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1. 1 3 for air cleaner strap to shroud For spacer plate to case upper l 427 252 NUT 3 8 16 thread hex grade 51 16 1 440 22 WASHER 3 84 1 0 x 11 16 O D x For cylinder studs 3 22 thick plain hardened steel 1 For cyl head at Hi temperature switch 428 PD 205 NUT 5 16 24 thread Seez proot 2 2 for carburetor mounting 441 PH 30 WASHER 4 D plain coppet I 10 manifold upper to lower branch For fuel pump heat shield obsolete used for stud mounting 442 77 WASHER 5 16 1 0 5 8 C 429 207 NUT 7 16 1 20 thread Seez prof 4 bain sieel cre er ay asa dere tegis 3 For manifold to cylinder heads 1 generctor adju sting strap 2 for generator bracket mounting 431 PE 3 LOCK WASHER 1 4 sptinglock 51 2 4 fuel pump adapter 442 79 WASHER 7 1691 D nar dened 2 8 flywheel screen For center shell bearing hanger mtg 26 for air shrouding 4 for control panel 443 PH 84 WASHER 1 4 1 0 x 1 290 0 1 169 1 for distributor clamp thick 12 4 for mounting voltage requlator 4 for cylinder shrouds to cir shroud l for heat defl bracket L H side 2 for cylinder shroud to case l for oil tube clamp V 46 5D i for cylinder shroud clip to pump 4 for cyl hold down clips 465 D 4 for voltage regulator mounting 1 Delc
2. 93 12258 NUT CHOKE LEVER for 1 2 3 4 5 14 93 T 41 10 LOCKWASHER Choke Lever Nut 93 C112 12 93 C112 21 SPRING CHOKE LEVER for 1 2 3 4 14 SPRING CHOKE LEVER for 5 bes Description SCREW Bracket for 1 2 3 4 5 14 LOCKWASHER Bracket for 1 SCREW TUBE CLAMP for 1 2 3 4 5 14 CLAMP BRACKET for 1 BRACKET CHOKE for 1 2 3 4 5 14 93 131 4 2 1 RETAINER CHOKE SHAFT PACKING For 1 2 3 14 15 93 T57 4 t WASHER CHOKE SHAFT PACKING For 1 2 3 14 15 2 3 4 5 14 2 3 4 5 14 TM 9 3431 254 14 amp P 5 LIST Model 87A8 ZENITH CARBURETOR L 57 L 77 Series Description Description 1 39 ee NN 93 T2158 NUT Clamp Screw for 1 2 3 4 5 14 93 83 98 1 1441 2 3 4 6 93 C63 9 PIN Washer Retaining for 1 2 3 14 15 1 93 83 129 BOWL Fuelfor5 14 15 93 130 4 WASHER Shaft Thrust for 1 2 3 14 15 93 75 24 FIBERWASHER a 93 T 52057 1 RETAINER Throttle Shaft Packing 93 52 7 29 JET Mainfors shua Sa a oca ege vase Ev One for 4 5 93 C52 7 34 JET Mainfor required n 93 52 7 38
3. ELBOW 1 84 P T x 4 inverted tubing nut 4in cylinder heads for oil return line l in top of crank case COUPLING for obsolete crankshaft oil ADAPTER FITTING forcilline gauge OIL SPRAY ELBOW for govemor 1575 replaced by RF 1514 H13 tef 295 299 300 301 302 303 304 305 TM 9 3431 254 146 for Models V 465D and 4600 V 461D Part D nsn No Net w Number 0 1377 Y FITTING tor bii retum line to case 2 1 1377 replaced 1377 RF 1378 COUPLING for obsolete oil collet adapter 1 1392 ADAPTER for obsolete of collet COUP IAS AE 1 2 RF 1420 FITTING for oil line connections to case 1 2 RF 1421 ELBOW n carburetor fuel inlet i 1 RF 1423 NIPPLE for oil fter mounting 1 2 RF 1511 ELBOW 459 in center becring hanger 1 For oil pressure iine NOTE 2eainnin c with engine serial No 4802236 the oil dip stick used in con unction with fom ed adapter tube replaces dip stick with straight cdapter and those mounted directly in to case cutis notin e for serv ice Order by part num ber indicated blade of dio stick RJ 173 RJ 173 A Optionai RK 179 C RM 845 A RM 850 A 1049 RM 1049 K RM 1351 A RM 1513 A 5 56 RV 38 S3 RV 41 A S1 DIP STIC
4. 8 32 5 16 SHAFT and GEAR distributor SUPPORT SCREW 8 32x3 8 SUPPORT pecring SNAPRING distributorshatt s BEARING cemend eerte tnter SWITCH assembly NUT switchsctew ee HH LOCKWASHER switchscrew ew o ox oe eo Roe o o ok n fo noe eoe e Port Number 31 2514 31 6018 31 2457 31 12499 31 8514 31 6540 31 06120 31 R2477C 31 22480 31 3K1 31 B1498B 31 C5949 31 814980 31 XU2425 31 31SS14A 31 195 31 6S4U 31 6030 31 C6032B 31 S2568 31 2492 31 G3861 31 A2492A 31 UU 2563C 18 31 A1498J 31 Q2566 31 55963 31 52563 18 31 2565 31 AZ5957 31 F 2572 31 M2570 FIG B 107 MAGNETO PARTS LIST ber 15 a vendor identification When NOTE Code number 31 prefixed to the part ordering parts please use number with code as shown INSULATING SCREW switch 3 SNAPRING shaft VENTCOVER VENTSCREEN SAF TSEAL WASHER secliouter COUPLING complete 18 laq mgle LOCKSPRING pawl COUPLING COUPLINGSHELL INSULATEDLEVER WASHER At lt 5 INSULATINGBUSHING ees WIRExssemblyseenne menn SCREW clio 6 22 1 4 COILCLIP SNAPRING bearing BEARING driveend STOP PIN TP WASHER seal inner PAWLSPRING
5. PLATE Specification 222 SCREW button head 1 4 20 x 1 2 KEY 3 8 x 3 8 x 195 8 csset SHAFT KEY 1 2 x 1 2 x 2 7 8 BALL BEARING GEAR intemal sha t counter 2 BALL BEARING PLATE COVEE uy SCREW hexehead 3 215 x 1 SEAL shaft counter SHAFT Operating eren cei rt nclf doaepoint 1 2 13 x 3 4 NOGOM hand edente utt dod i SCREW cap hexehead 5 8 il x i 1 2 wo WASHER lock S einch HOUSING clutch RING Sndp ci opone abeo BALL BEARING KEY 1Z4 x 1 4 177 85 azu SHAFT clutch BREATHER oil PIPE breather oil HOUSING gear 15 w 78 M503 78 M2004R 78 5079 78 43169 78 A 60 78 2245 78 115 78 B1538D 78 1990 78 B1535C 78 103F 78 5 385 78 2137A 78 15370 78 11982 78 15358 78 117 8 78 1930 78 120 8 78 117 3 78 43177 78 1473 78 6479 78 M2051AD 78 M2051AD 78 5805 78 M163 78 2727 78 A1587 778 2002 G 78 204
6. nit 18 1945732 For Y J 41 D 1119257 18 18 1943385 SCREW covet sss eee 2 18 1948328 For 1 41 1119152 D 19 18 1878502 5 2 2 2 2 2 2 2 22 2 0 3 6 18 1912176 SPRING current regulator armature 20 18 124818 NUT 3hockmcuntattaching iiie 3 6 18 1949142 SPRING voltage regulator armature 1 21 18 273484 SCREW Shock mount atteching 3 7 181910174 RESISTOR F 22 18 1878503 TERMINAL CLAMP s uuu MU pee 18 1910174 RESISTOR to relay 18 1879663 GROMMET 3 18 1912159 ADJUSTING SCREW relayarmature 1 18 1944590 SCREW requlator armature adjusting 2 18 1911034 RUBBER SHOCK MOUNT longi4hole 1 18 1911028 RUBBER SHOCK MOUNT short 3hcle 9 3431 254 146 SK 1474 5 8 8 YB 69 ALTERNATOR MOUNTING BELT DRIVEN FOR MODEL 4650 Standard equipment place Generator V 465D engines beginning with Serial 5734200 STANDARD ACCESSORY DRIVE STANDARD ENGINE SUPPORTS Ret Port A No 1 Number Description Req Description SPECIAL ENGINE PARTS REQUIRED LOCKWASHER 5 16 spri
7. For air cleaner connection qt carbu retor ond air cleaner ends HOSE CLAMP 2 3 81 For air cleaner tube to elbow RUBBER 5 For air cleaner tube RUBBERELBOW r For air cleaner RUBBER For starter Bendix housing OIL FILLER and BREATHER FUEL STRAIN LQ 32 Repair Kit bowl gasket screen FUEL PUMP with gasket low dome style LP 38E S1 pump with cover rotated LQ 46 Repair Kit see ML 34 Repair Instructions in rear section Of manual LP 38 3 81 high dome style pump Replaced by L P 38E 2 S1 LQ 30 Repair Kit D 38 3 S NOTE Specify part number or model designation stamped on car See carbu D t2 TM 9 3431 254 14 amp P INTERCHANGEABLE PARTS for Models 4650 and V 460D V 461D ef Port le Number jescripsion Req Lb Oz 205 MD 390 PULLEY fot enerator 5 206 168 MAIN BEARING ASSEMBLY both ends 2 2 8 Consisting of 207 1 137 1 Bearing cup 208 168 1 Searing cone Not sold separately 209 169 ROLLERBEARING centermain es 1 12 Std Size Obsolete used conjunction with collet for oil distributio
8. LOCKWASHER bearing ret plate LOCKWASHER brush lead screw Req 1 PP PP pear 029 r Ref No Part Number YB 62 B YB 62 8 9421423 18 120380 8 1915265 18 1888439 8 1914579 18 1904661 8 9421424 18 120638 8 1915172 18 1911324 8 121743 8 121743 18 1914580 18 1904370 8 453460 8 132688 8 225577 8 225577 8 1913960 18 1843646 8 1858753 18 1858753 18 809961 18 809961 8 826319 8 1881409 18 1857412 8 809945 8 809945 8 200382 8 124545 8 124545 8 125609 8 125609 18 125609 18 1880641 18 823551 8 809062 8 809062 18 809593 8 809593 18 819104 8 819104 18 1947350 18 804080 18 1911097 18 1911097 Description LOCKWASHER top of field frame LOCKWASHER shaft nut D E LOCKWASHER terminal stud LOCKWASHER thru bolt NUT shaft DIE cone ex e des NUT terminalstud SCREW bearing retainer plate SCREW brushlead SCREW top of field frame SCREW poleisho yaaa snes WASHER insulating field term WASHER felt D E s sd WASHER plain terminal stud WASHER brush arm WASHER spacer WOODRUFF KEY WICK D E not illustrated
9. You can help improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual direct to Commander US Army Armament Munitions and Chemical Command ATTN DRSMC MAS Rock Island IL 61299 A reply will be furnished directly to you Operator Organizational Direct Support and General Support Maintenance Manual Including Repair Parts List for Welding Machine Model GCC 300W NSN 3431 01 032 6289 NOTE This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to whom this equipment is issued Manufactured by Hobart Brothers Company 600 W Main St Troy Ohio 45373 Procured under Contract No DAAA09 78 C 2082 INSTRUCTIONS FOR REQUISITIONING PARTS NOT IDENTIFIED BY NSN When requisitioning parts not identified by National Stock Number it is mandatory that the following information be furnished the supply officer 1 Manufacturer s Federal Supply Code Number 28835 2 Manufacturer s Part Number exactly as listed herein 3 Nomenclature exactly as listed herein including dimensions if necessary 4 Manufacturer s Model Number GCC 300W 5 Manufacturer s Serial Number End Item 6 Any other information such as Type Fram
10. 9 63 347 SCREW 1 4 20 3 3 head 2 44 63 P T 808 1 DRIVE KEY Im Forin struction piate 45 63 PT 1060 5 FITTING orreieaseceanng 10 63 T 819 LUBRICATION COVER when specitied 1 Lincoln 5007 T 11 63 576 SCREW 5 10 z4x 1 8 round head 1 46 202 LOT BEARING twas 284882 63 CLA 2175 7A i CLUTCH ASSEMBLY 8 MODEL 13 63 GR 117 OIL LEVEL PLUG s 7 1 rere te OT e 888 15469 SCREW 216 hexagon sj 8 47 63 CL 8512 10 CLUTCHBODY For mounting cover to housina 16 6 amp 3 353 LOCKWASHER 3 8 tor cover to housing 8 48 63 CL 7039 1 FACING 796 3 segments 17 63 GR 114 DOWEL PIN i 8 xl onc 1 49 63 CL 8575 SEPARATOR SPRING 3 18 63 GR 753 OIL FILLER 2 83 1 1 50 63 1 85131 PRESSUREPLATE 19 63 6 117 OIL DRAIN PLUG 3 5 7 1 51 63 CL 8515 1 ADJUSTMENT NUT 20 63 GR 236 tor oil ner pipe 63 CL 11905 ADJUSTMENT NUT PLATE rot List 21 63 189 SNAP RING or drive 1 52 63 CL 9216 ADJUSTMENT LOCK rectaces 2123515 22 63 GR ioranve shaft 1 63 GR 855 SEAL RETAINER israrnve shaft 53 63 CL 8807 1 SCREW 4 20 x 3 3 head 23 63 GR 243 SNAP RING for vearina n housinc For adju
11. 22 22 BUSHINGior terminal stud inside 5 Con sisting of CONTACT BREAKERARM CONDENSER 8 869704 doner ee SPRING CLIP for copies SUPPORT for cap spring clip and locator POINT SUPPORT torcapspringclip 4OUSINGASSEMBLY esee Includes PIPEPLUG ior r a BUSHING notillustrated PACERWASHER forqear SEARSHIM 00S asneeded SEARSHIM 010 asneeded t tef 10 37 t 29 INC 14 42 Description 18 1862218 PIN for gear mounting cose j 1 18 1883121 SPRING tor fly weight 2 18 1885558 LOCKWASHER or hold down plete 2 18 1885557 PLATE for flyweight hold 4 je d 18 1942038 Hl 18 1921271 FLYWEIGHT amp 1871637 2 18 1947952 18 811912 SPACER WASHER or weight siate 18 453299 LOCKWASHER tor breaker olate screw 1 18 453299 LOCKWASHER for condenser T t a screw 1 18 453299 LOCKWASHER tor spring clin support 3 18 1914144 LOCKCLIP for terminal 18 817363 NUT for terminal stud 1 18120622 NUT t
12. 9 md 93 83 98A 93 83 1294 9 T5624 93 52 7 29 93 0327 34 93 52 7 38 93 52 7 41 93 7 23 93 138 24 93 791 1 93 730158 14 93 730153 9 Wiza 9916271 93 8190 30 92 146 25 93 181 296 LQ 37 93 K2212 9 3431 254 14 amp P BOWL Fuel for 1 2 3 4 eee BOWL Fuel for 1 4 15 FIBER WASHER Main Jet 4 ET JET Main 1 sore eves a ET Maia for 2 3 4 JET Main for 14 15 cece mos reet FIBER WASHER Passage umim simus PLUG Main PLUG 1 8 Pipe Bowl Drain SCREW Bowi to Body Long SCREW Bowl to Body Short a ma a ma os sa se aa GASKET Flange Zamith C14 1244 4 AUTO CHOKE ASSEMBLY fer 15 d AUTO CHOKE ADAPTER ASSEM for 15 AUTO CHOKE ADAPTER GASKET for 15 GASKET SET REPAIR KIT for 1 2 3 14 15 REPAIR for 4 L eerte AA tu 1 2 5 SZ 4 mi meee md eter es f Parts Included in Repair Gasket Set 5 5 Sold Separstely NOTE The Idle Air Bleed Bushing and Weil Vent Bushing are calibrated parts of the Throttle Body item 26 ond are readily removable
13. BUSHING 5 0 1 PLAIN WASHER arm LOCK WASHER No 2 br LO CKWASHER No 10 LOCKW ASHER 1 4 am SCREW bnishlead 8 32 x1 4 hs NUT atm terme 1 4428 Li esce ese eene n NUT field temm 10 32 RIVET ins brushholder a RIVET qrd brushholder brush Screw fld term term 20 MMUTATOR END HEAD ASSEMBLY Consisting of BEARING COVER FELT WICK eee BRONZE BEARING OIL RETAINER not il ustrated r rm F2 p Part Number Description 28 P90 33 28 GGW 2030F ARMATURE ASSEMBLY includes 28 GJR 1003B DRIVE HEAD ASSEMBLY Consisting of BEARINGRETAINER RETAINER forielt wasner 28 GG 164 FELTWASH ER 28 GEE 27 GASKE Tiorretainer SCREW retainer 9 32x1 2 LOCK WASHER retainer 10 DRIVEENDHEAD 28 295 BALLBEARING Nc 2037 n6 28 X 2961 RHODE PEE 28 GR 32 RETAINER 28 6 205 2 002 0 1 210 0 LO CKWASHER thr bolt and ard SCREW arcund L 4 28x9 18 eee KEY Woodruff LOCKWASHER D e id 28 90 338 TERMINAL STUD amp PARTS 28 90 32 BRUSH ARM amp SPRIN
14. x EN Brennen 19 xCiltR STATOR HOBART BROS CO TROY OHIO 46373 USA 2 6 CONN SEN GCC 300 W 2 Figure 2 7 Diagram Conn d3pT pSc TEepe 6 WL 6 STARTER SOLENOID 777 3 BATTERY BATTERY AMMETER d BATTERY AMMETER ALTERNATOR O A STARTER IGNITION SWITCH RED WH BROWN IGNITION SWITCH OFF START ANTI DIESELING SOLENOID LOW PRESSURE SWITCH 9 STARTER BATTERY CONFIDENTIAL Thie drowing lnshiding oll thereon a the esclusive and conkdential pro au disclosed fa albe whole or in end be not te be copied reproduced ANTI DIESELING SOLENOID patty of Hebert by escept with written permiqien Company of Trey Obla apna A GEN FELO FLASHER N a GEN DIAGRAM 12 V SEE DIAGRAU con _ LOW TEMP PRESSURE SWITCH SAFETY SWITCH J DISTRIBUTOR SPARK PLUGS TO FLASHING CIRCUIT SEE GEN DIAGRAM GEN DIAGRAM TEMPERATURE SAFETY SWITCH MEM PCF p iM GO BOT BCALE Daama TOLERANCUS 54106 AALY Ut trc PARE LN ue FRE DUCED AL COU 1 5 Figure A 8 Diagram Engine d pIl vGSc It
15. DRIVE SHAFT PIN orgeat au ava qii Inr LOCKWASHE SCREWtorconnector aT 86 32 thread x 3 16 long roun head for connector screw 6 SCREW for breaker plate mounting 10 32 thread 5 16 long fillister head 55 28 90 390 Distr Shaft Bearing amp Parts Pkg 28 P 90 337 Terminal Stud amp Parts Pkg 28 90 429 Cap Clamp Spring Pkg 28 P90 427 Distr Shaft Gear amp Parts Pkg 28 P 90 728 Wick and Washer Pkg 9 3431 254 14 amp P FIG B 97 12 Volt 17 Amp CURRENT VOLTAGE REGULATOR YJ 41 D Negative Ground No 119257 YJ 41 Positive Ground No 1119152 D Parts are identical for both regulaters except for contact support as noted polarity NOTE Codenumber 18 prefixed to the part number is avendoridentification When orderingparts pleaseuse number with code as shown of Port ie 9s ref Part Description ta Description 4 Number RE eq 084931886 SER 15 1861933941 GROUNDLEAD ASSEMBLY eem 1 2 18 1931887 GASKET 3 16 18 1924764 SCREW 10 CKWASHER elcy armature ps De tgo 2 3 18 1939646 RELAY ARMATURE S II 17 18 1874495 LOCKWASHER Shock mountattach screw 3 CONTACT SUPPORT
16. 2 TERM CRI POS CC TO STARTER SOLENOID 12 ni ar POS CV MULTI WIRE s Rs 1 POS MICHO WIRE Tea T TU M 2 AE 4 2 x 15 15A C84 204 HORART BROR CO TROY OHIO 46373 USA DWG NO x p DIAG SCHEMATIC G CC 300 W 440780 Figure 6 Diagram Schematic 6 WL 86 X 46 BASE RUNNING METER AUMETER VOUT METER a 5 M WMREAKERS BROWN _ ___ SEE ENGINE DIAGRAM GFF tt GEN Fikt o CONTROL FLASHING REACTOR M e 7 112 ate 11124 MRUNT e WIRE FEEDER 5 RECEPTACLE RACTIFIER pie vunn tg SE ECTOR SwiTCH cv Q 4 SEE ENG e eos cv 4 zl DIAGRAM E NE s ee nmm 8 ASSEUBLY 490779 RECTIFIER t6 CAPACITOR GENERATOR ess STATOR af BROWN e e 12 f amp TH 120 114 SA 104 spo sue iw BALLAST RINGS _ SN se RESISTOR 5 GtN REV FEL OS TAECOS BEARING END L3 T
17. Range Switch Dismantling Figure 8 TM 9 3431 254 14 amp P TROUBLESHOOTING The following chart contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the machine Each symptom of trouble is followed by a list of probable causes and pro cedure to correct them TROUBLE POSSIBLE CAUSE REMEDY ENGINE Engine will not start Engine starts but won t con tinue in operation WELDING GENERATOR No output Generates less than 10 volts No voltmeter reading no ammeter reading 16 see Engine Instruction Book and Parts List a Engine ignition problem b Overspeed relay control board malfunction a Faulty ignition switch b Timer Board malfunction c Overspeed relay control may be causing engine to stop due to increase in engine speed after break in Loose connection Open circuit in revolving field coils Engine speed too slow Brush and slip ring dirty Defective rheostat Range Switch positioned between setting Range Switch defective Defective wiring Shorted diode Lose of residual magnetism Faulty voltmeter Faulty ammeter Generator does not build up loss of magnetism a See Engine Manual b Refer to Control Box Malfunction page 18 for detailed troubleshooting instruc tions Replace ignition switch Same as b above Readjust engine no load operating speed Check connectio
18. VOTE Fete Pe HYPE I For adfusting strap bracket 11 YL35312 GROUND WIRE t 1 1 Altemator to coil strap 26 XDY7B SCREW 5 16 18 thread x 7 8 long i hexagon head S grade 5 1 1 12 YL377 30 IGNITION WIRE ASSEMBLY 1 2 For adjusting strap ct bracket Altemator Ammeter 10 gage with teminals 30 long 27 XD169 SCREW 5 16 18 thread x 1 1 1 long E hexagon head S grade 5 1 1 1 For adjusting strap at altemator STANDARD HARDWARE i 28 XD170 i SCREW 1 2 x 13 x 21 4 long hex 15 78 NUT 5 16 18 thread hexagon steel 2 i agon A e d For adjusting strap For Altemator mounting NUT 1 29 13 thread hex steel For Altemator mounting MODEL 87A8 CARBURETOR TM 9 3431 254 14 amp P L 57 L 77 Series OPERATION and SERVICE DESCRIPTION ar 5 5 zontal wit E con rale cha a y a ME ven Hation and on and air dea ane de must 60 ME mi Jus Tuen e on el air Patio 15 jet 5 et centrally lo located The all qas Surroun 5 ids the disc arge sim he center fhe ul bo IS 3 ruction permits extremely hig e Oper tion In any The venturi m iE art of the throttle bod gesting the yo of
19. 9 3431 254 14 amp P DEPART MENT OF THE ARMY TECHNICAL MANUAL OPERATOR ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS LIST FOR WELDING MACHINE MODEL GCC 300W 3431 01 032 6289 HEADQUARTERS DEPARTMENT OF THE ARMY August 1984 Safety Warnings Although welding equipment and processes are not particularly hazardous there are certain safety practices the user must follow to protect himself and others from injury These practices are outlined in American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING and in the following warnings The usermust also closely follow the installation operation and maintenance instruc tions contained in this manual It is assumed that anyone using this welding equip ment has had extensive training in welding practices Anyone not having this training shouldn t attempt to weld INSTALLATION OF EQUIPMENT Electrical equip ment shall be installed and maintained in accordance with the National Electrical Code NFPA70 and local codes Ground all power supply and auxiliary en closures to an adequate electrical ground such as an approved building ground cold water pipe or ground rod Have only qualified electricians do electrical installation troubleshooting and main tenance work on welding equipment Always use welding cable for the ground return circuit from the work to welder never use pipes carrying gas or f
20. 1 3 8 FUEL STRAINER ASSEMBLY 1 7 Consistingof UES SUR 2 PH 426Gromm 1 bowl Tillotson No OW 449 T 3 PH 442 Washers 6 205 5 1 3 FUEL STRAINER ASSEMBLY 1 6 SE ANSA Serien Without shut off valve cover md 4 104 Lok Thread screws glass bowl Tillotson No OW 444 FUELSTRAINERASSEMBLY THE FOLLOWING REPLACE STANDARD PARTS Without shut off valve in cover md metal powl Tillotson No OW 476 T 194 1 51 FLYWHEEL 1 The following serviceable parts are Includes 43 Ring Gearandtapped terchangeable for the above fuel holes for mounting rotating screen strainers FIL TERSCREEN 1 1 U 226 A STARTINGCRANKASSEMBL Y 1 GLASSBOWL 2 75 06137 METALBOWL 1 1 75 0W 447 CLAMP WIRE m d THUMB NUT AS SEMBLY 1 1 BOWL GASKET Wisconsin No Q 0 553 1 1 GLASS BOWL REPAIR KIT Parts included LQ 32 Repair Kit iRet Mumber 500 PD 173 A 501 PG 914 A 502 145 3 503 121 504 111 505 TC 365 F 506 TC 368 G 507 134 0 508 527 Description LOCKNUT for adfusting screw Part of standard engine Not part of this assembiy BRACKET control lever ADJUSTING SCREW 6 3 4 long RETAINER for adjusting screw spring SPRING fo
21. 313025 Models V 460D 4610 3 498 to 3 499 PISTON CYLINDER AT PISTON SKIRT THRUST FACES 0025 to 003 PISTON RING COMPRESSED GAP 008 024 PISTON RINGS SIDE CLEARANCE IN GROOVES CONNECTING ROD TO CRANK PIN SIDE CLEARANCE CONNECTING ROD SHELL BEAR ING TO CRANK PIN PISTON PINTO CONNECTING ROD BUSHING 2 0005 to 00117 0000 te 00087 PISTON TO PISTON sah CENTER MAIN SHELL BEARING TO CRANKSHAFT JOURNAL 0013 to 00387 STANDARD CRANK PIN DIMENSIONS 1 355 N 1350 WIDTH 1 072 2 1238 DIA GRIND 2 1233 ALL CRANK 5 CYLINDER BORE V 465D 3 748 to 3 749 002 to 004 008 to 016 0005 0018 2 3020 DIA GRIND 2 3025 CENTER MAIN SHELL SEARING 2 3000 R 2 3005 FOR OBSOLETE ROLLER BEARING Fig B 48 PISTON RING AND CLEARANCE CRANKPIN CENTER BEARING DIMENSIONS Piston and connecting rod is sub assembled to the cylinder barrel and the complete unit is mounted to the crankcase Lubricate the piston assembly and cylinder walls with No 30 S A E oil and stagger the ring gaps 90 around the piston Use a standard B 30 2 RING COMPRESSOR PISTON AND CONNECTING ROD FLAT ON CYLINDER BARREL AK Fig 49 automotive type ring compressor and insert rod end into cylinder from cylinder head end Note Rod bear i
22. APPENDIX list e 6 xo ec eee dee ES a Wow wow ow wo aie EAM ae Se Tua ATO SE A APPENDIX PAGINE p Re Re he ak Se Ee eh ii Page thru A 25 4 26 thru A 30 thru Instructions RECEIPT OF EQUIPMENT Check the equipment received against the invoice to make certain that the shipment is complete and undamaged If the equipment has been damaged in transit notify the carrier railroad trucking company etc at once and file a claim for damages Give the MODEL SPECIFICATION and SERIAL num bars of the equipment anda full description of the parts in error Refer to EQUIPMENT IDENTIFICATION on front sheet of this manual for an explanation of the specification numbers Best results with this equipment will be obtained ONLY if the responsible operating and maintenance personnel have access to this manual and are familiar with the instructions contained herein Generally it is good practice to move the equipment to the site of installation before uncrating Use care in un crating in order to avoid damage to the equipment when bars hammers etc are used A lifting eye which ex tends through the top of the cabinet has been provided to facilitate handling with acrane or hoist DESCRIPTION OF EQUIPMENT The Model GCC 300 W gasoline engine driven welding generator is a self contained uni
23. B 8 GENERAL INFORMATION AND DESIGN These engines are of the four cycle type in which each of the four operations of suction com pression expansion and exhaust requires a complete stroke This gives one power stroke per cylinder for each two revolutions of the crankshaft COOLING Cooling is accomplished by a flow of air circulated over the cylinders and heads of the engine by a combination fan flywheel encased in a sheet metal shroud The air is divided and directed by ducts and baffle plates to insure uniform cooling of all parts Never operate an engine with any part of the shrouding removed because this will retard the air cooling Periodically remove the cylinder head shrouding and clean out all the dust and chaff which may have col lected between the fins of the cylinder barrels and cylinder heads Dirt deposits between the cooling fins and in the shrouding will and cause the engine to See 5 CARBURETOR The proper combustible mixture of gasoline and air is furnished by a balanced carburetor giving correct fuel to air ratios for all speeds and loads IGNITION The spark for ignition of the fuel mixture is directed from the coil to the spark plugs at the proper time by a distributor Electric starter and generator are furnished with distributor ignition Magneto ignition can be furnished in place of distri butor when specified The high tension magneto used is
24. FIG B 104 WIRING DIAGRAM 10 WIRE MIN AMMETER DISCHARGE CHARGE IGNITION STARTING SWITCH ju 12 VOLT BATTERY CABLE F CUSTOMER STARTING SOLENOID FURNISHED BY CUSTOME ARTING MOTOR SPARK PLUGS IGNITION COIL CARBURETOR Walser sagu g TEMPERATURE SAFETY SWITCH ce EC REGULATOR ANTI DIESEL DISTRIBUTOR AND SOLENOID ACCESSORY DRIVE CUTPUT WIRE 310 MIN ALTERNATOR B 77 9 3431 254 14 amp P YB 69 ALTERNATOR Part No 12N451 SERVICE INSTRUCTIONS In Motorola Automotive Products Inc RA Series Alternator Systems 25 49 Service Manual MOTOROLA AUTOMOTIVE PRODUCTS INC 9401 W GRAND AVE FRANKLIN PARK ILLINOIS SERVICE PARTS Except for Drive Pulley Ref 3 and Regulator Ref 29 all other Alternator components should be ordered from a Motorola Automotive Products Distributor or Dealer Motorola Part No 20 136 NUT pulley mounting 5 8 18 thread hex 15 1 INSULATOR SLEEVE nylon 19 32 long 20 5 WASHER solitlock 5 84 11 25 RETAINER rear bearing MD 405 PULLEY drive 14 18 HOUSING rear ci 3 1 BRUSHASSEMBLY 20 32 SCREW tapping No 8 x 1 2 20 99 SCREW topping 10 x 1 2 with lock washer 7 8 FAN normal rotation clockwise 20 92 SP ACER fon md pulley 7 16 14 1 HOUSING 20 33 LOCKNUT hex No 10 24thread NUT square No 10 32threod 15 4 INSULATING WASHER N
25. For the Twin Disc clutch pull adjusting lockpin out and insert a piece of 1 16 diameter wire into the hole on the side of the lockpin to keep pin in outer position See Fig B 24 Turn the adjusting yoke in a clockwise direction as shown or wedge a screw driver into the adjusting yoke and against the side of the inspection hole opening to keep yoke from turning and then turn the take off shaft counter clockwise Tighten yoke enough so that the operating lever requires a distinct pressure to engage Remove wire from lockpin and trim adjusting yoke slightly to allow lockpin to snap into hole in floating plate A new clutch requires several adjustments until fric tion surfaces are worn in Do not let a new clutch slip this may ruin the friction surfaces CLUTCH REDUCTION UNIT 27 The clutch in the clutch reduction units is of the dry disc type the same as is used in the power take off units Therefore no oil should be put in the clutch housing The throwout bearing should be lubricated once a day before starting Add grease to fitting thru opening on side of housing as illustrated in B 27 using the Fig B 27 226226 ROCKFORD CLUTCH REDUCTION UNIT same type grease as used in the clutch power take off units Twin Disc units have an external grease fitting for the throwcut bearing The shifter shaft should be lubricated periodically if external oil fittings are provided for this purpose
26. HUB cssembly 13 iaganale COUPLINGSPRING GEAR BUSHING COUPLINGNUT Description SETS CREW coil 5 15 24 x 7 8 SCREW cover 6 32x1 4 Req i 5 LIST 1 57 1 77 Series 24 a 5 BY amp Pare Number 93 7 2158 93 C53 9 93 C130 4 9215257 1 93 17489 T 93 9 75 93 46 49 f 93 111 155 93 21 42 91315554 T M 5 S 9 358 10 93 CR27 241 93 827 241 1 93 27 307 93 CR27 451 93 29 1037 93 29 1429 93 C29 1386 93 29 1688 93 29 1886 M S S 93 152 24 N S 93 CR37 1x1 T 93 C102 113 93 C102 123 93 102 129 93 7315554 T 93 79 20 f 93 C31 17 35 93 C31 66 35 93 56 96 40 93 C56 104 42 93 C56 104 45 93 C56 124 40 92 7573 93 76 59 1 93 1 20 18 33 C120 81 93 C35 97 93 142 55 93 C52 2 12 MODEL 87A8 Description NUT Clomp Screw for 1 2 3 4 5 14 Washer Retaining for 1 2 3 14 15 WASHER Shaft Thrust for 1 2 2 5 4 RETAINER Throttle Shaft Packing One required for 4 5 SEAL Throttle Shaft One additional for 4 5 BUSHING Throttle Shaft M EEDL Idla Ad justing o SPRING Adiusting Needle PLATE SCREW Throttle Plate ROLL PIN Throttle Lever
27. j 12 for mounting unit to housing 1 600 205 HOUSING for drive hub 4 5 1 Not part of WW i65 Assembiy 601 NC 163 2 DRIVE HUB 115 612 7 LOCKWASHER 5 8 Positive is For mounting housing to crankcase i 602 464 STUD for housing tocrankcase mounting 4 13 i 613 86 LOCKWASHER 1 2 Countersunk 2 5 1604 489 RETAINER for drive hub sss 1 2 For mounting hub retainer I 605 PL 150 1 for drive l 1 2639 SCREW 1 2 13 thread x 1 1 44 long gt m socket flat head B 607 50 79 ASSEMBLY NUMBER 1 id For mounting hub retainer EN 615 XD 29 SCREW 3 8 i6 thread x 1 1 4 Long hexagon 22 2 2 1610 15 NUT 5 8 18 thread hexagon steel For mounting housinq to crankcase 8 for mounting ciutch to drive hub Not part ot WW 165 Assembly RF 1096 ELBOW checking 21 press nct STANDARD HARDWARE 1 j A case face iilustrated in oii header upper TM 9 3431 254 14 amp P FIG B 88 CLUTCH REDUCTION UNIT ASSEMBLIES
28. number int Piet 526 1 ion part ich is In Women the ERE VENTURI WELL VENT DISCHARGE JET MAIN JET METERING WELL Fig B 101 HIGH SPEED SYSTEM the sizes of of the di Ghar ge jet onno the 512 of it stat main M dm t oi rn of he the main jet 15 ek yt size of main jet openin CHOKE SYSTEM Fig B 10 paun tin gaap aur much tg dose mixture of of i ns alr tete inq d e Car ure eic 60 Set on the ding system Which m makes the mi ture king th th th ttle gore ue eto Pe ray eg eer ro ie e cho Fi 5 then then ed a um er m when the Tudi sul iy vai ed up the 15 ap OF to no W position ADJ USTMENTS Adjust the throttle stop screw to obtain the desired idlin speed by turning screw in clockwise to Increase sp and out counters clockwise to decrease engine speed should B 73 TM 9 3431 254 14 amp P Adjust the idle adjusting needle obtain smooth idling of the engine at idling sp ed Turn the needle out counter clockwise to make the mixture richer and in clockwise to make it leaner CHOKE PLATE VENTURI CLOSED POSITION THROTTLE PLATE i Ui d LOSED POSITION Fig 102 CHOKE SYSTEM SERVICE AND REPAIR PROCEDURE IDENTIFYCARBURETOR Check the numbers on the metal identification disc pinned to the
29. B 81 82 blank Order the Secretary the Army JOHN A WICKHAM JR General United States Army Chief of Staff Official ROBERT M JOYCE Major General United States Army The Adjutant General DISTRIBUTION Tobe distributed in accordance with Special Distribution List d RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING THis FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS y Add FORA CAREFULLY TEAR IT sd 1d GUT FOLD iT AND DROP IT PUBLICATION NUMBER PUBLICATION DATE PUBLICA TITLE TM 9 3431 254 14 amp P Welding Machine BE EXACT PIN POINT WHERE IT 5 IN THIS SPACE TELL WHAT 15 WRONG Tu PARA FIGURE TABLE ANO WHAT SHOULD BE DONE ABOUT NO GRAPH NO NC Reference to Page 2 should read Page 3 PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE Your Name Your Signature DA FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE TO YOUR HEADQUARTERS RECOMMENDED CHANGES EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WiTH FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT PUBLICATION NUMBER PUBLICATION DATE PUBLICA TITLE TM
30. QF 93 A RC 91 RF 934 1 RF 1096 RF 1299 RF 1319 RF 1368 RF 1374 RF 1514 INTERCHANGEABLE PARTS Description INSERT BUSHING 1 3 8 LD x I4 O E defor exhaust upper to lower fold gasket 1 upper to lower manifold center flange GASKET with INSERT For inlet manifold port to cylinder ead QEB 85 65 replaced by 85 GASKET carburetor ae GASKET 148 LD x 12 C D For exhaust port in cylinder head GASKET exnaust upper to lowermanifok IGASKET for upper to lower manifold icen ter flange iGASKET tor pump adapter GASK ET for fuel mounting I GASK ET for spacer plate to GASKET for gear cover to spacer IGASKET for oil pan GASKET tor cvlinder head QD 757 replaced 757 l GASKET for arm cover i GASK E T main pearing plate 003 thick SASK main searing plate 008 thick for main bearing plate 0056 thick Used in V 460D engines only ISHIM for main bearin plate 014 thick SCREENM oroilfillertube IPIPENIPPLE 1 38 x 19 long in car suu as u uha seat ELBOW 45 l in fuel pump outlet I for low oil pressure check on en gines with housing at end ELBOW in header for oil pressure line tocenterbecringhenger
31. SCREW Lever Stop LEVER and STOP Throttle for 1 2 4 LEVER and STOP Thretrle for 14 15 LEVER and STOP Throttle 3 LEVER and STOP Throttle for 5 2 SHAFT and LEVER Thrortle for 1 2 SHAFT and LEVER Throttle for 3 SHAFT and LEVER Throttle fee 14 15 SHAFT and LEVER Throttle for 4 SHAPT and LEVER Thrortle for 5 SHAFT wove wee a WASHER THROTTLE LEVER SPACER For 14 18 BODY Throttle PLUG Choke Shaft Hole for 1 2 3 4 5 14 One additional in Theettle Shaft Hole for T PLATE Choke 1 2 3 4 5 PLATE Choke for 14 4 4 PLATE Choke for 1 SCREW Choke Plate FIBER WASHER Fuel Valve Seat VAL Y and SEAT Fuel for 1 2 3 14 15 VALVE ond SEAT Fuel for 4 5 JET Discharge foe T J ET Discharge for 2 3 4 L 4 Oischorge dag 14 14 J ET Discharge for 5 FIBER WASHER Weil reete WELL Metering AXLE Float for 1 2 3 14 15 AXLE Float for 4 5 LLLI FLOAT ASSEMBLY e UU GASKET Bowl to Body 3 ET Idle aos se U u u lt 9
32. TM 9 3431 254 14 amp P FIG B 87 WW 165 DRIVE HUB AND HOUSING ASSEMBLY FOR CLUTCH POWER TAKE OFF AND CLUTCH REDUCTION UNITS NOTE THE DRIVE HUB AND HOUSING ASSEMBLY PART NUM STAMPED ON THIS am 602 612 610 OPTIONAL CO CLUTCH POWER TAKE OFF 5 oR CLUTCH REDUCTION UNIT The above assembly suitable for mounting the following Clutch Power Take Off and Clutch Reduction Units 229421554 WISCONSIN MOTOR PART NUMBER MANUFACTURER S PART NUMBER REDUCTION RATIO ROTATION AT TAKE OFF SHAFT DESCRIPTION ROCKFORD 4856 WC 329 ROCKFORD GRA 4812 ROCKFORD GRA 4813 TWIN DISC C108 E3 6 RG4 Clutch Power Take Off A Clutch Reduction Unit 2 77 to Clutch Reduction Unit 2 00 to 1 Clutch Reduction Unit 3 60 to 1 Enginewise Tounter Enginewise Counter Engine wise Enginewise REFER TO ROCKFORD OR TWIN DISC ILLUSTRATIONS FOR PARTS LIST OF CLUTCH POWER TAKE OFF AND CLUTCH REDUCTION UNITS NOTE Engines equipped with a Clutch Power Take Off or Clutch Reduction Unit require special 75 1 51 Part D ipti jRef Part No Number escription t Description WW 165 DRIVE HUB and HOUSING ASSEMBLY Consisting of the following parts LOCKWASHER 3 8 Positive amp for mounting clutch to drive nup 2 for mounting unit to housing i
33. YL 352 30 with Delco Remy regulator 3 for starting motor mounting 433 80 LO CKWASHER 3 8 intemal 2 418 YL 353A 27 GNITIONWIREASSEMBLY 1 1 For atr shroud to gear cover Ammeter to solenoid 434 37 LOCKWASHER 5 8 4 419 IGNITIONWIREASSEMBLY For engin e supports to crankcase YL 352 11 For generator to regulator field term 1 1 Y L 355 10 For gen erator to regulator am term 1 i 435 46 LO CKWASHER 5 16 extemal tooth 5 3 for mounting camshaft 420 YL 357 42 IGNITIONWIREASSEMBLY 1 i 2 for aenerator bracket Safety switch to distributor 436 PE 75 iLOCKWASHER 5 16 IET c enn 1 MISCELLANEOUS STANDARD i ror coil clamp and ground wire 637 SPACER fuel pump defl not ilust 1 1 437 18 PLUG 1 8 slotted steel 3 2 for upper oil header 424 77 NUT 1 4 20 thread hexagon steel 2 1 1 for 011 pump lock screw hole For voltage regulator mounting 4 lower oil header i for oil line fitting in case 425 PD 198 LOCKNUT 1 4 20thread 2 V 461D For atr cleaner strap 3 V 465D i438 XK 3 jPIPEPLUG 3 5 square i For timing hole in gear cover 426 78 NUT 5 164 18 thread hexagon steel 6 2 for generator mounting 439 PH 14 WASHER 5 26 1 0 x 19 328 2 Da l for generator adju sting strap iPlain copper
34. gradually as the engine warms up Push it all the way in as soon as the engine will run smoothly without being choked It may require choking even if engine is warm ENGINE THROTTLE 9 Pull OUT to idle the engine Shove IN to obtain operating RPM Control handle may be turned to lock in position at any setting desired When shutting the engine down always pull the throttle control handle all the way OUT AUXILIARY POWER OUTLETS TWIST LOCK Receptacle 10 Provides 115 volt 4 kVA AC power Circuit is protected by a circuit breaker CB4 of 20 ampere value A receptacle cover protects the receptacle when not in use b STANDARD DUPLEX Receptacle 16 Provides 115 volt 4 kVA AC power Circuits to the separate out lets of the receptacle are protected by circuit breakers CB2 and CB3 from overload The duplex receptacles have covers provided for protection when the receptacles are not in use NOTE Full auxiliary power output is available only when the generator is turning at 1800 RPM The engine driving this generator should be governed to within 3 of the speci fied generator speed 1800 RPM START RUN OFF Switch 12 Place in START position to crank the engine for starting When engine TM 9 3431 254 14 amp P has commenced to fire and has attained the running mode piece switch in RUN position For engine shut down place switch in OFF position WIRE FEEDER CONTROL RECEPTACLE 13 When unit is used wit
35. size pistons and rings This work should be done by an authorized service station If in the opinion of the service station attendant a chrome re ring is necessary use piston ring set indicated in Parts List Section PISTON RINGS Figs B 46 B 47 B 48 If a ring expander tool is not available install rings by placing the open end of the ring on piston first as shown in Fig B 46 Spread ring only far enough to slip over piston and into correct groove being care ful not to distort ring Assemble bottom ring first and work upward installing top ring last The outer dia meter of the too compression ring is chrome plated Mount scraper ring with scraper edge down otherwise oil pumping and excessive oil consumption will re sult Refer to Fig B 47 correct placement of rings for the V 460D V 461D and V 465D PISTON B 28 Fig B 49 The piston skirt is cam ground to an elliptical con tour Clearance between the piston and cylinder must be measured at the bottom of the piston skirt thrust face Refer to Chart Fig B 48 for proper clearance The thrust face on the piston skirt is 90 from the axis of the piston pin hole PLACE OPEN END OF RING 5 FIRST AS SHOWN Fig B46 71152C 9 3431 254 14 amp P V 465D PISTON V 460D V 451D PISTON CHROME FACED COMPRESSION RING COMPRESSION RINGS G SCRAPER OIL RING WITH EXPANDER SCRAPER
36. 59 2 Gear K 122 Shaft 61 5 111 5 111 for rep lace ment order 51 1 51 and 59 1 14 17 KC 59 1 Drive Gear inner for I 11B lt C 56 A 3 8 wide for K 111A K 111 KC 59 2Drivengearfor 111 8 KC 58A 2 8 wide 49 9 49891 For K 1lllA oil pump lt 56 A 1 3 8 wide For ioil pump K D 12 1 52 Drive Shaft for 111 Includes KC 539 1 Gear lt D 121A S1 with 56 Gear For K 111A K 111oil pumps KD 122 Stub Shaft 500 4995 For K ill B 1 11 oil PUMPS KD 122A 4973 4970 sess For 111 oil PUMP 64 Pin 1 8 dia x 3 44 long for Ani ver genes ru Fast te Mees al ag PD 195 Jam Lock nut 7 16 20 thread or gear mounting REA Reh PARANA DEG AGAR DORI PL 137 Key No 1 Woodruff for drive 501 5005 QD 535 A Cover gasket RD 2E Ser n irren eee eer RD 126 A Screen OIL PUMP STANDARD HARDWARE PE 14 Lockwasher No 10 spring lock cover for screen 7 Screw for screen No 10 32 thrd x 3 8 long steel round head X 8 Screw for cover No 10 32 thread x 1 2 long steel round head 56 Screw fr cover No 10 32 thread x 1 1 4 long steel round head 61 Set screw foc screen adapt er No 10 32 thread x 3 16 ong m po o SOM un 187 188
37. 93 488 T SEAL ThrottleShoft 93 52 7 41 JET One additionalfor4 5 42 93756 23 93 9 75 BUSHING Throttle Shaft 9 c46 49 43 93 C138 24 PLUG MainPossoge NEEDLE Idle Adiusting up 44 93 T91 1 PLUG 1 8 Pipe BowiDrain aaa 3 C111 155 SPRING AdjustingNeed I 45 93 30158 14 SCREW owitoBody Long 21 42 PLATE Throttl 46 93 T301S8 9 SCREW BowltoBodytShort 93 731555 4 SCREW 47 9 12 GASKET Flange ZenithC141 4 6 3 5 5 ROLLPIN ThrottleLaver a aaa 22 93 162 71 AUTO CHOKE ASSEMBLY 15 93 T858 10 SCREW LaeverStop 5 7 93 190 30 AUTO CHOKE ADAPTER ASS for 15 93 CR27 241 LEVER and STOP Throttle for1 2 4 Z 93 146 25 AUTO CHOKE ADAPTER GASKET for 15 93 CR27 241 1 LEVER and STOP Throttle for 14 15 93 181 296 GASKETAET Sees eere teda 1 93 CR27 307 LEVERondSTOP Throttlefor3 93 CR27 451 LEVERandSTOP Throttlefor5 LQ 37 REPAIRKITforl 2 3 14 15 93 K2212 REP AIRKIT 1 93 C29 1037 SHAFT and LEVER Throttlefor1 2 93 C29 1429 SHAF T andL EVER Throttlefor3 93 C29 1386 SHAFT and LEVER Throttle for 14 15 93 C29 1688 SHAFTandL EVER
38. BENDIX DRIVE ASSEMBLY NOTE Code number 28 prefixed to the part number is a vendor identification When ordering parts please use number with code SOND 21 22 23 25 26 27 Part Number 28 MDL 1064 28 MZ 19S 4 28 MDU 200SAS 1 28 GJ 208 28 MDT 1002 28 MDL 2048C Description FRAME and FIELD ASSEMBLY includes SCREW for pole INSULATING WASHER for terminal stud INSULATION for field connection BRUSH PLATE ASSEMBLY Includes GROUNDED BRUSH 2 tite e BRUSH SPRING INSULATING WASHER for term stud inner TERMINAL STUD isto 5 INSULATING BUSHING for terminal stud FIELD COME PKG rat em Aa Includes PLAIN WASHER 5 16 for terminal stud LOCKWASHER 8 for terminal stud SCREW for terminal stud and ground lead No 8 32 thread x 5 16 long round head LOCKWASHER 5 16 for terminal stud NUT for term stud 5 16 18 thread hex SCREW for brush plate not illust NUT for term stud 5 16 18 thread hex THRU BOLT PKG SE one odo mon ao EE eo LOCKWASHER 1 4 for thru bolt COMMUTATOR END HEAD ASSEMBLY FELT for end head ioca enl ARMATUREASSEMBLY THRUST WASHER 1 32 thick for armature 1 commutator end THRUST WASHER 3
39. See Filter instructions Page 11 5 Rotating screen must be kept clean Accumulated dirt caked on screen will restrict cooling 6 Read instructions on aircleaner regarding its care The entire air cleaner should be removed from the engine at least once a year and washed in a sol vent to clean out dirt gathered in the back fire trap and filter element 7 The collector type pre cleaner must be emptied of accumulated dirt frequently depending on dust conditions Do not use oil or water in pre cleaner this must be kept dry 8 Do not allow shrouding to become damaged or bad ly dented as this will retard air flow Never operate engine with air shrouding removed Every 4 to 8 hours depending on dust conditions check air cleaner and change oil Se P Eze B 13 Every 8 hours check crankcase oil level Keep filled to full mark oil gauge saber but no more Every 50 hours drain crankcase and refill with fresh oil See Lubrication atnd B 10 Fig B2 281380C B 5 9 3431 254 146P EXHAUST MUFFLER CARBURETOR ANTI DIESELING SOLENOID CHOKE BUTTON VARIABLE SPEED OIL FILLER AND GOVERNOR CONTROL BREATHER CAP OIL PRESSURE GAUGE IGNITION STARTER SWITCH AMMETER CYLINDER NUMBERS VOLTAGE REGULATOR IGNITION COIL FLYWHEEL SHROUD GENERATOR DISTRIBUTOR PRE CLEANER FUEL PUMP HEAT SHIELD OIL BATH AIR CLEANER GA
40. This bearing is packed with enough grease when the unit leaves the factory to last 6 to 8 months under the most severe use Greasing twice yearly is sufficient for the bearing under normal use Pressure fittings are not recommended because grease under pressure may go through the bearing grease seal and onto the commu tator causing poor commutation and possible damage to the commutator Dirt causes more ball bearing failures than any other thing Dirt may get into the grease when the bearing cap is removed for inspection Therefore it is not ad visable to inspect the bearing more often than about twice yearly and then before removing the bearing cap always wipe it absolutely clean Remove as much old grease as possible and wash out cap and bearing with kerosene MIL PD 680 DO NOT use gasoline Fill the clean bearing cap about 1 3 full of high quality ball bearing grease Work as much grease as possible into the bearing Place cap into position and bolt tightly MIL L 10924 WARNING Do not use gasoline or other highly flammable solvents for cleaning bearings CAUTION Do not overlubricate or allow lubricant to become contami nated Do not use ordinary cup grease or graphite based lubricants Manufacturer has available a special ball bearing grease part 4141 32 0 45 kg containers ENGINE Refer to specifics on lubrication Engine Manual for EXCITER AUXILIARY BRUSHES INSPECTION Eve
41. Throttiafor 4 93 C29 1886 SHAFT EVER Throttlefor 5 N S S SHAFT Throttle iiie tentiae 93 T52 24 WASHER THROTTLE LEVER SPACER ee E N S 5 BODY Throttle tette 93 CR37 1x1T PLUG Choke Sha t Hole for 1 2 3 4 5 14 One additional in Throttle Shaft Hole fo 93 C102 113 PLATE Chokeforl 2 3 4 5 93 102 123 PLATE Chokefor14 93 102 129 PLATE Chokefor15 93 731555 4 SCREW ChokePlate 93 T56 20 FIBERWASHER FuelVolveSegt MN red VALVE and SEAT Fuel for 1 2 3 14 15 93 C81 66 35 T VALVEandSEAT Fuelford 5 Parts Inciuded in Repair Kit Gasket Set N S S Not Sold Separately NOTE The Idle Air Bleed Bushing and Well Vent Bushing are calibrated ports of the Throttle Body Item 26 and are not readily removable 93 56 96 40 JET Dischorgefor1 93 66 104 42 JET Dischargefor 2 3 4 93 66 104 45 JET Dischargefor14 15 93 C66 124 40 JET Dischargefor5 93 756 73 FIBERWASHER Well 93 76 50 1 WELL Metering 93 C120 18 1 2 3 14 15 93 120 81 AXLE F loatfor4 93 C85 97 93 C142 55 GASKET BowlteBody ssec rne 93 C52 2 12 au TM 9 3431 254 146 69 ALTERNATOR Engine Model V 465D 5PECIFICATIONS
42. 10 amperes positive If the battery has been damaged or heavily discharged the meter will indicate a much greater current NOTE The following welding termi nals are located on a panel on the left hand side of the generator NEGATIVE WELDING TERMINAL A common connection which connects to the WORK material being welded by the WORK lead Se TM 9 3431 254 14 amp P CONTROLS INSTRUMENTS AND OUTLETS Con tinued mk L T T KA I POSITIVE MICRO WIRE TERMINAL For semi automatic automatic welding processes using 1 wire d so gt 40 POSITIVE MULTIWIRE TERMINAL semi 3 3 automatic automatic welding processes using 40 0 100 200 300 400 500 600 700 800 POSITIVE SHIELDED METAL WELDING LOAD AMPS TERMINAL For Stick welding in the CC mode Amp Characteristics Constant Current Fasten electrode lead to this terminal NOTE To obtain reverse welding polarity simply reverse the connec 60 tions to the positive and negative MULTI WIRE terminals a SPECS GiOIA t 50 RHEO SET 50 96 RHEO SET MIN 40 o 30 a 3 4 20 10 COMO SS 80 ETAT o 50 100 150 200 250 300 350 400 LOAD AMPS 0 Amp Characteristics Constant Voltage MICRO WIRE Figure 2 SPECS 6101 1 AMEO SET MAX RHEO SET 50 MODE SEL
43. 17 Condensation on spark plug electrodes Breaker points pitted or fused Breaker arm sticking Distributor condenser leaking or grounded Spark timing wrong See B 13 ENGINE MISSES Spark plug gap incorrect Seg Page B 17 Worn and leaking ignition cables Weak spark or no spark in one of the cylinders Loose connection at ignition cable Distributor breaker points pitted worn or incorrect gap See Distributor Timing Page B 14 Water in gasoline Poor compression See Compression Sticky valves ENGINE SURGES GALLOPS Carburetor flooded Governor spring hooked into wrong hole in lever Governor rod incorrectly adjusted See Governor Ad justment ENGINE STOPS Fuel tank empty Water dirt or gum in gasoline Gasoline vaporized in fuel lines due to excessive heat around engine Vapor Lock See Stopping En LPage Vapor lock in fuel lines or carburetor due to using winter gas too volatile in hot weather Air vent hole in fuel tank cap plugged Engine scored or stuck due to lack of oil Ignition troubles See Ignition Page B 21l Wire from anti diesel solenoid to starting switch dis connected or damaged ENGINE OVERHEATS Crankcase oil supply low Replenish immediately lenition spark timed wrong See Neon Lamp Timing Low grade of gasoline Engine overloaded Restricted cooling air circulation Part of air shroud removed fro
44. 189 190 191 192 194 19 194 197 198 20 20 Se 2 77 8 51 buretor where Y 83 1 LD 257C S1 10 2580 51 125131 L J 300 M LJ 392 A RF 1495 8 1495 LK 24 LK 9 LL 30 A LL 89 LL 146 LO 60 i LP 19 B LP 38E 2 S1 9 3431 254 14 amp INTERCHANGEABLE PARTS for Models V 465D and V 460D V 461D Description CARBURETOR ASSEMBLY Zenith outline No 12708 Wisconsinassembly includes Anti diesel solenoid valve 3 QC 12 A gaskets 2 171 studs LQ 37 Repair Kit for carburetor orderinq replacement carburetor or Parts retor bulletin in back of manual for service parts list ANTI DIESEL SOLENOID VA LEE vounted in carburetor bo wl Includes PK 162 locking tab MANIFOLD ASSEMBLY ower inlet Includes 4 XD 17B Screws xx 1 Plug LD 257A Sland LD 2578 S l replaced LE 257 C 81 MANIFOLD ASSEMBLY upper exhaust Includes 2 162 Screws 4 17 screws LD 258B S1 replaced 1 2 258 51 TUBE orair cleaner connection OIL FILLER LJ 300 AL replaced by 1 3 00 PUSH ROD CASING ASSEMBLY Consi sting of HF 585 Collar LJ 392 Casing TUBE for standard RJ 173 dip stick ForRJ 173 A starter 11 415 Tubetor obsolete RJ 163 Install dip stick tubes with Loctite HOSE CLAMP 2 1 4 1
45. 490841 4 20 490842 4 490863 4 4 490886 4 65 490869 4 46 490870 4 45 490871 4 49 490874 2 12 490877 4 47 490879 4 48 490890 D 490891 A 4 73 490898 Sen 490910 1 83 490910 2 4 490915 2 52 490921 2 490923 4 490995 3 3 491065 2 1 491071 4 61 491072 4 75 491077 4 53 491078 4 58 491082 1 4 5 491083 4 50 491084 4 51 491085 4 54 491086 4 69 491090 4 15 491096 4 13 491099 2 50 491102 2 491104 4 11 491111 4 52 491114 4 19 491115 4 18 491116 4 491117 4 491118 4 9 491120 4 91 491121 2 23 491122 4 71 491123 4 62 491160 4 76 TM9 3431 254 14 amp P NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 491164 4 70 491167 4 491168 5 27 491170 5 491171 5 54 491173 4 84 491176 2 54 491177 491178 2558 491181 2 95 20 491182 4 56 5 491184 1 4 17 491188 4 78 491190 4 2 5CW 96 3 3 5CW 974 4 23 5CW 975 A 4 22 50GH 937 0 2 4 50 5 306 4 50NH 270 A 4 6FW 5651 A 4 39 76B 1149 4 74 THE FOLLOWING ITEMS WERE ADDED TO UPDATE THE NUMERICAL INDEX A 28 4 48 84 2 491162 4 37 491174 4 93 491253 4 9 3431 254 14 amp P Diagrams 1 Note the model and specification number shown on the equipment nameplate 2 Locate these numbers in the model and specification numbe
46. 64 5 3900 60 5 65 5 HORSEPOWER The horsepower given in the above chart is for an atmospheric temperature of 60 Fahrenheit at sea level and at a Barometric pressure of 29 92 inches of mercury For each inch lower Barometer reading deduct 3 296 from above horsepower For each 10 higher temperature there will be a re duction in horsepower of 1 For each 1000 ft altitude above sea level there will be a reduction in horsepower of 342 The friction in new engines cannot be reduces to the ultimate minimum during the regular block test but engines will develop at least 85 per cent of maximum power when shipped from the factory The power will increase as friction is reduced during a few days of operation The engine will develop approximately 95 of power shown on chart when friction is reduced to a minimum For continuous operation limit to 80 of horsepower shown as a safety factor INSTRUCTIONS FOR STARTING AND OPERATING LUBRICATION Before starting a new engine fill crankcase with the correct grade of lubricating oil as specified in Grade of Oil chart Fill through the breather tube opening with 6 quarts of oil and check level by means of the oil gauge saber When replacing oil filter an addi tional 1 quart of oil is required For run in of new engines use same oil as recom mended in Grade of Oil Chart The standard oil gauge saber is located on the left side below the oil filler breather tub
47. 74193 74400 77574 77910 VENDOR S AND ADDRESS Cutler Hammer 1391 W St Paul Avenue Milwaukee Wisconsin 53233 Lord Manufacturing Company Inc Sterling Road South Lancaster Massachusetts 01561 J B T Instruments Inc 424 Chapel Street P O Box 1818 New Haven Connecticut 06508 Main Line Supply Co Inc 805 E Third Street Dayton Ohio 45402 Ohmite Manufacturing Company 3601 W Howard Street Skokie Illinois 60076 Syntron Company 1938 Black Street Homer City Pennsylvania 15748 Triplett Electrical Instrument Company Harmon Road Bluffton Ohio 45817 Carling Electric Inc 505 New Park Avenue West Hartford Connecticut 06110 Heinemann Electric Company 2612 Brunswick Pike Trenton New Jersey 08802 Hobbs Division Stewart Warner Corporation Yale Blvd and Ash Street Springfield Illinois 62705 Richland Auto Part Company Inc 151 Distl Avenue Mansfield Ohio 44903 Shakespeare Products Division of Shakespeare Company Inc 241 E Kalamazoo Avenue Kalamazoo Michigan 49001 CODE 79470 81074 81082 81091 81703 83315 91929 92701 98410 16764 19728 TM 9 3431 254 146 VENDOR S NAME AND ADDRESS The Weatherhead Compeny 300 East 131st Street Cleveland Ohio 44108 Holub Industries Inc 414 HI Center Sycamore Illinois 60178 Electric Auto Lite Company Lebanon Road Cincinnati Ohio 45241 Pass amp Seymour Inc Solvay Station Syracuse New York 132
48. 9 3431 254 144 Welding Machine IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT PARA FIGURE TABLE GRAPH NO NO PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER DA FORM 2028 2 P S AF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS PREVIOUS EDITIONS JUL 79 AND GIVE IT TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 DRSMC OP 16 83 FILL IN YOUR UNIT S SOORESS 7 Py BACK DEPARTMENT OF THE ARMY POSTAGE AND FEES PAID OF THE ARMY DOD 314 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 Commander US Army Armament Munitions and Chemical Command ATTN DRSMC MAS R Rock Island IL 61299 JNN 031 801834 3NOTV uvis THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches Y Kilometer 1000 Meters 0 621 Miles WEIGHTS 1 Grom 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Lb 1 Metric Ton 71000 Kilograms 21 Short Tons LIQUID MEASURE 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces SQUARE MEASURE 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Sq Kilometer 1 000 000 Sq Meters 0 386 Sq Miles CUBIC MEAS
49. CV welding 8 Strike arc 9 Adjust Fine Current Control if required 10 If Range Switch must be adjusted break arc Do not change setting of Range Switch while welding MICRO WIRE WELDING to 045 inch 1 143 solid wire at 250 amperes 1 Attach a welding lead to the work end to the NEGA TIVE CC W terminaL Attach a lead to the wire feeder and to the POSITIVE CV MICRO WIRE terminal CAUTION Be certain to check circuit compatibility for wire feeders Damage to welding generator circuits and wire feeder may result if circuits are incompatible 2 Connect control leads between wire feeder and Wire Feeder Receptacle 3 Plug wire feeder power leads to 115 V AC duplex receptacle on the Control Panel if wire feeder is equipped with standard AC plug 4 Set MODE SWITCH to CV welding mode 5 Set Toggle Switch to CV welding 6 connect shielding or cooling accessories which may be used with certain types of welding guns 7 Start generator engine adjust Throttle to produce rated operating RPM 8 Proceed with welding as instructed in wire feeder manual MULTI WIRE WELDING 045 inch 1 143 mm and larger diameters at welding currents over 250 amperes 1 Attach a welding lead to the work and to the NEG ATIVE CC CV terminal Attach a lead to the wire feeder and to the POSITIVE CV MULTI WIRE terminal 10 2 Make certain that the correct guides and wire feed rolls are installed in the wire feeder for th
50. DOWEEPIN CE chet ya DOWEL PIN PLATE felt washer retainer D E OIL WICK p s PLUG C E not illustrated No TM 9 3431 254 B 93 60 Neg Grd 12 V 17 AMP GENERATOR Prestolite GJY 7401SN 60 Grd 12 V 17 AMP GENERATOR Prestolite 74015 Service parts interchangeable both generators REF NO 29 COMMUTATOR END HEAD ASSEMBLY amp 18 54 T Ar 41 44 49 E REF NO 40 DRIVE END HEAD ASSEMBLY FRAME amp FIELD ASSY 47 NOT SERVIC 42 43 48 2 NOTE Code number 28 prefixed to the part number is a vendor identification When ordering parts please use number with code 10 Part Number 28 2012 5 28 1005 28 2002 28 GJC 38A 28 X 3326 Description FRAME and FIELD ASSEMBLY includes WA SHER ins field WASHER plain field term sae BUSHING ins eid BRUSHARM INSULATION brusnnoider BUSHING ins arm term BRUSH SPRING HOLDER cor ground BRUSH SET for service FIELD COIL ASSEMBLY consisting o STUDtortieidterminal 10 32 LD COIL right FIELD COIL latino rata HOLDER temm ins POLESHOE
51. DRIVE ASSEMBLY FIG B 74 FLYWHEEL AND AIR SHROUDING GROUP Parts are identified by reference number See parts list for correct part number 9 3431 254 146P 461 432 436 281214 1 281151C 281152 1 FIG B 77 GENERATOR AND REGULATOR MOUNTING GROUP Parts are identified by reference number See parts list for correct part number TM 9 3431 254 14 amp P t308 449 u 51 94 281213C 1 FIG B 78 CONTROL PANEL GROUP FIG B 79 AIR CLEANER GROUP um n ras Mi 02 Xx ju qi ORAIN LINE PUS 3 ROO CASING INSERT BUSHING 4 REQ 1 4650 GASKET BUSHING 3 REQ EXHAUST PORT 2 RING 4 REQ O RING 6 REQ CYL HEAD EXH PORT X PORT CYL HEAD GASKET 4 REQ z A M 27 2 OIL ZOLLET COUPLING ANGE FUEL PUMP 15 2 e ij NG 2 REQ GASKET 3REQ ADAPTER GASKET F of ACCESSORY ORIVE GOVERNOR CYLINDER HEAD CYLINDER JASE HOUSING GASKET HOUSING GASKET 4 REQ Oo C 50 GASKETS 4 REQ COLLET ADAPTER 2 RING OIL PUMP FUEL PUMP COVER GASKET GASKET 003 204 THICK MAIN BEARING PLATE GASKET 2 REQ ie D OIL PAN GASKET i be i e ROCKER ARM COVER CRANKCASE GASKET SASKET MAIN BEARING PLATE c GASKET GEAR COVER GASKET 4 REQUIRED SASKET 2 RE FIG B 80 Ref No 257 ENG
52. HOSE AIR CLEANER SUPPORT AIR CLEANER RECEPTACLE CANOPY SHIELD HEAT FUEL TANK SUPPLIED W ENGINE UNITS PER ASSEMBLY 9 3431 254 14 amp P Selector Switch Contactor Ballast Resister FuelLine Group Figure A 5 TM9 3431 254 14 amp P FIG NO A 5 NHA ITEM NO QO N Pp 10 RH 12 14 25 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NO 430547 490420 430258 430259 430141 DATA 3165 370704 356089 3 16DA 954 2 430139 370711 430172 1 430146 400562 8 430265 370708 370714 402070 370710 430145 370706 491182 491181 350855 350854 490442 350849 350853 12CW 1693 491168 490890 W 10750 8 W 10902 1 W 11608 2 402265 402927 2 W 10869 14 355325 11 405091 1 490898 W 10119 1 W 10888 2 353630 3 W 10883 0 W 10886 1 NEXT HIGHEST ASSEMBLY NOMENCLATURE CONTRACTOR 350 A DC ASSEMBLY FOR NHA SEE FIG A 4 ITEM 68 PLATE MOUNTING INSULATOR CONTRACTOR BASE CONTRACTOR TIP CONTACT COIL 300 A POLEPIECE CONTRACTOR SUB ASSEMBLY PIN SPRING LEAD PIGTAIL SUPPORT CONTACT MOVING PIN SUPPORT SUPPORT ARMATURE SPRING TAIL ASSEMBLY PLATE MOUNTING MICRO SWITCH INSULATOR MICRO SWITCH SWITCH MICRO PLATE ARMATURE STOP PLATE ARMATURE FRAME CONTACTOR RESISTOR BALLAST ASSEMBLY FOR NHA SEE FIG A 4 ITEM ITEM 56 MOUNTING BOTTOM
53. INSULATING BUSHING for terminal stud BRACKET iorcopsprirq BRONZEBEARING TERMINALSTUD INSULATING WASHER for terminal stud CLAMP SPRING for cap NUT for terminal stud 1 0 32 thread PLAIN WASHER for terminal stud 10 LOCK WASHER for terminal stud 10 RIVET for clamp spring stud BASE 16 No AD 6004 2N 108 51 Less Condenser AD 6004 26 ASSEMBLY gt NN 0 p non oe e e 28 16 2035 28 16 21681 5 x e 28 165 325 28 1G 1180L 28 X 1590 PG 543 A w NOTE Parts less part number not serviced separately All Parts are Identical Except Spring Set for Governor Weights as Noted When ordering parts please use number with code 187616 Port 4226 Number Description zi T HRUST WASHER inner for drive snc t THRUST WASHER outer for drive shaft THRUST WASHER cr drive short lower SNAPRING srcorm_ 28 1G 1324D DISTRIBUTOR CAP ASSEMBLY inciuaes PLUNGER CONTACT and SPRING 28 G 1657R ROTOR SPRING SET governor weights 19 51 28 IGC 200S for 1 51 108 51 5 FELT WICK or cam CAP PLUG PKG for vent not illust FELTWICK notillustrated
54. No 1 and 3 cylinders See ili Starting JUL Solenoid lt I Spork Plugs Ignition Starting Switch Starting Motor Carburetor Anti Diesel Solenoid Hi Temperature Safety Switch Fig B 17 MAGNETO IGNITION WIRING DIAGRAM The magneto is driven at crankshaft speed clock wise direction when viewing gear end of magneto The magneto distributor rotor turns at half engine speed Magneto breaker point gap is 0 015 inch at full sepa ration If the ignition spark becomes weak after con tinued operation the breaker points may have to be readjusted or replaced Refer to Manufacturer s Bul letin in rear of manual for service and adjustment of breaker points IGNITION SPARK B 18 If difficulty is experienced in starting the engine or if engine misses firing the strength of the ignition spark may be tested as follows Disconnect the cables from all towers on the distributor cap except the center coil tower Insert a stiff piece of wire or metal rod into one of the sockets Hold the terminal for this tower 1 8 inch from the wire or rod as shown B 18 Turn engine over slowly two complete revolu tions with the hand crank and watch for a spark to discharge during the cranking cycle Fig B 18 27779 Repeat this check with each the other cables A good spark at each of the towers will elimi nate the ignition coil and distributor as
55. No s WC 329 and WC 330 Adaptable to WW 165 Drive Hub and Housing Assembly 229636C Parts are identified by reference number See parts list for correct part number 9 3431 254 14 amp CLUTCH REDUCTION UNIT ASSEMBLIES ROCKFORD WISCONSIN REDUCTION ParT NO PART NUMBER RATIO GRA 4812 WC 329 2 77 to 1 GRA 4813 WC 330 2 00 to 1 PARTS LIST NOTE Code number 63 prefixed to the part number is a vendor identification When ordering parts please use number with code as shown 1 Rockford Rockford REF No 1 REF No 2 REF No 3 REF No 4 REF No BREF No 6 Assembly No Assembly No Housing Cover Cover Drive Gear Drive Shaft Driven with Clutch less Clutch Gasket and Shaft Beoring Gear Ref No 1 to 46 63 GR 852 1 ME 200 63 GR 853 E 2 u 101 GR i GRA 4812 GRA 4M12 GR 851 GR 101 3 63 GR 111 18 teeth was GR 856 50 teeth 163 GR 852 2 200 63 GR 853 2 GRA 4813 4 13 GR 851 GR 101 3 63 GR 111 23 teeth was GR 856 46 teeth Not serviced individuaily order 63 UGR 1 851 Housing and Cover Assembly THE FOLLOWING PARTS ARE IDENTICAL FOR THE ABOVE ASSEMBLIES EXCEPT WHERE NOTED Ref o No Ref Part r No Description Number Description Req 7 63 P T 1593 INSTRUCTION PLATE atas 1 43 63 PT 718 1 LOCKWASHER clutch gedy
56. Oil Filter For run in of new engines use same oil as recom mended in Grade of Oil Chart Follow summer recommendations in winter if engine is housed in warm building Check oil level every 8 hoursof operation The old oil should be drained and fresh oil added after every 50 hours of operation To drain oil remove drain plug in oil pan at oil filter side Oil should be drained while engine is hot as it will then flow more freely FUEL The fuel tank should be filled with a good quality gasoline free from dirt and water Some of the poorer grades of gasoline contain gum which will deposit on valve stems piston rings and in tie Various small passages in the carburetor causing serious trouble in operating and in fact might prevent the engine from operating at all Use only reputable well known brands of REGULAR GRADE gasoline The gasoline should have an octane rating of at least 90 Low octane gasoline will cause the engine to de tonate or knock and if operation is continued under this condition cylinders will score valves will burn B 10 8 Fig B 6 83622 pistons and bearings will damaged etc Be sure that air vent in tank cap is not plugged this would impede the flow of fuel to the carburetor FUEL PUMP and PRIMINGI Eig B5 The diaghragm type fuel pump is actuated by an ec centric on the cam illustrated in cross sec tional view of engine Hand Primer for hand crank engine
57. The distributor generator regulator and igni tion coil furnished are products of either the Delco Remy Company or Prestolite Company It is suggested that when replacement of any of these parts becomes necessary that the replaced parts be of the same manufacture as the other components TIMING FIRING ORDER The firing order of the cylinders is 1 3 4 2 and the battery type distributor rotates at one half engine speed as is the case with conventional in line en gines The intervals between the firing of the cylin ders is 180 No 1 cylinder is the one nearest to the flywheel in the left bank of cylinders when viewed from the flywheel end of the engine No 3 cylinder is the other cylinder in this bank No 2 cylinder is the one nearest to the flywheel in the right bank of cylin ders and No 4 is the other cylinder in this bank The TM 9 3431 254 14 amp P ROCKER ARM ASSEMBLY FOR 1 CYLINDER y Z both Valves Closed when X Marked Flywheei Vane is Locoted shown Inlet Rocker Arm Movement during Cranking Cycle just before Compression Stroko INLET ARM CENTERLINE fer CYLINDER EXHAUST VALVE 52 AEN ROCKER ARM Ne a Leading Edge of Marked Vane on Flywheel Running Spark Advance is for Timing Light Check cylinders are numbered from 1 to 4 on the cylinder head covers TIMING MARKS Refer td Fig B
58. UNITS PER ASSEMBLY 9 3431 254 148 Frame Engine Group Figure A 4 A 10 TM9 3431 254 14 amp P FIG NO A 4 ITEM vo Q N P Z m 1 lS 20 21 22 29 24 25 26 27 28 29 30 31 32 33 34 35 36 34 38 39 40 41 42 43 NOT ILLUSTRATED PART NO 49116 491190 351978 90863 91082 1 90174 90175 90040 91118 HF 567 491104 50NH 270 490083 491096 358836 91090 90258 91184 1 91115 91114 90842 90841 4DW 77 5 975 5CW 974 NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER NO NUMBER 402037 13 491167 491162 A 25 6FW 5651 356189 W 10931 3 W 10933 3 361182 5 491253 4 4 4 4 4 4 NOMENCLATURE FUEL CAP FUEL ASSEMBLY YOKE LIFTING ASSEMBLY PLATE HINGE UPPER PLATE HINGE LOWER HINGE DOOR DOOR SIDE LEFT LATCH DOOR HANDLE DOOR LATCH SPACER DOOR LATCH STRAP FUEL TANK TANK FUEL ASSEMBLY GAUGE FUEL SUPPORT FUEL TANK REACTOR CONTROL GUARD EDGE TRIM SHIELD HEAT ENGINE SHIELD HEAT COMP PANEL TERMINAL ASSEMBLY PANEL TERM OUTPUT SHUNT 800 A 50 MV ASSEMBLY BUSHING BAR BUS L SHAPED SCREW 1 2 13 X 1 1 4 HHC ST SCREW 1 2 13 X 3 4 HHC ST WASHER LOCK 1 2 STEEL WASHER STEE
59. V 465D and V 460D V 461D lef Port E Mo Net Wt lef Port D 5 Net We Number Description Req 1 6 No Number iA te Lb Oz 106 RV 34 A OIL PRESSURE RELIEF VALVE ASS Y 1 6 338 TC 389A l obsolete Gear bushing 1 2 For TC 405 and TC 405B 307 SD 255 TAG for YC 27 B ignition starting switch 1 i 339 442 Flyweightrollpin 2 H 340 VE 549 8 Contro l rod to carburetor 1 Lt 308 50 265 TAGforchokeinstructions eee 1 1 GOVERNOR STANDARD HARDWARE 309 50 312 ENGINENAMEPLATE 1 343 PE 4 Lock washer 5 1 60 for housing 4 1 NOTE When ordering name plate give 344 PH 332 Washer 1 84 1 0 x 5 16 0 0 Model Specification Number and Serial between control rod and lever 1 1 Number for correct stamping 345 XD 16 Screw 5 16 18 x 773 hex 4 1 For govemor housing 310 SE 48 SCREENorflywheelshroud 1 1 346 32 Cotter pin 3 64 dia 3 34 long forcgontrolrod 1 1 311 5 239 FLYWHEELSHROUD 1 16 8 NOTE The following parts are not included in T 89 etc for service 312 5 240 CYLINDERSHROUD L H s de 1 1112 347 PD 173AAdjustingscrewnut 1 1 313 5 240 CYLINDERSHROUD R H side 1 112 348 145 Adjusting screw 6 3 4 lon 1 2 349 388 1 1 3 3
60. VOLTS 12 VENTILATED Yes BRUSHES 2 CONTROL Voltage LUBRICATION Bearings are pre lubricated No PRECAUTIONS Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator Asa precautionary measure disconnect ground battery terminal when charging battery in vehicle Connecting charger in reverse will destroy the rectifier diodes in the alternator Do Not under any circumstances short the field terminal of the alternator to ground as permanent damage to the regulator may occur Do Not remove the alternator from the vehicle without first disconnecting the grounded battery cable RATED OUTPUT 37 Amperes ROTATION Clockwise at drive end additional lubrication necessary Regulator Do Not operate engine with battery disconnected or dis connect the alternator output lead while the alternator is operating as damping effect of the battery will be lost The voltage will rise to an extreme value and permanent damage to the regulator may occur Do Not disconnect the voltage regulator while the alterna tor is operating because the large voltage transient that occurs when disconnection takes place may damage the regulator Caution Output wires from Alternator to Ammeter and from Ammeter to battery terminal on starting solenoid must be of sufficient size for charging 37 amps Use No 10 gage stranded wire or larger
61. cable clamp to the positive battery post first then the other cable clamp to the negative post CAUTION A short circuit to rectifier is created if a battery is installed with polarity reversed Current can flow from positive terminal of battery through negative and positive rectifiers and into heat sink From heat sink a completed circuit exists back to neg ative battery terminal Full battery voltage will be impressed on rectifiers in the alternator The resulting high current will damage rectifiers and or wiring harness See Engine Diagram for correct battery connection 8 Pump gasoline into fuel tank using care not to spill fuel on canopy or engine Be sure air vent on fuel tank is open Observe SAFETY WARNINGS when filling fuel tank 9 Check to be certain that there are no obstructions in any rotating parts 10 Check to be certain that none of the oil connections on the engine show leaks NOTE There is only one point of lubrication on this generator DO NOT lubricate the generator bearing at this time See MAINTENANCE section for frequency of greasing the generator bearing GROUNDING The frame of this unit should be grounded for personnel safety Where grounding is mandatory under state or lo cal codes it is the responsibility of the user to comply with all applicable rules and regulations Where no state or local codes exist it is recommended that the National Electrical Code be followed These r
62. care must be exercised in reassembly so the right screw will be used in the proper place Tighten the capscrews and nuts of the manifolds cylinder heads gear cover oil pan connecting rods cylinder barrels main bearing plate and the spark plugs to the specified torque readings indicated in the paragraphs of reassembly relative to these parts While the engine is partly or fully dismantled all of the parts should be thoroughly cleaned Use all new gaskets and O rings in reassembly and lubricate all bearing surfaces The following procedure is for complete disassembly of an engine As disassembly progresses the order may be altered somewhat as will be self evident to the mechanic Reassembly of the engine should be made in the reverse order TESTING REBUILT ENGINE An engine that has been rebuilt with new connecting rod shell bearings and having cylinders rebored or replaced and fitted with new pistons rings and valves should go through a thorough run in period before any load is applied to it The engine should be started and allowed to run for about one half hour at about 1200 to 1400 R P M without load The R P M should then be increased to engine operating speed still without load for an additional three and one half to four hours The proper running in of the engine will help to establish polished bearing surfaces and proper clear ances between the various moving parts and thus add years of troubl
63. fitted with an impulse coupling that provides a powerful spark for easy starting LUBRICATION SYSTEM A gear type pump provides pressurized lubrication to the connecting rod bearings camshaft bearings tap pets valve train and to an oil spray nozzle in the gear cover The spray nozzle lubricates the governor and gear train The oil expelled from these areas form a mist which lubricates the cylinder walls and the anti friction crankshaft bearings All of the circulated oil passes thru a full flow oil filter Crankcase impurities are collected in the filter element thereby minimizing friction and reducing wear to critical moving parts of the engine GOVERNOR A governor of the centrifugal flyball type controls the engine speed by varying the throttle opening to suit the load imposed upon the engine All engines are equipped with either fixed speed governors a variable speed regulator to control the governed speed of the engine or an idle control TM 9 3431 254 148 ROTATION The rotation of the crankshaft is clockwise when viewing the flywheel or cranking end of the engine This gives counter clockwise rotation when viewing the power take off end of the engine The flywheel end of the engine is designated the front end and the power take off end the rear edhe engine HORSEPOWER CHART IE 4650 1600 40 9 46 1800 45 6 47 5 2000 50 2 52 4 2200 53 8 56 7 2400 56 8 50 0 2600 58 4 63 0 2800 60 2
64. following capscrews 4 from flywheel shroud to cylinder shrouds 4 from heat deflectors and 6 from inside flywheel shroud to gear cover The flywheel shroud air cleaner and control panel assemb ly can be removed as illustrated in in reassembly insert rubber Bendix cover between flywheel shroud and starter pad on gear cover GENERATOR Fig 3 Disconnect ignition wires from field and armature terminals Take out the capscrew holding the adjust ing strap to generator By taking cut the 2 capscrews which hold the bracket to the engine supports the generator can be removed as shown in Note that the holes in the generator bracket are slot ted for belt alignment in reassembly DISTRIBUTOR AND ACCESSORY DRIVE Fig 38 Disconnect ignition wire at distributor and take off distributor cap leaving high tension cables in place Remove 2 capscrews holding the accessory drive housing to the gear cover As illustrated in Fig B 33 the distributor and accessory drive housing can be withdrawn from the gear cover as a complete unit ACCESSORY DRIVE HOUSING DISTRIBUTOR Fig B 33 277790 25 TM 9 3431 254 14 amp P SHROUD TO HEAT DEFLECTOR MOUNTING HOLES LEFT HAND CYLINDER SHROUD SHROUD TO CRANKCASE MOUNTING HOLES VOLTAGE REGULATOR Fig B 34 277800C CYLINDER SHROUDING 34 Remove ignition coil and generator adjusting strap from left hand side of engine Disconnect No 1 and No 3 w
65. governed control engine speed is extremely dangerous Tine governor is provided as a means for controlling the engine speed to suit the load applied and also as a safety measure to guard against excessive speeds which not only overstrain all working parts but which might cause wrecking of the engine and possible injury to bystanders All parts of the engine are designed to safely with stand any speeds which might normally be required but it must be remembered that the stresses setup in rotating parts increase with the square of the speed That means that if the speed is doubled the stresses will be quadrupled and if the speeds are trebled the stresses will be nine times as great Strict adherence to the preceding instructions cannot be too strongly urged and greatly increased engine life will result as a reward for these easily applied recommendations STOPPING ENGINE To stop engine turn ignition starting switch to off position If the engine has been running hard and is hot do not stop it abruptly from full load but remove the load and allow engine to run idle at 1000 to 1200 for three to five minutes depending on how hot the engine has been This will reduce the internal tem perature of the engine much faster minimize valve warping and of course the external temperature in cluding the manifold and carburetor will also reduce faster due to air circulation from the flywheel One of the main troubles c
66. is furnished as an option and is a necessary function when starting a new engine for the first time or when enigine has been out of operation for a period of time Gravity feed and electric start engines do not require hand priming When priming a distinct resistance of the fuel pump diaghragm should be felt when moving the hand lever up and down If this does not occur the engine should be turned over one revolution so that the fuel pump drive cans will be rotated from its upper position which prevents movement of the pump rocker arm Assuming the gasoline strainer is empty approximate iy 25 strokes rimer lever are required to fill the bowl After strainer bowl is full an addtional 5 to 10 strokes are required to fill the carburetor bowl When carburetor is full the hand primer lever will move more easily STARTING ELECTRIC STARTING MOTOR A 12 volt starting motor with an attached starting solenoid is provided as standard equipment on this model engine unless otherwise specified Do not oil Bendix drive Keep screw threads clean and if necessary lubricate with powdered graphite STARTING PROCEDURE Check crankcase oil level and fuel supply Open fuel valve 2 Disengage clutch if furnished 3 New engines require priming refer to Fuel Pump paragraph for instructions 4 Set throttle about 1 2 open if variable speed gov ernor control is furnished with a two speed con trol start in full load
67. plate assembly 5 which includes plate lugs bushing and also the contact mount and actuating screws off from the post 8 on the back plate This post extends through the switch and Pro trudes out through the front panel 6 4 Clean the internal parts of the switch removing congealed grease preferably using a non flammable sol vent 5 Check for and remove any burrs which may be found on the switch contacts 7 using a fine file or suitable sandpaper 6 Apply a light coat of grease recommended for use on electrical equipment and reassemble the switch Follow the above sequence in reverse to reassemble the switch See Figure 8 TM 9 3431 254 14 amp P ADVERSE WEATHER PRECAUTIONS Continued OPERATION IN SALTWATER AREAS a CANOPY Wash canopy regularly to remove salt film Repaint any damaged places andoil the side panel hinges regularly b COVERING To protect generator as much as possible from salt water atmosphere keep the side panels on the canopy closed It is advisable to keep the unit covered with a tarpaulin if available while not in operation Salt water should be wiped from the engine and all terminals and connections in the electrical system wiped dry Keep all linkage oiled c BRUSHES The brushes of the exciter should be inspected regularly to make certain that they are free in the holders Lift the brushes in the brushholders about every two days to insure their freedom to slide within
68. position 5 Turn ignition starting switch to start position and at the same time pull out choke button only sufficient to start the engine Release choke but ton to open position after engine starts but re choke if it tends to stop Even hot engine quires amomentary choking when starting when engine starts release switch to run position If flooding should occur continue cranking with the starting motor but with choke open choke button in After engine starts allow it to warm up a few minutes before applying load as prescribed in Warm Up Period paragraphs New engines started for the first time should be run in gradually to insure trouble free service and long engine life Refer to Starting and operation of New Engine instructions oh page for correct running in procedures WARM UP PERIOD The engine should be allowed to warmup to operating temperature before load is applied This requires only a few minutes of running at moderate speed Racing an engine or gunning it to hurry the warm up period is very destructive to the polished wearing surfaces on pistons rings cylinders bearings etc as the proper oil film on these various surfaces cannot be established until the oil has warmed up and become sufficiently fluid This is especially important on new engines and in cool weather Racing an engine by disconnecting the governor or by doing anything to interfere with the
69. replacement while simple are not recommended unless adequate test equipment is available Under no circumstances should any attempt be made to remove the magnetic rotor from the housing unless specific instructions for releasing the shaft are available TIMING THE MAGNETO TO THE ENGINE If the magneto has been removed from the engine for servicing the operator must follow the engine man ufacturer s instructions for timing the magneto to the engine Refer to lfagneto Timing in engine instruction manual When installing the magneto on the engine be sure the magneto is properly attached and that the housing to engine gasket is in good condition SPECIAL DRIVE GEAR The magneto is equipped with a special drive gear mounted directly on the impulse coupling If it is ne cessary at any time to remove the drive gear special care must be exercised in reassembly It is possible to be off 180 in mounting the gear with relation to the correct location of the timing mark on the gear Assemble gear as follows Remove magneto end cap cover and turn distributor rotor until it is in firing posi tion for No 1 cylinder as illustrated in Fig B 106 Re tain rotor in this position and fit the drive gear to the impulse coupling lugs so that the prick punch mark on front of gear is located as shown lo DRIVE a GEAR CAN ROTOR FIRING POSITION FOR No 1 CYLINDER MOUNT GEAR WITH PRICK PUNCH MARK LOCATE
70. share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
71. sheet metal_ ___ long stove head For mounting name plate SCREW 1 4 20 thread x 2 1 4 long steel round head 2 req d for V 461 For air cleaner strap clamp SCREW hexagon head pu DENT 4 for cylinder hold down clips l for Delco Remy distr clamp SCREW 1 2 long for Prestolite clamp SCREW 1 4 20 x 1 1 4 long hex hd For Delco Remy voltage regulatormt g SCREW 1 4 20 X 1 1 2 0 For Prestolite regulator SCREW 5 16 18 x 1 2 long hex hd For generator bracket SCREW 5 16 18 thread x 1 2 long 1 8 thick hexagon head ur dik usay s For flywheel shroud to gear cover XD 13 1 replaced by XD 172 SCREW 5 16 18 x 5 8 long hex hd 16 for oil pan 2 fuel pump mounting 4 for cleaner strap mounting 4 for spacer plate to case l for oil pressure red valve SCREW 5 16 18 x 3 4 long hex hd 3 for generator adjusting strap 2 for spacer plate to gear cover for bearing retainer plate fan end SCREW 5 16 18 thread x 7 8 long hexagon head for SCREW 5 167 18 x 5 8 long hex hd For RF 1514 gov oil spray elbow XD 17 1 long for obsolete RF 1375A gov oll spray elbow svo 13 ee RIA sy yQ ha 28 27 11 Port Number 4624 XD 17 B 463 XD 19 464 XD 21 465 22 466 XD 29 467 XD 52 468 XD 1
72. sttaight eene 1 WASHER lock 5 3 inch 1 NUT jam SASH LG oue Au s I FITTING hydraulic 1 ec TM 9 3431 254 14 amp FIG B 90 YA 42 12 Volt STARTING MOTOR PLATE 5063 NOTE Code number 18 prefixed to the part number is a vendor identification When ordering parts please use number with code as shown Ref Part Ref Part T No N Number Description Rea No Number Description Pe 1 18 1928966 FRAME C E Includes bushing 1 39 18 453478 SCREW field lead attach to connector 2 18 1906945 BRUSH i petet Fd re texere epe etd 4 42 18 1913960 SCREW 00165008 ette cer el 3 18 1926617 BRUSH HOLDER 2 43 18 1917084 SCREW Switch 2 4 18 1938587 BRUSH HOLDER Insulated 2 44 18 833602 WASHER thrust C 5 5 18 1926622 SPRING bitish 2 46 18 1853917 THRUST WASHER D E e THRUBOLT 2 6 18 1928015 SUPPORT pkg BRUSH HOLDER 2 19132009 UBO Includes Ref Nos 7 25 33 38 56 49 18 810620 BUSHING D E not illustrated 7 18 1926605 LEAD brushqrund 2 52 18 1926604 GROMMET field frame 1 8 18 1937548 FIELD COIL ASSEMBLY 4 coils 1 53 18 1927853 INSULATOR field coil 4 10 18 1947996 ARMATURE i 55 18 12454
73. the source of trouble If there is a weak spark or none at all check breaker point opening for 0 020 inch gap It may be necessary to install a new condenser or the ignition coil may be faulty SPARK PLUGS Fig B 19 The spark plugs should be removed periodically cleaned and re gapped Approximately every 350 hours of operation replace spark plugs with new plugs of correct heat range like Champion 14 mm No N 12Y or equal The width of the gap between the points of the two electrodes must be very carefully and precisely set because incorrect settings will have an adverse af fect on engine operation Check spark plug gap with a wire type gauge and regap as shown in Fig B 19 Spark plug gap 0 030 of an inch Use a new gasket when mounting either old or new plugs and thoroughly clean threads in cylinder head before installation Tighten spark plugs to 22 foot pounds torque If torque wrench is not available 9 3431 254 14 amp P SET GAP WIRE GAUGE Fig B 19 277779 tighten plug until it begins to seat the gasket then turn 1 2 to 3 4 of a turn more RESTORING COMPRESSION On a new engine or on one which has been out of op eration for some time the oil may have drained off the cylinder so that compression will be weak This may cause difficulty in starting To remedy this con dition remove the spark plugs and squirt about a fluid ounce of crankcase oil through the spark plug hole into each
74. the vane should line up with the running timing hole the flywheel shroud see Fig B 14 If it does not the dis tributor clamp screw should be loosened and the dis tributor body turned slightly clockwise or counter clockwise as required until the white flywheel vane matches up with the advance timing hole Be sure clamp screw is then carefully tightened If the engine is running below 2000 R P M when tim ing the automatic advance in the distributor will not be in the full advance position and thus the timing would not be accurate DISTRIBUTOR MAINTENANCE The normal breaker point gap is 0 020 inch at full separation and can be adjusted Jin the following man ner with reference to Fig s B 11 or B 12 Turn engine over by means of the starting crank until the distri butor breaker arm rubbing block is on a high point of the cam Loosen the stationary contact lockscrew very slightly and insert a feeler gauge between the points By means of a screw driver inserted into the adjusting slot of the Delco Remy distributor or by the adjusting screw of the Pestolite distributor open or close points as required until a slight drag is felt when sliding feeler gauge between the points Tighten lockscrew and recheck gap Every 50 hours of operation the oiler on the side of the Pestolite distributor base should have 3 to 5 drops of medium engine oil added The old style Delco Remy distributor has a built in oil reservoir
75. use metal rod to apply the canvas RANGE SWITCH MAINTENANCE Due to a tight fit of the switch housing burred contacts or congealed grease operation of the switch may be come stiff or totally impaired The switch will have to be dismantled to inspect and dean it Proceed as follows to service the switch Sed Figure 8 for details and call outs found in the text NOTE It is not necessary to discon nect the wiring from the switch Do not remove the switch assembly from the front panel as a complete assembly but remove it by disassem bling as follows 1 Remove three screw 1 and take the handwheel assembly 2 off fromthe switch 2 Remove the snap ring 3 and washer 4 Snap ring pliers will be needed to remove the snap ring 3 Slide the front plate assembly 5 which includes plate lugs bushing and also the contact mount and actuating screws off from the post 8 on the back plate This post extends through the switch and Pro trudes out through the front panel 6 4 Clean the internal parts of the switch removing congealed grease preferably using a non flammable sol vent 5 Check for and remove any burrs which may be found on the switch contacts 7 using a fine file or suitable sandpaper 6 Apply a light coat of grease recommended for use on electrical equipment and reassemble the switch Follow the above sequence in reverse to reassemble the switch Sed Figure 8 TM 9 3431 254 14 amp P
76. use highly volatile fuels to cold start this engine Make sure that no loose bars tools parts etc are in or on any part of the engine as they could cause serious dam age to the engine generator or personal injury to anyone standing nearby Do not use flammable cleaning materials gasoline naptha etc to clean unit Do not use chemically treated cleaning rags to clean terminal blocks or electrical components FIRE PREVENTION AND PROTECTION Do not weld in locations with a flammable atmosphere such as produced by degreasing cleaning or spray ing operations or in atmospheres containing ex plosive vapors gases mists or dusts Do not weld near combustible materials Provide a fire watch operator if necessary Do not strike an arc a compressed gas cylinder or on containers in which flammable materials have been stored Port able fire extinguishers shall be provided end main tained FOR DETAILED SAFETY INFORMATION Always refer to latest issue 1 ANSI 287 1 Practice for Occupational and Educational Eye and Face Protection 2 ANSI 241 1 Standard for Men s Safety Toe Footwear 3 NFPA 70 National Electrical Code 4 AWS A6 0 65 Safe Practices for Welding and Cutting Containers that Have Held Combustibles 5 OSHA 29CFR1910 Occupational Safety and Health Standards 6 ANSI 249 1 Safety in Welding and Cutting 30 August 1984 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
77. vt 6 06 lt Tue rc BROS CO TROY OHIO 46373 USA DWG NO re LAYOUT DIM __ t 300 ui 4331112 Figure A 9 Layout Dim d3yI vSC ltv 6 WL Models V 465D V 461D V 460D TM 9 3431 254 14 amp APPENDIX BOOK OF INSTRUCTIONS 4 Cylinder Valve In Head Engines READ THE STARTING AND OPERATING INSTRUCTIONS THOROUGHLY BEFORE STARTING A NEW ENGINE BECOME ACQUAINTED WITH THE ENGINE COMPONENTS THEIR LOCATION MAINTENANCE AND ADJUSTMENT REQUIREMENTS 3 3 4 Bore 4 Stroke 177 cu in Displacement 3 1 2 Bore 4 Stroke 154 cu in Displacement 1 2 Blank TM 9 3431 254 14 amp P READ THESE INSTRUCTIONS CAREFULLY All points of operation and maintenance have been covered as carefully as pos sible but if further information is required inquiries sent to the factory will receive prompt attention When writing the factory ALWAYS GIVE THE MODEL SPECIFICATION AND SERIAL NUMBER of engine referred to STARTING AND OPERATING OF NEW ENGINES 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 Neither is there a quick way to force the establishment of good bear ing surfaces These can only be obtained by running a new
78. 06 370708 370710 SIQILY 370714 4DW 77 00078 A A A A A A A A A A A 00562 8 A 00641 8 A 00642 4 A 00647 8 A 00782 2 A 01564 5 A 02037 6 A 02037 13 A 02063 5 A 02070 A 02087 1 4 4 4 4 4 4 4 4 4 4 4 4 402265 402530 402531 402662 402668 402670 402788 402809 402889 1 402927 2 404042 1 404065 3 404154 11 404277 404278 404856 404875 404889 1 404889 3 404889 4 404955 TM9 3431 254 14 amp P NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 405485 1 A 4 44 405532 A 4 64 405561 A 2 19 405574 A 2 20 405660 A 2 53 405663 4 72 405664 4 405668 4 405753 5 41 405755 5 42 405776 4 81 405777 4 79 405778 4 82 405779 4 89 410541 5 49 2 41 430139 5 8 430141 5 4 430145 5 18 430146 5 11 430172 1 5 10 430258 5 2 430259 5 3 430265 5 13 430547 5 A 4 68 430548 2 A 5 50 A 2 36 430548 4 A 2 35 490018 3 A 4 90 490040 A 4 8 490083 A 4 12 490174 A 4 6 490175 4 7 490258 4 16 490337 3 14 490420 5 490442 5 23 490463 2 42 490581 3 2 25 490692 3 20 490717 5 47 490718 5 490779 2 56 490793 1 3 17 490806 3 TM9 3431 254 14 amp P NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 490831 EA 1 8
79. 09 Mulberry Metal Products Inc 2199 Stanley Terrance Union New Jersey 07083 Hubbel Corporation 407 E Hawly Mundelein Illinois 60060 Honeywell Inc Micro Div 11 W Spring Street Freeport Illinois 61032 Harry Davies Company 700 N 27th Camden New Jersey E T C Inc 990 E 67th Street Cleveland Ohio 44103 Delco Remy Division General Motors Corp 2401 Columbus Avenue P O BOX 2439 Anderson IN 46011 Prestolite Co 511 Hamilton P O Box 931 Toledo OH 43601 TM9 3431 254 14 amp P NUMERICAL INDEX EXPLANTION THE PURPOSE OF THIS INDEX IS TO ASSIST THE USER IN FINDING THE ILLUSTRATION AND DESCRIPTION OF A PART WHEN THE PART NUMBER IS KNOWN PART NUMBERS ARE ARRANGED IN APLPHA NUMERICAL SEQUENCES THUS ANY PART NUMBER BEGINNING WITH THE LETTER A WOULD BE LOCATED AT OR NEAR THE TOP OF THE INDEX LIST LIKEWISE A PART NUMBER 9 WOULD BE LISTED NEAR THE END OF THE LIST AND FAR BELOW A PART NUMBER 1000 THE FIGURE NUMBER AND ITEM NUMBER LOCATION OF THE PART IS DIRECTLY OPPOSITE THE PART IF THE PART IS USED IN MORE THAN ONE PLACE EACH LOCATION IS LISTED COMMENCING WITH THE FIRST LOCATION THE PART IS LISTED NUMERICAL INDEX PART NUMBER FIGURE AND ITEM NUMBER A 25 A 4 38 AAW 1323 An 3 22 AAW 835A A 2 3 1233 4 AW 459 28439 5 51 AW 590 A 2 31 C 3 3 15 CW 1150 2 28 CW 1160 3 4 6080 2 29 1458 2 48 400 0 2 49 HF 567 A 4 10 336 4
80. 10 Remove screen over flywheel air intake opening by taking out the screws holding screen in place This will expose the timing marks on flywheel shroud also the vane on flywheel marked by an X and the letters DC NOTE On engines equipped with a rotating screen attached to the flywheel the leading edge of the marked vane is identified by an stamped on the outer rim of the screen thereby not requiring removal of the rotating screen when timing the engine TIMING INSTRUCTIONS The No 1 piston must be on top dead center of the compression stroke before distributor can be mounted With reference to Fig B 10 this can be accomplished as follows 1 Remove rocker arm cover from No 1 cylinder bank 2 Turn engine over with hand crank until the inlet valve opens and then closes 3 Continue turning the engine over until the leading edge of the marked vane the flywheel is in line with the centerline mark of the No 1 and 3 cylinder banks 4 DISTRIBUTOR TIMING With the No 1 piston now on TDC of the compression stroke refer to for the revised Delco Remy distributor or for Prestolite and mount distributor as follows a Before mounting distributor to housing take off distributor cap remove rotor and dust cover b Hold distributor with face up and terminal wire or terminal stud away and in a 12 o clock posi tion as shown Mount rotor on shaft and turn un til the rotor contact points in an approxim
81. 14 SE 241 4 HEATOEFLECTOR L H side i oa jae SE 24 1 replaced by SE 24 1 4 351 96 16 ADAP TER PRIMER assem for fuel pum 1 1 Optional Consistina of 315 5 241 IHEATDEFLECTOR R H side 1 1112 352 JK 50 tQePockingring essere 1 1 353 1 45 Spring 1 1 316 5 242 ICYLINDER HEAD COVER L H side 1 1132 354 1110 Plunger also order TA 1 15 1 l 355 114451 Shaft with JK S0 packing 1 317 5 242 CYLINDER HEAD COVER F H side 1 1 2 356 TA 115 Handle nenne 1 1 357 6 1 1 320 89 52 GOVERNOR ASSEMBLY beginning with 358 Adapter order complete serial 5356806 gear bushing deleted 1 3 8 96 16 Adapterprim ef assembly 1 89 52 for serial 45075776 to 85356805 replaced 7 89 52 jnter 358 96 20 ADAPTER less primer i Ses ls 1 3 changeable as a complete unit i Includes i EET 89 1 previous to sedal 5075776 3 8 gas TA 1110 1 Plunger 1 1 E wide face gear train Use T 89M S1 360 TF 122Y 2 ACCESSORY DRIVE ASSEMBLY e 7 replacement S gines beainninqg with serial No 507 5776 Assemblies consist of TF 122H 1 previous to engine serial 321 PM 173 CGovemorspring i I iNo 5075776 22 391 0 Thrust sleeve and bearing 1 5 For 89 52 qo vemor Assemblies consist cf TC 391 B ior obsolet
82. 190 2 HF 627 spacers hanger to case SCREW 5 16 18 thread x 2 1 2 long hexagon head SAE grade 8 Upper to lower manifold flange FC 171 studs replaced by XD 162 SCREW 3 8 16 x 1 2 long hex hd For flywheel shroud to gear cover XD 114 1 XD 171 i SCREW 3 8 16 thread 2 1 2 long hexagon head S A E grade 8 bearing cup to hanger replaced by For center shell SCREW 1 4 20 x 7 8 long hex hd For fuel pump adaptor mounting SCREW 5 16 18 thread x 3 8 long Allen head zone rete eda eae tats For locking idler stud PIPE PLUG 1 8 square head lefor upper header on case face l for inlet manifold tap KEY No 5 Woodruff Furnished with generator For heat shield support 1 DOME BOLT fuel pump 28 x 114 lg 1 Replaces bolt furnished with pump 10 to TM 9 3431 254 14 amp P FIG B 83 FUEL STRAINER ASSEMBLIES FIG B 84 ROTATING SCREEN a cm FACE TOWARD SCREEN 74918C Part D a lo Net ef Port _ Number escription teq Oz lo Nunlier crip te 5 3 FUELSTRAINERASSEMBLY 1 PER 5 1334 With shut off valve in cover and glass 4 bowl Tillot son No OW 418 T 1 5 205 52 ROTATINGSCREENASSEMBLY
83. 3 Install the idle jet 38 using small screwdriver 4 Install the bow drain plug 44 REASSEMBLE CARBURETOR BODIES Install fhe three bowl assembly screws 45 46 through the fuel bowl and into the throttle body and draw down irmly and evenly SPECIAL TOOLS The special tools recommended are 1 161 83 Main Jet Wrench 2 161 85 Fuel Valve Seat Wrench Nn TM 9 3431 254 14 amp P L 57 L 77 FIG B 103 CARBURETOR PARTS LIST Series CARB ZENITH WISCONSIN WIS ENGINE CARB ZENITH WISCONSIN WIS ENGINE REF NO ASSEM NO PART NO MODEL REF NO ASSEM PART NO MODEL 1 11288 1 57 VP4D 14 12708 12 77 51 4600 2 11532 L 57 1 VG4D LZ 77B S1 V 461D V 465D 3 12347 L 57 B 40 15 12825 LZ 77C S1 V 465D 4 13401 L 57 E VG4D Choke V 461D 5 13714 L 57 G VH4D 47 21 22 4 PA 43 24 Refer to Engine Parts List NOTE for V 461D V 465D Fuel Bowl 46 Sah 45 Ports are identical for all carburetors except Solenoid Valve those identified by carburetor Ref Now Part Part Number Description Nos SCREW Lever Swivel for 1 2 3 4 SCREW Lever Swivel for 1 2 3 4 5 14 14 P scis 93 C105 3 93 C105 302 93 141 8 93 T8S8 8 93 C110 7 93 C109 60 SHAFT CHOKE for 1 2 3 4 5 14 SHAFT CHOKE for 15 93 C106 2 LEVER CHOKE for 1 2 3 4 5 14
84. 30 468 XD 83 For obsolete roller type 9 3431 254 14 amp P INTERCHANGEABLE PARTS for Models V 465D and V 460D V 461D Description SCREW hexagon head 8 for rocker arm bracket 2 for gear cover to spacer SCREW 5 16 18 thread x 7 8 long hexagon head S A E grade 5 2 for generator to bracket 5 16 18 thread X 1 long 8 for upper to lower manifold SCREW 5 16 18 thread x 1 1 4 long hexagon head sesh as a ee Pa WCG 3 for camshaft gear 8 for gear cover to crankcase SCREW 5 16 18 thread x 1 1 2 NOAM 22 ayy yy YR taa es For obsolete collet coupling adapter SCREW 5 16 18 thread x 13 4 hexagon head y iya ya acc pores For gear cover mounting SCREW 3 8 16 thread x 1 1 4 long hexagon head ii Liar REG 6 for main bearing plate end 3 for starter motor mounting SCREW 5 thread x 1 3 4 long hexagon headless syne Thus cae ot er Ge Pies IA For mounting engine supports SCREW 7 16 14 thread x 2 1 4 long hexagon head S A E grade 5 For shell bearing hanger to case SCREW 7 16 14 x 3 long hex za 2 for center bearing cap to hanger 2 for center bearing hanger to case center bearing Replaces XD 146 2 3 4 long but add 468B XD 162 469 171 470 XD 176 41 XD 175 472 XE 55 473 1 474 475 PB
85. 3431 254 14 amp P CENTER BEARING Secure bearing hanger to crankcase after crankshaft TAP CAP SCREWS i i inni ALTERNATELY HANGER BODY end play is adjusted Note Beginning with engine serial No 4052826 the capscrews for mounting the bearing hanger to crankcase were lengthened to 3 inches and a spacer added under the screw heads see Fig 62 Thus all 4 screws for the center main bearing hanger assembly are the same minimizing the possibility of improper assembly Install hanger capscrews with spacers finger tight and position bearing hanger so that there is a minimum of 040 inch clearance between the sides of the bearing han HANGER CAP ger and crankshaft cheeks Tighten hanger to crank case capscrews 60 foot pounds torque Fig B 59 277776 pe MAIN i EARING HANGER CRANKCASE 7 MANGER 8055 p LOW MELTING POINT GREASE SPLIT BEARING FRACTURED s RETAINING RING BEARING ROLLERS GROOVE SPACER Fig B 60 277778 FINGER TIGHTEN HANGER TO together with retaining ring The ring must overlap B 42 7 both mating edges of the bearing Insert shouldered a dowel pin into either hole of the bearing race and MINIMUM CLEARANCE 040 30TH place the hanger body against the bearing so the i dowel slips into the dowel pin hole see Fig B 62 Hold hanger body against bearing place cap in posi BEARING HANGER CLEARANCE tion and dra
86. 355 JAM NUT 5 8 18 for grease tube 1 28 29 30 63 359 63 1001 203 63 CL 2175 35 63 CL 8512 10 63 CL 7039 1 63 CL 8575 63 CL 8513 1 63 CL 8515 1 63 CL 11905 63 CL 9216 63 CL 8807 1 63 CL 3468 63 UCL 4 8611 1 RELEASE SLEEVE BEARING ASSEM 63 CL 8611 1 63 UCL 7 7392 63 CL 33351 63 CL 7356 63 CL 9464 63 CL 8556 1 63 CL 8484 63 CL 7107 63 CL 8557 63 CL 8400 3 CL 7130 63 CL 6965 4 Description LOCKWASHER tor iam nut KEY fort takesoffsishfaft 1 4 X xx 437 8 PILOT BEARING scaled 2 7 A 4856 s 46 192 4813 CLUTCH ASSEMBLY 8 Model Congsistina Te CLUTCH BODY FACING Anco 796 Set at 3 sen SEPARATOR SPRING I PRESSURE PLATE ADJUSTMENT NUT ADJUSTMENT NUT PLATE ct ADJUSTMENT LOCK SCREW for adjustment lock LOCKWASHER tor adjustment lock Consistina of RELEASE _ RELEASE BEARING ASSEMBLY Con sisting of BEARING HALF nct serviced sep 1 BEARING HALF not serviced SCREW 5 16 24 x 114 hexagon heud ELASTIC STOP NUT 5 1 6 21 throug LEVERSPRINGSET LEVER s CLEVISPIN forlevertobody RETAINING RING fer lever clevis pin CONNECTINGLINK nm CLE VISPINIorconnoecttnaiink RETAINING RING for link clevis pin 0 2 4 2 Qr o
87. 4 bank of cylinders starting with No 4 inlet valve Mark each rocker arm with chalk as adjustment is completed to prevent repetition With spark plugs re moved turning crankshaft is made easier ROCKER ARM COVERS Fig B 21 When reassembling rocker arm covers after timing or valve tappet adjustment carefully replace the cover gaskets to prevent oil leaks If oil does appear around the rocker covers re assemble in the following manner 1 Check gasket face surface of rocker arm cover at the rounded end for paint accumulation sed Fig 21 5 off any paint that forms hump Smooth scraped area with emery cloth or steel wool 2 Clean gasket faces on the cylinder head and rocker arm covers 3 Spread thin coat of perma tex into the rocker arm cover to hold gasket in place This will prevent gasket slippage or deformation wnen mounting cover to cylinder head 4 Use new gaskets Old gaskets harden take a set and will very likely leak GOVERNOR OPERATION The centrifugal flyball governor rotates on a station ary pin pressed into the upper part of the timing gear cover The governor is driven off the camsha t gear and tums 1 8 faster than crankshaft speed Flyweights are hinged to lugs on the drive gear Hard ened pins on the flyweights bear against a flanged sliding sleeve moving it back and forth as the fly weights move in or out The motion of the sleeve is transmitted through a bal
88. 4 amp P LOW PRESSURE OIL HEADER OIL PRESSURE GAUGF Sa OIL SPRAY NOZZLE Lubricates Governor and Gear Train PRESSURE REDUCING VALVE For Low Pressure Oil Header HIGH PRESSURE rea GIL HEADER iens ADJUSTING SCREW OIL PRESSURE RELIEF vaive LOCK 5 EXPANSION PLUG 3 4 dia OIL PUMP STRAINER SCREEN OIL DRAIN PLUG Fig B 7 LUBRICATION SYSTEM 3 16 Allen wrench remove the outer lock screw With the same wrench adjust spring tension by means of the adjusting screw turn clockwise to increase gauge pressure counter clockwise to reduce pressure NOTE With engine running at 1800 R P M and engine oil hot adjust oil pressure 40 to 45 P S I Idle engine at 1000 R P M and if oil pressure falls below 15 P S I check for irregularities in the oil pump bear ings and oil connections After adjustment is made mount outer lock screw firmly in place Use a new 3 4 inch expansion plug to seal off any oil which may by pass the screw threads LOW PRESSURE SYSTEM The upper or low pressureoil header supplies oil to the camshaft bearings tappets valve train and gover nor gear train nozzle at 3 to 4 P S I thru a pressure reducing valve from the main or high pressure oil header This pressure is not registered on a gauge but can be checked by connecting a low pressure gauge to the 1 8 pipe tap located at the take off end of the engine above t
89. 53 2 TAs 4 56 PT A 4813 Consisting ot 63 P T 300 30 HOUSING 4 3 E 4556 1 62 P T 300 9 4819 63 P T 1593 INSTRUCTION PLATE 63 347 5 4 7 20 x 3 8 rd hd instr plate 2 63 1068 5 188 2 2 63 1059 BEARING RETAINER 63 44 LOCK PLA TE 1 63 P T 349 SCREW 5 15 13 x 1 2 hex lock 63 350 LOCKWASHER 5 1 6 for lock plate 63 P T 1012 GREASE FITT in of PT A 4819 2 63 P T 989 PIPE PLUG 1 8 in shatt of 4856 63 P T 808 1 DRIVEKEY e i dee cannes l 63 P T 718 1 LOCKWASHER for zlutchbody 63 706 NUT for cluten 1 63 200 eonan oE 1 63 351 KEY tor yoke 15 Woodruif 2 63 P T 744 SET SCREW 5 16 18 x 1 4 flat point i For grease hole plug 63 P T 770 GASKET or instruction plate 1 63 UP T 81 CLUTCH YOKE ASS Con sistina of 1 CLUTCHYQKE a a sas nein i 63 352 _SCREW 3 8 16 x 14 hexagon head 2 63 353 LOCK WASHER 3 8 2 63 UP T 769 SHIFTER LEVER ASS Consisting of SHIFTINGLEVER 1 63 P T 604 SCREW 3 8 16 x 14 hexagon nead 1 63 P T 353 3 5 63 1026 3 GREASETUBEASSEMBLY 63 CL 4
90. 6 WOODRUFF KEY D E 1 ICD RE 56 18 1926600 PIN brushholder 2 1 18 1958452 DRIVE ASSEMBLY Service complete replacement use Eclipse 28 A3491 1 58 18 809593 DOWEL PIN DE 04 15 18 1958451 DRIVE HOUSING includes Ref No 49 1 8 1831931129 POLE SHOE 4 16 18 1935706 CONNECTOR switch 1 THE FOLLOWING PARTS ARE NOT ILLUSTRATED 17 18 1467 MAGNETIC SWITCH a 18 1958453 CENTER BEARING PLATE 1 25 18 453435 LOCKWASHER brush support attaching Includes Sells Se ed ER EUIS 4 18 1880471 BUSHING center bearing 27 18 453435 LOCKWASHER field lead attach screw 18 132900 SCREW center bearing plate attaching 4 eaaa i 18 1962276 LOCKWASHER center bearing plate 33 18 120361 NUT brush support attaching screw 4 attaching s so eS eek eto 4 37 18 1926648 SCREW brush attaching 4 18 1947777 OIL SEAL center bearing 1 38 18 274738 SCREW brush support attaching 4 18 802694 0 2 1 91 26 STARTING MOTOR 12 Volt Prestolite No 9 3431 254 14 amp MHA 7004 Replaces MDY 7006 FRAME and FIELD ASSEMBLY pues Ref No g 15 Sh 37 SERVICED SEPARATLEY See Ref ERPIN Ref No
91. 64 thick use as req d 282433C Ref Part No No Number Description 28 t THRUST WASHER 080 thick use as req d 29 THRUST WASHER 1 16 thick use as req d 31 KEY for mounting Bendix Woodnuff No 6 1 33 28 SAW 4201 SOLENOID STARTING SWITCH 1 34 TERMINAL 0 32 thread 1 35 TERMINAL LOCKWASHER No 10 1 36 TERMINAL 5 16 24 thread 12 37 TERMINAL LOCKWASHER 5 16 2 38 28 SS 6R CONNECTOR for solenoid switch 1 39 SCREW or solenoid switch mounting 2 No 10 32 thread x 1 4 long round head 40 LOCKWASHER for solenoid mounting 2 No 10 Snakeproof 4 28 EB8 40A BENDIX DRIVE use Eclipse 28 A3491 1 52 28 MDL 73 GASKET for bearing 1 53 28 MDL 2080A BEARING ASSEMBLY intermediate 1 54 28 P5 1375D PINION HOUSING ASSEMBLY includes 1 55 28 MG 77A BRONZE BEARING for pinion housing 1 56 DOWEL PiN Ra hurt eR 1 57 LOCKWASHER No 10 for bearing plate 58 SCREW for bearing plate mounting 2 No 0 32 thread x 7 16 Long round head 28 MDL 2012CS BRUSH SET 28P90 711 TERMINAL STUD PKG vex 28 P90 263 ARMATURE THRUST WASHER PKG NOTE Items less part number are not serviced separately B 65 TM 9 3431 254 14 amp P FIG B 92 2 Volt 17 Amp GENERATOR 62 Negative Ground YB 62 Positive Ground Delco Remy 1102343 Del
92. 65 78 1037 78 1663 78 1292 78 1284 78 1283 78 M2046AF 78 M2027AN 78 M268 78 200288 3 6 1 ROTATION Enginewise When ordering parts please use number with code as shown Description FITTING operating shaft was M102 cil cup 2 SCREW hex read 172 13 x 3 4 22 1 CLUTCH 2 108 assembly 1 PLATE sana ss i YOKE 3d usting 1 PIN lock adjusti 1 SPRING pin lock adjusting 1 PIN lever finger was 316210 was d YOKE adjusting essem 1 cotter s 4 LEVER finger wo 4 SLEEVE sliding 1 SLEEVE siidin iink lever 8 LINK lever 8 I totter wes 1927 3 roil pin 3 COLLAR ussembi 1 NUT exi 379524 SHIM j 2 SCREW 3 24 iwas 5 200245 2 j COLLAR split not serviced EE PLATE hu b andececk i SPRING PLATE 1 i PLUG pipe square aecd 3 dein Ch 1 PLUG saucre nea 3 4 inch RING driving 1 i BALL BEARING pilot 1 1 WASHER lock crits not SCREW nex head 3 8 18 x 1 1 2 2 WASHER lock 3 3 usu sa alus 2 FORK throwout 3 1 HOSE flexible assembly j HOSE flexible m FITTING 30 dearee E 1 FITTING
93. 67 SW 102A 2 45 SW 167 1 2 43 5 46 SW 218A 5 48 2 40 SW 231 2 SW 299 2 46 W 10051 8 A 2 11 W 10119 1 A 5 36 W 10750 8 5 28 W 10869 3 A 4 88 W 10869 7 A 4 86 W 10869 14 A 5 33 W 10883 0 5239 W 10886 1 A 5 40 W 10888 2 A 5 37 W 10902 1 A 5 29 W 10931 3 A 4 42 W 10933 3 A 4 41 W 10981 A 2 W 11521 2 A 3 5 TM9 3431 254 14 amp P NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER W 11608 2 A gt 5 30 W 2974L 2216 W 9916 13 2 22 W 9917 4 2 27 2CW 1693 2CW 1914 3 4 60 2CW 1915 20 4 55 2CW 2234 4 57 6DA 4249 8 2 44 6DA 4249 8 A 5 55 6DA 954 2 Ee moy 6DW 335 A 4 59 25 5 328 4 77 350849 5 24 350853 D 5225 350854 350855 A gt 8 21 351316 2 34 351541 4 351683 A 3 13 351978 A 4 3 353630 3 5 38 355325 11 5 34 355897 A 3 44 356089 3 356189 4 40 356265 3 12 326733 31 A 3 1 356773 35 3 6 357080 3 4 357083 Ac 2 21 357520 AS 3 2 358140 4 4 87 358642 358680 39 358836 4 14 358951 2 24 359210 2927 2295237 3 19 299575 2 A 359576 A 430324 399977 A 2 32 359878 2 229952 Soke 361182 5 4 43 361182 11 4 366589 A gt 2 38 TM9 3431 254 14 amp P NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 366798 A 2 368805 AF552 269092 369094 369095 370704 3707
94. 760 18 SWITCH TOGGLE V15605 NO 8860 K5 COVER RECEPTACLE DUPLEX V81703 NO WPDC RECEPTACLE DUPLEX 3 WIRE V81091 VO 5250T CLAMP PLASTIC V81074 SPACER CAPACITOR 5uF 400 V DC CIRCUIT BREAKER 40 AMP V74193 NO AMI A3A CIRCUIT BREAKER 15 AMP V74193 NO AMI A3 A CIRCUIT BREAKER 20 AMP V74193 NO AMI A3 A RESISTOR 100 W 50 OHM V44655 NO 0959 BRACKET MOUNTING BOARD INSULATING RECEPTACLE V98410 NO 11674728 RECEPTACLE AMPHENOL V14894 NO MS3100R AMMETER BATTERY V09527 NO 4015 METER FREQUENCY V31356 RECTIFIER SILICON V04713 NO 447 INSULATOR FLASHING KIT BOARD FLASHING ASSEMBLY FUSE 4 AMP METER HOUR RUNNING TIME V74400 RESISTOR DISCHARGER V44655 GAUGE OIL PRESSURE V81082 VOLTMETER DC SINGLE SCALE 0 100 V60741 RHEOSTAT ASSEMBLY RHEOSTAT 150 WATT 200 OHM BRACKET MOUNTING RHEOSTAT ADAPTER RHEOSTAT TO RHEOSTAT SWITCH RANGE ASSEMBLY PLATE BACK MOUNTING RING CONTACT RING CONTACT BAR BUS HUB DRIVING FRICTION BALL MOVABLE ASSEMBLY CONTACT SPRING PLATE FRONT WASHER THRUST WASHER SPRING HANDWHEEL RANGE SWITCH ASSEMBLY UNITS PER ASSEMBLY TM9 3431 254 14 amp P FIG NO A 2 ITEM NO 45 46 47 48 49 50 9 52 53 54 95 56 NO SW 102A SW 299 404955 HF 1458 W 10981 HF 400 0 491099 04042 1 90915 05660
95. 91176 91178 90779 00647 8 01564 5 BORA NOMENCLATURE HANDLE RUBBER PLATE NAMEPLATE RANGE COARSE CURRENT ROD THROTTLE V77574 CLAMP THROTTLE ROD CONTROL CHOKE V77910 PANEL REAR LOWER NAMEPLATE IDENT NAMPLATE INDENT GOV T LABEL IDENT GEN BRACKET SELECTOR SW SWITCH SELECTOR ASSEMBLY FOR DETAILS SEE FIG A 5 BOX CONTROL ASSEMBLY FUSE ABC 10 AMP PLUG ON CONTROLS V00779 NO 1 480438 0 NOT ILLUSTRATED UNITS PER ASSEMBLY REF TM9 3431 254 14 amp P FIG NO A 3 ITEM NO 22 gt Q NP O o 2 22 23 NO 490995 3 356773 31 357520 5CW 96 CW 1160 W 11521 2 356713 35 359210 358642 358880 402530 402531 402788 356265 351683 490337 C 31 359952 490793 1 60GJ 18 490806 359537 490692 35957522 355897 AAW 1323 490910 1 491121 NOMENCLATURE GENERATOR 300 A AC ASSEMBLY HOUSING EXCITER ASSEMBLY BEARING SPACER BEARING GASKET BEARING BEARING BALL HOUSING GEN ASSEMBLY ARMATURE ASSEMBLY BRACKET BRUSHHOLDER ASSEMBLY BRACKET GUIDE BRUSHHOLDER CAP BRUSHHOLDER BRUSH AC COVER EXCITAR GROMMET LEAD HOLE VI1702 COVER GENERATOR KEY ARMATURE COVER HOLE FLYWHEEL HOUSING HOUSING FLYWHEEL KEY COUPLING FAN AND COUPLING ASSEMBLY FAN FLYWHEEL FLANGE DRIVING ASSEMBLY HUB COUPLING DISC FLEXIBLE COUPLING CABLE BONDING INT COVER HOLE FLYWHEEL HOUSING
96. APACITOR 1 uF 400V DC V14655 NO DPMS 4P1 PLATE RECT OUTPUT NEG PLATE RECT OUTPUT POS BRACKET MOUNTING SPACER MOUNTING INSULATOR LEAD PANEL SIDE RIGHT PANEL SIDE LEFT FRAME MOUNTING BAR MOUNTING GEN BRACE DOOR LEFT ASSEMBLY CABLE BATTERY NEG RESISTOR BALLAST ASSEMBLY FOR DETAILS SEE FIG A 5 MOUNT SHOCK V16238 NO J256 3 SUPPORT ENGINE ASSEMBLY WASHER CUP CABLE BATTERY POS PANEL FRONT ASSEMBLY HOLDDOWN BATTERY BATTERY V72560 NO 1980031 CABLE BONDING EXT ENGINE WISC BRACE THROTTLE GROMMET V02231 NO G 1068 CLAMP CONTACTOR ASSEMBLY FOR DETAILED SEE FIG A 5 BRACE DOOR RT ASSEMBLY REACTO R STABILITY ANGIE MTG FRONT PANEL LABEL OIL FILTER ON FRAME LABEL CAUTION FAN GUARD ALTERNATER LABEL LUBE LABEL FUEL BRACE CANOPY CLAMP DIAGRAM GEN LAMINATED DIAGRAM ENGINE LAMINATED LINKAGE THROTTLE SHIELD HEAT MANIFOLD SPACER HEAT SHIELD SLEEVING CHOKE PLATE SEL SW BRACE MTG ON LEG OF CONTROL REACTOR DOOR RIGHT SLEEVING THROTTLE ELBOW STREET 90 V31510 NIPPLE PIPE UNITS PER ASSEMBLY TM9 3431 254 14 amp P FIG ITEM NO NO A 4 81 82 83 84 85 86 87 86 89 90 91 92 93 PART NO 405776 405778 404154 11 491173 NO NUMBER W 10869 7 358140 4 W 10869 3 405779 490018 3 491120 402809 491174 NOMENCLATURE ELBOW 45 V31510 PIPE EXHAUST CLAMP EXHAUST PIPE EXHAUST AIR CLEANER amp CLAMPS CLAMP HOSE HOSE AIR CLEANER CLAMP HOSE ADAPTER HOSE
97. B 37 9 3431 254 14 amp P OBSOLETE 108 SERVICEABLE FIG B 65 CYLINDER HEAD AND ROCKER ARM ASSEMBLIES xn 198 7 190 S 432 124 ee 467 5 88 28714621 FIG B 66 CRANKCASE AND OIL PAN GROUP Farts are identified by reference number See parts list for correct part number TM 9 3431 254 146P i88 Mi 281149 1 FIG 67 CARBURETOR AND MANIFOLD GROUP Parts are identified by reference number See parts list for correct part number TM 9 3431 254 14 amp P A YAN a 7 V Ya 1716 180 182 281144 OBSOLETE Crank Gear Oil Collet Group 281148 1 FIG B 69 IDLER GEAR BEARING RETAINER AND OIL COLLET GROUP Parts are identified by reference number parts list for correct part number B 40 9 3431 254 14 amp P MC 432 286 160 I 281145 FIG 70 OIL LINES PRESSURE VALVE RELIEF VALVE AND OIL FILTER Parts are identified by reference number See parts list for correct part number TM 9 3431 254 14 amp P 551 PRIMER ASSEMBLY 281143C 334 FLYWEIGHT ASSEMBLY 33 HOUSING ASSEMBLY 282432 FIG B 72 Ref 320 GOVERNOR ASSEMBLY Parts are identified by reference number See parts list for correct part numbers 9 3431 254 14 amp P 460 432 439 360 ACCESSORY
98. BAR BUS BOARD RIGHT BOARD LEFT U BOLT LONG RESISTOR BALLAST U BOLT SHORT BRACKET RESISTOR LINE FUEL ASSEMBLY NIPPLE PIPE PLUG PIPE TEE PIPE VALVE 1 4 TURN SHUT OFF V79470 NO 6824 CONNECTOR MALE CLAMP HOSE HOSE RUBBER 5 8 OD X 5 16 ID ELBOW MALE BARBED LINE OIL COUPLING PIPE ELBOW MALE TUBING ST 1 4 DIA ASSEMBLY CONNECTOR FEMALE CONNECTOR MALE UNITS PER ASSEMBLY REF BER PRPEPEPRPENP EP TM9 3431 254 14 amp P FIG NO A 5 NHA ITEM NO 41 42 43 44 45 46 47 48 49 50 51 52 53 54 59 NEXT 5 ASSEMBLY NOT ILLUSTRATED PART NO 491178 491177 491170 405753 405755 389092 402668 369095 SW 167 1 490717 366798 SW 218A 410541 430548 2 AW 459 368805 369094 491171 16DA 4249 8 NOMENCLATURE SWITCH SELECTOR ASSEMBLY FOR NHA SEE FIG A 2 SUMMARY CABLE SWITCH SELECTOR ASSEMBLY ACTUATOR SWITCH SWITCH MICRO BUSHING SWITCH MICRO INSULATOR SW 1 4 WASHER THRUST PLATE BACK CONTACT MOVABLE SA CONTACT SPRING RING CONTACT CATCH FRICTION BALL PLATE FRONT SHAFT ACTUATOR HANDLE SWITCH RING SNAP EXT ITEM 55 UNITS PER ASSEMBLY REF PPRPRPRPRPEPNWHEENNFPRPNER MANUFACTURER S CODES Explanation 9 3431 254 14 amp P
99. CRANK SHAFT OIL COLL ET COUPLING ADAPTER i SLOT BEARING RETAINER PLATE 3 8 16 FOR PULLER 277802 Caution It will necessary to rotate shaft so that counterweights clear the lugs in the crankcase for the center main bearing and the lugs on the center bearing hanger will have to line up with the clearance slots in the crankcase face In reassembly rotate crankshaft oil collet so that slot engages with tab on bearing retainer plate as illustrated in Fig B 58 Mount main bearing plate gas kets and shims and torque capscrews A 32 feat pounds Check end play and add or remove gaskets to give the necessary 002 to 004 inch movement Center main bearing roller type can be disassembled in the following manner Loosen and back out bear ing hanger capscrews approximately 1 2 inch Tap capscrew heads lightly and alternately with a hammer as illustrated inf Fig 89 to break cap away from hanger body Do not pry cap and body apart Remove capscrews and separate hanger and cap from bearing Take off retaining ring from outer bearing race and re move bearing halves and rollers from crankshaft In reassembly coat inside of bearing halves with a low melting point grease or petroleum jelly Do not se a standard lubricating grease With reference to press 16 rollers into the grease of each of Bearing halves assemble to crankshaft and clip B 33 9
100. D The remaining studs can be disassembled after cylin der is taken off in reassembly place a new gasket at bottom of cylin der barrel It will be necessary to compress the piston rings in order to slip the cylinder over the piston as shown in Fig B 43 A piston sleeve can be made from the lower portion of a scrap cylinder The sleeve is 214 inches long with a 7 8 inch wide slot The inside diameter is tapered from the middle to the bottom 3 750 to 4 000 for V 465D 3 500 to 3 750 for V 461D V 460D Fig B 42 s Z A STAPERED END PISTON SLEEVE SLEEVE Fig B 43 277795C Slip sleeve over and slightly below top of piston Ex tension of piston out of sleeve will act as a pilot for mounting cylinder Lubricate cylinder bore and press barrel on to piston and against sleeve Force piston into bore by tapping cylinder barrel with a rubber mallet as illustrated in Fig 43 When bottom ring of piston is securely in cylinder lower sleeve and re move thru slot Continue to press barrel over piston until it is snug against crankcase Mount cylinder studs and remainder of parts per Cylinder Head paragraphs of reassembly CYLINDER PISTON and CONNECTING ROD Fig B 43 Fig B 45 After removing cylinder heads and before attempting to loosen connecting rod caps it is advisable to hold down both banks of cylinder barrels lest they be come loosened and damaged when rotating the crank shaft This can b
101. D AS SHOWN Fig B 106 DRIVE GEAR MARKING AND ASSEMBLY 9 3431 254 14 amp P ILLUSTRATED GD 103 A DRIVE GEAR YQ 8 YQ 9 Ref Part Mumber No Y 128 S1 FM X4B7D Poinrs Condenser KIT Overhaul 1 31 8S9D 2 31 7800 4 31 8682 S 131 24608 6 31 2765 7 31 2766 8 31 62501 9 31 10814D 10 31 6Y 2430 12 31 H2498 13 31 01498 14 31 Q5952 15 31 656U 16 31 02458 17 31 14986 18 21 2437 20 31 656 21 31 856 22 31 85969 23 31 62788 25 31 855 26 31 AXMR2433 27 31 5939 28 31 05950 29 31 9 30 31 856 31 31 X4631 33 31 61498 34 31 5950 35 31 12514 36 131 8 1 37 31 8LW5 Description SCRE W cover 3 32x39 16 COVER end p GASKET endcapcover BRUSHcndSPRING DISTRIBUTORROTOR SPRINGCLIP rotor SEAL shaft da ida n dU sd dead SCREW endcop 10 24x7 B GASKET endecpa SNAPRING rotorgear SUPPORTSCREW 6 32x3 8 WASHER supportscrew H6 SNAPRING fulcrum Pin see T POIN TSE T clockwise 5 5 32 3 8 SUPPORTSCREW 8 32x3 8 EN WASHER supports crew 8 Bs CAMWICK clockwise theres 5
102. D STATE ELECTRONIC CONTROL MODULE SERVICE POLICY Because of the definite superiority of certain solid state control components over conventional electro mechanical relays and regulators product lines now incorporate solid state controls for applications in which they may be used to advantage To facilitate tasting and servicing these control components and circuits have been assembled as modules on printed circuit boards mounted in such a manner as to be quickly and easily removed Electrical connections to other components of the unit are by means of plug in or Faston connectors In recognition of the fact that most users of this equipment lack the facilities and specially trained personnel nessary to service and repair solid state electronic equipment the manufacturer has established a control module exchange service plan Under the Control Module Exchange Plan the owner of the equipment may exchange the entire module in which fault has developed for a new or factory rebuilt replacement A standard exchange price has been established for each module design which applies without regard to the amount of repair required to the original turned in which is applied against the cost of the replacement Exchange prices for specific modules may be determined by contacting an author ized distributor or by writing to the factory giving the SPECIFICATION MODEL and SERIAL numbers of the unit in which the module is in
103. DERING ENGINE REPAIR PARTS B 3 630 11 TM 9 3431 254 14 amp P SAFETY PRECAUTIONS Never fill fuel tank while engine is running or hot Do not operate engine in a closed building unless avoid the possibility of spilled fuel causing a fire the exhaust is piped outside This exhaust contains Always refuel slowly to avoid spillage carbon monoxide a poisonous odorless and invi sible gas which if breathed causes serious illness When starting engine maintain a safe distance from and possible death moving parts of equipment Do not start engine with clutch engaged Never make adjustments on machinery while it is I f connected to the engine without first removing the Do not spin hand crank when starting Keep crank ignition cables from the spark plugs Turning the ing components clean and free from conditions machinery over by hand during adjusting or cleaning which might cause the crank jaw to bind and not re might start the engine and machinery with it caus lease properly Oil periodically to prevent rust ing serious injury to the operator Never run engine with governor disconnected or op erate at speeds in excess of 3000 R P M load Precaution is the best insurance against accidents Keep this book hardy at all times fami liarize yourself with the operating instructions TM 9 3431 254 14 amp KEEP CLEAN PREVENT OV This engine is cooled by lt flow of air from a comb
104. ECTOR SWITCH This control is not RHEO SET MIN shown on the front panel view but it is located below the control panel on the right hand side of the lower panel This handle when in the UP position places the machine in CC mode and when in DOWN position in CV mode Welding Terminals LOAD VOLTS CONTACTOR CONTROL This item is not shown but is a timer used to control the length of meltback 92 730 00 150 200 250 300 time to prevent wire electrode from freezing to the LOAD AMPS weld puddle Voit Amp Characteristics Constant Voltage VOLTAGE REGULATOR The voltage regulator not shown maintains the exciter voltage to within Welding Generator Electrical Characteristics 596 Figure 3 SPECIFICATIONS Weiding CC DCSP or DCRP Welding CV Multi Wire than Micro Wire 250 Auxiliary AC Single Phase 60 Hz less more TM 9 3431 254 14 amp Welding Generator and Exciter Table 1 V 465D Brake Oil Displacement Horsepower System Gasoline 177 cu in 7 ats 15 gallons 5 2901 3 1800 1840 6 6 liters 56 8 liters Table 2 INSTALLATION LOCATION For best operating characteristics and longest unit life take care in selecting an installation site Avoid loca tions exposed to high humidity dust high ambient temperature or corrosive fumes Moisture can condense on electrical components causing corrosion or shorting of circuits Dirt on c
105. ER ASS Lv 1 67 63 CL 8400 ICLEVIS PIN for con necting link 5 Tonsisting or a 1 68 63 CL 7130 RETAINING RING fortinx clevispin 6 0 PT 604 SCREW 3 84 15 1 4 nexagonhead 1 69 63 CL 6965 OR IVING RING 63 353 LOCKWASHER 3 3 ee eee M P 42 63 PT 706 NUT n i NER 63 GR 23 K E Y for sumut shaft not illustrated i 9 3431 254 14 amp P FIG B 89 CLUTCH REDUCTION UNIT ASSEMBLY WISCONSIN No WC 360 TWIN DISC No C108 E3 6 RG4 Adaptable to WW 165 Drive Hub and Housing Assembly REDUCTION GEAR C 108 3 6 RG4 248594C Parts are identified by reference number See parts list for correct part number TWIN DISC PART C 108 E3 6 RG4 ITE Code number 78 prefixed to the part number is vendor identification Description bas 20 21 22 23 24 25 26 27 28 Port Mumber 78 A1339 78 1965R 78 M2023F 78 M2032AZ 78 A3115 78 M2033T 78 M166 78 A 5001 78 M178 78 8533 78 M2002U 78 510 78 2757 78 M2039J 78 M2022Z 78 3799 78 M2006H 78 M2046AF 78 7583 78 M105B 78 2510 78 2923 78 171 78 2032 78 3113 78 M639B 78 2830A 78 8531 SETSCREW SEAL TM 9 3431 254 14 amp P TWIN DISC CLUTCH REDUCTION UNIT ASSEMBLY REDUCTION RA TIO WC 360 PART NO PARTS LIST GASKET plate specification
106. Every 200 hours of operation remove oil plug in base and refill with No 20W oil Seal plug in reassembly The new style Delco Remy distributor does not have an external oil plug since it is self lubricated by oil in the accessory drive housing Every 100 hours apply 3 to 5 drops of light engine oil 10W to the felt in the top of the cam sleeve and 1 or 2 drops to the breaker arm pivot TM 9 3431 254 14 amp P Every 200 hours add small amount of high melting point grease to breaker arm rubbing block or oil the cam wick Avoid excessive lubrication oil that may get on the contact points will cause them to burn GENERATOR 12 volt 17 amp generator is furnished as standard equipment unless otherwise s pecified The generator is manufactured by either the Delco Remy Company or Prestolite Company Every 50 hours of operation add 3 to 5 drops of medium engine oil into the oil cap at both ends of the generator ELECTRICAL WIRING CIRCUITS Beginning with engine serial No 3979807 the stan dard wiring circuits for all electrical equipment is for negative ground polarity instead of the pre viously furnished positive ground The wiring diagram Fig B 15 illustrates a negative ground circuit To wire equipment that has posi tive ground polarity reverse terminal connections at the ammeter coil and battery Be sure polarity of generator and regulator is known when re wiring Do not use positive ground generat
107. Figure 7 LOSS OF MAGNETISM If generator fails to build up voltage after attaining full RPM 1800 1825 RPM it may be caused by the exciter having lost its residual magnetism in shipping or moving the unit Verify this loss of magnetism by measuring the A C exciter output voltage at the receptacle If less than 6 volts proceed as follows Shut engine down Replace 4 ampere fuse in the auto matic field flashing circuit See Connection Diagram Restart the engine to remagnetize the generator SLIP RING CLEANING If the slip rings get dirty clean them while they are ro tating by using a wooden stick to apply a piece of heavy canvas to them 14 WARNING Do not use a metal rod to apply the canvas RANGE SWITCH MAINTENANCE Due to a tight fit of the switch housing burred contacts or congealed grease operation of the switch may be come stiff or totally impaired The switch will have to be dismantled to inspect and dean it Proceed as follows to service the switch See Figure 8 for details and call outs found in the text NOTE It is not necessary to discon nect the wiring from the switch Do not remove the switch assembly from the front panel as a complete assembly but remove it by disassem bling as follows 1 Remove three screw 1 and take the handwheel assembly 2 off fromthe switch 2 Remove the snap ring 3 and washer 4 Snap ring pliers will be needed to remove the snap ring 3 Slide the front
108. G 14 amp P EC 82434C NOTE Items less part number are not serviced separately TM 9 3431 254 14 amp P FIG B 94 YF 34 DISTRIBUTOR Delco Remy No 1112695 NOTE Code number 18 prefixed to the part number is a vendor identification When ordering parts please use number with code as shown di pan Description Number 18 1960833 CAP ASSEMBLY includes Ref Nos 23 24 38 2 18 1954566 ROTOR 3 18 1954557 4 18 1928111 ette 5 18 1960814 BREAKERPLATE Liens 6 18 1964208 HOUSING ASSEMBLY Includes Ref No 18 7 18 1970035 GEAR 8 18 9417392 PIN for gear mounting 9 18 1954548 PLATE orfiyweighthold 10 18 1970505 CAMAUTOMATIC 13 18 1970504 SPRINGiorfiy weight stes 14 18 1880902 PUY WEIGH Tis 15 181970032 MAINSHAF Tand WEIGHTPLATE 17 181960325 leq 1 1 N 2 let Part No Number 18 181950569 22 18 1954563 23 18 1954571 24 18 1957573 26 18 453461 27 18 1914916 28 18 453647 31 18 810074 32 18 1912129 33 18 811912 34 18 1960824 35 18 1961088 36 18 1963858 37 18 1963555 38 18 1938193 Description
109. HANGE MULTIPLY Centimeters Inches 0 394 Meters Feet 3 280 Meters Yards 1 094 Kilometers E Miles 0 621 Square Centimeters Square Inches 0 155 Square Meters Square Feet 10 764 Square Meters Square Yards 1 196 Square Kilometers Square Miles 0 386 Square Hectometers Acres 2 471 Cubic Meters Feet 35 315 Meters Cubic Yards 1 308 Milliliters Fluid Ounces 0 034 Liters Pints 2 113 Litersi i Quarts 1 057 Liters Gallons 0 264 Grams Ounces 0 035 Kilograms Pounds 2 205 1 0 0 2 0 Kilometers Hour Miles Hour 621 6829 2 0 L0 L t NSN SNIHOVW SNIGT3A d 9bPl vSZ LEvE 6 NL This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do do it am tired sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to
110. INE GASKET SET Parts are identified by reference number See parts list for correct part number 9 3431 254 146P 5 LIST FOR STANDARD ENGINE Models V 465D V 461D V 460D ACCESSORIES COMMONLY SUPPLIED ON THESE ENGINE MODELS BEGIN ON PAGE 56 NOTE If weights differ V 461D weight is shown first REF PART NUMBER NO NO MODELS MODEL DESCRIPTION REQ V 460D V 46iD V 465D 85 99 AA 111 CYLINDER BARREL 4 11 8 12 8 86 105 51 AB 105A S1 CYLINDER HEAD ASSEMBLY consisting of 4 5 8 1 Head 2 AF 51 Springs 1 150 Insert 2 AD 44B Guides 1 AG 26A Seat 1 264 Insert 1 AE 88D Valve 1 AC 4 Rotator 1 532 Stud 1 AE 89 Valve 2 AH 19 Locks i RF 1319 Elbow NOTE Order Rocker Arm assembly separately 87 SeeFig B A 5 CRANKCASE ASSEMBLY includes 1LJ 300M Tube RF 1420 Fitting 1 ME 137 1 Bra cup RF 1 423 Nipple 2 291 Pins 1 R5 Tube 8 PF 18 Plugs IRJ Saber 1 RC 91 Screen RV 34A Valve 1 1319 Elbow 1 58 Flua 2 RF 1372A Fitting 1 1 Plug NOTE with serial 4904657 the basic standard crank case part number became 55 E for Model V 465D and 55 Model V 461D modified lubrication system Previous to the apove serial No 55 is required for V 465D BA 55 for 4610 V 460D Special machining is indicated by a number stamped on the crank case in the lo
111. K 19 lona below 211 filler RJ 163 obsolete 3 7 3 blade RJ 159D 1 0 long to serial 3655793 DIP STICK 1 44 lon starter side RJ 163A obsolete 3 5 3 lona blade RJ 159J 59 long to serial 3655793 OIL SLING or crmkshaft Beginning with serial 4904657 2 021 LD RK 179B previous to serial 49 04657 S QO ISP e umor RAUS OIL LINE 1 4 x 8 5 long with nuts Reducing vaive to upper oil header OIL LINE 4 tucing 744 lone with nuts i header to reducing valve RM 1122 B replaced by RM 8 50 A FLEXIBLE HOSE 3 long with fitting For header to oil pressure gauge FLEXIBLE HOSE 13 lora with fittina For fuel line pump to carburetor OIL RETURN LINE cylincer to case includ es JK 52 C rin RM 1351 51 used previous to No 3477845 not available use 2 RM 1351 and 1 1377 OIL LINE 5 15 tubing with nuts header to center bearing hanger OILPRESSUREGAUGE OIL FILTER CARTRIDGE 3 pack OIL PRESSURE REDUCING VAL YE With J K 52 O ring fcr engines begin ning with Ser al No 3488820 RV 4 1 and RV 33 B for engines to and including Serial 3488819 for re placement use 41 52 includes oll lines 1 is 4 1 3 2 i 2 1 2 2 2 1 2 1 8 1 5 4 2 1 2 1 5 1 1 1 4 9 3431 254 14 amp P INTERCHANGEABLE PARTS for Models
112. L CAD PLATED NUT 1 2 13 HEX FLANGE STEEL WASHER BAKELITE WASHER FLAT 1 2 ST SCREW 1 2 13 HHCS DRILLED FOR ITEM 30 SCREW 6 32X3 16 RD HD MH ST SCREW 1 2 13 X 1 3 4 HHC ST SCREW 8 32 X 3 8 RD HD MH ST WASHER 8 LOCK STD WASHER 8 FLAT BRASS MUFFLER SUPPLED W ENGINE GROMMET V02231 NO M 40 B RECTIFIER OUTPUT ASSEMBLY BRACKET MTG LONG WASHER INSULATING BUSHING BRACKET MTG SHORT DIODE POSITIVE BASE V58849 NO R5330 DIODE NEGATIVE BASE V58849 55330 SLEEVING POSITIVE BASE BAR BUS RECT UNITS PER ASSEMBLY N 5 Q 0 44 4 io N gt N W REF TM9 3431 254 14 amp P FIG NO A 4 ITEM NO 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 T 3 74 75 76 77 78 79 80 NO 4 4 4 4 4 4 4 4 4 4 A 4 4 4 4 4 4 4 4 4 4 4 4 4 4 35154 4 ILLUSTRATED 05485 90870 90869 90877 28 90871 91083 084 111 077 085 2CW 1915 20 91182 2CW 2234 91078 6DW 3 2CW 1914 3 91071 91123 02087 90910 05532 90886 02037 J 336 30547 91086 91164 91122 05663 9089 91072 05668 05664 90923 91160 91188 91117 05777 02063 i 35 2 6 AW 1233 76B 1 49 50 5 306 25 5 328 357080 3 361182 11 5 NOMENCLATURE C
113. N NUMBER 6101A 1 9 3431 254 14 amp P Welding Machine Figure A 1 TM9 3431 254 14 amp P UNITS FIG ITEM PART PER NO NO NO NOMENCLATURE ASSEMBLY A 1 6101A 1 CC CVR WELDINGMACHINE REF 1 NUMBER CONTROL PANELS UPPER END LOWER FOR DETAILS SEE FIG 2 REF 2 NO NUMBER GENERATOR GROUP FOR DETAILS SEE FIG A 3 REF 3 NO NUMBER FRAME AND CANOPY GROUP FOR DETAILS SEE FIG A 4 REF TM 9 3431 254 14 amp Controi Group Figure A 2 9 3431 254 14 amp FIG ITEM NO NO N P gt 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 NO 491102 491066 400641 8 AAW 835A 50GH 937 0 404278 402662 404875 404856 404277 402670 W 10051 8 6DA 4137 490874 404889 3 404889 1 404889 4 W 2974L 400078 490831 405561 405574 402889 1 W 9916 13 404065 3 358951 490581 3 400782 2 W 9917 4 CW 1150 DW 6080 400642 4 490921 AW 590 359576 359577 359578 351316 430548 4 430548 2 357083 366589 AW 459 366798 SW 218A 410541 490463 SW 167 1 16DA 4249 8 SW 231 A 5 A 6 BLANK NOMENCLATURE PANEL CONTROL ASSEMBLY PANEL AMMETER DC SINGLE SCALE 0 800 V60741 KNOB RHEOSTAT V92701 NO 4103AX RECEPTACLE 3 WIRE V83315 COVER RECEPTACLE V81703 NO WPC 5FS SWITCH TOGGLE V73559 NO 2GK71 73 CAP AND CHAIN ASSEMBLY V07497 NO 9
114. S FOR PROTECTING ENGINES FOR WINTER OR SHORT STORAGE PERIODS To protect the cylinders pistons rings and valves and keep them from rusting and sticking a half and half mixture of kerosene and good engine oil the same kind of oil as used in the crankcase of the en gine should be injected into the pipe tap opening on the intake manifold while the engine is warm and running at moderate speed About a quarter of a pint is necessary or enough so that a heavy bluish smoke will appear at the exhaust The ignition switch should then be shut off and the engine stopped This fogging operation will leave a coating of oil on the above mentioned parts protecting them from the atmosphere Drain crankcase oil while the engine is warm as the oil will flow more freely than when cold Drain fuel lines carburetor fuel pump and tank of all gasoline to prevent lead and gum sediment from in terfering with future operation Gasoline fumes from gradual evaporation is a dangerous fire hazard The air cleaner should be thoroughly cleaned of all oil and accumulated dust and the sediment removed from the oil cup at the bottom of the cleaner Tape or otherwise seal off the air cleaner or carbure tor intake as well as the exhaust and breather open ings for the duration of the storage period The outside of the engine including the cooling fins on the cylinders and heads should be thoroughly cleaned of all dirt and other deposits All expose
115. SEAL cronksheft cover PH 495B was used DIL SEAL for crankshaft 7 C end IPE 14 496 replaced by gt H 4968 PLAIN WASHER special for manifold mounting I LOCKSCREW ocroilcump THUMB SCREW orcylinderzead covers te shroud fuse wit h 4442 washer STUD 2 3 2 lgu for GC 23 idler year Beginning with eng serial No 5075776 PJ 105 D 2 5 8 lg for GO 28B sear Previous to engine serial Mo 5075776 RETAININGRING for piston pin 37 replaced 37 WIREBAIL for rocker arm cover WOODRUFF KEY special flywheei WOO DRUFEKEY No 9 lcs For crank shaft gear SPRING for camshaft hrust plunger ENGINE GASKET SET with rings See illustration page 43 Q 32A C 32B replaced by Q 32 C GASKETSET or valve grinding ee Consisting of 4 1 252 4 35 4 757 8 1 55 4 56 4 CD 758 4 1534 replaced Q 34 A INSERT BUSHING 1 41 D x 14 C D For exhaust port in cylinder head lig 10 lle Ref No 260 261 262 264 265 266 267 268 269 270 271 272 273 274 275 277 278 279 280 281 282 283 284 285 286 Port Number QB 85 08 85 QC 12 A QC 66 QC 67 QC 70 QD 67 QD 538 A QD 633 1 QD 634 QD 635 A QD 757 8 QD 758 QD 761 QD 761 A QF 93
116. SEAL tornousing PRIMARY WIRE ASSEMBLY SCREW for mounting 8 22 SCREW for meunting SCREW for breaker plate i SCREW orcontac adjiustmentemeeee een SCREW or hold down plate mounung 5 005 gt 2 25555555 1 210 4 3 SPACER gear 5 i for weight piute GROMMET in housing for primary wire RETAINER leq FIG B 95 25 51 DISTRIBUTOR Obsolete Optionally Used On V 460D and V 461D Engines Previously Serial 4427547 9 3431 254 148 No 1112596 i 3M 7e 6 21 13 30 1 INC 43 Number 18 811735 18 1938193 18 820445 18 1900119 18 1889966 18 1914309 18 1916806 18 1916805 18 1855720 18 1848038 18 813238 18 1928111 18 1847643 18 1889967 18 1889999 18 1847289 18 1947954 18 125947 18 1909003 18 811912 18 810074 18 810078 18 1881717 3 INC 38 45 Description CAPASSEMBLY Inciudes CARBON BUTTON not illustrated HOUSINGCOVERASSEMBLY Inciudes GASKET notillustrated FELT SEAL net illustrated 5
117. SOLINE STRAINER FUEL PUMP OIL GAUGE SABER STARTING SOLENOID STARTING MOTOR OIL FILTER OIL DRAIN PLUG OPTIONAL AND FILLER LOCATION M B 6 Fig 3 313029 TM 9 3431 254 14 amp P IGNITION COIL E 7 RP 1 SD n T GENERATOR DISTRIBUTOR VOLTAGE REGULATOR ACCESSORY DRIVE ASSEMBLY CARBURETOR GOVERNOR ADJUSTING SCREW LEVER Ne GOVERNOR ASSEMBLY N sPRING N lt Nye gf e 5 ANTI DIESELING N SOLENOID ASRS M 2 Ex 2 FLYWHEEL gt lt Us AIR SHROUD 9 5 THRUST PLUNGER T vwrA aa V kei Dxo d gt OIL SLING TEN d lt f a SECIONAL VIEWS OF ENGINE TM 9 3431 254 14 amp k PRESSURE REDUCING VALVE BATH AIR CLEANER PRE CLEANER pu GASOLINE STRAINER EXHAUST VALVE L _ QIL FILLER AND ROTATOR BREATHER a i om ADJUSTING EXHAUST MUFFLER SPARK PLUG OIL DIP STICK IDLER SHAFT LOCK SCREWS STARTING SOLENOID Z STARTING MOTOR OIL PRESSURE RELIEF VALVE DRAIN PLUG CENTER OIL FILTER MAIN BEARING Fig B 5 MODELS V 460D V 461D AND V 465D
118. The following list is a compilation of vendor code with names and addresses for suppliers of purchased parts listed in this publication The codes are in accordance with the Federal Supply Codes for Manufacturers Cataloging Hand book H4 2 and are wranged in numerical order Vendor codes are inserted in the nomenclature column of the parts list directly following the item name and description They are eesily recognized because each code number is pre ceded by for vendor The manufacturer s pert number follows immediately after the code number CODE 00779 02231 04713 07497 09393 09527 11702 14655 14894 VENDOR S AND ADDRESS Amp Inc P O Box 3608 Harrisburg Pennsylvania 17105 Anchor Rubber Company 840 S Patterson Blvd Dayton Ohio 45402 Motorola Semiconductor Products Inc 5005 East McDowell Rd Phoenix Arizona 85008 Amphenol Corporation Amphenol Cable Division 6235 S Harlem Avenue Chicago Illinois Rochester Gauges Inc of Texas P O Box 20180 Dallas Texas 75220 Faria Thomas G Faria Road Uncasville Connecticut 06382 Syracuse Rubber Products Inc 500 S Huntington Syracuse Indiana 46567 Cornell amp Dubilier Electric Corporation 50 Paris Street Newark New Jersey 07101 Bendix Automotive Service Division of Bendix Corporation South Bend Indiana A 17 TM 9 3431 254 14 amp P CODE 15605 16238 31356 31510 44655 58849 60741 73559
119. The reduction unit is operated in oil and the gear case oil level must be maintained to the oil saber gauge mark or plug opening see Fig 27 In Twin Disc units high grade transmission oil S A E No 90 to No 110 Viscosity must be used For Rockford units use No 30 S A E crankcase oil Change oil every 2000 hours of service while unit is warm If clutch slips heats or operating lever jumps our the clutch must be adjusted Release clutch operat ing lever and remove hand hole plate The clutchu in the clutch reduction units is the same as is used in the clutch power take off units Refer to Clutch Ad justment paragraph for adjustment of the clutch in the Twin Disc and Rockford clutch reduction in units A new clutch generally requires several adjustments until the friction surfaces are worn in HIGH TEMPERATURE SAFETY SWITCH Fig B 28 The high temperature safety switch is mounted on the cylinder head near the No 4 spark plug This safety switch will automatically stop the engine when head temperatures become critically high If an extreme cylinder head temperature causes the switch to automatically short out the ignition system and stop the engine a waiting period of about 5 mi nutes will be required before the switch has cooled off sufficiently to allow the engine to be resatrted An overheated engine will score the cylinder walls burn out connecting rod and crankshaft bearings also warp pistons and valves The cause o
120. URE 1 Centimeter 1000 M Ilimeters 20 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet TEMPERATURE 5 9 OF 32 2129 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 1 Liter 1000 Milliliters 33 82 Fluid Ounces 320 Fahrenheit 5 equivolent to 00 Celsius 9 5 32 F APPROXIMATE CONVERSION FACTORS TO CHANGE MULTIPLY Inches Centimeters 540 Feet Meters 305 Yards Meters 914 Miles Kilometers 609 Square Inches 5 Square Feet Square Yards Square Miles Metric Tons Newton Meters Kilopascals Kilometers Liter Square Centimeters Square Meters Square Meters Square Kilometers Short Tons Pound Feet 3 2 Pounds per Square Inch Miles per Gallon 45 093 836 590 102 738 145 354 2 0 0 1 6 0 0 2 Acres Square Hectometers 0 405 Feet Cubic Meters 0 028 Cubic Yards Cubic Meters 0 765 Fluid Ounces Milliliters 29 573 Pints Liters 0 473 Quarts Liters 0 946 Gallons Liters 3 785 Ounces Grams 28 349 Pounds Kilograms 0 454 Short Tons Metric Tons 0 907 Pound Feet Newton Meters 1 356 Pounds Square Inch Kilopascals 2 6 895 Miles per Gallon Kilometers per Liter 0 425 Miles Hour Kilometers per Hour 1 609 C
121. able connections at the bat tery starting motor and starting switch also check for broken or frayed cables Test starting switch and starting motor and replace or repair if necessary COMPRESSION If the engine has proper compression considerable resistance will be encountered in turning the engine over with the starting crank If this resistance is not encountered compression is faulty Following are some reasons for poor compression Cylinder dry due to engine having been out of use for some time See Restoring Compression Page B 17 Loose or broken spark plug In this case a hissing noise will be heard in cranking engine due to escap ing gas mixture on compression stroke Damaged cylinder head gasket or loose cylinder head This will likewise cause hissing noise on compression stroke Valve stuck open due to carbon or gum on valve stem Valves adjusted with insufficient clearance under valve stems See Valve Tappet Adjustment Page B 17 Piston rings stuck due to carbon accumulation Scored cylinders This will require reboring the cy linders and fitting with oversize pistons and rings or replacement of complete cylinder barrels IGNITION No spark may be attributed to the following Ignition cable disconnected from coil distributor or spark plugs Cables wet Broken ignition cables causing short circuits Spark plug insulators broken Plugs wet or dirty Spark plug point gap wrong Page B
122. after every other oil change If operating conditions are extremely dusty replace filter after every oil change The oil filter is easily removed by unscrewing it from its mounting pad on the side of the crankcase Refer to Oil Filter in disassembly instructions Wnen re assembling a new filter add a film of oil to the face of the rubber gasket at the base turn filter to a snug fit then turn more Do not over tighten Pour 1 additional quart of oil into crankcase when replacing oil filter Use only a Wisconsin oil filter specially designed for this model of engine Refer to parts list for correct service part number BREATHER CAP The crankcase is ventilated thru a breather cap mounted to the top of the oil filler tube as illustrated in Fig 7 At every oil change it is recommended that the cap be cleaned by washing in kerosene OIL PRESSURE AND ADJUSTMENT HIGH PRESSURE SYSTEM Oil supplied to the center main and connecting rod bearings at 40 to 45 P S I gauge pressure was 50 5 1 is controlled by a pressure relief valve perly adjusted at the factory Readjustment when necessary must be made while engine is running Refer to Fig B 7 and the following instructions The oil pressure relief valve is located beneath the starting motor and next to the oil filter The stub end of the valve is closed off by an expansion plug Re move plug from the end of the valve then with a B 11 TM 9 3431 254 1
123. after adjusting pressure as Pressure Adjustment instructions at front of manual OIL PRESSURE REDUCING VALVE B 56 To replace the oil pressure reducing valve loosen the 4 oil line nuts at the valve and at the fittings on top and side of crankcase Remove valve mounting cap screw and lift valve away from crankcase The oil lines will become unseated without being deformed In reassembly hold valve in proper location but do not mount Place oil lines in position and engage tubing nuts 2 to 3 turns Secure valve in place with capscrew and then tighten tubing nuts ASSEMBLY and DISASSEMBLY PROCEDURE with obsolete ROLLER type CENTER MAIN BEARING Engines previous to serial No 4904657 With reference to Fig B 57 remove oil coupling from crankshaft oil collet Take out the adapter mounting screw and slip oil coupling out of collet In reassem bly use new O ring seals at both ends of the coupl ing and on the shoulder extending into the crankcase Lubricate O rings for ease in assembly Remove the center main bearing hanger to crankcase mounting screws and spacers Tip case back on en gine supports and remove main bearing plate gaskets and shims Slip a length of pipe over the gear end of the crankshaft and with the assistance of another per son withdraw crankshaft with center bearing thru the main bearing plate opening as illustrated in TM 9 3431 254 146P OIL COUPLING TO COLLET
124. air t at passes nro ou eh Sel fhe ven uri size t ATE Size that permit full power development should be used PITOT TUBE BOWL VENT PASSAGE FLOAT Fig 99 FUEL SUPPLY SYSTEM OPERA LO 51 SUPPLY SYSTEM Fig B 99 uel und ia por al pressure EUN float chamber movi ae xd doses A wnen Its axle he nedi e ful read amp the a leve in the OW SYSTEM Fig 1007 At k late gst closed thy high Surti ition nee the e edge or t Ire ingle p ate wes le discharge hols are A Tis fer 10 Ing oer rottle eration IS aed the IDLE AIR IDLE AIR BLEED PASSAGE THROTTLE PLATE IDLE DISCHARGE HOLES MET ERING AT R IDLE ADJUSTING EDLE IDLE JET IDLE FUEL PICKUP PASSAGE MAIN JET Fig 100 IDLE SYSTEM main jet Fue from the float Tu r flow through Into t e meterin ng ali E or thr amp d Ik asi i fmt I caftra es He FA nm ps to ulsion mn umo eel YU Ro We seh stra nes dud se out s ot a justin ion tor each t Gn the needle an VS cule qt kure ric cunt gt uining sion reac Eius e alr USER and akee the mixture leaner HIGH SPEED SYSTEM EIS m Er d e venturi foe sufficien in im d nar jet to draw an emu ulsio lim and ell w d ar at eri fen E
125. alling out Lubricate shaft so that rocker arm bearings won t operate dry when engine is started CAMSHAFT Fig 51 Fig 52 Pull tappets outward to clear lobes while camshaft is being removed Withdraw tappets from inside the crankcase In reassembly clean and lubricate tappets Insert thrust plunger and spring into end of camshaft as these hold shaft in place endwise See Fig B 52 The camshaft gear has offset mounting holes to pro vide accurate assembly for valve timing The gear can only be out on the correct way for matching up the tim ing mark with that of the crankshaft See VN y 5 e OFFSET E EA HOLES ECC THRUST PLUNGER Ce NC an SPRING 271 BW CAMSHAF T 5 GEAR TIMING MARKS CRANKSHAFT GEAR Fig B 52 277794C CENTER MAIN BEARING Fis Fig B 34 V 465D Note Beginning with engine serial No 4904657 a shell type center main bearing replaces the split rol ler bearing The bearing and hanger assemblies are not interchangeable for service replacement unless the complete crankshaft assembly is changed and the crankcase modified The following instructions apply to the current pro duction engines with shell center main bearing Refer tol Page for overhaul procedures relative to the now obsolete roller type center main bearing and crank shaft oil collet Caution Do not attempt to remove crankshaft from en gine without first
126. ary treatment apply a drop of 2 Butyn solution to eyes at two hour inter vals or applications of sweet oil at hourly intervals for as long as acute burning sensation persists Always wear Safety glasses with side shields when in a weld ing area Grinding and chipping and cleaning of slag from the welds pose a safety hazard Safety Warnings OPERATING PRECAUTIONS Avoid contact with electrode and ground circuits taking care to insulate yourself from ground Use rubber mat or drywood when welding in damp locations or on metal floors Do not weld items lying on a concrete floor crete can explode when hot Do not loop an ener gized cable around your body Use only fully insulated electrode holder Maintain holder ground clamp and welding cables in good condition Make certain all connections are tight and that any cable couplings or splices are fully in sulated Do not simultaneously touch electrode holders connected to two welding machines or contact other personnel with energized electrode or holder Never dip electrode holder in water to cool it or lay down on ground surface Do not use a welding current in excess of rated cable capacity as the cables will overheat DO NOT use a welding machine to thaw frozen water pipes The possibility exists when this is attempted to cause fires explosions and or damage to the welder WARNING Do not operate in an enclosed area without adequate ventilation Do not
127. at du XD 83 Screws Ref 468A 2 1 NOTE assembly does not 111 AN 41 S1 COVER for rocker arm includes gask et clude center main bearing l 113 BD 108 S1 GEAR COVER ASSEMBLY 120 BG 308 52 i MAIN BEARING PLATE ASSEMBLY Includes Take off EI 3 8 1 3 Plug Includes 1 52 Button 1 ME 137 1 Bearing cup PH 496C seal 1 PE 4988 Oll seal 11 TC 388 1 Shaft 121 BH 155 E OIL denen Rettore 1 2j 114 BG 352 BEARING RETAINER PLATE TEPORE cade wiih shell type ct beoring 122 Bi 3544A BRACKET for Prestolite generator 1 1 8 5577 eil collet roller ctr bearing 1 354 For Delco Remy generator 124 72 1 ENGINE SUPPORT tides suas 2 18 32 E Lecce 018 TM 9 3431 254 14 amp P INTERCHANGEABLE PARTS for Models V 465D V 460D V 461D et Part a 25 Seb Fig 82 CRANKSHAFTASSEMBLY Includes 2 168 Bearings 1 GA Gear 1 PL 156 Key 1 137 5 Shell Brg 1 179 sling NOTE The basic crankshaft part number raised letters side of No 2 counterweight is 75 for engines with shell center bearing 75 with obsolete roller type center bearing Dash numbers are added to the basic part number to identify special machining at th
128. ate 2 o clock position as illustrated in Fig B 11 1 o clock position as in c Assemble distributor to housing properly mesh ing the gears while retaining the terminal wire B 14 TERMINAL WIRE n CLAMP SCREW DISTRIBUTOR CLAMP ROTOR SHAFT ROTATION ROTOR CONTACT APPROX 2 O CLOCK POSITION ROTATE BODY CLOCKWISE UNTIL BREAKER POINTS ARE JUST BECINNINC TO OPEN ADJUSTING SLOT LOCKSCREW TERMINAL STUD APPROX 12 O CLOCK iR ADVANCE ARM MOUNTING SCREW CONTACT APPROX O CLCCX POSITION BREAKER POINT ADJUSTING SCREW ROTOR LOCKSCREW ROTOR SHAFT ROTATION Jf amp _ COUNTER CLOCKWISE ROTATE sov CLOCKWISE UNTIL BREAKER POINTS ARE JUST BEGINNING TO OPEN 1 CONDENSER ADVANCE ARM CLAMP SCREW Fig B 12 PRESTOLITE DISTRIBUTOR or stud in an approximate 12 o clock position d Mount distributor clamp to drive housing Fig 1 but do not tighten screw If applicable as per tighten advance arm mounting screw to the drive housing Adjust breaker point gap to 0 020 inch maximum opening see Distributor Maintenance f With the clamp screw loose turn distributor body slightly in a counter clockwise rotation so that breaker points are firmly closed Then turn dis tributor body in a clockwise rotation until break er points are just beginning to open At this point a slight resistance
129. aused by the abrupt shut ting off of a hot engine is vapor lock This will result TM 9 3431 254 146P in hard starting which can be overcome by choking the engine when cranking or waiting until the engine has cooled off sufficiently to overcome the vapor lock ANTI DIESEL VALVE High compression engines have a tendency to occa sionally diesel after the ignition has been shut off To rectify this condition an unti dieseling solenoid valve is provided to assure immediate stopping When the ignition is turned off the solenoid becomes de energized and releases a valve that shuts off the fuel supply in the carburetor thus stopping the en gine CAUTION Engine will not operate if ignition wire from anti diesel solenoid to starting switch is disconnected If solenoid is removed from carburetor for same rea son use a new fibre washer in reassembly and tighten to 100 inch pounds torque OIL FILTER A full flow oil filter is furnished on this model of en gine as standard equipment Since all of the circulat ed oil passes thru the filter it is very important that it be serviced regularly in order to function properly When the filter element becomes clogged the oil by passes the filter material by means of a relief valve located in the top of the oil filter See Fig B 7 As a result there is no variation in oil pressure to indi cate that the oil filter is clogged anti requires re placement The oil filter should be replaced
130. buretor until tne bent end of the rod will register with hole in lever then screw rod in one more turn The extra turn wiil shorten CARBURETOR THROTTLE LEVER WIDE OPEN SWIVEL BLOCK f BENT END N 2 AN GOVERNOR LEVER LEVER PUSH TOWARD CARB IN 22 2777960 FULL HO ee LOAD LOAD a GOVERNOR REM NO SSE SEE T HOLE 1500 OL 1600 825 700 1855 4 1800 5 955 Hil MN b UL OS 4 0 OO x e j 2500 2695 Here 2600 2745 2700 aso 255 0 2990 3065 14 3000 3175 12 Fig 23 the linkage slightly will enable the carburetor throttle lever to bounce back from the stop pin rather than jam against the pin when a load is suddenly ap plied to an idling engine This will eliminate exces sive wear on the threads in the carburetor throttle swivel block The governor lever Fig B 23 is furnished with 12 holes for attaching the governor spring It is very im portant that the spring is hooked into the proper hole to suit the speed at which the engine is to be opera ted The Governor Lever Chart shows the full load and no load speeds of the engine and the hole cor responding thereto for either a fixed speed a vari able speed or two speed over center idle control governor Note that the full load speed is less than the no
131. can be felt as the breaker point cam strikes the breaker arm g Tighten clamp screw The No 1 cylinder is now ready to fire in the retarded position The breaker point gap of 0 020 of an inch should be checked and adjusted per paragraph e before dis tributor body is set and locked in place as per para graphs f and g because any change in gap open ing will affect the ignition advance Mount dust cover and distributor cap ROTATION Fig B 13 DELCO REMY DISTRIBUTOR MOUNTING 313024C If care is exercised in the preceding instructions the spark timing should be accurate enough for satis factory starting however checking spark advance with a neon lamp as described in Neon Lamp Tim ing is necessary The No 1 terminal tower for the Delco Remy distribu tor is located in an approximate 2 O CloCK position the distributor cap as illustrated in Fig B 13 and in an approximate 1 o clock location for the Prestolite distributor The terminal sequence is 1 3 4 2 in a counter clockwise direction Mount ignition cables to spark plugs of like numbers with the center terminal tower connected to the ignition coil See Wiring Dia gram Fig B 15 The cylinder shroud covers are marked for spark plug identification C NEON LAMP TIMING Fig B 14 The engine should be timed to the 23 advanced posi tion at not less than 20po R P M Check timing with a neon lamp as shown in Fig B 14 insert a small screw driver
132. cation shown in Add this number to the basic crankcase part number Order by complete number and by giving the Model Specification and Serial Numbers of the engine Fig B 81 226222 89 08 223 08 232 PISTON standard 2 m 4 15 NOTE Pistons are also furnished 010 020 030 overs ze 90 DE 76 DE 80 PISTONPIN standardsize oisi eene ania rni raid i n da da ee va ATE Cn dd dada aa a 1 4 NOTE Piston Pins available 005 010 oversize 91 DR 48 A DR 60 PISTONRINGSET standardsize for 1 DR 48 replaced by DR 48 A DR 49 TRI CROMERE RINGSET standard 1 NOTE Ring Sets are available 21 0 020 and 030 oversize 93 LO 115 A L0 127 A PRE CLEANER 1 1 8 00 0453 P8H00 0234 Servi ce Parts 2 8 93A 22 10 3587 22 20648 ruo MT 93B 22 P 20115 22 P 20227 Hm 1 93C 22 P10 3589 22 P 20650 Sleeve Assemb 1 94 L0 159 4 S1 L0 185 S1 OILBATHAIRCLEANER DonaidsonCo eec nennen enn 1 5 9 FGA05 2522 06 0022 Service Parts 5 0 94 22 2706 22 2691 Assembly 948 22 17242 22 17702 Inner Cup 94 22 17244 22 17703 Outer Cil Cup 94D 50 161 50 161 Decal 9777 Body Assembly not serviced separately LO 90 5 S1 Air Cleaner No A 552 for V 460D and V 46 1D engines previous to Serial 3477993 Replaced b
133. ce a day if engine is operating in very dusty conditions Once each week in compara tively clean conditions Remove oil cup from bottom of air cleaner and clean thoroughly Add the same grade of oil as used in the crankcase to the level line indicated on the oil cap Detailed instructions are printed on the air cleaner Operating the engine under dusty conditions with out oil in the air cleaner or with dirty oil may wear out cylinders pistons rings and bearings in a few days time and result in costly repairs Once a year oftener if conditions are severe remove air cleaner from engine and soak in solvent to clean out accumulated dirt from element Caution Do not clean with gasoline naptha or benzine COLLECTOR PRE CLEANER HOSF CONNECTIONS OIL BATH AIR CLEANER OIL CUP OIL LEVEL Fig B 8 277798C PRE CLEANER The collector type pre cleaner mounted to the top of the air cleaner as illustrated in Fig B 8 removes the larger dirt and dust particles before the air reaches the main air cleaner Clean bowl regularly of accumulated dust and dirt Do not use oil or water in pre cleaner this must be kept dry Daily attention to the air cleaner and pre cleaner is one of the most important considerations in prolong ing engine life GASOLINE STRAINER The gasoline strainer is very necessary to prevent sediment dirt and water from entering the carburetor and causing trouble or even complete sto
134. co Remy No 1102225 Ref No Do H gt 10 11 12 15 16 17 18 19 20 21 22 23 24 PLATE 052 NOTE Code number 18 prefixed to the part number is a vendor identification When ordering parts please use number with code as shown YB 62 B 18 1946595 18 1932506 18 1944373 18 1908829 18 1925378 18 1925379 8 1935778 18 1922701 8 1939902 8 954378 8 1873830 8 817224 8 1923284 8 1858749 8 1858749 8 1911263 8 1912008 8 1912073 8 809763 8 456413 Part Number YB 62 18 1935696 18 1932506 8 1878183 8 1908829 8 1922288 18 1922289 8 1952297 8 1936388 8 1912725 18 954378 18 1873830 8 817224 18 1921369 8 1921860 18 1921362 18 1885090 18 1911263 18 1912008 18 1912073 18 809763 18 1880781 18 1904377 Description FRAME commutator end Includes Ref Nos 42 44 47 48 GROUND BRUSH HOLDER PKG INSULATED BRUSH HOLDER PKG ARMATURE ceceno ue FIELD COIESET z ten ee tts Includes Ref Nos 16 and 40 DOLESHOE 3 Ene BALL BEARING D E FRAME D E Includes Ref 43 COLLAR i eda STUD armature terminal STUD field terminal to brush BUSHING armature terminal BUSHING field terminal PLATE bearing retainer GASKET bearing retainer plate INSULATION field coil THRU BOLT O an
135. ctors can now be removed In reassembly tighten gear cover capscrews to 18 foot pounds torque GEAR TRAIN B 37 With the removal of gear cover and oil sling the gear train will be exposed as shown in Remove camshaft thrust plunger and spring to prevent their being lost Future reference can be made o Fig 7 when assem bling crankshaft and camshaft as accurate location of the timing marks is essential for proper engine operation SPACER PLATE FLANGE FOR ACCESSORY DRIVE HOUSING Ose m ALLEN HEAD LOCKSCREW RA D V SN J OIL PUMP N Fig B 38 277782C 9 3431 254 146P SPACER PLATE FLANGE FOR ACCESSORY DRIVE LOCKSCREW HOLE HOUSING MACHINED FLAT HD WOOD ENGINE FIXTURE Fig B 39 ENGINE SUPPORTS AND OIL Fig B 39 Use a work bench with a clearance hole of at least 2 inches in diameter for the engine crankshaft to extend thru and tip the engine over to rest on the main bearing plate or if convenient construct an engine fixture by making a box from 2 x 6 lumber as illustrated in Fie B 39 Make the box about 16 inches square x 8 inches high with a 2 inch clearance hole in the top and open at the bottom 277783C With engine tipped over on tak off end remove en gine supports and oil pan In reassembly use a new gasket underneath oil pan mount with oil drain to ward side opposite f
136. cylinder Turn the engine over several times with the starting crank to distribute the oil over the cylinder walls Then reassemble spark plugs and compression should be satisfactory VALVE TAPPET ADJUSTMENT Fig The clearance between the valve and rocker arm with the tappet in its lowest position valve complete ly closed and the engine cold Inlet 0 008 inch Exhaust 0 014 inch The rocker arms can be identified as follows When facing the side of the engine the exhaust rocker arm D ADJUSTING SCREW 6 w 5 Se ROCKER ARM DW CN VA NS SR INLET y EXHAUST ROCKER ARM 55 1 Fig 20 27444 TM 9 3431 254 14 amp P is to the right in the cylinder head and the inlet rocker orm to left Measure tie clearance between the top of the valve and the nose of the rocker with a feeler gauge as shown ia FEB 20 By means of inch tappet wrench turn the tappet adjusting screw ciockwise to decrease valve clearance and counter clockwise to increase the clearance The sequence in which the tappets are adjusted is determined by the 1 3 4 2 firing order Start by adiust ing No 1 inlet valve clearance first then iust a short turn of the crank No 3 iniet can be adjusted Return to 1 cylinder and adjust the exheust clearance then adjust the No 3 exnaust The same procedure applies to the No 2 and No
137. d unpainted metal parts should be coated with grease or heavy oil Before starting the engine after the storage period remove crankcase drain plug so that any condensa tion which may have collected may be drained before new crankcase oil is added It is highly 9 3431 254 14 amp P ed that the crankcase bottom cover be removed and scrubbed of all sediment which may have collected there When reassembling the bottom cover a new gasket should be used Fill crankcase with the correct grade of oil to the full mark on the saber Do not use any oil heavier than SAE No 30 Also be sure to put oil to the proper level in the air cleaner Refer to Lubrication and Air Cleaner It is advisable to use new spark plugs at the begin ning of the operating interval especially if the en gine has given considerable service Refuel engine and follow the starting instructions as shown on preceding pages of this manual It is suggested that machines be stjored inside a building If this is not possible protect the en gine from the weather by a proper covering 9 3431 254 146P DISASSEMBLY AND REASSEMBLY O F ENGINE Engine repairs should be made only by a mechanic who has had experience in such work When disassem bling the engine it is advisable to have several boxes available so that parts belonging to certain groups can be kept together Capscrews of various lengths are used in the engine therefore great
138. der side of case as illustrated i Fig B 53 Draw cap to hanger screws finger tight until the two dowels are just entering holes With a hand wrench alternately turn each screw 1 2 to 3 4 turns to evenly pull cap tight to hanger body Torque screws 32 to 35 foot pounds Secure bearing hanger to crankcase after crankshaft end play is set Install capscrews and washers torque to 60 foot pounds Be sure oil fitting passages are clean Connect oil line from header to bearing hanger B 32 MAIN BEARING PLATE and B 55 Remove main bearing plate gaskets and shims from take off end of engine Slip a length of pipe over the gear end of the crankshaft and with the assistance of another person withdraw the shaft thru the main bear ing plate opening as illustrated in Removal of crankshaft with center hearing hanger assembled to it applies only to the obsolete split roller bearing Caution It will be necessary to rotate the crankshaft so that counterweights clear the center main bearing hanger lugs in crankcase In reassembly Holes for the main bearing plate are off set for correct mounting Assemble main bearing plate gaskets and shims and torque cap screws to 32 foot pounds Check end play and add or remove gas kets to give the necessary 002 to 004 inch move ment with engine cold IDLER GEAR AND SHAFT Fig B 55 Fig 58 A tapped hole in the side of the crankcase contains 2 setscrews for locki
139. ding generator shaft by a flexible coupling IDENTIFICATION The welding generator unit has an identification plate attached to the control panel below on the left hand side The unit is identified as to SPEC num ber by the dash number which follows it as ex plained on the front sheet of this manual The engine identification number will be found on the engine name plate attached to the air shroud of the engine When ordering spare parts or communicating about this ma chine be sure to specify the engine serial number engine type unit specification and serial numbers Left and right hand sides of the unit are determined when facing the control panel TM 9 3431 254 14 amp P 15 14 Frequency Meter Hour Meter Oil Pressure Gauge Range Switch Welding Voltmeter Welding Ammeter Fine Current Control Choke Control Engine Throttle O OQ G N 10 Twist Lock Receptacle 115 V AC 11 Receptacle Cover i3 12 U 12 Start 13 Wire Feeder Receptacle 14 Slave Receptacle 15 Toggle Switch 16 Duplex Receptacle 115 V 17 Cover 18 Circuit Breaker 40 amperes 19 Circuit Breaker 15 amperes 20 Circuit Breaker 20 amperes 21 Battery Ammeter Control Panel Figure 1 CONTROLS INSTRUMENTS AND OUTLETS FREQUENCY METER 1 Registers the frequency of the voltage supplied to the receptacles both the du plex receptacle a
140. dy and fuel bowl with reduced air pres sure Be sure all carbon deposits have been removed trom throttle bore and idle discharge holes Reverse the flow of compressed air all bay es to insure the removal of ail dirt NEVER USE DRILE OR WIRE TO CLEAN OUT JETS OR IDLE HOLES INSPECTION OF PARTS Float Assembly Replace if loaded with gasoline da maged or if float axle bearing 15 worn excessively In spect float lever for wear at point of contact with fuel valve needle Replace if wear is excessive Float Axle Replace if any wear has occurred on the earing surface Fuel Valve Needle amp Seat Assembly Replace as a com lete unit Wear ol any of these parts can seriously atfect the operation of the Tloat 4 Idle Adjusting Needle Inspect end the needle t make sure it 15 smooth and free of grooves Replace if pitted or grooved Gaskets Seal and Retainer Replace all gaskets throttle shaft seal and retainer each time the carburetor 1s overhauled 6 ch ck Specifications Verify the correctness of the lowing arts Numbers will be found on the parts Main Jet Idling Jet and Fuel Valve w N REASSEMBLY ASSEMBLY OF THROTTLE BODY Install the fuel valve seat 31 and fibre washer 30 using Zenith Tool No C161 85 2 Install the main discharge jet 32 using a small screw driver 3 Install fuel valve in seat 31 followed by float 19 m ax
141. e See ig 1 When specified a saber can be furnished on the opposite side behind the starting motor TM 9 3431 254 14 amp P High grade oil of the body suited to the requirements of your engine is the most important single item in the economical operation of the unit yet it is the cheapest item of operating cost Select your oil solely on quanlity and suitability never on price for no one thing is so sure to bring abut unsatisfactory performance and unnecessary expense as incorrect lubrication High grade highly refined oils arres ponding in body to the S A E Viscosity Numbers listed in Grade of Oil Chart will prove economical and assure long engine life SERVICE CLASSIFICATION OF OIL In addition to the S A E Viscosity grades oils are also classified according to severity cf engine ser vice Use oils classified by the American Petroleum Institute as Service MS SD or SE These types of oil are for engines performing under unfavorable or severe operating conditions such as high speeds constant starting and stopping operating in extreme high or low temperatures and excessive idling GRADE OF OIL SEASON OR TEMPERATURE GRADE OF OIL MIL L 46152 SAE 30 Spring Summer or Fall 1209 to 40 F Winter MIL L 46152 40 F to 15 F SAE 20 20W 15 F to O F SAE 10W Below Zero SAE 5W 20 Use oils classified as Service MS SD or SE Crankease Capacity 6 Qts Additional for
142. e Number and Electrical Characteristics if applicable 7 If DD Form 1348 is used fill in all blocks except 4 5 6 and Remarks field in accordance with AR 725 50 Complete Form as Follows a In blocks 4 5 6 list manufacturer s Federal Supply Code Number 28835 followed by a colon and manufacturer s Part Number for the repair part b Complete Remarks field as follows Noun nomenclature or repair part For NSN 3431 01 032 6289 Manufacturer Hobart Brothers Company 600 W Main St Troy Ohio 45373 Model GCC 300W Serial of end item Any other pertinent information such as Frame Number Type Dimensions etc 9 3431 254 14 amp P TABLE OF CONTENTS SAFETY WARNINGS Page INSTRUCTIONS OF ROUIPMENT 5 4 X oe Ee S WU eic so DESCRIPTION OF EQUIPMENT 2 i e Ge ae om WU OR Oh de YS SS Deer OY Se gt Ae Ue c Su BUN e Wa Moo a AR cbe e t Sa ENGNG A ne A LIE doge Gs UP SE SU ae AOE ART aput n wa a dar qr a Yami Gare Controls Instruments and Outlets Xr d
143. e T 89F S1 and 361 GD 120 Drvegear for TF 122Y 2 1 D i 89 52 gqovemor GD 120A ior TF 122H 1 assembly M 323 TC 395 57 HOUSING ASSEMBLY 112 362 1F 470Spccer ordriveqeqr 1 1 Censistinq 363 1J 320 GDriveshoftassembly 1 1 4 324 PF 18A Pipe plug 1 B8 slotted 2 1 Consists of 326 PH 571Oi1 seal replaces PF 118 1 1 364 GF 90 Gear for distributor drive 1 Retainer end PH 318 A Seal 365 IX D 1 10 327 QD 615AHousinggasket 1 1 366 112 Bearing 1623 8 1 E 28 5 52 Plug 1 2 expansion 1 1 367 ME 139 Bearing No 1633 8 1 4 29 TC 395 Housing order TC 395 87 1 1 14 368 408 Pin for distributorgear 1 84 330 TC 398 Crossshaftandlever 2 x 7 8 lona rellpin 1 1 331 181 1 3 281 1 88 x 7 8 taper 332 XH 1 Pin for yoke No 3 44 pin replaced by PA 408 longtaper a aaa 1 1 369 108 Lockdngs 3 1 334 TC 405 L GEAR amp FLYWEIGHT ASS Y 1 1 371 AD 363 1Drivepulley tens 111 For T 89M S2 governor 372 H 541 seal Replaces PH 2 74 1 1 TC 405 obsolete T 89F S2 gov 373 K 107 Lock nng for bearing in for replacement use TC 405L housing eene etre 1 1 405 For obsolete 89 F S 1 gov 374 20 616 Gasketforhousing 1 1 for replacement use 405 i 375 TB 141C SlHousingos
144. e a pilot bearing grease fitting at the end of the drive shaft and are lubricated same as the housing bearing CLUTCH ADJUSTMENT ol Fig B 26 If the clutch begins to slip it should be readjusted otherwise it will become overheated and damaged First remove the clutch inspection plate and release the clutch operating lever For the Rockford clutch turn engine over by means of the hand crank until the clutch adjustment lock is visible thru the inspection opening in the clutch housing see Fig B 25 The clutch must be held stationary either by means of a drift punch wedged in place as shown or by some convenient method of keeping the take off shaft from turning Loosen screw holding the adjustment lock in place Insert a screw driver in one of the notches and turn the adjusting ring in a counter clockwise direc tion one notch at a time until a very firm pressure is required to engage the clutch with the operating lever Tighten adjusting lock screw and mount inspection cover LOOSEN LOCK SCREW id LOCK OPERATING PREVENT CLUTCH FROM L TURNING BY MEANS OF DRIFT PUNCH OR SIMILAR TOOL TURN ADJUSTING RING COUNTER CLOCKWISE Fig B 25 ROCKFORD CLUTCH ADJUSTMENT 2262276 B 19 9 3431 254 14 amp P CL OPERATING LEVER N am Q ADJUSTING LOCKPIN PULL OUT BM ADJUSTING YOKE CLOEKWITSE DIRECTION sx Fig B 26 TWIN DISC CLUTCH ADJUSTMENT 104578C
145. e accomplished by means of a steel retainer bar and the cylinder hold down studs as shown in Insert a drift punch in crankshaft crank pin hole and turn shaft over so that the nuts for the No 1 connect ing rod cap are accessible Take off the 2 nuts loosen DRIFT PUNCH ROD BEARING PARALLEL WITH FLAT ON CYLINDER CYLINDER RETAINER cm ju idi il CYLINDER PISTON AND CONNECTING ROD ASSEMBLY Fig B 45 281382C TM 9 3431 254 14 amp P and remove connecting rod cap by tapping lightly on the end of the bolts Use a brass rod so as not to up set bolt threads Remove cylinder retainer bar and withdraw cylinder barrel piston and connecting rod as illustrated ir Fig B 44 Place on rod immediate ly so that it will not be mismatched in reassembly Remove No 3 cylinder assembly and then do like wise with the No 2 and 4 cylinder bank Identical numbers are stamped on the side of the rod with its corresponding cap These numbers must be on the same side of the connecting rod in reassem bly Sed Fig B 48 Install new nuts on connecting rod bolts and torque to 32 foot pounds Cylinder barrels should be put back on the crankcase in the same location they were removed from Use a new gasket at bottom of barrel Clean all dirt and chaff from between fins and bottom of flange If the cylinders are worn more than 005 inch over size they should be reground and fitted with over
146. e axle to maintain proper balance of load ing on the tongue end of the unit NOTE The unit should be operated in as near a normal horizontal posi tion as possible and never at greater than 15 from horizontal INITIAL PREPARATION FOR USE 1 Open canopy doors on sides of the generator com partment Latch the doors in the open position by use of the safety latches provided 2 Inspect unit thoroughly to be sure it is in proper working order Check all fuel and wire connections to be certain they are secure Tighten any loose screws nuts or bolts Check closely for any damage which may have occurred in transit 3 Remove all special tags from the machine read care fully and follow any special directions they may carry Keeps tags with manual for future reference 4 Check that oil pan drain plug is closed Fill engine with the correct type of oil as specified in the engine manual 5 Make certain that all air passages and cooling fins are free from foreign matter Use dean dry compressed air to blow dirt and dust out of cooling passages and control cabinet 25 psi 172 kPa maximum pressure 6 The storage battery is shipped dry charge from the factory Proper steps to install electrolyte must be taken before use 7 Attach battery cables to poles of battery as indi cated on wiring diagram The negative pole should be grounded to the frame of the unit in a secure manner WARNING Connect proper battery
147. e diameter of wire electrode to be used 3 Proceed as in steps 2 through 8 preceding DRAWING AUXILIARY POWER Electric power may be drawn from the receptacles on the control panel at any time that the generator is operating at rated RPM VOLTAGE REGULATION The output voltage will be maintained within 5 by the voltage regulator if load is added or removed any re sulting voltage increase or decrease will be recovered within one second STOPPING THE ENGINE 1 Break the welding arc 2 Pull the engine throttle control OUT from the panel as far as it will go Engine will reduce RPM Move the START RUN OFF Switch to OFF position 3 Allow engine to cool sufficiently then check coolant and crankcase oil level If engine oil is to be changed it can be done most effectively while engine is still warm 4 After engine has cooled completely fill the fuel tank See SAFETY WARNINGS at front of this manual for precautions that should be taken when filling the fuel tank STORAGE NIGHTLY After operation the following steps should be taken before storing the welding machine for short periods of time 1 Close fuel shutoff valve at the tank and cover unit with a tarpaulin if stored outdoors 2 Clean up around work area Put all tools parts and supplies in their proper places 3 Disconnect welding leads from machine Coil them and store away in their place 9 3431 254 14 amp P Exciter Auxiliary Brushes
148. e free service to the life of your engine ACCESSORIES Remove clutch or clutch reduction unit if engine is equipped with either of these accessories AIR CLEANER can be removed as a complete unit when flywheel shroud is removed Disconnect tubing and elbow connection from carburetor to air cleaner CONTROL PANEL can remain on flywheel shroud but disconnect ignition wires from anti diesel sole noid starting solenoid choke wire at carburetor hose at oil pressure gauge variable speed control ignition wires at coil and voltage regulator battery terminal OIL FILTER is removed by tapping side of cartridge with a mallet to break the seal Then pierce can with screw driver or similar pointed tool to serve as a handle for unscrewing filter from case Place a pan under the filter to catch oil leakage when filter is re moved Refer to Oil Page BL1 1 for ment instructions STARTING MOTOR is removed by disconnecting ig nition wires at solenoid and taking out the three cap screws holding starter to flange on gear cover Note The rubber Bendix cover will drop off when flywheel shroud is removed FLYWHEEL B 30 After the flywheel screen has been removed drive out the starting crank pin in the crankshaft and straighten out the bent tabs lockwasher By means of a 214 socket power wrench 214 offset box wrench as shown in remove flywheel nut Strike the handle of the wrench a sharp b
149. e take off end The dash number will be found stamped on the cheek facing the take off end of the shaft as illustrated in Fig B81 by complete part number 1 dash number added to basic number md by giving the model specification md serial numbers of the engine CAUTION Engines equipped with hydraulic pump require a hardened crankshaft gear GA 49 A identi Hed by a 1 16 wide gwa ve the gear hub When ordering crmkshaft with hardened gear add on 54 behind the crankshaft part number 2 CA 75 C series crankshaft be used in place 75 seres by changing over the shell center bearing assembly modifying crankcase for an intemal oil pressure line 1 1 4 Fig B 82 71057 26 71 51 CONNECTINGRODASSEMBL Y la fa fp Includes 1 HG 131C Busning 2 PD 247 Nuts 2 PE146 2 Bolts 1 4 IDA 7 1 51 replaced by 714 51 NOTE The connecting rod Is fumished L 55 the shel I bearings Refer to reference number 153 for part number of the stendard size and the undersize shell bearings available 37 EA 132 IC ANSHAET 11 116 replaced by 132 38 67 8 IVALVETAPPET oos dis 8 2 F 67 replaced by F 67 B 40 166 ROCKER ARM and BRACKET 55 4 1 4 Consisting of 41 166 Bracket PONE 7 42 FX 167A 51 Focker am assem exhaust Includes PI 194 Ad screw 43 16 51 Focker arm assembly inle
150. e valves After valves have been lapped in evenly remove and wash both valves and head thoroughly with kerosene and re assemble Valve guides in the cylinder head are replaceable The valve stem has a clearance of 002 to 004 in the guide When the clearance becomes 006 the guide should be driven out and a new guide pressed in place Allow 1 32 to 1 64 clearance between the valve guide boss and the bottom of the valve guide shoulder Check guide for 3440 3445 LD after pressing in place Ream if necessary VALVE SEAT INSERTS are not replaceable due to method of installing If seat inserts become worn and ground down to the extent that the seats are wider than the valve face replace cylinder head ROCKER ARM ASSEMBLY Fig B 50 Very little wear will occur to the rocker arms as long as they are adequately lubricated If replacement is necessary remove the complete rocker arm bracket ROCKER ARM VALVE LIFTER ASSEMBLY Fig B 50 277775C CAMSHAFT ASSEMBLY VALVE TAPPETS Pull Outward Fig 51 277803C TM 9 3431 254 14 amp P assembly shown Fig B 50 from the cylinder head Take out shaft setscrew from bottom of bracket with a 1 8 Allen wrench and tap shaft out toward set screw end of bracket using a brass rod In reassembly be sure set screw seat in shaft is lined up with tapped hole in bracket After tightening set screw in place prick punch threads to prevent screw from f
151. eads in reassembly Tighten manifold to cylin der head nuts to 25 foot pounds torque The upper to lower manifoid nuts are tightened to 15 Ibs terque and the enti diesel solenoid mounted to the carburetor is tightened to 100 inch pounds torque FUEL PUMP Loosen screw on heat deflector at fuel pump Remove 2 capscrews holding pump adapter to crankcase Swing heat deflector bracket to one side and remove complete pump adapter and strainer assembly GOVERNOR Remove the 2 bottom screws holding the governor housing to the gear cover and spacer plate Top 2 screws were removed when spark plug wire clamps were taken off After removing governor housing the gear and flyweight assembly can be slipped off shaft in gear cover In reassembly refer to Governor Adjustment in Operoting Instruction Section of manual for setting engine operating speed GEAR COVER Fig B 30 Remove capscrews from front face of gear cover and 2 screws from rear at No 2 cylinder Tap gear cover HEAT DEFLECTORS STARTER FLANGE GEAR COVER Fig B 36 277785 GOVERNOR GEAR CAMSHAFT THRUST PLUNGER AND SPRING CAMSHAFT GEA YON 5 e 290 CRANKSHAFT GEAR IDLER GEAR TIMING MARKS ACCESSORY ORIVE GEAR OIL PUMP GEAR Fig B 37 277784C alternately from starter flange to accessory drive housing opening and remove as illustrated in Fig Note that dowel pins will remain in cover Cylin der heat defle
152. eferred to in the ports list as being used with the shell type center bearing or obsolete roller type center bearing A ef Port D Ref Part D S Number escription No Number escription 103 AD 44 B VALVE STEM GUIDE inlet and exhaust 8 G 353 A CENTER MAIN BEARING HANGER I ASSEMBLY for shell type bearing wwe 4 104 AE 38 D VALVE exhaust stellite seat includes 116 368 Dowel pins 2 1 105 AE 89 VAL VE inlet XD 176 Screws Ref 470 2 l I 353 replaced by 353 1106 51 VALVE SPRING NOTE hanger assembly 5 fumished LESS the shell bearing Refer to reference number 154 for part number ot the standard 107 AG 26 A SEAT or valve spring inlet size and the undersize shell bearings available VALVE ROTATOR ses s 115A BG 346 51 CENTER MAIN BEARING HANGER 108A AG 35 ROTATOR exhaust not available ASSEMBLY tor obsolete roller 1 io Obsolete Used on V 461D previous to Serial BG 304 S1 For V 460D but 346 51 4602108 For replocement use AG 40 l aged indis oldea i in its piace and AG 4 rotator at assemblies include rocker end n place AG 26 seat 116 P amp 368 Dowel pins 2 117 376 Bearing dowel pin d 109 AH 19 LOCK for valve spring Se
153. em into the guides to a bot tomed position The spring attached to the brush will determine the pressure at which the brush contacts the slip rings 5 To fit new brushes to the slip rings lay a strip of No 00 sandpaper smooth side down on slip ring surface and draw sandpaper in the direction of rotation of the slip ring lifting the brush on the return stroke Con tinue until the brushes have same curvature as the slip rings Blow all carbon dust out of the machine using not over 25 psi 172 kPa air pressure CAUTION When removing the lead wires do so one at a time and replace each brush accordingly to insure that the lead wires are put back onto the proper brushes 13 9 3431 254 14 amp P Exciter Auxiliary Figure 7 055 5 generator fails to build up voltage after attaining full RPM 1800 1825 RPM it may be caused by the exciter having lost its residual magnetism in shipping or moving the unit Verify this loss of magnetism by measuring the A C exciter output voltage at the receptacle If less than 6 volts proceed as follows Shut engine down Replace 4 ampere fuse in the auto matic field flashing circuit See Connection Diagram Restart the engine to remagnetize the generator SLIP RING CLEANING If the slip rings get dirty clean them while they are ro tating by using a wooden stick to apply a piece of heavy canvas to them 14 WARNING Do not
154. en proceed with servicing the magneto SERVICING BREAKER POINTS Remove the end cap cover distributor rotor and the end cap Then inspect the breaker points for ting oxidation and shorting If points are worn or shorted they should be replaced To remove the point set take out the breaker arm terminal screw releasing the breaker arm spring coil lead and condenser lead Remove the fulcrum pin snap ting and slide the breaker arm off the fulcrum pin Remove the contact support locking screws and lift off the contact support The installation of new points is the reverse of the removal After the points have been installed they should be adjusted to the correct clearance of 0 015 inch at high point of cam Be sure the points are clean and bright before adjusting them Insert a screwdriver in the slot of the support bracket and pi vot it between the two small bosses on the bearing support until the desired clearance is obtained Then clean the points again before sealing the magneto FIELD SERVICE NOT RECOMMENDED The cam wick if dry or hard should be replaced with a new factory impregnated wick Other than this the Type FM X4B7D Magneto does not require field lubrication No attempt should be made to oil or grease the magneto bearings The magneto lubricant should be replaced only during the overhaul of the magneto by an authorized service station using recommended lubricant and factory engineered parts Coil and condenser
155. engine carefully and under reduced speeds and loads for a short time as follows First be sure the engine is filled to the proper level with a good quality of engine oil see Grade of Oil chart Before a new engine is put to its regular work the engine should be operated at low idle speed 1000 to 1200 R P M for one half hour without load The R P M should then be increased to engine operating speed still without load for an additional two hours If at all possible operate the engine at light loads for a period totaling about eight hours before maximum load is applied This will greatly increase engine life The various bearing surfaces in a new engine have not been glazed as they 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 be ruined forever Our engine warranty is printed on the inside back cover of this manual Read it carefully For Your Own Record THIS MANUAL IS FOR MY MODED at RIPE ENGINE SPEG SERIAL No THE ABOVE INFORMATION WHICH WILL BE FOUND ON THE INSTRUCTION PLATE ATTACHED TO THE AIR SHROUD OF THE ENGINE SHOULD FILLED YOUR PROMPT ATTENTION TO THIS MATTER WILL MAKE IT CONVENIENT FOR YOU IN THE FUTURE AS THIS INFORMATION MUST BE GIVEN WHEN OR
156. equirements and recommendations apply to rub ber tire mounted equipment as well as other equipment In addition to the usual function of protecting per sonnel against the hazard of electrical shock due to fault in the equipment grounding serves to discharge the static electrical charges which tend to build up on the surface of rubber tire mounted equipment WARNING These static charges can cause painful shock to personnel and can lead to the erroneous conclusion that an electrical fault exists in the equipment If a system ground is not available the unit s frame must be connected to a driven ground rod see Figures 4 hnd 5 or to a water pipe that enters the ground not more than 20 30 105 9 1 13 6 Soil Treating Material copper sulphate magnesium suiphate or rock salt ptaced in circular trench and covered with earth Grounding Conductor _ Approx 305 mm 8 Inches 457 mm Approx Ground Outside Ground Figure 4 Grounding Conductor to the red with an approved ground Not less than 8 Ft 2438 mm 6 Inches 152 Approx TM 9 3431 254 14 amp P 10 feet 3048 from the unit The ground wire must be No 8 size or heavier NOTE The ground wire must be as short as possible in order to produce the most efficient installation TREATING AN OUTSIDE GROUND The soil treating materials are placed in a circular trench around the rod but not in direct co
157. er dirt or gum in gasoline interfering with free flow of fuel to carburetor Anti diesel solenoid valve at carburetor inoperative Check operation of valve A solenoid click should be heard when ignition switch is turned to start position If not Check for disconnected loose or broken wire Remove solenoid from carburetor clean plunger and seat with solvent Check plunger for spring tension Replace solenoid valve if the above does not rectify the problem Poor grade or stale gasoline that will not vaporize sufficiently to form the proper fuel mixture Carburetor flooded due to excessive choking See Starting Procedure Page B 10 Dirt or gum holding float needle valve in carburetor open This condition will be indicated if fuel conti nues to drip from carburetor with engine standing idle Often tapping the float chamber of the carburetor very lightly will remedy this trouble Do not strike carbu retor with any metal tool If due to flooding too much fuel entered the cylinder in attempting to start the engine the mixture will most likely be too rich to burn In that case starting may be accomplished by continued cranking with the car buretor choke open 9 3431 254 146P To test for clogged fuel line loosen fuel line nut at carburetor slightly If line is open fuel should drip out at loosened nut If the starter is dead or is unable to turn the engine over check battery and c
158. erminal Stud outside dos 18 1923540 NUT for hold down plate mountina 222222 2 18 453418 SCREW breaker piate supports ene 1 18 453304 SCREW for condenser mounting 1 18 1914916 SCREW for contact adjustment 1 18453461 SCREW tor spring clip support 2 18 1914142 INSULATING BUSHING for tem incl stud DE ae Ys b eae aee ee 3 18 1904376 LOCKWASHER or terminal stud in side 1 181963555 FELT WICK replaces 15 81 3639 1 9 3431 254 148 FIG B 96 10 51 DISTRIBUTOR YF 10A S1 Obsolete NOTE Code number 28 prefixed to the part number is a vendor identification NOTE YF 10C Si Replaces YF 10A S1 Part Number erer 28 IAD 1100LE1 28 IAD 2004 28 IGS 2224LB 28 1BB 2042SS1 28 IAD 2015 No s AD 6004 2F BREAKER PLATE ASSEMBLY Description SPRING CLIP forcentactcrm SCREW spring clip 86 32 x 5 16 hex hd BREAKERCONTACTSET CON DENSER for Y F 12C S1 Y F LOCKWASHER No 5 2 for con denser mtg 1 spring clip PLAIN WASHER for contact lockscrew 8 PLAIN WASH ER for spring clip screw 6 LOCKSCREW for breaker contact 85 32 thread x 3 16 lon fillister head SC REW fcr condenser mounting 6 32 thread x 5 32 long fillister head 10 51 DUST COVER ASSEMBLY includes FELTWASHER BASE for terminal INSULATOR for terminal stud BRACKET for breaker plate Not illust
159. f the over heating condition will have to be remedied before the engine is restarted See Engine Overheats paragraph in Troubles Causes and Remedies section EN N NN ee HIGH TEMPERATUR 5 SAFETY SWITCH TROUBLES CAUSES AND REMEDIES Three prime requisites are essential to starting and maintaining satisfactory operation of gasoline en gines They are 1 A proper fuel mixture in the cylinder 2 Good compression in the cylinder 3 Good spark properly timed to ignite the mixture If all three of these conditions do not exist the en gine cannot be started There are other factors which contribute to hard starting such as too heavy a load for the engine to turn over at a low starting speed a long exhaust pipe with high back pressure etc These conditions may affect starting but do not necessarily mean the engine is improperly adjusted As a guide to locating any difficulties which might arise the following causes are listed under the three headings Fuel Mixture Compression and Ignition In each case the causes of trouble are given in the order in which they are most apt to occur If a remedy is apparent no remedy is suggested STARTING DIFFICULTIES FUEL MIXTURE No fuel in tank shut off closed or cap vent plugged Fuel pump diaphragm worn out or punctured Carburetor not choked sufficiently especially if en gine is cold See Starting Procedure Page 10 Wat
160. function pagel 18 for detailed troubleshooting instruc tions o Check engine RPM should read 1825 1840 no load b Same as d above 5 Check engine RPM b Replace defective coils a Ground welding generator chassis b Ground work and work table to plant ground o See welding head manual Increase shielding by trial and error See welding head manual Increase wire feed See wire bum off rate charts e trial error welding head manual Check for overheated connections and tighten ha Check contact tube hole size and replace with proper tube a Clean contacts Refer to Control Box Malfunction page 18 for detailed troubleshooting instruc tions e Use larger leads b Check line voltage 17 TM 9 3431 254 14 amp P CONTROL BOX MALFUNCTION TROUBLESHOOT ING INSTRUCTIONS The control box used on the GCC 300 W is composed of several printed circuit boards However troubleshooting is no more difficult than troubleshooting conventional control circuits Do not overlook the obvious As in the case of all electrical equipment loose connections are the primary cause of malfunction both internal and external to the welding machine In general the things to look for are bad grounding connections worn con tact tubes tips dirty cable liners shorted control cables wrong control settings blown fuses wo
161. h a wire electrode feeder the con trol and power connections to the wire feeder are made to this raceptacle CAUTION Before a wire feeder is connected to this unit be sure that electrical wiring and functions of such a unit am compatible otherwise dam age to the generator circuit as well as the wire feeder may occur SLAVE RECEPTACLE 14 Source of 24 volt power for user s requirements Use in conjunction with the Toggle Switch below TOGGLE SWITCH 15 This switch selects the power output mode when the selection of 24 volt out put power from the Slave Receptacle or welding current from the terminals is to be made Place the switch in SLAVE RECEPTACLE position for supply of 24 volt power Place the switch in CV WELDING position when desiring to use the machine for welding CIRCUIT BREAKERS 18 19 20 Four circuit breakers located on the front panel protect the auxiliary exciter circuit from overloads Two breakers are rated at 15 amperes and protect the standard duplex outlet Another breaker is rated at 20 amperes and protects the Twistlock outlet while the fourth breaker Main Breaker is rated at 40 amperes and protects the entire auxiliary power supply circuitry from cumulative overloading BATTERY CHARGING AMMETER 21 This meter indicates the charge or discharge current through the battery for all engine electrical requirements except the starter Under normal operating conditions the ammeter should indicate 5
162. he camshaft plug Operate the engine at 1800 R P M when making this check The pressure reducing valve mounted on the crank case in front of No 2 cylinder beneath the air duct of No 2 4 bank is pre set by the manufacturer not ad justable If valve becomes faulty it should be re placed with a completely new unit EXHAUST ROCKER ARM War TUE Line 3 to 4 p s i 5 INLET ROCKER ARM A S Rose OIL FILLER AND BREATHER GAUGE SABER Dip Stick 1 8 INCH PIPE PLUG Eor Checking Low DRAIN HOLES For Push Rod Tubes CENTER MAIN BEARING CYLINDER WALLS AND MAIN BEARINGS ARE LUBRICATED BY OIL MIST AND SPRAY THROWN OFF THE CONNECT ING RODS AND CRANKSHAFT OIL FILTER HIGH OIL PRESSURE LOW OIL PRESSURE STILL OIL or OIL FILM 274443 1 CENTER MAIN 4650 Beginning with serial 4904657 shell type ter main bearing replaces the roller bearing lub rication to the connecting rod bearings is modified as follows Oil pressure to the rods is channeled thru the crankshaft by means of an oil line correction to the center main bearing instead of thru a collet on the crankshaft gear See AIR CLEANER The oil bath air cleaner illustrated in Fig 8 must be serviced frequently depending on the dust condi tions in which the engine is operated Service daily or twi
163. he voltage between the contactor coil and ground This value should be 115 volts DC If you have no voltage but have 115 volts AC at the receptacles the contactor control board is probably faulty Replace the control box assembly b If there is 115 volts DC between the contactor coil and ground the contactor coil is probably faulty Replace contactor 4 NO AC VOLTAGE a Check fuse in field flashing circuit on control panel If fuse is blown replace with 4 ampere fuse b Measure voltage between exciter positive slip ring and ground while starting It should be 12 volts DC if not the voltage regulator board is probably faulty Re place the control box assembly If there is 12 volts DC between the slip ring and ground the exciter is not building up and there is probably nothing wrong with the control box See Loss of Magnetism 5 HIGH AC VOLTAGE a Adjust the voltage regulator by removing the con trol box cover and adjusting the potentiometer in the upper right hand and cornerof the control box If this does not bring the AC voltage down the voltage regulator is probably faulty and the control box assembly should be replaced IMPORTANT 18 IF CONTROL S MALFUNCTIONING AS DETER MINED BY THE TROUBLESHOOTING INSTRUCTIONS IN THIS TECHNICAL MANUAL ORDER A REPLACEMENT FROM THE FACTORY AND RETURN THE DEFECTIVE BOX FREIGHT PRE PAID FOR APPLICABLE EXCHANGE CREDIT 9 3431 254 14 amp P SOLI
164. i nation fan flywheel encased in a sheet metal shroud ing The air is divided and directed by ducts and baffle plates to insure uniform cooling of both banks of cylinders If dirt and chuff are allowed to late in the cylinder shrozding or in the V between cylinder banks the flow of cooling air will be re stricted creating an overheating condition which could result in costly repairs The rotating screen illustrated in Fig B 4 iis recom mended for engines operating in dusty and dirty con ditions The screen deflects foreign materials away from the air intake opening and helps maintain maxi mum cooling efficiency Keep rotating screen clean Even a small section of screen clogged up with dirt will restrict the intake of cooling air enough to bring about an overheating condition With reference to FiguresB1 and B2 follow these few cleaning and maintenance instructions to insure trou ble free and satisfactory engine performance 1 Cylinder head covers can removed by releasing snap Clips and unscrewing wing nut Clean cut all dirt and chaff from interior of shroud and from tween fins of cylinders and heads 2 Remove dirt and chaff from cylinder heat deflectors at manifold ports 3 Keep space between cylinder banks clean Fig 277793 ERHEATING 4 Replace this oil filter cartridge every cther oil change If operating conditions are extremely dusty replace cartridge aag oil change
165. inder head and rocker arm assembly off cylinder The oil drain line will slip out of adapter in crankcase Pull out push rods and rod housings See In reassembly place a new O ring under collar of push rod housing Press collar end of tube into tap pet hole by hand do not drive tubes in place with a hammer Use new ring for push rod housing to cess in cylinder head Spread a light film of grease on cylinder head gasket so it will stick in plats dur ing reassembly Place new O ring on oil drain tube Note When reassembling cylinder heads on a com plete overhaul it will be necessary to square up the inlet and exhaust port flanges with those of the mani fold see Place a parallel steel bar across the ports and tap the heads lightly with a rubber mal let to rotate them until they are square Turn cylinder head nuts to a snug fit and re check alignment Torque cylinder head nuts alternately and in 3 steps First 8 then 15 and finally 20 foot pounds torque m ROCKER ARM PUSH PUSH ROD T 1 ASSEMBLY HOUSING EXHAUST AND INLET PORT FLANGES 277794C Rocker arm assembly can be left bolted to the cylin der head unless head or rocker arms need replacing CYLINDER BARREL Fig 8 42 Fig B 43 Turn crankshaft over until piston in the cylinder barrel that is to be replaced is at the top of its stroke Remove top cylinder stud flanged on Model V 461D or hold down clip as used on Model V 465
166. into the No 1 terminal tower on the distributor cap making contact with the spark plug wire terminal Connect the red terminal clip from a conventional type timing lamp to the metal portion of the screw driver One of the other two timing lamp wires is con nected to the battery and the other to ground CENTERLINE OF No 1 3 CYLINDER BANKS No 1 SPARK PLUG pP NWIRE TOWER x WHITE VANE SCREW DRIVER REO INSULATED TERMINAL CLIP RUNNING SPARK ADVANCE TIMING HOLE Fig B 14 277786C TM 9 3431 254 14 amp P BATTERY STARTING SOLENOID T lt rsaaawanarawapannawasaamasnananaaspunqunamayan Pr r Eel nali 124 id MOTORI atj ROTATION CARBURE TOE Kotta FE3SLATOR h 43 22 21 HI TEMPER ATURE ok a SAFETY SmIT A rus E DISTRIBUTOR ANTI DIESEL 1 5 SOLENOID DRIVE il m PRESTOLITE D hi REGULATOR 28 denGUNO x P 8844 24 4 GENERATOR r Sell Fig 15 DISTRIBUTOR WIRING DIAGRAM Chalk or paint the end of the X marked vane on the flywheel white Then with the engine operating at 2000 R P M or over allow the flash from the neon lamp to illuminate the whitened vane At the time of the flash the leading edge of
167. ires at spark plugs and remove spark plug wire clamps at top of governor housing Take out the 2 capscrews which attach the cylinder shroud to the heat deflector at the take off end of the engine and the 2 screws mounting the shroud to the crankcase The left hand cylizder shroud with voltage regulator and spark plug wires attached can be removed as shown in Feg B 34 Right hand cylinder shroud is re moved in like manner MANIFOLD AND CARBURETOR Fig B 35 Disconnect fuel line at carburetor and control rod at govemor lever Unhook governor spring and remove the 4 nuts and ciamp washers which secure the mani fold to the cylinder heads The two manifold branch es carburetor and speed control bracket assembly can be lifted off as a complete unit See 8 35 MANIFOLD ASSEMBLY CARBURETOR ANTI DIESEL SOLENOID ALIGNMENT ALIGNMENT NOTCH 4 INSERTS AND GASKETS IN 7 CYL HEAD INLET PORTS 7 INSERTS AND GASKET IN Fig B 35 277792C Note that the exnaust manifold gaskets and inserts will remain in the cylinder head ports whereas the inlet gaskets wiil stay in the manifoid ports New gaskets should be mounted accordingly in reassembly To prevent restriction in ports because of misalign ment Letween the manifold and cylinder heads there is a cast notch on top of the No 2 and the No 3 in let posts of the manifold These notches are to match up with a similar notch the inlet port of the cylin der h
168. l thrust bearing to the ernor lever which in turn is connected to the carbu retor throttle lever A spring connected to the gover nor lever tends to hold the governor flyweights to their inner position also to hold the carburetor throttle open As the engine speed inc eases centri fugal force in the flyweights acts against the spring and closes the throttle to a point where the engine speed will be maintained practically constant under varying load conditions This speed can be varied to B 18 GASKET SURFACE FOR PAINT ACCUMULATION Fig B 21 suit conditions by adjusting the governor spring tension GOVERNOR ADJUSTMENT 22 Fig B25 The governor connection to the must very carefully adjusted for length otherwise the gove will not function properiv and cause the engine to surge badly With the engine at rest the governor spring will keep the flyweights in and the control rod must be of such length as to hold the carburetor throttle wide open at that point With the control red disconnected from the governor lever as illustrated in Fig B 22 push the rod toward the carburetor as far as it will go This will put the carburetor throttle lever in a wide open position The governor lever should then be moved as far as pos sible in the same direction Holding both parts in the above position the rod should be screwed in or out of the swivel block on the car
169. lammable liquids For engine driven equipment used indoors pipe the exhaust gases to a suitable exhaust duct or to the outdoors Never locate engine exhaust near an air conditioner intake VENTILATION Provide ventilation in accordance with American National Standard 249 1 Section 8 Adequate ventilation must be provided for operator safety when welding lead zinc beryllium copper cadmium and other materials that may produce toxic fumes DO NOT weld in locations close to chlorinat ed hydrocarbon vapors coming from decreasing cleaning or spraying operations The heat or rays from the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Do not weld on containers which have held toxic materials without exercising all proper precautions ELECTRIC MOTOR DRIVEN OR TRANSFORM TYPE WELDERS Be sure that the disconnect switch or circuit breaker is in the OFF position be fore doing any installation or maintenance work inside the welding equipment or on the service lines to the equipment ENGINE DRIVEN WELDERS Secure engine gen erator canopy doors in the UP position by tying them to each other or to the lifting eye to prevent them from falling accidentally Always shut unit down be fore removing the fuel tank cap and filling the tank Do not completely fill the tank because heat from the engine and or generator may expand the fuel enough to cause it to overflow and possibl
170. lange on spacer plate for acces sory drive housing and tighten capscrews to 18 foot pounds torque Mount engine supports with machined flats toward flange side of spacer plate where accessory drive housing is mounted Use Perma tex on capscrews for both engine supports and oil pan Tighten capscrews for engine supports to 40 foot pounds torque OIL PUMR Fig B 38 Fig Remove locknut and driver gear from shaft If gear is too tight to remove by hand use a pulley hammering on end of shaft to loosen gear will damage pump Take out slotted pipe plug from bottom of crankcase and with a 5 32 inch Allen wrench remove lockscrew as shown Fig B 38 Withdraw the pump from in side the crankcase as illustrated in Fig B 39 If pump fits too tight to remove by hand tap front of pump housing not shaft with hammer and brass rod In reassembly be sure lockscrew seat in pump hous ing lines up with lockscrew hole in crankcase B 27 9 3431 254 14 amp P SPECIAL individual cylinder heads barrels pistons and rings con be removed for replacement without a major gine disassembly by means of a special piston sleeve Refer to Fig s B 4 B 42 B 43 and Cylinder Head Cylinder Barrel paragraphs CYLINDER HEAD Fig Remove rocker arm cover means of screw driver wedged under the bail wire Take off the 4 nuts and washers from cylinder barrel studs Lift cyl
171. lding s amp 4 v s Q a Row Vo E WE Drawing Auxiliary Power w c9 xo woe o Ro we W PURGE Voltage Regulations s w s oe xo a e o 9 X 3 ok R W ls S Stopping the BAGINE sso woe HE hon Que ed DEOLAQE dea fi aw os W 4 MAINTENANCE is ura s WOH Ww ww XO X He GS qot dod d Snare dot we CLEANING a ean ha Whee S a 0 p is AE Exciter Auxiliary Brushes 292525 sean o k Ron TOSS OE A SOROR ee ee E 6 died Slip Ring Cleaning ware s a SU as qeu ay ae Range Switch Maintenance 4 6 6 6 6 6 koX Xe ew WOW Wu WU ww noo aria l Al TM 9 3431 254 14 amp P TABLE OF CONTENTS CONTD TROUBLESHOOTING feta le seco d Control Box Malfunction Troubleshooting Instructions Exchange Service Policy
172. le 1 hove noe rt end of and push through the other side Press axle 35 into slotted side until the axle is centered in bracket 4 FLOAT SETTING a Fuel Level Check position of float assembly 36 for correct measurement to obtain proper fuel level by using a depth gage E Do not bend twist or apply pressure on the float body b With bowl cover asambl 26 1n an inverted position viewed from free end of float 36 float body must be centered and at right angles to the machin d sur face The float setting 15 measured from the machined surface no gasket of float bowl cover to top side 0 oat body at highest point This measurement should be 31 32 plus or minus 1 32 c Bending Float Lever To Increase or decrease dis tance between float body 36 and machined surface 26 use lope nosed pliers and bend lever close to float body Replace with new float 1f position is off more than 1 16 Install throttle body fuel bowl assembly gasket 37 on raachined of duetile body En Install idle adjusting needle 17 and spring 18 Screw needle IN clockwise until it seats lightly against the idle discharge hole then back it out 1 turns as pre liminary idl adjustment REASSEMBLE FUEL BOWL 1 Install the main det 4 D and fibre washer 40 using Zenith Tool No C161 8 maip jet wrench 2 Install the main jet hex ug 43 and fibre washer using 9 16 end wrench
173. load speed and this must be taken into consi deration when readjusting the governor As an ex ample if the engine is to be operated at 2000 revolu tions per minute under load the spring should be hooked into the 6th hole in the governor lever and the spring tension adjusted by means of the adjusting screw to run 2200 R P M under no load The speed at full load will then be approximately 2000 revolu tions per minute Bp tachometer revolution counter should used against the crankshaft to check speed while adjust ing the governor spring tension Tightening the ad justing screw locknut will give higher speeds while loosening the locknut will lower the spring tension and reduce the R P M CLUTCH AND REDUCTION UNITS CLUTCH POWER TAKE OFF Fig 2 The clutch available on this engine is of the dry disc type No oil should be put into the clutch housing but grease gun fittings are provided for periodic bear ing lubrication The housing bearing should be greased every fifty hours of operation and the clutch throwout 9 3431 254 14 amp P T 9 INSPECTION PLATE mE TOT THROWOUT BEARING GREASE FITTING HOUSING BEARING GREASE FITTING Fig B 24 226229 bearing greased every day before starting Use general lube grease MIL L 10924 Rockford PTA 4856 units have a sealed pilot bearing and require no external lubrication Obsolete PTA 4819 units hav
174. low with a soft hammer to loosen nut Do not use an open end monkey or pipe wrench The flywheel is mounted to a taper on the crankshaft Take a firm hold on the flywheel fins pull outward and at the same time strike the end of the crankshaft several times with babbitt hammer see Fig B 30 The flywheel will slide off the taper of the crank shaft Do not use a hard hammer as it may ruin the crankshaft and bearings Remove Woodruff key from crankshaft In reassembly be sure the Woodruff key is in position on the shaft and that the keyway in the flywheel is Fig B 29 27T181C Fig B 30 277788 lined up accurately with the key After mounting seat flywheel on crankshaft taper by slipping a piece of pipe over the end of the crankshaft and against the hub of the flywheel and striking the end of the pipe a sharp blow with a hammer FLYWHEEL SHROUD Fig B 3 Remove cylinder head covers by dis engaging 3 clips and taking out the thumb screw Disconnect No 2 and No 4 spark plug wires hi temperature switch wire Slip wires thru grommet in shroud HEAT DEFLECTOR CAP SCREW HOL ES STARTER BENDIX COVER FLY WHEEL SHROUD COVER CLIPS CYLINDER SHROUD CAPSCREW HOLES Fig B 31 277799 TM 9 3431 254 14 amp P EE LA i Z SLOTTED HOL ES ADJUSTING STRAP IN GENERATOR BRACKET FOR BELT ALIGNMENT Fig B 32 277791 out the
175. m engine Dirt between cooling fins on cylinder or head Engine operated in confined space where cooling air is continually recirculated consequently becoming too hot Carbon in engine Dirty or incorrect grade of crankcase oil Restricted exhaust Engine operated while detonating due to low octane gasoline or heavy load at low speed ENGINE KNOCKS Poor of low octane rating See Fuel Page Engine operating under heavy load at low speed Carbon or lead deposits in cylinder head anced too far See Neon Lamp Timing age B Loose or burnt out connecting rod bearing Engine overheated due to causes under previous heading Worn or loose piston pin Ty 39 ENGINE BACKFIRES THROUGH CARBURETOR Waterr or dirt in gasoline Engine cold Poor grade of gasoline Sticky inlet valves Overheated valves Spark plugs too hot See Spark Plugs Hot carbon particles in engine LOW or NO OIL PRESSURE Oil pressure gauge defective Oil line to gauge clogged up Crankcase oil supply low Faulty oil pump Gears worn or broken Cover worn Loose cover or body Gasket damaged Faulty relief valve Clogged or leaky oil line connections Strainer screen clogged up Oil too thin due to dilution or too light of grade used Worn rod bearings HIGH OIL PRESSURE Oil pressure gauge defective Oil too heavy Faulty relief valve Clogged pressure line INSTRUCTION
176. n 169 530 030 undersize bearing assembly 12 1 3 184 replaced by MH 184 A 211 194 51 FLYWHEEL ASSEMBLY standard i 51 Includes 212 GH 43 Ring i 2 10 NOTE Because f the variations flywheels for mounting rotation screens stub shafts etc only th e stam dard nna flywh eel s list ed Therefore Model Specification and Serial Numbers of engine when ordering new eel 214 291 DOWEL PIN for gear cover 2 LO 315 334 PIN fo ticcank I 1 216 P8 146 2CONNECTINGRODBOLT 2 J 218 171 i STUD 5 164 x 1 5 184 long 2 i carburetor mountina 719 529 STUD for cylinder md head mounting pilot long fo router boss of tio 1 2 33 2 2 3 220 529 ISTUD tor cylinder head and Temp 1 switch moun ting 89 i 1 16 long for outerbossotNo 4cylinder eee i i 221 PC 530 STUD tor cylinder md head mounting 110 long or middle head bosses 3 4 1 223 PC 532 I STUD in cylinder head for maitold mounting 7 169 x 2 3 8 long 4 2 1 225 PD 193 2 NUT forflywheelmounting a 1 10 226 PD 247 gt LOCKNUT 5 8 24 thread ne 8 En For connecting bolt i PD 200 replaced by FD 247 227 PD 228FASTENER I
177. nd the twist lock receptacle on the front panel HOUR METER 2 Registers the operational time of the unit Records cumulative number of hours that the engine has been in operation Use the hour meter to schedule periodic maintenance and inspections OIL PRESSURE GAUGE 3 The gauge indicates the oil pressure of the engine The scale of the gauge is 0 to 75 psi 0 to 517 kPa At 1800 RPM the oil pres sure should read 45 to 50 psi 310 to 345 kPa when the engine is at operating temperature RANGE SWITCH 4 This is the coarse current control with five detent positions and is used in the constant current mode only Clockwise rotation in creases current counterclockwise rotation decreases current CONTROLS INSTRUMENTS AND OUTLETS tinued WELDING VOLTMETER 5 This is a single scale meter calibrated 0 to 100 volts Prior to striking the welding arc the voltmeter will register open circuit voltage and arc voltage when the welding arc is being sustained WELDING AMMETER 6 This is a single scale meter calibrated 0 to 800 amperes and will indicate welding current FINE CURRENT CONTROL 7 This control operates in both constant current and constant voltage to permit vernier adjustment of welding current Clock wise rotation increases welding current and counter clockwise rotation decreases current CHOKE CONTROL 8 Pull choke control knob out when starting a cold engine and push it in
178. ng idler shaft in place See Fig B 55 Remove screws with a 5 32 Allen wrench Dis assemble shaft and gear from case by means of the 3 8 16 tapped puller hole in end of idler shaft Center main bearing hanger Applicable to obsolete split roller bearing only CRANK SHAFT COUNT ERWEIGHT 2 SETSCREWS CLEARANCE SLOT FOR IDLER SHAFT Fig B 55 277806C In reassembly be sure oil groove in shaft is facing up Drive shaft into crankcase with soft metal ham mer and maintain a 003 to 004 inch clearance be tween idler gear and shoulder of shaft see Lock shaft in place with the 2 Allen set screws OIL PRESSURE RELIEF VALVE Fig 7 Fig 5 If it becomes necessary to remove the oil pressure relief valve illustrated n Fig 85 either for cleaning or replacement first unscrew hex adapter and remove expansion plug from adapter With a 3 16 inch Allen wrench remove outer adjustment lockscrew see Insert 4 inch rod into the cross hole in valve body and turn counter clockwise for removal Do not use a pipe wrench or pliers to remove valve body reassembly use new O ring in valve body and apply sealer to threads of hex adapter Assemble ex TUBING NUT MOUNTING SCREW PRESSURE REDUCING VALVE Gear oil collet for engines with obsolete split roller bearing OIL PRESSURE RELIEF VALVE HEX soar Ten Ade IN SHE Fig 56 277780 plug
179. ng lock l for adjusting strap bracket i 1 5 240 CYLINDER SHROUD L H side 1 14 4 2 for adjusting strap 2 YL 376 27 IGNITION WIRE ASSEMBLY 1 i2 7 LOCKWASHER 1 2 spring lock 1 Dd Ammeter to solenoid 410 with Altemator mounting EE i teminals 27 long Not illustrated 46 LOCKWASHER 5 16 external tooth 2 i ALTERNATOR MOUNTING PARTS Per Altemgtor bracket wnsuppstta 52 4 PE75 LOCKWASHER 3 16 LD intemal BI 379 al at 32 Pippo z extemal tooth galvanized 1 1 4 MH184A BELT altemator drive csse 3 a wina 2 5 PG1182 STRAP altemator adjusting 1 a 77 WASHER 5 16 1 0 5 8 steel 2 1 6 PG1183 BRACKET adjusting strap 1 Eoft Altemator brack etts Supports i 7 Y869 ALTERNATOR RAE ME Includes adjusting strap ermator 8 405 Driven pulley 8 9 53 Regulator n 1 6 24 14 SCREW 5 16 18 thread x 5 8 long 10 YL 392 Wire assembly 1 1 hexagon head S A E grade 5 2 1 regulator to For Altemator bracket to supports Refer t i
180. ng should be parallel to flats at base of cylinder barrel for correct assembly to crankshaft see Fig Gently tap piston into cylinder and to bottom of bore Use the wooden handle end of hammer as shown in Fig B 49 VALVES Fig B 5 Replace valves that are burned or pitted A leaky valve can usually be determined by a hissing noise in the exhaust or intake manifold when cranking the engine slowly by hand The exhaust valves are furnished with positive type rotators Refer to Parts Section for mounting The valve rotates slightly each time it opens and thereby prevents the build up of foreign deposits on the valve face and stem Valve grinding should be done by an authorized ser vice dealer since he has the necessary equipment and experience to do a good job To remove valves use a standard automotive valve lifter as illustrated in Fig B 50 and remove spring seat locks Release valve lifter and take out valve spring and exhaust rotator or spring seat The valve face is ground at 45 to the vertical center line of the valve stem and the valve seat insert should also be ground at a 45 angle After grinding valves and inserts should be lapped with a suitable lapping compound or they will leak due to improper seating within the first few hours of operation While lapping occasionally lift the valves and reset them 1054 4 in different position to insure uniform seat which will show entirely around th
181. ns completely Replace coil s increase engine speed to 1800 1840 RPM no load Check brushes and clean slip rings Replace or repair Adjust to detent position Repair or replace Check and repair Check and replace defective diode Replace fuse See LOSS OF MAG NETISM a Check connections and replace meter if necessary b Check connections or replace meter c Replace fuse See LOSS OF MAG NETISM 9 3431 254 14 amp P TROUBLE POSSIBLE CAUSE REMEDY No voltmeter reading no ammeter reading continued d Faulty regulator board Voltage too high Engine overspeeding b Faulty regulator board Voltage too low Engine running underspeed One or more revolving field coils shorted Operator gets shock when welding generator is touched Operator gets shock when ground cable work or work table is touched Welding generator not grounded Work table and work not grounded Abnormal current fluctuation voltage nearly constant Irregular wire feed speed Inadequate shielding of arc by flux or gas Wire feed rate too slow Too much shielding gas Loose cable connections Welding contact tube tip on wire feeder makes poor contact with electrode Contactor fails to open a Contactor contacts sticking Line contactor fails to close a Faulty Control Board Contactor chatters a Line leads too small b Low line voltage d Refer to Control Box Mal
182. ntact The crystals are gradually dissolved by surface waters and the solution is carried into the most useful area of earth surrounding the electrode rod Flood the trench several times when making original installation See Figure 4 TREATING AN INSIDE GROUND Reduce the diameter of the hole to 6 inches 152 mm pour soil treating material in around the rod Add enough water to dissolve 8 pounds 3 62 kg of soil treating material Flood the hole every 6 months and replace the soil treat ing material when it is all dissolved Figure 5 Fasten Grounding Cond c of Grounding to the rod with an approved Conductor ground clamp Removabia Cover Floor N x qi gt aa Not fess than 8 Ft 2438 mm Rod Soil Treating Materia Inside Ground Figure 5 9 3431 254 148 UNIT DIMENSIONS The unit dimentions are shown Figure 6l The unit frame is drilled and tapped for 3 8 16 UNC bolts for mounting The unit should be firmly attached to support base to prevent movement during operation WELDING LEADS shows welding lead sizes recommended for various lengths of leads The footage shown includes complete welding circuit both electrode and work 61 3 4 1568 5 mm Engine Le M SIDE ViEW Gross Weight 1620 Pounds 735 Kg 42 3 4 067 mm x leads TRANSPORTING MACHINE WITH A FORKLIFT TRUCK To
183. o 10 x 1 2 BEARING iront 1 29 DIODE ASSEMBL Y 1solation RETAINER front bearing 15 2 INSUL ATOR SLEEVE nylon 3 32 long WOODRUFFKEY No 5 20 34 NUT hex No 10 24 thread ROTO Rises ASSEMBLY 20 1 BOLT machine No 10 32 x 2 7 8 long BEARING 202 sealed 53 REGULATOR Model 8AF 20 STATORASSEMBL Wisconsin Port No DIODE ASSEMBLY rectifying negative 3 6 COVER brush holder black printing DIO DE ASSEMBLY rectifying positive SHIELD dust I DUC a NUT temminal 1 4 20thread hex INSUL ATING WASHER No 10x 3 4 O D WASHER teminal 1 4 split lock 9 3431 254 14 amp P Y 128 Serie Magneto Service Instructions 128 51 For Engine Models V 461D and V 465D GENERAL DESCRIPTION Type FM X4B7D Magneto is de signed and engineered to provide quick easy starting and maximum dependability of operation with minimum service The compact alnico magnetic rotor assures an intensely hot spark under most operating conditions SERVICE PROCEDURE The first step in magneto field servicing is to exa mine the magneto for corroded high tension towers broken wires or high tension wires not pushed far enough into the magneto tower to make good contact Then test the ignition spark while the engine is being cranked Hold the ignition wire 1 4 in away from the engine block If a strong spark is observed the magneto is not the cause of the engine malfunc tion If no spark is se
184. o Remv distr clamp 432 4 LOCK WASHER 5 16 springlock 68 1 4 for air cleaner strap to shroud 444 PH 513 WASHER 13 22 I D x 13 16 O D x 16 for o l pan 1 89 thick steel hardened 15 4 for air shroud to gear cover For cylinder head mounting 18 for gear cover and spacer to case 2efor tuel pump mounting 446 794 PIPENIPPLE 1 8 x3 4 lonq 1 2 fot carburetor mounting For fuel strainer mounting 6 for bearing ret plate end Continued Number 448 SA 58 449 XA 33 450 XA 34 451 XA 67 452 74 455 XD 7 455A XD 4 456 XD 8 XD 9 1457 XD 13 458 XD 172 459 XD 14 460 XD 15 461 XD 16 462 XD 14 Description PLUG 3 expansion For Oll pressure relief valve PLUG 1 3 8 For camshaft end hole SCREW 1 44 20 thread x 3 8 long indented hexagon 8 for flywheel screen 3 for heat deflectors to case 4 for cylinder shroud to heat deflectors 4 for heat deflectors to shroud 4 for cylinder shroud to air shroud 4 for control panel l for heat brxt L H side SCREW 1 47 20 thread x 1 2 long Indented hexagon 2 for R H cylinder shroud to case 1 all tube clamp V 465D SCREW No 4 x 1 4 self tapping
185. o oe bs 46 424 Ab Ce URS Ram e e rd de do ded INSTALLATION hme WA 39 X ER a RO hoe W Wu a RO W N h aca K Safety RUE voy y X A Nose e AU CN P a Kok Y E Ue es N Installatie e oy ce UR ood Portable Insta caesus XD wwe Oe MEME UR d e 3k n Sa g nitial Preparation fOr USB iaca a SOR GO Wedge he qo XU qos iSo 55 s ae decir ah a 6 w NDE DAMEN S018 ate nde Sy 6205 956 Re Re ed ew Transporting Machine with a Forklift Truck OPERATION sore dite ds ok dr NS do Vo a ee Q ae Qe Prestarting InStructlon8 s soea a a a a a Starting the Engine ssa ia w sow REREAD XO A X GLA WeldMg was ed e A a exo OR A d RO cae gets Shielded Metal Arc Welding s s s lt w aos a w W Q e Q a al W s Micro Wire Welding wow ask ow om C aa W 4 Multi Wire We
186. omponents helps retain this mois ture and also increases wear on moving parts Adequate air circulation is needed at all times in order to assure proper operation Provide a minimum of 12 inches 305 mm of free air space at both front and rear of the unit Make sure that the ventilator openings are not obstructed SAFETY Refer to additional installation instructions under SAFETY WARNINGS in this manual INDOOR INSTALLATION If unit is to be operated inside a building make certain there is adequate ventilation to carry off escaping ex haust fumes and to provide an ample supply of oxygen 5 9 3431 254 148 INDOOR INSTALLATION Continued Place unit so that exhaust fumes are carried out of the building using the shortest exhaust pipe extensions pos sible and one with the fewest possible number of bends Exhaust back pressure can seriously affect engine efficiency Minimum inside diameter of exhaust exten sion should be 2 1 8 inches 54 mm All exhaust connections must be gastight Provide at least 2 feet 610 mm of space on all sides of unit for ventilation and servicing PORTABLE INSTALLATION All exhaust connections must be gastight Provide at least 2 feet 610 mm of space on all sides of unit for ventilation and servicing The engine of the welding machine must be placed at the tongue end of the portable mounting for proper balance If leads etc are to be stored on the unit they must be forward of th
187. or and regulator in a negative ground circuit or vice versa Polarity does not affect starting motor coil and distributor MAGNETO TIMING For engines furnished with magneto ignition in place of distributor ignition timing is accomplished in the following manner Expose timing marks on flywheel and shroud Refer to Timing Marks paragraphs on 2 Position No 1 piston on compression stroke as per Timing Instructions paragraphs on Page 14 3 With No 1 piston on compression stroke turn en gine over past top dead center until the leading edge of the X marked vane on the flywheel is in line with the vertical centerline mark on the shroud as shown in Leave flywheel in this position flywheel keyway will be on top 4 Remove inspection hole plug located in gear cover at magneto mounting flange 5 Assuming the magneto is removed from the engine set magneto for spark discharge to the No 1 ter minal This is accomplished by use of a short stiff length of wire placed into the No 1 terminal socket and bent to within 1 8 inch of the magneto frame Then turn the magneto gear in a clockwise rotation tripping the impulse coupling until a spark is observed between the wire and frame Re tain gear in this position 6 Place gasket on flange and mount magneto to en gine meshing the gears so that when magneto is assembled the gear tooth marked with an X will be visible through the lower half of the ins
188. orspacerplate 2 1 1 228 85 LOCKWASHER Iorflywheelnut i 1 229 PF 52 BUTTON for camshaft thrust plunger 1 1 230 PF 101 THRUST PLUNGER for can shait 1 1 232 PG 314 CLAMP for gnition wlres csse n 2 1 1042 replaced by 314 234 556 CLAMP 2 7 64 1 0 for YF 41A coil 4 4 6 556 2 11 64 1 D for YF 3BA 4 zp C C O lef Part No Number 235 PG 792 8 236 1205 236 PG 543A 1 237 PG 959 238 PG 1039 239 1050 241 2 198 PH 442 243 484 245 496 2454 PH 496 8 246 501 248 143 8 249 P1 148 250 PJ 105 3 251 37 252 138 253 PL 145 254 PL 156 256 108 257 9 32 Q 34 A 259 48 83 Desctiption ADJUSTING STRAP for generator CLAMP for Y F 34 Delco Remy distribu tor on eng nes beginning with Serial No 4420865 CLAMP for Y 10 Prestolite distribu tor and obsolete 25 Delco Remy distributor P920 replaced by FG 543 4 1 BRACKET for generator adjusting strap SPEED NUT for cylinder head cover nnne nte nada nn BRACKET or heat defl L H side RUB8ERGROMMET 2 in shroud for ignition wires i fot grouping ignition wires atdistr WASHER rubber faced not illustrated For cylinder head cover thumb screw CLAMP WASHER for rmiioid mounting OIL
189. ortens engine life considerably Crank engine no longer than 15 sec onds at a time and wait a short period of time between cranking attempts to allow starting motor to cool 4 Check engine for low oil pressure leaks or mal functioning parts If oil pressure is not sufficient at least 8 psi 55 kPa after 10 seconds stop the engine to determine cause Minimum oil pressure is 8 psi 55 kPa in idling mode Observe precautions listed under START ING AND STOPPING THE ENGINE in the Engine Starting and Operating Instructions WELDING After all Prestarting Instructions have been carried out the controls for using the generator may be set and welding accomplished Follow the procedures below for various types of welding available with this machine SHIELDED METAL ARC WELDING 1 Attach a welding lead to the work and to the Positive CC terminal Attach a welding lead to the Negative CC CV terminal See Table correct lead sizes These connections are for stick welding DCSP Transpose these connections for DCRP 2 Start engine and bring to rated RPM 3 Set the Range Switch to the desired amperage range Be certain that switch is in detent position so that arrow on switch coincides with arrow on panel 4 Insert correct electrode in electrode holder 5 Set Fine Current Control at minimum setting 6 Set Mode Switch to CC TM 9 3431 254 14 amp P SHIELDED METAL ARC WELDING Continued 7 Set Toggle Switch to
190. pection B 16 No 1 erminal Indicated Vertical Ceriterline Mark End Cap Other Terminals Follow Firing Order in a Clockwise Rototion EXON 3 79 8 e E Running Spark Advonce for Timing Light Check t Magneto IS Flywheel Keyway BI nes Gear Tooth Visible in am Lower Half of Inscection Hole dj i y with Flywheei Positioned as shown Leading Edge of X Merka d Flywheel Vane Fig 16 hole in gear cover See Magneto Timing Diagram Fig B 16 Securely tighten nut and capscrew for mounting magneto The No 1 terminal is identified on the magneto cap The terrninals follow the proper firing order of 1 3 4 2 in a clockwise direction viewing the cap end The leads from the magneto should be connected to spark plugs of corresponding numbers see Firing Order paragraph Page B 13 and Wiring Diagram When magneto is properly timed the impulse coupling wil snap when the DC X marked vane of the fly wheel lines up with the mark on flywheel which in dicates the centerline of the No 1 and 3 cylinders This can be checked by turning crankshaft over slow ly by hand The impulse will also snap every 180 of flywheel rotation thereafter The running spark advance is 23 To check timing with a neon light the advance is indicated by a hole on the flywheel shroud 23 before centerline of the
191. places with compressed air not over 25 psi 172 kPa WARNING Make sure that no loose bars tools parts etc are in or on any part of the engine as they could cause serious damage to the engine genera tor or personalinjury to anyone standing nearby 4 If the unit is operated indoors make sure that an ex haust line is properly connected to the engine exhaust systern and discharges out of doors Avoid short bends or reduction in line size in exhaust pipes and locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back pressure on the engine Back pressure can cause engine damage and loss of power 5 Attach welding leads as described under INITIAL PREPARATION FOR USE Observe Table deter mine that welding leads are proper size for amperage being used for welding NOTE Read NEW ENGINE BREAK IN information in EN GINE STARTING AND OPERATING INSTRUCTIONS STARTING THE ENGINE 1 Carefully read and follow Safety Warnings in front of this manual and instructions in preceding section en titled INITIAL PREPARATION FOR USE 2 Open fuel shutoff valve at fuel tank 3 Pull choke knob out if engine is cold Turn igni tion switch fully to the right until engine starts then let switch return to center position Adjust choke setting to keep engine running smoothly and push choke in all the way as soon as possible CAUTION Unnecessary use of choke sh
192. ppage of the engine This strainer has a glass bowl and should be inspected frequently and cleaned if dirt or water are present To remove sediment bowl loosenLnut belbw bowl and swing wire bail to one side see Fig B 9 There will be less danger of breaking the gasket if the bowl is given a twist as it is being removed Clean bowl and screen thoroughly Replace gasket if it has become damaged or hardened Repair kits are available for service replacement refer to parts list in rear of manual CARBURETOR ADJUSTMENT The main metering jet in the carburetor is of the fix ed type that is it requires no adjustment The idle needle should be adjusted for best low speed opera tion while carburetor throttle is closed by hand For illustrations and more information see Carburetor 9 3431 254 14 amp P Fig 9 83419C 1 Manufacturers Instruction Bulletin in the back of this manual IGNITION SYSTEM A battery ignition system is standard equipment on this model of engine The distributor is of the auto matic advance type and it is driven off an engine speed shaft through a pair of two to one ratio gears thus driving the distributor rotor at one half engine speed in a counter clockwise direction when viewed from above The running spark advance of the engine is 23 and the distributor is fully advanced at 2000 R P M Engine must be running at 2000 R P M or over when checking or adjusting spark advance NOTE
193. r adjusting screw FULCRUM PIN for lever support PIN for adjusting screw swivel VARIABLE SPEED LEVER CONTROL 511 512 513 514 PD 77 PE 3 PH 77 A XA 80 XI T X1 7 PN 100 26 TM 9 3431 254 FIG B 85 TT 90 VARIABLE SPEED GOVERNOR CONTROL ASSEMBLY Description STANDARD HARDWARE NUT 1 4 20 thread hexagon steel For fulcrum pin to bracket LOCKWASHER 1 44 Positive For fulcrum pin to bracket PLAIN WASHER 5 671 0 x 5 8 O D x 1 169 thick steel For variable speed lever SCREW 6 32 thread x 4 lg round nd For cotter pin in lever COTTER PIN 1 16 x 1 26 long sesse l ior variable speed lever pin i for adjusting screw spring l for chain at control COTTER PIN 3 32 x 3 44 long For chain at lever 1 0 GALVANIZED SAFETY CHAIN 26 links long For control to lever 14 amp P 268463C ipe 2 9 3431 254 14 amp P FIG 86 328 POWER TAKE OFF ASSEMBLY 4496356 NOTE Code number 63 prefixed to the part number is a vendor identificoti on When orderi 9 parts please use number with code as shown ef CO 00 4 OW k C Part Number Description a 63 PT A 4M141 USING ASSEM less sluten E TA 4858 i
194. r columns beiow 3 Use only those diagrams and instructions that are applicable MODEL CONNECTION SCHEMATIC ENGINE OUTLINE NO DIAGRAM DIAGRAM DIAGRAM DIMENSION LGN e CAPACITOR SUPPRESSION 23 8 55 hab CIRCUIT BALAREA tu Csacutd oaganga 114 e CIRCUIT 154 CIRCUIT BAEARER at PON 3 91084 BALOGA ACCTIF LEA orf fetRA1OR FIELO SYSTEM A 116 VAC MECEPTACLE ACCEPTACAE wine 4 290 VAC AECEPIACLE Twist LOCK Save RECEPTACLE u CONTROL ALACTON t REVOLVING FIELS 95 20 Excitea Staton Cat GENERATOR BEVOL Vind FIELES 18 12 STATOR 45 58 orm nt Ares ta 000 000v 4 FREQUENCY FRONT DECK fid METER 4 s e re 5 CONTROL RH SIAT 200 150 as 84515104 0 Or 1004 REAR DECA DISCHARGE 84545144 300 BALLAST RESISTOR 8004 MANGE SWITCH ee Bn suite 1 n Cv OR SLAVE MECEPTACLE SELECTOR Switch gt SLIP nines 4 N 21711114111 2 CONTROL BOX ASSEMBLY 490779 TITTAT SEE ENG DIAGRAM 9 a 4 4 lt IK WELO
195. removing center bearing hanger With reference to disconnect oil pressure line at center bearing hanger and at oil header behind fil ter by using a 1 2 inch hex tubing nut wrench Re move hanger to case screws and washers Then loosen and back out cap to hanger screws about 1 2 inch Tap screw heads eor and alternately with a ham mer to break cap away from hanger body TM 9 3431 254 14 amp P OIL Turn Fitting Slightly Remove 011 Line OIL gt PRESSURE LINE 45 ELBOW 4 CENTER J BEARING CAP HANGER HANGER 5 5 HANGER ip e CASE SCREWS Fig B 53 329160C TS CENTER BEARING HANGER DOWEL PINS AN NA SHELL BEARING LOCATING LUGS Fig B 54 329161C Do not pry cap and body apart Separate and remove hanger and cap with shell bearing from crankcase HANGER CAP Check bearing and crankshaft journal for visible wear see Clearance Ch rt Fig B 48 If clearance ap proaches 005 inch replace shell bearing with suit able undersize In reassembly Clean thoroughly and apply a film of oil to the bearing surfaces Mount center main bearing after crankshaft is assembled to crankcase and end play is set Dowel pins in cap are off center so that when hanger is mounted to cap the locating lug on both bearing halves will be on the same side Sce Fig B 54 As semble hanger so that 45 oil line elbow is facing to ward oil hea
196. rn con tactors and misconnection from wire feeding equipment The only equipment needed to property detect problems in this control box is a simple volt ohm meter If the control box is suspected of being the cause of a prob lem first check the fuse on the top of the control box If itis blown replace witha 10 ampere fuse 1 ENGINE WON T START amp Check to see if the relay on top of the control box is closing f not check with volt ohm meter VOM to make sure that 12 volts DC power is present on pin 10 yellow wire with the ignition switch in the RUN position and in the START position Also check pin 12 brown wire for 12 volts DC with the ignition switch in the START position If these tests show 12 volts DC at these points the malfunction is probably in the control box which should be exchanged No attempt should be made to repair the box 2 ENGINE STARTS BUT WILL NOT CONTINUE TO RUN a Using a VOM check for 12 volts DC current between the positive terminal on the ignition coil and ground during starting and after the ignition switch is released to the RUN position There should be 12 volts DC between the coil and ground for a minimum of 10 seconds after the engine starts f not the control box timer board is probably malfuctioning If there is 12 volts DC at this point check the engine oil pressure and low oil pressure switch for proper operation 3 CONTACTOR WILL NOT CLOSE a Using a VOM measure t
197. ry three months weekly during heavy usage in dust laden air remove the covers from the exciter auxiliary brushes They are located at the control panel end of the generator If the brushes are worn unevenly or are shorter than 7 16 inch 11 mm replace all 3 brushes 9 3431 254 146P NOTE Under normal use the slip rings will turn a dark brown color CAUTION Don t allow any of the brushes to wear far enough that the lead imbedded in the brush can rub on the slip rings INSTALLATION Refer to Figure 7 1 Disconnect leads A from connectors on brushholder caps B 2 Lift brush D from brushholder C for inspection If brushes are worn unevenly or are shorter than 7 16 inch 11 mm replace them 3 Inspect slip rings whenever brushes are removed for servicing brushes or brushholders Note surface condi tion of rings Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes or by oil on the rings Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are revolving slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with compressed air Do not use over 25 psi 172 kPa air pressure to blow dirt out 4 Slip new brushes into brushholder guides and piece caps on top and screw th
198. sembly 1 3 38 Assemblies consist of Includes 59 O Ring 335 GD 100A 3 Gear for TC 40 L 12 541 Oil seal GD 100A For obsolete 405 8 Replaces 130 1 51 141 52 GD 100B For obsolete 405 7 336 PH 313 ABushinqwasher 1 1 337 TC 322D S1Fl ywetghtassembly 2 3 Includes TC 328D Thmst pin 9 3431 254 14 INTERCHANGEABLE PARTS for Models V 465D V 460D V 461D sate Feit Description do det Ref Par Description Na No Number teq b Oz No Number Req Lb 415 YL 352 11 IGNITIONWIREASSEMBL Y 1 l for org plate and obsolete collet Ignition coil to Presto lite distributor coupling adapter NOTE Coil wire 15 an integral part of l for covemor 011 spray elbow 34 See Delco Remy Distributor l for generato adjusting strap bracket Parts List for service number 8 for rocker am bracket mounting 2 for generator mounting screws 416 YL 352 26 IGNITIONWIREASSEMBLY 2 l 2 for generato adjusting strap l for starter solenoid to switch 1 of press red valve l for coil to ignition switch l for ignition coil clamp 417 YL 352 26 IGNITION WIRE for Prestolite 1 1 433 5 LO CKWASHER 3 8 spring lock 9 Regulator to ammeter batt term 6 for main bearing plate end
199. stalled This Exchange Plan applies only to specified solid state control components and circuity which have failed due to electrical fault or normal deterioration resulting from use and age The plan does not cover parts which have been physically damaged through accident or abuse or to which unauthorized repairs have been made or attempted 19 20 Blank APPENDIX TM 9 3431 254 14 amp P Parts List EQUIPMENT IDENTIFICATION An identification plate on the unit s control panel shows its model number serial number and specification number Whenever ordering parts or making inquiries furnish all these numbers NOTE A specification number must have a dash number suffix 1 2 3 etc in order to be a complete number HOW TO USE THIS PARTS LIST The part name listings may be indented to show part relationships as indicated In the following example Units Fig per Application No No Nomenclature Assembly Code 1 123456 Assembly Not Shown 1 234567 A detail of assembly 1 345678 A sub assembly 1 456789 A detail of sub assembly Item 2 1 567891 A sub assembly of Item 2 1 678910 A detail of sub assembly 4 Locate the specification number below that appears on your unit and note the APPLICATION CODE letter adjacent to it If no application code appears below the parts list is applicable to only the one specification number that ap pears below SPECIFICATIO
200. stment ock replaces 72 2917 1 24 63 GR 758 OIL SEAL fcr drive shaft 1 54 63 CL 3468 LO CKWAS HER 1 4 ha 25 63 GR 854 OUTPUT SHAFT For adjustment leek 26 63 GR 105 SEAL RETAINER for outputshatt 55 63 UCL 3 8611 1 RELEASE SLEEVE BEARING ASS EM 27 63 68 232 2 OIL SEAL for output shat 2 1 Consisting 5H 1 56 63 CL 861 1 1 RELEASE SLEEVE 1 28 ME 199 BEARING for sutput shatt was GR 762 57 63 UCL 4 7392 RELEASE BEARING ASSEMBLY 1 29 63 GR 106 KEY fer driven deat 4 s 58 Consisting ot E RAE 1 BEARING HALF notservicedsep 30 ME 201 BEARING for sutput snaft Was GR 357 59 BEARING HALE sot setvieea sep 31 63 200 YOKE SHAFT 1 60 63 1 3335 1 SCREW 5 16 34 2 32 63 351 KEY for NO 15 5oodmif 2 61 63 CL 7356 ELASTIC STOP NUT 2 241rreaa 2 33 63 GR 877 WASHER ot driven Dea sess 62 63 CL 9464 LEVER SPRING SET ZEE 34 63 UP T 811 CLUTCH YOKE ASSEMBLY 1 63 63 CL 8556 1 ett E Ee Pag vs 3 HEUS 64 63 CL 8484 LEVIS P N to body 2 35 CLUTCH YOKE 1 Er Ie ay 36 amp 3 P T 352 SCREW 3 816 hexagon head 2 65 53 CL 7107 RETAINING RING forlevercievis pin 3 37 63 P T 353 LOCKWASHER 3 9 2 66 63 CL 8557 CONNECTINGLINK 6 38 63 UPT 769 SHIFTER LEv
201. t Includes PI 194 Adj screw 44 EX 169 ARockerqomnshaft 3 45 Pl 194 Tappet adjusting screw 2 1 46 PM 185 Shoftspring 1 1 47 XE 73 Lockscrew for rocker arm shaft 44 20 x 5 84 long Allensockethead i 1 61 62 63 65 166 67 168 169 70 171 172 173 174 175 176 177 178 180 181 182 183 184 Port Number 55 IK 56 59 5 111 8 Description RING 16 r p X 7 16 l for qovernor spray fitting 2 for oil coupling to collet with obsolete roller ctr bearing used o RING 37496 evaded ewe Fh cod For push rodcasing at both ends O RING 3 6 1D x1 290 0 l for pressure relief valve l for collet adapter to crankcase seal with obsolete roller ctr bearing 0 RING 1 1 16 LD X 1 5 16 0 0 For distributor mounting OIL PUMP ASSEMBLY complete NOTE Beainning with serial No 5190840 111 01 1 2wide intemal gears replaces 1 11 111 with 3 8 wide gears Pumps are Interchangeable changeable number as unit jump v 1 gears related parts noted oil pump Pump assemblies consist GD 94C Pump Drive Gear external KA 61D 1 S13ody assembiy K i 1 1B cludes C
202. t mounted on a welded steel frame The unit is a single operator system design ed for constant current or constant voltage welding The unit is covered by a sheet metal canopy bolted directly to the frame The canopy has doors enclosing the genera tor section but the engine compartment is open at the sides with a cover over the top The control panel is at the generator end of the unit The revolving fields of the generator are axially mounted on a single heavy duty shaft supported by a ball bearing at the exciter end and by the engine coupling at the drive end GENERATOR The generator is air cooled by a shaft mounted fan which draws air through the exciter end and circulates the air through the interior of the generator Air flow is also directed over the stability reactor and output rectifier The welding generator is a three phase alter nating current wye connected unit The output of the welding generator is rectified to direct current and stabilized by a ballast resistor or a stability reactor depending upon the mode of welding EXCITER The exciter or auxiliary generator whose output pro vides power to a bridge rectifier for excitation of the welding generator service power for the contactor control and voltage regulator and to the auxiliary power receptacles on the generator control panel ENGINE The engine used in this unit is an air cooled Industrial Gasoline engine Model V 465D It isdirectly coupled to the wel
203. the holder Wipe dry all the parts that can be reached and use compressed air if available to dry the parts of the generator that cannot otherwise be reached See MAINTENANCE for brush care d BATTERY TERMINALS Thoroughly clean the battery terminals and connections Coat terminals and connections with petroleum jelly to retard corrosion MAINTENANCE NOTE Check the Starting and Operat ing Instructions for the Model V 465D Air Cooled Engines furnished with this manual for all engine related maintenance A proper preventive maintenance program consisting of a schedule of inspection and cleaning is the basis of good welding machine care and the key to long un troubled operation INSPECTION A periodic inspection of the equipment should be es tablished and maintained The following inspections and time periods are recommended EVERY DAY Check all power cables and hoses for cuts and other damage Repair any damage im mediately to prevent shorts damage spreading etc Check for oil or fuel leaks Check oil pressure at 1800 RPM If oil pressure is less than 15 psi 103 kPa shut off engine and check for defective oil pump filter or clogged oil lines Check battery ammeter Charging rate with fully charged battery should be 2 to 3 amperes at 1800 RPM ONCE A WEEK Check tightness of all electrical connections If arcing has occurred at any connection recondition it and if it s a power cable connection cover ma
204. ting surfaces with a light uniform coat of electrical joint compound before reassembling Elec 12 trical joint compound is available in 5 oz 141 8 g tubes 903170 part no EVERY MONTH Check generator for amperage and voltage output If generator fails to build up voltage after starting the exciter may have lost its residual magnetism Refer to instructions under LOSS OF MAGNETISM CLEANING The unit should be cleaned periodically as required Do not allow a dust buildup to occur on the unit Do not operate the unit if moisture accumulation or condensa tion has occurred Use clean dry compressed air with a pressure not to exceed 25 psi 172 kPa to clean dust and dry moisture from surfaces and terminal blocks WARNING Do not use flammable cleaning materials gasoline naptha etc to clean unit Do not use chem ically treated cleaning rags to clean terminal blocks or electrical com ponents Blow out generator windings with compressed air not over 25 psi 172 kPa pressure or remove with a suc tion type cleaner with a non metallic nozzle If wind ings should become slightly damp use space heaters or electric light bulbs to effectively dry out the windings If dampness is excessive apply external heat under a canvas cover well vented Heating should not exceed 194 F 90 C LUBRICATION WELDING GENERATOR The generator end bear ing is the only point on this generator requiring lubrica tion
205. top of the throttle body or indented in it am number 15 the sssembly number the number wil the letter L pre f part number for t ssembly Exploded view Page B 75 The exploded view identifies the serviceable component parts of the carburetor and shows their relationship to the complete assembly Use the key numbers on the exploded view to identify and locate parts when performing both the disassembly arid assembly operations DISASSEMBLY SEPARATE CARBURETOR BODIES Remove the three bowl assembly screws 45 46 and separate fuel bowl 39 from throttl body 26 DISASSEMBLE FUEL BOWL 1 Remove the main jet plug 43 and fibre washer 42 using a 3i 2 Remove the main et and fibre washer 40 using Zenith Tool No C161 83 main jet wrench 3 Remove the Idle Jet 38 using small screwdriver 4 Remove the bow drain plug 44 DISASSEMBLE THROTTLE BODY 1 Remove the float axle 35 by pressing against the end with the blade of a screwdriver A R movi the float 0 needle 3 Remove 5 Remoye the main discharge jet 33 using a small screwdriver 6 Remove the fuel valve seat QD and fibre washer 30 using Zenith Tool No 6 85 7 Remove the idle adjusting needle 17 and spring 18 CLEANING horoughly clean all metal parts i inse in E solvent Blow ite sages in throttle Bo
206. transport the machine with a forklift truck run a chin through the lifting eye of the machine and wrap it around the tines of the forklift truck Then hook the chain to itself Once this is done you are ready to transport the machine with the forklift truck 27 3 4 704 mm a2 086 VIEW Outline Dimensions Figure 6 Weiding Current Amperes 125 150 175 LENGTH OF LEAD CIRCUIT IN FEET AND METERS TOTAL OF BOTH ELECTRODE AND WORK LEADS SE aS 18M 31M 38M 48M 52M 61M 59M 76M 83M 107M 122M 152M No 4 No 4 4 2 2 No 2 4 0 1 0 1 0 2 0 3 0 3 0 3 0 4 0 4 0 No 1 No 2 1 1 0 20 2 0 3 0 4 0 Suggested Welding Lead Size Guide Table 3 TM 9 3431 254 14 amp P OPERATION PRESTARTING INSTRUCTIONS In all probability the welding unit will be moved from one location to another many times during its lifetime of service Therefore reference to INITIAL PREPARA TION FOR USE is suggested each time the unit is moved prior to using it 1 Check the supply of fuel and crankcase oil See Engine Operating Manual 2 Inspect the unit thoroughly to be sure it is in proper working order Check all fuel line and wire connections to be certain they are secure Tighten any loose screws nuts or bolts 3 Wipe off the entire unit and clean the air passages control box and hard to reach
207. w the capscrews finger tight until the 2 For obsolete center main rollar bearing dowels are just entering holes With a hand wrench alternately turn each screw to turns to evenly draw cap tight to hanger body Torque capscrews to 40 foot pounds alternately in 3 stages 15 30 and 40 ft lbs A few squirts of oil in the hanger cap oil hole will help to dissolve the bearing grease HANGER BODY DOWEL PIN HOLE DOWEL PIN Fig 61 277777 9 3431 254 146P REPAIR PARIS LIST READ THESE INSTRUCTIONS BEFORE ORDERING PARTS The MODEL SPECIFICATION and SERIAL NUMBERS of your engine shown on the name plate prominently located on the engine MUST BE GIVEN WHEN ORDERING PARTS COPY THE ABOVE SPECIFIED INFORMATION INTO THE SPACES PROVIDED BELOW SO THAT IT WILL BE AVAILABLE TO YOU WHEN ORDERING PARTS TO INSURE PROMPT AND ACCURATE SERVICE THE FOLLOWING INFORMATION MUST ALSO BE GIVEN 1 State exactly quantity of each part and part number 2 State definitely whether parts are to be shipped by express freight or parcel post 3 State exact mailing address TM 9 3431 254 146P 281153C 2 FIG B 63 CRANKSHAFT PISTON AND CONNECTING ROD GROUP Parts are identified by reference number See parts list or correct part number B 3 6 TM 9 3431 254 14 amp 281154 2 FIG 64 CYLINDER AND HEAD GROUP Parts are identified by reference number See parts list for correct part number
208. y 1 0 159 4 51 Interchangeable 22 P 8723 Cil Cup Assembly must be used 1 2 90 5 51 service TM 9 3431 254 14 amp P PARTS LIST Models V 465D and V 460D V 461D PART NUMBER MODELS V 460D V 461D DESCRIPTION 531 STUD for cylinder head and rocker am bracket mounting top center 11554169 long 4 95 STUD 11 5 169 with flanged enc V 461D engines beginning with Serial No 3685187 1 Leere e ce e ee cass cose se eae 4 4 PC 531 for V 461D engines previous to Serial No 3685187 96 PG 456 B STRAP for mounting air cleaner Z 1 8 97 PG 1212 CLAMP for Of filler tube Peor 4 98 PG 1230 CLIP for cylinder hold down 1 99 QD 839 GASKET for cylinder base 1 65 O Ring for V 461D replaced by QD 841 SE 286 HEAT SHIELD for fuel pump a INTERCHANGEABLE PARTS for Models V 465D and V 460D V 461D NOTE Beginning with engine serial number 4904657 for model V 465D the method of lubricating the connecting rod bearings changed from a crankshaft gear oil collet with roller type center main bearing to a shell center main bearing containing a pressure oil line from the oil header Component parts are not interchangeable and cre r
209. y ignite If fuel spillage does occur wipe up all fuel before starting the engine If spillage is excessive and pene trates the welder enclosure or canopy remove enough components to permit complete cleanup Open canopy doors if unit has them and blow compressed air over the equipment to clear away the fumes When servicing the battery do not smoke cause sparking or use open flame near the battery as it gives off flammable hydrogen gas Exercise care in working around the engine when it is in operation to prevent injury from rotating fans belts pulleys or from hot exhaust system compon ents OPERATORS PERSONAL PROTECTION Wear dry gloves jackets or sleeves and aprons of chrome leather safety shoes welding helmet and any other necessary articles to prevent injury from arc burns Always protect your eyes by wearing a welding hel met fitted with a double lens a colored arc ray lens inside and a clear glass lens on the outside see table below Protect the eyes of personnel in the area by use of opaque non reflecting and non flammable screens MAX ARC AMPS LENS SHADE NO Below 30 Amperes 6 30 to 75 Amperes 8 75 to 200 Amperes 10 200 to 400 Amperes 12 400 and over 14 Suggested Lens Shades for Arc Welding and Cutting WARNING Do not use ordinary gas weld ing goggles These goggles do not provide sufficient eye protection In case of eyeburn obtain professional medical atten tion immediately For tempor

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