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Operator Repair - Pitt Auto Electric Company

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1. Higher oil pressure may be experienced during cold starts INFORMATION FOR ORDERING PARTS When ordering parts refer to the engine name Cation number is listed This data is of vital importance plate attached to side of the cylinder block which lists in obtaining the correct parts always include this the model and serial number In most cases a specifi information on your parts order MADE IN USA WISCONSIN MOTORS LLC MEMPHIS e TENNESSEE Z TME27 08500 1001 Vontmental Section 1 General Information Overhead valve engine design provides the higest power output and operating efficiency The valves are located in the cylinder head which permits larger valves to assure improved combustion and engine output The ease of ser vicing the valves coupled with the improved cool ing of the exhaust valves and ports are important features of engine maintenance Overhead valve design minimizes the tendency to impose thermal deformation on the cylinder structure Engines of this type being narrower in frontal elevation lend themselves to a more favorable ar rangement of the engine accessories such as carburetor starter alternator and filters for in dustrial applications CONTINENTAL OVERHEAD VALVE ENGINE The Continental Overhead Valve Engines range in size from 1 35L 82 to 2 68L 164 cubic inches displacement The combustion chamber design has been tailored for the required turbulence charge flow and bur
2. Read and observe safety warnings on pages 1 and 2 Gasoline must be drained from carburetors following tests on engine or equipment if it is to be stored for a period of 2 weeks or more to pre vent harmful residue resulting from fuel vaporiza tion 24 Main Discharge Jet Porous Drain Plug Figure 1 Residue formed in the carburetor is very harm ful and will result in malfunction of the engine All carburetors have a drain plug in the bottom of the carburetor bowl which should be removed and drained dry Figure 1 All engines shipped from the factory have had the fuel drained from carburetor before shipping AN WARNING Painting of porous carburetor drain plug can cause fire hazard Read and observe safety warnings on pages 1 and 2 IMPORTANT On all gasoline engines with updraft car buretors it is very important not to paint over the powdered bronze carburetor drain plug shown in Figure 1 This has to remain porous to drain off excess gasoline from over choking If this plug is sealed gas can back up into the air cleaner hose and create a fire hazard If the carburetor is to be painted coat this porous plug with a thin coat of grease to prevent any sealing action A WARNING ENGINES USING NATURAL GAS OR LIQUID PET ROLEUM GAS LPG SEE WARNINGS ON PAGES 1 AND 2 Consult handbooks and safety instructions provided by manufacturer of end item in which such engine is used or handbooks a
3. Under extreme dust conditions more frequent replacement will be required Replace when power loss remains after servicing or when the in take manifold vacuum exceeds 250mm 10 water using a good water manometer mechanical vacuum gauges read in mercury and 25mm 1 is equivalent to 346mm 13 6 of water A Ya Teaspoon of Dust per Hour Can ruin an Engine in One 8 Hour Day PCV SYSTEM AM connections must be air tight Blow by circulates into the intake manifold maintaining crankcase pressure within a narrow range regardless of operating speed or load Servicing of the PCV system is usually confined to cleaning the PCV orifice and or valve along with cleaning the air inlet where applicable Typical Continental Motors PCV System Installation CHECK OIL PRESSURE Note oil pressure gauge which should indicate the following pressure range at full throttle and a minimum of 0 5 Bar 7 paunds pressure at idling speed MODEL OIL PRESSURE 2 8 4 1 Bar 40 60 PSI Standard Engines on some special customer specifications this may change Higher oil pressures may be experienced during cold starts 41 NOTE ANY UNUSUAL NOISE Operators familiar with daily engine operation soon become alert to any noise not normally pre sent This is very valuable in correcting defects in the early stages and preventing expensive repairs or delays EVERY 50 HOURS 1 REPEAT DAILY OPERATIONS OUTLINED Follow pr
4. either by gravity or under pressure of a fuel pump The carburetor mixes the fuel with proper propor tions of air and at the same time breaks it into very fine spray particles This atomized spray changes to vapor by absorbing heat as it travels through the intake manifold to the combustion chamber Fuel must be vaporized since it will not burn as a liquid GRAVITY FUEL SYSTEM This is the most simple fuel system and is generally used on power units as it eliminates the need for a fuel pump it only requires that the tank be located higher than the carburetor All power units with a fuel tank should have a combination shut off valve and an efficient metal edge type filter This filter prevents all foreign par ticles and water from entering the carburetor With reasonable care in filling the tank with clean fuel this filter will require only seasonal Cleaning of both the filter and tank CAUTION It is recommended that the fuel shut off valve be kept in the closed position except when unit is in operation MECHANICAL FUEL PUMP NOTE Not available on the 2 cylinder engine The Mechanical Fuel Pump is generally used when the fuel supply is below the level of the car buretor Fuel Pump This mechanical fuel pump mounts on the cylinder block pad and is driven by an eccentric on the engine camshaft contacting the fuel pump rocker arm Constant fuel pressure is maintained by an air dome and a pulsating di
5. 4 SECTION 1 General information Continental Overhead Valve Engine llle eh 5 SECTION 2 Operating Instructions Preparation of a New Engine for Operation CU POT EL 7 Starting the ENGINE sri cea en mr as Lu mana aie denied Rw a aus rsen cu et t cb cuui tn Td 7 Stopping the Engine uud uk mue bts S erui dee a eir aeu od eO i wg frs do rara se ecd dte A 9 l E MUStS TOF VOUFEngiTIBS ora Race ede iii 9 Cold Weather Operation v ep ERE Ee A CREAR ROC a CRUS ON AR ORAE GR te 9 Engine Preparation for Winter Use lees hh s 10 Preparation of Engine for Seasonal Storage 11 SECTION 3 Lubrication Engine EuUbDriCatl D SYSTEM uid dese xao deii e ANDR EA ACORN E aU E EUR PEE a 13 A SE Re T A O gs Sean GER eerie nde Recs is 13 Lubrication Recommendations 2s ua ee EX vx ep Muse REUS YR SESS EN EM 13 SECTION 4 Cooling System Cooling SyStelTi sn vv vae dai Deb ion emen S aeuo ren buta e aet rat a cof oe ue a o dus ee ee ers 15 Effect of Altitude on CODINA suec ed lan eau es ac bon aoe eo Raa eee eee 16 ANFO 0S NEN EE CT ST ET AA D O He A I DTP 16 Cleaning Goolino SYST MES cout suco Zoo Re ERN CIO RES eo ed EC oe ean ee a ooa d s ecd 16 Testing Lnermostal ie cette wea xo ex pari eed doe Sce es Obs ac RUE Dacia GR M ERROR de SU d 17 Radiator Pressure Cap icai ce AO e e dea Re he OER SD ww EN CR a oh dd dad 18 Pan Belt Tensor d Eod gc en a ee cbe we soU Eti n eia ok Bet om
6. WISCONSIN 4 MOTORS LLC 2020 Fletcher Creek Drive Memphis Tennessee 38133 www wisconsinmotors com 2006 All Rights Reserved onsin Motors LLC FORWARD Good operation and a planned maintenance program as outlined in this manual are vital in ob taining maximum engine performance and long engine life The instructions on the following pages have been written with this in mind to give the operator a better understanding of the various problems which may a rise and the manner in which these problems can best be solved or avoided The operator is cautioned against the use of any parts other than genuine Wisconsin Motors LLC parts for replacement or repair These parts have been engineered and tested for their particular job and the use of any other parts may result in unsatisfactory performance and short enginel ife Wisconsin Motors LLC distributors and dealers because of their close factory relations can render the best and most efficient service THE LIFE OF YOUR ENGINE DEPENDS ON THE CARE IT RECEIVES The MODEL SPECIFICATION and SERIAL NUMBER of your engine must be given when order ing parts The MODEL and SPECIFICATION number are on the nameplate The SERIAL NUMBER is stamped either on the crankcase or the engine s identification tag Copy the MODEL SPECIFICATION and SERIAL NUMBER in the spaces provided below so that it will be available when ordering parts MODEL SPECIFICATION SERIAL NUMBER To insure prompt an
7. c Install second segment on bottom side of the expander spacer with segment gap ap proximately 90 from the expander gap in opposite direction from which the top seg ment has been installed d Recheck assembly rings should be free to move in the groove however a slight drag will be evident because of the side scaling action of the ring assembly BE SURE EX PANDER SPACER REMAINS IN BUTTED POSITION 3 To install the balance of the rings use a ring tool with recess side up and place the ring in with the bottom side up Start with the lowest ring first a Position ring in the tool so the expanding fingers will fully engage both ends b Apply pressure on handles so ring is com pletely expanded Pass the expanded ring and tool recessed side down over the piston to the proper groove Install Tapered Rings with Top Side Up CAUTION Some piston rings are taper faced These are clearly marked TOP on the side to be up when assembled on piston and some rings have the top side marked with a color band or a PIP mark 4 When pistons are ready for installation in the cylinders oil generously Compress rings careful ly using a good ring compressor and a light tap on the head of the piston will allow the assembly to go into the cylinder very easily If any difficulty in tapping piston and ring assembly into the cylinder is encountered the compressor should be remov ed and rings checked for correct in
8. 5 Compensating System Provides a mix ture which decreases in richness as the air speed increases 6 Choke System Delivers additional fuel to the manifold for cold engine starting CONTINENTAL CARBURETOR The Continental CK series carburetor has the following adjustments 1 Idle Fuel Adjusting Needle should be seated lightly with small screw driver turning in clockwise It is then backed out counter clockwise 1 turns as a preliminary setting Fuel Flow is regulated like a water faucet turn in to shut off back out to open 2 Fixed High Speed Jet is not adjustable For high altitude it may be exchanged for reduc tion in size to lean the fuel in compensation for the lighter thin air The size must be carefully determined first by testing a smaller jet with 025 050mm 001 to 002 smaller passage depending on the elevation 2A Main Jet Adjusting Needle available for use with the fixed high speed jet for altitude compensation Turn in for leaner mixture and out for richer mixture CAUTION Improper adjustment of the main jet could lead to engine damage 3 idie Speed Adjusting Screw turn in clockwise until throttle valve is slightly open Adjustment to recommended idle speed can be made after installation to engine Turn screw Typical Continental Carburetor 2 A Main Jet Adjusting Needle available for use with the fixed high speed jet for altitude compensation T
9. its polarity must be connected correctly to pre vent damage to the electrical system com ponents positive to positive negative to negative Regulator Most regulators are fully transistorized and com pletely sealed These cannot be adjusted or repaired and it can be assumed that this type regular will outlive the other components in the charging system On current Delco MCI alternators the regulator is inside the alternator housing and the case must be split to replace Care should be taken in the operation to insure correct assembly Other regulators are adjusted and repaired in accordance with the manufacturer s instruc tions Installation of Regulator for Alt rnator To insure proper operation and to protect the alternator and regulator the following steps should be observed during installation 1 2 NOTES _ Make sure regulator is of the same voltage and polarity as the alternator and battery Disconnect battery cable at battery ter minal Make sure the mounting area of the alter nator and regulator base are clean and make a good tight connection Connect alternator in accordance with the manufacturer s instructions 5 Do not flash field or ground terminals of the regulator 6 Reconnect battery cable 7 Start engine and observe ammeter A High charge rate is normal for the first few minutes but will decrease as the regulator warms up Note When servicing the charging syst
10. pump is driven off the crankshaft and protected by a large screen inlet An adjustable by pass valve maintains suitable oil pressure from idle to maximum speed automatically Refer to page 4 for complete oil pressure figures CAUTION if the oil pressure is erratic or falls below these limits stop the engine IMMEDIATELY and find the cause of the trouble Refer to trouble shooting section for this information A full flow oil filter is provided to remove dirt and foreign elements from the oil The removal of grit sludge and foreign particles causes filter elements to clog and become ineffective unless they are normally replaced every 100 hours or more often if conditions require s ROCKER BEARINGS TAPPET OIL GALLERY CAM CY BEARINGS O Y PR RELIEF VALVE CRANK amp ROD BEARINGS AANA sits OUMP OIL SUMP PICK UP Full Flow Filter System Oit Pump OIL CHANGE FREQUENCY Engine oil does not wear out However the lubricating oil in internal combustion engines becomes contaminated from the by products of combustion dirt water unburned fuel entering the crankcase and the detergents holding the car bon particles in suspension in the crankcase Oil Filter The schedule for changing oil is directly dependent upon the operational environment an extremely clean operation could go 100 hours while a dirty operation foundry or cement factory could be 50 hours or less see Su
11. 44 Inspect radiator mounting Inspect water pump and connections for leaks Check fan and accessory drive belts 3 ADJUST VALVE TAPPET CLEARANCE Check and adjust intake and exhaust valve tap pets to following clearances at idling speed and running temperature Adjusting Valve Tappet Clearance MODEL INTAKE EXHAUST 4 CARBURETOR 0 36mm 014 0 46mm 018 Clean exterior and check mounting to manifold Adjust carburetor air adjustment for even runn ing and adjust idle speed to 400 600 R P M minimum 800 1000 R P M on 2 cylinder engine Inspect throttle and choke linkage for free operation sii Carburetor 5 FUEL SYSTEM 6 SAFETY AND THERMAL CONTROLS Replace fuel filter element Inspect control wires and connections Inspect fuel pump mounting and gasket Check all connections for leaks Examine armored capillary tubing on water temperature element for visual damage that may cause faulty operation Fuel Pump Mounting NOTES 4 CO 46 This section includes instructions for repairs and overhaul of the component units of Continen tal industrial engines Provide a clean place to work and clean the engine exterior before you start dis assembling dirt causes engine failures Many shop tools have been developed to save time and assure good workmanship these should be included in your equipment Use only genuine Continental parts in Con t
12. AWAY SEAT CARRIES HEAT AWAY FROM CORE QUICKLY Y FAOM CORE SLOWLY Cold Normal Hot Spark Plugs Examination of a used spark plug will show if it is in the correct heat range for the operating con ditions If the plug runs too hot the insulator will blister or crack and the electrodes burn away rapidly lf the plug remains too cool soot and carbon will deposit on the insulator causing foul ing and missing Faulty Spark Plugs Left cold plug used in an engine that should have a hot plug Right hot plug used in an engine that should have a cold plug Spark plug electrodes will wear in the course of time and present day fuels have a tendency to form rusty brown oxide deposits on the insulator tip Therefore it is necessary to periodically clean the plugs with a plug cleaner and to reset the gaps to specifications Spark plugs must be correctly installed in order to obtain good performance from them It is a sim ple but important matter to follow the following procedure when installing plugs 1 Clean the spark plug seat in the cylinder head CRANKSHAFT PULLEY METHOD Schematic Diagram Showing Typical Timing Light Hookup 2 Use new seat gasket and screw plug in by hand 3 Tighten all 14mm plugs to 40 Nm 30 LB FT torque with socket wrench of correct size DISTRIBUTOR IGNITION TIMING With Timing Light Normally Continental industrial engines with distributor ignition are timed to have the distr
13. Surge Adjustment When Surge Screw is supplied Turn governor idle surge adjusting screw IN or to the right until corrected CAUTION Do not turn bumper screw in far enough to reduce the maximum governed speed for full throttle CAMSHAFT TIMING GEAR CAMSHAFT BEARING SHAFT BEARING SEAL SEAL SPRINC PIN re ADJUSTING SCREW El Exploded View of Cam Gear Governor 26 FIGURE 1 4 C ntinued surging may indicate an ex cessive looseness or binding or governor linkage and sometimes too lean a fuel mixture TM GOVERNOR LINKAGE Cam Gear Governor TM GOVERNOR LINKAGE TM20 UPDRAFT SHOWN TM GOVERNOR LINKAGE TM27 DOWNDRAFT SHOWN TMe7800320 TM275004207 TM27S00206 CONSTANT SPEED GOVERNOR AN WARNING Extreme caution must be exercised when making gover nor adjustments to avoid personal injury due to fan blades belts and hot manifolds Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 Constant Speed Governor is a precision mechanical g
14. and observe safety warnings on pages 1 and 2 A Check radiator hoses and engine for water leaks Tighten hose clamps repair leaks and in stall antifreeze to the level required for winter protection 3 LUBRICATION SYSTEM A Drain oil and change filter Add oil of the proper winter grade B If the unit employs a fluid coupling torque con verter transmission or differential check the instruction manuals for the proper winter grade lubricant and install it 4 FUEL SYSTEM A Check the throttle and choke controls for satisfactory operation and adjust as required B Check the carburetor and clean as required Check and adjust the carburetor idle speed control 5 EXHAUST SYSTEM A Check the rain cap if supplied for proper operation and repair as required 6 INTAKE AIR SYSTEM A Be sure all hoses and clamps are properly seated and tight B Check instructions on the oil bath air cleaner Clean and refill with the recommended winter grade of oil Service dry type air cleaner as specified 7 MISCELLANEOUS A If the engine is equipped with a preheater or cold starting aid check the operation accord ing to instructions repair or adjust as required B Check and adjust tappets WINTER MAINTENANCE 1 Perform maintenance in accordance with in struction manuals 2 Change oil at least every thirty days 3 If unit is only used for short periods and does not get thoroughly warm operate it for
15. be ruined forever IMPORTANT SAFETY NOTICE Proper repair 1s important to the safe and reliable operation of an engine This Service Manual outlines basic recommended procedures some of which require special tools devices or work methods Improper repair procedures can be dangerous and could result in injury or death READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warning labels have also been put on the engines to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons These labels identify hazards which may not be apparent to a trained mechanic There are many potential hazards for an untrained mechanic and there 1s no way to label the engine against all such hazards These warnings in the Service Manual and on the engine are identified by this symbol WARNING Operations that may result only in engine damage are identified in the Service Manual by the word CAUTION Wisconsin Motors LLC cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this manual are therefore not all inclusive If a procedure tool device or work method not specifically recommended by Wisconsin Motors LLC is used you must satisfy yourself that 1t is safe for you and others You should also ensure that the engine will not be damaged or made unsafe by the procedures you choose IMPORTATNT t
16. borein direct relation to the worn area so that should the worn area be off center slightly there will be no partial ridge remaining Drain the crankcase and remove the oil pan Remove the cap screws holding the connec ting rod caps to the rod Keep the cap and bolts in numerical order so that when the pistons and rods are removed from the engine the cap can be reassembled and kept with its mating part Push the pistons and connecting rods up through the top of the cylinder carrying with them all the carbon and metal chips left from the cleaning and ridge reaming operation When doing this every precaution must be taken to prevent damage to cylinder bores by the sharp corners and rough edges of the con necting rods lt is important to remove the glaze on the cylinder bores by using a cylinder hone with an adjustable stone tension in order to assure quick seating of the new pistion rings If the cylinder glaze is not removed you will have no assurance as to when the rings will begin to function properly and control the oil this is especially true when chrome rings are used The following step by step procedure is recommended a To get the correct cross hatch pattern with a cylinder hone use a top quality electric drill with a speed of 500 R P M or less and 280 grit stones Honing Cylinders b Cover the entire crankshaft with a clean slightly oily cloth to prevent abrasives and dirt from getting on the
17. brackets for cracks or other damage VALVE PUSH RODS 1 Inspect push rods for bends or twist and ex amine the ball and cup ends for excessive wear Replace rods that are faulty or excessively worn 2 To prevent damage to push rods replace after the cylinder head is installed esta ro erani pd etui innate cy tardus gn M P p M MM s NT Sui jd sient qma Rid Pn HS a He Ha Push Rod Inspection for Runout 52 CHECKING BORE WEAR 1 Clean the ring of carbon from around the top of the cylinder bore formed above the travel of the top ring 2 Determine the original diameter of the cylinder barrel by checking this unworn area with a pair of inside micrometers at intervals of approx imately 45 Measuring Original Bore Diameter Above Ring Travel 3 Check in same manner the top of the ring travel area approximately 6mm 1 4 below the shoulder 4 The maximum difference in the above checks indicates the amount of cylinder bore wear If less than 0 20mm 008 re ringing will be suitable and if over 0 20mm 008 re boring is recommended PREPARING CYLINDER WALLS FOR RE RINGING OR RE BORING 1 Ridge ream the cylinders to remove the unworn area at the top so that the new rings when assembled will not bump and distort both themselves and the piston lands AK gt AO a Ridge Reaming Top of Cylinder Bore Several good makes of ridge reamers are available which will ream the top of the
18. cylinder bore in an inverted position and then insert each ring one at a time about 50mm 2 down in the bore and bring the bottom edge of the piston up against the ring to square it up in the cylinder bore If the ring does not have sufficient end gap clearance file one end of the ring until sufficient clearance is ob tained Check the gap between the ends of the ring with a feeler gauge in accordance with specifica tions shown in the Limits and Clearance chart Prior to installing the rings on the piston check each ring in its respective groove to the limits specified in the manual If ring to land clearance exceeds maximum serviceable limits pistons must be replaced Checking Ring Clearance in Groove RECOMMENDED METHOD OF INSTALLING PISTON RINGS 1 Prior to ring assembly check the ring grooves for nicks and burrs This is done by rotating each unassembled ring around its groove to be sure of free action Installing Rings with Ring Expander Tool SEGMENT G p va 7 A SEGMENT M GAP Three Piece Oil Ring 2 The 3 piece oil ring should be installed first on the piston from the top side so skirt will not be scratched a Place stainless steel expander spacer in groove with ends butted b Install steel segment on top side of ex pander spacer with gap of segment approx imately 90 beyond gap of stainless steel ex pander spacer making certain that the ex pander spacer is stil in a butted position
19. ees acabe C be e RUM EE M as dace S T pop Red at d 54 Anas RA eoi M De f arcs e o eof Gin we teres e wes 55 Piston and Connecting Rod Assembly 55 PISTON RINO S os mel ed dot Rd ER RN AC a RU dea ay dE NS a eee tp Que eei A 56 Recommended Method of Installing Piston Rings 56 Crankshaft and Main Bearings 2 1 6 5 08s wa ca i Rao URS id ees eos OR sa 57 A TERT TTC ES C TEIL LL DIL CPC 58 er rii sia nano du Co ARR At e a eee oar 60 TAD S ruit uci deu dena oti ee se da aso Dole ORAE FRAU dh erp e de Ce 60 Hear Crankshaft Oll Seals xx Zee poh xcvi med de o tad ea SE iau S Ese 60 OUI PHA s sa al Re Sot A dictio us deese Rae i der deoa d ded 62 Ra ESI dS ET ECTS db ra a ile ra DEA LECT 63 Grankshart End Playa ect e ro tox dotate a ate to Sen oi eda doe dap ee SS A eaters 64 Flywheel and Flywheel HOUSING uk IRA EC di A eu armee banda 64 REASSEMDIING ENGINE iraniens da aisi P oru a ew QR KO EE ES RR ON CEN entes 65 Installing Oll P alise SNS un Ix As rq intr cp Pad 66 Installing FICO ciutat ic atre ebbe n ar BCG Harsch die En dog Li Ne cara A ne ot ide 65 SECTION 10 Trouble Shooting Starting Motor Will Not Crank Engine e hahere err hn 67 Engine Cranks But Does Not Start 24 oou oer as IA A el ide dO di 67 Engine Runs with Continuous Misfiring 68 Engine Runs Une ven 2 ac poc rc A C Arad aac
20. enters the manifold and passes thru the thermostat to the radiator Upon leaving the cylinder head the water enters the thermostat housing in which is mounted the positive shut off thermostat which controls the opening to the radiator or heat ex changer Upon being discharged from the ther mostat housing the water enters the radiator or heat exchanger depending upon the application where it is cooled before re entry into the engine Continental industrial engines operate most ef ficiently with water temperatures of 81 93 C 180 200 F and a thermostat and by pass system is used to control these temperatures The thermostat valve remains closed and only allows the water to recirculate within the engine itself until normal operating temperatures are reached This provides for both rapid and even temperature increase of all engine parts during the warm up period When desired temperature is reached the thermostat valve opens allowing all the water to circulate through both the engine and radiator while shutting off the by pass system IMPORTANT Present thermostats begin to open at 81 C 180 F and are fully open at 94 C 202 F Operation of engines in this temperature range is not harmful However temperature gauges are not always accurate and may sometimes indicate higher than actual temperature This can lead operators to believe engines are overheating when they are actually operating normally Ove
21. exists and the govern ing lever remains stationary holding a constant engine R P M Adjustment The desired engine speed is ob tained by increasing or decreasing the governor spring tension Cam Gear Governor 29 This built in cam gear governor is sealed dust proof engine lubricated is compact and easily adjusted The control shaft floats on two needle bearings to remove friction for closer and more accurate control through the whole power range This governor is normally used on all industrial applications Control rod movement is determined by ac celerator pedal or hand control linkages The idle surge adjusting screw if supplied should be adjusted in just far enough to eliminate any tendency of the engine to surge ADJUSTMENTS 1 Linkage Adjustment With the engine stop ped and spring tension about normal the gover nor should hold the throttle butterfly in the wide open position The governor to carburetor control rod should be adjusted in length so that the throttle stop lever is 0 4 0 8mm 1 64 1 32 off the stop pin Be sure that the bumper screw if supplied is backed out so as not to interfere Make certain that all linkage at governor and carburetor operate free without any binding 2 Speed Adjustment To increase speed in crease spring tension by use of the adjusting screw To decrease speed decrease spring ten sion by use of the adjusting screw 3 Idle
22. is flush or slightly below the oil pan rail This insert insures complete cure of the RTV Crankshaft Oil Seal in Block Install Curing Insert 61 8 Prior to installing oil pan apply a small bead of RTV material to the rear bearing cap and filler block as shown Fill 5 Dowel holes with RTV Applying RTV to Rear Bearing Cap and Filler Block OIL PUMP The oil pump is assembied to the front of the cylinder block and front main bearing cap and is held in place by capscrews The extended portion of the body acts as a pilot fitting closely in a counterbore in the block and bearing cap maintaining a definite relation ship between the crankshaft and the oil pump assembly The pump is driven by a hardened key mounted in the crankshaft Previous Oil Pump NOTE Later model oil pumps do not have an ex tended nose for piloting to the crankcase Too T 1044 should be mounted on the crankshaft nose while installing this type of oil pump Remove tool after tightening oil pump mounting screws to torque specification If tool is not available install pump against cylinder block and snug up screws by hand Rotate the crankshaft two or three times then tighten the screws to torque specification Rotate the crank to be sure the pump does not bind Oil Pump Removal When the pump is removed and disassembled examine the impellers cover and cavity for wear Inspecting the key and keyway at the same time If scored or w
23. side walls This assures it being seated firmly on the bottom of the counterbore 41 26 34 26 1 625 1 349 35 0 29 13 28 87 1 38 1 147 1 137 43 0 43 0 1 69 1 69 60 4 60 4 2 38 2 38 8 717 8 692 8 717 8 692 3432 3422 3432 3422 47 65 47 65 1 876 1 876 Inside Diameter Guide Distance Intake to Ex Valve Seat Material If Used 7 49 7 33 295 288 35 513 35 482 1 3981 1 3971 SAE J 610 Grind the intake and exhause valve seats in the head in accordance with instructions in the Valve Guide Data and limits and clearance chart Before removing the arbor indicate the seat Total indicator reading of the run out must not be more than 0 05mm 002 Use a pilot having a solid stem with a long taper as all valve seats must be ground concentric and square with either new or worn valve stem guide holes 49 ER Grinding Valve Seat ve d RS ES Indicating Valve Seat VALVES 1 Inspect valves for condition and replace any that are necked cracked or burned also any on which valve stems are bent or worn more than 0 05mm 002 over the maximum allowable limits Reface or replace all valves ORIGINAL REFACED IF AREA A IS LESS THAN 50 OF ORIGINAL DISCARD VALVE Allowable Head Thickness of Refaced Valves 2 All valves having less than 50 margin thickness outer edge of valve head after 50 refacing has been completed must be re pla
24. td Xd c amd A 68 Engine Runs Improperly eiii lc e ec A race ie Rae ee d ace eue a e aa 68 Lack Ol ROWE onc oe nike ens ze Bel Y RETRO RR E EOS UR ouo aa TR Mos dise ari dog OSA RN 68 Poor Compres SiON 225 ars KC de a A nare uario ee UU dut 68 Overhiealinig uestes s darian intimement ele el Ree nave e ES 68 Low OIl Pressile noera aae Ad Tosca a Ra iii on dominicale 68 High Oll Pressure euo ee e gaat ASA A pa os Oe ASS o a 68 High Oll Consumption vox do ep as RMS AA Io ape E qd se dura 69 Engine Knocks and Other Noises 44 69 SECTION 11 Torque Specifications 71 72 SECTION 12 Limits and Clearance Data 73 74 76 LIMITED PARTS WARRANTY WISCONSIN MOTORS LLC herein Wisconsin warrants to the original retail purchaser herein Purchaser that each new Wisconsin engine or service engine assembly herein engine s will be free from defects in material and workmanship for a period of one I year after delivery or for up 2 000 hours of operation by the Purchaser whichever occurs first Wisconsin s obligation under this Limited Warranty shall be limited at Wisconsin s option to repairing or replacing the engine which upon examination is found to be defective in material or workmanship The repair or replacement of any engine under this Limited Warranty shall not extend the term o
25. this center ter minal to one of the cap terminals which in turn is connected to the proper spark plug The spark produced by this high tension current ignites the fuel in the cylinder This process is repeated for every power stroke of the engine and at high speeds an impulse may be required as often as 300 times per second Ignition Coil The function of the ignition coil is to transform the low voltage supplied by the bat tery into the high voltage to jump the spark plug gap An ignition coil has two windings wound on a soft iron core the primary winding which consists of a comparatively few turns of heavy wire and the secondary winding of many thousand turns of very fine wire The primary winding is wound around the outside of the secondary winding soft iron shell encloses the outside of both win dings and serves to complete the magnetic cir cuit Ignition coils do not normally require any ser vice except keeping all terminals and connections clean and tight The coil should be kept reasonably clean however it must not be sub jected to steam cleaning or similar cieaning methods that may cause moisture to enter the coil SEALING NIPPLE HIGH TENSION ME TERMINAL E PRIMARY O TERMINAL SPRING WASHER SEALING GASKETS 57 SECONDARY 4 WINDING Y PRIMARY TH WINDING COL CASE COM CAP YHYNE TIE RIA D PORCELAIN M INSULATOR E Cutaway View of an Ignition Coi
26. zero R P M Each cylinder will fire at the proper time because of close tolerances in the trigger wheel 29 design Elimination of points and condensers and their inherent problems such as rubbing block wear plus the longevity of solid state circuitry of fers much less downtime and more economical operation This system uses an oscillator as its sensor Acting as a Metal Detector it senses the trigger wheel teeth turning with the distributor shaft The presence of metal each tooth causes a change to occur in the oscillator which in turn commands the control unit transistor switch to turn off This off condition causes the primary current to stop flowing and the magnetic field which built up during the on time now will collapse across the secondary coil winding causing the high voltage to fire the spark plug The sensor is a coil of very fine wire molded in to a plastic housing This plastic housing is mounted on the movable base plate and is con nected directly to the circuit board The sensor is not replaceable The electronic control system is a completely self contained solid state device which is coated to provide a moisture proof barrier lt is not repairable and if necessary must be replaced asa complete assembly The Integral system houses the electronics in side the distributor Only two connections are made to the coil IGNITION SYSTEM COMPONENTS The Battery supplies the voltage for producing a c
27. 1 At Idling Speed which may be due to A Too wide spark plug gaps B Poor Carburetor idle adjustment C Wrong float level D Carburetor or intake manifold air Jeaks E Leaky cylinder head gasket 2 At High Speed which may be due to A Weak valve springs B Spark plug of wrong type or incorrect gap E ENGINE RUNS IMPROPERLY 1 Back Firing into Manifold indicates Too Rich a fuel mixture into carburetor indicates Too Lean a mixture may be due to A Late Ignition Timing B Clogged Air Cleaner C Fuel line restrictions D Clogged carburetor jets E Sticking Valves F Weak or broken valve springs 2 Excessive Ping Detonation results in damaged pistons and bearings and is caused by pre ignition or using inferior grade of gas 3 Engine Idles Too Fast indicates im proper throttle adjustment or weak throttle return springs 4 Engine Dies When Idling which in dicates incorrect speed or mixture adjustment clogged idling circuit in carburetor or wrong choke adjustment or air leaks in intake manifold 68 5 Engine Stumbles on Accelera tion which may be due to defective ac celerator pump or air in fuel lines 6 Defective Spark Plugs F LACK OF POWER which may be due to 1 Poor Compression 2 Wrong Timing 3 Throttle control not opening fully 4 Air leak in fuel system 5 Restri
28. 2 4 Pros et oe statue ote aoe MANS etarras bella EII NS A 7 ra A RE F iu P gf P rr a aeu iw ut EK us f fue fe n ES ffl fog E i o ur D A F 3 A F E WE og cud d sf Sor lx etn Pinte of oy ae we 9 2 9 4 oat atetet ass y A tss veo eel wr eta eta ata es caer marcas Pe Se dr at TS A E H D RUP TES Le 2 7 1 DER tomates st o too ets ste atom ste ELEMENT INNERCUP ee o gt III 4 e 9 9 9 Ce S AS a ele 4 9 9 Pete te tate tate OIL Sectional View of Oil Bath Cleaner CAUTION Do not steam clean or use high pressure air to clean the filter element as it opens a direct channel through the filter which permits oil as well as dirt to pass directly through the oil bath cleaner DRY TYPE REPLACEABLE AIR FILTER Dry type air filters are optional equipment on many engines and it is most important that the dirt buildup in the cartridge does not reduce the air flow sufficient to cause a noticeable loss in power They should normally be serviced every 50 hours in the following steps Extreme conditions will require daily cleaning Remove cover and cartridge after removing wing bolt do not allow dirt to fall into the ex posed carburetor Clean cartridge by gently tapping flat on a smooth horizontal surface to shake out the dust A WARNING Wear protective glasses or a face
29. 4 9 9 b um v a P 4 9 9 9 NH E 9 P amp A amp 9 9 9 0 9 V 9 P O 6 amp amp 0 OB b 5 4 b n 9 e P v Cross section of a typical Continental Overhead Vaive Industrial Engine Section 2 Operating Instructions The person operating the engine naturally assumes responsibility for its care while it is being operated This is a very important respon sibility since the care and attention given the engine goes a long way in determining how long a period it will operate satisfactorily before having to be shut down for repairs The operating and preventive maintenance in structions for the Overhead Valve type engines are simple and should be followed without devia tion The entire aim in setting forth these instruc tions is to give you a benefit of the knowledge and experience gained over a long period of collabora tion between Engineering Research and Field Ser vice PREPARATION OF A NEW ENGINE FOR OPERATION Before placing a new engine in operation it must be thoroughly inspected for external damage and particular attention paid to the following items 1 Inspect Engine Hold Down Bolts To make certain that they are firmly set 2 Close water drain cock on the side of the block In some cases this may be a pipe plug Fill radiator and water jacket with coolant see Cooling System section 4 Water Drain Cock 3 Fill Crank
30. 7 ADJUST IDLE MIXTURE FOR HIGHEST RPM AND RESET IDLE SPEED TO 400 600 R P M AND 800 1000 R P M ON THE 2 CYLINDER ENGINE Repeat again at end of 500 hours EVERY 250 HOURS 1 REPEAT DAILY AND 50 HOUR SCHEDULES Follow previous instructions 2 CLEAN EXTERIOR OF ENGINE Use steam if available otherwise any good commercial engine cleaner to wash down the engine 3 CHECK GOVERNOR CONTROL Clean and lubricate all governor linkage to in sure free operation of governor Free up any joints that may be binding or rods or levers that may be twisted Check for full throttle opening 4 CLEAN SPARK PLUGS Clean depressions around plugs before remov ing them then clean and re set electrode gap to 0 8mm 032 on standard plugs install spark plugs 14mm and tighten to 40 Nm 30 Lbs Ft torque RES Re Set Spark Plug Gap 5 CHECK DISTRIBUTOR Remove Distributor Cap Clean cap and ex amine for cracks carbon runners corroded ter minals or if the vertical faces of the inserts are burned if found install a new cap If the horizontal faces of the inserts are burned replace the cap and rotor as this is due to the rotor being too short Check Mechanical Advance Mechanism for freeness by turning the breaker cam in the direction of rotation and then releasing it The ad vance springs should return the cam to its original position To ensure proper operation the diaphragm in the vacuum advance uni
31. Bore Piston Pin Hole Dia Ring Groove Width 4 1 Max Wear Limit Width Ring Groove Width 2 Max Wear Limit Width 42 Ring Groove Width 3 Max Wear Limit Width Piston Fit Feeler Gauge Lbs Pull PISTON RINGS Ring Width 1 Wear Limits Min Width Ring Width 2 Wear Limits Min Width Ring Width 3 Wear Limits Min Width Ring Gap Clear 1 Ring Gap Clear 2 Ring Gap Clear 43 Ring Side Clear 1 Ring Side Clear 2 Ring Side Clear 3 METRIC 91 039 91 000 0 20 28 582 28 577 2 080 2 060 2 131 2 060 2 040 2 111 4 040 4 020 4 089 0 08 2 3 4 5Kg 1 990 1 960 1 905 1 990 1 960 1 905 4 007 3 904 3 853 0 25 0 50 0 25 0 50 0 38 1 40 0 120 0 070 0 100 0 050 0 136 0 013 ENGLISH 3 5842 3 5827 008 1 1253 1 1251 0819 0811 0839 0811 0803 0831 1590 1583 1610 003 5 104 078 077 075 078 077 075 1578 1537 1517 010 020 010 020 015 055 0047 0028 0039 0020 0054 0005 NOTES 74 A WARNING Read and observe all individual safety warnings as you use this manual to operate service or repair your engine See pages 1 and 2 Imp rtant Safety Notice and Warnings 0 cece eee tee eee eee 1 amp 2 Eo Llc cacy ae ar RA A Gala anata hk bos we hae Sede EE ated eee a oe 3 Continental Industrial Engines Specifications
32. N The upper main bearing shells are grooved The lower main bearing shells on some models are not The ungrooved bearing sheli must be placed in the bear ing cap not in the block or oil to the bearings will be cut off To remove the upper half of the bearing shell use a special tool obtainable at most parts houses which is a pin and an angular head It may be inserted in the oil hole of the crankshaft and as the crankshaft is turned in a clockwise direction the head of this pin picks up the bearing shell and forces it out of the bore in the block The thickness of the bearing shells is given in the Limits and Clearance Chart and if this Measuring Bearing Thickness thickness has been reduced more than 0 013mm 0005 beyond the maximum allowable tolerance the bearing shell must be replaced 8 lf visual inspection of the crankshaft shows no indication of excessive wear or scoring the clearance of the bearing should be checked 9 Check each bearing one at a time by using a piece of Plastigage of a diameter specified to check certain clearances Checking Bearing Clearance with Plastigage By placing the Plastigage on the crankshaft bearing surface and tightening the bearing and cap in place the width of the Plastigage after crushing will determine the bearing clearance CAUTION When using this method DO NOT TURN the crankshaft as that would destroy the Plastigage If crankshaft is scored or wor
33. O E P RA 7 cylinder Head Gasket Piston Water Push Rod Jacket A a 3 pd A Tappet Camshaft Connecting Rod Heavily Ribbed Block Counterweighted Crankshaft Heat Treated Alloy Steel Connecting Rod and Main Bearing Cap Bolts 9 9 o 9 9 9 9 9 o o a o E o Non o P pa n a e n Ve C4 EMI Yon s o o 5 o u eo ch CHE e Moo oW e halo n o 9 o m a a o m aaup b w Rm 4 9 R9 9 ao 9 9 4 4 e ease L a 9 b amp 4 amp d P amp amp DEI eae ee ease se Tes s ose Nut 9 o amp 6 a a 1 eae m a RD m v 9 ee ee rss DE ee ae gt oe ae DE ee a CORRE CODEN DRE ao nana a ROO OOO CIAO ate e re m dae itm EME OM v xem TRE Det eee rre Oil Pump Pick up 9 qe eee 9 e 9 9 5 V F 9 9 O D NW G O O GO EU P Pease b URA La fess 0 000 9000 0 0 000000 4 0 0 0 00 0 00 4410 0 0 nee ne 9 9 9 V 9 0 O 4 5 se GO 4 amp b n 4 4 P 9 e 2 e e a a 2 9 h 9 4 P 9 9 GO 9 9 9 4 9 9 9 6 t amp ot e a bo 4 4 9 9 9 8 8 b 4 6 9 BOR e 9 9 a B 9 9 9 9 9 9 9 9 5 9 9 Gt eae naos BON 4 e 9 B B 4 9 b 6 9 9 9 2 e 9 9 9 t v 9 6 t 60 amp 9 9 9 6 9 9 9 amp amp 9 9
34. OR REBUILT ENGINE for peak performance and economical operation the following adjustments should be made at end of first day s operation 1 Torque down cylinder head to specifications 2 Adjust valve tappets to specified clearances 3 Adjust idle mixture and idle speed to 400 600 R P M 800 1000 R P M on the 2 cylinder engine 10 FOLLOW PREVENTIVE MAINTENANCE SCHEDULES RECOMMENDED this will avoid troubles which might cause expensive breakdowns and maintain your engine for depen dable and economical operation 11 IDLING ENGINE slow engine to low idle 600 R P M depending on the application for about 5 min utes after each operating period before stopping too rapid cooling down may cause distortion DONOT RUN AT LOW IDLE FOR PROLONGED PERIODS temperatures are higher the contaminated gases remain in gaseous form and the engine operates clean as long as breather system is kept clean however temperatures below this will result in injurious sludge formation It is vitally im portant therefore to maintain oil and crankcase temperatures above 57 C 135 F as shown on the following chart REACTIONS WITHIN ENGINE CRANKCASE F TO TEMPERATURES DURING OPERATION C 350 300 H CLEAN ENGINE 250 PERATION YA OPE 200 150 LIQUID CONDENSATION Siudging Etching of Parts Ring and Valve Sticking and Burning of Bearings 100 OOO 32 0 SNOW ICE Sludge and Freezing of Oi Screens F
35. Obtained with a Cylinder Hone After all honing operations are complete thoroughly wash the bores with soap and water to remove all traces of grit Kerosene or other solvents will not remove the grit Rinse the block with clean clear water and dry with compressed air Cleaning Bores When you have finished cleaning the block run a clean dry paper towel through the bores The paper towel should come out clean Cleaning Block 54 If not the bores must be rewashed As soon as the bores have dried lubricate with engine oil immediately to prevent rust This completes the honing operation PISTONS Check the pistons for excessive ring groove wear and replace any that exceed the allowable limits in our limits and clearance data The cylinder walls and pistons must be per fectly clean and dry when fitting pistons in the cylinder bores Pistons should be fitted with the block and piston at room temperature 20 0 21 0 C 68 70 F PISTON FIT ON STANDARD PISTONS with 2 3 to 4 5 kg 5 to 10 Pull TM series 0 08mm 003 Check the piston fit in the bore using a half inch wide strip of feeler stock of the thickness specified in the Limits and Clearance Chart the feeler being attached to a small scale of approx imately 7 kg 15 Lbs capacity Checking Piston Fit in Bore When the correct fit is obtained you must be able to withdraw the feeler with a pull of 2 3 4 5 kg 5 10 pounds on the scale with
36. ak the threaded end off cast iron cam shafts Assembie camshaft nut and torque to specifica tions shown in section 11 Do not use impact wrench or over torque cam nut Torquing Cam Gear Nut Check camshaft end play as shown in illustra tion Refer to limits and clearance section for cor rect dimension Checking Camshaft End Play 4 Drive the crank gear on the shaft making sure that the marked teeth on the cam gear strad dle the marked tooth on the crank gear which assures you of the crankshaft and camshaft being in t me 63 Timing Gears Ace bic According to Timing Marks CRANKSHAFT END PLAY The crankshaft end play is controlled by the center flanged bearing No shims are required If end play exceeds 0 18mm 007 using a feeler gauge replace the flanged bearing End play should be between the 0 17mm 0067 and 0 04mm 0015 limits Flanged Bearing Controls Crankshaft End Play FLYWHEEL AND FLYWHEEL HOUSING NOTE On early models special capscrews having sealing bands are used in the upper holes to mount the flywheel housing to the cylinder block These special capscrews must be used to prevent oil leakage Special Capscrews 64 Checking Flywheel Run Out The flywheel is machined and balanced so that the clutch face and locating counterbore will run true with its axis To be sure that the crankshaft flange has not been sprung or otherwise damaged or that the co
37. an cause corrosive burns Always wear eye protection Use of jumper cables or battery charging shouid be done only as directed by manufacturers safety instructions Read and observe safety warnings on pages 1 and 2 1 Clip blue secondary lead of light to the 1 spark plug leave spark plug wire on plug 2 Connect primary positive lead red to positive terminal of battery 3 Connect primary negative lead black to cylinder head capscrew or alternator bracket Disconnect vacuum line from distributor to manifold and clamp end of line leading to the manifold 4 Start engine and run at idle speed 400 R P M or lower so the automatic advance of the distributor is completely retarded THIS IS VERY IMPORTANT TO OBTAIN CORRECT TIM ING 5 Direct timing light on the crankshaft pulley or on the flywheel through opening in bell hous ing and note timing marks as light flashes 6 Timing is normally at 2 BTDC unless specified otherwise on your engine specifica tion sheet 7 To advance timing turn distributor body clockwise To retard timing turn distributor body counter clockwise 8 When timing is correct tighten distributor clamp screw securely Then re check timing again with light 9 This operation is best performed in a shaded area so timing light is visible Checking Flywheel Timing with Timing Light DISTRIBUTOR IGNITION TIMING Without Timing Light Emergency Method 34 1 Remove 1 Spark Plug
38. and allow engine to run at governed speed no load If a surge is noted lengthen screw B at spring anchor and readjust Screw to obtain desired no load R P M 8 Wheng vern r adjustment is completed make sure that all lock nuts are tight in order to main tain the adjustment VARIABLE SPEED GOVERNOR AN WARNING Extreme caution must be exercised when making gover nor adjustments to avoid personal injury due to fan biades beits and hot manifolds Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 Variable Speed Governor 1 Start Engine and idle until warmed to operating temperature 2 Set Specified High Idie No Load Speed by moving throttle to required position and adjusting high speed screw A 3 Check Regulation by Applying and removing engine load 1 If regulation is too broad increase spring tension with sensitivity screw B and read just high speed screw A throttle stop to ob tain high idle speed If regulation is too narrow decrease spring tension with sensitivity screw B and read just high spee
39. and flushing necessary only after long periods of operation Please reference SPB 90 409 RADIATOR The radiator or heat exchanger consists of a series of metal tubes through which the coolant is circulated In standard radiator design fins are connected to the metal tubes to give an extended surface through which heat can be dissipated It is important that these tubes be kept clean on the inside and the fins free of dirt on the outside so the maximum heat transfer can take place in the radiator 16 If the coolant is hot or if the engine has been running loosen the pressure cap to the first stop and let the pressure out of the cooling system before removing the radiator cap Read and observe safety warnings on pages 1 and 2 A Radiator Coolant inlet Blowing out between the fins of the radiator using compressed air in a direction opposite to that of the fan circulated air will serve to keep the cooling surfaces of the core free of dirt and other particles Operating conditions will determine the frequency of this service Every 500 hours of operation the radiator and cooling system should be well cleaned and flushed with clean water Radiator Drain Wherever possible only soft clean water should be used in the cooling system Hard water will cause scale to form in the radiator and the engine water jackets and cause poor heat transfer Where the use of hard water cannot be avoided an approved water so
40. aphragm operated and controlled by linkage which adjusts itself to pressure demands Fuel Pump Tests The fuel pressure may be measured by installing a pressure gauge between the fuel pump and carburetor The fuel pump size and static pressures 1800 R P M for the overhead valve engines are ENGINE DIAPHRAGM MAX MODEL DIAMETER FUEL PRESSURE LIFT TM 82 6mm 77 116mm Hg 3m 3 1 4 1 1 2 2 1 4 PSI 10 Smoking or open flame should be avoided any time the fuel system is being repaired or serviced The area should be properly ventilated Improper handling of fuel could result in an explosion or fire causing bodily injury to yourself or others Read and observe safety warnings on pages 1 and 2 When pressures are below the range the pump should be disassembled and reconditioned with the special overhaul kits available Maintenance Fuel pump trouble is of only two kinds either the pump is supplying too lit tle gas or in rare cases too much If the pump is supplying too little gas the engine either will not run or it will cough and falter If too much gas it will not idle smoothly or you will see gasoline dripping from the car buretor If the engine is getting too little gas the trou ble may be in the pump fuel line plugged filter or the gas tank First be sure there is gas in the tank then disconnect the pump to carburetor line at the pump or carburetor and turn the engine over a few t
41. area of Form in Place gasket must intersect vertical cavities both sides Top View Crankcase contact face Rear Bearing Cap and Filler Block See notes 1 and 2 Form in Place gasket materia to plug holes Min 6 0mm 236 deep from contact surface OIL PAN A in place gasket should be applied to the oil pan and filler blocks as shown here Tighten the screws in accordance with limits prescribed in the torque chart to avoid looseness or overstressing When engine is completely assembled and fill ed with proper oil See Lubrication Sec set tap pets according to the following chart MODEL INTAKE EXHAUST 0 46mm 018 Setting Tappets See Notes 1 and 2 Form in Place Gasket See Notes 1 and 2 Form in Place gasket material must extend from side seal recess to inner edge of seal re tainer as shown both sides IMPORTANT After assembly of the bearing cap to the crankcase fill bearing cap side slots to capacity using RTV and syringe furnished in kit Sealant must bleed out chamfer at crankcase split line 9 0 mm 35 5 mm 30 a vk The two curing inserts pipe cleaners in cluded in the kit must be used as follows Dip the curing insert into a container of clean water and insert full length into bear ing cap side slot cavities filled with RTV material making certain the insert is cen trally located in side slot install curing insert until approximately 5 8 p
42. ark on cup avoid overfill ing Replace cup and check all connections to manifold Be sure that no unfiltered air can enter the engine intake manifold lf a dry type air cleaner is used clean element with compressed air See Daily Instructions 4 CHECK FAN BELT TENSION Inspect wear condition of fan belt note align ment and check belt tension which should allow not over 13mm 1 2 deflection on the long span Fan Belt Tension 5 CHECK BATTERY KNWARNING Stop engine before checking battery terminais or elec trical connections Do not hold ignition wires with bare hands since shocks of other injuries can result Sparks or flames near a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 Check specific gravity of each cell which should be at least 1 250 Add distilled water if re quired to raise level 9 5mm 3 8 above the separators Checking Battery Particular attention should be given the battery during cold weather The cranking power of a fully charged battery 27 C 80 F is reduced 60 18 C O F yet the power required to crank the engine is 2 1 2 times greater at 18 C 0 F than 27 C 80 F 6 TORQUE DOWN CYLINDER HEAD TO SPECIF ICATIONS IN MANUAL
43. assembling Water Pump 5 Remove lock rings 7 holding bearing and shaft assembly in body after which shaft 10 can be forced out through the front with an arbor press or lead hammer DO NOT ATTEMPT TO DRIVE WATER PUMP SHAFT 10 OUT THROUGH REAR OF HOUSING To do so will damage the housing beyond repair REASSEMBLY AND INSTALLATION 1 Reassemble pump replacing worn or failed parts Seal contact surfaces must be smooth and flat The bushing should be replaced if scored or cut A light film of lubricant applied to the face of the seal will facilitate seating and sealing 20 Drive Shaft out in this direction 2 Use thick soapsuds on both the seal and shaft when assembling in order to prevent damage to the seal 3 The fan hub must be installed prior to replac ing rear plate The shaft must be supported during this operation to prevent damage to the seal and bushing 4 Mount pump assembly on block using a new housing gasket 5 Install fan belt and adjust belt tension to have 13mm 1 2 deflection on long side Pull out the alternator by hand as bearing damage will result with a pry bar 6 Refill cooling system Please reference SPB 88 374 Section 5 Fuel Systems The basic purpose of the fuel system is to store convey mix fuel with air then vaporize and in troduce the mixture into the engine Fuel is stored in the tank it is filtered and flows through the fuel supply line to the carburetor
44. at least an hour once a week to get it thoroughly warm This will avoid excessive sludge in the oil and reduce dilution of oil with raw fuel in the crankcase PREPARATION OF ENGINE FOR SEASONAL STORAGE 90 DAYS TO 6 MONTHS CAUTION Before starting the processing engine must be cooled down to the surrounding temperature since oil will adhere much better to cold metal surfaces 1 Drain Oil from Oil Pan and replace drain plug 2 Refill Oil Pan with high grade SAE 30 or 40 engine oil to 1 2 its normal capacity 3 Start Engine and run above 600 R P M for 2 minutes to complete oil distribution on all surfaces Do Not Run Longer Than 2 Minutes 4 Stop Engine Remove al Spark Plugs 5 Pour Approximately 90 Grams 3 Ounces of SAE 30 or 40 Engine Oil into each Spark Plug Hole 6 With Ignition Cut Off Crank Engine with Start r for at least a dozen revolutions to distribute this oil over the cylinder walls and valve mechanism 7 Drain Oil from Pan and Reassemble Plug 8 Drain Cooling System and Close Drain Cocks A WARNING Smoking or open flame should be avoided any time the fuel system is being repaired or serviced The area should be properly ventilated Improper handling of fuel could result in an explosion or fire causing bodily injury to yourself or others Read and observe safety warnings on pages 1 and 2 9 Drain All Gasoline from tanks lines and carbureto
45. at half engine speed G Timing Gear Noise Loose or worn gears rattle or knock tight gears hum 3 Vibration Originating at Engine The most common sources of vibration originating in or on the engine as distinguished from Causes created outside the engine are as follows A Misfiring B Misalignment of engine C Bent or off center coupling D Engine loose on bed and type of mountings E Out of balance condition of flywheel and clutch assembly 69 NOTES ul Sd i i a R 70 Section 11 Torque Specifications NOTE The Following Torque Values are based on Phosphate Coated Fasteners Class 10 9 4 12 9 and Black Oxide Coated Fasteners Class 8 8 4 9 8 CYLINDER HEAD Connecting Rods CAUTION High limit is max THD MAT L TORQUE SE CLASS Nm LB FT imum DO NOT Torque beyond 3 8 SAE GR 8 61 68 high limit M14 150 162 110 120 Flywheels 68 75 6875 Flywheel Housings M10 61 68 Rear End Plates 8 9 20 24 k Manifolds 8 8 9 8 15 18 M10 8 8 9 8 34 40 25 30 M10 8 8 9 8 34 40 25 30 Sheet Steel Oil Pump J 8 8 9 8 20224 15 18 90 100 140 150 A 38 41 2830 M16 163 176 120 130 8 00 00 dq 00 And Misc Brackets Rocker Shaft 23 27 17 20 Supports 8 8 9 8 88 98 2024 1518 Accessories 25 30 M10 8 8 9 8 40 IEEE z alo am o Crankshaft Pulle Rocker Cover 71 NOTE The Following Torque Va
46. ates that the primary circuit is OK trouble may be in secondary circuit due to 1 Broken or grounded high tension wire from coil to distributor 2 Wet high tension wires 3 Faulty distributor cap or rotor 4 Broken secondary winding of coil C Excessive Ammeter Reading Discharge over 5 amps indicates a short in the primary winding which may be due to 1 Shorted or grounded primary winding 2 WEAK SPARK may be caused by A Loose ignition wiring connections B Wet spark plug wires C Cracked distributor cap D Weak ignition coil 3 GOOD SPARK AT EACH PLUG indicates that ignition system is OK and trouble is in fuel 67 system which may be due to A No Gas in Carburetor which may be due to 1 No gas in tank 2 Clogged filter or lines 3 Faulty fuel pump 4 Leaky fuel line from tank 9 Plugged vent in fuel tank cap B Gas in Carburetor which may be flooded due to 1 Too much choking plugs are wet 2 Wrong float level 3 Choke not operating correctly 4 Water in Gas C ENGINE RUNS WITH CONTINUOUS MIS FIRING Due to 1 Uneven compression 2 Wet or deteriorated high tension wires 3 Cracked distributor cap 4 Faulty spark plugs if spark plug porcelain is white when removed use Colder plug if light brown OK if Black or oily use Hotter plug D ENGINE RUNS UNEVENLY
47. case with oil Use the oil recom mended for the ambient temperature see chart on page 14 4 Engine Accessories see that all points re quiring lubrication are properly lubricated Radiator Coolant Inlet 5 Electrical Connections Check storage battery terminals and all electrical connections Check each spark plug wire for tightness A WARNING Stop engine before checking battery terminals or elec trical connections Do not hold ignition wires with bare hands since shocks or other injuries can result Sparks or flames near a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 Electrical Connections STARTING THE ENGINE A WARNING Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 Normally check daily preventive maintenance schedule before starting See section 8 1 Disen
48. ced To check this dimension compare the refaced valve with a new valve Checking Valve Face in V Blocks 3 Check all refaced or new valves in V blocks with indicator to determine if the contact face is true with the stem within 0 05mm 002 If not repeat the refacing operation 4 After the valves and seats have been refaced and reground coat the seat lightly with Prus sian blue and drop the valve into position oscillating it slightly to transfer the blue pat tern to the valve face This should show a con tact width of 1 6 to 2 4mm 1 16 to 3 32 and should fall well within the width of the valve face leaving at least 0 4mm 1 64 on either side where the blue does not show If the con tact is over 2 4mm 3 32 wide the seat in the head may be narrowed by using a 15 stone to reduce the outside diameter or using a 60 or 75 stone to increase the inside diameter Checking for Proper Valve Seating Never allow valves to set down inside the seat After the narrowed down seat is brought within specifications the seat should be retouched lightly with the original stone to So remember do not lap valves in after remove burrs or feathered edge grinding 5 Coat the valve stem with a light film of engine Oil VALVE SPRINGS 1 Check all valve springs on a spring tester to make sure they meet specifications regarding weight and length Valve Position in Head A poor valve g
49. crankshaft c Remove the excess carbon desposits from the top of the cylinder wall before beginning the glaze breaking operation This is to pre vent loading the stones d Insert hone in cylinder and expand to cylinder wall with slight tension Using a clean brush wet cylinder wall and stones with kerosene Use a hand drill and surface hone cylinder with a rapid up and down mo tion to produce a good crosshatch pattern Apply kerosene continuously and increase tension on hone adjustment until a good pattern and finish is obtained A smooth finish of 0 25 0 38 micrometers 10 to 15 micro inches is desired The honing operation will produce a sharp edge at the bottom of the bores Upon completion of the honing operation remove this sharp edge with a piece of number 500 emery cloth If this edge is not removed it can cause shaving of the piston skirts Removing Sharp Edge After Honing e Clean the loose abrasives from the stones by using kerosene and a wire brush IMPORTANT Stones must be used wet Keep ap plying kerosene during honing to prevent stones from drying out and causing an incorrect honing pattern f The most desirable cylinder finish is 0 25 0 38 micrometers 10 15 micro inches with this finish the depressions in the surface tend to keep a supply of lubrication bet ween the mating parts This finish can be obtained by using 280 grit stones on the hone 93 Desirable Crosshatch Pattern
50. ct warranty or tort including negligence failure to warn or strict liability or otherwise shall Wisconsin be liable Purchaser or to Purchaser s officers employees or representatives or to any third party for any special indirect con sequential or incidental damages including but not limited to loss of profit or revenues loss of use of equip ment or services furnished by Wisconsin damage to associated equipment cost of capital cost of substitute products facilities service or replacement power or down time costs In no event shall Wisconsin s liability for any claim for any engine exceed Wisconsin s price for the engine or engine component part that gives rise to the claim Purchaser assumes all other risks and liabilities for any loss damage or injury to persons property or the environment arising out of connected with or resulting from the use or subsequent sale of the engines either alone or in combination with other products Purchaser expressly agrees that the remedies granted to it here under are Purchaser s sole and exclusive remedies with respect to any claim of Purchaser arising under this Limited Warranty SERVICE AND PARTS Available from your Authorized WISCONSIN Service Center ANN California Proposition 65 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WISCONSIN MOTORS LLC SALES OFFICE 2020 Fl
51. ction in air cleaner should have vacuum less than 250mm 10 water 6 Exhaust line obstructed should have back pressure of not more than 500mm 20 water 7 Poor fuel 8 Piston rings sticking or worn G POOR COMPRESSION check with com pression gauge if irregular seal the piston with a teaspoonful of engine oil poured through the spark plug hole and take a sec ond reading if pressure does not increase this will indicate that poor seating of valves are at fault Poor compression may be due to 1 Valves holding open no tappet Clearance 2 Leaky cylinder head gasket 3 Broken or weak valve springs 4 Burned or sticking vaives 5 Badly worn broken or stuck piston rings 6 Wrong valve timing 7 Bent push rods H OVERHEATING 1 Lack of water in radiator 2 Fan belts slipping 3 Thermostat sticking or inoperative 4 Radiator clogged or leaky 5 Late ignition timing 6 Back pressure in exhaust line 7 Defective water pump 8 Overloading of engine LOW OIL PRESSURE 1 Low Oil level 2 Oil pressure gauge or line faulty 3 Oil too light diluted 4 Suction screen plugged 5 Dirt in relief valve or broken spring 6 Worn bearings 7 Worn or damaged oil pump impeller 8 Worn Cam Bores or Journals J HIGH OIL PRESSURE Sshould not exceed recommended pressures except when engine is starting up col
52. d _ N mg IGNITION N SWITCH N N IGNITION n COIL N N NN S N HIGH TENSION WIRING KE LOW TENSION WIRING Schematic Drawing of Ignition System 12 Volt These parts can be divided into separate cir cuits consisting of a low tension circuit carrying battery voltage and a high tension spark circuit of about 20 000 volts The primary section is the low voltage section and is composed of the battery the ignition swit ch the ignition coil primary winding distributor electronics and associated wiring Integral Primary Ignition System The secondary section is the high voltage sec tion and is composed of the ignition coil secon dary winding the distributor cap the rotor the spark plug cables and the spark plugs The electronic ignition system maintains a tun ed condition longer since there are no points or condenser Breaker point erosion and rubbing block wear is eliminated Wear on the distributor shaft and shaft bearings is greatly reduced Dwell is permanently controlled by the electronics and total electronic switching offers improved star ting The system is easy to troubleshoot requiring no elaborate test equipment or procedures The electronics are fully protected with a moisture resistant material and are designed to resist shock and vibration Protection against reverse polarity and over voltage is built into the system The system will trigger at any speed above
53. d Abnormally high oil pressure is not desirable because it increases oil consump tion possible causes of high oil pressures are 1 Engine oil too heavy 2 Stuck relief valve 3 Obstruction in distributing line 4 Faulty oil pressure gauge K HIGH OIL CONSUMPTION 1 Oil leaks 2 Too high oil level 3 Incorrect grade of oil used 4 Clogged crankcase breather 9 Oil pressure too high stuck relief valve 6 Piston rings not run in due to too smooth cylinder bore finish or glazed condition 7 Worn broken or stuck piston rings and clogged oil control rings 8 Worn pistons and bores 9 Worn bearings 10 Worn valve guides Manifold may be removed for visual inspec tion L ENGINE KNOCKS AND OTHER NOISES 1 Operating Knocks which may be due to A Pre Ignition Most common cause is due to wrong type plugs which are too hot B Carbon noticeable when engine is ac celerated while hot clean head and pistons C Timing early timing causes knocks similar to carbon but may tend to kick back when starting D Fuel detonation knock caused by poor gas E Overloads particularly at lower operating speeds 2 Mechanical Knocks result from wear abuse or improper adjustments which may be due to A Crankshaft and Main Bearings 1 Worn or burned out Main Bearings A heavy dull knock when accelerati
54. d accurate service the following information must also be given 1 State EXACTLY the quantity of each part and part number 2 State definitely whether parts are to be shipped by express freight or parcel post 3 State the exact mailing address IMPORTANT READ THESE INSTRUCTIONS CAREFULLY All points of operation and maintenance have been covered as carefully as possible but if further information is required send inquiries to the factory for prompt attention When writing to the factory ALWAYS GIVE THE MODEL SPECIFICATION AND SERIAL NUMBER of the engine referred to ing an rating New Engin Careful breaking in of a new engine will greatly increase its life and result in trouble free operation A factory test is not sufficient to establish the polished bearing surfaces which are so necessary to the proper performance and long life of an engine These can only be obtained by running a new engine carefully and under reduced loads for a short time Be sure the engine is filled to the proper level with a good quality engine oil For proper procedures to follow when breaking in a new engine see Testing Rebuilt Engine The various bearing surfaces in anew engine have not been glazed asthey will be with continued operation and it is in this period of running in that special care must be exercised otherwise the highly desired glaze will never be obtained A new bearing surface that has once been damaged by carelessness will
55. d screw A throttle stop to ob tain desired high idle speed If governor surges under load decrease spr ing tension with sensitivity screw B and readjust throttle lever position to desired high idle speed 2 3 27 4 Stop Screw C Set for low R P M or idle Velocity G vernors are generally used to stop prevent engine speed from exceeding a predeter mined maximum The governor is mounted bet ween the carburetor and manifold flanges In its most simple form it consists of a main body which contains a throttle shaft a throttle valve Repeat above steps as required until desired performance is obtained When adjustment is complete lock all lock nuts to maintain set tings HINGED LEVER GOVERNOR A WARNING Extreme caution must be exercised when making gover nor adjustments to avoid personal injury due to fan blades belts and hot manifolds Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 The hinged lever governors are basically the Same as other Governors except the governor arm is
56. dic lubrication Precautions to be observed when testing or ser vicing the alternator system 1 IV Disconnect the battery before connecting or disconnecting test instruments except voltmeter or before removing or replacing any unit or wiring Accidental grounding or short ing at the regulator alternator ammeter or ac cessories will cause severe damage to the units and or wiring To avoid damage to the regulator do not at any time connect battery to the regulator field terminal The field circuit must never be grounded on this system between the alternator and the regulator Grounding of the field termina either at the alternator or regulator will damage the regulator If itis necessary to solder any lead to a rectifier lead use a pair of pliers as a heat dam between the solder joint and the rectifier The alternator must not be operated on open circuit with the rotor winding energized Do not attempt to polarize the alternator No polarization is required Any attempt to do so may result in damage to the alternator regulator or circuits Grounding of the alternator output terminal may damage the alternator and or circuit and components Reversed battery connections may damage the rectifiers wiring or other components of the charging system Battery polarity should be checked with a voltmeter before connecting the battery If a booster battery or fast charger is used
57. e sees eene eene nennen Page 39 SECTION 9 Engine Repair and Overhaul eese Page 47 SECTION 10 Trouble SOON sitios Page 67 SECTION 11 Torque Specifications note tr Page 71 Continental Industrial Engines METRIC ENGLISH METRIC ENGLISH No of Cylinders 3 3 4 4 Bore amp Stroke 91 x 103 2 3 58 x 4 06 91 x 103 2 3 58 x 4 06 Displacement 2 0L 123 CID 2 68 L 164 CID Compression Ratio 8 2 1 8 2 1 8 2 1 8 2 1 Max Oil pressure 2 8 4 1 Bar 40 60 PSI 2 8 4 1 Bar 40 60 PSI Min Oil Pressure Idling 0 5 Bar 7 PSI 0 5 Bar 7 PSI Firing Order 1 3 2 1 3 2 1 3 4 2 1 3 4 2 Main Brg Frt 73 x 23 8 2 88 x 94 73x 23 8 2 88 x 94 Main Brg Int 73 x 23 8 2 88 x 94 2 73 x 23 8 2 88 x 94 Main Brg Thrust 73x 31 8 2 88 x 1 25 73x 31 8 2 88 x 1 25 Main Brg Rear 73 x 23 8 2 88 x 94 73x 23 8 2 88 x 94 Conn Rod Brg 49 2 x 24 5 1 94 x 96 49 2 x 24 5 1 94 x 96 Oil Capacity Crankcase 4 73L 5 quarts 5 7L 6 quarts Filter 95 L 1 quart 95 L 1 quart Total 5 68 L 6 quarts 6 6 5 L 7 quarts Valve Clearance Intake 36 01 4 36 01 4 Exhaust 46 018 46 018 Water Capacity Engine 2 84L 3 quarts 3 6L 3 8 quarts Weight approx with accessories 227 kg 500 Ibs 243 kg 536 Ibs Spark Plug Gap 0 8 032 0 8 032
58. e clamp 4 Turn on the water and let it fill the radiator CAP CLOSED FLUSHING GUN aer WATER AIR NEW HOSE NEW HOSE Reverse Flushing Radiator 5 Apply air pressure gradually to avoid radiator damage 6 Shut off the air again fill the radiator with water and apply air pressure repeat until the flushing stream runs out clear 7 Clean and inspect radiator cap To Reverse flush the engine water Jacket 1 Remove the thermostat 2 Clamp the flushing gun in the upper hose 3 Partly close the water pump opening to fill the engine jacket with water before applying the air 4 Follow the same procedure outlined above for the radiator by alternately filling the water jacket with water and blowing it out with air 5 5 Bar 80 PSI until the flushing stream is clear FLUSHING GUN Reverse Flushing Engine TESTING THERMOSTAT Remove the water outlet elbow Before testing clean and examine the thermostat If the valve can be pulled or pushed off its seat with only a slight effort when cold or it does not seat properly the unit is defective and should be replaced The thermostatic operation can be checked in the following method 1 Hang thermostat by its frame in a container of water so that it does not touch the bottom 2 Heat the water slowly and check temperature with a thermometer 3 If the valve does not start to open at temperatures of 81 93 C 180 200 F or if it opens well b
59. e cylinder block or cylinder head 7 ENGINE LOAD INDICATION a manifold vacuum of 127mm 5 inches of Mercury indicates the recommended continuous full load operation and a vacuum of 460 500mm 18 20 inches of Mer cury indicates normal idling vacuum Between full COLD WEATHER OPERATION Battery condition is very important for proper star ting The oil used during cold weather should have a cold test below the lowest anticipated temperatures that will be encountered during its use The multigrade lubricating oils 5W 20 and 10W 30 are ideal for cold starting with its reduced initial drag until warmed up when they assume the characteristics of the heavier oil Sludge formation at low temperatures is a close second to dirt in causing engine damage and wear This is formed by the piston combustion gases mixing with the fine oil mist in the crankcase and condensing on a cold surface This condensation forms both a sulphuric and sulphurous acid which combines with the oil to become a highly injurious sludge This dew point is about 57 C 135 F when crankcase load and idling vacuum gauge readings may be used to approximate the percent loss Below 127mm 5 of Mercury indicates engine is overloaded for continuous duty 8 AVOID COLD SLUDGE CONDENSATION by protecting unit to maintain crankcase temperature over 57 C 135 F Use a proper temperature range thermostat and warm engine up thoroughly 9 BREAKING IN A NEW
60. e gradually therefore if the carburetor operated satisfactorily when last used it can reasonably be assumed that some other part of the engine is at fault which should be corrected before disturb ing the carburetor Dirt is the main enemy of good carburetion as it fills up the minute air and gasoline passages and accelerates the wear of delicate parts Never use a wire to clean out restriction in jets as this will destroy the accurate calibrations of these parts always use compressed air The jets are made of brass to prevent rust and corro sion and a wire would cut or ream the hole in the jet and ruin it Maintaining correct fuel level in the carburetor bowl is important as the fuel flow through the jets is naturally affected by the amount of fuel in the bowl After a carburetor has been in service for some time the holes in the jet and the float valve and seat become worn from the constant flow of fuel through them and should be overhauled by a com petent carburetor service station Do not experiment with other size jet or any so called fuel saving gadgets as your arrangement has been thoroughly tested on a dynamometer program DRAINING FUEL FROM CARBURETOR A WARNING Smoking or open flame should be avoided any time the fuel system is being repaired or serviced The area should be properly ventilated Improper handling of fuel could result in an explosion or fire causing bodily injury to yourself or others
61. e odes 18 Walter PUFT D css it de Ba ee So Le iE 19 SECTION 5 Fuel Systems Gravity FUSE SVSITGITY ALL di Goes Sii a a E e MOM tdi 21 Mechanical Fuel PUPITD eb aa a den Ack da raa AAS UR au E E RR lt 21 Elecincal Fue PUTID s suos ar Ron Rand er dca E dete aed d qutd AGI Dern aee x Grande GUN ee 22 RAL UNG OM tons 605 sai rt OTI TET D T LETTERE TUM 22 Teledyne Continental Carburetor cele s 22 Zenith GC ATDUFBIOP Lov OE al d PU a ea an ettari tds 23 GarDUFetor GhOKGS vacca o be and dr eor unt edi Ce Le ar DH iC ERA dabo a Ele vai rte 24 Draining Fuel from Carburetor oe ooo ira daa e CE 24 SECTION 6 Governors Checking and Adjusting Mechanical Governor Linkage 1 25 Cam Gear QOVOITIOE ss o eI RC pra RR UR dura mouse estre Doe wc e de ae RU pA Rar e e n i edet 25 Constant Speed Govea 26 Variable Speed Governor ecco ieee es ea rdv Ka e Ee a b ea ene RUE MN En 27 Hinged Lover GOVBITIOF oui Gone CS EDEN E E v Vane Rae eG oe a Raa Ree 27 Veloclly GOVEDO o en pda IS te Xe uolo d wee Bede uox RE cae od dra de Or a a 28 SECTION 7 Ignition System Electronic Ignition System D DR de leek it tw de oe us 29 Ignition System COMPONENTES isa A oes See WX EN uos e aera e Res 30 Distributor Maintenance iux 53 Alas amp ECC eod On Re do RIS NOI i RC dde el aa E 32 Spark PIUGS uxo bent iba r ID dieta da aera lig dre a a Ree idas 32 Distributor Ignition Timing With Timi
62. e threads in the block and on the cap screws have been properly cleaned Should these tapped holes need cleaning or recondition ing care should be taken to use the proper tap Tap M10 x 1 5 CLASS 6G M12 x 1 75 CLASS 6G 4 Using a chain hoist lower the cylinder head assembly evenly over the locator stud Replace 65 the locator stud with the proper cylinder head capscrew 5 The cylinder head capscrews require no sealant but should be installed with a light coating of engine oil or lubriplate to reduce fric tion and insure proper clamp load and head capscrew torque See torque chart on page 72 for proper torque and sequence Please reference SPB 90 391 CAUTION No substitution of cap screws should be made as these materials are heat treated Use only genuine Continental parts 6 Install the spark plugs at this point Having the plugs in now eliminates the risk of dirt and foreign objects falling into the cylinder INSTALLING OIL PAN Before assembling the oil pan make sure the contact surfaces are flat and clean of any gasket material or oil A form in place gasket material is used for seal ing the engine oil pan to the crankcase The form NOTES 1 Parts must be assembled within 20 minutes after applying gasket material 2 Caution must be used in handling the gasket materials Read Labels 2 0mm 080 dia bead of Form in Place gasket material applied to oil pan and filler block as shown This
63. ealed type and are packed with special lubrication for the life of the bearing The water pump requires no attention other than bearing replacement when it shows ex cessive looseness or if a water leak develops which shows a damaged or badly worn seal that needs replacement AN WARNING Corrosion inhibitor can cause damage to the eyes or skin If contact is made immediately wash skin with water For the eyes immediately flush the eyes with water for several minutes In either event seek prompt medical attention Read and observe safety warnings on pages 1 and 2 REMOVING WATER PUMP The water pump assembly can be removed from the engine as a unit for service or repair in the following manner 1 Drain coolant 2 Remove fan by taking out four cap screws 3 Loosen alternator so that fan belt can be slacked off enough to slide over pulley 4 Remove fasteners holding the pump body to the front of the block and remove the pump assembly yea Removin Water Bum DISASSEMBLY OF WATER PUMP When replacement of any internal parts becomes necessary disassembly must be in the following sequence in order to prevent damage to the pump 1 Use puller to remove the fan hub 11 from shaft 2 Remove countersunk screws 1 holding cover 2 removing cover and gasket 3 3 Use puller to remove impeller 4 taking precautions to prevent damage to the casting 4 Remove seal 5 and gasket 6 19 Dis
64. efore installing break edge C slightly on both cap and block to avoid cutting the seals during installation and coat seal edge E contacting the groove with sealing com pound NOTE This oil seal can be installed without remov ing the crankshaft in this case use only light grease in the seal groove to assist sliding the seal in place Apply pressure to the seal so that it will hug the crankshaft which will also help moving it in place 3 Apply a light coat of cement national oil seal or EC 847 to the butting ends of the crankshaft oil seal halves Allow to become tacky before assembling Lightly coat the crankshaft con tact edge of the seal with graphite grease to prevent damage prior to use 4 Install Crankshaft 5 Apply a light coating of RTV Gasket Material to surface B and graphite grease to the oil seal lip Carefully install the combination rear bear ing cap and filler block on to the dowels Insert the capscrews and torque to 150 162 Nm 110 120 Lb Ft 6 After the rear cap is in place and torqued in ject RTV into each side seal slot D as shown in illustration Force the RTV into the channels until a steady flow comes out the corner chamfers Installing RTV in Rear Filler Block NOTE Oil leakage will occur if any voids are left along these slots Filler Block and Seal 7 Dip the curing insert in clean water Force the insert into the RTV filled channel until it
65. efore the 81 C 180 F point is reached the thermostat should be replaced When replacing the thermostat in the water header be sure the counterbore is clean Thermostat Open 185 F Checking Thermostat When installing a new thermostat in the water header make sure that the temperature sensing unit goes in first or faces toward the cylinder head Installing Thermostat Installing New Gasket 18 Assemble new water outlet elbow mounting gasket Thermostat flange must seat in counter bore with gasket sealing contact between it and the outlet elbow RADIATOR PRESSURE CAP AN WARNING if the coolant is hot or if the engine has been running loosen the pressure cap to the first stop and let the pressure out of the cooling system before removing the radiator cap Read and observe safety warnings on pages 1 and 2 Many operations use a pressure cap on the radiator to prevent overflow loss of water during normal operation This spring loaded valve in the cap closes the outlet to the overflow pipe of the radiator and thus seals the system so that pressure developing within the system raises the boiling point of the coolant and allows higher temperatures without overflow loss from boiling Most pressure valves open at 0 3 or 1 0 Bar 4 1 2 or 15 PSI allowing steam and water to pass out the overflow pipe however the boiling point of the coolant at this pressure is 107 C 224 F or 120 C 248 F a
66. em never remove a unit until tests have shown it to be defective Reference always should be made to the manufacturers maintenance manuals for complete trouble shooting instructions 37 38 Section 8 Preventive Maintenance In order to obtain maximum efficiency from your gasoline engine a definite maintenance pro gram should be set up and followed Haphazard maintenance will only lead to faulty engine perfor mance and shorten engine life All moving parts in the engine are subject to wear however wear can be reduced by careful operation and a planned maintenance program In general gasoline engine operation demands careful attention to the cleanliness of air fuel and oil and maintaining coolant operating temperatures of 81 93 C 180 200 F The following pages covering Daily 50 250 and 500 hour maintenance have been worked out with our field service division as Minimum Re quirements to keep your engine in dependable operating condition DAILY PREVENTIVE MAINTENANCE SCHEDULE 1 OVERALL VISUAL INSPECTION OF ENGINE Look for evidence of fluid leaks on floor cylinder head and block indicating loose fuel oil or water connections tighten if found Check for Possible Leakage 2 CHECK OIL LEVEL OF ENGINE The dipstick indicates the high and low oil level in the crankcase make allowance for additional oil drainage back into oil pan if engine has not been stopped 15 m
67. etcher Creek Drive Memphis Tennessee 38133 Phone 901 371 0353 or Toll Free 800 932 2858 www wisconsinmotors com JUL 2006 LIT 10137
68. evious Instructions 2 CHANGE CRANKCASE OIL Engine life is dependent upon clean oil being circulated to all moving parts therefore the fre quency of oil changes and oil filter replacement is very important and should be made at regular scheduled periods The schedule for changing oil is directly depen dent upon the operational environment an ex tremely clean operation could go 150 hours while a dirty operation foundry or cement factory could be 50 hours or less Replace the oil filter element every time the oil is changed Thoroughly ciean the filter cover and sealing surfaces before replacing new element and gasket Do not put kerosene into the crankcase The best method is to drain the oil when the engine is thoroughly heated which will carry off most of the sediment Some operators unwisely put kerosene in the crankcase after draining the engine oil then turn the engine over with the starter in the belief they are doing a better job of crankcase cleaning In doing this kerosene is circulated through the oil pump the main oil header and the branches leading into the engine bearings thereby washing away the protective oil film In addition some of the kerosene will be trapped and remain to thin out the new oil reducing its lubricating qualities 42 3 SERVICE AIR CLEANER If oil bath air cleaner is used remove bottom half of air cleaner clean thoroughly and fill with engine oil to oil level m
69. f the engine warranty beyond the original term as set forth above All repairs qualifying under this Limited Warranty must be performed by Wisconsin or one of its authorized Distributors or Warranty Stations In the event that any engine is found to be defective during the warranty period the Purchaser shall notify Wisconsin or one of its authorized Distributors or Warranty Stations of any claimed defect within thirty 30 days after such defect is discovered The engine claimed to be defec tive must then be promptly delivered to an authorized Distributor or Warranty Station for inspection repair or replacement The Purchaser is responsible for all transportation charges in connection with any covered war ranty work In connection with a covered warranty repair or replacement Wisconsin may in its sole discretion assumere sponsibility for a portion of the labor necessaryf or removala nd reinstallation of an engine However the Purchaser shall be responsible for other labor charges not assumed by Wisconsin and for all labor charges and travel expenses incurred in connection with travel to and from Purchaser s location This Limited Warranty shall not apply to A Defective conditions caused in whole or in part by an engine which has in Wisconsin opinion been subjected to negligence in use misuse abuse improper installation or application improper maintenance or repair alteration repair or alteration by an unauthorized repair facility over
70. ftener can be used CLEANING COOLING SYSTEM Deposits of sludge scale and rust on the cool ing surfaces prevent normal heat transfer from the metal surfaces to the water and in time render the cooling system ineffective to properly main tain normal operating temperatures The ap pearance of rust in the radiator or coolant is a warning that the corrosion inhibitor has lost its ef fectiveness and should be cleaned before adding fresh coolant Dependable cleaning compounds should be used Follow the precedure recommended by the supplier This is of prime importance because dif ferent cleaners vary in concentration and chemical compositions After cleaning and flushing the system should be filled with an ap proved anti freeze compound containing a rust and corrosion inhibitor or water with a corrosion inhibitor REVERSE FLOW FLUSHING Whenever a cooling system is badly rustclogg ed as indicated by overflow loss or abnormally high operating temperatures corrective cleaning by reverse flow flushing will most effectively remove the heavy deposits of sludge rust and scale The reverse flow flushing should be per formed immediately after draining the cleaning solution It is advisable to flush the radiator first allowing the engine to cool as much as possible Reverse flush the radiator as follows 1 Disconnent the hoses at the engine 2 Put radiator cap on tight 3 Clamp the flushing gun in the lower hose with a hos
71. gage Power Take Off if equipped Starting engine under load throws overload on starter and battery 2 Open Throttle Control about 1 3 open 3 Turn on Ignition Switch 4 Pull Out Choke if manually operated But avoid flooding the engine Operate the engine without choking as soon after starting as possible E dle Power Take off 5 Push Starter Button In Keep on until engine Starts but not longer than 15 seconds at a time 6 Warm up Before Applying Load Idle the engine at 600 1000 R P M for a few minutes to cir culate and warm oil then increase the speed to approximately half throttle until the engine water reaches 100 F This procedure will prolong the engine life 7 Check Oil Pressure MODEL OIL PRESSURE TM 2 8 4 1 Bar 40 60 PSI Higher oil pressure may be experienced during cold starts 8 Check Water Temperature See Instrument Panel Typical Instrument Panel 9 Check Ignition Timing refer to pages 33 and 34 Distributor Ignition Timing 10 CAUTION After starting new engine run it at idle for 5 minutes then stop engine and recheck oil level in crankcase then bring oil level to high mark on dipstick IMPORTANT Breaking in a new or rebuilt engine for peak performance and economical operation the following adjustments should be made at end of first 50 hrs operation 1 Torque down cylinder head cap screws to specification 2 Adiust valve tappets
72. ggested Oil and Filter Change Intervals page 14 Please reference SPB 82 328 13 LUBRICATION RECOMMENDATIONS Motor oils used for internal combustion engine lubrication perform many useful functions in cluding Dissipating heat sealing piston rings preventing metal to metal contact wear and reducing power loss through friction The lubricating oil recommendation is based upon engine design type of service and the at mospheric temperature prevailing High quality oils are required to assure maximum perfor mance long engine life and minimum cost of operation Continental industrial engines operate in a wide range of service conditions and seasonal temperatures so our recommendations are given for various types of service and ambient temperatures LUBRICANT DESIGNATIONS We recommend using oil described below for all Continental industrial applications Gasoline LPG Natural Gas API SAE Fuel Type ASTM Classification Gasoline SE SF SE CD SF CD LPG Natural SE SF SE CD SF CD Gas Service typical of industrial gasoline engines operating under engine manufacturer s warran ties Oils designed for this service provide more protection against oil oxidation high temperature engine deposits rust and corrosion in gasoline engines than oils which are satisfactory for API Engine Service Classifications SD or SC S A E OIL BODY GRADES The oil grades available from the lightest SAE 5W to the heavies
73. he information specifications and illustrations in this book are on the basis of information available at the time it was written The specifications torques pressures of operation measurements adjustments illustrations and other items can change at any time These changes can effect the service given to the product Get the complete and most current information before you start any job Continental Distributors Dealers have the most current information which is available For a list of current Distributors Dealers refer to directory LIT101 7 or www wiscosninmotors com N WARNING Most sub systems used in conjunction with Wisconsin Motors LLC industrial engines including but not lim ited to radiators hoses fans fuel tanks fuel lines or other fuel systems components hydraulic pumps and generators are not supplied by Wisconsin Motors LLC but are provided by the manufacturer of the end item in which the engine is used Some of the dangers assoicatied with servicing such items are generally mentioned in this manual however the appropriate handbooks and safety instructions procided by the manufactureer of the end item should always be consulted prior to undertaking any work on sub systems attached to the engine to avoid any hazards inherent to these sub systems N WARNING Read and observe all individual safety warnings as you use this manual to operate service or repair your engine Always exercise caution whenever worki
74. ia Wear Limits Max Dia VALVES INTAKE Stem Dia Wear Limits Min Dia Seat Angle Stem Clearance Limits Wear Limits Max CI Desired Stem Clear VALVES EXHAUST Stem Dia Wear Limits Min Dia Seat Angle Stem Clearance Limits Wear Limits Max Cl Desired Stem Clear VALVE SPRINGS Outside Dia Length Valve Closed Load Valve Closed Wear Limits Min Wgt Length Vaive open Load Valve open Wear Limits Min Wgt shown are for TM METRIC 60 4 16 700 16 675 8 717 8 692 8 775 8 660 8 635 8 585 29 45 0 082 0 032 0 132 0 056 8 640 8 615 8 565 44 45 0 102 0 052 0 152 0 076 34 85 42 0 24KgF 21 5KgF 32 88 47 54KgF 42 5KgF ENGLISH 2 3 8 6575 6565 3432 3422 3447 3409 3400 3380 29 45 0032 0012 0052 0022 3402 3392 3372 44 45 0040 0020 0060 0030 1 372 1 6535 52 8 47 34 1 294 104 6 93 5 standard engines ENGINE MODEL CAMSHAFT Brg Journal Dia 1 2 3 Wear Limits Min Dia Bore Inside Dia 1 82 43 Bore Clearance Limits End Play CONNECTING RODS Bush Hote Dia Brg Hole Dia Brg Thickness Wear Limits Min Thk Dia Crank Pin Wear Limits Min Dia Clearance Limits Disired Clearance Wear Limits Max CI Side Play Desired Side Play MAIN BEARINGS Dia of Brg Bore in Block Brg Thicknes
75. ibutor points start to open when ft cylinder is on compression stroke and the flywheel mark 2 BTDC Before Top Dead Center and 5 BTDC for LPG engines lines up with the pointer in the bell housing or crankshaft pulley NOTE Some special units have different ignition timing Check your specification for correct tim ing A A CAUTION Before ignition timing can be checked or adjusted remove the vacuum advance line at the distributor and clamp the rubber tube leading to the intake manifold After setting the timing remove the clamp and reconnect the rubber tube to the vacuum advance unit on the distributor To ensure proper operation the diaphragm in the vacuum advance unit and the line to the manifold should be checked periodically for leakage If the diaphragm is ruptured the vacuum advance hous ing and linkage must be replaced There are two methods of checking ignition tim ing with or without a timing light The preferred method is to use a timing light in the following sequence Paint a line on the flywheel or in some cases on the front pulley so the timing mark will be more legible under the timing light Please see BLUE T ent SPB 67 368 NE a BLACK 33 AN WARNING Disconnect fan before timing engine to avoid personal injury Do not hold igntion wires with bare hands since shocks or other injuries can result Sparks or flames near a bat tery could cause an explosion or fire Battery acid c
76. if the intervals are usually long that it be shut down Governor Lever This may vary with the application STOPPING THE ENGINE 1 Disengage Power Take Off 2 Reduce engine Speed to Idle if hot run engine at idle for several minutes to cool 3 Turn off ignition Switch If engine continues to run due to high combustion chamber temperatures either continue idling to further cool or shut off fuel supply CAUTION NEVER PULL OUT CHOKE WHEN STOPPING ENGINE BECAUSE RAW GASOLINE WILL WASH LUBRICANT FROM CYLINDER WALLS 11 MUSTS FOR YOUR ENGINES 1 OIL PRESSURE should be up to recommended pressure at operating speed and over 0 5 Bar 7 PSI at idle 400 600 R P M and 800 1000 R P M on the 2 cylinder engine 2 AMMETER should register Charging at all times engine is running A voltage regulator may limit it to a very low reading 3 WATER TEMPERATURE normal operation 81 C 96 C 178 205 F pressure cap determines higher temperatures Overheating is detected by loss of coolant FREQUENT READINGS OF GAUGE SHOULD BECOME A HABIT 4 MUFFLER RESTRICTION should not exceed 508mm 20 water or 38mm 1 1 2 Mercury In spect mufflers periodically for restrictions to pre vent burned valves 5 CLEAN AND SERVICE AIR CLEANER as recommended to maintain its efficiency 6 WHEN ENGINE IS OVERHEATED do not add water allow engine to cool so as to prevent cracking th
77. imes with the ignition off If gas spurts from the pump or open end of the line the pump gas line and tank are OK Checking Fuel Flow If there is little or no Flow check the follow ing 1 Look for leaky diaphragm cover gasket or line connections tighten them 2 Look for clogged fuel line Blow out with compressed air 3 Make sure that all pump cover screws and ex ternal plugs are tight 4 Inspect flexible fuel line for deterioration leaks chafing kinks or cracks If none of these items restore proper flow remove the pump for replacement or overhaul If getting too much gas an oversupply of gasoline is generally caused by trouble other than the fuel pump so first check the following 1 Excessive use of hand choke Loosely connected fuel line or loose car buretor assembly screws 3 Punctured carburetor float 4 Defective carburetor needle valve 5 Improper carburetor adjustment If none of these items corrects flooding remove the fuel pump for replacement or overhaul m ELECTRIC FUEL PUMP Many Continental industrial engines use elec tric fuel pumps operated from the storage battery supply The pump should be mounted close to the fuel tank so as to provide fuel pressure at all points along the fuel line and so eliminate vapor lock The electric fuel pump is energized in the igni tion circuit which assures quick filling of car buretor and fuel line to effect easy starti
78. in two parts Pivoted on a pivot bolt it is spring loaded to hold the arm in a Straight posi tion except when low idle is desired When carburetor lever is forced to idle position by speed control lever this in turn pivots top half of governor arm forward On some models a small coil spring loaded throttle lever and shaft on the carburetor is used to get idle position VELOCITY GOVERNORS BN NGI fe Extreme caution must be exercised when making gover nor adjustments to avoid personal injury due to fan blades belts and hot manifolds Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 28 and a main governor spring The main governor spring is attached by linkage to the governor shaft and the spring force holds the throttle valve open When the engine is started air flows through the carburetor throat and the governor throat The velocity of the air creates a pressure above the throttle valve When thiS pressure exceeds the force exerted by the spring the throttle will move toward a closed position The adjusting screw va
79. inental engines since years of development and testing have gone into these specifications to assure maximum life and performance CYLINDER HEAD The cylinder head is an important part of the engine assembly since it contains the combus tion chamber valves and cored passages for air exhaust and water flow REMOVING THE CYLINDER HEAD 1 Drain water from engine and disconnect radiator or heat exchanger hoses 2 Remove cylinder head cover by removing the capscrews holding the cover to the cylinder head 3 Remove rocker arm shaft assembly and push rods Grip the push rods and snap them sideways out of the tappet sockets as shown in the illustra tion This method serves to break the hydraulic connection and permits lifting the push rods out and leaving the tappets in place Removing Push Rod from Ball Socket of Tappet Section 9 Engine Repair and Overhaul CAUTION Make a sketch showing the proper location of the cylinder head cap screws for use at reassembly 4 Loosen and remove the capscrews holding the cylinder head to the block 5 Lift the cylinder head off the engine and carry to a clean bench for further disassembly DISASSEMBLY OF CYLINDER HEAD 1 Remove al carbon from combustion areas using scraper and wire brush 2 Using a C type valve spring compressor remove the valve spring retainer locks retainers rotors springs and oil guards on valve stems placing all parts in a container
80. ing Diagram Delco 10SI MC ALTERNATOR amp REGULATOR BATTERY 12V 8 0 CABLE Delco 1081 Series MCI Cypr IEEE GN SW AMMETER A Seren ER Y SWITCH SOLENOID SW E LS 10 WIRE BLACK ame 0 CABLE BATTERY Wiring Diagram Prestolite ALTERNATOR VOLTAGE REGULATOR ATTACHED 35 A WARNING The charging circuit consists primarily of an alternator regulator battery and wiring When analyzing the charging circuit the components should be checked in the following order Wiring Wiring in the charging circuit should be care fully inspected for frayed insulation or other damage and replace any wiring that is defec tive Also inspect all connections to the alter nator regulator and battery including all ground connections and clean and tighten as required Battery The lead acid storage battery used on automotive and industrial applications is an electrochemical device for converting chemical energy into electrical energy It has three major functions 1 lt provides a source of current for starting the engine 2 lt acts as a stabilizer to the voltage in the electrical system 3 It can for a limited time furnish current when the electrical demands of the unit ex ceed the output of the generator Stop engine before checking battery terminals or elec trical connections Do not hold ignition wires with bare hands since shocks
81. inutes The most efficient oil level is between the two dipstick levels IMPORTANT Do not add oil until oil level ap proaches the low mark then add only enough to bring it to high level NEVER above Do not operate the engine with oil below low level mark SF Check Oil quem Engine 3 CHECK RADIATOR Fill radiator with clean water or anti freeze to normal level maintained due to expansion when heated Visually inspect fan and belt for condition and adjustment 4 FILL FUEL TANK Fill fuel tank at end of each day s operation to prevent condensation forming in tank Clean filler cap and area round spout before filling to prevent entrance of dust into fuel system 5 CHECK AIR CLEANER All engines when operating consume several thousand cubic feet of air per hour Since dusty air is full of abrasive matter the engine will soon wear excessively if the air cleaner does not remove the dust before entering the cylinders On any air cleaner operating environment dic tates the air cleaner service periods In extremely dusty operations this may be once or twice daily In dust protected areas the air cleaner should be serviced when changing oil Two basic types of air cleaners are normally used the oil bath type and the dry replaceable element type 39 OIL BATH AIR CLEANER The oil bath air cleaner must be given close and frequent attention The efficiency of an oil bath cleaner is very closely linked
82. l ANWARNING Stop engine before checking battery terminals or elec trical connections Do not hold ignition wires with bare hands since shocks or other injuries can result Sparks or flames near a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 Ignition coils can be tested for grounded wind ings by placing one end of the test probe on a clean part of the metal outer shell and touching the other end of the test probe to the primary and high voltage terminals If tiny sparks appear at the points of contact the windings are grounded If the coil is further suspected of being faulty remove and check its operation on a coil tester and replace it if inoperative Most coil testers compare the operation of the coil being tested with one known to be in good condition This test should be made with the coils at room temperature and then warming the coils five minutes by connecting the primary to a battery of the same voltage rating as the coils Re check the comparison test to see if the expansion due to heating has caused some defect The ignition coil center tower rubber Boot should always be replaced when a new coil is in stalled Carbonized tracks in the rubber Boot form when a coil fails due t
83. lu s are to be used only if Torque Value for specific part to be installed is not listed on preceding sheets TORQUE Phosphate Coated Fasteners EE Nm LBFT Nm LBFT e 41 ee air 68 Ma 2024 1518 2024 1518 34 40 25 30 2530 7581 55 60 122 135 90 100 90 100 190 203 140 150 190 203 A E ee ee ae BOLTS AND SCREWS PROPERTY CLASS MARKING IDENTIFICATION SYMBOL The property class symbols for metric bolts and ES STUS screws are given in table at right Marking shall be BOLTS SCREWS SMALLER located on the top of the head Alternatively the AND STUDS THAN M12 marking may be indented on the side of the head for hex head products STUDS All metric studs used are of property class 10 9 If marked marking will be at nut end Cold Torquing Procedure Step 1 Torque with Hand Torque Wrench to TORQUE SEQUENCE TM20 M 10 Mi2 Hot Retorquing Procedure TM27 Step 4 Retorque with Hand Torque Wrench after engine reaches normal 5 operating temperature to the following values in one single smooth motion M10 a NOTE SH Socket Head Cap Screw HH Hex Head Cap Screw Torque all cylinder head capscrews using the proper torquing sequence shown here 72 Section 12 Limits and Clearance Data NOTE Dimensions ENGINE MODEL VALVE GUIDE Intake amp Exhaust Length Outside Dia Stem Hole D
84. n enough so that new bearings wil not fit with the required clearance it should be removed and reground Standard crankshafts may be reground to decrease the diameter a maximum of 1 0mm 040 Before shaft is reground it must be checked for straightness and straightened if necessary to be within 0 05mm 002 indicator reading When reground the fillet radii must be within dimen sional limits and must be perfectly blended into thrust and bearing surfaces The crankshaft must be nitempered after regrinding AVOID SHARP 4 INSUFFICIENT CORNERS 4 FILLET 2 8R 11 on all crankpins 3 0R 12 on all mains Crankshaft Fillet Radii Replacing Bearing 59 CAMSHAFT 1 Remove the screws holding the camshaft thrust plate to the front of the cylinder block which makes it possible to pull the camshaft for ward out of the bearings 2 Before removing the camshaft completely check the clearance of the bearing journals in the block To do this use strips of feeler stock 6mm 1 4 wide with edges dressed with a stone to eliminate any burrs or feathered edges If clearance is equal to or greater than the amount indicated under wear limits check the diameter of the camshaft journals to determine the next step Excess wear at these positions re quire replacement of the shaft 3 Tappets can then be lifted out and lined up in sequence for installation in the same location unless inspection shows that they req
85. n locating trouble is to never make more than one adjustment at a time then locate the trouble by a process of elimination Remember the cause is usually Simple rather than mysterious and comp licated Following are listed some of the normal com plaints encountered in routine operation of all gasoline engines and the probable causes A STARTING MOTOR WILL NOT CRANK ENGINE 1 Weak or dead battery 2 Poor ground connection 3 Faulty starting switch or relay 4 Defective starting motor 5 Internal engine seizure turn engine manually to determine cause B ENGINE CRANKS BUT DOES NOT START Disconnect one spark plug wire turn ignition on with starter cranking engine and free end of wire 3mm 1 8 from cylinder head note spark A WARNING Do not hold igntion wires with bare hands since shocks or other injuries can result Sparks or flames near a bat tery could cause an explosion or fire Battery acid can cause Corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufacturers safety instructions Read and observe safety warnings on pages 1 and 2 1 NO SPARK A If Ammeter Shows No Discharge it in dicates an open primary circuit due to 1 Open primary wires 2 Defective ignition switch 3 Faulty coil B Normal Ammeter Reading Discharge 2 5 amps this indic
86. nd safety instructions of the manufac turer of the natural gas or LPG system BEFORE under taking any work on such system or before any work is begun on the engine or engine sub systems requiring engine operation a a rn a a CAUTION Prior to the use of gasohol fuel contact the engine manufacturer em TRE Section 6 Governors GOVERNORS The governor is a device which controls engine speed either keeping it operating at a constant speed or preventing it from exceeding a predeter mined speed Continental industrial engines use many types of velocity and centrifugal governors however the majority use centrifugal Mechanical governors CHECKING AND ADJUSTING MECHANICAL GOVERNOR LINKAGE The following is a step by step procedure to follow in checking and adjusting the governor linkage 1 With the engine stopped and spring tension about normal the governor should hold the throttle in the open position The governor to carburetor control rod should be adjusted in length so the throttle stop lever is 0 4 0 8mm 1 64 to 1 32 off the stop pin 2 Make certain that all linkage Is free with spr ing at Operating tension Disconnect the gover nor spring and check movement of levers and rods 3 The hinged lever governor eliminates the need for a spring loaded throttle lever on the carburetor As the carburetor lever is forced to idle position by the speed control lever this in turn pivots the top half of
87. ng When fuel pump trouble is suspected discon nect the fuel line at the carburetor and turn on the ignition switch Pump fuel into a small container 22 then place your finger on the outlet side of the fuel line If the pump stops or ticks very infre quently the pump and fuel line connections are satisfactory Remove your finger from the outlet side of the fuel line and if ample fuel flows the pump is satisfactory If fuel does not flow and all connections are tight the pump should be replaced or repaired Always be sure of a good ground and check for faulty flexible fuel lines and poor electrical con nections CARBURETOR Continental industrial gasoline engines use various models of carburetors The carburetor mixes fuel with air and meters the mixture into the engine as the power is demanded Most carburetors incorporate the following systems to provide the flexibility and sensitive requirements of varying loads and con ditions 1 Float System Controls the level and sup ply of fuel 2 Idle or Low Speed Furnishes the proper mixture for the engine idle light load and slow speeds until the main metering system func tions 3 Main Metering System Controls the fuel mixture from part throttle operation to wide open throttle 4 Power or Economizer Systems op tional Provides a richer mixture for max imum power and high speed operation and a leaner mixture for part throttle operation
88. ng Light 4 80 33 Distributor Ignition Timing Without Timing Light 80 34 Charging Ric liar da AA chili Vale nude 35 SECTION 8 Preventive Maintenance Daily Preventive Maintenance Schedule ec eee ns 39 On Bath Air CISNE pde d X ESQ pad e essit adm Vra e to des 40 Dry Type Replaceable Air Filter us NS sun cea WR ed UE IDEE EC ee EY E NOE OE E dae dao 40 PW OY SLO srad s ee eae see ee Gale aa ee eb EDS a O Co hdi 41 50 Hour Preventive Maintenance Schedule 42 250 Hour Preventive Maintenance Schedule 43 500 Hour Preventive Maintenance Schedule 44 SECTION 9 Engine Repair and Overhaul Cylinder HO Adra ds Ae ace a wes Se e to ON PSS due 47 Valve GUIDES itia dal ad ess al A DAS pa 48 Valve Seat Inserts aida A A A AAA AE 48 Valve Guide Data uz sd A A AA AS RR AA AAA A 49 MANS carcasa dao ir ia dos Ec PET PIE 50 Valve SDIIngs 22822 eee cates ARR ne AE Va a A IA AA 51 ROCKET AIMS sita ba A dass GA cn de dia a da De 52 Valve Push ROOS uud iie di A a AA EA EA 52 Checking Bore Weal misa ted desuper ac Ub ope ACAD Mel nee 52 Preparing Cylinder Walls for Re Ringing or Re Boring 52 PISOS Dia ua uai Bane ao n scd Gee bo do a A aet ddr acd ls addons dioi 54 PISLIOIT PINS aia e Us dede aea
89. ng under load Locate by shorting out plugs on both sides of the bad bearing 2 Crankshaft End Play excessive end play is indicated by an intermittent knock which will come and go when the load is released and engaged B Connecting Rod Bearings 1 Worn or Burned out Bearings The worst condition a light pound or metallic knock is noted at idling and to about 2 3 maximum NOTES speed Bad bearings can be determined by shorting out plugs C Pistons and Wrist Pins 1 Loose Wrist Pins noise doubles when the correct plug is shorted out most noticeable at idling speed 2 Piston Loose in Cylinder Piston Slap is noted by metallic knocking at low speed under load but disappears at high speed also most noticeable when starting cold test by shorting out plugs D Broken Piston Ring or Pin Sharp clicking noise that won t short out E Valves 1 Burned Valves and Seats or Bent Push Rods engine misses especially at low speeds or acceleration under load 2 Weak or Broken Valve Springs missing at low or high speeds when under load 3 Sticking Valves loss of power and pop ping sound when bad 4 Tappet noise excessive clearances cause noise when cold which diminishes at normal operating temperature 5 Bent Push Rods engine misses at all speeds and loads excessive tappet noise F Camshaft Noise due to loose journals or end play usually occurs
90. ng with an engine or any associated system Injuries may be caused by lack of care when working with or near moving parts hot parts pressurized systems electrical equipment or fuel systems Always wear eye and hearing protection when working on or near engines Improper attire such as loose clothing ties rings soft shoes or bare feet could be hazardous and should be avoided when servicing engines Use or service of the engine including the use of modified parts or materials not in accordance with manufacturer s specifications could damage your engine or cause personal injury N WARNING Starting fluids or aids such as ether or gasoline must not be used in a diesel engine air intake system The use of these fluids will cause severe internal engine damage and or bodily injury N WARNING Some equipment and materials used in the overhaul or maintenance of an engine such as machine tools electrical equipment compressed air solvents diesel gasoline or other fuels may be dangerous and can cause injury Always observe safety precautions associated with these items CONTENTS CONTINENTAL INDUSTRIAL ENGINES SECTION 1 General Information nadia Page 5 SECTION 2 Operating Instructions iii Page 7 SECTION 3 PAID TAC ALON iaa ias Page 13 SECTION 4 COOMNE SV SUC WN ici is Page 15 SECTION 5 FUESE a In er Page 21 SECTION 6 COVE Sa Page 25 SECTION 7 Ignition SYSTEMS a Page 29 SECTION 8 Preventive Maintenanc
91. ning characteristics to provide depen dable and economical heavy duty service Some of the principal design features are 1 Individual Porting of the intake manifold whereby each cylinder is fed with the fuel air mix ture individually and not influenced by other cylinders of the engine This is accomplished by casting the cylinder head with individual intake valve passages for each cylinder and connecting these passages to an intake manifold which also has individualized passages for each cylinder This equal distribution results in maximum power smooth operation easy starting and longer engine life 2 Water Jackets completely surround all cylinder bores to a depth sufficient to cover the hot piston ring travel resulting in minimum bore distortion for good oil control yet maintaining low heat rejection to the coolant CHOICE OF FUELS Continental Industrial Engines have been tailored for heavy duty opera tion for use with gasoline LPG natural gas and non leaded fuels that meet a minimum octane of 85 motor method OHV Design Individual Porting Oil Filler Ca All Metric Fasteners Oil Guard Jr Valve Spring Positive Rotation Standard on Exhaust A eer Head Cover Rocker Arm TI RAS TES CT OVE D Resistor Type Spark Plugs and Solid State Ignition IN NO Ay an ay 7 ULM VT Br TE se ns We uu 3 ee Ee x WA TE Intake Valve Cylinder Head Chrome Top A
92. o a burned tower and if the rubber boot is not replaced early failure of the new coil can be expected When the ignition coil is wired up incorrectly with the distributor it can cause high speed miss ing loss of power and performance under heavy loads Distributor The distributor conducts and in terrupts the current through the primary winding of the ignition coil at the correct time and distributes the high tension voltage to the correct spark plug There are two separate electrical circuits in a distributor The sensor and trigger wheel device are in the primary circuit and carry low voltage current while the cap and rotor are in the secondary circuit and carry the high voltage spark current Rotor Leads to Coil Mechanical Advance Drive Shaft Cutaway View of Distributor The triggering system is mounted on a plate in the top part of the distributor housing The rotor is mounted above the triggering system and turns with it to make a connection between the cap center contact and various side contacts Continental industrial engines have distributors equipped with a mechanical advance which varies the timing by advancing the breaker cam as the engine speed increases This mechanism consists of weighted levers which revolve with the distributor rotor and act against a set of springs As the speed of rotation increases the weights are moved out and the timing is ad vanced With this arrangement it is
93. of solvent Removing Valve Springs 3 Remove the valves and place them in order in a rack with holes numbered for both intake and exhaust so they will not be mixed in handling Valves in Rack 47 4 Clean the cylinder head thoroughly with a solvent or degreasing solution and blow it off with air pressure Inspect carefully for cracks VALVE GUIDES 1 Clean the valve stem guides removing lac quer or other deposits Do not use tools that remove metal 2 Check guides for wear by using a telescope gage and 1 micrometer Replace all guides that are worn bell mouthed or have increased 0 038mm 0015 in diameter See Limits and Clearance Sec tion 12 and Valve Guide Data page 49 for max imum diameter permissible to determine actual amount it has increased Remove all valve guides when necessary by pressing them out from the combustion chamber side 3 Replace worn guides as required by pressing in new guides to the correct depth as given in the Section 12 limits and clearance data and valve guide data page 49 Removing Valve Guides from Combustion Chamber Side CAUTION When replacing guides do not ream since these are all pre reamed before being ferrox coated any further reaming will remove the coating VALVE SEAT INSERTS IF SUPPLIED 1 The exhaust valve seat insert is held in place by a shrink fit Inspect all exhaust valve inserts in the head and replace any that are loose cracked or otherwi
94. or other injuries can result Sparks or flames near a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 Refer to equipment manufacturer for battery recommendations Alternator The alternator differs from the conventional D C shunt generator in that the armature is the stationary member and is called the stator while the field is the rotating member and is called the rotor Alternating current is rectified changed to direct current by means of diode rectifiers rather than mechanically with brushes coming into contact with the various segments of the rotating armature on the generator With this construction the higher current values involved in the armature or stator may be conducted to the external circuit through fixed leads and connections rather than through the rotating commutator and brushes as in D C generator The comparative ly small values of current supplied to the field may be conducted without difficulty through small brushes and rotating slip rings The alternator is somewhat lighter and more compact in design than the conventional D C generator of comparable electrical size and is equally as simple to service and test Each bearing is prelubricated which eliminates the need for perio
95. orn badly they must be replaced Examine the pick up screen for clogging or damage impeller inner Impeller Outer Body N SE po dicil Oe P 2l 9 Sa LD Md A Plunger Spring TN ep N Cap N e E Note Refer to Service Bulletin 88 379 issued October 1988 62 O jw TN e Aet b eee Current Oil Pump ze O ring at pump inlet Examine the O Ring at the pump inlet lf dam aged replace Engine oil pressure must be maintained to specification for satisfactory engine life The oil pump must be fully seated in the counterbore No gaskets are used in this assembly see note for later model oil pumps Install mounting capscrews and tighten to 20 24 Nm 15 18 Lb Ft 1 Timing gears should be inspected for ex cessive wear and or pitting and replaced if necessary 2 Examine the camshaft thrust plate carefully for scoring and wear and if any indication of either shows a new thrust plate should be assembled Camshaft Thrust Plate 3 Assemble the cam gear to the camshaft by driving or pressing it on at the same time holding the camshaft forward with a suitable bar through the fuel pump opening in the block so there is no possibility of the camshaft bumping the expan sion plug at the rear end and forcing it out of posi tion thus causing an oil leak CAUTION NEVER USE THE CAMSHAFT NUT TO PRESS THE GEAR ONTO THE CAMSHAFT This will bre
96. overnor mounted on the left hand side of the engine driven from the front end gear train Linkage from the governor thru a cross shaft controls the carburetor Adjustments The desired engine speed is obtained by increasing or decreasing the gover nor spring tension 1 Start the engine Warm up 2 With engine warmed up adjust high no load speed approximately 150 R P M higher than the required speed under load by turning screw A in or out thus either increasing or decreasing ten sion on the spring 3 Apply the desired load and readjust screw A in order to obtain the required speed under load Release load and note R P M at which engine set tles out Constant Speed Governor Again apply load and observe the drop in R P M before governor opens throttle to compensate 4 The range of governor s action is indicated by the differential between R P M under load and that under no load This can be varied and the sensitivity of governor changed by changing the length of screw B 5 T broaden the range of the governor and pro duce a more stable action lengthen screw B and compensate for this change by turning screw A in to restore speed 6 To narrow the range and increase the sensitivi ty of the governor reverse procedure outlined in 5 Changing the length of screw B has the same effect as using a stronger or weaker spring 7 With the governor adjusted for desired perfor mance release the load
97. possible to have a retarded spark for idling and obtain a 31 gradual advance in spark timing as the engine speed is increased The ignition system also features vacuum ad vance for optimum part throttle economy With this system spark timing is not only adjusted for the rotating speed but also for the load applied to the engine As load is decreased timing is ad vanced and as load in increased timing is retard ed until only the mechanical advance is used DISTRIBUTOR MAINTENANCE The distributor operation is vital to the operation of the engine and the following items should be carefully in spected every 250 hours of normal operation however dirt dust water and high speed opera tion may cause more rapid wear and necessitate more frequent inspections 1 Remove Distributor Cap Clean cap and examine for cracks carbon runners corroded terminals or if the vertical faces of the inserts are burned if found install a new cap If the horizontal faces of the inserts are burned replace the cap and rotor as this is due to the rotor being too short 2 Check Mechanical Advance Mechanism for freeness by turning the breaker cam in the direction of rotation and then releasing it The advance springs should return the cam to its original position 3 To ensure proper operation the diaphragm in the vacuum advance unit and the line to the manifold should be checked periodically for leakage tf the diaphragm is r
98. protector whenever air hoses are used Never use air pressure that is more than 2 Bar 30 pounds per square inch and make sure the air line is equipped with a water filter to prevent damage to parts Read and observe safety warnings on pages 1 and 2 Cartridge can be cleaned best by blowing com pressed air from inside out Do not apply air closer than 50mm 2 and don t use more than 2 Bar 30 PSI pressure CAUTION Do not damage gasket surface or bend outer screen Wipe inside screen cartridge gasket surface inside cover and mounting seat before installing element Place cartridge on mounting seat make sure outer edge of cartridge fits inside edge of bottom plate Replace cover and assemble wing bolt finger tight to insure air filter seal CAUTION Do not wash or oil cartridge Replacing New Cartridge Replace immediately if bent crushed or dam aged Dry type air cleaners are efficient only as long as top and bottom sealing edges are not damaged Also surface of air cleaner base and cover where air cleaner cartridge seals must be clean and not damaged such as dents or bends Often in cleaning the cartridge it is tapped against surfaces that are not flat thus damaging sealing edges Regardless of how clean the paper is if edges are damaged dirt will enter the engine The element should be replaced every 250 hours or when servicing does not result in full power recovery whichever occurs first
99. put your thumb over the spark plug hole and crank engine by hand until air is exhausting 2 Set piston at 2 BTDC 5 BTDC for LPG engines by slowly cranking until correct mark on flywheel or crankshaft pulley will line up with the pointer in bell housing or gear cover CAUTION When engine specifications have special timing other than 2 BTDC Before Top Dead Center they must be followed in order to obtain satisfactory service in special applications or higher altitudes 3 Loosen the distributor clamp bolt and install a test lamp on the two coil terminals rotate the distributor until the light is extinguished then clamp the distributor in place Crank Pulley Timing Mark CHARGING CIRCUIT MURRAY SAFETY SAT TE TO TO WATE Temperan ee f 1 Gu Lia E TO gt gt Oral ti EE Ka ITION der SOC an pa en PREMSURE m B e 119 i Y HOT NOTES l ALL WESS did Aude UN rt NOTE Z ro it ITERA RUE 60 3 TUD Cubes Talar ALL OF TIO Ca CERTAAJ UNITS MA BR DELETEO B CUSTOMS AMMETER ripest a Ee fugite ec ARC STEAM T RECIEN 2 Power Unit Wiring Diagram C gt gt IGNITION SWITCH uz So NOTE 14 WIRE IS RED AND 10 WIRE IS BLACK TO COIL i 8 14 WIR AMMETER FIELD 4 STARTER SWITCH BATTERY 4 10 WIRE 14 WIRE 3 7 o D STARTER amp SOLENOID RECTIFIER AR HO CABLE asse jn E goos f E O a TN Wir
100. r a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 1 ELECTRICAL SYSTEM A Battery replenish water and test for condition and state of charge Replace if required B Wiring check battery cables connections and other wiring Be sure connections are clean and tight and that cables and wiring insulation are in good condition C Alternator and regulator run the engine and check the ammeter to be sure the alternator is charging and the regulator is functioning pro perly Check and adjust alternator belt tension D The standard overhead valve engine uses solid state ignition with no points to clean or adjust Clean regap or replace spark plugs as required Check ignition harness for loose connections and frayed insulation repairing or replacing as required Check and clean the inside and outside of the distributor cap Remove the high tension lead from the coil tower and clean the coil tower Be sure all weather protective rubber caps are in good condition and firmly in place 2 COOLING SYSTEM A WARNING If the coolant is hot or if the engine has been running loosen the pressure cap to the first stop and let the pressure out of the cooling system before removing the radiator cap Read
101. r bowl 10 Replace All Spark Plugs 11 Seal Air Cleaner Inlet Exhaust Outlet with weather proof adhesive tape 12 Check Oil Filler Cap Gas Tank Cap and Radiator Cap to make certain they are securely in place Note If Mil L21260 No 30 oil is available substitute in Steps 2 and 5 SHORT TERM STORAGE 30 TO 90 DAYS If the shut down period is to be over 30 days duration the following instructions should be adhered to 1 Stop engine remove spark plugs 2 Pour approximately 90 grams 3 ounces clean engine oil in each spark plug hole 3 With ignition cut off crank engine with starter at least a dozen revolutions to distribute this oil over the cylinder walls and valve mechanism 4 Replace all spark plugs 5 Remove drain plug from carburetor bowl and drain fuel 6 Replace drain plugs Caution Gasoline evaporates if left in carburetor for long periods This evaporation of gasoline will leave a gum and varnish coating over jets and moving parts when engine is started up again you may have flooding or poor operation from car buretor NOTES 12 Section 3 Lubrication ENGINE LUBRICATION SYSTEM Continental Industrial engines have full pressure lubrication to all main connecting rod and camshaft bearings as well as rocker arms and timing gears Tappets are splash lubricated by overhead oil return OIL PUMP On all engines a large capacity Gerotor type oil
102. red fit with better than 75 bearing area contact on the pin PISTON AND CONNECTING ROD ASSEMBLY 1 Assemble the pistons on the connecting rod by first heating them in some form of oven or in hot water to a minimum temperature of 71 C 160 F When heated the piston pin will enter the piston very easily and can be tapped through the connecting rod and into place without distort ing the piston The snap rings must be assembled in the grooves making sure they are fully seated in place 2 The piston pin hole in the connecting rod must be parallel to and in plane with the large bore in the bearing end of the connecting rod Checking Connecting Rod for Twist and Alignment This may be checked on a fixture with the piston pin assembled in the rod before assem bling the piston but regardless of this preliminary check the completed piston and rod assembly must be rechecked and there must not be more 99 than 0 05mm 002 twist or out of squareness checked over a spread of approximately 100mm 4 If excessive replace the rod Checking Connecting Rod Assembly for Alignment Pistons are cam and taper ground and this must be taken into consideration when checking alignment of the assembly since the diameter in line with the piston pin would be less at the top of the skirt than at the bottom PISTON RINGS Check the piston rings in the cylinder for gap Checking Ring Gap 96 To do this insert a piston in the
103. rheating is always accompanied by loss of coolant water In case of doubt this should be checked 411461141111 Ra SET RTE 1 9 L e F o a At be tage o RE e HE i A Y LIT N v QU peter RSC y f 7 4 E ud TS y f 9 AV rei cort Qua iH PE Axe Tu Fi UAB Tas DER 5 Sectional View Showing Water Passages in Head and Block EXPANSION OF WATER Water has always been the most commonly used coolant for internal combustion engines because it has excellent heat transfer ability and is readily obtained everywhere Like all liquids it expands when heated the rate of expansion being 1 32 liter per liter 1 4 pint per gallon when the temperature is raised from 4 to 81 C 40 to 180 F For example If a 4 gallon cooling system is fill ed completely full of water at 4 C 40 F 1 pint will be lost through the radiator overflow pipe by the time the water temperature reaches 81 C 180 F WATER FILTERS In some areas the chemical content of the water is such that even the best of rust inhibitors will not protect the cooling system from the for mation of rust and scale There are instances where this corrosive ele ment has eaten holes through cast iron parts such as water pump impellers and bodies This condi 15 tion is caused by electrolysis taking place in the parts involved Where these conditions exist water filters should be incorporated in the assembly to remove these trouble
104. ries the spring tension When this closing action of the valve exactly balances the spring governing action takes place and maximum speed is fixed at this point When load is applied the engine speed tends to drop the velocity of the gas through the manifold and the pressure against the governing valve is reduced and the spring opens the valve to feed more gasoline to the engine to handle the in creased load demand Thus an almost constant speed is maintained whether the engine is runn ing with or without load The Hoof Velocity Governor is adjusted by removing the seal wire and with screwdriver turn clockwise to increase speed and counter clockwise to reduce speed Velocity Governor Section 7 Ignition Systems Continental industrial spark ignited engines are equipped with an electronic ignition system The ignition system has the job of producing and delivering high voltage surges of about 20 000 volts to the correct spark plug at the correct inter vals and with the correct timing for the engine Each high voltage surge produces a spark at the spark plug gap to which it is delivered so that the mixture of air and fuel in the cylinder is ignited ELECTRONIC IGNITION SYSTEM This battery ignition circuit consists of the bat tery ammeter ignition switch ignition coil distributor spark plugs and low and high tension wiring ELECTRONIC DISTRIBUTOR EA Black Re
105. rinding job cannot be cor rected by valve lapping For example after the valve has been hand lapped it would look like this when cold The thin line visible here shows where the valve lapped into its seat Keep in mind that the engine is now at rest and cold Valve Spring Tester Springs when compressed to the valve open or valve closed length must fall within the specifications shown on the Limits and Clearance chart when new and must not show more than 10 loss to re use This illustration shows the same valve only now it has reached normal operating temperature Notice that the lapped area of the valve and the seat no longer match each other This is perfectly normal due to expan sion of the valve Now you can see that the ef fects of the lapping job are lost completely 2 All intake and exhaust valves have oil guards Soak in boiling water for several minutes prior to installation Installing Oil Guards 91 Valve Assembly 3 Reassemble the valves and springs in the head with the oil guards retainer and retainer lock ROCKER ARMS 1 Inspect the rocker arm shaft for wear If the shaft has shoulders on it due to wear replace Blow out oil holes with air 2 Examine rocker arms for cracks condition of valve contact surface and worn bushings Replace all defective rocker arms or any having over 0 13 mm 005 clearance between shaft and arm 3 Inspect the rocker arm
106. rotrudes from slot Cut off flush with pan rail Bottom View Oil Pan Contact Face Typical RTV Oil Pan Application for the Overhead Valve Engine 66 Section 10 Trouble Shooting A WARNING Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 A preventive maintenance system including in spection lubrication and adjustment as recom mended in our Maintenance Section will prevent the greater portion of gasoline engine troubles Failure of a gasoline engine to start is mainly due to two things ignition trouble or failure in the fuel system Operators handling the same engine every day soon develop a sense of impending trouble when abnormal operation occurs Immediate attention to these danger signals can prevent major failures insure dependable operation and in crease the life of the engine Operators should depend on their well developed senses of feeling hearing seeing and smelling and repiace their sense of taste in this type of work with a generous amount of Com mon Sense A good rule to follow i
107. rts or subassemblies made up of several parts When reassembling pistons and connecting rods use a good ring compressor and oil the bores thoroughly hammer handle may be used to bump the pistons out of the ring compressor in to the cylinder bore NOTE The pistons have offset piston pins Be sure to install pistons with notch in top toward the front of the engine and the numbered side of the connecting rod facing the camshaft as indicated in the photograph below Once more we call attention to care demanded to prevent connecting rods damaging the cylinder bore finish and at the same time as they are assembled over the crank pin locate them carefully in order to protect the bearing surfaces Always lubricate the bearings with clean engine oil when assembling and tighten them to the torque specified INSTALLING HEAD 1 Make sure that gasket contact surfaces on the head and block are clean smooth and flat Check flatness with straight edge and feeler gauge in three positions lengthwise and five crosswise The maximum permissible is 0 10mm 004 low in the center lengthwise gradually decreasing towards the ends or 0 076mm 003 crosswise or in localized low spots If these limits are exceeded replace the cylinder head Checking Cylinder Head Flatness Crosswise 2 Use new cylinder head gasket which is precoated thus no cement is required 3 Before installing head cap screws in the block be sure th
108. s Wear Limits Min Thk Dia of Main Brg Jr Wear Limits Min Dia Clearance Limits Desired Clearance C S End Play PISTON PIN Length Diameter Wear Limits Min Dia Desired Fit Bush Hole Dia Fin Wear Limits Max Dia Pin Cl in Bushing Desired Pin Fit TAPPET Outside Dia Bore in Block Wear Limits METRIC 47 511 47 486 44 336 44 311 42 749 42 723 ENGLISH 1 8705 1 8695 1 7455 1 7445 1 6830 1 6820 0 025 001 Under Minimum New Shaft Diameter 47 625 47 600 44 450 44 425 42 862 42 837 0 139 0 089 0 038 0 178 30 175 30 150 52 375 52 362 1 567 1 554 1 542 49 212 49 187 49 162 0 080 0 016 0 048 0 091 0 28 0 15 0 20 78 019 78 00 2 484 2 471 2 459 72 974 72 944 72 918 0 133 0 058 0 096 0 17 0 04 71 0 70 7 28 575 28 571 28 562 Light Push 28 598 28 588 28 623 0 013 0 028 0 020 25 324 25 311 25 364 25 344 0 13 1 8750 1 8740 1 7500 1 7490 1 6875 1 6865 0055 0035 0015 0070 1 1880 1 1870 2 0620 2 0615 0617 0612 0607 1 9375 1 9365 1 9355 0031 0006 0019 0036 011 006 008 3 0716 3 0709 0978 0973 0968 2 8730 2 8718 2 8708 0052 0023 0038 0067 0015 2 795 2 783 1 1250 1 1248 1 1245 1 1259 1 1255 1 1269 0 0005 0 001 1 0 0008 9970 9965 9986 9978 005 73 ENGINE MODEL PISTONS Cylinder Dia Wear Limits Cy
109. s and Pumps Resulting in Burned 50 aou oi du Bearings and Stripped Pump Gears When sludging conditions prevail the oil should be examined daily and changed as it may freeze or clog the inlet strainer and cause bearing or oil pump failures High Altitude Operation High Altitude opera tion reduces the power output approximately 312 for every 305 meters 1000 feet of altitude above sea level High Temperature Operation for every 5 C 10 F above 29 4 C 85 F carburetor air temperature a power loss of 1 results ENGINE PREPARATION FOR WINTER USE More than 90 of the hard starting complaints in cold weather are the direct result of inadequate at tention to preparation for winter use and proper maintenance An engine not properly prepared and out of tune requires more cranking energy and time which puts a heavy load on batteries So in variably batteries run down and the engine is blamed for hard starting Putting your engine in proper condi tion and keeping it that way pays big dividends by reducing costly down time Use the checklist which follows to get your engine ready for winter Then use the winter maintenance schedule to keep it in peak operating condition dur ing the winter months CHECKLIST A WARNING Stop engine before checking battery terminals or elec trical connections Do not hold ignition wires with bare hands since shocks or other injuries can result Sparks or flames nea
110. se damaged Use puller for removing faulty insert 2 When required to replace with new insert clean and counterbore for 0 25mm 010 48 larger insert using counterbore tool with cor rect fitting pilot When machining the counterbore be sure to go deep enough with the tool to clean up the bottom so that the insert will have full contact to carry away the heat Wis Con Total Power does not recommend installing new inserts having the same outside diameter as the one removed The following chart shows the dimensions of Standard Inserts and Counterbores DIMENSIONS OF STANDARD INSERTS AND COUNTERBORES Outside Dia Inside Dia of Insert of Counterbore Press Fit A B 35 513mm 35 410mm 077mm to to to 35 482mm 35 385mm 128mm 1 3981 1 3941 003 to to to 1 3971 1 3931 005 Engine Model Insert and Counterbore When OVERSIZE inserts are used dimensions of the insert and counterbore increase propor tionately 0 25 0 50mm 010 020 depending on the oversize Chilling Inserts VALVE GUIDE DATA D Distance E Length of Guide G haust E H O D of Valve Seat Insert if Used Thickness of Valve Seat Insert If Used New insert installation must have a press fit Chill insert in container with dry ice for 20 minutes before assembling Insert may then be installed in the counterbore using a piloted driver and arbor press without the possibility of shearing the
111. some elements and offset the elec trolytic action EFFECT OF ALTITUDE ON COOLING Water boils at 100 C 212 F under at mospheric pressure at sea level This pressure becomes less at higher altitudes and the reduced pressure causes water and other liquids to boil at a lower temperature ANTI FREEZES Water freezes at 0 C 32 F forms solid ice and expands about 9 in volume which causes tremendous pressure and serious damage when allowed to freeze inside the cooling system When operating temperatures are below 0 C 32 F an anti freeze liquid must be added which will lower the freezing point a safe margin below the anticipated temperature of outside air OPERATING TEMPERATURE RANGE 0 to 12 C 12 C to 23 C 23 C to 34 C 32 to 10 F 10 to 10 F 10 to 30 F ANTI FREEZE ETHYLENE GLYCOL permanent type When there are no leaks add water only to make up for evaporation CORROSION INHIBITORS Corrosion inhibitor can cause damage to the eyes or skin If contact is made immediately wash skin with water For the eyes immediately flush the eyes with water for several minutes In either event seek prompt medical attention Read and observe safety warnings on pages 1 and 2 Ratio Ethylene Glycol to water Water forms rust due to its natural tendency to combine chemically with iron and air in the system Rust inhibitors for water are inexpensive simple to use and make cleaning
112. speeding casualty or improper storage transportation or handling and B Engine tune ups and normal maintenance service as specified in the Operator s Manual including but not limited to valve adjustment normal replacement of service items fuel and lubricating oils fan belts anti freeze etc Wisconsin reserves the right to modify alter or improve any engines without incurring any obligation to modify or replace any engines previously sold without such modification alteration or improvement Written and oral representations made by Wisconsin s employees or agents before or after sale of the engine are not to be considered warranties or additional obligations unless they are in writing and signed by an officer or authorized employee of Wisconsin THIS LIMITED WARRANTY IS THE SOLE AND ENTIRE WARRANTY PERTAINING TO WISCONSIN S ENGINES AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES OF ANY NATURE WHATSOEVER WHETHER EXPRESS IMPLIED OR ARISING BY OPERATION OF LAW TRADE USAGE OR COURSE OF DEALING INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND ANY WARRANTIES RELATING TO MATERIALS OR COMPONENTS MANUFACTURED BY ANY PARTY OTHER THAN WISCONSIN PURCHASER REPRESENTS THAT IT ALONE HAS DETERMINED THAT THE ENGINES PURCHASED ARE SUITABLE FOR AND WILL MEET THE REQUIREMENTS OF THEIR INTENDED USE Limitation of Liability and Remedy In no event whether arising out of breach of contra
113. stallation in the groove CAUTION The pistons have offset piston pins Be sure to install pistons with notch in top toward the front of the engine and the numbered side of the connecting rod facing the camshaft CRANKSHAFT AND MAIN BEARINGS 1 Using a puller remove pulley from crankshaft 2 Remove screws and remove gear cover 3 Remove the crankshaft gear and keys 57 Removing Crank Gear 4 Using a puller remove cam gear Removing Cam Gear with Puller holding pump to front of the engine 6 Remove each main bearing cap one at a time and inspect the bearing and crankshaft jour nals If there is any indication of flaking out scoring or actual wear they must be replaced BEARINGS Tri metal bearings when new are smooth and highly polished However a very few hours of S Appearance of a Good Bearing 58 5 Remove the oil pump by removing cap screws Scored Bearing Due to Dirt or Lack of Oil operation will change their appearance complete ly The bearing surface becomes a leaden gray in color and develops minute craters almost cellular in appearance as indicated in the photograph which follow the pattern of the matrix This ap pearance is a natural characteristic of this type bearing and in no way indicates failure 7 Ifthe visual inspection appears satisfactory they shouid be removed and checked for thickness using a ball micrometer Removing Main Bearing CAUTIO
114. t SAE 50 are 20 50 0 so CL PACA Multi Grade Oils such as SAE 5W 20 and SAE 15W 50 have the starting grade characteristics of the lighter oil and after warm up have the running characteristics of the heavier grade The following SAE grades are general recom mendations for Continental Industrial engines during changing seasonal atmospheric temperatures AVERAGE AMBIENT TEMPERATURE AT WHICH ENGINE STARTING 1S REQUIRED C 30 18 17 5 16 27 38 E 20 0 20 40 60 80 100 LL LOL LL LVL LL SAE 30 ML LLLA SE ULL I SAE20N EL 0 MI LLL LLL UMM Yi YI co NEP TEE SAE5W 20 PA For engines in continuous duty oil viscosity should be based on sump oil temperature LE Sump Oil Temperature SAE Grade 210 250 F 40 99 121 C 30 160 210 F 30 71 99 C 10W 30 10W 40 20W 40 15W 40 20W 50 15W 50 130 160 F 20 55 71 C 10W 30 10W 40 The Multi Grade oil used should cover the single grade recommendation for the at mospheric temperature involved e g SAE 10W 30 covers SAE 10W SAE 20W SAE 20 and SAE 30 SUGGESTED OIL AND OIL FILTER CHANGE INTERVALS Light Duty Operati n 25 Max C ntinu us Rating and Standby Continuous Duty at Continuous Duty Rating CLEAN DIRTY ENVIRONMENT ENVIRONMENT Gasoline 100 Hours Max 50 Hours 100 Hours Max LPG Natural Gas 100 Hours Max 50 Hours 200 Hours Max NOTE 1 Lube oil and filter must al
115. t and the line to the manifold should be checked periodically for leakage If the diaphragm is ruptured the vac 43 cuum advance housing and linkage must be replaced Check distributor clamp bolt and if found loose retiming the engine is necessary The Electronic Ignition Distributor requires no adjustments due to the elimination of the points and condenser sensor and trigger wheel device replace the points and condenser in the distributor and provide the precise timing needed to fire the plugs lt is not repairable and if necessary must be replaced as a complete assembly A WARNING Stop engine before checking battery terminals or elec trical connections Do not hold ignition wires with bare hands since shocks or other injuries can result Sparks or flames near a battery could cause an explosion or fire Battery acid can cause corrosive burns Always wear eye protection Use of jumper cables or battery charging should be done only as directed by manufac turers safety instructions Read and observe safety warnings on pages 1 and 2 6 INSPECT IGNITION WIRES AND CONNEC TION Examine ignition wires for breaks in insulation chafing and loose connections Replace if defec tive 7 1F DRY REPLACEABLE ELEMENT AIR CLEANER IS USED REPLACE ELEMENT EVERY 500 HOURS 1 REPEAT DAILY 50 HOUR AND 250 HOUR SCHEDULES 2 COOLING SYSTEM Clean radiator core by blowing out with com pressed air
116. t sea level When a pressure cap is used an air tight cooling system is necessary with particular attention to tight connections and a radiator designed to withstand the extra pressure FAN BELT TENSION When tightening fan belts loosen the alter nator adjusting bolts and pull out on the alter nator by hand until the belt is just snug Under no circumstances should a pry bar be used on the alternator to obtain fan belt tension or damage to the bearings will result When adjusted correctly the fan belt deflection on the long side should not exceed 13mm 1 2 Adjusting Fan Belt Tension CYLINDER BLOCK WATER DRAINS When the cooling system is to be completely drained there is a drain plug on the right hand side of the cylinder block which drains all cooling water which might be trapped in the base of the block CAUTION OVERHEATED ENGINE Never pour cold water or cold anti freeze into the radiator of an overheated engine Allow the engine to cool and avoid the danger of cracking the cylinder head or block Keep engine running while adding water WATER PUMP The water pump is located on the front of the cylinder block and is driven by the fan belt from the crankshaft pulley The inlet of the water pump is connected to the lower radiator connection and the outlet flow from the pump is through integral passages cast in the block No lubrication of the pump is required as the bearings are of the permanently s
117. the feeler inserted between the piston and the cylinder midway bet ween the piston pin bosses where the diameter of the piston is the greatest Check the fit of the piston when it is approximately 50mm 2 down to the cylinder bore in an inverted position PISTON PINS Check the bushing in the upper end of the con necting rod for wear If worn and you are using the original pistons with a service set of rings an oversize piston pin may be obtained in 0 08 or 0 13mm 003 or 005 oversize Checking Piston Pin Bushing for Wear The piston pin hole in the piston and the bushing in the connecting rod may be honed to in crease their diameter to obtain the desired fit as shown in your Limits and Clearance Chart OLD BUSHING Pressing in Piston Pin Bushing Note that while the chart specifies a light press fit of the pin in the piston there is a definite clearance of the piston pin in the connecting rod CONNECTING ROD Replace the bushing in the connecting rod if new pistons and sleeves are used Using the arbor press press out the old bushing and press in the new one making sure the oil supply holes line up after which the bushing must be honed to ob tain the correct fit of the pin in the bushing as shown on Limits and Clearance Chart If there is an excess of stock in the piston pin bushing it may be reamed first then honed In any event the final operation should be done with a hone to obtain the desi
118. the governor arm for ward slowing the engine to idle Mechanical Governor Linkage CAM GEAR GOVERNOR A WARNING Extreme caution must be exercised when making gover nor adjustments to avoid personal injury due to fan blades belts and hot manifolds Bodily injury or death may result to individuals during operation of an engine within any enclosure not ade quately or properly ventilated Engine operation in any enclosure requires adequate and proper ventilation to avoid asphyxiation or other interruption of normal breathing to supply sufficient air to cool the engine provide air to mix with fuel and to carry away heated air from the building Read and observe safety warnings on pages 1 and 2 The Cam Gear Governor is used on most in dustrial units requiring normal industrial speed regulation These governors differ from conven tional centrifugal governors mainly in the round steel balls used as the actuating force producer instead of pivoting masses of weight When the governor is driven at increasing speeds by the engine the hardened steel balls move outward forcing the conical upper race and lever assembly toward a closed throttle position An externally mounted spring imposes tension on the lever assembly toward the open throttle position As the engine speed increases the cen trifugal force created by the balls will increase un til a balanced condition between the governor force and the spring force
119. to specified clearances 3 Adjust idle mixture and idle speed to 400 600 R P M 800 1000 R P M on the 2 cylinder engine WARM UP NEW ENGINES When new engines in distributors or dealers Stock showrooms etc are started up for any reason they should be brought up to operating temperature in order to eliminate all condensa tion before stopping If they are stopped while still cold condensa tion will settle on valve stems and guides as well as other moving parts and rust and sludge will form Soon valves rings etc will be stuck by this rusting and sludging action Engine should be operated long enough to bring oil and water temperature to normal operating temperature be sure breather or vent ilation system is open so vapor can be expelled SPEED CONTROL The throttle control is used to close the car buretor butterfly valve to limit engine speed below governed speed Engines are provided with a mechanical elec tronic or velocity governor set to maintain the load and speed specified when the engine is ordered If individual requirements necessitate a change of governed speed reset governor as outlined under Governor adjustment but do not exceed manufacturer s recommended maximum speed since this has been worked out with the end product requirements in mind When extended periods occur between the ap plications of load it is recommended that the engine be throttled down to minimum idling speed or
120. to the amount and viscosity of the oil used As dirt is strained from the air flowing through the cleaner it thickens the oil in the cup and also raises the oil level in the cup The proper method of servicing an oil bath air cleaner begins with pouring the old oil from the cup Wipe the cup with a clean cloth Refill the cup to the mark being careful not to exceed this line It is generally recommended to use SAE 20 oil in the summer and SAE 10 oil or lighter in winter gu Ning Fill Oil Bath Air Cleaner Cup to the Indicated Mark 1 SERVICING REMOVABLE PRE FILTER Some oil bath air cleaners have removable prefilters which stop all lint chaff and fibrous materia that enter Remove the pre filter every time the air cleaner is serviced and wash out all chaff or dust in a sol vent 2 SERVICING MAIN FILTER ELEMENT This filter element is made up of thousands of steel springs interlocked and compressed to a mass of uniform density which traps the oil and completes the cleaning process Normal service completely remove the air cleaner every 4 6 months remove the bottom half and pre filter then immerse and back flush the main filter element with a cleaning solvent Severe service will require cleaning of this ele ment ev ry week or more frequently if required Be sure element is dry of all cleaning solvent before reassembling 40 taii o 6 9 6 a 9 9 a el 0 e note a e 9 o
121. uire replacement CAUTION When installing camshaft use special care to prevent camshaft bumping and loosening expansion plug at rear of crankcase causing an oil leak TAPPETS ACCEPTABLE NOT ACCEPTABLE Valve Tappet Wear Comparison 1 Inspect each tappet carefully Two or three small pits on the contact face is acceptable more than that calls for replacement of the tappet 60 Oversize tappets are available as required 2 Check the outside diameter with a micrometer to determine if replacement is necessary because of wear Refer to limits and clearance section 12 REAR CRANKSHAFT OIL SEALS The overhead valve engines have the rear crankshaft oil seals incorporated in the combina tion rear main bearing cap and filler block The newer type crankshaft oil seal has a stif fener ring imbedded in the rubber and no metal re tainer is required Rear Main Bearing Cap and Filler Block The overhead valve engines have a good trouble free rear crankshaft oil seal if carefully installed IMPORTANT Installing rear oil seals correctly demands careful workmanship Install seal with lip pointing toward engine Worn oil seals should be replaced in the follow ing manner 1 Remove rear bearing cap and filler block assembly by using a puller as shown Remove old seals and thoroughly clean all contact surfaces 2 Install crankshaft oil seals A on engine block and main bearing cap B
122. unterbore in the flywheel which locates it on the crankshaft is not damaged mount an in dicator on the flywheel housing and check the flywheel for runout Caution When checking runout remove spark plugs to allow engine to be turned over freely The indicator should be set up so that it con tacts the clutch face or the vertical surface of the clutch counterbore then turn the flywheel at least one full revolution at the same time holding against the crankshaft to offset the possibility of end play Excessive runout of the flywheel in either posi tion is probably caused by dirt in or damage to counterbore locating the flywheel on the crankshaft flange He locate the indicator to check the inside diameter of the counterbore In both cases the maximum indicator reading must not be more than 0 20mm 008 When assembled mount the indicator on the flywheel so that it contacts the housing face and turn the crankshaft at the same time holding against it to counteract end play The maximum indicator reading must not exceed 0 20mm 008 Checking flywheel Housing Face Re locate the indicator to contact the housing bore and check this in the same manner The same runout limits prevail Checking Housing Bore REASSEMBLING ENGINE In the foregoing we have outlined procedures for checking repairing or replacing the many wearing parts in the engine In most cases the instructions have covered the reassembly of pa
123. uptured the vacuum advance housing and linkage must be replaced SPARK PLUGS A spark plug consists of two electrodes one grounded to the outer shell of the Ceramic insulator Electrodes Sectional View of Spark Plug 32 plug and the other well insulated with a core of porcelain or other heat resistant material The space between these two electrodes is called the gap which should be set at 0 8mm 032 for Con tinental OHV engines Correct and uniformity of the gaps of all spark plugs in the engine is impor tant for smooth running Spark plug gaps are best checked with a wire gauge unless the points are dressed to obtain a correct reading with a flat gauge The adjustment should always be made on the side electrode and never on the center electrode which may cause a broken porcelain Gapping the electrode tip is more easily done with proper tools GAPPING THE SPARK PLUG This illustration shows the use of the gapping tool which both measures and adjusts the electrode gap Checking Spark Gap Spark Plugs must operate within a certain temperature range to give good perfor mance not too hot and not too cold The ability of a spark plug to conduct heat away from the center electrode and porcelain is controlled by the design of the shell and insulator so varying the length of the insulator below the gasket shoulder controls the temperature LOW INSULATOR HIGH SEAT CARRIES INSULATOR HEAT
124. urn in for leaner mixture and out for richer mixture CAUTION Improper adjustment of the main jet could lead to engine damage 3 Idle Speed Adjustment Screw turn in clockwise until throttle valve is slightly cracked open Adjustment to recommended idle speed can be made after installation to engine Turn screw clockwise to increase speed or counter clockwise to lower the R P M ZENITH FACET CARBURETOR The Zenith Facet 267 series updraft carburetor has the following adjustments 1 Idle Fuel Air Adjusting Needle The idle fuel air adjusting needle controls the amount of fuel air mixture discharged into the air stream Turning the idle adjusting needle in results in a leaner mixture Turning the idle adjusting needle out results in a richer mixture 2 Fixed High Speed Jet is not adjustable For high altitude it may be exchanged for reduction in size to lean the fuel in compensa tion for the lighter thin air The size must be carefully determined first by testing a smaller jet with 001 to 002 smaller passage depending on the elevation Zenith Carburetor 267 Series clockwise to increase speed or counter clockwise to lower the R P M Zenith Carburetor 228 Series The Zenith Facet 228 Series downdraft car buretor has the following adjustments 1 Idle Fuel Air Adjusting Needle The discharge of the idle fuel air mixture into the air stream is controlled directly by the idle adj
125. urrent flow through the ignition circuit The Ammeter indicates the amount and direc tion of current flow The Ignition Switch is an Off and On switch Current flows only when this switch is closed and returns by the ground through the engine or frame The resistance of the primary 30 winding of the ignition coil restricts the primary current flow The Ignition Coil consists of two windings a primary winding and a secondary winding and is a transformer to increase the voltage high enough to jump a spark gap at a spark plug The Distributor interrupts the primary winding current in the ignition coil and distributes the high tension current to the correct spark plug at the correct time The Spark Plugs provide a spark gap in the com bustion chamber The compressed air and fuel mixture is ignited when the high voltage jumps across this gap The Low Tension Primary Wiring conducts bat tery current through the ignition coil and con tacts The High Tension Secondary Wiring conducts the high voltage produced by the ignition coil to the distributor and from the distributor to the spark plugs Operation A primary current flows from the battery through the ammeter and ignition switch to the coil primary winding then to ground The collapsing field induces a very high voltage in the secondary winding which is carried by the high tension wire to the center terminal of the distributor cap The rotor connects
126. usting needle located in the throttle body at the lower idle discharge hole Turning the idle needle valve in clockwise results in a leaner mixture of fuel air since less of the fuel air mixture is discharged in to the air system through the idle discharge hole 2 Fixed High Speed Jet is not adjustable For high altitude it may be exchanged for reduction in size to lean the fuel in compensa tion for the lighter thin air The size must be carefully determined first by testing a smaller jet with 001 to 002 smaller passage depending on the elevation 2A Main Jet Adjusting Needle available for use with the fixed high speed jet for altitude compensation Turn in for leaner mixture and out for richer mixture CAUTION Improper adjustment of the main jet could lead to engine damage 3 Idle Speed Adjusting Screw turn in clockwise until throttle valve is slightly open Adjustment to recommended idle speed can be 23 made after installation to engine Turn screw clockwise to increase speed or counter clockwise to lower the R P M CARBURETOR CHOKES Manually Operated Choke is operated by a flexible cable control from the instrument panel or rear house panel While this is the most simple type it is most important that the operator have the choke valve in wide open position when engine operating temperature is reached Carburetor Service In general any change in carburetor action will usually com
127. ways be changed after the first 50 hours of operation of a new or rebuilt engine 2 Environmental installation fuel system and general engine conditions can all influence lubri cant performance Lube oil analysis programs are recommended in all applications for optimum engine performance and life Standard Continental supplied starters and alternators have sealed bearings requiring no lubrication Check your specification for ac cessories which may require periodic lubrication Section 4 Cooling System The function of the cooling system is to prevent the temperatures in the combustion chamber which may reach as high as 2200 C 4000 F from damaging the engine and at the same time keep the operating temperatures within safe limits Maintaining the cooling system efficiency is important as engine temperatures must be brought up to and maintained within satisfactory range for efficient operation however this system must be kept from overheating in order to prevent damage to valves pistons and bearings COOLING SYSTEM All Continental industrial engines have the cooling water force circulated by a water pump and use a thermostat and by pass system to con trol the temperature range The coolant from the pump enters the front of the block passing along and between the cylinder bores and is metered by the head gasket into and across the cylinder head to cool the valve seats and guides The heated coolant then

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