase 3
19274 - Plate, Ident, Engine Switch
196914 - Voltmeter, AC
196915 - Ammeter (% Rated Load)
31-FX - Frequency Meter
3302 - Connector
6-32 - Nut, Hex, Cap-Ext Lockwasher
6-32 x 3/8 - Screw, RD-HD, S
6308/PW5 ~ Resistor, SW, 1K, WW, 10%
8-32 - Nut, Cap-Ext, Lockwasher
8-32 x 3/4 - Screw, RD-HD, $
NOTE: Mounting Hardware Furnished W/Meters
Figure 14. Control Panel Assembly (19356)
27
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19181 - P/N Includes Complete Voltage Regulator 19181-2 - Chassis, Regulator (All Resistors Less
W/Volts Adjust Rheostat & Knob Element).
19181-1 - Element, Regulator Plug-In Resistors - Part Numbers and Value as indicated
above.
Figure 15. Voltage Regulator (19181)
28
When the magnet coil is energized, the moving arma-
ture is attracted to it. This movement is opposed by
the reference springs and the armature moves only
when the magnetic pull and the pull of the springs
are not equal. As the armature moves, It opens or
closes fingers, depending upon the direction of motion,
increasing or reducing the amount of resistance inthe
field circuit and thus maintaining a constant output
voltage. An example of the operation of the regulator
is as follows: If the generator is operating at rated
voltage with full load, the regulator is in equilibrium
with a certain amount of resistance in the field circuit,
Should the load suddenly be removed, the output
voltage would tend to rise, increasing the coil voltage
and moving rhe armature towards the core. This
action would open more fingers and insert more
resistance in the field circuit, reducing field current
and restoring output voltage to its original value,
(2) Maintenance. Keep the regulator free of
dust, dirt, grease and moisture. Do not disturb setting
of the adjustable resistor on the chassis.
(3) Replacement of Parts. Limit replacement
of parts in the regulator to the plug-in unit, the
regulator chassis and to the voltage adjusting rheostat
Resistance of chassis resistors are givenas reference
only, in the event conditions warrant substitute re-
placements; otherwise, if resistors burn out, the
chassis should be replaced as a unit,
(4) Adjustments. The complete regulator is
designed and specifically set and adjusted to operate
to the characteristics of the generator set The range
of the voltage adjusting rheostat is the only adjustment
that may be required during its operational life. This
range can be adjusted by moving the center tap slide
of the adjustable resistor on the regulator chassis.
The voltage operating range is adjustable to +5% of
rated voltage at full load by means of the adjusting
rheostat, The range should be adjustable through the
following values on a 120 volt base,
Noload. . .......... +... ... 121-139 volts +1%
Full load. era, 114-128 volts +1%
125% load . . ..... e... 112-124 volts +1%
(5) Removal-Installation. No special pro-
cedures are required to remove or install the voltage
regulator or its parts. When removing or installing
the plug-in unit use care so that pins are not damaged
and that they are alined. À pin is either added or
deleted to provide necessary keying. Carefully press
unit into socket by hand. Be sure to replace the
securing clamp.
19. EXHAUST GROUP
a. General.
Since exhaust fumes are dangerous, make a
thorough check of the exhaust tubes and muffler to
see that there are no leaks and that fumes are being
conducted away from inhabited areas,
b. Muffler.
See that the muffler is mounted securely.
Check for corrosion in exhaust tubes and muffler.
Replace any corroded parts showing breakage.
20. COOLING SYSTEM GROUP
a. Engine.
See that engine shrouds are secure in place
and that engine cooling air flow occurs.
b. AC Generator.
Check openings in generator end cover and
under stator housing for air flow.
21. FUEL SYSTEM GROUP
a. Fuel Tank.
Be sure that fuel tank is kept full. Depending
on local conditions (extreme cold, high humidity)
drain tank enough to remove condensed moisture
from bottom of tank.
b. Fuel Lines.
Check fuel lines for secure fit and tight
connections. See that the lines are not damaged.
¢. Auxiliary Fuel Valve.
Check this valve for proper action
d. Engine.
For maintenance of fuel system of engine,
refer to Appendix A.
22. IGNITION GROUP
a. Unit.
Check wiring (refer Fig. 17) between control
panel and engine for secure fit. See that it is not
deteriorated. Replace badly frayed wire.
b, Engine.
Check engine ignition wiring (Fig. 16) for
secure fit, See that it is clean and not frayed or
deteriorated. Replace deteriorated wires (refer to
Appendix A).
23. ELECTRICAL SYSTEM GROUP
a. General.
Keep electrical parts clean. Remove loose
dust and dirt. Remove scum accumulations with suit-
able solvent.
29
TO SPARK PLUGS
SUPPRESSORS
STOP « e >
BUTTON К
MOMENTARY Nr
CONTACT SWITCH = \
NORMALLY CLOSED
~~ 97
LOW OIL PRESS. (SI) SWITCH
TT
—
MAGNETO
Figure 18. Schematic of Engine Ignition System
b. Wiring,
Check wiring for secure connections. Keep
terminals clean and free of corrosion See that in-
sulation ig not frayed, broken or deteriorated. Replace
damaged wires and wires having damaged insulation.
c. Switches.
Check switches for proper action
d. AC Generator.
See that generator load leads are secure and
in good condition.
24. HOUSING GROUP
a. Check the shipping box for good condition.
Retouch or repaint to original finish, Replace ob-
scured identification markings.
b. Check box lining paper. Replace if torn or
damaged.
¢. See that inspection door is secure,
d. Account for mounting bolts. Keep in good
condition,
e, Replace wood panels or sections of the box
if badly damaged or deteriorated. Treat new wood
30
with pentachlorophenol wood preservative. Treatsur-~
faces thoroughly before and after fabrication
25. STRUCTURAL GROUP
a. Check mounting hardware on skid for secure
fit. See that wood panels are secure and not damaged.
Check shock mount mounting areas for deterioration
Paint exposed metal hardware surfaces, or apply
light film of diesel or engine oll to prevent rust
Keep clean and free of moisture.
b. Replace rotted or damaged wood panels.
Original skids were pressure creosoted to 8 1b/cu, ft.
retention. Treat new panels as indicated or with a
suitable available preservative.
26. ACCESSORIES
a. Engi ne.
For accessories integral to the engine refer
to Appendix A. See that engine lifting eye bolt assem-
bly and handcrank are kept in good condition and
properly stowed.
b. Unit Operational.
Keep fuel drum adapter and its strainer screen
clean; replace damaged screen. Replace worn fuel
hose. Keep hand tools in good condition and stow
properly. Maintain line voltage indicator and amprobe
volt-ammeter in clean condition. Be sure ground rod
is properly installed and in good condition.
T6 17 Ti2 J |
T3 TIO T9 T4
TS T2 TH T8
ee 20 V —pi—— 120V — —»
> 240V >
- (20V > L2 IA L3
| PHASE - 3 WIRE - 120/240 VOLTS
L2 L3
| PHASE - 2 WIRE - 120 VOLTS
L2
SE
208 V
TOITS Lo 208У
T6 TIO
T4 TI
| т2\-^-^А-А-ЛТ5 | ТВ TI
et — 120V — выч 20V ——
Li L3 LO
-4-240V > al——— 240 V >
ll —— 120V — — <a — —— 20 V —» L?
= 2380V — —— — >
LO Li L3
« 208V—— e 3 PHASE-3 OR 4* WIRE
240/1120)* VOLTS
3 PHASE - 4 WIRE - 120/208 VOLTS
TI yx 148 T? ry yyy T10
Te yy q 15 T8 -y yyy TI
T3 rwYyYx TE TS ууу T12
GENERATOR WINDINGS
*NOTE: Although delta is commonly used in the
standard three (3) wire configuration, there are
locations where the occasion arises to tap, at
the mid-point, one (1) phase of a three (3) wire
delta circuit, while using the standard three
phase leads for a normal three phase load. The
center-tapped delta winding is called upon, in
addition to its function with the other two phases,
LI Ге > 40V lg 240V T2 a] L2 to carry a minimal 120 volt lighting load. This
circuit is designed to satisfy certain minimal
« “16 V > (3 ph-1 ph) characteristics found in some older
3 PHASE- 4 WIRE - 240/416 VOLTS structures.
Figure 17. AC Generator Schematic Diagrams
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Note
Account for and maintain operational ac-
cessories as functional parts of the unit.
27. TROUBLE SHOOTING
a. General.
When trouble shooting the engine generator
set follow a logical systematic method, utilizing your
primary trouble shooting tools, the wiring diagram
(see Fig. 18) and the functional! information given for
the various components (para. 11). Remember the
basic function of the engine generator set is to produce
power within its rated capacity (para. 3), To accom-
plish this liquid energy, the fuel is converted to
mechanical energy (in the engine) which provides the
drive power for the ac generator that produces the
electrical power. To aid in the final overall per-
formance of the unit, operational, regulation, and
safety components and systems are added. With this
in mind, functional disturbances can be categorized
into operational, safety, regulation, mechanical drive
power, and electric power groups. The trouble shoot-
ing tabulation (para. c.) is divided into the groups
given and present typical troubles with probable
cause and remedy.
(1) Operational.
b. Electrical Failure.
If generator set fails to produce electric
power, the cause may be inside or outside the unit.
To ascertain where the fault lies, turn off the genera-
for main switch, disconnect external lines, use tester
furnished or test light, across the output terminals,
then switch on the main switch. If test light lights or
voltage readings are correct, the fault is in the ex-
ternal lines, which should thenbe corrected. However,
if test light does not light, then the fault is within the
unit. Proceed to check load connection board, control
panel and instrument wiring and internal lines to
generator. Remember, one disconnected or improperly
connected wire 1s sufficient to cause lack of power.
If wiring between instruments, control panel and
generator is correct, then the fault is in the generator
itself. First, check the brushes, see that they are
properly seated and connections are secure. Examine
slip ring and commutator to be sure that they are
clean and free from pits and mica ridges; these faults
may also cause decreased output and efficiency of the
unit before a total breakdown occurs.
c. Trouble Tabulation.
This tabulation is divided into trouble, possi-
ble cause and remedy and categoried into operational,
safety, regulation, mechanical power and electric
power trouble groups,
Trouble
Fuel delivery to engine stops or
is erratic.
No response to control switches
or knobs.
Improper meter reading or
indication,
Improper generator set output,
Possible Cause
Fuel tank empty. Dirty fuel. Lines
dirty, cracked or loose. Defective
fuel pump.
Loose wires or connections. No
actuating voltages, Defective circuit
Or circuit part.
Component of circuit meter is
monitoring, is defective or not
functioning properly. Loose
connections.
Load connections not correct
Faulty load, Generator set com-
ponents malfunctioning.
Remedy
Maintain equipment services.
Replace fuel. Check lines and
connections; replace or tighten.
Clean or replace fuel pump
(Appendix A).
Locate actuated part in circuit
diagram (see fig. 18). Trace
wiring, check connections; cor-
rect loose connections; replace
indicated faulty part. Check ac-
wating voltage peculiar to that
circuit.
Locate meter in circuit diagram
Trace wiring, check connec-
tions; replace or splice broken
wires, replace indicated faulty
part. Check actuating voltage or
condition for the meter. If cir-
cuitry is correct or condition
(temperature, oil pressure or
current is satisfactory) check
circuit with external meter to
see if meter is defective, Re-
place defective meter,
Shut down unit immediately.
Check and correct load connec-
tions. Determine if load or
generator set is at fault. (Par.
b. above),
33
(1) Operational (Contd)
Trouble
Load Switch-circuit breaker trips.
(2) Safety.
Trouble
Engine does not start or starts and
after operation shuts down for no
apparent cause.
Unit utility fuse burns out.
External safety devices keep activa-
ting (fuses burn out, circuit breakers
dump load).
(3) Regulation.
Trouble
Frequency cannot be maintained or
engine keeps racing and/or slowing
down. Frequency does not stabilize.
A-c output voltage changing cannot
be maintained. Voltage doesn't
stabilize,
Possible Cause
Unit operating at overload.
Possible Cause
Engine pressure safety switch
activated or shorted oul
Utility line to generator receptacle
overloaded.
Excessive load. Defective safety
device,
Possible Cause
Excessive changing load. Governor
cannot control engine speed; out
of adjustment or defective.
Excessively changing load. Voltage
regulator cannot maintain voltage.
Remedy
Check and adjust load. Reset
load switch. If condition con-
tinues shut down unit and check
external and internal circuits.
Remedy
Locate safety switch in wiring
diagram (figs. 16 & 18), Check
circuit for continuity or
grounds. See that conditions for
which safety switch was install-
ed doesn’t exist. Replace safety’
switch if defective.
Adjust load, replace defective
fuse.
Shut down unit. Check load and
adjust. Reset or replace safety
device. If condition continues,
check and replace defective
safety device.
Remedy
Check load and adjust as re-
quired. Adjust engine governor.
Replace governor if adjustment
cannot be made.
Check load and adjust as re-
quired. If load is not at fault
check voltage regulator. Re-
place plug in unit with known
good one, See if resistors in
regulator are good, Check a-c
generator brushes and rigging.
Replace if faulty.
(4) Mechanical Power. In addition to the trouble shooting items listed below, refer to the engine section
(Appendix A).
Trouble
Engine will not turn over and fire.
Engine turns but will not start.
34
Possible Cause
Loose or defective wiring,
Engine flooded.
Carburetor passages restricted by
water, ice Or corrosion
Fuel pump defective.
Restricted air cleaner.
Remedy
Tighten all loose connections or
replace.
Push choke control all the way
in and turn engine over, If car-
buretor continues to flood, re-
pair it.
Clean fuel system, Replace or
repair carburetor.
Replace fuel pump.
Remove air cleaner and clean
filter,
(4) Mechanical Power. In addition to the trouble shooting items below, refer to the
engine section (Appendix A). (Contd)
Trouble
Engine turns but will
not start (Contd).
Engine lacks power,
(5) Electric Power,
Trouble
Complete electric fallure, Load
switch - circuit breaker trips.
Generator does not build up and
produce voltage.
Blackened collector rings.
Intermittent sparking at brushes.
Possible Cause
Air leaks around intake manifold,
Spark plugs damaged, dirty or wet;
gap improperly Spaced.
Magneto brush worn or damaged.
Magneto coil defective.
Magneto condenser defective.
Magneto improperly timed to engine,
Breaker points improperly spaced,
burnt or wet,
Low or poor compression
Defective ignition system.
Carburetor not operating properly.
Restricted muffler.
Possible Cause
Improper load Generator set not
operating properly.
Generator exciter open or shorted.
Loose leads.
Main generator field shorted,
open or grounded.
Voltage regulator not functioning.
Excessive sparking or flashing
at brushes.
Check for open armature winding.
Remedy
Replace manifold gaskets.
Clean, adjust and test spark
plugs. Replace any defective
plugs.
Replace magneto brush.
Replace magneto coil.
Replace magneto condenser.
Time magneto to engine,
Clean and adjust, or replace
breaker point.
Overhaul engine - grind valves
and replace.
Check ignition wiring, spark
plugs and magneto.
Check the operation of the car-
buretor. A lean fuel mixture will
cause burned valves and exces~
sive engine temperatures.
Inspect muffler. Replace if
defective.
Remedy
Shut down unit, Determine if
power failure is causedíroman
external or internal source.
(Par. b. above)
Check continuity of exciter.
Check brushes, Replace defec-
tive part
Check and tighten terminals.
Replace mainfields. If grounded
due to moisture, cleanby spray-
Ing with suitable solvent and
bake,
Replace plug in unit. Check all
terminal connections,
Sand or turn down collector
rings.
Replace short brushes.
Adjust springs - replace weak
brush springs.
Locate and repair bad coil or
repair defective joint.
35
(5) Electric Power. (Contd)
Trouble
Possible Cause
Remedy
Excessive hum.
Regular clicking.
Brush chatter,
Vibration.
Overheating (check with thermom-
eter; don’t depend on the hand).
Collector ring hot,
Uneven air gap.
Foreign matter in air gap.
Extreme vibration
Alignment of unit.
Dirt or alignment
Check brushes.
Measure with feeler gauge.
Check rotor for balance. Check
bearing.
Remove rotor and clean
Check brushes and spring set.
Tighten mounting bolts to base
and engine.
Blow out all dirt in unit, use
solvent on wound sections to
remove sticky dirt. Check flow
of ventilating air, Check for
grounds,
Excessive brush pressure,
PARTS LIST
28. PART ORDERS
a. The parts list is contained within the legend
of the illustration.
b. To order parts give the Engine Generator Set
Model Number, the part number and the nomenclature
shown in the illustration. The wiring diagram (Fig.
18) shows the relative position and gives the ref-
erence symbol (ie: TBI, CT-1 ete.) of the electrical
36
component in the generator get, When ordering these
parts give the model number of the engine generator
set, part number and the wiring diagram reference
symbol with nomenclature.
с. Refer to the engine and test equipment sections
respectively for parts peculiar to these components
and their accessories. It is recommended that these
parts be ordered through the HOL-GAR parts supply
system.
APPENDIX A
ENGINE SECTION
FOR
ONAN AIR-COOLED GASOLINE ENGINE
MODEL
J120-S/967F
Permission to reproduce the information in this engine section by the HOL-GAR Manufacturing Corporation has
been granted by ONAN, Division of Studebaker Corporation.
TABLE OF CONTENTS
SECTION I
INTRODUCTION
General . .. Lo... aM
Description. .. . 1144444 44 4 8 8112 81 2 2 2 2 20
Data .. 212412 1 4 44 4 44 4 4 44 4 141 LL 1 44 114
SECTION II
OPERATIONAL INFORMATION
Preparation of Engine. . ee
Starting - Stopping . . . .. . oo... LoL ol
Unusual Operating Conditions, . . ............
Protection of Engine for Extended Periods... ...
SECTION II
CHARTS
м оо вор
GENERAL MAINTENANCE, REPAIR AND REBUILD
Preventive Maintenance ..................
Trouble Shooting .. 11140444 4 4 és: rara a
Ventilation System, .. 12.421 4 4 4 221 4 4 42 42
Fuel System . . ... 22022 4 4 1 4 LL 2 4 4 44 1 12
Ignition System .. 1111114 1 4 0 4 4 4 8 4 ee.
Governor System... ..... 2.412 1 4 12 a.
Oil System . 1. 1211 4 44 4 4 4 4 4 4 4 4 0 8 4 0 8 a ae 0
Starting System... .....224 44 41 442 444114 0
Cylinder Heads and Valves . ...............
Pistons, Connecting Rods and Cylinders. ..... ..
Engine Disassembly .. ... 1.11 4 4 4 4 44 4 2 44»
Assembly Torques., 124114412110 4 ee
Special Tools ...... 222114 121111 4 4 21220
Clearance Data .... 11210 1 4 0 1 4 1 0 1 4 121 21 à
Engine Parts.......2,.102422 242111121222
Engine Trouble Shooting . . . . .. ............
Fuel System Trouble Shooting ..............
Ignition System Trouble Shooting ............
Goverpor Trouble Shooting ...............,
Oil System Trouble Shooting ................
Cylinder Heads and Valves Trouble Shooting. , . . ..
Pistons, Connecting Rods and Cylinder Trouble
Shooting. ....._. r0emareror 4 4 ине нау
= - = +
x > x +
GS-107-AC
Instruction Manual
Operation * Maintenance * Overhaul
Parts List
Generator Set
Hol-Gar Model GS-107-AC
Stock No. 6115-000-0006
Serial Nos, 1-1503
November 1968
Paragraph Page
1 A-1
2 A-1
3 A-1
4 A-1
6 A-2
6 A-3
7 A-3
a 8 A-3
ao 9 A-5
RE 10 A-9
ao 11 A-10
Ce 12 А-15
киль 13 А-20
a 14 A-21
aa 15 A-23
Ce 16 A-23
Е 17 A-26
..…. 18 A-30
ce 19 A-35
2... 20 A-36
... 21 A-36
Ces 22 A-36
A-1ii
Figure
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LIST OF ILLUSTRATIONS
Title
Engine Lubrication Oil Level... .. 11.421245 4 4 8 44 4 2 8 4 42 44 0
Lubrication of Governor Linkage .. .. 12.224411 44442 2 4 44 4 0
Typical Engine Cooling Air FlOW 2. 122445044444 122 2 211 2 45 6
Engine Gasoline Fuel System. ... 21442 44 412 8 4 4 4 14 441 12110
Primary Filter... ....144 45 14408 44 6 4 4 4 4 4 4 4 aaa arm
Measuring Fuel Pump Pressure, . .... 212244 64 4 4 48 4 4 1 3 4 2 0
Cross Section of Fuel Pump ... 11.122022 2442241 4 8e 4 re.
Manual Choke .. 1.112024 44 4 4 2 4 4 8 4 8 4 4 4066 4 2 1 2 44 4 2 4 1 1e 0
Carburetor Inlet Valve .. 1.211444 4 4 4 4 4 4 4 4 4 1 1111 24 11 2 446
Carburetor Idle Circuit (Left) And Main Load Circuit (Right) .. . . . .
Carburetor Adjustments ... . 1122421421 1 4 1 1111212 41 0121»
Measurements of Carburetor Float Level .... ...............
Foam Element Type Air Cleaner . . ... ... monverdoacorano nn.
Cutaway View of Impulse Magneto .......2.4 4442 4 41 41 14 2120
Connections for Testing the Magneto Coil . ..................
Timing Distribution Gear . . . 1.420444 44 441 44 41 24 2 4 1 4 aa
Removing Dry Cup and Spring 1... 414 644414442411 4 44 12 20
Installing Drive Spring In Cup ..... 2422264 4 444 4 44 4 2 4 1 1446
Driven Fan and Trip Arms ......2242 24214 2 4 4 8 4 6 4 4 4 4 4 4 4 446
Lag Angle Punch Marks . ....... e. redada aran ao eno
Constant Speed (1 Spring) Governor .......... .. «coor...
Governor Adjustment .. 1.1 24142444 4 4 4 4 4 4 4 6 4 ea ra a dino rm.
Oil By-Pass Valve. 1.414444 84 44 4 4 4 4 44 4 4 anita vda em
Rocker Box Oil Line ...... 11120221 4 111214 4 4 4 4 0 4 4 8 1 1 4 a +
Crankcase Breather. ... 11442044 44 4 4 2 4 4 4 1 141 LL 1e 111 1140
Adjusting Valve Clearance ...... 4242 4 4 4 4 8 4 4 4 4 4 8 4 4 4 A 0 44 6
Cross Section of Valve Assembly ... 1.221112 4111 4 4 4 4 4 4 1 200
Cutting Out Valve Seat with Onan Tool (420B272). . . ............
Peening Valve Seat .. 1.122420 4 42 4 4 42 8 4 14 V2 1 4 4 1 14 2 124 0
Installing Puskhrod Shields. 1... 142444 444$ 4 4 4 4 4 6 4 4 4 8 iu.
Sequence for Tightening Head Bolts .. .. 1. NG
Piston Rings. 1... 2244 4 4 114 11 LV ALL 2 4 1 LL 141111 1 111110
Measuring Piston Ring End Gap... ...4 22444 24 4 4 2 aan andar em
Connecting Rod... ..... aaa aa oo» nad rana
Top of Piston .. 1... 2.220204 22214 11111041 2 4 2 4 narra ad oa»
Connecting Rod Wimess Mark .... 2.244444 2 4112 414 441 14210
Pulling Flywheel.. .. 1... 42244 4 64 4 4 44 4 4 se ce
Gear Cover Oil Seal. . .... 122411 011 41 41 22 4 4 4 4 4 4 4e 0 4 84 8
Gear Cover Installation .. 1.114245 4 44 4 4 6 84 4 4 4 4 0 4 4 84 ann
Cross Section of Governor Cup .... 2.222424 12 414 4 41 4124 4e
Measuring Camshaft End Play .. 12241444 4 4 2 4 4 4 2 44 211224»
Camshaft Bearing Installation ,... 22244404 44 404 8 4 4 4424 4 4 240
Aligning Timing Gears ......20 220124 42441214 0 2 4 0 4 8 a
Removing Crankshaft Gear . . ... . . 2024 4 244 4 11114111 421 4 Là
Main Bearing Installation .... 2444444 44444 4 4 2 4 4 ono
Main Bearing Pressing Plates...,... 2222204 421 4 4 redada
Center Main Bearing Installation .. . 12144142 4 14 11 44 1112110
Crankshaft End Play .. 11424 124 42 4 4 4 4 4 4 4 4 2 4 A AL 4 1 2 22 120
Place Bolt Identification .. .... 14442242 4 4 4 4 4 nado ao 2 0
Crankcase and Oil Base Group. .. .. 1.442114 21 4144 04 4 4 00 6
Cylinder Head, Valve and Rocker Box Group ........-........
Crankshaft and Flywheel Group .. .. 2.242444 4 4 4 4 44 4 2 4 444 440
Camshaft Group ..... 2244 41442 2 41 21 2 1 01 4 2 4 4 0 4 6 5 4 as
Piston and Connecting Rod Group... .. 1.242204 2411411141 1210
Gear Cover Group... ... 2241 4 44244 4 4814 4 4 4 8 44 a adan ed.
Oil System Group .....2 22124 421444 2444 44 4 4 1e 84 as
Governor Control Group. ..... RR N
Fuel System Group ..... 2441414444 4 24 4 4 4 4 4 6 4 4 A a aero.
Carburetor Parts Group . . . ... 141 241444 4 4 4 4 4 4 4 4 8 4 4 4 da o».
Manifold Group... ... 444244 44 4 4 a roer crearon an e mea
Air Housing Group. .. 1.114421 4 222 2 4 4 4 4 141 1 LL 4 nm en
Ienition Group. ..... 2.222414 2 44142 4 4444 4 2 4e 4e 4 8 A
Magneto Parts Group .......2 221102004404 4 4 2 11 111111 2420
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SECTION |
INTRODUCTION
1. GENERAL
a, This appendix A contains information for the
operation and maintenance of the ONAN four-cycle,
four cylinder, aiy-cooled, gasoline engine Model J120-
S/867F, and a parts list: Included are complete
procedures and data for major repair. It describes
preventive maintenance and periodic service to keep
the engine in top operating condition. A schedule is
presented to encourage the operator to perform the
service as suggested and then to adjust the schedule
to make it valid for the conditions under which the
equipment is being operated. Trouble-shooting charts
throughout the manual help locate and diagnose trou-
bles. A major chart provides direction to solutions
to probable causes. Then specific charts that offer
remedies are provided for the various systems, parts,
and components of the engine.
Dimensions, clearances, and test specifications are
tabulated. Many illustrations have been included to
support the written test, but use the parts section
for exploded drawings of related components,
b. By using paragraph references, repetition has
been kept to a minimum. Each component or system
is covered independently and then tied together with
related procedures using the paragraph references.
2. DESCRIPTION
The J120-8/887F engine has a vertical inline
block, overhead valves and utilizes spark ignition by
magneto for firing. Connecting rod bearings and main
bearings are military standard types. Normal engine
speed is up to 2700 rpm. A constant speed, flyball
type mechanical governor is standard for this engine.
The engine uses low octane (regular) gasoline and is
manual start.
3. DATA
Manufacturer. , . ..,....... ONAN, Division
of Studebaker Corp.
Model. . .............. . J120-S/967F
Specification. ........... Mil-E-11275, Mi!-
E-11278 per PHS-CC-
G-202(27-July-1962)
Cylinder. . . .. .., ........ 4
Cylinder Firing Order. . . . .. 1-2-4-3
Displacement. . . ......... 120 cubic ins.
Воге .. . ............. 3-1/4
Stroke . ............... 3-5/8
H.P. at 1800 rpm (nominal) . . 30.5
Compression Ratio. .. .. ... 6. 5:1
Connecting Rod Bearings. . . .
Main Bearings, Precision
Military Standard
Be ee ee eee Military Standard
Magneto, Integral (gear driven) Standard
Starting . .............. Manual (hand crank)
Governor Regulation (nominal). 5%
Choke. . ............... Manual
Total Air Requirement
(1800 rpm). . .......... 925 cfm
Cooling Air.......... 890 cfm
Combustion Air .. .. .. . 35 cfm
Inlet Vent. . . ........... 24 sq. ft.
Outlet Vent (area when duct
is used*; w/o duct, make
vent 28 large as possible). . 160 sq. ft. *
Air Cleaner. .. ..,........ Dry Type
Fuel Pump Lift . . . ....... 8 ft,
Oil Filter (Full Flow)... . Std.
Oil Capacity . . . .. a 6 gts (U.S.)
Exhaust Connection Siz
(Pipe Tapped). . . ....... 1-1/2
Height . . .............. 25 ins,
Width, , ............... 20 ins.
Length .............. 37 ins.
Weight. ...... 375 1bs.
Torque € Clearance Data. . . .
SECTION II
OPERATIONAL INFORMATION
4. PREPARATION OF ENGINE
a. Installation
(1) Location. Provide adequate access for
service and repair. Protect the engine from adverse
weather. Consider location of related systems, such
as fuel, exhaust and ventilation,
See pars. 19 & 21
(2) Mounting. Be sure the engine is level
and securely mounted. Maximum tilt: for front or rear
lift is 30°; left lift (carburetor side) is 40°; and right
lift is 45°. Compensate for any titt when checking
crankcase oil.
(3) Ventilation. Good ventilation is needed to
cool the engine and to support combustion. Avoid re-
circulation of ventilating air, Locate vents so the flow
A-1
of air from the inlet to the outlet will pass over the
engine. The outlet should be slightly higher than the
inlet. Allow for heat produced by complementary
equipment.
(4) Exhaust. Exhaust is poisonous, Pipe
exhaust gases outside. Exhaust pipes must not ter-
minate near inlet vents. Avoid sharp bends. Use
sweeping, long radius elbows. Use a section of seam-
less, flexible tubing between the engine and any rigid
piping to restrict vibration. Increase pipes 1 size for
each additional 10 foot span. Protect walls and par-
titions through which exhaust pipes pass with a metal
shield. Install a suitable muffler preferably as close
to the engine as practicable. Pitch exhaust pipes
downward or provide a condensate trap at the point
where 2 rise in the exhaust system begins.
(5) Oil Drain Extension. For service con-
venience, install an oil drain extension made from
standard pipe and fittings in the 1/2 inch tapped oil
drain port in the oil base. Consider installing a
suitable valve.
(6) Fuel Supply. Locate separate fuel tanks
no lower than 8 feet below the engine fuel pump. Use
auxiliary fuel pump to provide additional lift. Avoid
gravity feed of fuel to the engine from tanks not
mounted ai engine. When sharing a fuel tank, do not
connect to an existing line at a point above the fuel
supply level. The fuel supply line must be air tight.
Install a shut-off valve at the fuel tank for service
convenience. Run a vent to the outside of a com-
partment within which a fuel tank is installed, Use a
clean fresh “regular”? grade of gasoline. Do not use
highly leaded ‘‘premium’’ grades. Never {ill the tank
while the engine is running. Leave room for expansion
when filling the tank OBSERVE SAFETY PRECAU-
TIONS WHEN HANDLING GASOLINE.
b. Lubrication
(1) Crankcase Oil The capacity ts 6 quarts.
Be sure that engine is level when filling for the first
time. Fill to the full mark (F) on the indicator (fig.
A-1) with proper grade of engine oil (para. 14). Do
not mix brands or grades. Always install dipstick
indicator air tight,
\ ALWAYS REPLACE CAP
TIGHTLY, OR OIL LEAKAGE
MAY OCCUR.
CAP AND OJ) LEVEL
INDICATOR
[оды
NEVER
OPERATE ENGINE
WITH OIL BELOW
L OIL FIRL
1 TUBE
Fígure A-1. Engine Lubricating Oil Level
A-2
(2) Governor Linkage. Lubricate the linkage
at the carburetor and ball joint ends with powdered
graphite (preferably) or a light sewing machine oil
(fig. A-2).
SHIF
SHIFT SLEEVE
Y
>
LUBRICATE
Figure A-2. Lubrication Of Governor Linkage
5, STARTING-STOPPING
a. General.
The following instructions pertain to engine
starting only. Refer to equipment instructions of
which engine is a component, for complete starting
procedure.
b. Preliminary.
Be sure the installation is complete and the
engine is serviced with lubricating oil and fuel. Heavy
exhaust smoking from burn-out of rust inhibitor oil
is normal during the first few minutes of the initial
run, If the engine fails to start at the first attempt,
remove the spark plug(s), clean in gasoline, dry, and
reinstall.
с. Manual Crank Starting.
(1) Prime carburetor; make certain priming
lever is down when finished.
(2) Set the hand choke as required by tem-
perature.
(3) Engage the crank with the crank dog.
(4) Position crank handle at 7 o'clock.
(5) Pull crank with hard, steady pull to 12
o'clock.
(6) See that oil pressure is at least 20 psi.
(7) Readjust choke as engine warms up.
d. Load Application.
Apply the load for new and reconditioned en-
gines in 4 steps. Wait 30 minutes between each step.
Maximum and thrust on the main bearings should
not exceed 1000 pounds,
e. Stopping.
Disconnect 2g much load as practical from
the engine before shut-down. Stop engine having mo-
mentary contact stop switch by holding switch to
stop position until engine stops completely. Releasing
switch before engine is fully stopped will allow engine
to continue to run.
f. Inspection.
Make a visual inspection of engine. Check for
oil and fuel leaks. Check for excessive vibrations,
Be aware of unusual noises.
6. UNUSAL OPERATING CONDITIONS
a. High Temperatures.
(1) See that nothing obstructs air flow to and
from the engine.
(2) Keep the cooling fins clean, See that air
housings are properly installed and undamaged.
(3) Keep the ignition timing properly adjusted.
(4) Be sure fuel-air mixture gives best
operation.
b. Low Temperatures.
(1) Use the proper SAE No. oil for the tem-
perature conditions. Change oil only when warm from
running. If an unexpected temperature drop occurs,
move the engine to a warm location, or apply heat
directly to the crankcase until the oil flows freely.
(2) Use fresh, winter grade (not *premium”'
type) gasoline. Protect against moisture condensation
Below 0°F, open the carburetor main jet 1 additional
turn
(3) Keep the breaker points and the spark
plugs clean and properly adjusted.
(4) Partially restrict the flow of cooling air;
however, use care to avoid over-heating.
c. Extreme Dust and Dirt,
(1) Keep the engine clean. Do notallow cooling
fins to become coated or obstructed with debris.
(2) Service the air cleaner as frequently as
necessary,
(3) Change crankcase oil every 100 operating
hours.
(4) Keep oil and gasoline supplies in dust-
tight containers.
(5) Keep the governor linkage connections
clean.
d. High Altitude.
For operation at altitudes of 2500 feet or
more, close the carburetor main jet adjustment
slightly to maintain proper air-to-fuel ratio. Refer
to paragraph 11 e, Maximum power will be reduced
approximately 4 per cent for each 1000 foot increase
to altitude.
7. PROTECTION OF ENGINE FOR EXTENDED
PERIODS
a. General,
Unless otherwise directed by pertinent govern-
ing specifications, use the following procedure to
protect an engine (only) that is to be out of service
for more than 30 days.
b. Protection Procedure.
(1) Run the engine until thoroughly warmed up,
(2) Turn off the fuel supply and run until the
engine stops from lack of fuel.
(3) Drain the oil from the oil base while still
warm. Attach a warning to refill before operation.
(4) Remove each spark plug. Pour 1 oz, (two
tablespoons) of rust inhibitor (or SAE #50) oilinto the
cylinder. Crank the engine over a few times. Leave
at top center position. Reinstall each spark plug.
(5) Service the air cleaner.
(6) Lubricate the governor linkage, Protect
against dust ete. by wrapping with a clean cloth
(7) Plug the exhaust outlet to pr event entrance
of moisture or dirt.
(8) Wipe the entire unit clean. Coat parts
likely to rust with a light film of grease or Oil
(8) Provide a suitable cover for the entire
unit.
SECTION III
GENERAL MAINTENANCE,
8. PREVENTIVE MAINTENANCE
a, General.
Routine periodic service is important The
following tabulated maintenance is recommended to
REPAIR AND REBUILD
keep the engine in good operating condition and is
based on units operating under favorable conditions.
Use the tabulation as a guide, and revise it so the
schedule of service periods become valid for the
engine under prevailing operating conditions.
A-3
INTERVAL (HOURS)
SERVICE ITEMS 8 100 200 500 1000 5000 SERVICES NOTES b. below/PARS
Inspect Engine Generally | x (1)
Check Fuel Supply X (2)
Check Oil Level X (3)
Lubricate Governor
Linkage xa (4)/par. 13
Service Air Cleaner
Foam type ха (5)/par. 111.
Change Crankcase Oil b x (8)/par. 14
Crankcase
Breather x 14g
Clean and Adjust
Spark Plugs X (7)/12£,
Check Breaker Points X (8)/12e.
Empty Fuel Sediment
Bowl x (9)/ (11)
Check Valve Clearance d R (11)/(16)
Replace Oil Filter с X (10)/ 14
Clean Carburetor x (11)/ 11
Clean Engine X 10a.
Clean Rocket Box Oil
Line Holes X (11)/ 14d.
Clean Combustion
Chamber x (11)/ 11a.
16a.
Grind Valves X (11)/ 16
Complete Reconditioning x (11)
. See service note para.b(6)
. .See service note para.b(10)
Ro op
Service more often under extreme dust conditions.
. . . Tighten head bolts and adjust valve clearance after first 50 hours on a new or overhauled engine,
b. Service Notes.
These supplement the service tabulation (para.
a. above).
(1) Inspection. Check for leaks, loose con-
nections, etc. Keep engine clean.
(2) Fuel Supply. Check supply to avoid run-
ning out of fuel. Never fill tank while engine is run-
ning. Use clean, fresh ‘regular’ grade gasoline.
Never fill completely; allow some space for expansion.
(3) Oil Level, Keep leve) to the F (fill) mark
On the indicator, when adding, use the same brand as
in crankcase.
(4) Governor Linkage. Use lubricating gra-
phite on the ball joint, and link-to-throttle, If graphite
is not available, use a light sewing machine type oil.
(5) Air Cleaner. (refer para 11f.). Foam
type - Wash element in gasoline or diesel fuel every
200 hours. Saturate with SAE 20W motor oil, and
squeeze as dry as possible.
(6) Crankcase Oil. Change oil only when
warm after operating. If oil is too cold to flow, do not
start engine, Move to a warm location or apply heat
externally until oil flows freely. The oil filter is a
A-4
full-flow type. Change the oil every 100 operating hours
unger the following conditions: extremely low tem-
peratures, short periods of operation, when using
highly leaded gasoline, extremes of dust and dirt.
(7) Spark Plug. Remove spark plugs. Clean
and adjust electrode gap. If engine runs rough or if
plug fails to pass a standard test, install new spark
plugs.
(8) Breaker Points. Refer to paragraph 12
for correct gap distances. Replace burned or faulty
points. If only slightly burned, dress smooth with
file or fine stone. Measure gap with thickness gauge.
Ignition breaker points must be correctly gapped
Crank engine to fully open breaker points. Loosen and
move Stationary contact to correct the gap. Retighten
and recheck gap. Ignition points should break contact
just when timing mark aligns for degree of spark
advance specified in clearances. Replace condenser
lí spark is weak or if points burn readily.
(9) Fuel Sediment. Empty carburetor and fuel
filter (strainer) bowls of any accumulated sediment.
Clean filter screen thoroughly. Reassemble and check
for leaks.
(10) Oil Filter. The oil filter is a full-flow
type (all oí) is filtered enroute to bearings). A by-pass
permits unfiltered oil to reach bearings if filter
becomes clogged. Place a drip pan below filter. Un-
screw oil filter counter-clockwise using both hands
or a filter wrench (box or strap type). Clean filter
mounting area. Turn new filter on hang tight, then a
1/4 turn further using a filter wrench. Change the oil
filter more often if, because of freezing temperatures
or extreme dust conditions, the oil becomes so black
and dirty the markings on the level indicator can’t be
seen through the oil,
(11) Major Engine Service. Remove carbon
and lead deposits from combustion chamber, valves,
etc. as often as experience dictates, depending on
Operating conditions, Adjust valve clearances when
cold. Flush rocker box cover oil line in fuel, and clean
Small holes using fine wire (do not enlarge holes).
Clean entire engine to insure efficient cooling and
operation Perform other services as inspection or
operation shows necessary.
9, TROUBLE SHOOTING
a. À good rule to follow in locating engine trouble
is to never make more than one adjustment at a time.
Stop and think how the engine operates, and figure out
the probable cause of any irregular operation. Then
locate the trouble by a process of elimination In many
instances, a symptom indicating trouble in one unit
may be caused by improper function of a closely
related unit or system. Remember that the cause is
usually a simple one, rather than a mysterious and
complicated one.
b. If a general tune-up is found necessary,
perform necessary operations in this sequence:
Spark Plugs, Ignition Cables, Ignition Points.
Ignition Timing, Valve Clearance, and Car-
buretor.
Chart ). ENGINE TROUBLE SHOOTING
TROUBLE POSSIBLE CAUSE REMEDY
Engine cranks too slowly
Engine cranks but won't start Fuel system faulty
Gasoline fuel
Oil in crankcase too heavy for low temperature = See para. 14 a. for oil
recommendations
Refill tank
Engine hard to start
No fuel in tank
Filter screen clogged
Water in fuel
No gasoline at carburetor
Defective fuel pump
Carburetor choked too much
Engine flooded
General
Ignition system faulty
Poor Compression
Poor Fuel
Wrong timing
Alr intake restricted
Restricted air intake
Poor fuel
Defective ignition system
Refill tank
Clean filter (para. 11)
Replace fuel
See Trouble-Shooting
Chart 2
Check choke adjust-
ment (para.11d.)
Correct operating pro-
cedures or adjust
choke
See Trouble-Shooting
Chart à
See Trouble -Shootiug
Chart 6 and par 16 g.
Change fuel
Retime
Clean air cleaner.
(para 11h.)
Clean air cleaner
(para 11h,)
Change fuel
See Trouble-Shooting
Chart 3
Chart 1. ENGINE TROUBLE SHOOTING (cont)
TROUBLE
Engine hard to start (cont)
Engine misses and backfires
but fails to start
Engine races (stop engine
immediately by closing
throttle)
Engine stops unexpectedly
Low engine power
POSSIBLE CAUSE
Incorrect timing
Defective fuel pump
Poor compression
Water in gasoline
Air leaks around intake manifold
[proper firing order
Ignition timing incorrect
Moisture on breaker points
Too much fuel caused by:
Disconnected governor mechanism
Defective governor
Incorrect governor adjustment
Vapor lock in fuel line, fuel pump or carburetor
Defective ignition
Lack of fuel
Internal seizure
Excessive crapkcase pressure, caused by
clogged breather
Restricted air intake
Poor fuel
Poor compression
Defective ignition (engine not firing on all
cylinders)
REMEDY
Repair or replace fuel
pump - For tests see
para,lic.
See Trouble-Shooting
Chart 6 and para
16b.
Change fuel
Inspect all gaskets on
manifold
Inspect ignition dis-
tributor system
Retime ignition
Clean points
See para. 13 &
Trouble-Shooting
Chart 4
See para 13 &
Trouble -Shooting
Chart 4
Allow engine to cool;
check for possible
over-heating, (para.
10b).
See Trouble-Shooting
Chart 3
Refill tank
To test, crank by hand.
Disassemble and
repair
Remove and clean
breather
Clean air cleaner
Change fuel (para. 11a).
Check compression,
para 16b. and
Trouble-Shooting
Chart 6
See Trouble-Shooting
Chart 3
TROUBLE
Low engine power (cont)
Engine misses at light load
Engine misfires at heavy load
Engine backfires
Excess oil consumption, light
blue smoky exhaust
Chart 1. ENGINE TROUBLE SHOOTING (cont)
POSSIBLE CAUSE
Incorrect ignition timing
Improper choke operation
Heavy carbon deposits in cylinders
Faulty carburetion
Spark plug gaps too narrow
Intake air leak
Faulty ignition system
Uneven compression
Spark plugs defective
Clogged carburetor idle jet
Defective high tension cables
Spark plug gap too wide
Clogged carburetor
Clogged fuel screen
Valve lash too tight
Defective ignition system
Poor fuel
Clogged fuel screen
Spark too late
Leaking intake valve
Improper firing order
Lean Fuel Mixture
Poor compression
Crankcase oil too light or diluted
REMEDY
See Trouble-Shooting
Chart 3
See para 11d.
Clean cylinders, See
para lla.
See Trouble-Shooting
Chart 2
Set at . 025"!
Inspect intake manifold
and carburetor
See Trouble-Shooting
Chart 3
See para 16b,
See para 12f,
Clean carburetor
Inspect and replace if
necessary
Adjust to .025
Clean carburetor
(para lle).
Clean (para. 11b).
Adjust lash (para 17a).
Ses Trouble-Shooting
Chart 3
Change fuel
Clean (para. 11g).
Time ignition
Check compression
Inspect ignition dis-
tributor system
(correct order
1-2-4-3)
Adjust carburetor
(para lle).
See Trouble-Shooting
Chart 6 and para
16b.
Change to correct oil,
para 14a. If giluted
see Trouble-Shooting
Chart 5.
A-7
Chart 1, ENGINE TROUBLE SHOOTING (cont)
TROUBLE
Excess oil consumption, light
blue smoky exhaust (cont)
Excess oil consumption, no
increase in smoke
Black, smoky exhaust,
excessive fuel consumption
fouling of spark plugs
with black soot, possible
lack of power under
load,
Dull, metallic thud; if not bad
may disappear after few
minutes of operation
Sharp, mefaltic thud,
especially when cold engine
first started
Tapping sound, clacking, light
clicking
Metallic knock under no
load conditions and when
stopping
Hollow clicking sound with
engine cool and under
load
Light pounding knock
Pinging sound when engine
is suddenly or heavily
loaded
POSSIBLE CAUSE
Engine misfiring
Excess oil in crankcase
Engine overheating
Defective intake valve stem oil seal
Worn infake valve, guide or valve stem
Faulty ignition
Oil leak from oil base or connections
Leaky crankshaft oil seals
Fuel mixture too rich
Choke not open
Clogged air intake
Worn crankshaft bearing
Low oil supply
Oil badly diluted
Valve clearance too great
Broken valve spring
Worn connecting rod bearings
Loose piston
Loose connecting rod bearing
Low oil supply
Oil badly diluted
Carbon in cylinder
Spark too early
REMEDY
See Engine Misfiring
this chart
Drain to full level
See para. 10b.
Replace (para. 16)
Replace (para. 16)
See Trouble-Shooting
Chart 3
Inspect engine; check
for clogged сгапк-
case breather
Inspect oil seals, para
18b. (2) and 18e. (5).
Check for clogged
crankcase breather
Adjust carburetor,
para lle.
See para 11d
Clean air cleaner,
para 11 1.
Replace bearing
Add oil
Replace oil
Check valve clearance
para 18a,
Replace valve spring
Replace bearings
Check piston clearance
Replace bearings
Add oil, check for
cause of low oil
Replace oíl
Remove carbon
Adjust breaker points.
Retime spark if
necessary
TROUBLE
Pinging sound when engine
1s suddenly or heavily
loaded (cont)
Engine overheats (see
para 10b.)
Low or high oil pressure
Spark plug fouled in short
Chart 1. ENGINE TROUBLE SHOOTING (cont)
POSSIBLE CAUSE
Wrong spark plug
Valve hot
Fuel stale or low octane
Lean fuel mixture
Englne hot
Defective ventilating system
Defective installation
Improper lubrication
Late ignition timing
Fuel mixture too lean
See Trouble-Shooting Chart 5
Wrong spark plug gap.
REMEDY
Install correct spark
plug
Adjust valve clearance
Use good, fresh fuel
Clean and adjust
carburetor
Check air circulation
Check engine and
ducts
Inspect complete in-
staliation including
ducts etc.
Check oil system
Retime ignition
Adjust carburetor
(para 11e).
periods of time on
gasoline operation
Speed fluctuations or
incorrect speed
10. VENTILATION SYSTEM
2, Maintenance.
A pressure type of air cooling system is used
to remove heat produced during normal operation
Air is drawn into the blower housing at the front of
the engine and forced by blades on the flywheel past
the cylinders to a discharge on the right side of the
engine. All components in the ventilation system are
essential for adequate cooling of the engine. (flg. A-3)
Check all parts for proper installation. Clean the en-
gine cooling fins as required by operating conditions
to maintain efficient heat transfer to the circulating
air. Check for broken flywheel blades and cylinder
fins. Refer to paragraph b. for indicators of over-
heating. Make this maintenance a part of your regular
periodic inspection and repair program.
b. Overheating.
Sometimes difficult to detect, overheating of
air-cooled engines is usually indicated first by re-
current vapor locks and later by piston scoring. The
3 most probable causes of overheating are: (1) dirty
cooling surfaces, (2) operating without the engine air
Clean spark plugs and
set at 0.025”
See Trouble-Shooting Chart 4 & para 13.
housing, and (3) insufficient air flow resulting from
incorrect location or size of vents,
ACCESS
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must be properly installed when the engine
is running. Major damage could occur within
only a few minutes of operating without it.
11. FUEL SYSTEM
a. Description and Fuel.
This engine has a conventional gasoline fuel
system (fig. A-4). A fuel pump and carburetor are
used to supply a metered fuel-air mixture to the com-
bustion chamber. A manual choke is used instead of
an electric type. Regular grade gasoline should be
used in these engines; they don’t need premium gaso-
lines. One of the most important things to consider
is the content of Tetra Ethyl Lead in the fuel, Pre-
mium fuels contain more lead than regular, but the
lead quantity also varies among the many brands of
fuel. Especially in constant speed operation, the build
up of deposits in the combustion chambers is pro-
portional to the amount of lead in the gasoline. So
more lead means more deposits and more frequent
head removal for cleaning, On engines that require
frequent combustion chamber cleaning, the period be-
tween cleaning can often be extended by changing fuel.
If fuel is stored for any great length of time, it can
oxidize and form gums - the fuel becomes stale.
ONAN recommends changing stored fuel as often as
every season to insure fresh fuel, especially where
there is a great change in weather between seasons,
(AIR CLEANER
REMOVED)
ELECTRIC CHOKE
FUEL LINE
FUEL PUMP
E NN A F UEL FILTER
7
Figure A-4. Engine Gasoline Fuel System
(Electric Choke Shown Not Used, Refer To
Figure A-8 For Manual Choke)
A-10
b. Maintenance.
For gasoline fuel systems, periodic mainte-
nance should consist of cleaning the fuel strainer,
cleaning or replacing the air cleaner (para. i. below)
and cleaning and adjusting the carburetor, For service
periods, see paragraph 8.
To clean the fuel strainer, remove the fuel sediment
bowl and the screen (fig. A-5) and thoroughly wash
the screen. At the same time, remove the carburetor
float bowl and clean it. Reassemble and check for
leaks.
Figure A-5. Primary Filter
c. Gasoline Fuel Pump.
The fuel pump is on the accessory side of the
engine. If fuel doesn’t reach the carburetor: check the
fuel tank and see that fuel valve is open; remove the
line from the pump outlet and work the priming lever
on the pump (if no primer, crank engine). Fuel should
spurt from the pump; but if not, remove the pump for
repair or replacement
(1} Testing. If the fuel pump delivers fuel,
test it with a pressure gauge or manometer. Perform
these tests before removing the pump from the engine,
Disconnect the pump outlet line and install a pressure
gauge (fig. A-6).
Test the valves and diaphragm by operating the prim-
ing lever a few times and watching the pressure. It
shoulan’t drop off rapidly after priming has stopped.
Next run the engine at governed speed of 1/2 throttle
on the fuel remaining in the carburetor, and measure
the fuel pump pressure developed. Pressure should
be between 2 and 3 psi with the gauge about 16'' above
the fuel pump.
A low pressure reading indicates extreme wear in
one part or some wear in all parts, and the pump
should be overhauled or replaced. If the reading is
above maximum, the diaphragm is probably too tight
or the diaphragm spring too strong. This can also
be caused by fuel seeping under the diaphragm re-
tainer nut and between the diaphragm layers, causing
a bulge in the diaphragm. Overhaul the pump and re-
place the defective parts.
Low pressure with little or ng pressure leak afier
pumping stops indicates a weak or broken spring or
worn linkage, and In most cases the pump should be
replaced
PRESSURE
Figure A-8. Measuring Fuel Pump Pressure.
(2) Removal & Disassembly (fig. A-7).
(a) Remove the pump inlet and outlet.
Remove the 2 capscrews holding the pump to the
engine and lift it off.
(b) Notch the pump cover and body with
a file so they can be assembled in the same relative
position, and remove the 6 screws holding them
together.
(c) Tap the body with a screwdriver to
Separate the 2 parts. Don't pry them apart- this
would damage the diaphragm.
(d) Remove the screws holding the valve
plate to the cover and lift out the valve and cage
assemblies.
(e) Drive out the rocker arm hinge pin.
(£) Remove the rocker arm, spring and
link,
(g) Lift out the diaphragm assembly and
diaphragm spring.
(3) Repair. Fuel pump failure is usually due
to a leaking diaphragm, valve or valve gasket A
kit is available for replacement of these parts.
Because the extent of wear cannot be detected by the
eye, replace all parts in the kit. If the diaphragm is
broken or leaks, check for diluted crankcase oil
Occasionally, failure is due to a broken or weak
spring or wear in the linkage. In those cases, install
a new pump.
(4) Assembly.
(a) When installing a new diaphragm,
soak it in fuel before assembling. Insert the diaphragm
spring and soaked diaphragm into the pump body.
(b) Insert the link and rocker arm into
the body; hook it over the diaphragm pull rod. Align
the rocker arm with the rocker arm pin hole and
drive in the pin. The priming lever must be in the
position shown in figure A-7wheninstalling the rocker
arm.
(¢) Compress the rocker spring and
install between the body and rocker arm.
(d) Insert the valve cages, gaskets, and
valve cover plate. Position the inlet valve with spring
showing and the outlet valve with spring in the cover
recess,
(e) Assemble the cover to the body with
notch marks lined up. Install the screws but don’t
tighten.
(£) Push the rocker arm in full stroke
and hold it in this position to flex the diaphragm.
NOTE: The diaphragm must be flexed or it will
deliver too much fuel pressure.
(g) Tighten the cover screws alternately
and securely, then release the rocker arm.
(h) Install the pump on the engine; be
careful to get pump arm over cam on camshaft,
Repeat the pressure test, paragraph c. (1) above.
d Manual Choke (fig. A-8).
A manual choke is provided at the front of the
engine. It is used to reduce the amount of air entering
the carburetor. Pulling choke out reduces air in fuel-
air mixture, Pushing in provides a balanced fuel-
air mixture. It is adjusted as may be required by
operating conditions.
e. Carburetor.
The gasoline carburetor is a horizontal draft
type, with an upturned intake horn (air cleaner adap-
ter). The carburetor consists of 3 major sections -
the bowl and float, the idle circuit, and the load circuit.
Fuel enters the carburetor through the iniet valve
(fig, A-9) and passes into the float chamber. To con-
trol the fuel level in the bowl, the float closes the
inlet valve when fuel reaches a certain height, and
opens it when the fuel lever drops.
A-11
VALVE AND CAGE
ASSEMBLIES
ROCKER
COVER ARM
RAGM SPRING
DIAPHRAGM ==
SPRING E
ROCKER Y
ARM PIN
ROCKER ARM
BODY
PRIMING LEVER
O
FILTER
ELEMENT
ROCKER Е
ARM PRIMARY
LINK FILTER
BOWL
Figure A-7. Cross Section Of Fuel Pump.
TOMANVAL CHOKE CONTROL
KNOB ON OUTSIDE OF
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CARBURETOR
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FUEL INLET
4 VALVE
ELOAT
The idle circuit (fig. A-10) supplies fuel atidling speed.
Since the throttle plate is nearly closedatidle, the in-
taxe manifold vacuum is high. The pressure difference
between the manifold and float chamber causes fuel to
flow through the idle circuit. The pressure difference
draws fuel up through the hollow center of the main
adjusting needle, through passages in the carburetor
body to the idle ports. Bleed holes inthe main adjust-
ing needle allow air to bleed in and mix with the fuel.
When the throttle is almost completely closed, the fuel
passes out through the idle port which is controlled
by the idle adjusting needle. As the throttle is opened
to increase power, it gradually exposes the idle
transfer port through which fuel is also drawn.
As the engine governor opens the throttle further
under increased load, the increased air flow through
the carburetor produces a Jow pressure at the venturi
(narrow section of the carburetor throat). This pres-
sure drop draws fuel up the main nozzle to be mixed
with air at the nozzle opening. This is the load cir-
cuit (fig. A-10); the main adjusting needle controls
its fuel delivery.
At the same time, because the throttle is open, the
manifold vacuum decreases so the idle circuit be-
comes less effective. In a certain range, the two cir-
cuits blend, both delivering fuel, but as load is in-
creased, the load circuit takes over.
Whenever load is increased, with the load circuit in
operation, the governor opens the throttle to deliver
more fuel, The main nozzle won't immediately de-
liver this increased fuel because of the jet controlled
by the adjusting needle. To prevent a power lag when
load is increased, a metering wall around the outside
IDLE TRANSFER PORT
DCE JE PS J MAIN JET
5 ER FLOAT BOWL
VAPOR ЗЕРНА Bi Е
CASOLINETS: a С | ~— VENT
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PLATE | =~ METERING
1 WELL VENT
FLOAT
IDLE JET OPERATING
IDLE ET J MAIN JET
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FLOAT
Ss E UU M METERING
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MAIN JET OPERATING
Figure A-10, Carburetor Idle Circuit (Left) And Main Load Circuit (Right).
of the nozzle delivers fuel until the main jet can catch
up with the increased demand.
(1) Adjustment, Adjusting the carburetor
means obtaining the correct fuel-to-air mixture for
smooth, efficient operation. The carburetor should be
adjusted in 2 steps - first the idle adjustment, and
then the load adjustment. NOTE: If the carburetor
is completely out of adjustment so the engine won't
run, open both needle valves 1 to 1-1/2 turns off
their seats to permit starting. Don’t force the needle
valves against their seats, This will bend the needle.
Before adjusting the carburetor, be sure the ignition
system is working properly and the governor is ad-
justed. Then allow the engine to warm up.
(a) With the engine idling, turn the idle
adjustment out until the engine speed drops slightly
below normal. Then turn the needle in until speed
returns to normal.
(b) Apply a full load to the engine.
(с) Over-ride the governor and check
acceleration. If the engine accelerates evenly without
a lag, the main adjustment is correct. If not, adjust
the needle outward about 1/2 turn and apain check
acceleration. Continue until the engine accelerates
evenly without 2 time lag.
Finally, set the throttle stop screw (fig. A-11) to
allow 1/32'' clearnace to the stop pin with the engine
running at no load. This prevents excessive hunting
when a large load is suddenly removed.
(2) Removal and Disassembly,
(a) Remove the air housing door and top
panel.
(b) Remove the fuelline, governor linkage
and choke cable,
MAIN FUEL TH ОР $
ADJUSTMENT ROTTLE ST CREW
(B) FUEL IDLE
ADJUSTMENT
This distance 1/32”
| atno load
Figure A-11. Carburetor Adjustments.
(c) Remove the 2 carburetor mounting
nuts and pull off the carburetor.
(d) Remove the air cleaner adapter From
the carburetor.
(e) Remove the float bowl nut and pull
off the bowl.
(£) Remove the float pin and float
(g) Lift out the float valve and unscrew
its seat
(h) Remove the no load adjusting needle.
(i) Remove the load adjusting needle and
spring.
(j) Remove the throttle plate screws and
the plate, and pull out the throttle shaft.
(k) Remove the choke plate screws and
plate, and pull out the choke shaft.
A-13
(3) Cleaning and Repair. To clean the car-
buretor, soak all components thoroughly in a good
carburetor cleaner, following the cleaner manu-
facturer’s instructions. Be sure all carbon is cleaned
from the carburetor bore, especially in the area of
the throttle valve. Blow out the passages with com-
pressed air. If possibie, avoid using wire to clean
out the passages.
Check the adjusting needles and nozzle for damage.
If the float is loaded with fuel Or damaged, replace
it. The float should fit freely on its pin without bind-
ing. Invert the carburetor body and measure the float
level (fig. A-12).
If necessary, bend the small lip that the intake needle
rides on to adjust float level.
Check the choke and throttle shafts for excessive
side play, and replace if necessary. Don’t remove the
coating (olive drab color) on the throttle shaft. This
is Teflon, used to reduce wear and friction between
the shaft and carburetor body.
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Figure A-12, Measurement Of Carburetor
Float Level.
(4) Assembly and Installation.
(a) Install the throttie shaft and valve,
using new screws, (as shown in fig. A-10, left)
with bevel mated to the carburetor body. On valve
plate marked with the letter *'C”, install them
with the mark toward the idle port when viewed from
the flange end of the carburetor. To center the
valve, back off the stop screw, close the throtile
lever, and seat the valve by tapping it with a small
screw driver; then tighten the 2 screws,
(0) Install choke shaft and valve, Center
the valve in the same manner as the throttle valve
(Step (1)). Always use new screws.
(¢) Install the main nozzle, making sure
it seats in the body casting.
A-14
(d) Install the intake valve seatand valve.
(e) Install the float and float pin. Center
the pin so the float bowl doesn’t ride against it
(£) Check the float level with the car-
buretor casting inverted (fig. A-12 € par (3) above).
(g) Install the bowl gasket, bowl and
bowl nut. To ensure satisfactory fuel delivery, be
sure gasket is in place; tighten the nut.
(h) Install the load adjusting needle with
its spring. Turn in until it seats and back out 1
to 1-1/2 turns.
(i) Install the idle adjusting screw finger
tight. Then back out 1 to 1-1/2 turns.
(j) Install the air horn assembly and
gasket.
(k) Install the carburetor on the engine
and connect the gasoline inlet, governor mechanism,
breather hose, and choke.
(1) Install the air cleaner and the air
housing.
f. Air Cleaner (fig. A-13).
This consists of a foam element over a metal
retainer. About every 200 hours, remove the foam
element and wash it thoroughly in gasoline. Then
dip if in crankcase oil and squeeze as dry as pos-
sible. Replace element only if damaged,
AFTER WASHING ELEMENT
DIP IN OIL AND SQUEEZE
AS DRY AS POSSIBLE.
(See text)
Figure A-13. Foam Element Type
Air Cleaner.
Chart 2 FUEL SYSTEM TROUBLE SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
No fuel to carburetor
Defective fuel pump
Restricted fuel line
Clogged fuel strainer
Flooding Overchoking
Incorrect adjustment of carburetor float level
Excessive fuel
consumption
Engine overloaded
Poor compression
Carburetor out of adjustment
12. IGNITION SYSTEM
a, Testing.
The purpose of the ignition system is to pro-
duce a spark in each cylinder at the correct time to
ignite the fuel-air mixture, The most complete test
for an ignition system is to cbeck the final result,
spark on the spark plugs. Remove each plug in turn,
reinstall the ignition wire to that plug and hold the
plug base against a good ground on the engine. Then
crank the engine and watch Che spark A good blue
spark indicates a healthy ignition system, a weak
or yellow spark or no spark, a poor ignition system.
The defect can be caused by defective breaker points,
coil condenser, or wiring. A good spark on all but
1 cylinder indicates a defective spark plug or de-
fective high tension wire.
b. Gear Driven Magneto (Fig A-14).
This magneto has an impulse coupling which
serves as a spark retard device, in addition to pro-
viding a bot spark at manual cranking speeds. Itis
a Self contained unit in which a voltage is produced
in the primary windings of a coil multiplied in the
secondary winding of the same coil and distributed
to the spark plugs, It serves the same purpose as
the battery, coil, and distributor in a battery ignition
system,
The rotating member of the magneto comprises the
impulse mechanism, a permanent magnet, a breaker
cam, and a pinion gear. Other parts include a lam-
inated core, coil, condenser, breaker points, distrib-
ator arm gear, distributor cap, and a stop lever.
All these components, except the laminated core, can
be removed when necessary for service and repair,
In operation, the laminated core is magnetized by the
revolving magnet to produce a voltage in the primary
windings.
Vapor lock in fuel line or pump
Allow engine to cool; para, 10b.
See para lle. (1)
Clean or replace
Clean, (para 11b.) adjust serv-
ice periods and check source of
contamination
Adjust or repair choke
See para. Ile. (3)
Reduce load
See рага 165.
Adjust carburetor
When the breaker points open to interrupt current
flow in the primary, a voltage is induced in the sec-
ondary. The high voltage produced in the secondary
flows 10 the distributor arm gear, which in turn
distributes high voltage at the proper time to the
spark plugs, where it jumps the gap to ignite the fuel.
-
ZA a COIL
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DISTRIBUTOR
ARM GEAR
'Q 7 и
SZ PINION GEAR
ER BREAKER CAM
7 BREAKER POINTS
A CONDENSER
PERMANENT MAGNET
LAMINATIONS
Figure A-14. Cutaway View Of Impulse Magneto
(1) Maintenance. - Check the breaker points
periodically for pitting and for the proper clearance
of .015'* If the contacts are dirty, clean them with
lacquer thinner or any other suitable solvent If
the contacts are badly pitted, replace both the movable
and stationary parts.
(2) Testing. A simple test to determine
magneto performance is to hold one of the spark
plug leads about 1/4" from a good groun while
cranking the engine. If no spark occurs beheen the
lead and ground, test the coil, rotor, ponís, and
condenser. Make sure the stop button is not grounded.
A-15
(a) Coil (fig. A-15). This procedure is for
the Eiseman coil tester, Remove the coil from the
magneto; leave the laminated core in place in the
coil, Connect the ground lead of the tester to the
bare ground wire of the coil and connect the breaker
lead of the tester to the insulated primary wire of
the coil. Finally, connect the spark lead of the tester
to the high tension terminal on the coil, If the coil
requires more than 1.5 amperes on the core, replace it
For the spark output test, set the spark gap at 5
mm. Marginal leak tests should be made with the
Secondary terminal disconnected from the test lead.
TESTER
GROUND LEAD
PRIMARY WIRE
GROUND WIRE
MAGNETO
COIL 5
TESTER SPARK
LEAD
LEAVE CORE
IN PLACE
HIGH TENSION
CONTACT
Figure A-15. Connections For Testing
The Magneto Coil
(0) Magnetic Rotor. There's no easy way
to test the strength of the magnetic field produced
by the magnets on the rotor, but chances are if a
screwdriver is strongly atiracied, the magnetism is
satisfactory. Unless the results of the coil test indicate
there might be low voltage at the core, look for some
other cause of abnormal performance.
(c) Breaker Points. It may be desirable
to measure spring tension on the movable contact.
Get specification from a Wico representative. Check
contact alignment,
(d) Condenser. If a standard condenser
tester is available, test the condenser for capacity,
breakdown, and low insulation resistance. Otherwise,
replace the condenser the same time as badly pitied
breaker points.
(3) Disassembly, Repair and Reassembly. A
complete breakdown of the impulse magneto in the
parts catalog shows component relationships. Use
that breakdown to help with the disassembly, repair,
and reassembly of this magneto. Only the assem-
blies which may pose problems are covered here
in this manual. Obtain wear specifications from a
Wico representative.
A-16
$ CAUTION :
Under no circumstances should the screws
holding the laminated coil, the distributor
arm bridge, and the distributor arm contact
bar be removed. These parts demand precise
installation by factory trained personnel.
(a) Distributor Arm and Pinion Gear
(fig. A-16). Lift the geared distributor arm from its
pivot. Remove the screw holding the pinion gear, and
lift off the pinion gear. Check these parts for ex-
cessive wear. When installing these parts, make
sure their timing marks are aligned.
SC ARM GEAR
“ARM GEAR
THIS MARK
INDICATES
TOOTH THAT
FITS
BETWEENTHE
BEVELLED
TEETH
oy NION
GEAR
~~
Figure A-16. Timing Distributor Gear.
(b) Rotor. With the pinion gear off, the
rotor can be taken out after removing the 4 screws
holding the impulse stop. Then grab the drive cup
and pull the complete coupling and rotor assembly
out of the magneto,
It is practically impossible for the rotor to lose its
magnetism. A screwdriver strongly attracted to the
rotor is indication of a serviceable rotor.
When re-installing the rotor, make sure the rotorand
the inside of the housing are free from dirt and chips.
Have the impulse stop on the correct side and the
lag angle (Para. (4) (b) below) before tightening the
4 screws.
(¢) Drive Cup and Spring. Place the flat
sides of the rotor in a brass- jawed vise. Remove
the snap ring, thrust washer, and drive gear. Next,
turn the drive cup clockwise until the projections on
the drive cup clear the projections on the driven
flange. Then pull the drive cup outward far enough
for the spring to unwind.
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There is a pre-load of 1 complete turn on
the impulse spring, so be careful when re-
leasing the drive cup. When the spring has
unwound, pull the cup, with spring inside,
off the shaft.
DRIVE CUP
PROJECTION
ROTATE DRIVE CUP
UNTIL PROJECTION
SEPARATE
7
Ez
DRIVEN FLANGE
PROJECTION
ROTOR
BRASS JAWS
OR SHIMS
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Figure A-17, Removing Dry Cup
And Spring.
To get the spring out of the drive cup, use a screw-
driver as a pry and work the spring out.
To replace the spring, locate the spring over the
cup so the inner eye of the spring is over the slot
on the inside wall of the cup. Install the spring so
there is a clockwise spiral toward the inner eye.
Insert the outer eye as far as possible into the
proper slot. Insert the inner eye of the spring in
the drive cup spacer slot. With a serewdriver,
large enough to bind in the center hole of the spacer,
wind the spring around the spacer until the spring
slides into the drive cup. (This method of winding
the spring eliminates any possiblity of distorting or
scratching the spring surface.) The spring may be
more easily inserted if the lugs of the drive cup
are securely held in a vise.
To re-install the drive cup and spring onthe magneto,
first make sure all parts are clean, Pack grease
between the turns of the spring. Pull the inner eye
outward until 1 turn of of the spring stays out of
the cup (fig. A-18).
Then place the drive cup on the shaft and engage the
inner eve with the notch in the drive cup spacer
washer, Push the drive cup in; but keep it out far
enough so the projections on the drive cup clear
the flange. Set the spring pre-load as follows: make
a half turn and allow the cup projections to lock
agamst the driven flange; then with a fresh hold on
the drive cup, make the final half turn to give a 1
turn pre-load, Push the drive cup firmly into place.
Install the drive gear and snap ring.
WIND SPRING UNTIL
| IT FITSINTO CUP
ORIVE CUP
DRIVE CUP (LUGS
HELD IN VICE)
Figure A-~18. Installing Drive Spring
In Cup.
(d) Driven Flange and Trip Arms. (fig.
A-19). The driven flange assembly should pull off
easily, but if not, use an arbor press; support the
flange with a steel ring under the impulse stop
assembly. If the flange has {o be pressed off, it will
be necessary to install a new oil Slinger. To remove
the trip arms, push the point of a knife between the
trip arm pivot and snap ring, near the opening of
the snap ring. With the ring sprung out slightly; the
knife can be inserted between the pivot and snap ring,
directly opposite from the opening. Use new snap
rings to secure the {rip arms.
DRIVEN
FLANGE
Figure A-19. Driven Fan And Trip Arms.
When re-installing the trip arm snap ring, use a
socket, or tubular stock, of a size slightly larger
than the pivot, to force the snap ring over the trip
arm pivot.
(e) Impulse Stop, See para. (4) (b) below.
(f) Core and Coil. The assembly is held
in place by a clamp at each end. To remove the
assembly from the magneto, disconnect the primary
wire at the breaker points and then remove both
clamps. Pull on the coil hard enough to offset the
magnetic forces that tend to hold the core to the
laminations. If the core must be removed from the
A-17
coil, be sure to provide support so the primary
will not separate from the secondary when the
necessary force is applied to the core. The core
is held in by a spring wedge,
(4) Adjustments. There are only 2 adjust-
ments to be concerned with in respect to the magneto
a8 a upit- (1) the breaker point gap and (2) the lag
angle.
(a) Breaker Points. Adjust the points for
a fully opened clearance of 0,15''. Double check the
adjustment. Check point timing as explained in para-
graph (5) below.
(b) Lag Angle. Lag angle is the rotary
distance the point of ignition is retarded during
starting, Or it’s simply the difference in degrees
between ignition at starting (static) and at running.
The engines covered by this manual operate with
an ignition point of 25°BTC at speeds up to 2700
rpm. Ignition at starting occurs near TDC. It follows
that the desired lag angle is 25°C.
Maintain the lag angle adjustment made atthe factory.
Magnetos on units shipped after 12/1/62 had 2 punch
marks (fig. A-20) to indicate the proper relationship
between the impulse stop and housing. NOTE - if there
are no punch marxs on your magneto do not disassem-
ble the magneto until some kind of wiiness marks
are made to ensure correct reassembly,
(5) Timing. Ignition for operation up to 1800
rpm occurs at 25 BTC. During cranking when the
impulse coupling is in operation, the ignition point
is retarded about 25°. When the engine starts, cen-
trifugal force causes the impulse coupling fo be
disengaged, resulting in an automatic spark advance
to 25°BTC.
Begin by removing the spark plug from No. 1 cylinder
and turning the flywheel in the direction of normal
rotation until pressure builds up in the cylinder.
Then with No. 1 on the compression stroke, continue
turning until the 25° mark is aligned with the timing
pointer.
ALIGNMENT
PUNCH MARKS
Figure A-20. Lag Angle Punch Marks.
Turn the magneto until the white mark on the rotor
is visible in the window of the magneto. The white
mark is for positioning the magneto at No. 1 cylinder,
With the mounting gasket in place mount the magneto
on the studs. Push the magneto in s0 the gears mesh,
it may be necessary to rotate the magneto within the
elongated slots before the helical gear engages the
cam gear. Tighten the magneto to its mounting for
positive movement. Install the spark plug leads. Run
the engine and use a timing light to get exact timing.
Correct timing is 25°BTC and the white mark on the
magneto rotor should also be visible in the window
at this position. Move the magneto in the elongated
slots for precise location. Tighten the magneto to its
mount securely.
C. Spark Plugs.
This engine uses standard automotive spark
plugs. Champion H=8 or equivalent. The plugs should
be removed at regular intervals for cleaning and
inspection. If the plugs are in good condition; they
can be cleaned on a commercial plug cleaner and
re-gapped. For gasoline operation, the spark plug
gap should be set at .025'. But when Spark plug
electrodes become excessively worn or if the plugs
are damaged, replace them. When re-installing spark
plugs or installing new plugs, always install new
gaskets.
Chart 3. IGNITION SYSTEM TROUBLE SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
No spark
Defective high tension leads
Defective spark plugs
Defective magneto coil
Defective breaker points
Inspect points for dirt,
burning, pitting. Check
¢learance
Replace
Replace
Replace
Chart 3.
IGNITION SYSTEM TROUBLE SHOOTING (Cont’d)
TROUBLE
Weak, yellow spark -
usually causing hard
starting
Excessively burned or
pitted ignition points
Weak or no spark on
some cylinders -
usually indicated by
engine missing
Oil fouled spark plugs
Gag fouled plugs (dry
black fluffy deposit)
Burned spark plugs (dry,
shiny, glossy deposits
on insulator or pos-
sibly cracked insulator)
POSSIBLE CAUSE
Dirty, burned or pitied
breaker points
Defective ignition condenser
Defective spark plugs
Weak magneto coil
Dirty points
Breaker gap too small
Defective ignition condenser
Using the wrong ignition
condenser
Defective hi-tension leads
Defective spark plug
Worn rings or pistons
Worn valve stems or guides
Faulty ignition wires
Weak magneto coil
Too cold a plug
Excessive choking
Too rich a fuel mixture
Too cold a spark plug
Too lean a fuel mixture
Poor engine cooling
Poorly seated valves
Improper timing
Too hot a spark plug
Improper plug installation
Compression leakage through
the spark plug
REMEDY
Clean or replace the points
Test and replace if defec-
tive
Replace
Replace
Keep points clean at all
times
Adjust
Check the condenser on a
commercial tester
Use only the condenser
specified
Replace
Clean or replace
Check compression, (para
16b.)
Check clearance (para 16d.)
Replace
Test and replace if neces-
sary
Replace with hotter plugs
Check choke operation
Adjust carburetor
Change to hotter plugs
Adjust carburetor
Check ventilation system,
(para 10).
Check compression (para
16).
Retime the ignition
Change to colder plugs
Be sure seals and threads
are clean and gaskets
good; use only recom-
mended torque
Be sure seats and gaskets
are in good condition
A-19
13. GOVERNOR SYSTEM
а. Description.
The purpose of an engine governor is to
maintain a constant engine speed during changes in
power demands. A governor responds to changes in
power demands by varying the throttle position
The governor maintains engine speed at about 1800
rpm, The speed sensing device is a ball and cup
mechanism on the camshaft gear. A yoke, resting on
the cup, is connected to the governor arm, which in
turn is connected to the throttle lever. Any change in
engine speed is transmitted from the cup to the yoke,
and onto the throttle. Tension on the governor spring
determines the speed at which the engine is governed.
A stud screwed into the spring is used to vary the
number of effective coils for- getting the desired
sensitivity; the speed drop from no load to full load,
(fig. A-21).
E
CARBURETOR
Cd GOVERNOR LINKAGE
CAM on, GOVERNOR
GEAR Bi tha FLYBALLS
Na UN
Da da т 5
ZO
NL GOVERNOR
YOKE
> Es DE cove CUP
5 ENGINE SPEED
ADJUSTING STUD
AND NUT
(SEE INSET)
|
TURN TO INCREASE RPM.
(HOLD SPRING STUD
IN POSITION)
GOVERNOR ARM
GOVERNOR X
SHAE T
= > Wi
— 1
"e
>
GOVERNOR -
SPRING TURN FOR MINIMUM
GOVERNOR SPEED DROP, THEN
SPRING STUD ADJUST NUT.
GOVERNOR
SRRING NUT
* NOTE: GOVERNOR ARM SHOULD BE FLUSH WITH BOTTOM
OF HOLE IN GOVERNOR SHAFT
Figure A-21. Constant Speed (1 Spring) Governor
b, Maintenance.
The linkage must be able to move freely
through its entire level. Periodically lubricate the ball
joints with graphite or light non-gumming oil. Also
inspect the linkage for binding, excessive slack, and
Wear.
A-20
(1) Testing and Repair. Removing the gear
cover for access to the governor cup and other in-
ternal governor parts is covered in paragraph 18.
External service and repair is limited to testing
spring tension and checking ball joints,
(2) Adjustments. Speed and sensitivity ad-
justments of the governor are made at the same
place in the same way. Refer to the illustrations and
the appropriate procedures.
(a) Speed. Change the spring tension with
the speed adjusting nut while holding the sensitivity
stud in place with a screwdriver. More tension gives
more speed (fig. A-22). Turn the nut clockwise for
more tension and speed. Turn the nuit counterclock-
wise to reduce governed speed. Use a tachometer to
indicate engine speed.
(b) Sensitivity. There are coarse and
fine adjustments for sensitivity. The coarse adjust-
ment is made by relocating the spring in the notches
in the governor arm. Moving the spring up on the
governor arm will decrease sensitivity. The fine
adjustment is made by changing the number of effec-
tive coils in the governor spring by turning the
sensitivity stud farther in or out Turn the stud
counterciockwise to increase sensitivity. Adjust for
maximum sensitivity without a hunting condition (fig.
A-22). I the speed drops too much when full load is
applied, unscrew the governor adjusting stud to use
more coils of the spring. Hold the stud and turn the
speed nut slightly for more spring tension to com-
pensate for reduced rpm caused by making more
coils operative. A too close sensitivity adjustment,
approaching no speed drop when load is applied, will
result in a bunting condition (alternate increase and
decrease in speed).
(с) Throttle Stop Screw. Set the throttle
stop screw, located on the throttie lever; with no load
connected and while running at rated speed. Turn the
screw to give 1/32!" clearance between the screw
and pin. This prevenis starving when load is removed
SPEED | TURN TO INCREASE R.P.M
ADJUSTING NUT —== (HOLD SPRING STUD IN
GOVERNOR POSITION)
SPRING STUD a
(Sensitivity
Adjustment) TURN FOR MINIMUM SPEED |
DROP, THEN ADJUST SPEED NUT
Figure A-22. Governor Adjustment
TROUBLE
Speed too high (engine
races)
Speed too low
Hunting condition
Poor sensitivity
Governor acts slowly
Chart 4. GOVERNOR TROUBLE SHOOTING
POSSIBLE CAUSE
Governor incorrecily
adjusted
Governor yoke installed
backwards
Governor cup improperly
installed
Linkage binding
Governor incorrectly
adjusted
Low engine power (won’t
reach governed speed)
Governor spring tension
too great
Excessive wear in linkage
Binding in linkage
REMEDY
Adjust for proper speed.
Turn so machine side of
yoke touches governor
cup
Paragraph 18
Clean or replace linkage
Adjust for proper speed
See Troub!e-Shooting
Chart 1
Adjust sensitivity
Replace governor linkage
Clean and lubricate linkage
14. OIL SYSTEM
a. Description.
All working parts of the engine are pressure
lubricated. The oil system includes an oil intake cup,
gear type oil pump, by-pass valve, oil pressure gauge,
full-flow oil filter, and crankcase passages and
drillings. Oil is held in the oil base, drawn by the
pump, and delivered through the oil filter. Lines to
the rocker housing, drillings in the crankcase to
crankshaft and camshaft bearings, crankshaft pas-
sages to connecting rod bearings and connecting rod
Spray holes complete the cil system plumbing.
Because it helps to control oil consumption, the crank-
case breather is included in this system.
Normal oil pressure should be 25 psi or higher when
the engine is at operating temperature. If pressure
drops below 20 psi at half throttle or governed speed,
inspect the oil system for faulty components.
b. Maintenance.
Periodic oil system maintenance should in-
clude changing crankcase oil, cleaning the crankcase
breather (para h.), cleaning rocker box oil lines
(para e.) and replacing the oil filter (para. g.). Main-
tain service periods (para. 8).
Always use a good quality detergent oil classified
for service “DG” or “MS/DG”'. Service ‘DS?’ oil is
satisfactory but costs more. Use a single viscosity
ol, multi-viscosity oils increase oil consumption.
Use the proper SAE number for the expected ambient
temperatures.
Temperabures Commercial Military
Above 90” F SAE 50 OE50, Spec MIL-L-2104
30° to 90° F SAE 30 OE30, Spec MIL-L-2104
O to 30° F SAE 10W OE10, Spec MIL-L-2104
Below 0° F SAE 5\ OE-S, SpecMIL-L-10295
с. Oil Pump.
The oil pump is mounted on the crankcase
behind the gear cover and is driven by the crankshaft
gear,
(1) Removal.
(a) Remove the gear cover (para. léc.)
and oil base.
(h) Unscrew the intake cup from the pump,
(c) Remove the crankshaft lock ring and
gear retaining washer.
(d) Loosen the two capscrews holding the
pump and remove the pump.
(2) Repair. Except for the gaskets, compo-
nent parts of the pump are not individually available.
If the pump is defective or excessively worn, replace
it. Disassemble the pump by removing the two cap-
screws holding the pump cover to the body. Inspect
for excessive wear in gears and shafts. To improve
pump performance, adjust the gear end clearance by
changing the gasket thickness between the pump body
and cover. Use the thinnest gasket that permits free
movement of the pump shaft. Oil all parts when
reassembling the pump.
A-21
(3) Installation. Before installing, fill the
pump intake and outlet with oil for priming. Mount the
pump on the engine, and adjust for . 005" lash between
the pump gear and crankshaft gear. Mount the intake
cup on the pump so it is parallel to the bottom of the
crankcase.
d. By-Pass Valve (fig. A-23).
Located on the outside of the rear bearing
plate, the by-pass valve controls oil pressure by
allowing excess oil to flow directly back to the oil pan
Normally, the valve begins to open about 25 psi. It
is non-adjustable and normally needs no maintenance.
To determine if high oil pressure is caused by the
plunger sticking closed or low Oil pressure by the
plunger sticking open, clean and inspect the valve.
To remove the valve, unscrew the recessed plug in
the rear bearing plate, and lift out the spring and
plunger assembly, Determine proper valve operation
by checking the spring and plunger against the values
given below:
Plunger Diameter .3365'' to .3380°‘
Spring
Free Length
Force at 1-3/16"'
2-5/16 + 1/16"
2.225 + ,11 lbs.
REAR BEARING DS
PLATE — S _
6
N N
OIL BY- PASS En
SPRING ESA
Figure A-23, Oil By-Pass Valve
e Oil Lines (fig. A-24).
The rocker box oî line shoula be flushed with
fuel and the small holes cleaned with fine wire at
regular intervals. Clean out all other oil lines and
drillings with compressed air whenever the engine is
disassembled or overhauled. Reach the oil gauge
A-22
passage by removing the oil filter mounting plate.
Al] external oil lines, the rocker box Oil line and the
internal oil line to the rear bearing are replaceable,
if darnaged.
FLUSH ROCKER BOX O/L LINE WITH
FUEL AND CLEAN HOLES WITH FINE
WIRE.
Figure A-24. Rocker Box
Oil Line.
f. Oil Pressure Gauge,
The oil pressure gauge is located onthe lower
front corner of the cylinder block. If it is faulty,
replace it. Remove it with a wrench, and screw in a
new gauge. Before replacing, check for a clogged oil
passage behind the gauge.
g. Oil Filter.
The full-flow filter is mounted on the filter
plate at the left front corner of the crankcase. It
requires periodic replacement normally every 500
bours of operation. Remove the filter by turning
counterclockwise with both hands or a filter wrench.
Oil the new gasket and then install a new filter; turn
it hand tight plus 1/4 to 1/2 turn. If at any time the
oil becomes so dirty that markings on the dip stick
can't be seen, change the oil filter and adjust the filter
service period accordingly.
h. Crankcase Filter (fig. A-25).
The crankcase breather, located in the rear
left corner of the crankcase mainfains a partial
vacuum in the crankcase during operation to control
oil loss and ventilate the crankcase. It includes a
metal filter packed into the tube on the crankcase,
a rubber cap and hose connecting it to the engine
air horn
To disassemble, remove the rubber cap from the
crankcase tube. Check the baffle in the breather tube,
clean or replace if clogged.
TROUBLE
Diluted oil
Sludge in crankcase
Excess oil consump-
tion, light blue
smoky exhaust
Excess oil consumption;
no change in exhaust
Low oil pressure
High oil pressure
BREATHER TUBE
CAP :
FLAPPER — =
VALVE ¿Y
Chart 5, OIL SYSTEM TROUBLE SHOOTING
POSSIBLE CAUSE
Leaky fuel pump dia-
phragm
Worn compression rings
or scored cylinders
Dirty oil filter
Run for long periods
at idle
Worn or sticking piston
rings
Dirty breather system
Oil too light or diluted
Engine over-heating
Leaking oil seals
Leaky oil base gasket
Dirty breather system
Worn bearings
Oil by-pass stuck open
Oil supply low
Worn oil pump
Defective oil gauge
Oil by-pass stuck closed
Oil too heavy
Clogged oil passages
REMEDY
Rebuild pump
Inspect rings and cylinder
walls
Replace oil filter; adjust
oil filter service periods
Review operating proce-
dures
Check compression Clean
or replace rings
Clean (para 14h.)
Replace with proper grade
of oll - K diluted check
for cause
See para. 10,
Inspect crankshaft front
and rear oil seals
Check for leaks around
gasket. Replace if nec-
essary
Clean (para 14h.)
Rebuild engine
Clean by-pass valve
Add oil. Check cause of
oil consumption
Install new pump
Replace gauge
Clean
Replace with lighter oil
Clean all lines and oil pas-
sages
15. STARTING SYSTEM
This engine uses a manual starting system, It is
engaged and activated by use of the hand-crank at the
front of the engine. Gearing within the flywheel and
on the crankshaft facilitate eranking. Refer to parts
ASSEMBLY VASE TUBE FROM
CLEANER
list for parts in the system.
I BREATHER 16. CYLINDER HEADS AND VALVES
NOTE: FLAPPER VALVE ASSEMBLY NOT USED WITH
THIS ENGINE
Figure A-25. Crankcase Breather.
a. Maintenance.
Each aluminum cylinder head assembly con-
tains valves, valve seat inserts and guides, rocker
arms and spark plugs. The valve assemblies are
operated by pushrods running through the cylinder
head and push rod shields to the camshaft,
Check the valve clearances at regular intervals (para
8). In addition, scrape the combustion chambers clean
A-23
and inspect the valves and valve seats at regular .
periods, If the combustion chambers show excessive
carbon build up, clean them more often
Always check the valve clearance while the engine is
at room temperature (approximately 70°F). Turn the
flywheel so the cylinder for the valve to be checked
is 10° past the TDC position of the compression
Stroke, Adjust the clearance with the self locking nut
(fig. A-26 & A-27). The valve clearances are for in-
take 0.012 and for exhaust 0,015.
Figure A-26. Adjusting Valve Clearance.
b. Testing.
The cylinder compression test can be used
to determine the condition of valves, pistons, piston
rings and cylinders,
To check compression, run the engine until thoroughly
warm. Stop it and remove all spark plugs. Insert the
compression gauge in a spark plug hole, crank the
engine, and note the reading. To check for piston
blow-by, squirt a small amount of SAE 50 oil into
the cylinder and repeat the check. An increase in
compression with oil in the cylinder indicates piston
blow-by.
Compression of a standard new engine cranking at
about 300 rpm is about 110 psi. Compression should be
fairly uniform, normally with less than 10 psi dif-
ference between the highest and lowest cylinder, taken
at the same cranking rpm. Excessively high readings
indicate carboned combustion chambers.
Compression readings will deviate considerably from
the above readings because of differences in cranking
speed, altitude and ambient temperature conditions.
Therefore the specification is given only as a guide.
The best indication of leakage is the pressure dif-
ference between cylinders or a compression increase
when oil is added to the cylinder.
Another check of valve condition is to listenat the in-
take manifold (air cleaner removed) and the exhaust
outlet while the engine is turned over by hand. A hiss-
ing sound indicates a leaking valve. Be careful when
using this test because there will always be a slight
hissing during the start of each compression stroke as
the intake valve finishes closing. To detect piston
ring blow-by, listen at the oil fill opening. However,
A-24
if the valves are leaking badly, piston ring leakage
may not be noticeable.
ADJUST VALVE CLEARANCE ——— on ROCKER
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INTAKE
VALVE
ONLY
AT + VALVE SEAT
Figure A-27, Cross Section Of
Valve Assembly.
¢. Disassembly (refer fig. A-27).
Valves, tappets, rocker arms and pushrods
should be kept in order and refurned in order at
assembly.
(1) Remove the air housing access door and
air housing top.
(2) Remove the rocker box covers, spark
plugs, and connecting oil lines to the cylinder heads.
(3) Remove the intake and exhaust manifold
(4) Remove the rocker arms and push rods.
(5) Remove the capscrews holding each cyl-
inder head to the cylinder block,
(6) Remove each head. If it sticks, rap it
sharply with a soft hammer. Don’t use a pry.
(7) Using a valve spring compressor, dis-
assemble the valve assemblies.
d. Repair.
Thoroughly clean all components of the cyl-
inder head assemblies. Remove all the carbon deposits
from the combustion chambers and clean all gasket
surfaces,
(1) Valves. Remove all carbon and check
each valve for burning and pitting and each stem for
warping. Valves that are slightly pitted or burned,
refinish on an accurate valve grinder to a 45° angle.
But if they are badly pitted, or will have a thin
edge when refaced replace them.
Check refinished valves for a tight seat to the valve
seat with an air pressure type testing tool or by
applying Prussian blue or pencil marks on the valve
face and rotating it against the seat, If the valve seats
tightly, the Prussian blue or pencil marks will rub
off evenly all the way around the valve face.
(2) Valve Guides. Check valve-guide-to-
valve clearance, (para 17). If the proper clearances
can’t be obtained by replacing the valves, replace the
guides. Drive the old guides into the valve chambers,
Drive new guides in until they protrude 11/32'' from
the rocker box side of the head. Ream the new guides
to the proper diameter (para 17).
(3) Valve Seats, If the valve seatsare pitted,
refinish them. Using conventional seat grinding equip-
ment, reface each seat to a 45° angle and a seat width
of 3/64 to 1/16", You should be able to reface each
seat several times before it becomes necessary to
replace it. If, however, the valve seats are loose
or cannot be refaced, replace them, Use ONAN tool
#420B272 in a drill press (fig. A-28) to remove each
valve seat, Adjust the tool to cut 1/64'' from the
edge of the seat. Oil the pilot to keep it from seizing
in the valve guide, Cut each seat down to a narrow
rind on edges and bottom and break it out with a
Sharp tool. Be careful not to cut into the counterbore
bottom,
DRILL PRESS
ER,
BE SURE TO OIL
PILOT OF TOOL
AFTER CUTTING,
RINO IS EASILY
REMOVED
LO | =
æ
®
S de m
Ji EZ MAKE CUT 4%
Ss" adm mn! e FROM EDGE
= OF SEAT
Figure A-28. Cutting Out Valve Seat with Onan
Tool (420B272)
Thoroughly clean the valve seat counterbore and re-
move any burrs from the edges. If the counterbore
is damaged, it will have to be remachined for an
oversize seat Oversize seats are available in .002,
.005, .010. and .025"", Otherwise, install new standard
Size seat inserts,
Drive the new valve seat inserts in place. Be certain
that each seat rests solidly on the bottom of the
counterbore at all points. To make installation easier,
heat the cylinder head in an oven at 325° for about
1/2 hour and cool the valve seats in dry ice.
After installation and before facing the new seats,
peen the head material against the valve seat in the 3
areas between the machine roll marks (fig, A-29).
Face each new seat to a 45° angle and width of
approximately 3/64''. The finished seat face should
contact the approximate center of the valve face.
Check the contact point with either Prussian blue or
pencil marks on the valve face. Make any corrections
on the seat, not the valve face.
CROWD METAL OF HEAD
AGAINST VALVE SEATS
BY PEENING AREA ВЕ-
TWEEN MACHINE ROLL
MARKS.
MACHINE ROLL
MARKS
Figure A-29. Peening Valve Seat
(4) Valve Springs. Check the valve springs
on an accurate compression scale, Valve spring data
is given in paragraph 17. Replace any spring that is
weak, cracked or pitted or has ends out of square.
e. Assembly.
(1) Push a valve stem oil seal onto each
intake valve guide and clarap in place. Then oil the
Inside surface of each seal.
(2) Oil the stem of each valve lightly and
insert each in its own guide.
(3) Using a valve spring compressor, com-
press each valve spring with its spring retainer in
place, and insert the retainer locks.
(4) Install each head assembly and gasket
on the cylinder block and install the capscrews 1 or 2
turns,
(8) Make up push rod shield assemblies by
installing an ““O” ring on one end of the rod and a
spring, washer, and “O” ring on the opposite end,
(fig. A-30).
(6) Lift the cylinder heads and install the
pushrod shield assemblies (fig. A-30).
(7) Install the intake manifold to the heads
and tighten the nuts to 13 to 15 lb=ft. Tighten the
cylinder head capserews to 28 to 30 1b=ft following
the sequence in figure A-31.
(8) Install the exhaust manifold, oil lines,
spark plugs and carburetor.
(9) Install the valve stem caps.
BEFORE TIGHTENING
C CYLINDER HEAD BOLTS
rs LIFT HEAD SLIGHTLY
SHIELD WHILE DEPRESSING
(THIS END U VALVE PUSH ROD SHIELD
GOES INTO 3 Nw AND SPRING.
BLOCK) — INSERT UPPER END OF
YA om == SHIELD INTO HOLE PRO-
“O RING au FF — VIDEDIN HEAD.
SHIELD > os
. a 1
SPRING TÉ y NA
\ ~
CO wasn ER
@ "0" rine
SPRING
Figure A-30. Installing Pushrod Shields
Figure A-31. Sequence For Tightening
Head Bolts
(10) Install the pushrods, rocker arms, and
rocker arm nuts.
(11) Set the valve clearance.
Note
After the first 50 hours of operation, re-
tighten the cylinder head bolts and check
valve clearance.
(12) Reinstal) the rocker box cover.
(13) Reinstall the air housing and access
door.
A-26
17. PISTONS, CONNECTING RODS AND CYLINDERS
a. Removal and Disassembly.
The engine has aluminum pistons; each piston
is tapered and fitted with 2 compression rings, ex-
pander and an oi! control ring (fig. A-32). Full float-
ing piston (wríst) pins are held in place with a snap
ring at each end. The lower end of each connecting
rod contains half shell, precision bearings and the
upper end, semi-finished bushings.
rn GI HEAVIEST COMPRESSION
aa] N RING IN TOP GROGVE
7 E COMPRESSION RINGS
€ (A OIL CONTROL RING
| ола Анти PEA A
No RAIL
EXPANDER
Figure A-32. Piston Rings
TROUBLE
Poor compression
Valve breakage.
Valve burning
Sticking valves
Chart 6. CYLINDER HEADS AND VALVES TROUBLE SHOOTING
POSSIBLE CAUSE
Leaky head gasket.
Valves sticking.
Broken valve spring.
Leaky valves.
Burned valves and seats.
Insufficient valve clearance,
Weak valve springs.
Excessively strong valve
springs.
Worn guides which set up
thrust action.
Excessive valve clearance
Close valve clearance,
Weak springs.
High temperatures, causing
valve stretch,
Valve seat or face off center.
Loose valve seat inserts.
Improper cooling of valve
seats or guides due to
clogged cooling system,
Coked or gummed oil on stem,
Incorrect valve clearance.
Weak or broken springs.
Dirty, scored or gummy guides,
Incorrect clearance between
valve and guide.
REMEDY
Replace head gasket.
See Sticking Valves, this
chart.
Replace spring, check
valve condition.
Regrind valves.
Regrind valves and seats.
Adjust clearance.
Replace weak springs.
Replace springs.
Replace guides,
Adjust valve clearance,
Re-adjust valve clearance.
Replace springs,
Check for engine over heat-
ing.
Regrind seat, replace
valve.
Replace seats. Rebore and
use oversize if necessary.
Refer to paragraph 10.
Overheating
Clean or replace valve,
Adjust valve clearance.
Replace springs,
Clean or replace valves
and guides,
Correct clearance.
The connecting rods and caps are stamped with num-
bers for installation in the proper cylinder. When re-
moving piston assemblies, check the marking so each
can be reinstalled in the proper cylinder, and keep
all components of each piston assembly together.
(1) Drain the crankcase oil and remove the
oil base.
(2) Remove the air housing and cylinder heads.
(3) Scrape off the carbon ring at the top of
each cylinder to prevent damaging rings or pistons.
(4) Remove the connecting rod cap from each
connecting rod and push the assembly through the top
of the cylinder hore. If the ridge at the top of the cyl-
inder interferes with piston removal, cut it down with
a ridge cutter before taking the piston assembly out.
A-27
(5) Using a ring expander, remove the rings
from each piston.
(6) Remove the 2 retaining rings and push
the piston pin from each piston.
b. Cylinders.
The cylinder walls should be free of scratches
and pitting. Check each with an inside reading microm.
eter for excessive out-of-round or taper. The
original dimensions were 3.2495 to 3.2505". If neces-
sary, rebore the cylinder to fit the next oversize
piston. Pistons and rings are available in ,020, and
.040'' oversize. If the cylinders don’t need refinish-
ing, remove any existing ridges from the top of
the wall with a ridge cutter or, if the ridge is small,
a deglazing stone.
c. Pistons.
Thoroughly clean and inspect each piston
Clean the carbon from the ring grooves and be sure
all oil holes are open. If any piston is badly scored
or burred, loose in the cylinder, has badly worn ring
grooves or otherwise isn’t in good condition, replace
it. Check clearance to the cylinder by inserting
each piston in its cylinder. Check the clearance 90°
from the axis of the piston pin below the oil ring at
top of skirt. Pistons are selective fit, clearance
should be .002 to .004 inch. If it isn’t within limit,
replace the piston and check the cylinder for possible
reconditioning.
d. Piston Pins.
Each piston pin should be a thumb push fit
into its piston at room temperature. If the pin is
excessively loose, install a new one. If still too
loose, install the next oversize pin. If the piston is
worn enough that the oversize pin won't fit, replace
the piston,
e. Rings (fig. A-33).
Inspect each ring carefully for fit in the
piston grooves and seating on the cylinder wall, Fit
each ring to the cylinder wall at the bottom of its
travel, using a piston to square the ring in the bore.
Check the end gap with a feeler gauge. It should be
.010 to .02Q'. If the gap is too small, file the butt
ends of the rings. Dont use rings that need a lot of
filing; they won’t seat right on the cylinder walls, If
oversize pistons are used, use the correct oversize
rings,
When replacing piston rings, always de-glaze the
cylinder walls. Use either a de~glazing hone or emery
paper to break the cylinder glaze without changing
the diameter of the cylinder bore. Work the hone or
paper so you end up with a cross hatched pattern
After de-glazing, be sure to remove all residue from
the cylinder walls and the rest of the engine.
А-28
PISTON RING IN
CYLINDER BORE
Figure A-33. Measuring Piston Ring End Gap
f. Connecting Rods,
Clean the connecting rods and check each for
defects. Check the upper connecting rod bushings
for proper clearance with the piston pin. Clearance
should be .0002 to .0007'. If the bushings are ex-
cessively worn, press them out and install new ones,
pressing the new bushings in unti)] they are centered
in the connecting rod (fig. A-34). After installation,
drill the bushings with a 3/16" drill through the
counterbored hole in the connecting rod top. Finally,
ream the bushings to the proper size. Be sure the
connecting rod oil spray hole is open
4 J
x > 7 ORILLIS TO BE ©
A | THROUGH BUSHING |
4 AFTER ASSEMBLY IN
S ROD BUT BEFORE
BUSHING 15 FIN-
Y ( ISHED REAMED
— BUSHING TOBE
ASSEMBLED WITH
SPLIT IN THIS
PRECISION TYPE
- 77
BEADING CROSS - SECTION
MEASURE CLEARANCE IN
DIRECTION INDICATED
BY ARROW
Figure A-34, Connecting Rod
g. Connecting Rod Bearings.
Inspect the connecting rod bearings for burrs,
breaks, pits and wear. Measure the clearance between
bearings and the crankshaft journal. The clearance
should be .001 to .003 inch. If necessary, replace
with new precison bearings. For information about
the crankshaft connecting rod journals, see paragraph
18 f. .
h. Assembly and Installation
(1) Assemble the commecting rods and pistons
with pins and retaining rings. Facing the side of
connecting rod with oil spray hole, install piston
with arrow pointed to the right (fig. A-34 € A-35).
ARROW TOWARD EXHAUST SIDE OF ENGINÉ
TOP OF
PISTON
«—— VIEW
«— — REAR — ENGINE — FRONT — — — >
Figure A-35. Top of Piston
(2) Install all rings on each piston. Tapered
type rings will be marked “TOP” or identifled in
some other manner. Place this mark toward the
closed end of the piston Space the ring gaps 1/3 of
the way around the piston from one another. No gap
Should be in line with the piston pin. Oil the rings
and pistons.
(3) Position a bearing half in each connecting
rod. Be sure there is no dirt under the bearing, This
could cause high spots and early bearing failure.
(4) Oil the cylinder walls and pistons. Install
each piston in the proper cylinder using a suitable
installer. Each assembly should be installed with the
arrow mark on the piston toward the right when facing
front (flywheel end) of engine (fig. A-35).
(5) Position each connecting rod onthe crank-
shaft, oil the journal, and ingtall its rod cap with
bearing half. When installing the rod cap, position so
the raised witness mark on the forging matches the
mark on the connecting rod (fig. A-36).
0 (BE SURE THAT CONNECTING
ROD WITNESS MARKS ARE © O
ALIGNED
~~
mr
—
THLE] BRIEF AH Te Rn ри ТИЦ
NL
CRANKSHAFT
Мале!
О,
Figure A-36, Connecting Rod Witness Mark
(6) Tighten the connecting rod capscrews
to the specified torque.
(7) Crank the engine over by hand to see
that all bearings are free,
(8) Reinstall the oil base with a new gasket.
(9) Reinstall the cylinder heads, (para 16e.).
i. Break-In Period.
Whenever new rings or pistons are installed
or a cylinder refinished, the engine must be run-in
before regular operation can be resumed. Run the
engine for 15 to 20 minutes at no load, about 1/2 hour
at 1/3 load and 2 to 3 hours at 2/3 load. Then regular
operation can be resumed.
Chart 7. PISTONS, CONNECTING RODS AND CYLINDERS TROUBLE SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
Poor compression
Sticking rings.
worn rings.
Worn cylinder walls
and pistons.
Leaky head gasket,
Loose cylinder heads.
Tighten.
Replace rings, check cyl-
inder condition
Refinish cylinders, replace
pistons.
Replace head gasket.
Chart 7. PISTONS, CONNECTING RODS AND CYLINDERS TROUBLE SHOOTING (cont)
TROUBLE
Piston and cylinder
and ring wear
POSSIBLE CAUSE
Operated with dirty air
cleaner,
Air leak between air
cleaner and engine.
Faulty cylinder oil control.
Engine run on low or dirty
REMEDY
Change air cleaner service
periods,
Repair leaks.
Check rings.
Add or replace oil. Check
oil.
Overheating.
Worn connecting rod,
bushings and bearings
Badly diluted, dirty or
wrong grade of oil.
Clogged oil passages.
18. ENGINE DISASSEMBLY
a. General.
If engine disassembly is necessary, observe
the order presented below. As disassembly pro-
gresses, the order may be changed somewhat as will
be self-evident. The engine assembly procedure isthe
reverse of disassembly, Any special assembly instruc-
tions for a particular component are included in the
applicable paragraph. When reassembling check each
paragraph for these special assembly instructions or
procedures,
b. Flywheel (fig. A-37),
The flywheel is at the front end of the engine
and is tapered fit on the crankshaft. To remove it,
first remove the blower housing. The flywheel can
then be removed by using the crank dog as 2 puller.
To do this, first remove the crank dog and flywheel
mounting capscrew, Then remove the large washer
irom the flywheel! mounting capscrew and re-install
the screw part way. Install the washer into the crank
dog and re-install the crank dog so the washer bears
against the end of the flywheel mounting screw, Tighten
the 2 crank dog capscrews alternately until the flywheel
comes loose.
с. Gear Cover,
Detach the upper governor ball joint and re-
move magneto, Remove screws holding the gear cover,
tap it with a soft hammer.
A-30
Engine run with low oil.
cause of loss. If dirty,
adjust service periods.
See Trouble-Shooting Chart
2.
Add oil, check cause of oil
loss.
Change oíl. Check cause of
dilution. If dirty, check
service periods.
Clean oil passages and
drillings.
WASHER
CRANKDOG
CRANKDOG
MOUNTING
TIGHTEN
CRANKDOG MOUNTING
SCREWS ALTERNATELY
UNTIL FLYWHEELS
{ OOSENED.
Figure A-37. Pulling Flywheel
(1) Governor Shaft. The governor shaft is
supported by 2 sets of needle bearings, To remove
the shaft from the gear cover, remove the governor
yoke and pull the shaft from the gear cover. If the
shaft binds during operation, c¢lean the bearings; if
the shaft is loose, replace the bearings. To remove
the larger bearing, drive both bearing and oil seal
out from the outside of the gear cover, Remove the
smaller bearing with an easy-out or similar tool.
Press new bearings and an oil seal into place.
(2) Gear Cover Oil Seal (fig. A-38). Replace
the oil seal if damaged or worn. Drive the old seal
out from inside the gear cover. Lay the cover on a
board so the seal boss is supported. Using an oil
seal driver, insert the new seal from the inside with
the rubber lip toward the outside of the gear cover
(open side of seal inward) and drive it flush with the
outside surface. During gear cover installation, re-
verse the driver to protect the oi) seal,
A, FLUSH WITH THIS
SURFACE
ei - OIL SEAL
TH(S SURFACE MUST
BE CLEAN BEFORE
INSTALLING SEAL
Figure A-38. Gear Cover Oil Seal
(3) Gear Cover Assembly (fig. A-39).
(a) Work the governor shaft to check for
binding and see that the governor-shaft-end-thrust
ball is in place.
(b) Turn governor yoke so the smooth
side is toward governor cup.
(c) Turn the governor cup so the stop
pin in the gear cover will fit into one of the holes in
the cup surface (fig. A-39), Measure the distance
from the end of the stop pin to the mounting face of
the cover. It shouid be 25/32''. If it isn’t, replace the
pin.
(d) Using the oil seal driver or a piece
of shim stock over the crankshaft keyway to protect
the oil seal, install the gear cover, Tighten the
mounting screws to the specified torque, Before
tightening the screws, be sure the stop pin is in the
governor cup hole (fig. A-39).
(e) Install and retime the magneto (para
12 e).
d. Governor Cup (fig. A-40).
To remove the governor cup, remove the snap
ring from the camshaft center pin ang slide the cup
off. Be sure to catch the la flyballs that will fall out
when the cup is removed.
GOVERNOR ARM
GOVERNOR SHAFT YORE
(SMOOTH, SIDE TOWARD
GOVERNOR
- POSITION
DOvERNOR CUP
HAT x
ROLL PIN= = ==
FITS INTO
T-HOLE IN CUP
BE SURE THAT OIL
PASSAGES ARE OPEN
Figure A-39. Gear Cover Installation
(1) Repair. Replace any flyballs that have
flat spots or grooves. Replace the cup if the race
surface is grooved or rough. The governor cup must be
a free spinning fit on the camshaft center pin, but
should be replaced if excessively loose or wobbly.
Check the distance the center pin extends from the
carashaft gear. This distance must be 25/32'' to give
the proper travel distance for the cup. If it is less,
the engine may race, if more, the cup won't hold the
balls properly. If the distance is too great, drive or
press the center pin in. If it is too small, replace the
pin; it can’t be removed without damaging the surface.
In some cases, if the distance is too small, the head
of the governor cup canbe ground to give the necessary
7/32" travel distance.
WHEN GOVERNOR )S
PROPERLY ASSEMBLED
THE DIMENSION SHOWN
ON DRAWING WILL BE
AS INDICATED.
CAM SHAFT
GEAR
CENTER PIN
SNAP RING
GOVERNOR CUP
CAM SHAFT
GOVERNOR FLY BALL
Figure A-40. Cross Section of Governor Cup
(2) Installation. To install the governor as-
sembly, tip the front of the engine upward, Set the
flyballs in their recesses and position the governor
cup on its shaft. Finally, install the snap ring on the
center pin.
А-31
e, Camshaft,
The camshaft is a 1-piece machined casting
driven by the crankshaft, It rides on sleeve bearings
pressed into the crankcase, In addition to opening and
closing the valves, the camshaft operates the fuel
pump.
(1) Removal. Note that rocker arms, push-
rods and tappets, should be kept inorder and returned
in same order at assembly,
(a) Remove the rocker arms and push-
rods from the valve chambers.
(b) Remove the fuel pump from the engine.
(c) Remove the magneto (para 12).
(d) Remove the crankshaft gear retaining
washer by removing the lock ring on the crankshaft.
(e) Lay the engine on its side to avoid
dropping tappets, and remove the camshaft assembly
as a group. If necessary, pryitout with a screwdriver
between the camshaft gear and crankcase,
)
{ CAUTION $
Be sure the camshaft lobes don’t catch on
any pushrod tappetis as the assembly is being
removed.
(f) Remove the pushrod tappets. These
can be removed only from the camshaft end of the
pushrod holes,
(2) Repair. If a lobe has become slightly
scored, dress it smooth with a fine stone. If the cam-
shaft is badly worn or scored, replace it. For infor-
mation about the center pin, paragraph d. above.
(3) Camshaft Gear. This gear, a pressed fit
on the camshaft, is driven at 1/2 crankshaft speed.
The camshaft gear drives the magneto. To remove
the gear, use a hollow tool or pipe that will fit inside
the gear bore and over the center pin. Press the
camshaft out of the gear bore. Be careful not to
damage the center pin
(4) Camshaft Bearings. The camshaft bear-
ings should be replaced if the clearance to the cam-
shaft is greater than specified or if the bearings show
cracks, breaks, burrs, excessive wear, or other
defects (fig. 41).
The camshaft-to-bearing clearance should be .0012'' to
.0037''. To check the rear bearing, remove the ex-
pansion plug at the rear of the crankcase.
Press new bearings into place (fig. A-42) using 2
bearing driving tool. Press the rear bearing flush
with the bottom of the expansion plug recess. Press
the front bearing in flush with the crankcase front
surface 50 the crankcase and bearing oil passages
align. Don’t attempt to ream the bearings; they are
A-32
CAMSHAFT
PRESSED IN
> Ay MEASURE END PLAY
: a ,
CRANKSHAFT >
= ден PT
| Re Fs CRANKSHAFT
is GEAR
Figure A-41, Measuring Camshaft End Play
a precision type. After the rear bearing is installed,
insert a new expansion plug in the recess, using
sealing compound, and expand it into place with sharp
blows at its center.
(5) Camshaft Installation.
(a) Install the key and press the camshaft
gear on to its shaft,
(b) Install the governor components
(para. 10) on the camshaft.
(c) Slide the thrust washer onto the shaft.
(d) Lay the engine on its side or end and
insert the pushrod tappets.
(e) Install the camshaft assembly in the
engine. Align the timing marks on the camshaft and
crankshaft gears (fig. A-43).
(f) Replace the pushrods and fuel pump.
(2) Install and retime the magneto (para.
12).
f, Crankshaft.
The crankshaft is a counterbalanced type made
of ductile iron. The crankshaft rides on 3 bearings,
the front one housed in the crankcase andthe rear one
in the bearing plate. A split bearing provides support
at the center of the crankshaft.
(1) Removal.
(a) Remove the lock ring and retaining
washer in front of the crankshaft gear.
(b) Pull off the crankshaft gear. Ithas two
1/4-20'' UNC tapped holes for attaching a gear pulling
ring (ONAN tool 420A248). Use care not to damage
teeth if the gear is to be re-used (fig. A-44).
PRESS BEARING
FLUSH WITH
PRESS BEAR- La sm
Ema BOTTOM OF — №
ING FLUSHWITH F— =— — Te :
<« REAR
BEARING
[ | RECESS —
FRONT CRANK-
— CASE SURFACE
O. _ ALIGN OIL
HOLES
<“—FRONT
de) BEARING
Figure A-42. Camshaft Bearing Installation
THESE MARKS-(& |-
MUST COINCIDE Ar
WHEN INSTALL-
ING TIMING
GEARS
Figure A-43. Aligning Timing Gears
(c) Remove the oil pan and the piston-
and-connecting rod assemblies.
(d) Remove the bearing cap from the
cenfer main bearing.
(e) Remove the rear bearing plate from
the crankcase. For proper ¢rankshaft end play, either
re-use the original rear bearing plate gaskets or
measure their thickness and order new ones.
(I) Remove the crankshaft through the
rear opening in the crankcase. (Catch the upper half
of the main bearing supportas itslides off its mounting
surface).
CRANKSHAFT
Tigure A-44. Removing Crankehaft Gear
(2) Inspection Thoroughly clean the crank-
shaft and biow out all oll passages with compressed
air. Check all journals for out-of-round, taper,
grooves, Or ridges. Pay particular attention to ridges
or grooves on either side of the oil hole areas. Unusual
conditions here often point to previous neglect of oil
cleanliness precautions. If the journal dimensions are
not within the limits or the journals are scored, re-
place the crankshaft.
(3) Main Bearing. If the main bearing clear-
ances (para. 17 g.) are greater than the limits or the
bearings are worn, grooved or broken, replace them,
Precision replacement bearing inserts and thrust
washers are available for all main bearings. Don’t
attempt to ream the bearings. Align and press the new
bearings halves into the front and rear housings,
insert the center bearing when the crankshaft is
reinstalled. (fig. A~45)
А-33
REAR
a BEARINGPLATE 2
: E < ena Su
or = “ LO C K P | N LS ge ‘|
Dpt ddl dé ES al
та с il J 5
TE = OIL SEAL-
lI THRUST WASHER a WITH STEP Е
TT Y SURFACE
A1 NDA ALIGN OIL HOLES i (a
|
ad ey MAIN BEARING —— me 4 -—LIP FACING
ud bo MUST BE FLUSH WITH ‘ OUT
MEHR SN: INSIDE SURFACE
E LOCK PIN ‚
Tas
Figure A-45. Main Be
(4) Rear Oil Seal (fig. A-45). The crankshaft
rear oil seal is in the rear bearing plate. If damaged,
drive 1t out from the inside of the plate. Using the
oil seal installing tool, install a new seal with the
open side facing inward, Drive the new seal flush
with the rear surface of the bearing plate. Leave the
seal installer on during bearing plate installation for
protection.
(5) Installation. After crankshaft is installed
be sure it is not frozen in place,
(a) Press the main bearings into place
using a arbor press if available, if notavailable make
two plates as shown in figure A-46. Plates should be
1/8" or more thick, other parts consist of 3/8 dia-
meter (or larger) x 3'' bolt, 2 washers and a nut.
1. Wire bearings together firmly
making sure bearing tabs are the same side opposite
each other,
aring Installation
the rear main bearing on the lock pin side with tabs
next to Che bearing plate. Place bearings on a very
slight angle in gearing bore.
3. Position press plates, the plate
with 3 holes in the inside of block or an lock pin side
of bearing plate making sure to align holes with thrust
washer lock pins. Install bolt, washers and nut until
finger tight.
4, Use a light hammer and tap high
side until bearing is evenly in place (measure with
scale). Do not force too hard or damage may result.
5. After bearings are startedevenly
tighten nut. Remove wire after bearings are well
started.
6. Tighten until top plate contacts
block or bearing plate. NOTE: Be sure holes in plate
align with lock pins before pressing the bearing all
the way in bearing plate.
2. Position front maín bearing with (b) Install the thrust washers andlocking
tabs next to block and lined up with keyways, Position pins.
1/8" THICK OR
MORE с ^
2.
*
3/8" DIAMETER HOLE ————>O 3-1/2'sQ O “e
OR MORE DEPENDING LS
(BOTH PLATES O—1—5/16" DIAMETER HOLES (2)
Figure A-46. Main Bearing Pressing Plates
A-34
(c) Oil the bearing surfaces and install
the crankshaft from the rear of the crankcase, through
the rear bearing plate hole.
(d) Mount and secure the rear bearing
plate with the same thickness of mew gaskets as
removed.
(e) Heat the crank gear to about 350°F,
Install the key on the crankshaft, then drive the gear
into place. Install the retaining washer and lock ring.
(f) Set the upper half of the center main
bearing housing on the crankshaft and rotate it into
place. Be sure it is installed with the side marked
FRONT toward the crankshaft gear, Set the 2 position-
ing dowels on the upper bearing mount. Install the
center main bearing cap, and torque the bolts to 97 -
102 1b ft. (fig. A-47).
BOLT
CENTER MAIN
BEARING CAP
BEARING HALF
SIDE MARKED "FRONT"
TOWARD CRANKSHAFT
GEAR
PLACE UPPER BEARING
4 HOUSING HALF IN POS-
ra т 1 | TION (NDICATED By *
NE RA Y “Я BROKEN LINE ROTATE
DOWEL PIN +— 0 35 A INTO POSITION
| E > DOWEL PIN
‘BEARING 1 | @ Ca
SALE © —— == e CENTER MAIN BEAR-
ja! ING HOUSING
A (UPPER HALF)
IT BE SURE TO ALIGN OL
7 HOLES IN BEARING
J AND HOUSING
CRANKSHAF T—4 |
Figure A-47, Center Main Bearing Installation
(£) Check the crankshaft end play (fig.
A-48). Use enough rear bearing plate gaskets to
provide .010 to .015 inch end play.
(Ih) Install piston assemblies (para. 17h.)
g. Crankcase,
If the center main bearing support requires
replacement, the whole crankcase must be replaced
or returned to the factory to have a new housing
fitted.
19. ASSEMBLY TORQUES
a. Description
The assembly torques given here will assure
proper tightness without danger of stripping threads,
If a torque wrench isn’t available, estimate the degree
of tightness necessary for the stud, nut, or screw,
Be careful not to strip threads. Use reasonable force
only and a wrench of normal length
Specially designed place bolts (fig. A-48) don’t require
a lock-washer or gasket Don’t attempt to use à
lockwasher with these bolts; it will defeat their
purpose, Check all studs, nuts and screws often and
tighten as needed to keep them from working loose.
ma
REAR BEARING
e PLATE
TINE
in
/ NE MEASURE ENDPLAY
HERE
2 uu (REFER TO TABLE OF
DE ee ER Наса CLEARANCES)
Figure A-48. Crankshaft End Play
RECESS
<>, UNDER HEAD
<
2 Uy
€ Wr Z
Figure A-49. Place Bolt Identification
b. Torque Specifications.
Torques listed are in 1b-ft.
Center Main Bolt ...... 87-102
Connecting Rod Bolt . . . . 27-29
Cover-Rocker Box... .. 8-10
Cylinder Head Bolt. . .. . 28-30
Exhaust Manifold Nuts . . 13-15
Flywheel Mounting Screw. 65-70
Fuel Pump Mounting
Serews ... 14442440 15-20
Gear Cover. . ........ 15-20
Intake Manifold ....... 13-15
О1} Base Mounting
Screws ..... —. _—. . 45-50
Oil Filter . ..... ..... Hand Tight + 1/4-1/2 Turn
Oil Pump Mounting
Serews ........... 15-20
Rear Bearing Plate . . , . 40-45
Rocker Arm Nut . . . . .. 4-10*
Rocker Arm Stud , . . . .. 18-20
Spark Plug .......... 25-30
“This torque is due to friction between the threads
only and locks the nuts inplace. The rocker arm nuts
adjust valve lash.
А-35
20. SPECIAL TOOLS
a. General.
The listed special tools are available from
ONAN to aid service and repair work on the engine.
These are not supplied with the unit.
b. Tools.
Crankshaft Gear Pulling Ring. , . ....... 420A248
Driver, Front Camshaft Bearing. ......, 420A252
Driver, Rear Camshaft Bearing . .. ..... 420B250
Driver, Center Camshaft Bearing . . . . . . , 420B254
Driver, Valve Seat, ................ 420B270
Oil Seal Guide and Driver . .,......... 420B250
Valve Seat Remover . . .. ..........., 420B272
Replacement Bits for 420B272........ 4208274
Wrench, Oi! Filter - Box Type
(For Purolator full flow filter) ....... 420P268
21. CLEARANCE DATA
All values are inches unless specified (minimum/
maximum).
Magneto Breaker Point Gap (WICO). . . .... .. 015
Spark Plug Gap . . ................... 025
Ignition Timing Spark Advance. . ........ 25°BTC
Firing Order. ............... ...... 1-2-4-3
Camshaft
. 2.2500/2.2505
.1.18'75/1.1880
‚ 1.2580/1.2582
Bearing Journal Diameter, Front. .
Bearing Journal Diameter, Rear . .
Bearing Journal Diameter, Center .
Bearing Clearance Limit . ....... „0012/. 0037
End Play, Camshaft. ........... .007/.039
Cam Tappet Diameter ......... . .7475/.7480
Cam Tappet Hole Diameter.,..... .7505/.7515
Connecting Rods
Large Bearing Bore Diameter. . . . . 2.1871/2.1876
Small Bushing Bore Diameter
(without bushing) . . ........ .. 1,004/1,045
Piston Pin Bushing Inside Dia-
meter (bushing reamed) ....... .9903/.9906
Distance Center Large Bearing Bore
to Small Bushing Bore ........ 5.998/6.002
Clearance, Large Bearing fo
Crankshaft . ............... ,001/.003
Cylinder
Cylinder Bore ....... 3-1/4
Cylinder Diameter Limits (honed) . . 3.2495/3.2505
Crankshaft
Main Bearing Journal Diameter
(STD). ... aa 2.2430/2.2435
Crankshaft Main Bearing Clearance . ,0024/.0049
Connecting Rod Journal Diameter . .2,0600/2.0605
Connecting Rod Bearing Clearance. . .001/.003
End Play, Crankshaft. . ......... .010/.015
Piston
Piston Clearance to Cylinder Wall
(Selective fit 1/4 inch below oil
ring at top of skirt) .......... .002/.004
Piston to Cytinder (1-1/4 inch from
bottom of skirt), ..... ...... .008/.0028
A-36
Ring Groove Width Top .........
Ring Groove Width, 2nd .........
Ring Groove Width, 3rd .........
Piston Pin
Length
Diameter
Piston Clearance
Connecting Rod Bushing Clearance
(Pin in Rod)
Piston Rings
Ring Type
Valve, Intake
Stem Diameter.... ...........
SeatAngle. .. ...............
Valve Clearance . . . . .. «+ vv...
Valve, Exhaust
Stem Diameter .... 1.11 14144444
Clearance in Guide ............
Seat Angle. . .... o... avere
Valve Clearance . . ........,.,.
Valve Guide
Length _...................
Outside Diameter . ............
Cylinder Block Bore Diameter . . ..
Inside Diameter (after reaming)
Exhaust. .........
Intake . ..........
Valve Seats
Valve Seat Bore Diameter (standard)
Intake . ..........
Exhaust... .......
Seat Outside Diameter
Intake . ..........
Exhaust. . ........
Seat Width. . ,. ..............
Seat Angle. . ................
Avallable Oversizes ...........
Valve Springs
Free Length. . .. .............
Length, Valve Closed. ..........
Load, Valve Closed. ...........
Length, Valve Open. . . .........
Load, Valve Open , , ...........
22. ENGINE PARTS
a. General.
- 096/.097
‚ 0955/. 0965
‚1880/. 1895
2.738/2.753
.9899/.9901
Thumb Push Fit
.0002/.0007
Compression
Compression
Oil Control
.0925/.0935
‚ 0930/.0935
.1860/.1885
.010/.020
‚ 3405/. 0415
‚ 0005/.0025
45°
‚012
‚ 3405/. 3415
.0025/.0045
45°
.015
1-25/32
. 4690/. 4695
.467/.468
.344/,345
.342/.343
1.547/1.548
1.361/1.362
1.550/1.551
1.364/1.385
3/84/1/16
45%
.002/.005
.010 .025
1-7/8
1.528
45 - 49 lbs
1.214
83 - 93 lbs
(1) The parts are illustrated in groups of
related items, with the items listed within the legend
of the illustration (figs. 50 thru 63) Illustrations
represent typical items and not necessarily a part-
icular part number, Part numbers shown are for the
actual manufacturer of the engine, ONAN, unless
otherwise indicated. For some parts several numbers
are given with the pertinent manufacturer, Military
standard (MS) equivalent part numbers are alsolisted
when applicable. The legends contain the following
information for each part: Figure Index No, - De-
scription - (Quantity Used) - (ONAN Part No. Listed
First) - (Other Part No.) ec*
*Note: ec indicates emergency common, refer para.d.
below.
(2) Use part number and description to as-
sure proper identification. When ordering parts, it is
advisable to list the engine model number J120-S/967F
and serial number. Be sure to state quantity required,
method of shipment and correct destination.
(3) Order engine parts from ONAN or their
local authorized parts and service station, or from
the pertinent manufacturer, Parts may alsobe ordered
through the Hol-Gar Manufacturing Corporation’s
parts supply system.
b. Engine Orientation
Right and left sides are determined whenfacing
the blower or cranking (FRONT) end of the engine.
This applies to engine only.
с. Service Kits.
The following kits are peculiar to the com-
plete engine. For other kits refer to particular group
of related parts.
188K84
322K196
Engine .. 1.224421 114 44 4 4 40
Engine Overhaul Kit. ..............
d. Emergency Replacement Parts.
This engine is of the ONAN standard J series.
Many parts are interchangeable in the J30; J60 and
J120 engines. In emergencies when parts supply
sources may become limited, parts maybe canabilized
from other J series engines. Common parts are indi-
cated by ec (emergency common) in the legend listing.
e. Authorized Parts and Service Centers.
These are listed below by state. Those identi-
fied with a star have servicemen thathave been trained
at ONAN Factory Service School.
ALABAMA
Armsirong Equipment Company
* 43601 151 Avenue No.. P.O. Box 20137
Birmingham 6
Kennedy Engine Conpany
261 South Walér Siréel
Mobile
Armstrong Equipment Company
31 Highway Norh. P.O. Box B&B
Monlgamery 2
ALASKA
Alrport Machinery Company, tic.
P. O fox 538
Anchorage
The Carringlon Company
112 North Turner
Foirbianke. Alaska
K-P-R Incorporated
Box 2436
Jupeau
Alving's Marine Repair
Box 484
Kodiak
The While Diesel Eng.
Div. of the While Molar Company
000 Waler real
Ketehlkan
Y rangell Machine Works
W rane
ARIZONA
Commercial Distribularz
Corner Arrovo & Elm Strcats
Nopalea
Equipment Sales Company
720 South TO Avenuo
Phocnix
Wilco, Ine,
3042 North Stang
Tucson
ARKARSAS
Magneto Servier & Supply Company
018 K. West Avenue
Eldorado
Cantlat Cycle and Equipniont Co.
Y 1007 Conler Slreelt
Lutle Rack
CALIFORNIA
Valley Majnétn Service
1619 N Chester
Bakersfield
Johnson Brothers, Ine.
* 16 Yosemite Avenue
Fresno 21
Equipment Service: Inc.
* 1855 Cota Avenue
Long Beach
Swainharl Electríe Compran
#2900 Easl Olynipte Boulevard
Los Angeles
Calfornin Elcelric Works
424 - th Avcauc
Sun Diego 1
Cal. Weyt Elcetrie. Inc
$461 South Van Ness Avenue
Sau Francisco
Townkends Aulp Electmr Comjbay
205 Van Ness Avenue
Watsonville
COLORADO
BKS Industrial
Division of B. K. Sweeney Cu,
* 1601 23rd Street
Denver 17
A-38
AUTHORIZED PARTS AND SERVICE CENTERS
CONNECTICUT
Onan Eastern Corporation
* 21-34 Broadway
Long Island City 8, New Yark
Gelds and Foerst Marine Electric Co
Incorporalod {Aarine Only)
197 City Liland Avenue
New York
DELAWARE
Curllsy Ecyine aad Equipment Co,
Ww 2200 Sherwood Avenuo
Baltimore 1B, Maryland
DISTRICT OF COLUMBIA
Syuthers Oxygen Company
Р. О. Box 5087
washington 19
2000 52nd Avenue
Bladensburg. Md.)
FLORIDA
George's Electrie Repair
617 5. Andrewe Awenbe
Fi. Lauderdale
Davies Cycle Center
1407 Citrus Sirecel
Fort Myers
Fi. Myers Armature Works. lae
23383 2nd Street
Fi. Myers
Digscl Power. Ine,
511 5. Ira Strowl
Forl Pierce
Calling Manufacturing Company
130 Washington Avenue
Homestead
sarine-Industirial Equipment Curp.
x 110 Haints Strcel
Jacksonñmile 6
Key West Elccirical Repair
611 Front Street
Key West
Uniled Parts, Ine
320 South Dixie Highway
Melbourne
Molar Services. Inc
3026 North Miau Avenue
Box 217, Y. Y, Stalion
Miami 97
Peninsular Armalure Works. Inc
3525 № \. 5151 5ЕССе!
Miaml 42
NR. BD, Grabe, Lac,
“261 5.W. 6th Streel
Мапи! 36
Marine Electrical Service Ine.
Y 1450 NW. 22nd Coun
Miamt 35
Highway Equipment Cooipany
E 1016 Wesl Church Street
Orlando
Kennedy Pinriga Engint Co.
Р.О, Box 1387. Municipal Pler
Panama Cil
Green Machine Works
B Wuyust Cedar, E. O. Box 429
Ponsacoia
Tanipa Armature Works. Inc.
$01 South Mapgan Street
Tampa L
Marine Engine & Equipment Cu.
1713 North Dixie Highway
Wes! Paln, Heath
GEORGIA
Blalock Machinery € Equipnient Cr
920 Wexl Droad Avenue
Albany
Blilock Machinery & Equipment Co
k225 Forsylh Sireat S.W.
Atlanta 2
powers Aulo Elecirie
S65 Broadstireet
Augusta
Mowors & Molors. L'i4
1115 18rh Siréct
Columyus
Carburctor & Elcétrie Service
704 Third БВ геем!
Macon
Jones Equipment Company
81 Main Sirect. Garden Cuy
Savannah
HAWAII
Ho Irun Wáarks Co
P. 0. Box 987
1288 Kam Avenue
Hilo
Hongludu Iron Works Ca,
Р.О. Вох 3140
570 Auahi Street
Honolutu
Honolotu [ron Works Company
728 Maln Street
Kahalal, Maui
Honolulu Troc Warks Company
Kauai Branch
Май У, Кана
IDAHO
Oatiley-Moody Service. Ing.
B13 Grove Street. Вох 260%}
Boise
Intermountain Equipment Company
w Broadway al Myrtle Si reel
Bolse
ILLINOIS
Indust cial Engine & Parls Division
*Н. НВ. В. Zimmerman Company
2145 South Pulaski Road
Chicago 23
Ther Blectric £ Machine Works
{Welder Only)
17 Svulh Jefferson Street
Chicagin ©
National Industrial Supply Ce.
“Division of Nutional Auto Supply Co.
L100 1llinnig Avenue
East St. Louis
Autonotive Lgalllon Company
413 N. Franklin
Peoria
Lohse Lawn & Garden Center
wDiv. of Lohse Automotive Service
500 16th М тес
Восх кой
INDIANA
Evansville Auta Paris. Inc.
201-207 N.W. Riwrside Drive
Evansville
Binckberger Machluery. Ine.
Y630 High Street
Tori Wayne
Demon. Inc.
010 West Main Etruot, Bux 2:11
Oreenwoad
IOWA
Electrical Engineering £ Equp Co
Ex 1201 Walnul Streer
Dex Moines
B and G Aston ive Supply
1084 laws Street
Dubuque
KANSAS
Spulhwext Equipmenl Company
114 East Poplar
Dudere City
Kemper Aulo Elactrie
Garden Cily
Bell Engine Service
3810 Yest Tonth
Great Bend
The Carlson Company. Lac.
* 6045 Norih Broaduny, P O Dax 622
Wichita 1
KENTUCKY
Virgil Heck Equipment Company
wé20 Wosl Kentucky Street (Box 717)
Loutsvilhe |
Fall Cily Boat Works. Int,
(Marine Only)
132 N. Fabrth Strcel
Louisvilte 2
Marine Sales de Service Inc
(Marine Only)
1350 River Road
Louisville 6
LOUISIANA
Teche Trictor Conipany
P. 3. Box 238
Baldwin
Y Brady Eanginc Corgpany of Borwick. Ing
Berwick
Brady Engine Company of Galliano,
Inc,
Gallimno
Harvey Diesel, Inc.
2400 Desirchan Avenue
Harvey
Brady Engng Co of Houma inc.
* 1707 East Mon Street
Houma
Iberia Onan Servica
908 West 51. Peter
New Iberia
Menge Pump ang Machmery Co, Inc,
*225 Korth Market Street
Shreveporl
MAINE
Leen's Eleciric Mutor Service
* 54 Wilson Streel
Brewer
Stanley J Leen Co. тс,
+35 Цао Утес!
Portland
Mansol Marino Supply Co
Southwest Harbor
(Marine Qnly)
MARYLAND
Curtis Englne & Equipment Co.
w 2200 Sherwood Avénua
Ballimare LH
MASSACHUSETTS
J. H Westerheke Corn.
35 Teniciun SI
Drrehester 22
Superior Electrie Company, Lac
X 501 St. Jamés Avenue
Springfield
MICHIGAN
A. P, Hopkins Comporalian
w 13931 Oakland Avenue
Ва! гой! (Highland Park) 3
Marquette Public Service Garure
746 Y. Washington Si,
Marquelte
Elactri¢c Equipment & Seppiy Co.
x2101 Mcllweaith Street
Muskegon helghis
MINNESOTA
Minnasola- Chan Corpuratlon
W2525 East Franklin Avenuo
Minneapolis 6
Borvick Eleelric Malar Со
#3103 Maly Avenue
Moorhead
MISSISSIPPL
Kennedy Marine Engine Co,
ФР, O. Bux 167
y (Roynuir E Jackson Siy )
B Lud
Kennedy Marine Engine Co, of
Pascagoula
137 Delmás Avenue
Pascagoula
Taylor Machinery Corporation
«xl. 8. Highway BO ai South Gallatin
Jackson
MISSOURI
National industrial Sonply Co
«Division of National Auto Supply Co.
1100 [llinois Avérue
East 1. Louis
Oxygen Service Company
(Walder Only)
529 Southwest Blvd.
Kansas City
Welding Equipment Supply Co... ine.
* 1900 Truman Road
Karsas City
Vonélion Brat Harbor (Marine Only)
#Pyringe des Sloux
MONTANA
Grezt Northern Tool and Supply Co
wl224 Minngiola Avenue
Billups
Great Northern Tool and Supply Co
301 Second Street South
Creal Falls
NEBRASKA
Anderson Equipment Caompuny. lac
* $932 Center Stepet
Omaha ©
NEYADA
Clark County Wholesale Mercantile
Company
512 South Mala
Las Vegas
Aur Service Company
241 Sóulh Yırglaia Strect
Reno
NEW HAMPSHIRE
Wright Electrle Malora
*xD. W. Highway Nart»
Manchesler
NEW JERSEY
Ona Esstern Corporation
Xx21-14 Eraaduay
(Long Island Civ 6. N. Y.)
Geits 5 Focrsi Marine Electric Co.
Inc. (Marine Only)
197 Ely Island Avenue
(New York. N. Y.)
Rhoads Equlpmont Company
Y 1552 N. 19h Stroct
{Philadelphia dl. Pennsylvania)
WHEW MEXICO
Car Parts Dep. Inc
212 Lith Street
Alamogordo
Desert Industrial. Lne.
2531 Halnes тов!
Albuquerque
AUTHORIZED PARTS AND SERVICE CENTERS (Cont)
Air Equipment é Supply
1229. Canal Stree?
Carlsbad, New Maxica
Bl Paso Welding Supply
226 E. Dowman Sireel
las Cruces
Savage Brothers Eleclele
426 Eazl 2ad Street
Roswell
NEW YORK
Fox Equipment Company
*2018 Seneca Strcot
Buffalo 10
Onan Eastern Corporatlen
w 21-34 Broadway
Long Island City E
Gells À Focral Marine Electric Co.
Ing. (Marine Onty)
197 Clly Island Avenue
New York
R. B. Wing and Son Carporatian
#83 Second Avenue
Rensäclaecr
Berger Brothors Elictrie Motors. Inc
* 395 Slate Sirgel, Cor, Brown
Rochester E
Power Plant Enpinevring Co,
#925 Soulh Sallna Street
Syracuse 4
NORTH CAROLINA
H. B. Owsley & Son. Ine.
w Pincville Road
Charlotte
H. B. Ows1cp & Son. lue.
Вах 8627
Сгеснябого
I. B. Owsley & Som. (ne,
1212 North Vlan
Goldsbaro
NORTH DAKOTA
Horvick Electric Motor Co
* 305 Main Avenue
Faeyo- Moorhead
Paris Hardware
208 West Main Street
Mandan
Electric & Magneto Service Co.
101 Main Streel
Williston
OHIO
Air Cooled Engines. Inc.
wDieiston of Hopkinz & Kipp. Ine.
357 West Bowery Street
Akron 7 '
The Cinelnnati Elisctrie Equip. Co.
#16 East Tènd Sirect
Cincinnalt
Northmon Wedge ana Rega Ir
ВЯ Route No. 1. Box 75
Clayloan
Industrial Eagle Paris Co.
1431 East 320d Si reel
Cleveland 14
Pacis. Incorporated
2401 Carnegle Avenue
Cleveland 15
The Day and Maddock Co.
d201 Amira Avenue S,W.
Cleveland 2
Tullor Corporation
*947 W. Goodale Blvd.
Columbus 12
Efaw Elccirie 4 Radalor Co. Inc
307 South Markel $ reel
Et, Clabrsville
Howard T. Martarty Ca,
143 Broadway Avenue
Toledo
Althea Supply
249-237 Carry Stragt
Yellow Spriags
Cosa Supply Co:npany
620 Marrelln Strcèt
Zanesville
OKLAHOMA
Mechanical £ Electrical Equip. Co-
“712-714 Stal Wheeling
Tulsa
OREGON
Electrical Construcilon Company
FP I21-2147 NW. Thurmas Street
Puriland 10
PEN MSYLYAH{ A
Force Electric Inc.
1814-28 Union Avenue
Allowing
J €. Echullz
£2123 Parade Streel
Erie
C. Edgar Thoman Auto Elertric, Ine,
277 Valley Street
Lewistivn
Oll City Electric & Macooly
1 Central Avenue
Ol City
Rnrnads Equipment Company
#4852 N. 1541 Si ree
Pimade Iphin 40
Dravo-Doyle Company
2001 Prebiz Avenue: NUS,
Рин гу За
AF. Shane & Company
* 440 South Evuline SErvel
Pittsburgh 24
Fowler Engincerin Company
93 Alain рем
SC a
RHODE ISLAND
Schmid Elcetrie Compauy
KAY? Chestmut Stree
Providence
SOUTH CAROLINA
State Machinery & Supply Co.
4 1005 Meviiny Streci '
Wexl Columbia
SOUTH DAXOTA
Shakstad Elecirle and Machine Works
* 1400 "I" Avenue
Sioux Falls
TENMESSEE
Osborne Equipment Company
1501 East 31h Street
Chatiniooga
Osborne Equipment Cumpany
Xx Market 21 Front Slrcel
Knoxville
Marine and industrial Inc,
* 50 Soutk Pront Sirect. Dux 53
Memphis 1 -
Mephens Distribuby Company
“ 1201 North (sl Sircer
Nashellie 7
TEXAS
Oltftleld Mutur Service
Alice
Service and Supply
xP. O. Bux 101
1301 West 61h Avenue
Amarillo
Sei Garden Sales Cu ‚Inc.
(Marine Oniy)
Р. О. Вах 320
Brownsville
(луком по Equipmant Criwnpsany
* 3235 Halifax
Dallas 7
EB] Paso Welding Supply
P.O. Box 42, 1535 Baascil Ave
El Paso
Applied Power Equipnient & Wig. Co,
21333 Call Termina! Drive
Hous lon
Harrison Equipment Cn.
#1113 Bell Avenue. Box 1503
Meuston 4
Gordita Machinery Company
Вох В
Lahisork
MceEntyre Bros.
«2705 Kermit Highway
Odrsxa
x 3abine Propeller 4 Murine Service CD
West Lakeshore Drive
Port Arthur
Port Arthyr Eltetrie Servico
2619 Seventh Street
Pari Arthur
Gillesple Engine Sacuicé and Suppty Ca
Sabine Pase
Lirhtbuurn Equipment Cumpany
WEJII San Pedro Avenue, P, O. Box 13076
Sar AnMunia 13
UTAH
Motor Mercantile Cn,
54 West Tlh Soulh
Salt Lake СИ
VERMONT
T and EL Electric Co,
White River Junction
VIRGINIA
Paxton Company
wi0h9 Main S reel
Norfolk 10
J. F. Long Company
w1511 Rosepvath Tloud. Sotts AdédilInn
Richmond 38
WASHINGTON
Fremoni Electric Company
BOS Main Skreet
Bremaorton
Fremont Elccirie Campany
* 144 N, Mth Sireal
Sealtle
H and N Eleciric Motors, Ing
1311 North Washington Siroct
Spokane
Rowand Machinery Co.
AOA Division Sireet
Spokane
Wostiern Wright Mamne
1525 Commerce Siıreeli
Tacoma
WEST VIRGIKIA
West Virginia Tractor & Equiymenl Co,
wi70! Filth Avenue
Charleston 22,
West Vlmtimia Tratiar & Equipment Cu.
P_O_ 80x SÔT. Milfärd Sircer Ext
Clarksbury
WISCONSIN
Clymar Engineering & Sales. lac.
w416 West Walnul Street
Milwaukee 12
WYOMING
Power Servier Company
wP O Box 1:150 (395 Sul: Ash $1)
Casper
A-39
E
Cylinder Block Assy, Includes Brgs - (1) -
(110A1436)
Plate, Rear Brg, Less Bearing & Pin - (1) -
(101B376)
Gasket Kit, Rear Brg Plate - (1) - (101K358) ec
Bearing Half, Precision, Main-Front or Rear -
(4) - (101-375) - (MS 13989-1)
4A Bearing Half, Precision, Main-Center - (2) -
(101B381) - (MS 13987-1)
4B Bolt, Center Main Brg Hsg - (2) - (101A342)
4C Pin, Dowel, Center Main Brg Hog-(2)-(516 A149)
5 Pin, Lock, Crankshaft Thrust Washer - (4) -
(516472) ec
6 Washer, Crankshaft Thrust - (2) - (104A420) ec
7 Bearing, Precision Camshaft, Front, Std only -
(1) - (101B363) ec
8 Bearing, Precision Camshaft, Rear, Std only -
(1) - (101B365) ec
8A Bearing, Precision Camshaft, Center, Std only -
(1) - (101B364)
9 Tube, Crankcase Oil } Front - (1) - (120B586)
Rear - (1) - (120B585)
Do
wa Ca
Plug, Expansion, Rear Camshaft Opening -
(1) - (517-53) ес
Seal, Oi}, Crankshaft Rear - (1) - (509-86) ec
Bolt, Place, Rear Brg Plate, 3/8-16x1-1/4'' -
(6) - (805-19) ec
Tube, Oil Fill - (1) - (123A649) ec
Gasket, Oil Fill Tube Mtg - (1) - (1234667) ec
Cap & Indicator, Of] Fill - (1) - (123A898)
Gasket, Oil Fill Cap - (1) - (123A181) ec
Cap, Breather Tube - (1) - (123A787) ec
Tube, Breather - (1) - (123A645)
Not Used
Baffle, Breather Tube - (1) - (123-452) ec
Base, Of] - (1) - (102E478)
Gasket, Oil Base - (1) - (1028475)
Plug, Pipe, 1/2'', Oil Drain -
(1) - (505-56) ес
Not Used
Not Used
Pin, Dowel, Gear Cover Locating -
(2) - (518-141)
Figure A-50. Crankcase and Oil Base Group
A-40
ek
Head Cylinder - (2) - (110B1212) ec J60 only
Gasket, Cylinder Head - (2) - (110B1223) ec
J60 only
Guide, Valve - (8) - (110B1218) ec
Insert, Intake Valve Seat, Specify:
Std, .002, .005, .010, or .025 Oversize - (4) -
(110A1214) ec
Insert, Exhaust Valve Seat, Stellite, Specify: Std,
.002, .005, .010 or ,025 Oversize - (4) - (110A1215) ec
Valve, Intake - (4) - (110B1413)- (MS 13699-6)
Valve, Exhaust, Stellite - (4) - (110A860) -
(MS 13999-1)
Spring, Valve - (8) - (110A1221) ec
Retainer, Valve Spring - (8) - (110B1220) ec
Lock, Valve Spring Retainer - (16) - (110A858) -
(MS 13997-1) ec
Cap, Valve Stem - (8) - (110A859) - (MS 13998-1) ec
Seal, Oil, Intake Valves, Includes Retainer Rings -
(4) - (509A 90) ec
Arm, Rocker, Exhaust - (4) - (115B128) ec
Arm, Rocker, Intake - (4) - (115B128) ec
Ball, Rocker Arm - (8) ~ (115B127) ec
Locknut, Hex, Rocker Arm - (8) - (115B150) ec
Stud, Rocker Arm - (8) - (115A131) ec
Rod, Push, Valve - (8) - (1154145) ec
Tappet, Valve - (8) - (115A 132) ec
Guide, Push Rod - (2) - (115B142) ec J60 only
20
21
22
23
24
Cover, Rocker - (2) - (115D164) ec J60 only
Line, Oil, Rocker Cover - (2) - (120B561) ec
J60 only
Gasket, Rocker Cover - (2) - (115B130) ec
J60 only
Screw, Hex-Cap, Cylinder HD Mtg, 3/8-18x2"' -
(6) - (110A815) ec
Screw, Hex-Cap, Cylinder HDMtg, 3/8-16x4-~3/4"
- (10) - (110A 1225) ec
Screw, Hex-Cap, Cylinder HD Mtg, 3/8-16x4"" -
(4) - (110A 1282) ec J60 only
Washer, Cylinder HD screw - (14) - (526-174) ec
Stud, Carburetor Mtg ~ (2) - (520A526) ec
Stud, Exhaust Manifold Mtg - (8) - (520A608) ec
Not Used
Nut, Extension, Lifting Bar - (2) - (403A620)
Stud, Cylinder BD Mtg - (2) - (520A826)
Bar & Eye Assy, Lifting - (1) - (403A628)
Screw, Hex-Cap, Lifting Bar, 3/8-16x5-1/2" -
(800-67)
Shield, Pushrod - (8) - (115A137) ec
O-Ring, Push Rod Shield - (16) - (508-84) ec
Washer, Flat, Push Rod Shield - (8) -
(115A155) ec
Spring, Retaining, Push Rod Shield - (8) -
(115A148) ec
Stud, Intake Manifold - (4) - (520A338)
Figure A-51, Cylinder Head, Valve and Rocker Box Group
IE 1 20
| |]
1 Crankshaft - (1) - (104E460) Not as shown 11 Crank, Hand - (1) - (192B268)
2 Gear, Crankshaft - (1) - (104B418) ec 12 Key, Woodruff, Flywheel - (1) - (515-153) ec
3 Washer, Crankshaft Gear Retainer - 13 Washer, Flywheel Mtg Screw - (1) - (526A185) ec
(1) - (104A418) ec 14 Key, Woodruff, Crankshaft Gear - (1) -
4 Ring, Lock, Crankshaft Gear Washer - (515-1) ec
(1) - (518-188) ec 15 Flywheel Only - (3) - (134D1400)
5 Not Used 17 Hub, Flywheel - (1) - (134B1401)
6 Flywheel Assy, Includes Hub, Complete - 18 Washer, Flat, Special, Hub to Flywheel -
(1) ~ (134C 1446) (4) - (528A 187)
7 Not Used 19 Spacer & Washer Assy, Hub to Flywheel -
9 Screw, Hex, Flywheel, 7/16-14x5-1/2"' - (4) - (104A543)
(1) - (800-500) ec 20 Nut, Stover, 3/8-24, Hub to Flywheel -
10 Crankdog - (1) - (104B429) ec (4) - (115B150)
Figure A-52. Crankshaft and Fiywheel Group
A-42
fd pd
— OOM JO URW DN
Camshaft, Includes Center Pin - (1) - (1054230)
Key, Camshaft Gear - (1) - (515-1) ec
Pin, Camshaft Center - (1) - (150475) ec
Washer, Camshaft Thrust - (1) - (105A205) ec
Gear, Camshaft, Includes Flyball Spacer & Р1а!е - (1) - (1058223)
Flyball, Governor - (12) - (510-46) ec
Cup, Governor - (1) - (1904962)
Ring, Snap, Center Pin - (1) - (150478)
Not Used
Not Used
Washer, Thrust, Governor Yoke - (1) - (150A859)
Figure A-53. Camshaft Group
A-43
A-44
STD - (4) - (113A80) - (MS 13933-4)
1 Ring, Piston, Top Compression ” .020‘‘ Oversize - (4) - (113A80H) - (MS 13933-5)
| .040'' Oversize - (4) - (113A80L) - (MS 13935-6)
| STD - (4) - (113479) - (MS 13932-4)
1A Ring, Piston, Intermediate Compression { .020' Oversize - (113A79H) - (MS 13932-5)
.040'" Oversize - (113A79L) - (MS 13932-6)
STD - (4) - (113478) - (MS 13931-4)
1B Ring, Piston, Oil Control < .020"* Oversize - (4) - (L13A78H) - (MS 13931-5)
.040'" Oversize - (4) - (113A78L) - (MS 13831-6)
IC Ring, Expander - (4) - (113477) - (MS 13930-2)
2 Piston & Pin, Includes Retaining Rings, Specify: STD, .020'' or .040'' Oversize -
(4) - (112A 104)
| STD - (4) - (112C66) - (MS 13959-1)
24 Piston, w/o Piston Pin / .020'' Oversize - (4) - (MS 13959-2)
.040'* Oversize - (4) - (MS 13959-3)
Pin, Piston - (4) - (112467) - (MS 13996-2)
Ring, RTNG, Piston Pin - (8) - (112A68) - (MS 13962-1)
Rod Assy, Connecting, w/brgs, Pin Bushing, Bolts - (4) - (1144184)
Bearing, Connecting Rod, Upper or Lower Half - (8) - (114-181) - (MS 13994-1)
Bushing, Pin - (4) - (114B91)- (MS 13963-1)
Bolt, Place, Connecting Rod, 5/16-24x1-13/16'' - (8) ~ (805-12).
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Figure A-54, Piston and Connecting Rod Group
dodo 15400) JIB)
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08 (8120601) - (T}) - 19407 IE95) “Joxsen
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28 (28-506) - (T) - 10409 Tes ‘ПО ‘1895
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6
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29 +(984606) - (1) - 13845 10013409 TIO ‘TEAS Y
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*(94T-S18) - (1) - 112/1X2€-8 “UeW-XeH 'meloS IZ
(9£3A0ST) - (1) - 10ULIS409 ‘WAY GF
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(2920501) - (т) -
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A-45
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11
12
REAR BEARING
PLATE
Pump Assy, Oil - (1) - (120B547) ec
Gasket Kit, Oil Pump - (1) ~ (120K580) ec
Cup Assy, Oil Pump Intake - (1) - (120B601)
not as shown
Filter, Oil, 3-1/2'' lg - (1) - (1224185) ec
Gasket, Oil Filter Adapter - (1) - (1224188) ec
Adapter Assy, Oil Filter - (1) - (122C182)
Gauge, Oil Pressure - (1) - (193P122) ec
Elbow, Street 45°, (1) For Oil Gauge, (1) For
Low Oil Pressure Cut-off Switch - (502A53) ec
Not Used
Elbow, Inverted Male, Oil Line To Filter Adapter -
(1) - (502-19) ec
Line, Oil, Adapter Plate To Cylinder Head -
(1) - (120A582) ec
Not Used
13
15
16
17
18
20
21
22
Valve, Ofl By-pass - (1) - (120A539) ec
Spring, Oil By-pass - (1) - (120A555) ec
Plug, Pipe, 1/8", Counter Sunk, Oil By-pass -
(1) - (505-274) ec
Line, Oil, Cylinder-HD No. 1 To Cylinder-HD
№0. 2 - (1) - (1208575)
Connector, Inverted Male, Upper, Oil Line - (2) -
(502-87)
Tee, Restricted, Upper, Oil Line - (1) - (5024242)
Connector, Inverted Mate, Lower, Oil Line - (1) -
(502-30,
Wrench, Oil Filter - (Accessory, Not Furnished
w/this Unit) - (420P268) ec
Switeh, Low Oil Pressure Cut-off - (1) -
(309A 169)
Bracket, Oil Intake Cup - (1) - (1204602)
Figure A-56. Oil System Group
А-46
COIN ho —
Spring, Governor - (1) - (150A861)
Stud, Governor - Adjusting - (1) - (150A863)
Nut, Governor Adj Stud - (1) - (104A91) ec
Bracket Assy, Governor - (1) - (150A815)
Link, Governor - (1) - (1504841)
Joint, Ball - (1) - (150A639) ec
Nut, Keps, Ball Joint To Governor Árm - (1) - (870-131) ec
Not Used
Figure A-37. Governor Control Group
À-47
CD Со +4
о
6
7
TA
8
9
10
11
12
13
14
Carburetor, Manual Choke - (1) - (143C289)
Gasket, Carburetor Flange - (1) - (141A281) ec
Elbow, Inverted, Carb Inlet And Fuel Pump Inlet -
2) - (502-2) ec
Adapter, Air Cleaner, Includes Plastic Breather
Tube - (1) - (1404647)
Hose, Breather Cap To Air Cleaner Adapter - (1)
- (503A416)
Pan, Air Cleaner - (1) - (140C595) ec
Element, Air Cleaner - (1) - (140B640) ec
Retainer, Air Cleaner Element - (1) - (140B641) ec
Cover Assy, Air Cleaner - (1) - (140C744)
Gasket, Air Cleaner - (1) - (140C584) ec
Gasket, Air Cleaner Adapter To Carb - (1) -
(140A585) ec
Stud, Air Cleaner - (2) - (520A621) ec
Nut, Knurled, Brass - Air Cleaner - (2) -
(871-70) ec
Washer, Rubber, Air Cleaner - (2) - (140A602) ec
Gasket, Air Cleaner Cover Door - (1)- (1404725)
15
Tube, Air Cleaner Adapter Breather, Plastic -
(1) - (123A732)
16, 17, 18 Not Used
19
20
21
22
23
24
25
Line, Fuel Pump To Carb - (1) - (159B744)
Elbow, Inverted Male, Fuel Pump Outlet - (1) -
(502-2) ee J80 only
Pump, Fuel - (1) - (149A805) ec J80 only
Gasket, Fuel Pump Mtg - (1) - (149A 792) ec
Gasket, Fuel Pump Bowl - (1) - (149Р517) ec
Bowl, Fuel Pump - (1) - (149-116) ec J60 only
Choke, Cable Assy, Manual - (1) - (153B332)
Arm, Manual Choke - (1) - (153A326) ec
Bracket, Manual Choke - (1) - (1534327) ec
Clip, Manual Choxe Arm - (1) - (518P176)
Manifold, Intake - (1) - (154D749)
Gasket, Intake Manifold - (2) - (1544733)
Baffle, Distributor, Cylinder HD - (2) - (11041312)
Stud, Carb Mtg - (2) - (520A526)
Repair Kit, Fuel Pump, Includes Diaphragm Assy,
Valves & Gaskets - (149K8"75)
Figure A-58, Fuel System Group
js
O0®%020098à015DSOD IH
Repair Kit, Carb, Includes Parts Marked** -
(143K241)
Gasket Kit,
(143K201) ec
Gasket, Carb Mig, Shown In Fig. A-58 -
(141A281)* ec
Valve, Throttle ~ (1) - (143-202) ec
Shaft & Lever, Throttle - (1) - (143-234)
Choke, Valve - (1) - (143-220) ec
Needle, Idle Jet & High Speed Adj - (1) - (143-235)+*
Nozzle - (1) - (143-237)**
Shaft & Lever, Choke, Manual - (1) - (143-221) ес
Screw & Gasket, Bowl - (1) - (143-208) ес
Gasket, Fuel Inlet Valve - (1) - (143A15)* ec
Gasket, Bowl Screw - (1) - (143-209)* ec
Float & Lever - (1) ~ (143-105) ec
Carb, Includes Parts Marked* -
11
13
14
15
16
17
18
19
20
21
22
23
Bowl - (1) - (143-210) ec
Gasket, Bowl Ring - (1) - (143-77)* ec
Pin, Float Lever - (1) - (143-212)** ec
Valve, Fuel Inlet - (1) - (143-39)** ес
Serew, Idle Adj - (1) - (143-213) ec
Screw, RD-HD, #3-48x3/16, Choke & Throttle
Valve Attaching - (4) - (812-14)** ес
Plug, Welsh - (1) - (143-110) ec
Spring, Throttle Lever Adj Screw - (1) -
(143-214) ec
Spring, Idle Adj Screw - (1) - (143-112) ec
Spring, High Speed Adj Needle - (1) - (163-114)
Screw, Throttle Lever Adj - (1) -
(143-215)
Spring, Choke Shaft - (1) - (143-113)
Ball, Choke Shaft - (1) - (143-117)
Figure A-59. Carburetor Parts Group
A-49
A-50
a ONE
Manifold, Exhaust - (1) - (194D714) Not as shown
Gasket, Exhaust Manifold to Head - (4) - (1544463) ec
Flange, Exhaust Manifold Outlet - (1) - (1554782) ec
Gasket, Exhaust Outlet - (1) - (1544738)
Figure A-60. Manifold Group
DOOR
FASTENING
DETAIL
AIR CLEANER
ADAPTER
D DJ O NANA
Housing, Blower - (1) - (134D1087)
Housing, Cyl Air, Front - (1) - (134D1048) ec
Housing, Cyl Air, Rear - (1) - (134C1051)
Pan, Cyl Air Hsg, Bottom - (1) - (134D1418)
Cover, Cyl Air Hsg - (1) - (134D1201)
Panel, Air Hsg Door - (1) - (134D1202)
Bracket, Air Hsg Door - (2) - (13441089)
Screw, Fastener, Air Hsg Door € Cover - (6) - (134A1373)
Washer, Fastener, Screw RTNR, Air Hsg Door & Cover - (12) - (134A1180) ec
Clip, Fastener Screw, Air Hgg Door € Cover - (6) - (870-178) ec
Support, Blower Hsg & Grille - (1) - (134B1088)
Grille & Crank Support - (1) - (134D1091) ec
Retainer, Grille - (1) - (134A1092) ec
Baffle, Center, Carb Side - (1) - (134B1097)
Baffle, Center, Opposite Carb Side - (1) - (134B1098)
Grommet, Ignition Cables, Bottom Cyl Hsg - (2) - (508A5) ec J60 only
Figure A-61. Air Housing Group
1
5
6
7
12
45
46
Suppressor, Spark Plug - (4) - (314P32)
Nipple, Rubber, Spark Plug Cable - (4) - (160A558) ec
22-1/2'" LG - (2) - (187A1410)
Cable, Spark Plug, W/Items 1 & 4 17'' LG - (1) - (167A1427)
28-1/2'' LG - (1) - (167А1429)
O-Ring, Spark Plug Cables - (4) - (509P18)
Plug, Spark - (4) - (187-4) - (Champion, H-8 or Equal) ec
Gasket, Breaker, Plate Mtg - (1) - (160A721) ec
Magneto Assy, Includes Drive Gear - (1) - (1624242) - (WICO, XH-2686)*
Gear, Magneto Drive - (1) - (160B674)
NOTE: For breakdown see Figure A-83. Order magneto parts from nearest
WICO dealer or WICO Electric Company, West Springfield, Mass.
Figure A-62. Ignition Group
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Magneto Assy, Includes Drive Gear - (1) -
(162C242) - (WICO, XH-2686)*
Lock, Breaker Arm - (1) - (WICO, 4210)
Wiper, Cam, Felt - (1) - (WICO, 5077)
Screw, (2) Condenser Clamp, (2) Coil Core
Clamp - (4) - (WICO, 5411)
Core, Coil - (1) - (162-244) - (WICO, X5524)
Clamp, Coil Core - (2) - (WICO, 5633)
Coil - (1) - (162-246) - (WICO, X5700B)
Cap Assy, Distributor - (1) - (162-248) -
(WICO, X5777)
Screw, (1) Coil Contact, (2) Window Clamp
Plate - (3) - (WICO, 5538)
Gasket, Distributor Cap - (1) - (WICO, 5618)
Screw & Lock Washer, Distributor Cap Mtg -
(4) - (WICO, 5622)
Gasket, Window Seal - (1) - (WICO, 5719)
Window - (1) - (WICO, 5753)
Spring, Coil Contact - (1) - (WICO, 5773)
Plate, Window Clamp - (1) - (WICO, 5895)
Interlead, Secondary - (1) - (WICO, X6001)
Screw, Fixed Contact Clamp - (2) - (WICO, 5900)
Point Set, Breaker - (1) - (182-204) - (WICO, 5996)
Washer, Breaker Point Aligning - (1) -
(WICO, 3219)
Screw, Breaker, Spring Clamp - (1) - (WICO, 5431)
Washer, Breaker Point Aligning - (1) -
(WICO, 5717)
Felt, Breaker Arm - (1) - (WICO, 7644)
Housing Assy - (1) - (WICO, X6196)
Pivot, Breaker Arm - (1) - (WICO, 5603)
Bushing, Breaker Plate - (1) - (WICO, 5610)
Screw & Washer, Distributor Gear - (1) -
(WICO, 8486)
Gear, Distributor - (1) - (162-250) -
(WICO, 6865)
Condenser - (1) - (162-227) - (WICO, X6916)
Clamp, Condenser - (1) - (WICO, 6924)
Rotor Distributing - (1) - (162-251) - WICO, X9564)
Washer - (1) - (WICO, 10407)
“NOTE:
Coupling Assy, Impulse - (1) - (162-249) - (WICO,
X6516) Item 44 not part of this assy,
Washer, Flange Spacing - (1) - (WICO, M-42XA)
Arm, Trip, - (2) - (WICO, A-178X)
Spring, Drive - (1) - (WICO, 15-186)
Ring, Snap - (2) - (WICO, A-243X)
Washer, Drive Cup Spacing - (1) - (WICO, IVA-583)
Cup, Drive - (1) - (WICO, 2061A)
Spacer, Driven Flange - (1) - (WICO, 2122)
Flange, Driven - (1) - (WICO, X2286)
Retainer, Drive Spring - (1) - (WICO, 2288)
Nut, Lock, Impulse - (1) - (WICO, 6412)
Ring, Lock Impulse - (1) - (WICO, 6424)
Washer, Thrust - (1) - (WICO, 6425)
Gear, Drive - (1) - (160B674) Not Part of Item
31, Refer Fig. A-62
Spacer, Impulse - (1) - (WICO, 5518)
Spacer, Bearing Cage - (1) - (WICO, 5520)
Bearing & Cage Assy - (1) - (162-243) - (WICO,
X 5521) consists of:
Ring, Rtug, Rotor Brg - (1) - (WICO, 5516)
Bearing, Rotor - (1) - (WICO, 5517)
Cage Rotor Brg - (1) - (WICO, 5567)
Plate & Gasket, Impulse Stop - (1) - (162-245) -
(WICO, X5549)
Rotor - (1) - (162-247) - (WICO, Y5710)
Shield, Ball Brg - (1) - (WICO, 5926)
Seal, Oil - (1) - (WICO, 6199)
Slinger, Oil - (1) - (WICO, 8204)
Screw € Lockwasher, Impulse Stop Clamp -
(4) - (WICO, 6465)
Connection Assy, Grd - (1) - (WICO, X5654)
Washer, Lock, Grd Stud - (2) - (WICO, M-55XA)
Washer, Grd, Stud - (1) - (WICO, IXA-256)
Nut, Grd Stud - (2) - (WICO, 3230)
Stud, Grd - (1) - (WICO, 3945)
Connector, Grd - (1) - (WICO, 5635)
Lock, Insulating, Grd Stud - (1) - (WICO, 9820)
Insulator, Grd Stud - (1) - (WICO, 11874)
Button, Stop - (1) - (WICO, X5632)
Order magneto parts from nearest WICO dealer or WICO Electric
Company West Springfield, Mass. Give part number and description.
Figure A-63. Magneto Parts Group
А-53
APPE
NDIX B
TEST EQUIPMENT SECTION
TABLE OF CONTENTS
Paragraph Page
TEST EQUIPMENT
Voll-Ammeter. NR RR RR 1 B-1
Line Voltage Indicator . .. . . . i. iii iii ier ema, 2 B-2
LIST OF ILLUSTRATIONS
B-1 Amprobe RS-1 Volt-Ammeter. . .............. B-3
B-2 Amprohbe RS-1 Volt-Ammeter Scale Readings ..... B-4
B-3 Eight Ways To Use Ideal Line Indicator 61-005. .. . B-5
B-4 Ideal Line Voltage Indicator 61-005
(FSN 6625-284-0264) . . . . . . . + cv iv ven vr 0 B-6
VOLT-AMMETER
a. Description.
This is an Amprobe model RS-1 rotary scale
snap around instrument used to obtain voltage and
current values in a-c electrical circuits. It is supplied
with voltage test leads and case.
b. Data (Fig, B-1).
Manufacturer ........ Amprobe Instrument Cor-
poration
630 Merrick Road
Lynbrook, N.Y.
Model ............. Amprobe RS-1
. 0-5/0-15/0-40/0-100 am-
peres a.c.
0-150/0-600voltsa.c.
60 cycles
Within 3%of full scale
3000 volts a.c.
Scale Range, Current ..
Frequency ..........
Accuracy (volts & amps) .
Voltage Breakdown Test .
Patent Numbers (U.S.
Pat, Office) 2,033,845 and D160,179
Others Pending
+ " #4 + » & k "
c. Control Components.
The following controls are used to operate the
volt-ammeter.
Pointer Lock Button . . . . Locks (to right) or releases
(to left) meter indicator
pointer.
Encircles one conductor of
electric circuit to obtain
electrical current activity
Lo operate meter.
Transformer Jaws
Jaw Trigger Pressed to open One trans-
former jaw.
Rotary Scale Selector , , . Rotate to select proper me-
ter scale.
set indicator
pointer at zero.
Zero Adjust Screw Rotate to
Seale... ........... Indicates extent of elec-
trical activity in volts or
amperes.
Test Leads . . ........ Use to conduct electrical
activity to meter for
voltage readings.
Test Lead Receptacles . . On meter to insert bayonet
pins of test leads.
d. Reading of Scale (Fig. B-2).
(1) When taking either voltage or current
readings always start with the highest range scale and
then select lower scale ranges to obtain more accurate
lower readings.
(2) If reading is below half scale on the
lowest range of the meter, and greater accuracy is
desired, loop the conductor (if practical) two or more
times around the transformer jaws and divide the
reading by the number of turns,
e. Current Readings (Printed Black).
(1) Release pointer by moving lock button
to left.
(2) Turn rotary scale selector to obtain
highest current meter scale (100-Amps).
B-1
(3) Press jaw trigger to open jaws.
(4) Encircle one conductor with the trans-
former jaws. Release finger pressure from trigger
to allow jaws to close around the conductor before
reading meter.
(5) Obtain reading from scale. If required,
proceed to lower range scales (par. d. above).
f. Voltage Readings (Printed Red),
(1) Insert bayonet type pins of voltage test
leads into voltage receptacles at bottom of volt-
ammeter, Push in against the receptacle spring and
twist to lock in place.
(2) Turn rotary scale selector to obtain
highest voltage meter scale (600 volts).
(3) Release pointer by moving lock button
to left.
(4) Connect one test lead to one side of line.
Then with meter in one hand (or resting in suitable
position) touch the other side of the line with the other
test lead. If voltage does not exceed 600 volts, attach
second lead and read voltage on 600 volt red scale.
If voltage is below 150, rofate scale tothe lower range
scale (150 volts) and read voltage.
g, Maintenance,
(1) Storage. Keep meter clean. When not in
use, keep pointer locked. Store meter and leads in its
case.
(2) Zero Adjustment. For accuracy, set
pointer exactly on zero line by rotating the zero adjust
screw. Il, while adjusting the pointer swings away
from the zero line and does not come to rest directly
over it, it is possible that the scale window is static-
ally charged. To neutralize, fog the window, justas in
cleaning eye-glasses.
(3) Repairs. Refer to manufacturer para-
graph b. above.
2. LINE VOLTAGE INDICATOR
a. Description.
This is an Ideal model 61-005 line voltage
indicator used to obtain nominal voltage values and
current indications in electrical circuits. It is supplied
with voltage test leads.
b. Data.
Manufacturer ........ Ideal Industries, Inc.,
Sycamore, Illinois
Model ............. 61-005
Federal Stock Number .. 6625-284-0264
Scale Range, D-C Voltage . 115/230/600
A-C Voltage . 115/220/440/550
Current ,............ Indicator Light.
Patent Numbers. . . . . . 2,791,748
c. Control Components.
The following controls are used to operate the
line voltage indicator.
Test Leads . . . . ...... Use to conduct electrical
activity to instrument for
voltage readings, current
indications, frequency, or
circuit continuity tests.
Indicator Lights. ...... Coded Blk-Red. Negative
side glows when current is
DC. Both glow when current
is AC.
Voltage Scale ........ DC: 115/230 color coded
green; 800 red. AC: 115/
220 color coded green;
440/550 red. Indicator
moves down scale.
d. Operation.
Various methods of using the line voltage in-
dicator are shown and explained in figure B-3. NOTE:
This instrument is intended for intermittent service
only; continuous operation, especially on high volt-
ages, will burn out the coil. To prevent damage to
test leads, hold leads by plastic prod handles only.
All indications are relative for determining nominal
line voltage only. Try the instrument first on a known
voltage to become familiar with the indicators.
e, Maintenance.
(1) Storage. Keep instrument clean. Store in
secure place free from dust, dirt and excessive
vibrations.
(2) Repairs. Limit repairs to the replace-
ment of parts shown in figure B-4. Contact the manu-
facturer paragraph b. above for parts and repairs
which are beyond capabilities in the field, Always
include complete description, part number and name-
plate data for parts.
OPENING
TRANSFORMER
CASE
JAW
POINTER
LOCK BUTTON
JAW TRIGGER
ZERO ADJUST
SCREW
SCALE
TEST LEAD
RECEPTACLES ROTARY
SCALE
VOLTAGE SELECTOR
TEST LEAD Le
PINS FOR
METER VOLTAGE
TEST LEADS
W/PROBE
PINS & CLIPS
(VL-11)
Figure B-1. Amprobe RS-1 Yolt-Ammeter
RMP AMP
100° i”
3 ;
MZ A
3 -
bl= 7
0:
40: :
> -
- IR
8
0 В
If pointer indicates below 40 amps on 100-amp scale
set rotary scale selector to next lower current range
(40) and take reading as 35 amps.
wr “MU AMP АТР AMP AMP
1507 Mr u ue В: e
E
0: >
E -
ЕЕ JUL * x i
: ; Е 20 -
Wow as : TA
: R : T .
25° 100° ; 0s > `
. . 20 : IS N
Fig.” Fig. Fig. + Fig. Fa < Fig. x
#10 ja DO o #12 qu #13 SS FA ANNO ms gg
POINTER POINTER | POINTER POINTER POINTER | POINTER
READS 122.5| READS 440 |READS READS 32.5|READS 12.7 | READS 3.9
VOLTS VOLTS 76 AMPS AMPS AMPS AMPS
Each sub- Eoth sub. Heavy mark | fach xub- Hepvy mark | Each sub
divition bet. [division bet- [Between 60 | division obove 12 is | division
ween 100 A |ween 400 & |* 80 T, 70 between 30 |!3 amps. Бе! деп
150 is 5 volts|500 ix 20 [AMPI- Eoch 15 00 à Each sub- |3 pay,
sub-division division
vola baiwean 70 4 amp. batween 12 2 omp.
80 ix 2 amps & 13 «
5 amp.
Sample meter readings for voltage and current
readings on various scales.
Figure B-2. Amprobe RS-1 Volt-Ammeter Scale Readings
1 TESTING FOR AC OR DC VOLTAGE
® AND VALUE
Place one lesi prod on one termina)
ol the line, or pierce insulation with
prod Then place other prod on {er
minal, or perce Insulation of other
side of line. DC or AC voltage wil
be indicated by the scale and also by
the neon lamp. lí curreni ls DC, only
negative siga ol lamp will glow: hoh
sides glow ii current ls AC.
Hold one test prod on tha source side
of one {use and the other test prod on
the load side of the other fuse. If-there
iz no voltage indi-=ated, Ihe [use naxi to
the les! prod on tha load side Is blown.
lí vollage ls indicated, the fuse nexl to
lhe les! prod on the load side ls O. Y.
The same lest should (hen be made with
the prod on the opposite sides of the
same two (uses, to check lhe other fuse.
On a ‘hree phase circuit, lower than nor-
mal line veltage or no voltage with this
test fndicatas a blown luse.
Touch one lest prod 10 normal ground such as
conduit, elec. Touch the other test prod to each
of the line terminals unii) one Is found that does
noi give a voliage Indicallon, Thal one is (he
grounded circult.
TESTING FOR “GROUNDED” SIDE OF
MOTOR OR APPLIANCE
Twn appliance or motor “on”.
Touch one test prod to the frame
and the other prod io each of the
terminal connections. No glow or
scale Indication shows grounded
side.
5 LOCATING EXCESSIVE LEAKAGE TO
» GROUND
Hold one iest prod on normal
ground such as condult, etc
Touch othor test prod to terminal
of one side of line or unit being
loslad, lí result в normal voltsge
reading and brighl lamp glow,
tesl other side of line, or unit
A LOW resistance ground is in-
dicated by no scale reading. A
HIGH resistance ground leakage
is shown by a dull lamp glow,
and a aub-normal reading.
6 TESTING FOR 25 OR 60 CYCLE
* FREQUENCY
Hold ona ies prod lo each side of AC line.
A low frequency hum and slow vibrations
Indicate 25 cycle current. 60 cycle current
ls indicated by a higher frequency hum and
more rapid vibrations,
7 DETERMINING POLARITY OF DC
” CURRENT
Touch one lest prod to each side of the line.
Only one side of the neon lamp will glow,
and the lina corresponding to thai side ts
negative. Test prods are colorcoded to cor-
respond lo name plale.
8 CONTINUITY TESTS OF CORDS, MOTORS,
» APPLIANCES, ETC.
Plug cord into outlet and touch prods
to each cord terminal, Lamp glow and
scale ‘reading Indicales cord ls good
Connect one side of unil or appliance
cord to one slde of Jine. Touch other
lerminal or unit with ona test prod
and touch other prod to other sida of
ne. A brokan elrcuil la indicated by
no lamp glow or scale reading. A poor
contact (s indicated by a dull glow and
à partial scale reading.
Figure B-3. Eight Ways to Use the Ideal Voltage Tester
Case (H-427)
Nameplate (K-2045)
Adhesive Blank (L-4741)
End Cap (K-2043)
Screw (503.31)
Indicator (L-4731)
Indicator Spring (L-4736)
Coil Assembly (K-2046)
Test Prod Assembly (1 Blank, 1 Red) (61-021)
Carrying Case (Vinyl) (Optional) (61-009)
Carrying Case (Leather) (Optional) (61-010)
› <© со —2 СО с) 5 CO N >
Figure B-4. Ideal Line Voltage Tester 61-005 (FSN-6825-284-0264)
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