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1. ENGINE MODELS 444 5768 e E d EB E vibrating Current regulator Current setting amps hot 38 ENGINE MODEL SD 220 120 RA 140 VOLTAGE REGULATOR 25 AMP LOW SPEED CUT IN Delco DR 1118350 aor de nde E vibrating Current regulator Current setting amps hot 25 Air 3 oe m JU T5 Voltage regulator Voltage setting volts hot 1 2 AIT 499 075 Cutout relay Closing voltage volts hot 6 4 eco a 44 020 Point 020 Current and voltage specifications apply only at operating temperature Operating temperature shall be assumed to exist after not less than 15 minutes of continuous operation with a charge rate of 8 10 amperes RD 372 RD 406 RD 450 DR 1118732 45 vibrating 47 075 7 4 4075 6 4 020 020 d 2 tri 5 Q 4 lt O ri 29 WALSAS 7172 TWOMLOATaA Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS R 170 and RF 170 Series R 180 thru 184 RC 180 181 182 ENGINE MODEL BD 282 STARTING MOTOR Delco Remy DR 1108009 4 ux 5492 4 a 6 Number of field coils 4
2. volt and volt and current current 20 20 bali ball ball ball CW 042 0 2 o belt volt a current 1 70 1 95 50 7 5 1410 25 ball ball CW belt os es 8 volt current 1 70 1 95 25 11 1 CW belt eo 406 RD 450 Cont R 6602 volt and current belt 2 8 suoieojti2edg WALSAS TVOld 5 Z m lt 5 C Un rj Ze lt gt Z gt z Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS YOIH3ANY JO Sq31vV1S ENGINE MODELS SD 220 SD 240 BD 269 RD 372 RD 406 RD 450 Cont R 6602 gt GENERATOR 30 Delco zZ Remy DR 1102714 DR 1102714 DR 1102714 DR 1102714 DR 1102714 DR 1102714 Field Euren at 6 1 75 1 90 1 75 1 90 1 75 1 90 1 75 1 90 1 75 1 90 1 75 1 90 Cold output 2 30 30 30 30 VONS 4 4 0 a mos TTC amp ees 8 8 Z Rapid 1750 1750 C Hot output Amperes Controlled do do o Do Un Volts by current
3. s _ Stop light switch EJ ir cir Tete r1 26 f Q2 green wiper D 16 ga 16 ga NS 18 ga N Enlarged EE C Connectors M Trailer stop light view telay 1 Stop and light SR EMI j 7 Trailer tail light Park ge b Light ifo 2 8 Ea ry Regulator Battery liche ea Io ga 14 and terminal block assembly Horn button B 7168 Fig 6 Wiring circuit diagram R 185 truck and R 190 RF 190 R 200 R 210 RF 210 series trucks 11 512 20 5 561 HOUVW Z I 512 YOINSAY 20 S31v15 1 Donated by John amp Susan Hansen For Personal Use Only PARK LIGHT HEAD LIGHT AB I WINDSHIELD agr res ENERATOR FIELD MERE a L ENERATOR ARM START PUSH B GULATOR SWITCH RHD WINDSHIELD F k 17 2 MMETER FEED GN SW FEED DOE CIRCUIT __8 IGNITION BREAKER 2 a 8 14 SWITCH RHD domne WIPER SW e SWITCH T TARTING IGHT SW FEED 31 IMMER SW FEED GENERATOR A E CIRCUIT BREAKER 2 EVA LIGHT ay SWITCH Q 4 d itf LIGHTER AN INSTR LIGHT SPEEDOMET
4. 2 7227772 22222221 a a mme Lr il ULL t P d PII 9 S SP 777 A LAS EDO BRUSH CENTER BEARING BRONZE COMMUTATOR ARMATURE BEARING COMM END FRAME A 30821 wf DRIVE PINION Fig 1 Starter Delco Remy 1108009 CTS 12 MARCH 1953 Supplemental pages for CTS 11 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only STARTING MOTORS Direction of Battery rotation A 22796 Fig Wiring diagram of simple electric mo tor Showing current flow The armature wind ings and field windings are connected in series Delco Remy starter motors are all series wound units Brush Bronze bushing I dir d Bendix mm trame S Commutator drive 22719 Fig 2 Delco Remy Starter 1107074 Starting Motors or Cranking Motors The best assurance of obtaining maximum service from cranking motors with minimum trouble is to follow a regular inspection and maintenance procedure Periodic lubrication where required inspection ofthe brushes com mutator and drive arrangement are essentials in the inspectionprocedure In addition disas sembly and thorough overhauling of the cranking motor at periodic intervals are desirable as a safeguard against road failures from accumu PRINTED IN UNITED STATES OF AMERICA ELECTRICAL L LINE
5. ab groun block assembly AJ Temperature gauge 1 am E Junction block sender unit Fuel gauge sender unit a Ignition coil IE Distributor L H tank nA relay Battery ground strap p Un Sor QL Battery s plug Battery cable 5 C 4 S Generator pL Stop light Switch zs Oil pressure gauge _ gauge NUON Engine ground strap fender and 5 Dimmer switch gt Junction block how Magnetic starting switch N Headlight Starting motor Parking light B 4868 Fig 5 Diagram showing location of various electrical units L 190 And Up Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section B Page BATTERY Storage Battery Equipment Present production trucks are equipped with Auto Lite batteries Code Dating Each Auto Lite Battery bears a shipping code stamped on one button of one cell connec tor of the battery This button is indicated as A in Fig 1 Button A OO Standard assembly Reversed assembl e End to end assembl Positive button center cell 6 volt assembly Positive button cell adjacent to positive terminal cell 12 volt assembly Fig Month Year A 23439 Fig 2 The code
6. Ammeter 21 HR 85 Os Instrument light E lt lt Fuel x eue l6ga L 00 Starting push switch For models with Silver Diamond 43 Engines BR Battery 7 14ga E Di N y 48 20 ately OO 2 o qa o0 5 5 a X A B D E F G H J E feet DAOA 7 16ga i l Va HUUR Beam indicator light 1 i 7 14 12 16 14ga X Circuit breaker A E Ru PP Stop up and terminal block V2 12 assembly be 2 x4 Tail Map fim LL relay Enlarged e Fuel gauge sender unit view X X ul B 4737 Fig 2 Circuit Diagram L 110 Series to L 180 Series inclusive Not Metro 9 gt m O zv AJ C O N Un u s lt O gt 2 gt y uou eg WaLSAS TVOIADLOATSA Donated by John amp Susan Hansen For Personal Use Only Dash panel L N Beam indicator light j Instrument light D Ignition switch _ NS Speedometer Lighti itch N nM s f Ammeter gauge a LS ENS lt lt M Temperature gauge Sie LX 7 Instrument light FI Fuel gauge SH C ANC
7. 1 or bat 3 T 4 Junction block X Light switch _ 0 AS A ie Im Speedometer 222 EZ if Instr light Ign 3 X Sy aa Oil press 7 light Li Starting and ignition Dimmer switch wire dd mE o switch L H D e 1 19 7 Stop light switch we isi 2 eS AN K VN lj gt Trailer stop light 99 Fuel Trailer tail light S EOS Circuit breaker and L A button terminal block assembly Regulator OY Fig 4 Wiring circuit diagram R 170 170 R 180 series trucks not R 185 Hum 1 Instrument light High beam indicator Dome light switch Qn Cable Color or Description Generator feld Generator arm Regulator to amm Ammeter feed 12 Ignition switch feed Ign sw to ign coil Starting Dimmer switch feed 16 Parking feed Parking light leads 14x16 Tail light p lig Fuel gauge Fuel gauge Ignition coil to dist Head light ground Nat with cir letter A or black wiper Battery ground Engine ground Cab ground Battery cable
8. D Clean Threads Remove loose abrasive or other foreign material from the sparkplug threads by means of a wire brush a stiff tooth brush is also sat isfactory to complete the job of cleaning E Dress Spark Plug Gaps Before actually setting the gap of a cleaned spark plug it is highly desirable to pass a thin pointfile or nailfile between the sparkingareas of the center and ground electrodes This helps to produce flat parallel surfaces which resist growth better than sharp or uneven areas and facilitates more accurate gap gauging F Reset Spark Plug Gaps Reset all gaps by moving the ground or side electrode only Do not touch the center electrode as insulator tip fracture may result Bend the ground electrode towards the cen ter electrode Use a good feeler gauge to measure the clearances between the electrodes Refer to specifications for correct gap settings very slight drag should be felt when the feeler gauge passes between the electrodes The spark plug is now ready for testing SUITABLE SPARK PLUG CLEANING EQUIP MENT IS AVAILABLE UNDER SE 1634 AND SE 1637 BOTH TYPE CLEANERS ITEMS ARE ABRASIVE Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL R LINE MOTOR TRUCK SERVICE n Page 1 OILER MAGNETIC SWITCH COVER BAND FIELD COIL SS THRU 55 DRIVE SPRING DRIVE HOUSING e a a m a a 7 N VAr
9. Oil pressure gauge Cab ground strap eet pes 2 Starting push switch 4 4 07 _ N IN tail light Ignition coil M and stop light Circuit breaker and terminal block assembly 2 Battery cable Generator K AL v gt 2 Battery ET w SC Voltage and current CO regulator __Fuel gauge sender unit e a d is 22 R n M a Oil pressure gauge sender unit Distributor Battery ground strap Junction Stop light switch Horn Head light Parking light B 4696 Fig 3 Diagram showing location of various electrical units 1 110 Series to L 180 Series in clusive Not Metro 92 92 Son Why O O H gt So gt B Z O O AJ j AJ as Un T lt lt gt Z C gt VOINAWY 3O SALVLS GALINDO Ni O34NIUd D 14 16 ga 16 ga Junction block Engine ground Junction block 14 ga 16 ga 2 1 d 14 Sa E Donated by John amp Susan Hansen For Personal Use Only Fuel guage sender unit T QO Winds
10. 1 Ed Nat with cir letter F or red wiper 14 Instrument bus bar Horn push button Nat with cir letter P or green wiper HOLOIN ANITY Stop Tail Enlarged view A A Stop and tail light B 7 167 p aseg T o0 5 5 b amp 20527138 11 512 10 saded 0 91494 5 61 HOWVW Z1 512 iO S31vYv185 Ni 934 Donated by John amp Susan Hansen For Personal Use Only Park Head 16 ga Light light 17 18 Circuit E attery breaker i Ligh itch Starting motor 4 or Hi wight switc Windshield wiper motor Windshield wiper switch 4 Circuit breaker Speedometer Instrument light y Temperature p ems h beam 1 cmp indicator light 14 L Dome light switch S d a Cox Instr light Pd Dome light ay ground Oil pressure Q T Py rFuel di 24 Dimmer switch r 1p 1 s o S e 27 Horn P ll an relay j Combination switch ff Stop and tail light Stop light switch Horn 20 A top 5 Tail Junction block Enlarged view p y SC Trailer stop light Trailer tail light 1 Xe X Circuit breaker and
11. the generator which correctly polarizes it CAUTION Failure to do this may result in severe damage to the equipment since reversed polarity causes vibration arcing and burning the relay contact points QUICK CHECKS OF GENERATOR AND REGULATOR In analyzing complaints of generator regu lator operation any of several basic conditions may be found Low charging rate p Normal 5 A 22715 Fully charged 1 FULLY CHARGED BATTERY AND LOW CHARGING RATE This indicates normal generator regulator operation Regulator settings may be checked as outlined on following pages High charging rate Overcharging 42 22615 Fully charged 2 FULLY CHARGED BATTERY AND A HIGH CHARGING RATE This indicates that the voltage regulator is not reducing the generator output as it should high charging rate to a fully charged battery will damage the battery and the accom panying high voltage is very injurious to all electrical units This operating condition may result from a Improper voltage regulator setting b Defective voltage regulator unit c Grounded generator field circuit in either generator regulatoror wiring d Poor ground connection at regulator e High temperature which reduces the resistance of the battery to charge so that it willaccept a high charging rate even thouth the voltage regulator setting is normal If the trouble is not due to high tempera ture determine
12. Loosen door retaining screw on headlight Reassembly is accomplished by reversing body Remove door See Fig 1 the foregoing procedure PRINTED N UNITED STATES OF AMERICA ELECTRICAL SYSTEM Section F Page 2 Sealed beam unit A 22009 Fig 3 Removing sealed beam unit A 22010 Fig 4 Adjusting laterial or side beam Adjustment Headlight adjustment should always be effected ona level floor otherwise aiming of projected beams will be inaccurate should be empty Laterial or side adjustment is accom plished at screw in Fig 4 Truck PA 220n Fig 5 Adjusting vertical beam Vertical or up and down adjustment is accomplished at screw in Fig 5 When suitable headlight testing equipment is not available the following chart will be helpful Center of truck Left light Right light Head light y l Center height 777 777 7 2 e 4 6 D Projected beam pattern upper beam Floor line INSTR TUN 25 RKR e e 6 2 eS 254 254 e 55 e 59 52 44 L Aiming of headlights of Sealed Beam type is effected by projecting the COUNTRY UPPER BEAM of each individual headlight upon a screen or chart at a distance of twenty five feet from the headlight The truck should be squarely lined up with the screen Vertical lines on the char
13. Regulator terminal block assembly B 7180 N Y Park Head 91 17 18 Light light Fig 5 Wiring circuit diagram RC 180 series trucks Circuit Dig Cable oS i ma MB 16 Generator field 8 Generator arm 8 Regulator to amm 8 Ammeter feed 12 Ignition switch feed 16 Ign sw to ign coil 16 B head It leads H B indicator 14x16 L B feed Instrument feed cia Z ri lt ym gaug A J C C Un r1 lt ri 5 d TI m c ve gt E pressure gauge Q dh ot rt ber switch feed 2 6 8 8 E 22 p T 5 light grounc Nat with cir letter Battery ground ground Battery cable Nat with cir F or red wiper Instrument bus bar Horn push button Eas m E 6 2 c TT Z E 5 rt B TEER T P rt 5 5 or green wiper Donated by John amp Susan Hansen For Personal Use Only Uu 4H Le Description os x s Generator feld gt ed Generator arm Re gulator to amm Ammeter feed E d Ignition switch Ign sw to ign 14 16 Startin Ez Dimmer switch feed H
14. acranking motor that responds normally when the cranking motor switch is closed is usually considered to be in good condition Checking a cranking motor that does not oper ate normally is discussed ina following sec tion However the inspectionprocedure should include more than a mere check of the cranking motor operation the following items should also be inspected The mounting wiring and connections should be tight and in good condi tion The magnetic switch or solenoid where used should be firmly mounted and should op erate freely and without binding Next remove the cover band so the com mutator brushes and internal connections can be checked Examine the cover band for thrown solder which results if the cranking motor is subjected to excessively long cranking periods so it overheats This overheating causes the solder at the commutator riser bars to melt and be thrown out during cranking Bad con nections consequently develop whichinturn re sult in arcing and burning of the commutator bars and ultimate ruination of the armature If the bars are not too badly burned the arma ture can often be saved by resoldering the con nections atthe riser bars usingrosin not acid flux turning the commutator and undercutting the mica between bars Some cranking motor armatures are of welded construction with the armature coil leads welded not soldered to the commutator bars This type of armature should not be repaired by or
15. amp Susan Hansen For Personal Use Only ELECTRICAL p GTERNATIONAL 22 L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL Page 4 UA International Harvester Truck owners are withbattery warranties the manufacturer s subject to adjustment as outlined below Factory equipment or replacement bat teries are adjusted according to the following table Service Adjustment Chart Battery Eauibment Mileage Time Adjustment Adjustment ype 2H 105 2H 105R 15 000 7 1 2 Months 2H 120 2H 120R 18 000 9 Months 2H 135R 21 000 10 1 2 Months 3H 136R 18 000 9 Months AH 152R 18 000 9 Months 8T 200 24 000 8 Months Complaints on Battery Performance Any complaints pertaining to battery per formance should be referred to the nearest Auto Lite Service Station Complaints on Service Facilities Complaints on service facilities of Auto Lite distributors must be referred to the Sales Department Motor Truck Service Division Chicago Office Accompany complaint with all details concerning the battery and the truck from which it was removed The matter will be handled with the manufacturer from the Chicago Office and not by the District direct Batteries Older Than Four Months at Time of Delivery Motor Truck Service Bulletin No 82 1931 pertained to batteries which were on hand and which were older than four months according to code dating That bulletin advised that these batteries should be deliver
16. then recheck the gap making sure the gauge is a snug fit on all sides NOTE plate sticks to the armature and prevents it from turning To loosen tap the arma ture spring plate lightly with a screwdriv er 7 Connect for tuning test with the ammeter in series with the horn terminal and a 6 volt battery and the horn frame grounded to the other battery terminal Connect the voltmeter from the horn terminal to aclean spoton the horn frame Adjust the amper age draw for each horn to 15 amperes at 6 2 volts by loosening the lock nut on the circuit breaker contact and turning the ad justing screw Retighten the lock nut Horn Relay The horn relay is connected into the horn and battery circuit so as to makea more direct connection between the battery and horns elim inating the horn button wiring from the horn circuit proper so that higher voltage becomes available at the horns and better horn perform ance is obtained The horn relay consists of a winding assembled on a core above which an armature is placed The armature has a point positioned above a stationary point Horn Relay Operation When the horn button is depressed the circuit from the battery is completed through the horn relay winding this causes a magnetic field which pulls the relay armature down so that the circuit between the battery and horns is completed The horns function and will con tinue to function as long as the horn button re mains in the closed po
17. 16 Fuel gauge 29 16 Fuel gauge 33 16 Temperature gauge 36 16 Oil pressure gauge 40 16 Instrument lights 71 14 Wiper switch feed BO 14 Ignition coil to dis tributor 91 14 Headlight ground A 16 Natural with circuit letter A or black B Battery ground C 3 Engine ground D 12 Cab ground E Q Battery cable F 16 Natural with circuit Istter F or red G 14 Instrument bus bar H 14 Horn push button J 16 Fuel gauge ground P 16 Natural with circuit letter P or green L a8eg D 7 T1 O 5 AJ A Un U lt 2 T gt Z gt D y 1 5 4 5 TVOIN LOATH Donated by John amp Susan Hansen For Personal Use Only Qu motor y wiper switch _ Fuel gauge sender unit 3 Dash Instrument light R H tank gt lt ash panel P ERAS E Speedometer Kop Cigar lighter M RSN To taillight 2 Ignition switch TE Ammefer gauge oS and stop light lem e 3 Temperature gauge We S S We 67 Oil pressure gauge gt r ES Dy ZG n pe p DAC X Tachometer p gt lt Ny E Lue ON Starting push switch g T Light switch gt lt Ki e X n Dome light switch Beam indicator See S 4 Cab d m d a breaker and terminal
18. B feed B head It leads Head Starting push switch Fuel H B indi R H For Models R 193 Park light OSN ON HO ond R 1853 18 1141 I fees i 1 Windshield me switch T wiper mou Windshield r C R H D d wiper switch Es L 2 4 or Circuit I T 2 69 i 2 P or 7 17 8 16 Instrument feed zc 116 ga 1 II i 18 Fuel gauge 34 24 ma _ _ Lighter 18 Fuel gauge Q Junction block 1 1 bat 4 18 Temperature gauge _ _ L Light switch AB pressure gauge Q 17 Ne a 40 16 Instrument lights am T 1 Instrument light 16 Wiper switch feed Amm High b 80 16 Ignition coil to dist i di tor li 91 16 Head light ground A Distributor 4 indicator light A 16 Nat with cir letter ME o _ Tachometer A or black wiper e amp 1 27 em men ih Fuel light pha Cab grounc UD ue oe switch 4 Battery cable T O as 6 58 4 Dome light Engine ground Dimmer MEI E mm rmm ignition bus bar lt i T switc 16 za 16 Horn push button 14 gaj K
19. COUNTRY UPPER is de signed togive even roadillumination for a con siderable distance and is intended for use on 22007 the open highway when other vehicles are not Fig Removing headlight door approaching er The TRAFFIC LOWER is in tended for use in traffic Itis low enough on the left side to avoid glare inthe eyes of oncom ing drivers and at the same time the distribu tion of light on the right side will illuminate the road as far ahead as practical without causing glare on curves Changing from COUNTRY UPPER li BEAM to TRAFFIC LOWER BEAM is 3 m accomplished through use of the foot dimmer Ei l nod tena switch CAUTION Always use the TRAFFIC A NC E LOWER BEAM when meeting other vehicles gp Wm Replacements Sealed Beam Units Should a filament burn out or a lens break the entire Sealed Beam unit must be replaced Maximum lighting efficiency is thus assured The added cost of the replacement unit will be balanced or offset by the longer lived filament used in the construction of the sealed unit Fig 2 Remove retainer ring screws 2 Remove unit retaining ring by removing Replacement of a bulb or lens is accom three screws See Fig 2 plished only through the replacement of the 3 Remove unit from headlight body and dis entire unit do this connect three way connector at rear See Fig 3 1
20. Cam angle TTE rr 319 379 359 359 359 359 Initial setting engine degrees 2 BTC 2 BTC 3 BTC 5 BTC 5 BTC 5 BTC Vacuum advance engine degrees 15 159 none none none none Automatic advance engine degrees TT 30 30 27 229 229 229 Total advance engine degrees 329 329 309 279 277 279 Retard engine degrees none 20 20 none none none none Contact point setting 022 022 018 024 018 024 018 024 018 024 Contact point pressure ounces 17 21 17 21 17 21 17 21 17 21 17 21 Rotation viewed from top CCW CCW CW CW CW CW CCW Piring OPdef 2 6 153624 153624 153624 153624 153624 153624 DISTRIBUTOR TEST DATA Start advance Engine r p m amp 5 9 500 Engine degrees 2 Intermediate advance Engine 554 64 TTE 1800 1400 Engine degrees 20 13 13 13 Macimum advance Engine e ee 6 we e a 3000 3200 3200 3200 Engine degrees 30 22 22 Distributor vacuum control Delco Remy DR 1116049 DR 1116049 Distributor Test Stand figures will be one half of these specifications Test Stand r p m only For maximum engine r p m see Engine Section 8 a Z mi JR QO 5 um gt 7 Un u zs gt Z gt suo
21. Com Champion severe 4 J 6 J 6 J 7 J 6 J 6 7 6 Auto Lite service AN5 AN5 AN5 AN5 AN5 AN5 A Spark plug size 14 mm 14 mm 14 rnm 14 mm 14 mm 14 mm 18 mm Spark plug gap 028 032 028 032 028 032 028 032 028 032 028 032 023 027 C STARTING MOTOR Delco Remy DR 1107074 DR 1107074 DR 1107967 DR 1108217 DR 1109004 DR 1109004 Voltage T 6 6 6 6 6 6 12 Un Number of field coils 2 2 4 4 6 6 6 Bearing commutator end cast iron cast iron cast iron cast iron cast iron cast iron bronze lt Bearing center edea cast iron cast iron cast iron C Bearing drive end bronze bronze bronze bronze bronze bronze bronze Brush tension ounces 24 28 24 28 24 28 24 28 36 40 36 40 36 40 Z No load test with Solenoid or gt Magnetic Switch 2 Maximum amperes 75 75 60 70 70 65 Volis es chui eg EIS pe ere 5 7 5 7 5 0 5 0 5 7 11 4 R p m approx 5000 5000 6000 3500 2200 6000 Lock test Maximum amperes 525 525 600 600 600 725 VONS dr 3 4 3 4 3 0 3 0 3 0 5 0 Torque Ib ft min 12 12 15 22 35 44 Rotation viewed from drive end CW CW CW CW CW D mU MAGNETIC SWITCH Delco 0 It Remy DR 1465 DR 1465 DR 1465 DR 1465 DR 1465 DR 1465 oe Current consumption at 6 volts 5 7
22. Each circuit breaker is sealed non ad justable unit and consists of a bi metal plate contact points and is connected in series with its respective circuit Six 6 circuit breakers and two 2 ter minal blocks are included in the assembly as illustrated in Fig 8 and are located on the ve hicle at the engine side of the cab dash panel The circuit breakers and terminal blocks are similar in outward appearance but different in inward construction and function Circuit PRINTED IN UNITED STATES OF AMERICA Cut insulator to remove one or more circuit Independent breakers circuit breakers black body insulating material Insulator Do not remove permanently Body insulating Independent material terminal blocks gr Circuit breaker insulating in material terminal block assembly A 22719 Fig 8 Circuit breakers breakers can be identified by their green color body insulating material whereas ter minal blocks have black color body insulating material The headlight upper beam circuit andlower beam circuit have independent circuitbreakers to eliminate failure of bothcircuits at the same time should a shortoccur For example Should a short occur in the headlight upper beam cir cuit the lower beam circuit would not be a fected and could be utilized immediately by de pressing the dimmer switch Individual replacement of acircuitbreaker can be accomplished by disconnecting cables and cutting
23. at the back of relay and raise or lower the armature as required lighten screws after adjustment POINT OPENING Check point opening and adjust by bending the upper armature stop Fig 5 CLOSING VOLTAGE To check the closing voltage of the cutout relay connect the regulator to the proper generator and battery connecta voltmeter between the regulator GEN terminal and regulator base and connect an ammeter into the charging circuit at the regulator BAT terminal as shownin Fig 6 Slowly increase the generator speed and note relay closing voltage Decrease generator speed and make sure that cutout relay contact points open Adjust closing voltage by turning adjusting Donated by John amp Susan Hansen For Personal Use Only Mi N L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section H Page 5 screw Fig 7 Turn screw clockwise to in crease spring tension and closing voltage and turn screw counterclockwise to decrease clos ing voltage Upper armature stop bend to adjust point opening Point opening A 22533 Fig 5 Cut out relay point opening check and adjustment Battery must be disconnected when this check is made Connect to ground Regulator F e j Ammeter Voltmeter Generator A 22619 be made when checking and reverse current to Fig 6 Connections to relay closing voltage open relay points Voltage Regulator lwo checks and ad
24. for Installing Control Knobs Place the control knob in position on the shaft until the end of the shaft just begins to engage the locking hole in the tab portion of L LINE MOTOR TRUCK SERVICE MANUAL Retainer nut Ferrule nut shaft bushing Button shaft release Flat Circuit Rheostat on shaft Hole breaker in knob A 22502 Light switch Fig 9 the knob retainer spring Upon engagement with the retaining spring the knob cannot be easily pushed into position since the spring contacting the end of the shaft prevents fur ther movement With the knob inposition as shown Fig 10 and with the end of the thumb at the top edge of the knob face press the knob with a combination lifting and pushing motion performed simul taneously into position on the shaft The lifting motion serves to deflect the knob retainer spring tab and the pushing mo tion forces the knob into position Installation of the control button on the windshield wiper switch requires that the above instruction be carried out in detail since un reasonable pressure against the shaft of the windshield wiper switch is apt to damage the switch mechanism When the control knobs installed as instructed no difficulty should be experienced and the operation can be performed with ease NOTE The carburetor hand throttle con trol knob the windshield wiper control knob and the choke wire control knob are removed in the same manner
25. list from No 1 to 124 itemizes circuit numerals used on L Line Wherever a particular circuit is used on a vehicle the identification numeral for that circuit will always be the same For example the generator field circuit cable will consistently be Circuit No 1 the generator armature circuit will always be Circuit No 2 etc see list In the same manner if a circuit is not used on a vehicle the numeral for that circuit will not be used For example vehicles not having a 24 volt radio feed cable will not have a circuit No 48 in the harness Circuit numbers on the list for which no circuit description is given are not presently used by International and these circuits have been reserved for possible future assignment Circuit Nos 28 to 31 inclusive each per tain to fuel tank to receiver unit circuits Because of the variety of possible combinations for these hook ups reference should be made to the illustrations for proper connection of cables Fig 1 Circuit Diagrams Wiring circuit diagrams are illustrated in the owner s and driver s manuals and in the service manuals With each of these illustra PRINTED IN UNITED STATES OF AMERICA tions there is a key to the diagram which con tains pertinent informationas to circuit number and cable gauge Individual Cable Replacement It is recognized that replacement of one or more individual cables may be necessary and that complete harness replacement may be im pr
26. since defective wiring loose or corroded connections will prevent normal cranking action Lubr cation Bearings provided with hinge cap oilers should have 8 to 10 drops of light engine oil every 5 000 miles Grease cups should be turned down one turn every 5 000 miles and refilled with medium cup grease when required On tractor marine or stationary applications lubricate every 300 hours of operation as above Grease plugs on gear reduction cranking mo tors should be removed every six months so the grease reservoir canbe repacked with me dium grade graphite grease On some models oil wicks are used to lubricate the center and drive end bushings The wicks are saturated with oil before assem bly and should be saturatedagain whenever the cranking motor is taken off the engine or dis assembled Some cranking motors are equipped with oil less bushings These should be supplied with a few drops of light engine oil at any time that the cranking motor is disassembled for repair or service Avoid excessive lubrication since this might cause lubricant to be forced out onto the commutator where it would gum and cause poor commutation with aresulting decreaseincrank ing motor performance Lubricating The Bendix Drive Mechanism Bendix drives should be lubricated with a s aall amount of light engine oil whenever the cranking motor is removed from the engine for servicing Heavy oil or grease must not be used as this may retard
27. starting motor Blackout light switch TT to tail connec tion on trailer receptacle Blackoutlight switch SS to stoplight con nection on trailer receptacle Low air pressure indicator buzzer or light Ground on series parallel switch to am meter including circuit breaker Spotlight circuit for trucks and wreckers Winch torque limiter control Automatic choke Trailer receptacle to ground Headlight to ground Parking light to ground Starting motor relay to ground Starting motor relay auxiliary grounding circuit Tail light to ground Speedometer sender feed Tachometer transmitter feed Tachometer transmitter positive to tachometer positive Tachometer transmitter negative to tachometer negative PRINTED IN UNITED STATES OF AMERICA 100 101 102 103 104 105 106 107 108 109 110 111 112 143 114 115 116 117 118 119 120 121 122 123 124 Tachometer transmitter to ground Defroster switch to defroster motor including feed Heater switch to heater motor including feed Cigar lighter Fog light switch tofog light including feed Tractor light Back up Carburetor idle fuel shut off valve Marker or identification light circuit Clearance light circuit Mico brake lock circuit gauge switch C to ground dual safety tanks Lockoff solenoid valve to switch including feed Auxiliary amme
28. these subject the overrun ning clutch to extra strain so it tends to seize spinning the armature at high speed with re sulting armature damage On Bendix drive cranking motors broken Bendix housings and wrapped up Bendix springs may result if the driver closes the cranking motor switch during engine rockback after the engine starts and then stops again Another cause may be engine backfire during cranking which may result among other things from ig nition timing being too far advanced To avoid such failures the driver should pause a few seconds after a false start to make sure the engine has come completely to rest before an other start is attempted In addition the igni tion timing should be reset if engine backfiring has caused the trouble The third condition which may be encount ered when the cranking motor switch is closed with the lights turned on is that the lights stay bright but no crankingactiontakes place This indicates an open circuit at some point either in the cranking motor or in the cranking motor switchor controlcircuit Where the application is solenoid operated the solenoid control cir cuit can be eliminated momentarily by placing a heavy jumper lead across the solenoid main terminals to see if the cranking motor will op erate This connects the cranking motor dir ectly to the battery and if it operates it indi cates that the control circuit is not functioning normally The wiring and control un
29. thus giving the maximum point opening Loosen the clamp screw holding the contact support and adjust point opening by turning the eccentric screw in the contact support Tighten clamp screw check with gauge again after tightening clamp screw THE CONTACT POINTS SHOULD BE CLEANED BEFORE ADJUSTING IF THEY HAVE BEEN IN SERV ICE The cam or contact angle is the angle in degrees of cam rotation through which the points remain closed This angle increases with decreased point opening As the rubbing block of a new breaker arm wears in rounding the corners of the rubbing surface the contact angle increases CONTACT POINT PRESSURE Must fall within the limits given Weak tension will cause point chatter and ignition miss at high speed while excessive tension will cause undue wear of the contact points cam and rubbing block USE OF DISTRIBUTOR TEST FIXTURE The distributor test fixture accurately checks cam angle spark advance and synchronization on distributors removed from the car It will also show excessive distributor shaft eccen tricity as indicated by variation in synchron ization After a distributor has been repaired the calibration of the centrifugal automatic mecha nism should be checked Proper engine per formance cannot be obtained unless the centrifugal curveis within the limits specified for the particular engine THE CONDENSER Four factors affect condenser performance and each factor must be considered in mak
30. 22 E R p m regulator lse scs o eee 9 x sasse sewo Regulation arosa BEEN volt and volt and volt and volt and volt and current current current current current current 11 Brush tension ounces 24 28 24 28 24 28 24 28 24 28 24 28 zZ Bearing commutator end bronze bronze bronze bronze bronze bronze gt Bearing drive end ball ball ball ball ball ball 5 7 Rotation viewed from drive End CW CW CW CW CW CW G Type of 4 4 belt belt belt belt belt belt c WALSAS Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS ENGINE MODELS SD 220 VOLTAGE REGULATOR 30 AMP Delco Remy DR 1118303 DR 1118303 DR 1118303 DR 1118303 LIC vibrating vibrating vibrating vibrating Current regulator Current setting amps hot 30 30 30 30 AIt cw oi ea a O75 075 075 075 Voltage regulator Voltage setting volts hot 7 4 7 4 7 4 7 4 PADO 6x4 seriis 075 075 075 UT 5 Cutout relay Closing voltage volts hot 6 4 6 4 6 4 6 4 Ait GaP ee ee op os 920 020 020 020 Point 020 020 020 020 VOLTAGE REGULATOR 50 HIGH OUTPUT Delco Remy DR 1118333 DR 1118
31. 333 DR 1118333 DR 1118333 i37 rv vibrating vibrating vibrating vibrating Current regulator Current setting amps hot 50 50 50 50 FUIR HBdD sa ko 4 44 90 082 082 082 082 Voltage regulator Voltage setting volts hot 1 4 7 4 7 4 7 4 NIR PODS oy ee 075 075 075 Cutout relay Closing voltage volts hot 6 4 6 4 6 4 6 4 Air ue s 020 020 020 020 Point 020 020 020 VOLTAGE REGULATOR 40 LOW SPEED CUTIN Delco ROI elu 243 x Boh DR 1118366 DR 1118366 TU DE os m vibrating vibrating Current regulator Current setting amps hot 40 tee DUT sae ae 5429353 915 Voltage regulator Voltage setting volts hot 7 4 7 4 Air CAPs Lo age dox qo sos 07 5 QUSS esmes Cutout relay Closing voltage volts hot 6 4 6 4 Wu ee dod 6 44044 x 0x ew y kky 020 2526 asses Point opening 020 020 DR 1118303 DR 1118303 vibrating vibrating 30 2915 1 4 2015 6 4 020 020 30 075 1 4 Du 3 6 4 020 020 50 240 BD 269 RD 372 RD 406 RD 450 Cont R 6602 9 9 DR 1118333 DR 1118333 DR 1118368 vibrating 50 082 7 4 205 6 4 020 vibratin
32. 38 1 dE c 1 Speedometer 40 16 oc emp mc 71 16 Wiper swi I8 a i e eu T al Y Light em LL L Instr light 16 Ignition coil to dist 4 tdi tex ground 4 cator Ed cir letter P O Instr light N A D 12 N 6 224 Dome light 1 17 5 on switch HH ES or red ns er 16 ga Bat A light 14 Instrument bus 11 Distributor 16 Horn push button O L 2 Oil ples A Starting and ignition Nat with cir letter Dimmer switch AO uO C T switch L H D or green wiper 12 ga T1 1 j 5 ich Stop and tail light Stop light switch 18 Horn 29 e Stop 16 ga RO j lt 5 14 ai 8 20 ANS LIT Tie tail light 16 21 18 ga N Trailer stop light Horn relay 26 Connectors Enlarged view Park M 16 ga R 110 120 130 left hd It Light r ead L H D 14 ga R 150 to R 165 left hd It light 14 ga R 110 to R 165 right hd It Fig 1 Wiring circuit diagram R 110 120 R 130 R 150 R 160 series trucks B 7166 3eq e 7 2 A e Un lt U H zum S HS Parking light 1
33. 6 Ni Donated by John amp Susan Hansen For Personal Use Only BRUSH ARMATURE TERMINAL DRIVE END BRUSH ARM FIELD TERMINAL BRUSH SPRING ARMATURE FAN i Kg Q ME EA m ed 274 SY SAN Hh UA UB Uum m UU UNA ER UA ee 7 v 2 MOREE 4 Ecc wie PI LL 4 7 4 22 0 1 Y A cun Pa lt 1 Ree AM QM va vo 2 m 7 BAN YS KE 222 jj PULLEY 2 COMMUTATOR SS 2 COVER BAND THRU BOLT SEALED BALL BEARING gt COMMUTATOR Fig 1 Sectional View of Generator Delco Remy Model 1100019 and Model 1102785 JOIAWMS ANITY I 28 q uonoeg WALSAS TVOIY LOATH FIELD TERMINAL GROUNDED BRUSH HOLDER Fig ARMATURE TERMINAL INSULATED BRUSH HOLDER Donated by John amp Susan Hansen For Personal Use Only GROUND SCREW POLE SHOE SCREW FIELD con BRUSH ARM BALL BEARING INSULATION dmi c T WOODRUFF BRUSH hp Key mip Fos a M n ens
34. 6 volts amperes 1 62 1 82 Cold output Hot output Amperes Controlled icd 4 9 4 Volts DY CUFTONt o dowd dO Ce R p m regulator o ow d e pe cm 4 4 4 E ROME NR ELE eim db Ede ee PPAR eee Ede Boe e Brush tension ounces 28 Bearing commutator end TTD ball Bearing drive e 49 ball Rotation viewed from drive end CW Type aw ks SH SESH 45x03 XY s belt suor3e rjt22adg WALSAS 19 4926 LOA gt m JO Un lt C ZU 11 S LO 10 saged 661 HDUVNW ZI 6812 Q3aLinn NI Q34NIBd YOIMAWY JOQ SALYLS Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS R 110 THRU RF 210 NOT RA 120 RA 140 SD 220 BD 269 SD 240 BD 282 VOLTAGE REGULATOR Delco Remy 626444645 o DR 1118731 DR 1118732 _ EN NN 47 075 Voltage regulator Voltage setting volts hot 7 4 7 4 o6 ee eee o dw 075 075 Cutout relay Closing voltage volts hot PAD s 4 be x Point
35. 7 0 5 7 7 0 5 7 1 0 5 7 7 0 5 7 7 0 5 7 7 0 SE Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS ENGINE MODELS HEADLIGHT SEALED BEAM UNIT IGNITION SWITCH Delco Remy LAMPS BULBS Stop and tail light bulb Voltage Candle power COMAC ee wad Parking light bulb Candle power Contact Instrument light bulb Candle power p Contact 5 Beam Indicator bulb Voltage Candle power Contacl STORAGE BATTERY Type Auto Lite Specific gravity Fully charged at Recharge at wb wale we me S Amperes hours at 20 hour rate Amperes 20 minute rate Terminal grounded sp 220 SD 240 BD 269 RD 372 RD 406 RD 450 Cont R 6602 924791 924791 924791 924791 924191 924791 5930856 1116465 1116465 1116465 1116465 1116465 1116465 1116465 6 8 12 16 21 3 21 6 DC DC 6 8 12 16 3 3 SC SC 6 8 12 16 2 1 5 SC SC 6 8 12 16 l 1 5 5 2 105 2H 105 2H 135R 4H 152R 4H 152R 4H 152R 4H 152R 1 280 1 290 1 280 1 290 1 280 1 290 1 280 1 290 1 280 1 290 1 280 1 290 1 280 1 290 1 225 1 225 1 225 1 225 1 225 1 225 1 225 6 6 6 6 6 6 6 105 105 135 152 152 152 152 133 133 170 180 180 180 180 positive po
36. 8 16 Donated by John amp Susan Hansen For Personal Use Only ground r 20 18 4 Temperatur Circuit ae ga m ure ircui Head WZ Starting motor 4 Light breaker light E Generator Junction block 9 Q Distributor assembly L Circuit breaker and terminal block e NM A 9 PAR and switch Ignition cail A 9 4 sd eam indicator 077 OF 26 2 Y H H 4A _ 7 Instrument light lt Iu AL M i 97 I gt Battery T Temperature S Instrument cluster we 5 Instrument light 19 Dome light switch 9 Stop light switch 14141 7 Fig 2 Viring circuit diagram RM 120 RM 150 series trucks Horn button Engine ground Cable o Dome light Cable Color or Description Generator field Generator arm Regulator to am meter Ammeter feed Ignition switch feed Ignition switch to ig moon ng Light switch feed Dimmer switch feed High beam feed High beam indicator High beam head light leads Low beam head light leads Low beam feed Parking light leads Parking light feed Taillight Btop light Connector to relay Horn and horn re lay feeds stop light Instrument feed Fuel gauge Temperature ga
37. Bearing commutator cast iron Bearing center See eee eee eee ea bronze Bearing drive 4 544999 x ea x RU bronze Brush tension ounces TT 24 28 No load test with Solenoid or Magnetic Switch Maximum 70 bI o 66 twas eee Ga eee 5 65 EES EOS 5500 Lock test Maximum amperes p 570 VOUS 2 642668 RUE SUP VE dede 3 15 Torque Ib ft min 13 5 Rotation viewed from drive CW ENGINE MODEL BD 282 DISTRIBUTOR Delco Remy DR 1112359 Initial setting engine degrees 6 B T C p 9 INS LSAS 5 2 d 5 JI C Un ZU lt VWIINIWYV 30 531 15 NI Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS ENGINE MODELS 50 220 SD 240 BD 269 RD 372 RD 406 RD 450 Cont R 6602 COIL Delco Remy DR 1115327 DR 1115327 DR 1115327 DR 1115327 DR 1115327 DR 1115327 DR 1115251 DISTRIBUTOR DR 1112355 DR 1112355 DR 1112359 DR 1112357 DR 1112357 DR 1112357 Lype T vac auto vac auto automatic automatic automatic automatic automatic
38. DEAL OF HEAT IS GENERATED Use only glass or earthenware containers for storing and for mixing the acid In some localities acid can be purchased already mixed to 1 345 specific gravity Table 1 Warm or Tropical Climate Cold Climate em Final Filling Acid pin Sp Bau Sp Bau Sp m Gr m Gr m Gr m 1 290 31 5 1 245 28 5 1 225 26 4 tropical climate is that in which the temperature never falls below the freezing point of water 329 F 0 C Place the battery on charge at the ampere rate given below Battery Equipment ee P Ampere 2H 105R 2H 120R 2H 135R 3H 136R 4H 152R 8T 200 1 RO CO y For converting dry batteries to wet use a constant rate charger Do not use a constant potential charger The total initial charge must be for 52 hours However should the temperature of the electrolyte while on charge reach 115 F 46 C discontinue the charge and allow the battery to cool Then resume charging The electrolyte at the end of 52 hours charge with battery temperature at 80 F 26 79 C should be at the value given in Table 1 Make corrections for temperature when necessary according to previous direc PRINTED IN UNITED STATES OF AMERICA tions Adjust electrolyte specific gravity by adding distilled water to w aken and 1 400 spe cific gravity acid to strengthen When adjusting electrolyte char
39. Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL L LINE MOTOR TRUCK SERVICE MANUAL es Page l ELECTRICAL SYSTEM GROUP INDEX Page A 5 5 ES DS HEE REEDS DE SLE RR 4046 89 1 to 6 SECTION A a 44 5 43 9 eR SES 24934 Ade de 1 to 8 SECTION B Dale Pis a 9234 x9 9 39 eO d do E b d d SE xot M CU UR E 1 to 5 SECTION 20118 2 wv M Ru REUS UNUS EORR a 1 2 SECTION D DiS DUOS 423545 x ee X5 eee ee Se eS 1 to 3 SECTION E 4449 4 OREO EERE EDO RE eee 1 2 HesadhgBi5 wwe oe OS DREGE SA UD e EE DES RODS eS to 4 lo M iw ea GOS Ee Oa EES SE ES KE 1 2 SECTION H Regulators PVT ITTPTTTTTY 1 to 8 SECTION I Spark WERL or oe EUR Red cR ER 1 to 4 SECTION J Starting Motors Cranking 1to4 PRINTED UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only 11 612 20 saged 44 6 6561 HOUVN ZI 512 JO 631716 Ni Don
40. E d Manual Terminal Br 7 a 5 a iu 22006 Fig 3 Full automatic distributor Cover re moved Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section D Page 2 Distributor Maintenance LUBRICATION Do not remove pipe plug in distributor oil reservoir This reservoir back of the shaft bushing is filled with light engine oiland sealed before the unit is shipped The supply of oil is sufficient to last for 25 000 miles of operation under normal conditions Thus the plug need not be removed oftener than every 25 000 miles or at time of overhaul for lubrication except when unusual heat or other Operating conditions are experienced Grade SAE 20 oil should be added when needed Seal the plug with sealing compound that will hold against oil trace of high melting point ball bearing grease should be placed on the breaker cam every 1000 miles Every 5000 miles put one drop of light engine oil on the breaker lever pivot and a few drops on the felt wick under the rotor Inspection The cap should be removed at regular in tervals and the contact points rotor and cap examined Check the high tension wiring for frayed or damaged insulation and poor connec tions at the cap or plugs Replace if necessary Replace the cap or rotor if they arecracked or show carbonized paths indicating the secondary current is leaking to ground over the surface of the mater
41. ER HIGH INDICATOR LIGHT T INSTR LIGHT 3 69 JUNCTION BLOCK T B HD LT LEADS amp 18 PARKING FEED ARKING 1T LEADS o LIGHT VOLTAGE TEMP DIVIDER GROUND GA L PRESS GA dem ey A amt ee oe e ony AS 5 ED YY GN COIL TO DIST a N 38 L TACHOMETER LIGHT CONNECTOR 18 ra SWITCH Ne IGN amp START SWITCH LHD 1 DOME LIGHT STOP LIGHT SWITCH DISTRIBUTOR LETTER A BATTERY GROUND CAB GROUND BATTERY CAB LETTER INSTR BUS BAR HORN PUSH BUTTON 14 LIGHTER m ENGINE GROUND LETTER P EZE ag JUNCTION BLOCK 8 999 rg OW OR aval HHH 1155 I 83 pagg 14 GA 12 GA 16 GA REGULATOR MOTOR 7 LL IX CONNECTORS HORN BUTTON Lt 5 H BATTERIES JA Fig 7 Wiring circuit diagram 12 Volt System R 185 to R 210 RF 190 and RF 210 trucks GN SW TO IGN COIL Pe Bad e 4 HORN 8 STOP LT FEED ORN amp HORN RELAY FEED D Uu z 009 4 v 6 EAD LIGHT GROUND VOLTAGE DIVIDER FEED ATURAL WITH CIRCUIT NATURAL WITH CIRCUIT NATURAL WITH CIRCUIT
42. MOTOR TRUCK SERVICE MANUAL 4 1 CRANKING MOTORS Connector Field coil amp Magnetic switch Cover ru band ju Drive housing Oiler Drive spring Sag NIS 5 SAA SS Commutator Brush Armature Drive pinion A 22749 Comm end frame Fig 3 Delco Remy Starter 1107967 Magnetic switch Thru bolt Oiler Connector Terminal Cover band Oiler Grease plug Bronze Gear housing bearing PANES SEY Y Oil er LAY S ANS NE Brush NM UNE mia i pa Armature Ks MA 2 Field coil qe Reduction Commutator gears Gea Bendix drive Drive housing A 22747 Comm end frame Fig Delco Remy Starter 1108217 Cover Field Magnetic band switch Connector Terminal Gear housing Oiler j Bronze lt nd M bearing es pS ANGSTY gf MN Brush Comm end frame Armature Drive housing 22660 Fig 5 Delco Remy Starter 1109001 lations ofdustand grease and from normal wear ofparts This is particularly desirable oncom mercial vehicles where maintenance of oper ating schedules is of especial importance In addition to the cranking motor itself the exter nal circuit between the cranking motor and the Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section J Page 2 battery must be kept in good condition
43. PRACTICE The date received battery type code marking truck model and chassis serial num ber must be entered ona separate record card for each battery The specific gravity of each cell must be recorded on the card under TEST RECORD The date and the inspector s initials should also be shown in the space provided Any bat tery showing a specific gravity reading of less than 1 225 must be placed on the charging line and brought up to 1 280 1 290 at 80 degrees F battery temperature Subsequent inspections of the battery shall be made every thirty days and the specific gravity readings recorded and distilled water added if necessary This procedure shall fol lowduring the stay of the battery inyour stock Upon delivery of battery in a truck the record card shall be completed by recording L LINE MOTOR TRUCK SERVICE MANUAL the specific gravity readings of each cell date of delivery truck model and chassis serial number and the name of the purchaser The card will then be filed in a manner similar to the Customer s Record Card If the battery is delivered in a truck being transferred in another District the battery record card shall accompany the battery and shall be continued by the receiving branch Battery Maintenance The Ft Wayne and Springfield factories are exercising every care in the handling and rotation of batteries to assure the delivery of a fresh and fully charged battery with each and every t
44. PROPER SPECIFIC GRAV ITY READINGS 3 KEEPING OF FULL AND COMPLETE RECORDS OF THE BATTERY ON THE BATTERY RECORD CARD FORM CTS 7 4 PROPER AND CONSISTENT ROTATION OF BATTERIES IN STOCK DELIVERING THE OLDEST BATTERIES FIRST 5 INSTRUCTIONS TO THE CUSTOMERS IN THE PROPER CARE OF THE BAT TERY AND A CAREFUL STUDY OF THE REQUIREMENTS ON THE BATTERY AND CORRECTIONS FOR SAME IN THE CUSTOMER S TRUCK General Instructions Do not add anything other than distilled water or drinking water which is colorless tasteless and odorless to a storage battery The use of patent electrolytes or battery dopes are injurious and void the guarantee Use a strong solution of sodaand hot water for removing terminal corrosion and cleaning the battery To prevent corrosion apply vase line or cup grease to the terminals Moist Uncharged Storage Batteries To preparea battery for service which has been shipped dry all cells should be filled to 3 8 above the tops of the spacers with the electrolyte specific gravity of 1 345 CAUTION NEVER POUR WATER INTO SULPHURIC ACID Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section B Page 5 Important Instructions To prepare l 345 specific gravity electro lyte from full strength sulphuric acid stir con stantly while adding one volume of 1 835 acid to two volumes of water THIS MUST BE DONE VERY SLOWLY AS A GREAT
45. WIPER WIPER STOP D TAIL TRAILER STOP LIGHT scu rug TRAILER LIGHT odios B 7090 L 2824 25 2 11 3 AJ C lt 1 et o H gt p gt Donated by John amp Susan Hansen For Personal Use Only INTERNATIONAL VA IVA L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section A Page 1 CIRCUIT DIAGRAMS Electrical circuits for the various L Line trucks are illustrated on following pages Cables are protected wherever necessary by loom or conduit and by rubber grommets to prevent chafing where contact is made with the chassis cab body Cables are also securely clipped at important points and connectors are used to facilitate inspection and servicing All electrical connections must be kept tight and clean Wiring Harness Individual Cable Circuit Identification Wiring harness cable circuit identification has been established by Number Coding im printing numerals atregular intervals along the individual cables except for shortcables which are numbered only at the ends The prime purpose of cable identification is to facilitate wiring harness installation since in harness generally only the extreme ends of the indivi dual cables are visible The accompanying circuit numbered
46. actical For this reason the chart on each circuit diagram specifies the proper gauge cable to be used and which can be made up locally from bulk stock Circuit Numbers And Circuit Names CIRCUIT NO CIRCUIT 1 Generator field circuit 2 Generator armature circuit 3 Generator ground circuit 4 Generator regulator to ammeter or shunt 5 Ammeter or shunt to starter switch 6 Battery to starting motor switch mounted on starting motor 7 Battery ground including master switch if in this circuit 8 Shunt to ammeter positive 9 Shunt to ammeter negative 10 Circuit breaker common feed to any point fed from regulator Bat 11 Ignition switch feed or magneto ground 12 Ignition switch to ignition coil or booster switch to booster coil 13 Magneto ground 14 Magnetic starting motor switch to push button switch to feed 15 Main light switch feed 16 Light switch HT to service headlight or dimmer switch 17 Dimmer switch to upper beam andto beam indicator 18 Dimmer switch to lower beam Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL L LINE MOTOR TRUCK SERVICE MANUAL Section Page 2 VA V 19 Lightswitch Bod to blackoutdriving lamp 46 12 Volt radio circuit including radio including resistor Inaster switch 20 Light switch BHT to parking lamps or 47 Slip ring feed marker light 48 24 Volt radio feed 21 L
47. and feed 66 Auxiliary generator starter to transfer 37 Outlet socket or junction block switch including starter or relay 38 Dome light circuit including breaker and switch 67 Emergency stop switch ground 39 Map light circuit 68 Battery interconnecting cables 40 Instrument light circuit 69 Resistor to ground terminal on trailer coupling 41 Starting motor to battery series paral lel switch hook up 70 Regulator ground 42 Series parallel switch Bt to battery 71 Windshield wiper circuit 43 Series parallel switch A to battery 72 Low transmission oil pressure indicator circuit with feed 44 Series parallel switch to ground 73 Radio terminal box to ground 45 Series parallel switch B to starting motor 74 Series parallel switch to solenoid relay Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section Page 3 1295 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 Stop switch circuit SW to SS on blackout SW Fuel pump control feed Fuel pump switch to fuel pump left side Fuel pump switch to fuel pump right side Fuel gauge sender ground Ignition coil to distributor Battery to starting motor switch or term block including master switch Starting motor switch or term block to
48. ark Plugs In most cases it is possible toremove each sparkplug from theengine byhand Place each spark plug and its gasket in a suitable holder in the order of removal from the engine PRINTED IN UNITED STATES OF AMERICA Visual Inspection A Gaskets If the gaskets are not flattened Fig 1 or compressed itis an indication that the spark plugs have not been properly tightened to pre vent blow by between the spark plug and cylin der head This condition results in excessive burning of the electrodes and overheats the in sulator tip which may cause preignition 4 vy vU uk E 4 i lt Sis Ly 2 fe o ns J Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL 22 L LINE MOTOR TRUCK SERVICE MANUAL Page Z Ds If the gaskets are flattened or compressed to the point where they have become distorted out of round or torn it is an indication that the spark plugs have been tightened to the ex tent that damage may have been inflicted on the spark plug itself Fig 2 Excessive torque often causes strains on the steel shell of the spark plug which result in cracked insulators distortion of metal shell and gap setting as well as blow by between the component parts of the spark plug 9 AMD 2 AN S0 TH e ad by A 23172 If the gasket is properly compressed ap proximatel
49. ated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS R 110 THROUGH RF 210 NOT RA 120 RA 140 RD 372 ENGINE MODELS EU 52 RD 406 RD 450 GENERATOR Delco Remy DR 1100019 DR 1102785 DR 1102785 Field current at 6 volts 1 85 2 03 1 90 2 05 1 90 2 05 Cold output i cee ees F 45 VOUS 9 ae 8 RPM uou usd do we 8 T 2450 Hot output Amperes Controlled Volts i by current au Gls 0S x oe NC wd Ow wow WSS DES OO OH Ow age R P M POeBUISFOF ales 6 0 RWS OHS E s Teva du os qo a o c vow d volt and current Brush tension ounces 28 28 Bearing commutator end bronze bronze bronze Bearing drive end TTE ball ball Rotation viewed from drive end CW CW CW Type Of 6 2x99 belt belt belt 8 5 Z fi Q zs C O NN 2 2 lt p suorjeorroedg INX LSAS Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS RA 120 RA 140 ENGINE MODEL SD 220 GENERATOR LOW SPEED CUT IN Delco Rery s os settee acs av ects S CE DR 1105876 Field current at
50. ay indicate cabletrouble Care should be taken when installing a ca ble terminal It should never be hammered into place To do so may drive some of the active material from the battery plates into the bottom of the battery container or crackthe cellcover Also some metal may be shearedfrom the post making it too small for good contact when the next replacement is necessary The best prac tice is to pry the jaws of the terminalapart be fore slipping it over the post Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section C Page 1 IGNITION COILS 27 Secondary Distributor 7 3 ee ven i e d Battery gnition coi A 22612 Fig Schematic wiring diagramof the primary circuit of an ignition system DELCO REMY MODEL 1115327 IGNITION COIL The Delco Remy Model 1115327 Ignition Coil is oil filled and hermetically sealed to prevent the entrance of moisture The high tension terminal is protected by a bakelite in sulator which has high resistance to leakage acrossits surface andis notdamaged by leakage which might occur The coil should be mounted vertically with the high tension terminalddown or horizontally withprimary terminals in same horizontal plane Make sure the coilis mounted so the case is grounde
51. beenused are iden tified by a rusty brown to grayish tan powdery deposit indicating a balancedignition andcom bustion condition Fig 7 A 23177 Fig 8 5 NORMAL CONDITIONS where highly leaded gasolines have been used are identified usually by white powdery or yellowish glazed deposits Fig 8 Such deposits or ments do not interfere with spark plug ation and should merely be cleaned off at regu lar service intervals A 23169 Fig 9 C Conditions Of Electrodes The extent of service and mileage to which a spark plug has been subjected is generally best indicated by the degree ofwear ofthe elec trodes When the center electrode has become worn away or the ground electrode has become so badly eroded at the sparking area that re Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL AAA SYSTEM Section L LINE MOTOR TRUCK SERVICE MANUAL Page 4 VN V setting of the gap is either difficult or impos sible the spark plug is not fit for further effi cient engine service even if cleaned D Preliminary Examination If the spark plug in question exhibits insu lator cracks wornelectrodes or other obviously unsatisfactory conditions the spark plug does not warrant further attention and should be dis carded Cleaning And Adjusting A Remove Gaskets Regardless of the condition of the old gas kets they should be removed from the spar
52. bracket can be tilted to one side Fig 3 On positive grounded regulators the flat point is in the upper contact bracket so the bracket must be removed for cleaning the points A flat file cannot be used successfully to clean the flat contact points since it will not touch the center of the flat point where point wear is most apt to occur NEVER USE EMERY CLOTH OR SANDPAPER TO CLEAN THE CONTACT POINTS Spoon or riffler file To clean contact points lt gt loosen upper contact gt bracket mounting screws A 22532 Fig 3 Use spoonor riffler file to clean flat contact points in regulator THREE UNIT REGULATOR CHECKS AND ADJUSTMENTS Cutout Relay The cutout relay requires three checks and adjustments air gap point opening and closing voltage The air gap and point opening adjustments must be made with the battery disconnected Air gap oS check with N points just touching Adjusting screws loosen to set air gap A 22608 Fig Air gap check and adjustment Battery must be disconnected when this check is made AIR GAP Place fingers on armature directly above core and move armature down until points just close and then measure air gap between armature and center of core Fig 4 On multiple contact point relays make sure that all points close simultaneously If they do not bend spring finger so they do adjust air gap loosen two screws
53. ction of all parts Never clean the armature or fields in any degreasing tank or with greasedissolving materials since these may damage the insulation The ball bearing should be cleaned and repacked with a good grade of ball bearing grease The com mutator should be trued in a lathe and the mica undercut if necessary All wiring and connec tions should be checked Rosin flux should be used in making all soldered connections ACID FLUX MUST NEVER BE USED ON ELECTRI CAL CONNECTIONS Checking Inoperative Generator Several conditions may require removal of the generator from the engine and further checking of the generator as follows 1 NO OUTPUT Remove cover band and check for sticking or worn brushes and burned commutator bars Burned bars with other bars fairly clean indi cate open circuited coils If brushesare making good contact with commutator and commutator looks okay use test leads and light and check as follows a Raise grounded brush check with test points from A terminal to frame Light should not light If it does the generator is grounded raise other brush from commutator and check field commutator and brush holder to locate ground b If generator is not grounded check field for open circuit c If the field is not open check for shorted field Field draw at 6 volts Should be 1 75 to 1 90 amperes Ex cessive current draw indicates shorted field d If trouble has not yet been located remo
54. d and that the leads are tightly connected to the coil terminals If the coilis defective it must be replaced since the coil can not be repaired But before a coil is discarded it should be carefully checked ona good tester to determine that it is actually defective Construction and Operation The ignition coil is a pulse transformer that transforms or steps up the low battery or generator voltage to the high voltage necessary to jump the gaps at the spark plugs in the en gine cylinders This voltage may reach as much as 20 000 volts The ignition coil contains three essential parts a primary winding consisting of a few hundred turns of relatively heavy wire a sec ondary winding consisting of many thousand PRINTED IN UNITED STATES OF AMERICA Sealing nipple High tension terminal E Coil cap Primary terminal M CES Spring h f 3 washer 7 7 A E Sealing gaskets Secondary winding ACE e rov Wi PT wae Primary winding Coil gt rm Lamination E gt M if Porcelain insulator A 22552 Fig 2 Cutaway view of oil filled coil turns of very fine wire and laminated soft iron which serves concentrate the magnetic field lhe primary winding is assembled around the outside of the secondary winding and the lam inated iron is distributed so that one por
55. d firmly in place during check so that blade touches regulator base and shield at same time This temporarily cuts out voltage regulator unit Turn on lights and accessories to prevent high voltage during the test Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section H Page 8 With ammeter connected as in Fig 13 and regulator at operating temperature operate generator at 50 per cent above rated output speed and note current setting If necessary to adjust remove cover and adjust in same manner as voltage regulator unit Fig 11 by turning adjusting screw clockwise to increase current setting or counterclockwise to decrease setting See CAUTION note under Voltage Setting of Voltage Regulator If unitis badly out of adjustment readjust as explained under REGULATOR SPRING REPLACEMENT 2 JUMPER LEAD METHOD Remove the regulator cover and connect a jumper lead across the voltage regulator contact points Fig 13 Turn on lights and accessories to prevent high voltage during the test With generatoroperating 50 percent above rated output speed and with regulator at Operating temperature note the current setting 3 BATTERY DISCHARGE METHOD Partly discharge battery by cranking the engine for 30 seconds with ignition turned off Never use cranking motor more than 30 seconds continuously since this would overheat and damage it Immediately after cranking start engine turn on lights and accessori
56. d spring support upward carefully with small pliers until contact is made with screw head Final setting of the unit should always be approached by increasing spring tension never by reducing it If setting is too high adjust unit below required value and then raise to exact setting by increasing spring tension Or H 4 a Variable resistance Generator A 22620 Ammeter Voltmeter Fig 10 Voltmeter ammeter and variable resis tance connections for checking voltage regulator setting by the variable resistance method Adjusting screw turn to adjust setting Fig 11 Adjusting voltage regulator setting If the unit is badly out of adjustment refer to section headed REGULATOR SPRING RE PLACEMENT After each adjustment and before taking voltage reading replace the regulator cover reduce generator speed until relay points open and then bring the generator back to speed again VARIABLE RESISTANCE METHOD Con nect ammeter into charging circuit at terminal of regulator with 1 4 ohm variable resistance in series Connect voltmeter from regulator BAT terminal to ground as shown INTERNATIONAL V L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only in Fig 10 Increase generator speed to 25 per cent above rated output speed less than 8 amperes is obtained or less than 4 amperes on low outp
57. d to operate at a predetermined number of cycles per second to produce its character istic warning signal The pitch of the horns de pends upon the number of vibrations per second the high note horns having the greater fre quency Conditions Affecting Horn Performance The following conditions affect the per formance of the horns and should be checked before attempting to make any adjustments to the instruments PRINTED IN UNITED STATES OF AM RICA Low Horn Voitage If the horn produces a weak signal the voltage at the horn should be checked Connect a voltmeter from the horn terminal to ground whenchecking horns having one terminal Con nect the voltmeter across the horn terminals when checking horns having two terminals The voltage readings should not be less than 5 25 volts six volt system or 11 volts twelve volt system A lower reading would indicate either a low battery ora high resistance in the horn circuit Low Battery Check the battery with a voltmeter or hy drometer for condition of charge If low the battery should be recharged Loose or Corroded Connections in Horn Circuit Clean and tighten connections wherever necessary Check for defective wiring by con necting separate testleads from the horn to the battery loose connection or poor contact at the horn push button switch may cause the horn to operate intermittently Shunt around the horn button to determine whether there is poor contact at t
58. date will be found stamped on the positive connecter button on the cell adjacent to the positive terminal cell See Fig 2 In the first row are two symbols the first is the month shipment for example 8 9 which decodes August 1949 In the third row the second space is used to indicate whether the battery was built dry or wet If there is no symbol in the space the battery was built wet If the space contains a letter Y the unit was built dry If the letter Y is encircled thus the battery was built dry and made wet before shipment PRINTED IN UNITED STATES OF AMERICA the secondis the year of The following chartis the key to the code datings found on Auto Lite batteries used in International Motor Trucks of later manufac ture Month Year Month Januar Februar March 1949 9 April 0 Ma 1951 1 June 6 1952 2 Jul 1953 3 August 8 1954 4 September 9 1955 5 October 1956 6 November 7 Atmospheric Temperature Affects Battery Capacity The specific gravity of the electrolyte distilled water and acid solution must be maintained at 1 225 to 1 250 andthe level of the solution should be at the star level incellcov ers fully charged batte To eliminate the possibility of harmful sulfation of plates a battery with a specific gravity of 1 225 or less should be recharged to 1 280 1 290 at 80 degrees F battery temper ature The following cbart show
59. dinary soldering methods NOTE Regardless of the type of con struction never operate the cranking motor more than 30 seconds at atime without pausing to allow the cranking motor to cool off for at least two minutes Overheating caused by ex cessively long cranking periods may seriously damage the cranking motor When checking the brushes make sure they are not binding and that they are resting on the commutator with sufficienttension to give good firm contact Brush leads and screws should be tight If the brushes are worn down to one half their original length compare with new brushes they should be replaced Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section J Page 3 Note the condition of the commutator If it is glazed or dirty it can be cleaned in a few seconds by holding a strip of number 00 sand paper against it with a piece of wood while the cranking motor is operated brush seating stone can also be used for this purpose Move the sandpaper or stone back and forth across the commutator while the armature is spinning Never operatethe ranking motor more than 30 seconds at a time without pausing for afew min utes to allow the cranking motor to cool Blow out all dust after the commutator is cleaned If the commutator is rough out of round has high mica or is extremely dirty it will re quire turning down in a lathe and underc
60. e resistance Voltmeter ZZ ZZZZZZ ZZZ To battery A 22877 Fig 2 Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section H Page 1 REGULATORS Three Unit Regulator The Delco Remy three unit regulator 15 designed for use with shunt type generators with externally grounded field circuits The regulator contains a cutout relay a voltage regulator and a current regulator Fig 1 Voltage Cut Current Cut out regulator relay regulator 4 22609 Fig Three unit regulator Cover removed to show the Cut out relay Current regulator and Voltage regulator Cutout Relay The cutout relay has two windings assem bled on one core a series winding of a few turns of heavy wire and a shunt winding of many turns of fine wire The shunt winding is shunted across the generator so that generator voltage is impressed upon it at all times The series winding is connected in series with the charging circuit so that generator output passes through it Fig 2 Current Cutout Voltage Battery Series winding relay regulator regulator Bat Gen Field A 22740 Ammeter Fig 2 Wiring circuit of three unit regulator PRINTED IN UNITED STATES OF AMERICA The relay core and windings are assem bled into a frame A flat steel armature is attached to the frame by a flexible hinge so that it is centered just above the end of the core The arma
61. e i A o 52 4 k ET OR EEI ES ORT RIA EE NN MLE Trew en B dar eet IR N COPIE 9 THRU BOLT 2 COMMUTATOR AND SPRING m ES ARMATURE COMMUTATOR END FRAME DRIVE END FRAME A 30520 2 Sectional View of Generator Delco Remy Model 1105876 onu Ran 8 E x E 2 ri O ZU ZU c 7N 4 lt r1 Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section E Page 1 GENERATORS Ae g Fan Commutator m ae Armature terminal end frame Brush Field tom Field coil Bearing ja Oiler 4 wies _ bearing Brush arm DE end Ol Commutator reservoir Cover band Pole shoe Thru bolt A 22543 Fig Sectional view of generator DELCO REMY GENERATORS MODELS 1102674 AND 1102714 The Delco Remy Models 1102674 and 1102714 Generators Fig 1 are 6 volt 4 9 16 inch diameter frame size ventilated two brush Shunt units with a ball bearing supporting the armature at thedrive end and a bronze bushing in the commutator end They are force draft ventilated by means of a fan mounted back of the drive pulley which rotates w
62. ed and the cranking motor operates slowly or not atall the battery may b run down Or there may be some mechan icalcondition in the engine or the cranking mo tor thatis throwing a heavy burden on the crank ing motor This imposes a high discharge rate on the battery whichcauses noticeable dimming of the lights Check the battery with a hydro meter If it is charged the trouble probably lies in either the engine or cranking motor it self In the engine tight bearings or pistons or heavy oil place an added burden on the cranking motor PRINTED IN UNITED STATES OF AMERICA Lowtemperatures also hamper cranking motor performance since it thickens engine oil and makes the engine considerably harder to crank and start Also the battery is less efficient at low temperatures In the cranking motor a bent armature shaft loose pole shoe screws or worn bearings any of which may allow the ar mature to drag will reduce cranking perfor mance and increase current draw In addition more serious internal damage is sometimes found Thrownarmature windings or commutator bars which sometimes occur on overrunning clutch type cranking motors are usually caused by excessive overrunning after starting This is aresult of such conditions as the driver s keeping his foot on the cranking motor switch too long after the engine has started the driver s opening the throttle too wide in starting or improper throttle cracker adjustment Any of
63. ed in proper rotation but that they should be properly identified by stamping the letters IHC on the center cell connector button Battery Record Cards Form C TS 7 were to be notated with this information Customer Record Cards were to bear a nota tion to the effect that the battery was past the four months code dating PROPER AND CONSISTENT ROTATION OF BATTERIES IN STOCK MUST BE FOL LOWED AND THE OLDEST BATTERIES ACCORDING TO CODE DATINGS DELIVERED FIRST Strict Adherence to Instructions Necessary All persons who have occasion to handle batteries or battery transactions should thor oughly familiarize themselves with the instruc tions pertaining to maintenance of batteries policy There should be no departure from the instructions as outlined It must be remembered that while the manufacturer is under certain obligations in accordance with the warranty policy of the batteries we too are not absolved of obligation to the manufacturer to do our part of the arrangement and policy It is felt that of all the instructions outlined herein that the following are the most impor tant and no excuse can be accepted for depar ture from them 1 REMOVAL ALL BATTERIES FROM THE TRUCKS AT THE TIME THEY ARE RECEIVED AT THE BRANCH AND KEEPING THEM IN THE ATTACHMENT ROOM OR BATTERY ROOM UNTIL THE TIME OF DELIVERY 2 INSPECTION OF BATTERIES EVERY THIRTY DAYS AND MAINTAINING THEM AT THE PROPER WATER LEVEL AND AT THE
64. eed 16 head lt leads 46 indicator 14x16 L B feed 16 1 B head It lead 16x18 Parkin feed 18 Parking t leads 14x16 Tail lig 14 16 Stop light 14 Horn lead Horn relay feed 16 Instrument feed Fuel gauge emperature gauge ee pressure gauge Instrument lights Nat with cir etter ae wipe A 7 T IS Dome light 14 2 ga Ou p switch 22 Hom Horn Stop light switch b Stop relay E aea 4 Junction blocks A Tail a 18 ga 2m 16 ga 5 Connector QU Enlarged view E E T n lt Me A Trailer stop light NN AL ED XE E WS Park Head Light light 8 Horn button Fuel m O Regulator O 9 12 ga 14 6 DARRI Bat Fig 3 Wiring circuit diagram RC 160 series trucks Trailer tail light B 7179 SOLAWHS SOLL ANITA uonoes WALSAS AU IVODILOS ISM Donated by John amp Susan Hansen For Personal Use Only R H D For Models R 173 Starting push switch Fuel and R 183 switch eet 18 27 Windshield motor Windshield Generator MO 21 2 wiper switch motor Circuit 3 or TUYA breaker 7 j 20 Tint oF ue a Circuit Qa 3 2 7 breaker 4 6 5
65. es and note current setting with engine operating 50 per cent above rated output speed 4 LOAD METHOD If a load approximating the current regulator setting is placed across the battery during the time that the current regulator setting is being checked the voltage will not increase sufficiently to cause the voltage regulator to operate This load may be provided by a carbon pile or a bank of lights L LINE MOTOR TRUCK SERVICE MANUAL REPAIR SECTION Regulator Spring Replacement If it becomes necessary to replace the spiral spring on either the current or voltage regulator unit the new spring should first be hooked on the lower spring support and then stretched up until it can be hooked at the upper end Stretch the spring only by means of a screwdriver blade inserted between the turns or a similar manner do not pry the spring into place as this is likely to bend the spring supports After installing a new spring read just the unit setting as already described Replacing Contact Support Brackets Voltage or current regulator contact sup port brackets can be replaced by following the relationship illustrated in Fig 19 Note par ticularly that the connector strap is insulated from the voltage regulator contact mounting screws while it is connected to the current regulator contact mounting screws New bush ings should always be used when installing a contact support bracket since the old bushing may be distorted o
66. esistance after each voltage adjustment and then reduce and increase generator speed before taking the voltage reading PRINTED IN UNITED STATES OF AMERICA ELECTRICAL SYSTEM Section H Page 7 Regulator Jumper lead bridging voltage a regulator contact points s Y gt 2 X ETT AB Sr a LJ Ammeter Generator A 2264 Fig I3 Ammeter and jumper lead connections for checking current regulator setting by the jumper lead method Current Regulator Two checks and adjustments are required on the current regulator air gap and current setting The air gap on the current regulator is checked and adjusted in exactly the same manner as for the voltage regulator already described CURRENT SETTING To check the cur rent regulator setting the voltage regulator must be prevented from operating Four methods of preventing voltage regulator opera tion are available Regardless of the method used an ammeter must be connected into the charging circuit at the regulator BAT termi nal The first method should be used for pre liminary checks whenever possible since it does not require removalof the regulator cover The four methods are as follows 1 QUICK CHECK METHOD Insert screw driver blade through oblong hole in base of regulator until contact is made with shield around resistor Fig 12 Be sure to keep screwdriver at right angles to base and hol
67. g 50 082 1 4 075 6 4 020 vibrating 50 075 14 3 075 12 8 020 020 Current and voltage specifications apply only at operating temperature Operating temperature shall be assumed to exist after not less than 15 minutes of continuous operation with a charge rate of 8 10 amperes p 9 JNA ILSAS TVOIN LOATaA 3 Z m 20 2 C O Un rm 2 lt O 7 gt 2 C gt Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS 50 220 50 240 BD 269 RD 372 RD 406 RD 450 Cont R 6602 ENGINE MODELS SPARK PLUGS YOINAWY JO S31vY158 NI OalNiddd AC standard pro 44 Com 44 Com 45 Com 45 Com 43 Com 43 Com 82 Com Champion heavy duc J 7 J 7 J 8 J 6 J 6 J 6 5 Com Auto Lite service lion 5 5 AN5 AN5 AN5 BT4 AC hot eee sas 45 Com 45 Com 45 Com 44 Com 44 Com 44 Com Champion mod rate 5 J 8 J 8 J 8 J 7 J 7 Jet Auto Lite service AN7 AN7 AN7 AN7 AN7 m AC standard 44 Com 44 Com 45 Com 43 43Com 43 Com 82 Com gt Champion heavy 41 1 7 1 7 7 8 7 6 1 6 1 6 5 Com Auto Lite service AN5 AN5 AN7 AN5 AN5 AN5 BT4 AC cold E 43 Com 43 Com 44 Com 43 Com 43 Com 43
68. ge the battery for one hour before taking a final reading At the end of 52 hours the cell voltage of the battery while on charge at the proper rate should be between 2 5 and 2 7 volts at 809 F wash externally to Replace vent plugs and dry Battery is remove traces of acid now ready for service INSTALLATION OF CABLES When making replacement of original bat tery cables starting motor cables or other wires utilizing protective loom or grommets it is essential thatthe service cable be equipped with the same type loom or grommetprotection as was removed on the replaced cable or wire Cables that are replaced without proper loom protection create a fire hazard The wiring circuits on new vehicles are closely checked and approved by Underwriter Companies there fore the original circuits should be maintained both as to location and protective devices The loom or grommet is placed on cables for the purpose of safeguarding against chafing orcutting throughthe insulation at points where the cables contact the chassis When replacing cables customers trucks or when making sales of cables make certain that protective loom or proper grommets are provided where required The storage battery can deliver only what the battery cables are able to carrytothe elec trical system The battery cannot operate effi ciently if it has to overcome the resistance of a worn out corroded or undersize cable Faulty battery performance m
69. gulator setting b Oxidized regulator contact points which insertexcessive resistance into the generator field circuit so that out put remains low Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section H Page 4 L LINE MOTOR TRUCK SERVICE MANUAL c Generator field circuitopen within the regulator at the connections or in the regulator winding 5 BURNED RESISTANCES WINDINGS OR CONTACTS These result from open cir cuit operation open resistance units or high resistance in the charging circuit Where burned resistances windings or contacts are found always check car wiring before installing new regulator Otherwise the new regulator may also fail the same way 6 BURNED RELAY CONTACT POINTS This may be due to reversed generator polarity Generator polarity must be cor rected as explained on page 2 after any checks of the regulator or generator or afterdisconnecting and reconnecting leads Cleaning Contact Points The contact points of a regulator will not operate indefinitely without some attention has beenfound that a great majority of all reg ulator trouble can be eliminated by a simple cleaning of the contact points plus some pos sible readjustment The flat points should be cleaned with a spoon or riffler file On nega tive grounded regulators which have the flat contactpoint onthe regulatorarmatures loosen the contact bracket mounting screws so that
70. he push button switch Loose or Damaged Parts Horns usually have a rasping sound when vital parts are loose or broken loose dome may affect the tone Tighten all mounting nuts and replace all damaged parts Adjustment For Auto Lite Horn No HW 4007 1 Remove the horn dome To remove pry under the edge of the dome with a screw driver at a point approximately opposite the terminal Onhorns usinga gasket under the dome place the screwdriver between the dome bead and the projector and loosen with a twist of the screwdriver 2 Itisimportant thatthe horn circuitbreaker contact points be kept clean Rub briskly with crocus cloth then clean with linen tape and carbon tetrachloride Remove all residue by drawing a piece of clean tape between the contacts 3 Tighten all flange bolts 4 Tighten the two screws holding the circuit breaker with a socket wrench sure contacts are aligned and that the circuit Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section G Page 2 breaker spring does not rub against the armature bolt 5 Check the resistance of the resistor which is connected across the contact points Its resistance should be 2 5 to 2 8 ohms and is measured by placing a card between the contacts and measuringacross the resistor terminals 6 Check the armature air gap on all sides Adjust to 0495 by loosening the lock nut and turning thearmature Tighten the lock nut
71. hield wiper motor Generator Distributor 9 9999 9 Cx G ME RY Ignition coil te 7 CJ 6 G9 Dimmer switch Circuit breaker and terminal block assembly pr Starting motor NL s L O LLL relay Ba 2 or Ignition B or Bat T switch IF Windshield SS wiper Circuit F p switch XX breaker 7 B Circuit ari breaker Switc 71 40 Instrument light Speedometer N Instrument light M Tachometer M n Ammeter W Instrument light 5 Starting push switch TD 12 l6ga 7 7 D Fig Circuit Diagram 1 190 Series And Up Fuel guage sender unit 9 Circuit No or Cable Cable Color or i Gauge Description 1 14 Generator field 2 8 Generator arm 4 8 Regulator to am meter 5 8 Ammeter feed 11 14 Ignition switch feed 12 14 Ignition switch to ig nition coil 14 14 Starting 15 10 Light switch feed 16 12 Dimmer switch feed 17 12 High beam feed 17 14 High beam head light leads 17 16 High beam indica tor 18 14 Low beam feed 18 16 Low beam head light leads 20 14 Parking feed 20 16 Parking light leads 21 14 Taillight 22 14 Stop light 26 10 Horn and stop light feed 26 12 Horn and horn re lay feeds 21 I4 Instrument feed 21 16 Instrument feed 28
72. ial CONTACT POINTS That are burned or pitted should be replaced or dressed witha clean fine cut contact file The file should not be used on other metals and should not be al lowed to become greasy or dirty NEVER USE EMERY CLOTH CLEAN CONTACT POINTS Contact surfaces after considerable use may not appear bright and smooth but this is not necessarily an indication that they are not functioning satisfactorily OXIDIZED CONTACT POINTS May be caused by high resistance or loose connections in the condenser circuit oil or foreign mate rials on the contact surfaces or most com monly highvoltages Checkforthese conditions where burned contacts are experienced THE CONTACT POINT OPENING Must be set to specification Points set too closely may tend to burn and pit rapidly Points with excessive separationtend tocause a weak spark at high speed The point opening of new points may be checked with a feeler gauge Use ofa feeler gauge on used points is not recommended since the roughness of used points make it im possible to set the point opening accurately by this method A dial indicatoror a contact angle L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL N meter is recommended to check the point open ing of used points When necessary to check and adjust point opening with a feeler gauge proceed as follows Rotate breaker cam until breaker lever rubbing block is on the high point of the cam lobe
73. ightswitch R or HT on blackout switch to service tail light 49 Receptacle Auxiliary power outlet posi tive lead 22 Light switch H or S on blackout switch to service stop light 50 Receptacle Auxiliary power outlet nega tive lead 23 Light switch BS to blackout stop light 51 24 Light switch BHT to blackout tail light 52 6 Volt tap on taillight dropping resistor to 25 Horn switch including feed to horn or tail light horn relay 53 Electric brake control circuit 26 Horn relay feed and horn relay to horn 54 Fuel cut off circuit 27 Instruments feed instruments with polar ity 55 Flame primer low tension circuit a 56 Flame primer high tension circuit 57 Instrument panel ground 29 Fuel gauge sender to receiver 58 Compass light circuit 30 See illustrations Figure 1 m 59 Cab or hull ventilating fan circuit 60 32 Oil level gauge sender to receiver Ol Aalay generator field 33 Water and oil temperature gauge sender to receiver 62 Auxiliary generator armature 34 Low engine oil pressure warning light cir 63 Auxiliary generator ground cuit including feed 64 Auxiliary generator regulator to battery 35 High water temperature warning light cir including heater transfer switch cuit including feed 65 Auxiliary generator starter relay circuit 36 Oil pressure gauge sender to receiver including switch
74. ing any condenser tests BREAKDOWN is a failure of the insulating material a direct short between the metallic elements of the condenser This prevents any condenseraction LOW INSULATION RESIST ANCE or leakage prevents the condenser from holding a charge A condenser with low insu lation resistance is said to be weak All condensers are subject to leakage which up to a certain limit is not objectionable When it is considered that the ignition condenser performs its function in approximately 1 12 000 of a second it can be seen thatleakage can be large without detrimental effects It must be consid ered however in any condenser test HIGH SERIES resistance is excessive resistance in the condenser circuit due to broken strands in the condenser lead or to defective connections This will cause burned points and ignition failure upon initial start and at high speeds CAPACITY is built into the condenser and is determined by the area the metallic elements and the insulating and impregnating materials For a complete check of the condenser 15 desirable to use a tester which will check for the above four conditions Vacuum Automatic Vacuum controlled spark is combined with centrifugal automatic type distributors to ob tain greater economy and improved engine performance The centrifugal automatic spark mechanism is calibrated to give proper spark advance for the full load wide open throttle requirements of the particu
75. ion After the generator is reinstalled on the engine or at any time after leads have been disconnected and then reconnected to the gen erator a jumper lead should be connected MOMENTARILY between the BATTERY and ARMATURE terminals of the regulator before starting the engine This allows a momentary surge of current from the battery to the gener ator which correctly polarizes the generator with respect to the battery it is to charge Donated by John amp Susan Hansen For Personal Use Only NIA CTERNATONA L LINE MOTOR TRUCK SERVICE MANUAL T Page 1 HEADLICHTS Sealed Beam Headlights The optical parts are so constructed that the light source reflector lens and gasket are all assembled in one complete securely sealed unit Among the advantages of Sealed Beam head lights are a relief from glare in TRAFFIC LOWER BEAM because of better light dis tribution b maintained lighting efficiency since the optical parts of the unit are perma nently sealed against dirt moisture corrosion c longer lived filaments d re placement of complete optical unit in field assures original lighting efficiency thereby avoiding poor lighting results through use of improper lens reflectors or bulbs Sealed Beam headlights provide two sepa rate and distinct bearns and produce consider able more light than former type headlights There is a COUNTRY UPPER BEAM and a TRAFFIC LOWER BEAM The
76. ith the arma ture shaft The generator outputis regulated by the correct settings of the current and voltage regulator Generator Maintenance Generator maintenance may be divided into two sections normal maintenance required to assure continued operation of generator and the checking and repair of inoperative units Normal Generator Maintenance LUBRICATION The two hinge cap oilers should be supplied with 10 to 20 drops of light engine oil every 1000 miles of operation Do not oil excessively NEVER OIL COMMUTA TOR INSPECTION The cover band should be removed and the commutator and brushes in spected atregular intervals If the commutator is dirty it may be cleaned with 00 sandpaper Blow out all dust after cleaning NEVER USE EMERY CLOTH TO CLEAN COMMUTATOR If the commutator is rough out of round or has high mica it should be turned down on a lathe and the mica undercut PRINTED IN UNITED STATES OF AMERICA Worn brushes should be replaced They can be seated with a brush seating stone When held against the revolving commutator the abrasive material carries under the brushes seating them in a few seconds Blow out abra sive particles after seating brushes Check brush spring tension which should be approximately 24 28 ounces Generator Disassembly At regular intervals the actual mileage or time depending on the type of operation the generator should be disassembled for a thor ough cleaning and inspe
77. its must be checked to locate the trouble If the crank ing motor does not operate it will probably have to be removed from the engine so it can be analyzed in detail Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL Aj jn L LINE MOTOR TRUCK SERVICE MANUAL Page 4 VA Pole shoe Commutator Field coil Brush A 22800 Fig 6 Schematic wiring diagram of two pole four brush series wound cranking motor Field coil Commutator Brush Pole shoe A 22730 Fig 7 Schematic wiring diagram of four pole four brush series wound cranking motor Commutator Brush Field coil Pole shoe 22736 Fig 8 Schematic wiring diagram of six pole six brush series wound cranking motor
78. ittent surges current Each surge of current builds up a magnetic field in the coil The distributor then opens its circuit so that the magnetic field will collapse and cause the coil to produce a high voltage surge The second job that the distributor has is to time these surges with regard to the engine require ments This is accomplishedby the centrifugal and vacuum advance mechanism Third the PRINTED IN UNITED STATES OF AMERICA ELECTRICAL SYSTEM Section D Page 1 Rotor Cap Terminal V ge spring Weight spring Condenser Housing 92 t x t Weight base uw S Q Breaker cam A 22618 Bronze bushing Fig 2 Sectional view of distributor distributor directs the high voltage surge through the distributor rotor cap and high ten sion wiring to the spark plug which is ready to fire There are thus two separate circuits through the ignition distributor One of these is the primary circuit which includes the dis tributor contact points and condenser The other is the secondary or high tension circuit which includes the distributor cap and rotor DELCO REMY DISTRIBUTOR The Delco Remy Distributors used on BD and RD engines are full automatic units with centrifugal advance mechanism The SD engine uses adistributor having the vacuum automatic mechanism Eu GLA TE n EX LI UM LM E
79. justments are required on the voltage regulator air gap and voltage setting PRINTED IN UNITED STATES OF AMERICA AIR GAP To check air gap push arma ture down until the contact points are just touching and then measure air gap Fig 13 Adjust by loosening the contact mounting screws and raising or lowering the contact bracket as required sure the points are lined up and tighten screws after adjustment Adjusting screw turn to adjust closing voltage ANG Fig 7 cutout relay closing voltage AS i 5 m t Air gap check with points just touching A 22535 Fig 8 Voltage regulator air gap check Contact mounting screws loosen to set air gap VOLTAGE SETTING There are two ways to check the voltage setting the fixed resist ance method and the variable resistance method Figs 9 and 10 FIXED RESISTANCE METHOD With the fixed resistance method a fixed resistance is substituted for the external charging circuit by disconnecting the battery lead at the regulator and connecting the resistancebetween the regu lator BAT terminal and ground A test volt meter is connected in parallel with the fixed resistance as shown in Fig 9 The resistance must be 3 4 ohm for 6 volt units 1 1 2 ohms for 12 volt units 7 ohms for 24 volt units and must be capable of carrying 10 amperes with out any change of resistance with temperature changes See n
80. k plug before cleaning If new replacement gas kets are available the old ones should be dis carded B Degrease If Necessary Before abrasive cleaning any spark plugs which have oily deposits on the firing end or the outside of the spark plug should be degreased by brushing with gasoline naptha or other suit able solvent which will dry quickly by wiping with a cloth or by air blast Failure to do this with oil fouled spark plugs will result in pack ing ofthe cleaner abrasive inside the firing end of the spark plug C Apply Abrasive Blast Place the spark plug in the rubber cleaner adapter ofthe correctsize Hold the sparkplug at the terminalend and while applying the abra sive blast wobble the top of the spark plug in a circle By this method the abrasive will be able to properly clean the insulator tip and the electrodes Three seconds time shouldbe suf ficient to clean most spark plugs However ihe extent of cleaning time should be limited to only that which is necessary to clean off the deposits on the insulator nose Prolonged use of the abrasive blast will wear away the insu lator causing irreparable damage to the spark plug Visual inspection will indicate when the Spark plug has been properly cleaned Loose abrasive remaining inside the firing end should be removed by the use of the air blast jet on the cleaner Do not use picks screwdrivers etc to remove deposits inside the firing end of the spark plug
81. lar engine Indicator Vacuum unit support 2 Vacuum unit Return spring Diaphragm A 22617 Fig 4 Details of the vacuum advance mechan Sm PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section D Page 3 The use of the vacuumunit is accomplished by mounting it to the distributor clamp arm assembly The diaphragm in the unit is linked to the distributor so that advance and retard is obtained by moving the distributor in its mounting The movement of the diaphragm is actuated by vacuum from the engine manifold and a calibrated return spring When the engine is idling the vacuum unit has no action on the distributor When the throttleis opened slowly the vacuum is high and spark will be given additional advance to that of the centrifugal advance On full load wide open throttle when the vacuum is low or at high speed the vacuum unit will not advance the spark Under these low vacuum conditions Spark advance depends upon the centrifugal mechanism in the distributor Full Automatic lhere is no manually operated spark ad vance with this type of spark control thus making the variation of the spark dependent entirely upon the centrifugal automatic mecha nism Donated by John amp Susan Hansen For Personal Use Only 11 612 20 59389 je1uauo ddns 6561 SLO WOIMANY JO 631 1
82. lator circuits use a common resistor Fig 2 which is in serted in the field circuit when either the cur rent or voltage regulator operates second resistor Fig 2 is connected betweenthe regu lator field terminal andthe cutout relay frame which places itin parallel with the generator field coils The sudden reduction in field cur rentoccuring wheneither the current orvoltage regulator contact points open is accompanied by a surge of induced voltage in the field coils as the strength of the magnetic field changes These surges are partially dissipated by the two resistors thus preventing excessive arcing at the contact points L LINE MOTOR TRUCK SERVICE MANUAL Temperature Compensation Voltage regulators are compensated for temperature by means of a bi metal thermo static hinge on the armature This causes the regulator to regulate for a higher voltage when cold which partly compensates for the fact that a higher voltage is required to charge a cold battery Many current regulators also have a bi metal thermostatic hinge on the armature This permits a somewhat higher generator out put is cold but causes the output to drop off as temperature increases Regulator Polarity Some regulators are designed for use with negative grounded batteries while other regu lators are designed for use with positive grounded batteries Using the wrong polarity regulator on aninstallation will cause the regu lator contact poi
83. ltage between 2 4 and 2 6 volts Voltage between 2 35 and 2 55 volts Temp 110 degrees F battery is fully charged when the cell voltage values are as shown in above table and thereis no further rise in voltage over a period of two hours 7 Add water as necessary disconnect batteries from the charging line replace vent plugs wash the tops of the batteries and place in attachment room Excessive Evaporation of Electrolyte Indicates Overcharging When excessive evaporation of the elec trolyte is experienced you may be sure that it is an indication that the battery is being over charged Necessity for too frequent battery re charging may indicate that the battery is being undercharged PRINTED IN UNITED STATES OF AMERICA Battery Not to Blame for Failure When Conditions Adverse It has been shown that temperature plays an important part in affecting the capacity of a battery and that the colder the temperature the lower the battery capacity Bearing this in mind it will be seen thata fully charged battery is only partially capable at subzero tempera tures This fact coupled with the condition in which many engines are found brings about complaints regarding the size quality and construction of the standard equipment battery There are times when itis necessary to increase the size of the battery or starting motor but such action should not be considered a cure all for hard starting complaints d
84. n the generator voltage reaches the value for which the voltage regulator is adjusted the magnetic field produced by the two windings shunt and series overcomes the armature spring tension and pulls the armature down so that the contact points separate This inserts resistance into the generator field circuit so that the generator field current and voltage are reduced Reductionof the generator voltage re duces the magnetic field of the regulator shunt winding Also opening the regulator points opens the regulator series winding circuit so that its magnetic field collapses completely The consequence is that the magnetic field is reduced sufficiently to allow the spiral spring to pull thearmature away from the core so that the contact points again close This directly Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section H Page 2 grounds the generator field circuit so that gen erator voltage and output increase The above cycle of action again takes place and the cycle continues at a rate of 150 to 250 times a second regulating the voltage to a constant value By thus maintaining a constant voltage the gener ator supplies varying amounts of current to meet the varying states of battery charge and electrical load CURRENT REGULATOR ACTION When the load demands are heavy as for example when electrical devices are turned on and the battery isin a discharged condition the voltage may not increa
85. nnect a hotlead cable to the circuit breaker terminal marked BAT and atest light to the remaining terminal marked AUX If test light fails to light the circuit breaker is defective and should be re placed LIGHT SWITCH REMOVAL DELCO REMY 1 Pull light switch knob outward to head light bright position 2 Depress shaft release button Fig 9 on switch body and pull switch knob and shaft out of switch body 3 Remove ferrule nut by positioning a punch in one of the indentations in nut face and tap punch lightly turning nut in a counter clockwise direction 4 Unscrew switch retainer nut also shaft bushing out of switch 5 Remove various electrical cables from switch 6 The light switch pull knob can be re moved by inserting a thin tool in the smallhole in the knob and pushing the spring lock inside the knob forward toward knob end of switch Hold spring lock in forward position and pull knob off of shaft 7 Installation of thelight switch follows 8 Install electrical cables 9 Align flat on switch shaft with flat in rheostat assembly in switch see Fig 9 and push light switch shaft into its bore in switch body Install switch re tainer nut and ferrule nut Use same method for installing ferrule nut as prescribed for removal except turn nut clockwise 10 Align flat onlight switch knob with flat on shaft and push knob on shaft by fol lowing detailed instructions outlined below Instructions
86. nts to pit badly and give very short life As a safeguard against installation of the wrong polarity regulator all 1118300 type regulators have the model number and the polarity clearly stamped on the end of the regu lator base REGULATOR MAINTENANCE General Instructions l Mechanical checks and adjustments air gaps point opening must be made with battery disconnected regulator prefer ably off the vehicle CAUTION The cutout relay contact points must never be closed by hand with the battery connected to the regulator This would cause a high current to flow through the units which would seriously damage them 2 Electrical checks and adjustments may be made either on or off the vehicle The regulator must always be operated with the type generatorfor which it is designed 3 The regulator must be mounted in the operating position when electrical settings are checked and adjusted and it rnust be at operating temperature 4 After any tests or adjustments the genera tor onthe vehicle must be repolarized after leads are connected but before the engine is started as follows gt Repolarizing Generator After reconnecting leads momentarily connect a jumper lead between the GEN and BAT terminals of the regulator This allows a momentary surge of current to flow through Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section H Page 3
87. old start a spark plug must operate under extremely high temperatures in justa fewseconds and must withstand repeated terrific explosion pressures These conditions can be duplicated only in an engine Therefore the only reliable test ofa spark plug is to oper ate it in an engine under actual operating con ditions Removal of Spark Plugs A Disconnect Ignition Wires Detach ignition wires from each spark plug Most engines carry snap on type connectors which simply pull off Some have screw type terminal connections in whichcase it is neces sary toremove these terminal nuts before lift ing off the ignition wires B Select The Proper Size Deep Socket Wrench It is highly advisable touse the proper size deep socket type wrench to remove the spark plug from an engine Improper wrenches are often the cause of spark pluginsulator breakage C Loosen Each Spark Plug Two Turns Using the proper size deep socket wrench an extension shaft between wrench and handle is highly desirable loosen each spark plug two complete turns only All spark plugs loosen in a counter clockwise direction D Blow Out The Spark Plug Ports The action of loosening each spark plug two turns will also loosen any accumulation of dirt which may be embedded around the base of the spark plug Use a blast of compressed air to remove this debris and prevent its falling into the cylinder combustion chamber when the spark plug is removed E Remove Sp
88. or prevent normal ac tion of the drive mechanism The overrunning clutch drive is packed with lubricant during original assembly and requires no additional lubrication Never lubricate the commutator and do not attempt to lubricate the cranking motor while itis beingoperated Be sure tokeep grease or oil clean Lubricant should be kept in closed containers Periodic Inspection At periodic intervals the cranking motor should be inspected to determine its condition The frequency with which this should be done will be determined by the type and design of cranking motor as well as the type of service in which it is used Frequent starts as in city operation or door to door delivery service ex cessively long cranking periods caused by a hard starting engine condition excessively L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL NIWA dirty or moist operating conditions heavy vi bration all will make it necessary that the in spection checks be made at more frequent in tervals Generally speaking passenger car and other standard duty cranking motors should be inspected atapproximately 5 000 mile intervals Heavy duty units may not require as frequent inspection However where special operating conditions such as outlined above exist inspec tion at more frequentintervals may be required INSPECTION PROCEDURE Cranking motor action is indicative to some extent of the cranking motor condition Thus
89. ote on following page Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM L LINE MOIOR IRUCK SERVICE MANUAL Page 6 3 4 ohm 6 volt Regulator Fixed resistance 1 1 2 ohm 12 volt Regulator d 7 ohm 24 volt Connect to ground Generator A 22714 Voltmeter Fig 9 Fixed resistance and voltmeter connec tions to check voltage regulator setting by fixed resistance method Connections are simi lar for both two unit and three unit regulators NOTE With all 6 volt regulators having current ratings less than 15 amperes it is necessary to use 1 1 2 ohm fixed resistance to avoid interference from the current regula tor With all 12 volt regulators having current ratings less than 15 amperes a 2 1 4 ohm fixed resistance 3 4 ohm and 1 1 2 ohm re sistors in series must be used for the same reason With generatoroperating 25 percent above rated output speed and with regulator at oper ating temperature note voltage setting Cover must be in place To adjust voltage setting turn adjusting screw Fig 11 Turn screw clockwise to in crease voltage setting and counterclockwise to decrease voltage setting CAUTION If adjusting screw is turned down clockwise beyond normal adjustment range spring support may fail to return when pressure is relieved In such case turn screw counterclockwise until sufficient clearance de velops between screw head and spring support then ben
90. r damaged Radio By Pass Condensers The installation of radio by pass densers on the field terminal of the regulator or generator will cause the regulator contact points to burn and oxidize so that generator output will be reduced and run down battery will result If a condenser is found to have been connected to either of these terminals disconnectthe condenserandcleanthe regulator contact points as previously explained Current regulator UMS a B e Voltage sto abt gres iten i5 regulator Me EST Upper contact eA Men BN S cages Wi supports yin ie ae SUM m e S 15 AY d 5 V E mmy afr di tur ur or emm Ex 0722 _ Insulators A 22739 Fig 14 Relationship of insulators connector strap and upper contact support brackets in three unit regulator Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section I Page 1 SPARK PLUGS The sole purpose of a spark plug is to create a spark between the electrodes to ignite the fuel in the engine Therefore if anything is wrong with the spark plug that will prevent its firing all the other units in the electrical system will have functioned in vain From a c
91. r field DN D OME j 8 Generator arm 8 Regulator to am meter 8 Ammeter feed 14 Ignition switch feed 14 Ignition switch to ig nition coil 14 Starting 10 Light switch feed 12 Dimmer switch feed 12 High beam feed 14 High beam head light leads 16 High beam indica tor 4 Low beam feed 6 beam head ht leads 4 ing feed Parkins light leads 4 Windshield 12 wiper motor a Ignition switch Circuit Hor Ta y breaker 2lor jae Light Sf Circuit LRL A switch breaker or Bat Oil 4 Instrument light Generator Starting motor 14 ga Engine ground 49 49 L e 16 ga 83 em Ned Taillight Stop light Horn and stop light feed 12 Horn and horn re lay feeds 14 Instrument feed 16 Instrument feed 16 Fuel gauge 16 Fuel gauge 16 Temperature gauge 16 Oil pressure gauge 16 Instrument lights 14 Wiper switch feed 14 Ignition coil to dis tributor 14 Headlight ground 16 Natural with circuit letter or black Battery ground Engine ground Cab ground Battery cable Natural with circuit letter F or red Instrument bar Horn push button Fuel gauge ground Natural with circuit letter P or green c f Rm STE Temperature T E 26
92. rate of the smallest size battery according to the following chart Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section B Page 3 Batteries should remain on charge for a period of time sufficient to obtain normal volt age and specific gravity readings of each cell The required length of time will vary from 12 to 48 hours depending upon the state of dis charge of the battery at the time it was placed on the charging line Type of No of pie Battery Plates 2H 105 2H 105R 6 15 7 Amperes 2H 120 2H 120R 1 8 Amperes 2H 135R 9 Amperes 7 3H 136R es 8 Amperes 4H 152R 6 19 9 Amperes 8T 200 12 Amperes Temperature readings should be taken frequently to prevent the electrolyte tempera ture exceeding 110 degrees F at any time Should the temperature rise higher than 110 degrees F the charging should be discontin ued and the electrolyte allowed to cool The charging of the battery may then and only then be continued 6 Cell voltage is determined by a normal electrolyte temperature of 80degrees F Voltage readings are to be taken while the battery is on charge at the normal rate as specified in the foregoing chart The cell voltage of a fully charged battery on charge at the normal rate should read as follows Temp 80 degrees F Voltage between 2 5 and 2 6 volts Temp 100 degrees F Vo
93. rjeoryr2odg WALSAS WOM LOATaA ENGINE MODELS GENERATOR 50 Delco Field current at 6 volts AIHpereS s uuw wo oe e Cold output A IDDOTGS 4323a3 334 2 43 3 woo moo Ry n Rips oe wb oe PS xs Hot output Amperes Controlled Volts by current4 R p m regulator Brush tension ounces Bearing commutator end Bearing drive end TIT Rotation viewed from drive end Type of 4993 es GENERATOR LOW SPEED CUT IN Delco Remy Field current at 6 volts Cold output Hot output Amperes Controlled Volts by current4 R p m regulator Regulation 5 Brush tension ounces Bearing commutator end Bearing drive end Rotation viewed from drive end of 4 50 220 50 240 BD 269 RD 372 Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SPECIFICATIONS 1 70 1 95 1 70 1 95 1 70 1 95 1 70 1 95 50 50 50 50 4 5 7 5 7 5 1410 1410 volt and volt and volt and volt and current current current current 25 25 25 25 ball ball ball ball ball ball ball ball CW CW CW CW belt belt belt belt DR 1106758 DR 1106758 1 70 1 95 1 70 1 95 40 40 7 5 18 1165 1165
94. rmetically sealed type Rubber nipples on the high voltage terminals are valuable in preventing tracing or leakage of current across exposed surfaces If poor ignition performance is obtained and the coil is suspected of being the cause the coil may be tested on the truck or it may be removed for the test Donated by John amp Susan Hansen For Personal Use Only L LINE MOIOR TRUCK SERVICE MANUAL DISTRIBUTORS Distributors t ifs mes gt as Coil a heavy duty I A 22613 Showing re system circuit lationship of various units Fig 1 Ignition IGNITION DISTRIBUTORS The ignition system Fig 1 consists of the ignition coil condenser ignition distributor ignition switch low and high tension wiring spark plugs and a source of electrical energy battery or generator The ignition system has the function of producing high voltage surges and directing them to the spark plugs in the engine cylinders The sparks must be timed to appear at the plugs at the correct instant nearthe end of the com pression stroke with relation to piston position The spark ignites the fuel air mixture under compression so that the power stroke follows in the engine Function of Distributor The distributor has three jobs First it opens and closes low tension circuit between the source of electrical energy and the ignition coil so that the primary winding is supplied with interm
95. ruck delivered to the territory The territory must also follow this prac tice of rotation using the oldest batteries first as determined by the code datings stamped on the center cell connector button To facilitate truck movement in and around the District or Warehouse a service battery should be prepared having long cables and clip ends Battery Recharging Suitable and adequate equipment forbattery charging is available through the Motor Truck Service Section Chicago Office The general procedure in battery charging is as outlined 1 With vent plugs in place wash the top of the battery if necessary using a solution of water and common baking soda Rinse with clear water 4 Remove vent plugs from each cell 3 Fill the battery cells with pure distilled water to star level in cell covers 4 Connect battery to the charger unit in series connecting the positive terminal outlet from the supply line to the positive terminal post of the first battery Connect the negative terminal of the first battery to the positive terminal of the second battery and so on through the number of batteries being charged Do not attempt to exceed the capacity of the battery charging equipment in the number of batteries to be charged at one and the same time The last battery must have its negative terminal connected to the negative outlet of the charging unit 5 Adjust the charging rate in amperes to the lowest normal charge
96. s prescribed for the light switch control knob Flat on shaft 4 rpm Cm Knob stops here when IN fully installed A 23441 Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section G Page 1 HORN Contact point adjusting nut and screw Dome Contact point air gap Armature air gap adjusting nut L Contact points Spring plate Terminal i lose gap Armature Field coil Diaphram Auto Lite Horn No HW 4007 A 22744 Fig Electrically Operated Horn The electrically operated horns are vibrat ing type units that operate on a magnetic prin ciple to produce the warning signal Current from the battery flows through the windings within the horn power plant when the circuit is completed at the horn push button switch The magnetic attraction of the armature toward the pole causes a tension and slight movement of the diaphragm This movement opens the con tact points in series with the horn windings breaking the circuit When the current is in terrupted the armature returns to its original position relieving the tension of the diaphragm The slight return movement of the armature and diaphragm allows the contact points to close completing the circuit This cycle is repeated a great many times per second resulting in a rapid vibration of the diaphragm Each horn is designe
97. s the effect of atmospheric temperature on the capacity ofa battery 80 degrees above 0 Full 60 degrees above 0 88 Full 40 degrees above 0 75 Full 20 degrees above 0 62 Full Zero degrees 45 Full 20 degrees below 0 20 Specific Gravity Affects Freezing Point of Electrolyte Specific_gravity of the electrolyte deter mines the temperature at which a battery will be harmed or damaged by freezing Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section B Page 2 The following chart gives the freezing point of battery electrolyte at given specific gravities Electrolyte NUR Fr i Point F 1 280 90 degrees below 0 1 220 30 degrees below 0 1 210 20 degrees below 0 1 180 10 degrees below 0 1 160 Zero degrees 1 140 10 degrees above o 1 100 20 degrees above 0 1 000 32 degrees above 0 Battery Record Card Form CTS 7 The Form CTS 7 Battery Record Card is the record or history of each battery received and shipped The card has spaces provided for allnecessary information pertaining to the bat tery One of these record cards must be main tained for each battery and it should reveal the complete history of the unit while in your pos session Upon receipt of a shipment of trucks from one of the factories or from another Branch the batteries must be removed immediately and battery record cards filled out foreach battery THERE MUST BE NO DEVIATION FROM THIS
98. se to a value sufficient to cause the voltage regulator to operate Consequently generator output will continue to increase until the generator reaches rated maximum This is the current valuefor which the current regu lator is set Therefore when the generator reaches rated output this output flowing through the current regulator winding creates sufficient magnetism to pull the current regulator arma ture down and openthe contact points With the points open resistance is inserted into the generator field circuit so that the generator output is reduced As soon as the generator output starts to fall off the magnetic field of the current regu lator winding is reduced the spiral spring tension pulls the armature up the contact points close and directly connect the generator field to ground Output increases and the above Cycle is repeated The cycle continues to take place while the current regulator is in opera tion 150 to 250 times second preventing the generator from exceeding its rated maximum When the electrical load is reduced elec trical devices turned off or battery comes up to charge then the voltage increases to that the voltage regulator begins to operate and tapers the generator output down This pre vents the current regulator from operating Either the voltage regulator or the current regulator operates at any one time the two do not operate at the same time Resistances The current and voltage regu
99. sition L LINE MOTOR TRUCK SERVICE MANUAL Sometimes the armature spring Horn Relay Checks and Adjustments Three checks adjustments are required on the horn relay air gap point opening and closing voltage The air gap and contact point opening checks andadjustments should be made with the battery disconnected Air Gap The air gap should not normally require adjustment unless the relay has been misad justed Check theair gap with the points barely touching and adjust if necessary by bending the lower point support Contact Point Opening Check the contact point opening and adjust by bending the upper armature stop Closing Voltage To check the relay closing voltage connect a variable resistance of 10 ohms in series with the relay terminal and connect a voltmeter between the S and the B terminals as shown in Fig 2 With the horn button closed slowly decrease the amount of resistance in order to check the relay closing voltage Adjust the closing voltage by bending the armature spring post Bending down to increase the spring ten sion increases the closing voltage while bend ing up decreases the closing voltage NOTE Late type horn relay terminals do not carry any markings but relationship of the terminals is as shown in Fig 2 7 Switch closed Horn relay N SALE LLL To horns A 7 GS mm Sud IN 2 N Variabl
100. sitive positive positive positive positive positive 9 aseg 9 x gt 3 La WALSAS LOATaA TIVANVW 3OIA TJIS YOLOW 3NFTI 411 512 10 saved juauswayddns 61 HOWVIN 1 612 D2IH3WNY JO S34vV45 NI OAQ3ANIHg Donated by John amp Susan Hansen For Personal Use Only Cable Color or Description Generator fiel field Generator arm Regulator to amm _ 5 Ammeter feed Ignition switch feed Ign sw to ign coil tarting Light switch feed Dimmer switch feed Head de 1 Batte 16 indicator light m For Models R 153 L B feed ar SS an 163 16 L B head t 15 Light JN 1 Horn relay R H D 14 Ie 16 Parking feed 1 _ Starting push switch Windshield Parking light leads 5 MOOR 21 Tail light 17 L ol 2 i Ignition switch P d T Stop light T EN Horn to relay 16 i as 12 Horn relay feed MN NT F Dn e Windshield 16 Instrument feed Starting motor IW a wiper switch 18 Fuel gauge 18 3 DEL ui P 2 Circuit 18 Fuel gauge 18 Temperature gauge i 18 14 ga 14 STi 2 or P amp as ee breaker 36 18 O Gilt loa ge Lr EY breaker
101. t mark the distance between the centerlines of the headlights andare equal ly spaced from the center line of the chart Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section F Page 3 A horizontal line on the chart shall be placed ata level 3 inches below the height ofthe head light centers above the floor Each headlight must be adjusted so that the hot spot of the beam will be centered over the point of inter section of the vertical and horizontal lines In some states this aiming conflicts with ex isting laws and regulations wherever such is the case the legal requirements control and these instructions should be modified accord ingly Fig 6 illustrates the beam pattern to be attained PARKING LIGHTS 4 l M m W Ab CM ah aUe i E EN iul 4 E j i 1 M 3 QU t CM y Fig 7 The parking lights located just below the headlights are equipped with ordinary filament bulbs Should it become necessary to replace either a parking light lens or bulb remove the rim retaining screws as shown replace the necessary parts and reassemble CIRCUIT BREAKERS Independent current circuit breakers are used to protect the headlight high and low beam circuits parking lights tail lights stop lights and horn circuits from possible damage should a Short circuit occur
102. ter to ground negative 6 radio circuit including ratio master switch Direction signal left turn front Direction signal left turn rear Direction signal right turn front Direction signal right turn rear Direction signal feed circuit Voltage divider ground Voltage divider feed or instrument resis tor feed Overdrive relay to ignition switch Overdrive relay to overdrive governor including kickdown and overdrive switch Overdrive solenoid to ignition coil includ ing kickdown switch Overdrive solenoid to battery including relay feed Donated by John amp Susan Hansen For Personal Use Only 5 NM Section A L LINE MOTOR TRUCK SERVICE MANUAL TN Page 4 VWV gauge switch Underskirt tank Underskirt tank and right side auxiliary tank 30 29 Right side tank Underskirt tank and dual auxiliary tanks Left side tank 30 switch 30 31 Rear end tank Left side tank and right side auxiliary tank gauge switch 28 Underskirt tank and left side auxiliary tank A 22921 Fig Fuel tank to receiver circuits Because of the variety of possible combinations for these hook ups reference should be made to the above chart for proper connection of cables WOIMAWY JO SALVIS Q31IND NI Q3ANINg Donated by John amp Susan Hansen For Personal Use Only Cable Color or Description Fuel gauge sender unit _ 14 Generato
103. the cause of trouble by discon necting the lead from the regulator F terminal PRINTED IN UNITED STATES OF AMERICA with the generator operating at medium speed If the output remains high the generator field is grounded either in the generator or in the wiring harness If the output drops off the regulator is at fault and it should be checked for a high voltage setting or grounds High charging rate Discharged AND CHARGING RATE This is normalgener 3 DISCHARGED BATTERY ator regulator action Regulator settings may be checked as outlined in the following section 69 charging rate nderchargin Y d Discharged A 22614 4 DISCHARGED BATTERY AND LOW OR NO CHARGING RATE This condition could be due to a Loose connections frayed or damaged wires b Defective battery Low regulator setting c High circuit resistance e d Oxidized regulator contact points f Defects within the generator If the condition is not caused by loose con nections frayed or damaged wires proceed as follows to locate cause of trouble To determine whether the generator or regulator is at fault momentarily ground the F terminal of the regulator and increase gen erator speed If the output does not increase the generatoris probably at fault If the gener ator output increases the trouble is due to a A low voltage or current re
104. the insulator between the circuit breakers as shown in Fig 8 Remove circuit breaker from frame by pulling on terminal screws with pliers To install press circuit breaker into frame by hand A dead short in a circuit will cause the circuit breaker bi metal plate to heat suffi ciently and pull away from its contact points immediately cutting off the flow of current A partial short will cause intermittent current flow causing the lights to dim and flicker this should be taken as a warning and the vehicle brought to a safe stop as soon as possible In other units in addition to headlights a dead short canbe detected by the ammeter indi cating a heavy discharge momentarily until such time as the circuit breaker opens and the cir cuit is broken A partial short can be detected by abnormal fluctuation of the ammeter The two 2 terminal blocks in the assembly are used to connect circuits for fuel guage units dimmer switch feed cable side mounted fuel tanks fog lights directional signals etc Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section F Page 4 Testing The Circuit Breaker Should current flow in one of the circuits employing a circuit breaker be interrupted it is possible that there is a short in the circuit or that the circuit breaker is defective and is holding open To check for current flow through the circuit breaker remove the cables from both circuit breaker terminals and co
105. tion serves as a core for the windings and the re mainder asa shell aroundthe entire subassem bly This subassembly is then placed in the coil case and the remaining space nearly filled with insulating compound or oil and the coil cap assembled into place Fig 3 illustrates a heavy duty ignition coil used on motor coach truck and marine applications This coil also is hermetically sealed against the entrance of air or moisture and is oilfilled for greater insulation protec tion The fins cast the one piece case plus the oil filling permits improved heat radiation which is a factor in efficient ignition coil per formance Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section C Page 2 L LINE MOTOR TRUCK SERVICE MANUAL V T High tension terminal Primary terminals Coil cap Spring washer 2 ia Lamination One piece cast case Coil winding Porcelain insulator Fig 3 Cutaway view of heavy duty oil filled coil Coil case utilizes fins to aid in cooling for better ignition coil performance A 22544 Coil Service Ignition coils do not normally require any service except to keep all terminals and con nections clean and tight In addition the coil should be kept reasonable clean but it must not be subjected to steam cleaning or similar cleaning methods which may cause moisture to enter the coil unless itis of the he
106. ture has one or two contact points which are located just above a similar number of stationary contact points When the generator is not operating the armature con tact points are held away from the stationary points by the tension of a flat spring riveted on the side of the armature CUTOUT RELAY ACTION When the generator voltage builds up to a value great enough to charge the battery the magnetism induced in the relay windings is sufficient to overcome the armature spring tension and pull thearmature towardthe core so that the contact points close This completes the circuit be tween the generator and battery The current which flows from the generator to the battery passes through the series winding inthe proper direction to add to the magnetism holding the armature down and the contact points closed When the generator slows down or stops current begins to flow from the battery to the generator This reverses the direction that the current flows through the series winding thus causing a reversal of the series winding magnetic field The magnetic field of the shunt winding does not reverse Therefore instead of helping each other the two windings now magnetically oppose so that the resultant mag netic field becomes insufficient to hold the armature down The flat spring pulls the arm ature away from the core so that the points separate this opens the circuit between the generator and battery VOLTAGE REGULATOR ACTION Whe
107. uge Oil pressure gauge Dome light Instrument lights Ignition coll to dis tributor Headlight ground Battery ground Engine ground b ground Battery cable Horn button to con nector Fuel Enlarged view A A B 7181 9 mln Ee 5 2 2 m z AJ AJ C O 7 lt m 11 512 10 528984 ejuawalddag 61 HOUVW ZI SLO VOINAWY 20 S3LY1S8 CAILINN NI QA341NIHd Donated by John amp Susan Hansen For Personal Use Only Park Head Light light we Battery 2 i rey d F A Junction e Generator FECI 1 Distributor a Starting motor 7 4 or Hy 8 20 2 1 je ms T x ground ALIS 7 A 2 Ay 2 a Oil pressure ceo Dimmer a dune ea c UR Windshield wiper motor x i w 2 or P 591 hia PO Windshield AN reaker 1 or bat NN T wiper switch P Circuit b breaker Light switch LL 9 Instrument light 421 _L Speedometer Y beam indicator light light Fuel _Dome light Circuit No Cable Color or or Index Gauge Description _Letter Generator field _ Generator arm ___ Regulator to amm Ammeter feed Ignition switch feed Ign sw to ign coi Starting Light switch feed _ Dimmer switch feed Dui H B f
108. uring winter months Even when special equipment of this nature is installed it is still essential to l Use a lubricating oil with the correct body for Winter Service 2 Maintain distributer points in good condi tion and properly spaced 3 Have clean and properly spaced spark plug electrodes 4 Have good compression in the engine 5 Maintain alljoints and connections between the carburetor manifolds and engine in a gas tight condition 6 Ascertain that the carburetor choke valve is operating properly 7 Determinethat the engine is well grounded and that the ground straps are securely fastened to clean contacts Battery Warranties and Manufacturers Policy Storage batteries used in International Motor Trucks are limited to a free repair or replacement warranty of 90 days against defec tive material and workmanship beginning on the date the battery is placed in service In accordance with this arrangement service adjustments after 90 days are based on miles of service or months of service which ever occurs first Miles of service are men tioned for there are occasions when a customer will attain the limit of miles of service prior to the time limit set forth In such cases the adjustment will be made on miles of service and not on the time limit Auto Lite Batteries whether installed as factory equipment by the International Har vester Company or sold as replacements to Donated by John
109. ut 6 and 12 volt generators turn on lights to permit increased generator output Cut in resistance until output is reduced to 8 10 amperes 4 6 amperes on 6 and 12 volt gener ators having current ratings less than 15 am peres Operate until regulator reaches oper ating temperature Retard generator speed until relay points open then bring generator back to speed and note voltage setting Voltage readings must be taken with regulator at oper ating temperatureand with 8 10 amperes flow ing 4 6 amperes on low output units Cover must be in place NOTE Itis very important that the vari able resistance be connected at the BAT terminal as shown in Fig 10 rather than at the GEN terminal even though these terminals are in the same circuit An examination of the wiring diagram Fig 2 will show that the regu lation begins at the point where the shunt wind ings are connected to the series circuit Any small resistance added to the circuit between the generator and this point will simply be off set by a rise in generator voltage without affecting the output shown at the ammeter Blade of Oblong hole screwdriver must touch base and Shield shield 4 lt x Fig 12 Quick method for cutting out voltage regulator in order to check current regulator setting A 22536 Adjust regulator as previously explained In using the variable resistance method itis necessary to readjust the variable r
110. utting of the mica between the bars Quick Checks When in Trouble When trouble develops in the cranking mo tor system and the cranking motor cranks the engine slowly or not at all severalpreliminary checks can be made to determine whether the trouble lies in the battery in the cranking mo tor in the wiring circuit between them or else where Many conditions besides defects in the cranking motor can result in poor cranking performance To make a quick check of the cranking mo tor system turn on the headlights They should burn with normal brilliance If they do not the battery may be run down and it should be checked with ahydrometer Ifthe isina charged condition so the lights burn brightly operate the cranking motor Any one of three things will happen to the lights They will go out dim considerably or stay bright without any crank ing action taking place If the lights go out as the cranking motor switch is closed it indicates that there is a poor connection between the battery and the cranking motor This poor connection will most often be found at the battery terminals and correction is made by removing the cable clamps from the terminals cleaning the ter minals and clamps replacing the clamps and tightening them securely coating of corro sion inhibitor may be applied to the clamps and terminals to retard formation of corrosion If lights dim considerably as the cranking motor switch is clos
111. ve armature and check on growler for short circuit Donated by John amp Susan Hansen For Personal Use Only ELECTRICAL SYSTEM Section E Page 2 2 UNSTEADY OR LOW OUTPUT Check as follows a Check drive belt tension tension and b Check brush spring brushes for sticking Inspect commutator for roughness grease and dirt dirt in slots high mica out of round burned bars With any of these conditions the commuta tor must be turned down in a lathe and the mica undercut In addition with burned bars which indicate open circuit the open circuit condition must be eliminated or the armature replaced 3 EXCESSIVE OUTPUT Excessive output usually results from a grounded generator field grounded either in ternally or in the regulator Opening the field circuit disconnecting lead from terminal of regulator or generator with the generator Operating at a medium speed will determine which unit is at fault If the output drops off the regulator is causing the condition If the output remains high the field is grounded in the generator either at the pole shoes leads or at the F terminal L LINE MOTOR TRUCK SERVICE MANUAL 4 NOISY GENERATOR Noisy generator may be caused by loose mounting or drive pulley or worn dry or dirty bearings or improperly seated brushes Brushes may be seated by using brush seating stone referred to under Normal Generator Maintenance Installation Caut
112. y half of original thickness showing a flat clean even surface itis an indication that the spark plugs have been properlyinstalled Fig 3 B Condition of Insulator Firing End 1 OIL FOULING Fig 4 isusuallyiden tified by the wet black shiny deposit which re sults from the following engine and spark plug conditions Worn rings and pistons Worn valve stems or guides Weak battery Faulty ignition wires Distributor trouble Weak coil T oo cold a spark plug A 23173 2 GAS FOULING Fig 5 15 usually iden tified by ablack dry fluffy deposit which results from Excessive use of choke Improper adjustment choke Too rich an air fuel mixture Prolonged periods of engine idling Too cold a spark plug of automatic Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ELECTRICAL SYSTEM Section I Page 3 A 23175 3 BURNED OR OVERHEATED spark plugs Fig 6 are identified usually by dry shiny glassy deposits on the insulator or cracks in the insulator tip itself which result from Too lean an air fuel mixture Inefficient engine cooling Poorly seated valves Improper ignition timing Too hot a spark plug for the service Improper installation of spark plugs Compression leakage through spark plug A 23176 Fig 7 PRINTED IN UNITED STATES OF AMERICA 4 NORMAL CONDITIONS where regular or unleaded gasolines have

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