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900-0000 Onan V45 Genset Service & Parts manual (12

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1. 5 00 Start Relay Armature Blade Assembly 1 10 Charge Relay Assembly SOCORRO 4 50 Charge Relay Coil and Core Assembly P S 1065 1 50 Radio Choke Coil Small 3 1 1 00 65 Radio Choke 69 PARDO et NO 77510 77535 77570 js T7581 77623 77625 77661 77662 77665 77707 77973 77624 77678 TOOL GROUP DESCRIPTION Serewdriver T 5 5 Pliers 8 6 5 Wrench Adj 9 6 Wrench Breaker Point Wrench Open End 3 8 x 7 16 Wrench Open End 7 16 x 1 2 609 88496 Wrench Open End 9 16 x 5 8 0 90 9 9 6 E Socket 1 2 SRHOHESHEHHE EH OHH OR OHM EHO HODES Socket 9 16 eee Socket 3 EHD Handle For Sockets 2 929 CUM ERE Wrench Allen Head 5 16 Screw 2 Bag Cloth
2. Table of ClearanceS sid EAM dE ERR RES LEEREN MAJOR ENGINE 7 3 370 000 Generator Service Generator 00011 Reassembling the Generator ee esee nennen Storage Preparation for Withdrawal from Storage Instructions for Ordering Repair 285709 VENE EC S V Repair Parts 1 LIS OF ILLUSTRATIONS SUBJECT Proper lnstallation Plant 460698 98 9 6 Underground Exhaust Mufflor s Oiling 6 996 69946 9 9 6 9 6 6 9 6 6 Control PAPER CR AEN 7 Accessory Service Sheet 06 00006006 eis vient CU ERN ER ELA Ux a nds i Governor Internal E 6066 6 69 6 6 Governor External 6 64 6606669969 9 6 Fuel 96 6 9 6 6 6 666 6 Cylinder and Valve Service 1 Flywheel Puller 51 Alt
3. 2 00 011 Pump Driven Gear Idler 2 00 Oil Pump Body with Idler Shaft 5610 350 Oil Pump Assembly 45 LL00 011 Pump Inlet Covey 2 50 011 Pump Body 4 4 4 10 Shaft for Oil Pump Driven 25 Oil Pump Drive Shaft and Gear Assembly 2 00 Bushing for Oil Pump Drive 5 SCREWS NUTS AND BOLTS PRICE DESCRIPTION EACH 5 16 x 3 4 Screw Oil Pump TE ESLE NEES 64 6 2 05 5 16 Copper Washer Oil Pump Mounting 05 5 16 Lockwasher Oil Pump 05 5 16 Hex Nut Oil Pump 95 OIL BY PASS 1 PRICE DESCRIPTION EACH 011 Pump Outlet Tube 5 16 x 3 1 8 By Pass Terminal Block 1 50 Rear Main Bearing Oil Line 1 4 x 8 0 Front Main Bearing 011 Line 1 4 x 8 50 By Pass Block 05 By Pass Relief Spring 190 By Pass Relief Check Valve 205 By Pass Spring Adjusting Line 041 to 588 50 SCREWS NUTS BOLTS 3 Loc PRICE DESCRIPTION
4. Exhaust 6 6 6 6 6 were 6 Q Main Lites 9599096999 99090990090 959656 905696682959996049 09 Batterles Preparation for Operation E 9 66 689 9 8 6 9 6 6 Cooling 6 9 9 Lubrication 55 6 9 95 6 5 96 9689 6 888 99 8 6 Spark RE VEO REA aU a ICE NA Batteries Operation Starting the yeu ied bw Connecting the 7 1 a c c Stopping the Plante 5 8 6 Abnormal Operating Conditions Cold Weather a High Temperature Operation Dust or Dirt Control System Self LADS SES rmt Remote Dontroli seitawn e VK ES 0 Emergency Starting ee
5. 06 60 Fuel Tank Shut off Cock Manual Plants Only _ Street Elbow with Screen Manual Plants Only PRICE EACH 50 5 25 1 00 2 25 10 25 PRICE EACH 05 05 05 405 05 PRICE EACH 3 50 15 40 10 45 11 00 50 5 22 50 4 25 22 75 30 7 15 2 00 E 1 50 75 40 6 DISTRIBUTOR PRICE PART NO NE PART NO DESCRIPTION EACH 2307 Distributor Gear Thrust Washer 10 H 5800 Distributor Driven Gear HO HERO EE 5 1 25 5923 Contact Arm and Screw Set ee ee ee se 95 5924 Ignition Distributor Rotor 4 9 699 eee 6 9 50 3 5925 Distributor Assembly Less Gear 9 50 k 5926 Distributor Lock Clamp att os 35 5927 Distributor 4 69 6 6 8 6 9 1 25 5028 ignition Condeaser el WFD 50 5929 Distributor Gasket 4 99 6 10 16643 Distributor Shield 99969 8 6 6
6. AMRLLVS ANALIVG 625153 davi A 7 Z7 3NNd MOolvHiN35 1194 05 INSTRUCTIONS FOR ORDERING REPAIR PARTS FOR SERVICE OR PARTS SEE THE DEALER FROM WHOM YOU PURCHASED THIS EQUIPMENT OR REFER TO THE COMPANY REFERRED TO ON THE NAMEPLATE Following these instructions will help to fill your order promptly and correctly Be sure to state on your order the Model Number and Serial Number of the plant for which the parts are required Obtain these numbers directly from the nameplates on the plant Order parts by part numbers and complete descriptions as listed herein State the quantity of each part desired Do not order parts as sets unless they ar listed as sets in the parts list If unable to identify the part required return the old part to the address shown on the nameplate Be sure to print your name and address plainly on the package Regardless of any previous correspondence write a letter to the same address describing the part and stating the reason for returning it Ik Please ae not order parts in a letter in which some other subject treated State definite instructions when ordering parts All shipments are complete unless the packing list indicates items are back ordered Shipments properly packed and in good
7. QUAN USED NEN NN WN 0 NC GENERATOR PARTS 66 ge PRICE DESCRIPTION BACH Serews Nuts and Bolts 1 4 x 5 8 Rd Hd Screw Insul Ring to 520106388 xw PPP 05 1 4 Shakeproof Inside Washers Insulating King 7 to Spider F A AE 05 1 4 Flat Brass Washer Insulating Hing to Spider 05 10 32 x 7 8 Rd Hd Mach Screw DO Brush Jump er Teyminal eve sus vie 309 10 32 Flat Brass Wachee Brush Jumper Terminal 05 10 32 Hex Brass Nut DC Brush Jumper Terminal 05 10 32 Outside Shakeproof Lockwasher DC Brush Jumper 5 10 32 x 3 4 Rd Hd Mach Screw AC Brush Jumper Terminal eses 9 E E ee d 05 10 32 Outside Shakeproof Lockwasher AC Brush Jumper SD FO PET 95 Hex Brass Nut AC Brush Jumper Terminal 05 10 32 x 5 8 Rd Hd Mach Screw Brush Guide Bracket to Spider r 8999 05 10 32 Outside Shakeproof Lockwasher AC Brush M Guide Bracket to 05 10 32 Flat Brass Washer AC 20 Guide Bracket to ee e Mua 05 6 32 3 8 Rd Hd Mach udis 0 lane 111 812 E EV SEE RATEN Eu dE 205 o 6 32 Outsid
8. t gt 4 2 3 INGINE SERVI 105 DIAGNOSIS of Power Compression 5 Restricted Air intake 2M Carburetion 6 Low 061866 Fuel nnper pea bing 7 Restricted Exhaust Defective Ignition 8 Overheating Poor Compression Incorrect Valve Clearance 2 Leaking Gaskets Incorrect Valve Timing 6 Worn or Broken Rings Worn or Sticking Valves 7 Excessively Worn Cylin Weak or Broken Springs ders 8 Excessive Carbon Deposits Overheating insufficient Ventilation 5 Restricted Air Intake Improper Lubrication 6 Restricted Exhaust Improper Carburetion 7 Electrical Overload Improper ignition Timing Excessive Oil Consumption Worn Broken or Stuck Hings 5 Worn Bearings Worn or Scared Cylinders 6 Improper Lubricant Overheating 7 much Oil Leaking Seals or Gaskets 8 Excessive Oil Pressure Excessive Cylinder and Piston Wear tuck or Broken Rings Dirt improper Carburetion improper Lubricant Lack of Lubrication Overheating Improperly Fitted Pistons Rings 2 ONAN Connecting Red Bearing Failure Restricted Vil Passage 5 Bearing Journal Rough improperly Fitted Bearing 6 Loose Connecting kod Bent Connecting Hod 7 insufficient Oil Pres Lack of Oil sure 8 improper Lubricant Crankshaft Bearing Failure Restric
9. Screw Water Inlet to BLOCK sieves c e o v 9 4 5 16 Copper Washer Water Inlet to Block 3 8 x 1 1 4 Hex Cap Serew Crankcase inspection Plate 3 8 Lockwasher Crankease Inspection Plate 7 16 x 1 1 2 011 Base Mtg Scerew 7 16 Lockwasher Uil Base Mtg 99 5 16 x 2 Hex lid Cap Screw Valve Cover 5 16 Copper Washer Valve 5 16 x 3 4 Hd Cap Screw Int Man to Cylinder BloCKk sessossaacsssengosoonneoorusescon 5 16 Copper Washer Int Man to Cyi Block 5 16 x 1 2 Hex Hd Screw Cyl Block Side 5 16 Copper Washer Block 5 16 x 2 1 2 Hex Hd Cap Screw Gearcase Cover 5 16 x 7 8 Hex Hd Cap Screw Gearcase Cover 5 16 Copper Washer Gearcase 5 16 x 5 8 USS Allen Hd Set Screw Crankdog 5 8 x 1 1 4 Hex Cap Screw Fan Arm Mtg 5 8 Lockwasher Fan Mtg 1 2 Hex Nut Fan Support 5 16 x 3 4 Hex Hd Cap Serew Crank Guide Brkt 5 16 Lockwasher Crank Guide 5 5 16 Hex Nut Crank Guide 10 x 1 2 Self Tapping Screw Manual Choke Mtg 4554204 5 OER pus 1 2 Pipe Plu
10. 10 Charge Relay Frame 2 lt 25 Control Unit Base Ad cem a cr lS Control Box Side Panel Instrument Side Without Instruments 605 Wiwa SQ 99 969 99 5 00 Control Box Side Panel Plain aiel NEA 1 25 Control Box Cover 22 Ga 5996999998 699 9 9299 2 4 1 25 Control Base Clamp 1 8 x 1 l A x 8 1 2w 26 Wirs Outlet BOX 45 Control Panel Only Not Illustrated 1 50 Control Panel Assembly Without Box Not Illustrated 15 00 Double Filter Condenser 1 2 1 10 MFD 1 00 Start Stop Switch Panel Spacer POE TO 9 9 9 1 9 9 49 49 9 4 9 7 05 Push Button 6 96 15 Start Stop Switch Assembly 65 Fahnstock Clip f 68 6 6 1 05 8 32 x 5 16 Rd Hd Mach Screw for 15534 end 1431 2 used ES ERO OD HE CEES 05 8 32 x 3 4 Hd Mach Screw for 1552 2 used 05 8 32 Shakeproof Lockwasher for 10414 10420 05 Start Relay Assembly 9 9 6
11. 06 6 9 2 6 baw eee ee USED PRICE EACH 25 20 60 10 49 2 55 60 35 35 45 1 50 15 15 M oom D 1 T E ya 4 i 1 2 S i 1 2 5 n
12. GENERAL TROUBLE CAUSES lf trouble develops or the plant is not operating correctly gs check the oil and fuel to be sure that the proper gredes be ing used Check the wiring installation Refer to the chart below and take steps to return the plant to good running condi ME tion 1 1 Plant will not start or is hard to start Empty fuel tank E Poor grade of fuel used Fuel line clogged or air locked i Spark plugs fouled wrongly spaced or cracked Ignition wires loose 5 Ignition breaker arm sticking Stop button defective or shorted Oil too heavy due to drop in temperature Main line switch closed too heavy an electri cal load 2 Plant starts but will not produce current 2 Open switch or line wiring 5 Fuses blown Brushes stuck in holders not touching commutator Brushes worn too low 3 Plant runs too hot Spark timing r tarded improper exhaust discharge HO insufficient ventilation Radiator water level low te 011 level low 2 Oil too thin Carburetor mixture too rich m HO MO Excessive oil consumption 031 dirty not changed often enough b Fuel mixture too rich causing excessive cyl inder wear c Piston rings stuck caused by improper
13. Cylinder Head Cap Cylinder Head EA Cylinder Water Outlet Gasket Cylinder Head Stud Long Cylinder Head Stud T e iet 0 011 Level Gauge Tube 031 Level Gauge Bayonet Type 5 16 Half Cylinder Water Inlet aee SAN Crankease Assembly with Crankease Front Bearing Plate Main Bearing Front amp SS eesi s Crankcase Rear Bearing Plate Hear Bearing Plate Gasket 1 64 Vellumoid Crankease Inspection Plate Right Inspection Plate wi vus Inspection Plate Crankcase round RSE SEE Valve Tappet Valve Tappet Cover 058168 sees Fan Pulley and esas esee e vn Hand Crank 9696 9694969698 9099995296959869 Set Screw for Fan Pulley 5 16 x 5 8 Crankshaft Gear Steel Crankshaft Oil Seal 40076 290 0 EACH 20 7 50 85 50 00 85 3 50 20 65 65 20 25 35 4575 35 00 1 50 10 EE 4 0
14. Valve Stem Clearance in Guide Intake 002 003 Go No Go Gauge Valve Stem Clearance in Guide Exhaust 0025 003 Go No Go Gauge Crankshaft Main Dia 0015 0025 Micrometer Crankshaft End Play 015 020 Thickness Gauge Connecting Rod Bearing Dia 0015 0025 Connecting Rod Bearing End Play 004 006 Thickness Gauge Timing Gear Backlash 0047 005 Paper or Hand Fit Piston Cylinder Clearance 003 005 Thickness Gauge Piston Pin in Piston HAND PUSH FIT 1 Piston Pin in Rod 0002 0003 Drags when cold Camshaft Main Bearings 002 0025 Thickness Gauge Piston Ring Gap in Cylinder 008 915 Thickness Gauge MAJOR ENGINE OVERHAUL After long periods of time usually from one to five years or more of hard operation amp complete overhauling of the engine and generator will become necessary However major over hauling should not be attempted until crankease inspection has been made to determine whether or not it is needed No person unfamiliar with the operation of modern internal com bustion engines should attempt to overhaul this plant The disassembly of the engine and generator will follow a natural sequence and the sections on Yearly Engine Servicing and Generator Service should be thoroughly studied before start ing the work These two sections cover the disassembly of the generator in its entirety of the en
15. If tne interior surfaces of the generator are oily the generator will have to be disassembled and the parts thoroughly cleaned with a solvent such as gasoline benzine or carbon tetrachloride oily condition may be indication that the rear main bearing oil seal is leaking and needs replacing Check the condition of this seal and replace it if necessary while the generator is se parated from the engine Ihe following chart has been prepared to assist in locating both the most common troubles and their causes as associated with electric generators GENERATOR HEATING Poor Commutation Unequal Air Gap Reversed Field Coil 1 Overloading 4 2 shorted Coil or Coils 3 Grounded Armature or Commutator 6 Note Any of these conditions cause a large circulat ing current in the windings to the commutator the brushes and the brush connections and cause an artificial over loading of the armature FIELD COLL HEATING l Operating Speed Too High with a Resultant High Output Voltage 2 Partial Short Circuit of One Coil POOR COMMU LATION Br sh Pressure Insufficient l Brushes Unevenly Set 65 4 2 Brushes Not Fitted 7 Brush Pressure Uneven 3 Brushes Binding 28 Wrong Type of Brushes A Brush Spacing Unequal 9 Commutator Bars Loose 5 Worn Brushes 10 igh FALLURE OF GENERATOR BUILD UP 1 Plant Speed Below Normal peach Location Wrong 2 Heversed Field Win
16. M CONCRETE FORM A form should be built into which the concrete can be poured and al lowed to harden The form should be large enough so base will be of _ the minimum size TL A mixture of 1 cement 2 parts send and 4 parts gravel or crushed stone may be used Fill form tap down but do not move bolts Allow to for three days RUBBER BUSHING DETAILS r 3 8 NUT Ce WASHER BUSHING a OIL BASE BOLT RUBBER PAD E 557 QONCRETZ BASE Use the rubber mounting with the plant place one bushing between plant and base so that bushing fits in recess in plant Set Plant in place Assemble balance of bushings supplied mounting as shown above Tighten nuts but n t that busliings flatten or compress INSTALLATIONS ALL accessories necessary to put the plant into immediate serv ice are included with the plant However no main line wires or switches are furnished These must be purchased to meet the m mE individual requirements of each plant If special conditions are encountered additional equipment may be needed in addition TOP to that furnished and this too must be purchased Fa a E 9 Tank fuel tank is furiished with each If the tank is not mounted on the plant a flexible fuel line f f must be use
17. post of the second bat tery Then the negative post of the first battery and the positive 4 post of the second should be connected together If these connections are reversed the batteries would soon be dis charged and would eventually be ruined Cover the terminals with petroleum jelly to prevent corrosion Check the electrolyte acid in the cells of the battery if the batteries were received in a wet charged condition and the level of the electrolyte is low add distilled water to bring the level of the solution over the plates If the batteries were received in a dry charged condition add electrolyte to the batteries ing to the instructions attached to them 10 OPERATION STARTING THE PLANT Before attempting to start the plant sure that the dente ae been properly installed that lubricating oil fuel and cooling licuid has been been added that proper ventilation and ex haust has been provided Be sure that all the previous instruc tions on preparation have been followed Open the disconnect switch on the main line Manual Plants Insert the crank thru the opening in tor grille and engage it with the crankshaft so it can be pulled upwards With a strong upward pull turn the engine over Do not spin the crank and never take too tight a grip on the crank handle Hold the crank in such a manner that if the engine back fires or kicks bac
18. PART NO 5901 5902 5903 _ 5904 10697 3400X2 QUAN USED 2 2 PART NO 19922 19924 39928 19929 19932 QUAN USED CARBURETOR AND FILTER DESCRIPTION Gasoline Filter Bowl 1 25 Filter Bowl 1 5 Filter Bowl 2 Carburetor Zenith TU3Yl With Needle Bearings Street Elbow 1 88 Pipe 2 SCREWS NUTS AND BOLTS DESCRIPTION 1 4 x 1 1 2 Hex Hd Serew Carburetor PRICE EACH 30 9 75 25 2 25 PRICE EACH to Intake ike e 05 1 4 Lockwasher Carburetor to Intake Manifold CHOKE DESCRIPTION Choke Shaft wea cea Perak Choke Thermostat 1 Bracket for Automatic Electric Choke Element and Choke Electric Assembly SCREWS NUTS AND BOLTS DESCRIPTION 10 32 x 3 4 Rd Hd Mach Screw Choke to OS ERN A EIN 10 32 Lockwasher Choke to Carburetor 8 32 x 4 Rd Hd Mach Screw Choke Cover to BOOYvav dex ECKE d CE ERE RE a 6 32 Lockwasher Choke Cover to Body 9 9 5 32 x 3 16 Rd Mach
19. cess T 3 used Thr st Washer Throttle 549 6696 60 Taper Pin Thrust Washer 8 8 996 66669 Air Shutter 4 0 8 Retaining Screw Air Shutter 5 0 used Lockwasher Retaining 6609 6 6 6 8 6 6 Air Shutter Shaft 6 09 6 4 Gasket Throttle Body to BOWL Assembly Screw Body to 2 used Lockwasher Body to Bowl ener 2 used Assembly Fuel BOW 800065680600 Assembly Fuel Bowl Cover 5 6 8 96 996 696 0 6 66 Assembly 2 Float 23 1 6 uae wr Gasket Bowl to CONVO 000 1 1 2121 1 Assembly Screw Bowl to Gover h used Lockwasher Bowl to Cover eee sees used 1 8 Pipe Plug Bowl Lower Plugs 099 65999 996 69 6 9 9 66 6 9 96 6 Fibre WACKER oi yas A SOc 00010101 Assembly Main Jet Adjustment 959498 ss 6 86 6 Spring Jet
20. MODEL NO V45 SERVICE MANUAL AND PARTS LIST FOR YOUR ELECTRIC PLANT 53 READ THIS BOOK CAREFULLY AND PRESERVE FOR FUTURE REFERENCE 1 WARNING THIS ELECTRIC PLANT MUST BE INSTALLED AND BE OPERATED ACCORDING TO OUR INSTRUC TIONS AN IMPROPER INSTALLATION OR THE USE TN OF OIL OR FUEL OTHER THAN THAT RECOM MENDED IN THIS MANUAL RELIEVES THE MANU FACTURER OF ALL RESPONSIBILITY FOR PLANT PERFORMANCE READ THIS SERVICE MANUAL CAREFULLY PRINTED IN U IMPORTANT USE OF LEADED FUELS The performance of gasoline engines deteriorates with use until it eventually becomes necessary to remove the carbon grind the valves install new spark plugs etc Lead is added to many gasolines to increase the octane rating Due to the action of the lead in the combustion chamber on the valve seats and on the spark plugs the use of such fuels causes the engine performance to deteriorate more rapidly When using highly leaded fuel there is a regularly increasing lead con tent in the crankcase oil _If the gasoline contains 15 cubic centimeter or less of lead gallon there is little such However as the proportion of lead is increased the deterioration in engine performance is greatly accelerated Under normal operating conditions with unleaded fuel it may be necessary to remove earbon each 1000 oper
21. mechanical or electrical connections which may be loose gt Visual ly inspect the plant Replace any parts which may have been dam aged Cooling System A thermal syphon type cooling system is used on this plant Water rises when it is heated and as the liquid in the cylinder block and head becomes warmed it rises to the top of the radiator Cooler water from the bottom of the radiator takes its place and in turn becomes heated Air driven by fan over the radiator surfaces and fins cools the water in the radiator constant circulation is thus maintained capa city of the cooling system is 17 quarts Use only clean water or anti freeze in the syste Hain water be used but salt water or alkali water will cause corrosion in the radiator and should never be used Check all hose and block connections and tighten any that are loose Fill the radiator to a point somewhat below the level of the overflow pipe to allow for expansion of the li quid Test the tension of the fan belt properly adjusted belt be moved inward or outward about 3 4 V belts do not l 5 recuire the tension to prevent slipping that flat belts do and amp too tight belt will cause rapid wear of the fan hub If the belt requires a 6justing loosen the cap screw holding the fan support 2 to the cylinder water outlet turn the adjustment stud screw py re in or out to increase or decrease the tension
22. reduce the charging rate Check the specific gravity of the batteries at reguiar intervals with a good hydrometer A discharged battery will read from 115 to 1175 a half charged battery from 1200 to 1225 and a charged battery from 1250 to 1250 5 the in fully charged condition 44 allowed to stand in a discharged state the plates will harden or sulphate and the battery will not take or hold a charge If the batteries are in a discharged or near discharged condition during cold weather they may freeze and be ruined A discharged battery wiil freeze at about 20 above zero F while a fully charged battery will not freeze until it gets about 80 below zero Never add water to a battery during cold weather with out letting it stand in a warm place long enough for the water to become mixed with the electrolyte Water might freeze and crack the battery case if it was not given a chance to mix with the electrolyte If batteries are received in a Semi Dry condition from the manufacturer follow the instructions that accompany them for putting into service ACCESSORY SERVICE GOVERNOR The purpose of the governor is to keep the generator voltage within proper limits by holding the engine speed constant Failure of the governor to control the speed properly rate would cause varying briiliancy of lights or constantly chang ppliances whenever the load ing performance of
23. AVAILABLE FROM SUITABLE WINDOWS OR OPENINGS IN THE WALLS THROUGH AND AROUND RADIATOR AND PLANT SKETCH SHOWS AVERY SATISFACTORY METHOD OF AIR CIRCU LATION WITH AMPLE PROTECTION FROM OUTSIDE ELEM ENTS DO NOT OP YOUR NTI AT ANY TIME OPENINGS OR VENTILATORS SHOULD BE AT WITH LOUVERS COVER VENTILATORS OR OPENINGS WITH LARGE MESH SCREEN IF PLANT MUST INSTALLED IN BASEMENT SURE PROVIDE EXTRA CELLAR OPENINGS FOR THE AIR CIRCULATION NEEDED BY PLANT BASEMENT LOCATIONS ARE NOT RECOM MENDED BECAUSE OF DAMPNESS AND POOR AIR CIRCULA TION ALSO EVEN SLIGHT AMOUNT OF MECHANICAL NOISE IS USUALLY OBJECTIONABLE 2 DO INSTALL YOUR PLANT IN A HEN HOUSE OR BARM FEATHERS HAY OR STRAW WILL CREATE A FIRE HAZARD AND ALSO DAMAGE YOUR ENGINE PLANT BASE CONCRETE BASE Above base dimensions are a minimum and be larger Keep same bolt spacing base must be at least gt 24 from any wall 22 mes Use 4 3 8 9 bolts See that they extend 3 1 2 above the too of the concrete MOUNTING BOLT SUSPENSION Suspend mounting bolts from cross cleats nailed to the top of the con crete form before ouring concrete Place large washer under head of bolt and adjust for proper height 3 1 2 Be sure top of foundation is level and smooth to prevent plant base breakage f
24. Adjustment 3 5 6 999 4695 646 6669 896 66 896 Metering Well Fibre Washer Metering Main det 220055 98 8 4 8 8 849 6 Fibre Washer Main Assembly Fuel Valve Seat a E SS eee E Fibre Washer Fuel MA Ves 222 05 EACH 4 00 49 05 19 430 30 50 75 5 50 05 10 275 05 05 05 25 05 10 20 10 10 05 2 00 75 160 10 10 05 10 5 05 90 410 75 75 75 05 5064 572 A 2065 5060 77 5055 212 0 ey A EEL VI ADMIN AVAL A mer j i 21448 5194 s E 12820 10420 10414 1554 10616 CONTROL PARTS PART NO 513 523 527 528 529 512 543 544 545 546 547 572 585 566 _ 609 761 1004 2121 2122 2124 22001 22008 2201 2202 2203 2206 22101 22108 2211 2212 _ 2213 2216 2217 2218 2223 5500A 5505 5506B 5510 5511 5520 5521 5522 2223 5524 5526 5527 5539 5531 5533 5534 553
25. D C Side Reading Scale 2 50 Terminal Post Assembly Battery Negative 5 16 x 1 3 4 Cap Screw 00800001111 9 30 Terminal Post Assembly Battery Positive 5 16 x 2 Screw 9 30 Ignition Toggle Switch Arrow amp ceo otto 75 Start Relay Frame High wenecoeoous q 95 Start Relay to Control Pahel Connector Strap Assembly 35 Start Relay Coil _ P S 1579 ee en uA Tek 4 25 Start Relay Fram Insul Formica 50 Start Relay Frame to Control Panel Cable 6 Long 50 Charge Relay Armature and Blade Assembly 4 1 10 Start Switch Brush Reinforcing Strip 3 8 x 5 16 Brass 05 Fibre Coil Washer 1 1 2 Dosis LO Start Switch Armature Return Spring 410 Start Switch Lower Contact 56 Charge Relay Insulator Panel with Contacts 0 Charge Relay Insul Panel Reinforcing Strip 3 8 x 1 Brass 05 Start Relay Coil Core HRD ODE EES 035 Charge Relay Armature Return Spring
26. EACH 1 4 x 1 Hex H Cap Screw 011 Pump By Pass gt Mountings eis qa eso 05 1 4 Copper Washer 011 Pump By Pass Mounting 05 65 O PART NO 549 568 569 738 LOALA gt 1046 2084 5635 5636 12135 USED E PART NO 5584 10697 15168 W 226078 PART NO 5614 5616 5617 5618 5622 5624 56248 5667 75863 66 INTERNAL GOVERNOR _ DESCRIPTION Governor Weight Retaining Governor Arm Ball Governor Arm to Carburetor Control 4 Governor Regulator Spring Adjusting Serew Governor Cup and Stud Governor Spring Stop Stud ix Governor Weight Governor Spring and Arm Bracket USE Governor Arm Dated s as UR Governor Arm Spring SCREWS NUTS BOLTS ETC DESCRIPTION 1 4 x 1 Hex Hd Cap Screw Governor Arm Bracket Clamp 5 1 4 Inside Shakeproof Loekwasher Governor Arm Bracket Clamp 5 4 9 1 4 Hex Nut Governor Arm Bracket Clamp Screw Hex Nut for Governor Adjusting 10 32 x 3 8 Hd iach Screw Governor Arm to Brae
27. If the engine is in good condition S A E 20 oil should be ere ed with a change after every 100 hours of operation If the en gine is worn the 18 excessively high an 5 30 oil be used I 099348 ing Seton sen the system full of Soft 0 flushing it at regular intervals to remove 211 rust scale and foreign matter Flush the biock and the radiator An Check the 02 daily and add water whenever The radiator shell 211316 engine must be kept ies from dirt bugs leaves or any other matter which would reduce the cooling effect Tighten all hose connections replacing the hoses if nec essary Check the fan belt tension Replace the belt if worn or adjust it if S pe Ignition syste m the ignition adjusted properly at all times Advanced ignition reduces efficiency while retarded ignition causes overheating Check the ignition wires and 11 electrical connections Keep the spark plugs and breaker points clean and properly set Time the engine to operate just below the ping 9 i DUST OR DIRT Under such adverse conditions it is necessary to the plant and service it more often Pay m attention to the fol 4 points 5 dp 1 Keep the plant engine radiator and accessories as clean as possible 2 See that supplies of fuel and oil are
28. Radiator Base Stud 5 16 x 1 Hex Hd Cap Screw Radiator Mtg Screw 5 16 Lockwasher Radiator Mtg Screw 5 16 Hex Nut Radiator Mig Screw 4 54 4949698990 999596 8 x 3 8 Flat Hd Self Tapping Screw Rod Cover PRICE EACH 6 00 36 00 05 05 05 05 05 h FUEL PUMP DESCRIPTION PRICE EACH 50147 Fuel Line Flexible Tank to Pump 1 25 _ 657 658 655 747 748 750 751 5600 5604 5907 5919 5922B 10697 QUAN USED Fuel Pump Mounting Fuel Pump Glass Bowl AC 848004 Fuel Pump Bowl Gasket AC 854003 Fuel Pump Primer Lever AC 1522280 Fuei Pump Primer Lever Cover Gasket AC 3 Fuel Pump Diaphragm Kit Fuel Pump Filter Sereen Fuel Pump Eccentric Follower Lever Fuel Pump Eccentric Follower Shaft Pump Fuel Assembly Fuel Line Copper Tank to Pump Manual Plants with Mounted Tank Fuel Line Copper Pump to Carburetor Inverted Male Kibow SCREWS NUTS AND BOLTS DESCRIPTION 75 16 x 7 8 Hex Hd Cap Screws Fuel Pump 6 5 16 Copper Washer 15 25 0 25 0 75 20 1 25 60 6
29. SET UP IN WELL VENTILATED ROOMOF AMPLE SIZE AT LEAST IO X 10 INSTALL PLANT AT LEAST 24 AWAY FROM WALLS TO ALLOW EASY ACCESS TO PLANT FOR STARTING OR SERVICING RUBBER SHOCK ABSORBING BUSHINGS FURNISHED WITH THE UNIT SHOULD BE SET UNDER THE PLANT TO PREVENT THE SLIGHTEST VIBRATION SHOCK ABSORBING VALUE OF BUSH INGS WILL BE GREATER IF NOT BOLTED DOWN TOO TIGHT 5 PIPE BATTERY AND LINE CONNECTIONS ARE ON OPPOSITE SIDE OF THE UNIT AS SHOWN ABOVE EXHAUST TUB CAN BE RUN EITHER DIRECTLY TO THE OUTSIDE OF THE BUILDING OR INTO AN UNDERGROUND EXHAUST CHAMBER EXTREME SILENCE IS DESIRED CAUTION ALL EXHAUST CONNECTIONS MUST BE TIGHT AS LEAKAGE OF EXHAUST FUMES WHICH CONTAIN POLSONOUS MONOXIDE GAS IS EXTREMELY DANGEROUS PLANT MUST BE INSTALLED IN BASEMENT INSTALL WATER TRAP TO TAKE CARE OF CONDENSATION IN THE EX HAUST PIPE DO NOT RUN EXHAUST PIPE OVER TWENTY FEET 2 4 5 GROUND PLANT YO BATTERY NEG POST LINE WIRE WIRA ROUNDED USE WIRE SIZE 19 GROUND CLOS 8 ANTO SUITABLE GROUND FOR TH Eun PLANT CAN BE MADE BY 2201 BY DRIVING 2 PIPE 4 08 5 l FEET INTO GROUND AND FASTENING WIRE SAME a CAUTION DO NOT GROUND PLANT PIPE ANY Pi Whien RADIO 1S GROUNDED PROPER VENTILATION A FREE FLOW OF CLEAN FRESH AIR MUST BE
30. and maintenance proce dures be made at definite periods to keep the plant operating at maximum level of efficiency 1 is recommended that a service log be kept If operation is to be under abnormal conditions check those pages for correct maintenance DAILY 2 daily check of the INE points become matter of routine 1 Cooling liquid level 2 Crankcase oil level 3 Fuel supply do not fill tank while is running 4 inspection of operating gauges 25 Keep the plant clean WEEKLY MAINTENANCE Each week or after every 50 hours of 00 Oil Check the oil level adding whatever is necessary to bring it to the full mark on the gauge If necessary change oii l in cold change every 50 60 hours 2 high temperatures change every 100 hours 3 average temperatures change every 200 hours When changing oil run the plant until it is warm Then drain and refill with new oil Do not drain when the engine is cold fen Belt There should be 3 4 movement in or out from the normal position Adjust if necessary Check the water level ard add whatever is necessary anti freeze is used add the correct proportion Fuel Check the strainer on the fuel tank or pump Remove the filter bowl and screen and clean both ene check for leaks s I Batteries used check the water level Add distilled water to bring th
31. be necessary to reset the governor after major overhaul ing See the section on governor adjustment under accessory service for complete details on adjustment 27 FLYWHEEL PULLER ASSEMBLY FLY WHERE 89 PULLER 2c ES gt STEEL BLOCK h 0 b y 6 d Z FLYWHEEL THE REAR ENGINE VIEW SKETCH ABOVE ILLUSTRATES THE OPERATION OF THE FLYWHEEL PULLER IN REMOVING THE FLYWHEEL FROM THE CRANKSHAFT TAPER THE OUTER BOLTS OF THE PULLER ARE TURNED INTO THE FLYWHEEL HUB A STEEL BLOCK THEN PLACED OVER THE CRANKSHAFT END TO PROTECT IT FROM BEING DAMAGED BY THE CENTER BOLT OF THE PUL LER THE CENTER BOLT OF THE PULLER 15 THEN DRAWN DEAD TIGHT AGAINST STEEL BLOCK AND RAPPED SHARPLY WITH HAMMER AS SHOWN IN SKETCH THIS WILL LOOSEN THE FLYWHEEL FOR REMOVAL CRANK SHAFT TAPERE JE AND WASHER REMOVED We e E SA 7 elean and free from metal dust dirt oil and water 77 GENERATOR SERVICE The interior and exterior surfaces of the generator must be stream of compressed air directed thru openings in the generator frame after the cover has been removed is the most satisfactory method of removing ordinary accumulations of dirt and dust Be sure that the air stream is free from oil or water or the condition will be made worse
32. carbon from the piston heads If the rings have considerable tension are bright and shiny showing amp good fit to the cylinder walls are not worn exces sively and fit snugly in the piston grooves DAES them in the grooves from which they were taken If the rings show signs of wear thay should be replaced with new ones Fit each ring individually to the cylinder for which it is intended If necessary file the ends of the rings slightly so there will be an end gap of approximately 5010 when the ring is in position in the cylinder After the pistons and rings have been cleaned or replaced wrap clean rag or pieee of cardboard around the pistons to koep them from being damaged Valve Grinding Compress the valve springs remove the valve locks With the locks removed the washers valve springs and valves can be lifted out of the block Inepect the condition of the valves If the stems are worn or bent replace with new ones Pitted valve faces can be refaced on valve face grinder if the valve is otherwise good con dition However never use re faced valve that has a thin edge Valves with thin edged heads will warp or burn after a short time When refacing valves be sure to get true 45 angle to the faces Clean the valve heads stems and guides of all dirt and carbon If the valve guides are badly worn they be punched out and replaced with new ones Check the condition of the valv
33. correct setting for efficient economical operation but sometimes 1 may be necessary open the adjustment up to 1 2 turn more to rid the plant of hunting condition where the engine will alternately gain and lose speed the hoor MS ae ACCESSORY SERVICE CARBURETOR If increasing the jet opening by 1 2 turn will not correct the hunt the sensitivety of the governor must be decreased ser 4095 hunt can be drowned out by using a too rich fuel mixture but economy of operation would be impossible possible dam age to the plant could result If the plant operates unevenly under no load or light loud turn the idle jet needle into the carburetor body until the plant nearly stops Th n open it slowly to the point at which the en gine runs the smootnest Usually the setting for smooth economical operation will be between 1 2 and 1 4 turns Continued irregular operation of the engine hard Starting or loss of power may indicate that the main jet of the carburetor has become clogged The fuel passage in this jet is very small and if foreign material should succeed in getting thru the screen and filter bowl it can become lodged in this jet 1 will then be necessary to remove tne float bowl cover of the earbuvetor and remove and clean the jet Be careful to use 8 proper sized screwdriver whenever removing the main jet Otherwise the brass might burr or distort and be _worthles
34. current is used to excite the alternator stator coiis and also in the case of the self starting models to keep the starting batteries charged fhe exciter armature winding acts as a motor to crank the engine All the windings of the generator have been heavily lupregnated with insulating varnish and then baked to provide maximum pro tection against moisture penetration The plant is sufficiently insulated to operate invall types of weather and in all climates from the tropics to the arctic However the olant should oe Sheltered as mush as possible as it is impossible to entirely protect against corrosion and any plants operated in damp humid countries should be serviced more often than is normal The generator frame is rolled steel ring machined on the inside The pole pieces are punched from Laminations of 22 gauge electri cal steel The armature laminations are ounched from 26 gauge electrical steel A cooling fan is bolted to the engine end of the araature and it in turn bolts to the flywheel Cooling air is drawn in thru vents in the generator end bell band passed over the brushes comautator and collector rings and the arma ture and field windings and is then forced out thru openings in the adapter casting at the engine end of the generator The generator is shielded to minimize radio interference 1 is rated at 5000 watts 115 volts 60 cycle alternating current and operates within 40 Centigrade te
35. kept in air tight containers Strain them if they dirty 3 Check the ignition system breaker points and dni plugs more often Clean and adjust them when necessary Check the air cleaner daily Clean and refil with fresh 220222 wh never necessary LO a Clean the brush rig and armature often Be sure that the brushes ride easily in the holders CENE 35 io e n kaq w Wk EA IGROUND CONTROL PARTS RADIO INTERFERENCE CHOKE COIL S g REVERSE CURRENT A RELAY PS 1065 COIL CONDENSER 14 CHARGE RATE CONTROL RHEOSTAT START RELAY O START STOP GROUND ex O e O CHARGE RATE METER i 4 E Y and stopping either plant or at any remote point up to within 250 feet of CONTROL SYSTEM The self start and the control plants have a control cabinet mounted t the generator end of the plant The wiring diagram in this book out lines the electrical system of the entire plant Reference spud be made to this diagram whenever servicing the electrical SELP STARTING The s lf start type
36. line can be used and it should be inspected and drained often An underground exhaust muffler Refer to the illustration on the following page for details Em Groun unding The piant should always be grounded This be done by driving a grounding rod or 1 2 pipe into the gro nd s 18 near the plant Connect either the negative battery post lt the neutral white main line wire to the ground with a 10 or 12 wire and ground clamp Never use radio ground do not ground the plant itself Main 124466 External wiring should be of the correct size and sufficiently insulated to protect both the plant and the opera tor Consult the local code before making the installation A Main line fused switch or circuit breaker should be REE in the line near the planti Batteries When batteries are used with the plant dos should be on a wooden frame mat and connected to the plant with 352 the cables furnished The polarity markings of the battery posts and panel terminals must be observed See Battery Preparation 00 before connecting the batteries 95 2 CTUM e UNDERGROUND EXHA ST MUFFLER CONDENSATION TRAP SHOULD USED EXHAUST PIPE WALL SHIELD 7 WHENEVER EXHAUST PIPE RUNS UPWAPD UNION _ 2 30 PIPE NIPPLES 0 Ew x gt F
37. one commutator bar and the other end touched to each of the 3 other bars If it fails to light when touched to any bar the e wire leading to that bar is open and the armature must be re placed TESTING A C WINDING OF THE ARMATURE FOR OPEN CIRCUITS OR GROUNDS Place one end of a test lamp wire on the outer or insulated col lector ring and the other end on the inner collector ring the windings good condition the lamp will light If it fails to light the circuit is open and the armature must be re 28687 Place one end of the test lamp wire the armature shaft Touch the other end to each of the collector rings If the lamp lights the winding is grounded and the armature must be replaced Note Only competant well trained armature repair ser vice man is qualified to repair an armature that is either open or grounded The armature must be completely rewound to correct either of these conditions and no person with out special training should ever 0 to do this work 7 FILTER CONDENSERS Filter condensers mounted inside the gen erator frame one of these condensers Should become Shorted no current would be generated Disconnect the cond nser leads and try the plant with the condensers disconnected If the plant re operates satisfactorily check each condenser and replace the NEC one that is faulty It is necessary to use condensers in the gene
38. order when delivered to the transporta tion company Any claim fot loss or damage in transit should filed promptly against the transportation company making the delivery DI ae Prices quoted ficrein are F O B factory a ADD 15 TO ALL PRICES USTED 4 V45 ENGINE PARTS IN ORDER TO AVOID ERRORS WHEN ORDERING PARTS ALWAYS SPECIFY MODEL NUMBER AND SERIAL NUMBER OF YOUR PLANT 222 5656 gt 2213 97 5754 575 5619 5755 2200 L 545 22008 2202 2203 2217 546 2 547 2218 542 543 y V45 ENGINE ACCESSORIES IN ORDER TO AVOID ERRORS WHEN ORDERING PARTS ALWAYS SPECIFY MODEL NUMBER AND SERIAL NUMBER OF YOUR PLANT 657 59228 47 7 lt Thy FUEL PUMP a 2268 34 002 ELBOWS K 1 16689 5923 45 ENGINE ACCESSORIES IN ORDER TO AVOID ERRORS WHEN ORDERING PARTS ALWAYS 5937 5927 SPECIFY MODEL NUMBER AND SERIAL NUMBER OF YOUR PLANT 5924 159348 Cy 5944 16643 75857 9308 1 R 5 5 252 75754 B Co 5800 5816 9338 IGNITION COIL amp SPARK PLUG DISTRIBUTOR 19929A 19926 19922 EC 4 OIL GAU
39. pf control is used basically on the 0 plants It consists primarily of manually opereted start switch a charge relay a charging amm eter On the starting cycle the current flows from the starting batteries through the start switch to the generator which acts starting motor Upon starting the switch is released and opened thereby breaking that circuit As the plant gen erates current a charging current flows through the charge relay and ammeter to the starting batteries This type of control only permits shen rene at the stopping amp t either the remote station REMOTE CONTROL The remote type of control is used basically oh the A C plants It consists primarily of start stop switch start relay charge charge ammeter and amp charge rheostat plus set of remote terminals This control permits starting When the start button is pressed it s start Gas s The contacts of Pus relay close the starting circuit so that current from the starting batteries is fed to the generator whose exciter acts as starting motor Upon release 04 the start button the start relay operis and opens the starting circuit Upon reach p 105 speed the exciter part of the becomes a generator in itself Curr ent then flows into the charge relay rheostat and ammeter and then to the starting batteries The rheostat con
40. use with Pierce Governor 4 50 Fan Support Arm Used with Pierce Governor 1 50 Front Oil Retaining Washer 59 66995 59 555 9995 10 5 Front Oil 15 Gearcase Cover for Onan 2 50 Gearcase Cover 35 Cylinder Water Outlet Right Use with Pierce ad Au A D E 2 00 Intake gt 14 4 6 2 50 intake Manifold ev e vw I 10 Cylinder Water THLE 1977 TES 1 25 Cylinder Water Outlet Right 59969 99 99 096 21 50 Cylinder Water Outlet 1 50 Fan Assembly with Hub and Blade 8 50 Fan Blade Assembly eyes mor nee ken 4 50 1 Fan Hub Assembly 44444 4 00 Fan Support Arm Only nnn 50 Support Arm Bolt 5 8 x 121 20 erris 15 Fan Support Arm Adjusting 40 Belt 29033434 eva ve ee ne ev Oil Filler Tube Standard 15 75 011 Filler Tube ve Housed Models ee we e w o 9 9 9 99 75 Connecting Kod Insert Type Forged 3 75 Connecting Rod includes Inserts Bushings and Bolts 475 Bearing Insert Assembly
41. used 15 5154 Generator Frame End Bell Housing 6 50 S 5151 Generator Framd End Bell Band 65 5155 Generator Bearing 55 i 25 5156 Generator Bearing Cover Gasket 1 16 i 220 5160 Generator Bearing Stop 1 5 1 5170 Brush Spider Casting weave 2525 212040 Brush Rig 11 00 51754 Brush Rig Insulator Ring and DC Brush Guide Assembly 6 50 5179 A C Brush Guide and Insulator Panel 4 used Wake f wn 212A1011 Brush Spring used 35 570 5191 0 Ground Strap 020 x 1 2 x 2 1 2 zo o 0 15 5192 Jumper Legd 4E ee obese eas eos 30 5193 D C Jumper 11 Long Loop on Bach 2 o 30 5194 Jumper 2 Long 10 32 Loop on Bach PWG Verte na snowed mes 30 214415 D C Carbon Brush 1 2 x xi An EE 00101028 1 00 21248 Carbon Brush 9 32 x 7 8 x 1 1 4 3 7 x OD 2928 Filter Condenser l MFD L 8 95 5 2 0880 0 800 50 5 67 55
42. valves have been ground to their individual seats and all traces of carbon scraped from the blocks replace the valves valve springs washers and locks Install the cylin der blocks onto the crankcase compressing each piston ring care fully to prevent breakage Oil the pistons and piston rings be fore sliding then into the cylinder walls and be sure to use new cylinder base gaskets Clean the carbon from the cylinder heads Using new gaskets thru out replace the cylinder heads and draw them tight When tight ening the cylinder head nuts tighten them evenly and never draw one up tight until the others are nearly so Tighten the center one first and then tighten the others This assures a better seal and prevents the possibility of the head warping Tappet Adjustment Loosen the serews locking the tappet 1 levers to their bearings and push the levers as far into the crankcase as possible With each piston at top dead center on the compression stroke while making the adjustment insert an 008 feeler gauge between the camshaft and the face of the cam follower lever Pull the lever upward until the guage is squeez ed lightly between cam and the lever face and then tighten the cap screw securely CARBURETOR Remove the carburetor and disassemble it to clean out the jets and remove any sediment from the bowl See the carburetor accessory page Replace all gaskets including the one between the intake manifold a
43. without surging to give close If the governor surges at no load speed screw the bumper far enough to eliminate the surge and then lock it Do not screw B in far enough to crease the engine speed USA ON 26 1 MANUAL FUEL PUMP 70 FILL CARBURETOR How It Work By revolving shaft G the eccentric will lift rocker arm D which is pivoted at E and which pulls the pull rod F together with diaphragm A held between metal discs B downward against spring pressure C thus creating a vacuum in pump chamber M gt Fuel from the rear tank will enter at J into sediment bowl K and through strainer L and suction valve N into pump chamber M On the return stroke spring pressure C pushes diaphragm upward forcing fuel from chamber M through pressure valve O and opening P into the carburetor es When the carburetor bowl is filled the float in the float chamber will shut off the inlet needle valve thus creat ing a pressure in pump chamber M This pressure will hold diaphragm A downward against the spring pressure C where it will remain inoperative until the carburetor requires further fuel and the needle valve opens Spring S is merely for the purpose of keeping rocker arm D in constant contact with eccentric to eliminate noise Service Hints S rvice on the AC Fuel Pump is available through Unit
44. 0 DB 56 55408 5542 5545B 5554 5555 5556 5561 5562 5563 5568 5583 5596 5597 5598 5613 5619 5620 2623 5630 5631 56548 5657 5656 5722 57238 57235 5750 57508 57500 5751 5752 5754 5755 5861 5862 12047 120474 120494 12051 120578 12062 12063 i214l 76567 75858 ENGINE PARIS 0 PRICE DESCRIPTION EACH eM E 10 00 Camshaft Distributor Drive 1 25 Camshaft 2 75 Cam Follower 45 Cam Follower Lever Only 5 8 65 Cam Follower Shaft 1 2 00 Oil Base sa E ERS 222 011 Base Drain Nipple 1 2 x v UNT 15 Oil Drain Nipple 1 2 x 6 Housed Models 25 011 9 10 00 Cam Follower Shaft Spacer 3 32 Thick x 1 2 1 x 5 8 0 me 05 Follower Shaft Spacer 5 32 Thick x 1 2 DD 5 88 adv rasa was 05 Cam Follower Shaft Spacer 1 4 Thick x 1 2 0 2 s ER 05 Cam Follower Shaft Spacer 5 16 Thick x 1 2 I D x 5 8 O D ne 5 Gearcase Cover For
45. 2 Halves 1 0 Camshaft Bearing Front 70 Piston amp Pin ASSOMDLY 2990966699 5 50 011 Base Mounting Rubber Lower 1 7 8 Long 2 20 Oil Base Mounting Rubber Upper 1 Long 20 Piston Pin Pushina c yaz sma veles ue aa 45 Connecting Rod 1 5 10 Connecting Rod Bolt NU Gee a 05 Water Temperature 3 00 011 Drein Coupling 5 0 Poa d x Ima x i SCHEWS NUTS AND BOLTS DESCRIPTION 5 16 x 7 8 Hex Hd Cap Screw Rear Bearing u cu a Copper Washer Rear Bearing Plate 5 16 x 7 8 Hex Cap Serew Front Bearing 5 16 Plate 8 4 4 46 gt 96 422929 5 16 Steel Spring Lockwasher Front Bearing Plate 7 16 5 Cap Nut Cylinder Head 7 16 Copper Washer Cylinder Head Cap 5 16 x 2 3 4 Hex Hd Cap Serew Water inlet to Block ee 8 5 16 x 1 1 2 Hex
46. 5 5538 ENGINE PARTS DESCRIPTION Nuts vee peu A oqa Rear Camshaft Cam Gear Cam Follower Spring Camshaft Rear Bearing Hubbard Plug 2 Intake 1 Exhaust Vailve e T Exhaust Vaive 568 Valve TP 4 6 56656 656 e 6 6 Valve Spring A E ees Valve LoceK E EEE 0 8 Flywheel Nut Lockwasher tebe 9 Oil Filler Gap 0il Filler Neck ws Platon Pin BOCK RING e xw Ao aas Cam Follower Screw 1 4 x 3 4 5 Hardened Crankgear Nut SS RS RS Piston Pin 3 4 x 2 7 16 Compression Ring 3 32 x SESS 1 Oil Ring 3 16 x 3 S 7 se s Sas Cylinder Block Left 3 Cylinder Block Right 3 Exe du E e ER Cylinder Block Base Cylinder Block Stud Cylinder Block Stud Short wes Cylinder Block Hubbard Plug Cylinder Left 3 dc ee S 4 Cylinder Head Right 3 Cylinder Head Gasket
47. 50 75 1 00 25 PRICE EACH 05 05 59 wet PART NO 737 2107 5683 568s 5686 5689 5690B 5691 5692 5693 5881 78062A USED PRE EXHAUST MUFFLER 5 16 Hex Nut Exhaust Tube to Radiator 5 16 Lockwasher Exhaust Tube to Radiator 5 16 x 1 Hex Hd Cap Serew Exhaust Tube 2 nn 5 16 Lockwasher Exhaust eme DESCRIPTION EACH Exhaust Manifold 2 LO Exhaust Flange weak 10 Exhaust Tube Long l 1 4 x 24 Flexible Standard 6 4 4 5 6 75 Exhaust 1 1 16 x 36 Outlet Biardard Mode 1S xu e sud ose Vw ADO Exhaust Tube Short 1 1 4 x 16 Flexible Standard 55455 566 9 9 66 69 6 6 9 6 6 6496896999 0 Exhaust Tube Bracket Std 5 85 Exhaust Outlet 5258599 1 25 Exhaust Outlet Tee 1 1 2 1 75 Exhaust Tee Flange 1 used on Std 2 on Spec 40 Exhaust and Outlet 528 Nipple and Bracket Assy 1 x 4 Spec Housed Model Only 45 Exhaust Muffler As
48. 6 E 3 00 7 5944 Distributor Radio Shield Outlet Nipple Coupling Nut 25 16689 Distributor Shield Collar e525899 25902 552822a5 25 2997 9 2399959 996 85 SCREWS NUTS AND BOLTS qua PRICE USED DESCRIPTION EACH P 1 1 4 5 8 Hex Hd Cap Screw Distributor Clamp 05 1 1 4 Lockwasher Distributor 05 1 10 32 x 1 3 8 Clamp Screw Dist 1 05 1 10 32 Square Nut Distributor 1 05 2 10 32 Hex Nut Dist Coil Primary Terminals 05 2 10 32 Lockwasher Dist Coil Primary Terminals 05 62 PART NO 670 709 2325 78713 5930R 59218 59328 53228 29248 16646 5944 12317 16648 336423 336426 31447 31448 16741060 QUAN USED P PART NO 1745 1746 1747 1748 1763 17678 5939 IGNITION COIL AND SPARK PLUG DESCRIPTION Spark Plug gt Champion 6M gnition Coil Nipple COMOROS REE RHE ignition Coil 12 Volt Ignition Coil Clamp COPPERAS HaHa HH HSER EER ESET ERSD 1 Spark Plug Cable 1 16 Long Radio Shielded Spark Plug Cable 2 21 1 Long Radio Shielded Spark Plug Cable 3 9 1 4 Long Radio Shielded Spark Plug Cable 4 19 3 4 Long Ra
49. Any good grade of gasoline E a range of 67 to 80 octane can pe used either leaded Ethyl or unleaded leaded fuel will give more efficient operation by allowing the ignition timing to be further advanced without knocking or pinging It also has less tendency to form carbon However it will event ually form a coating over the internal surfaces which in the case of the spark plugs may cause hard starting Proper main tenance of the engine calls for periodic inspection and cleaning of the spark piugs and if followed this possible trouble will never develop Check the connections running between the fuel tank ard the buretor plants having mechanical fuel pump the pump will be located on the left side of the crankcase below the cylinder block Check the connections at the pump and be sure that the glass filter bowl is securely tightened and that is seats proper ly on the gasket The mer pump is equipped with a manual operating handle Use this handle to pump gasoline to the carburetor at any time the gas tank has run dry 1 will save battery wear great deal of hand cranking and can also be used to check the operation of the fuel pump Batteries Check the connections to the batteries The positive 4 terminal at the control box must be connected to the positive post of one battery The negative terminal of the control box must be connected to the negative
50. ECTION OF OIL FLOW FROM OIL PUMP THROUGH DISTRIBUTION BLOCK TO FRONT AND REAR CRANKSHAFT BEARINGS EXCESS OIL PRESSURE OPENS VALVE IN DISTRIBUTION BLOCK ALLOWING OIL TO ESCAPE THROUGH PRESSURE RELIEF OPENING BASE PRESSURE WHICH VALVE OPENS MAY REG ULATED WITH PRESSURE REGULATING BOLT PE 8 DUMP 5 OIL LINE HELICAL DRIVE GEAR SEEN BY PASS PRESSURE RELIEF TO OIL PRESSURE RELIEF MAGNETO GEAR BOX REGULATING GAMSHAFT CAMSHAFT GEAR HELICAL CAMSHAFT GEAR 222252 REAR MAIN BEARING OL DISTRIBUTION BLOCK OC 1 1 f 4 Nz REAR MAIN NS PLA we NOVA BYPASS L BALL CHECK EP E OIL LINE CRANKSHAFT MM DISTRIBUTION 7 PUMP SCREEN BLOCK TO PRESSURE REAR MAIN RELIEF OPENING B BEARING LINE DISTRIBUTION BLOCK RIGHT HAND INSPECTION t Pro 4 OIL OIL PUMP TO DISTRIBUTION BLOCK PREPARATION Spark Plugs Hemove the spark plugs and crank the engine several times Rust inhibitor was placed in the cylinders for protection before the plant left the factory Being an oily it is very apt to foul the spark plug points making starting difficult Clean the points an replace the plugs 1 Fuel
51. FAN HUB OH HOLE OSI DO OOK 9 5 2554 ROSS BO eS 5 1 SOS beoe 20 ats 54 ALYE COVER 554 PRR S S RENI DS IGNITION CABLE CAM FOLLOWER LEVER gt QHD SPARK PLUG SHIELD A ADJUSTING SCREW FOLLOWER LEVER SPARK PEUG FOLLOWER 2 BEARING amp SHAFT VALVE SPRING VALVE SPRING RETAIN WASHER CYLINDER HEAD NUTS CYLINDER CYLINDER HEAD GASKET PISTON AND RINGS VALVE SPRING RETAINER KEY 3 2 COMPRESSION amp OIL RING CAMSHAFT TAN 1 044 PISTON PIN M S FRONT CAMSHAFT BEARING PISTON PIN LOCK RING CAMSHAFT TIMING GEAR CONNECTING ROD CRANKSHAFT TIMING GEAR OL PUMP DRIVE 1 0 86 SHA 5 GOVERNOR FLYWEIGHT TTE GOVERNOR ARM GAS PUMP ECCENTRIC FOLLOWER SHAFT amp PADDLE EO GOVERNOR CUP STUD 4 TRAUST BEARING FUEL PUMP GAS 01 PUMP RADIATOR BASE FLEXIBLE GAS LINE R RADIATOR WATER OUTLET TO FUEL SUPPLY sale PULLEY 4 CRANK 6 PUMP DRIVE SHaf e OIL PRESSURE ADJUSTMENT E n OL PUMP OUTLET GEARCASE OIL SEAL OIL BYPASS TERMINAL BLOCK Ok PUMP GE ARS GEARCASE DIL B
52. Fi SECONDS 19 _ ACCESSORY SERVICE CARBURETOR 4 This plant is equipped with a downdraft carburetor of the adjust able jet type remove accumulated sediment 1 one of the most trouble free accessories on the plant dnd should not tampered with 5 The only and attention ordinarily required is to clean the bowl each year to However in the type of fuel used or in operating or climatic conditions may make read justment necessary to keep the plant operating efficiently MAIN JET ADJUSTING NEEDLE C73 7 MAIN JET ADJ NEEDLE SPRING UPPER BOWL PLUG CT91 FLOAT VALVE l FLOAT BALL BOWL MAIN JET C59 2 METERING WELL D9059 ZENITH TUY PLATE S44 IDLE JET NEEDLE 46 25 DLE SPRING ity cli SCHARGE NOZZLE THROTTLE PLATE C21 135 THROTTLE SHAFT BRONZE BUSHING Never make a final adjustment of the carburetor unless the plant has been in continuous operation for at least half an hour This will give the plant a ing temperature mple time to reach its normal operat if the plant operates unevenly under half load or full load turn the main jet adjusting needle out for 4 or 5 turns Then turn it and power Speed and power in toward the carburetor bowl until the plant begins to lose speed Slowly open it again until the plant regains maximum This will be the
53. GE 5 PART B2 148 1 021 135 115 5 3 CR22 1 C45 25 6111 9 C23 7 624 42 T1510 8 628 27 8810 9 71510 14 0111 62 CT52 8 C130 3 CT63 1 T15B5 3 CR22 1 023 213 142 2 285 20 25 83 7 2 C6 3D C85 15 C121 14 6144 12 T1510 8 T l 10 CT91 1 C138 23 150 23 673 7 0111 21 076 23 059 2 2 4 081 2 156 23 PART Assembly Throttle Ll 8 699 99 66 60 50 u Throttle 6 6 66 590066 Throttle Plate used Lockwasher Throttle Plate ScTeW Idle Adjusting 80790 5 6 45 64265 Idle Adjusting Screw Spring 256 5 6 esses 59 69 Throttle Shaft eae EDE SES TO Throttle Clamp Lever 14 lt 4 Clamp Screw Clamp Lever Throttle Stop 1 1 Clamp Screw Stop Lever 6 686 99 666 86 Throttle Stop SOPUM Spring Stop Screws Spacer Throttle Lever
54. IZONTAL RUN 20 GREATER THAN 10 FEET TUB NGI CUT BOTTOM AS SHOW FUEL Q DER TUBE 72 NUT SHUTOFF sss 1 o ROOM IN WHICH COPPER TUBING PLANT 3 INSTALLED S S DO NOT KINK MUST V pip FASTENING MIRE TO OR AMPLE FLOW 1 WITH CLAMP AS HON CAUTION BS 1 NOT GROUND PLANT 50 0R GAL 6 TANK RECOMMENDED OR LETHARGE 14 GROUND AS cy 75 GROUNDED 45 CLOSE TO 11 INTERFERENCE AS POSSIBLE mir RESULT ne oem LOCATE TANK 50 WATER Ez 3 AN L2 O EMER ME 7 SURE GROUND UNDERNEATH TANK TO FIRM FOUNDATION AS SETTLING OF TANK ATER j ROUNDING PLANT TION MAY DAMAGE TANK CONNECTIONS 4 22 22 a paration necessary before putting the plant into operation Fill th crankcase with 8 quarts of amp good of the cover and filter element from the air clean r Fill the body PREPARATION After the plant has been installed in the proper location on mounting base the following paragraph will outline the pre inspection Check all fittings bolts and nuts Tighten any
55. LEYIBLE TUBING PIPE GOOSENECK 3 2 0 FROM THE PLANT HAKE EXHAUST PIPE SHORT 2 POSSIBLE AS FEW 90 BENDS 5 POSSBLE USE SIZE LARGER PIPE EACH gt 10 FEET OF PIPE LENGTH GOOSENECK SHOULD BE AT LEAST 24 ABOVE GROUND TO ELIMINATE CLOGGING MUST BE LARGE ENOUGH Gp TO ALLOW AT LEAST 6 INCHES j CLEARANCE TOP BOTTOM Sunn 1 gt AND SIDES OF TANK FOP E OSA LEAST 24 FROM ANY HALL SAND OP LOOSE GRAVEL JES fees E BNO BOTTOM or Tam Sow s DRILLED WITH AS MANY 1 5252 CAS HOLES AS POSSIBLE TO ALLOW zry a 00 0 PA CONDENSATION SOAK INTO Ser Seo Ras ce ANNIS 3 OR LOOSE GRAVEL pepe Y EXHAUST PIPE FITTINGS SHOULD E lt BE WELDED TO CAN IF POSSIBLE 8 A 2 lt NES AN amp UNDERGROUND FUEL TANK dr VENT SHOULD BF PROTECTED FLEXIBLE TUBE FROM WEATHER BK GOOSE FUEL PUMP NECK WITH SCREENED S OPENING PREFERABLY 3 M EAVE OF ROOF K o O NE j GROUND PLANT TO BATTERY NEGATIVE POST 4 n JS OR WHITE GROUNDED FULLER PIPE OPENING MUST BE b AT LEAST 24 ABOVE GROUND LINE WIRE AT PLANT VERTICAL LIFT TO PUMP NO GREATER THAN FEET HOR
56. Lock the adjusting screw retighten the fan support arm when adjustment has been made The cooling system can be drained by opening the petcocks at the bottom of the radiator support casting ahd at the water inlet el bows the eylinder blocks lubricating oil Use an S A E 20 oil if the temperature ranges between 509 and 809 Fahrenheit Use an S A E 10 oil if the temperature is below 509 If the temperature range is below 19 check the section on Abnormal Operating Conditions the oper pesan 0 The oil oras is 8 type oil gauge extending fr m the right hand crankcase inspection plate Check the level daily maintaining the level between the full and the low marks on the gauge Never allow the level to drop 0 the low mark RC Pow 23565 drops of lubricating oil on the joints of the link age between the governor and the carburetor and on the carburetor throttle and choke shaft bearings Remove the plug in the fan hub and fill the fan oil regivoir to the point of overflowing Remove of the air cleaner to the level indicated with new oil of the same visiosity as that used in the 8 OILING SYSTEM THIS SKETCH ILLUSTRATES THE OPERATION OF THE MODEL V 45 FULL PRESSURE TYPE GEAR DRIVEN OIL PUMP OPEN ARROWS INDICATE THE DIR
57. Loosen this nut and back it off until the nut is even with the end of the bolt and then strike it sharp blow This will loosen the armature shaft and it can be drawn off over the stud when the nut is removed 43 dicates rough eccentric commutator severely burned bar GENERATOR SERVICE On medium sized generators a more flexible type of coupling is used which will allow for slight misalignment between the engine and the generator this arrangement a flywheel is tapered and keyed to the crankshaft machined surface at the end of ES the armature shaft fits against a similar surface on the flywheel and dowel pins lock them together drawbolt clamps the entire amp assembly together in a manner similar to the arrangement used on uud the smaller generators Loosening and removing the nut at the end of the armature shaft permits withdrawal of the armature If it is desired to remove the flywheel to check the rear main engine bearing oil seal Strike the flywheel amp sharp blow at the edge to loosen it pali it off On larger sized generators the armature is bolted to the genera tor blower The blower in turn is bolted to a separate flywheel Remove the four nuts just inside the rim of the blower Support the armature while these are being loosened and when the last one is off slide the armature over the studs and set it to one side where it cannot roll o
58. O4 2 AVY GINDLIMG 7 52 TOASLNOD SHOILIINMOI E Z F KISKON S Oh ORLIFO D 5 2 2 5 2015 FAO 6311311418 4015 18 15 LR 390430 i 845 8 ains 39 2 8 2 SIL FOIS A OSE IAO HED be FLEE SATIUS SII MOTIGO SHOIN IAL A 2 7 433074 04 OF IHL 7 7 76 AL LOOMI SHON MOA LHOT OFLPIFAO SE 734 OF CEQOIMOMY S MOVED W BNIOUVHO 39 NE AME LV NO DANAMOTIOS FIS 22 FHL DMI DSYNICRT AMIATAS AI IE FHL Sh NOOS SV MOI2 COd JD FHL HILME BNL LIND AL PIA CLAMANS MAD AR SVIS FHL HL NOLU SQd AML X ATONE F b 90925 OL 424185 HOLLINDI 084 03 310039 SNILUVIS 1T3S 0009 SPA
59. RDER 1 3 4 2 DIMENSIONS c LENGHT OVERALL 43 V2 WIDTH OVERALL HEIGHT OVERALL 34 _ MOUNTING NTER W WDE CONG 71 BAND prm 5 FET BEARING SHIELDED 306 Ay BRUSH GUIDE SPIDER COLLECTOR RINGS 2 0008 BRUSH GUIDE AC 58088 GUIDE SPRING AC BRUSHES 6680585 O C BRUSH GUIDE SPRING GUIDE GENERATOR FRAME STUD FIELO COILS ARMATURE ARBOR ARMATURE POLE SHOE FLYWHEEL NUT ARM DRIVE HUB ARM DRIVE amp BLOWER ARM DRIVE HUB DISC VEN BRUSH GUIDE 3 YEARLY ENGINE SERVICING 9 Remove the valve tappet cover and oil filler tube 10 Disconnect the ignition wires and remove the spark plugs ll Remove the cylinder head nuts and lift the cylinder heads from the blocks If they stick tap the head sharply with a lead hammer to loosen Never attempt to pry them off with a bar or screwdriver 12 Remove the cylinders blocks from the crankcase Be careful not to let the pistons drop on the edges of the crankcase and become damaged Inspect the pistons and piston rings carefully Remove the rings keeping them in order so they be replaced in the same grooves and positions Scrape any Carbon from the grooves in the oil control piston rings and from the grooves and oil return holes in the pistons Clean the
60. Screw Choke 8 32 Flat Washer Choke Cover 4 5 10 32 3 4 Hd Mach Serew Choke Cover lorm OOLOWeoesoeceesescecestcevecaecesascetcecevoneeen 10 32 Flat Washer Choke Cover Term Screw 10 32 Outside Shakeproof Lockwasher Choke Gover Term 5 4 64 6 44 10 32 Hex Nut Choke Cover Term Screw 10 32 Mica Washer Choke Cover Term Screw 10 32 Fibre Washer Choke Cover Term Sorew 10 32 Insulator Bushing Choke Cover Term Screw 05 PRICE EACH 35 75 40 1 50 3 00 PRICE RACH 05 05 05 08 05 05 05 05 05 05 05 05 05 8 32 x 3 8 Rd Hd Mach Screw Bimetal to Choke 20032 8 32 Flat Washer Bimetal to Choke Body 8 32 Lockwasher Bimetal to Choke Body 8 32 Hex Nut Bimetal to Choke Body gt 05 05 205 05 Meu PART NO 1037 5578 5605 5606 5697 5607A 5608 5699 5610 5611A 5612 QUAN USED PART 5582 5585 558 5587 5588 5589 2290 5591 120429 QUAN USED OIL PUMP PRICK DESCRIPTION MT 011 Pump Dewel Pin 3 16 E 911 Pump Screen cod 24 20 Oil Pump Driver Gear with
61. VICE EXTERNAL TYPE GOVERNOR GOVERNOR ARM x gre OV DRIVE GEAR y Z OPERATING FORK SHAFT ij d Ma JL 22 5 v gt 0 777 WEIGHT PIN 2 GOV SHAFT 1 2 55552 2 P ZS X 2 FY 22 4 Fi EY AN GY 2222 45 Wp XX P ZA 7 2222 AL eet mer 2 222224222222 PELLICO LLCC ES 2 GOV BUMPER SPRING SCREW Ye GOV OPERATING BUMPER SPRING SCREW Z FORK RISER LOCK NUT GOV BODY BUMPER SPRING GOV OPERATING FORK GOVERNOR ASSEMBLY Pierce industrial type governor is bolted to the top of the gearcase cover where it is driven by the camshaft timing gear There no routine servicing required for this governor fact it should never need attention unless the engine has been o overhauled To adjust the governor proceed as follows 1 With the spring tension on the main governor spring A adjust the length of the throttle control rod so the carburetor lever clears the wide open Stop by at least 1 64 NECEM 2 Loosen the lock nut and screw bumper D out far enough so it does not function Then adjust the gov P for the desired speed the adjusting Screw C 3 If the governor surges under load or port load condi tions screw the auxiliary adjusting screw D out few turns at a time until the surging stops Keep the screw D in as close as possible
62. YPASS OUTLET HOLE PUMP TO FRONT MAIN RADIATOR DRAIN COCK CRANKSHAFT TIMING GEAR UTZ GEAR DRIVEN OIL PUMP On B 1 DD EXHAUST OUTLET 4 22222 ER 0 29 DRAIN PLUG BASE Ed MOUNTING RUBBER BASE GASKET PUMP SCREEN PUMP INLET 70 4 ES L pU TE 287 al MR CLEANER FILLER CHOKE 800Y CABURETOR OIL LEVEL BAYONET GAUGE CYLINDER BLOCK BASE GASKET I GNITION DISTRIBUTOR DISTRIBUTOR SHAFT OILER REAR CAMSHAFT BEARING IGNITION DISTRIBUTOR DRIVE GEAR FRAME ADAPTER STUDS GENERATOR FRAME ADAPTER xu e 3 GENERATOR FRAME KCASE CRAN 6 5 i DN s 5 Q INSPECTION PLATE uA NYY Ue CRANKCASE 2 mm NI N IWS 2272 t 0 a ra n CRANKSHAFT REAR MAIN BLARING OIL SEAL CONNECTING ROD BOLTS REAR MAIN BEARING PLATE FRONT MAIN BEARING PLATE REAR MAIN GEARING 7 RONT MAIN BEARING CYLINDER BLOCK ORAIN COCK ELECTRIC PLANTS FROKT QF ENGINE FIRING O
63. accessories and a was increased or decreased Two types of governors are used on these plants With one the operating mechanism is built as an integral part of the camshaft The other is a commercial type timing gear and gearcase cover mounted to the top of the gearcase and driven by the camshaft timing gear Both types are as simple and trouble free as any mechanical unit be and neither type should need adjusting or servicing unless the plant has been overhauled or the adjust ment tampered with i INTERNAL TYPE GOVERNOR GOV LINK GOV LINK BALL JOINT Y 5 4 2 4 N 2 6 SPRING STUD gt PP veg THROTTLE ARM GOV SPRING w d MAC CLAMP SCREW T SSS GOV ADJUSTING CLAMP SCREW E SCREW pA GOV WEIGHT sroP SCREW 0 k GOV CUP in NL GOV SHAFT PADDLE SHAFT PIVOT BALL Cx ACCESSORY SERVICE The governor arm is linked to the carburetor throttle arm This whenever the load changes and the speed tends to gain or drop the governor mechanism immediately moves to offset the change in load and either opens or closes 555 throttle valve to compensate for the change oval headed thumb screw permits
64. adjusting the tension of the governor spring Turning the screw in towards the body of the governor arm bracket increases the tension on the spring the en gine speed and the generator voltage Turning the screw out decreases tension speed and voltage Whenever adjustment has been made and the voltage brought to the proper figure not to exceed 125 volts no load tighten the locknut against the bracket 1f f r any reason the governor arm has b come loosened from the governor shaft it will be necessary to reset the arm To do this loosen the governor amp rm clamp screw insert a screwdriver in the Slot in the governor shaft and turn it to the right as far as possible Allow the governor spring to hold the throttle arm against the stop and retighten the clamp screw securely This will correctly set the governor arm and it will then be necessary to reset the adjustment on the spring tension correct the npepe and voltage Four flyweights so pivoted to the face of the camshaft gear that as the engine speed increases the weights tend to fly out wards forcing the governor cup away from the gear The cup bears against a paddle welded to the governor shaft rotating the shaft and the governor arm attached to its end Tension of the governor spring against the governor arm resists this motion and it is the balance of force between the spring and the 527466 that main tains an even speed 1 26 ACCESSORY SER
65. an be unbolted from the frame allowing the moval of the field coils If the wires are not damaged piece of tape can be placed over the worn spot and the grounded field coils made serviceable again E TESTING FOR A SHORTED FIELD COIL shorted or partielly short ed fieid coil be tested by met r which will measure the amount of resistance in esch coil As the amount of resistance should be practically the same in each coii if one coil shows less than the others it is good indication that that coil is shorted If there are no instruments handy for meking this test a fairly accurate check can be made when the symptoms are first noticed by feeling the temperature of the coils before stopping the 1 ant If one coil is shorted it will run much cooler than the others and by feeling the generator frame where the pole shoes are bolted to it a shorted coil can be located shorted coil must be replaced TESTING THE D C WINDING OF THE ARMATURE FOR GROUNDS If one end of test lal lamp wire is 5 placed on a clean surface of the ar mature shaft the lamp should not light when the other end is touched to the commutator If the lamp lights the commutator or D C windings of the armature are grounded and the armature will have to be replaced TESTING THE D C WINDING OF THE ARMATURE FOR OPEN CIRCUITS test lamp should light when one end of the wire is connected to MENOR d
66. and sheet metal construction with the rear main bearing oil seal being larger and pressed into the rear main bearing front oil seal is pressed into the gearcase cover Both 86638 must be replaced whenever the engine is overhauled and at any other time when they fail to operate properly and allow oil to be thrown from the crankcase Use care when installing new seals not to dam the lip of the seals on the keyways on the crankshaft Grease the shaft carefully before slipping the seal over the shaft the seals into place and shellac the surface after the seal has been 0 x 56 HR d MAJOR ENGINE OVERHAUL The camshaft is driven by a helical cut steel gear keyed to the crankshaft and retained by a large hexagon nut and washer This gear meshes with a cast iron gear eyed to the camshaft and in place by a lock ring Ordinarily one 8 r should not he re piaced uniess the other is Before installing amp new crankshaft gear the timing marks on tthe two gears should be lined up to provide correct timing of the camshaft Then press or tap the gear in place and tighten it se curely The mesh between the gears should be checked carefully A piece of newspaper should pass between the teeth of the gears without binding A piece of heavy wrapping paper should not pass between the teeth This test indicates clearance or lash of from 003 to 005 1 will
67. ase Stud Short 3 8 x 9 3 A Radiator Base Gasket 1 8 Cork Radiator Hose Upper 1 5 8 x 5 1 2 Radiator Hose Lower Rt 1 5 8 4 1 28 Radiator Hose Lower Left 1 5 8 x 7 1 2 Fan Shroud 4 9 9 699 9 66 5 eee 6 9 5 6 9 6 Radiator Cap Assembly SOOM ESTER EH ERED ODEO ESHA EE Radiator Drain Nipple 1 8 x 6 9 Radiator Drain Lock Long 185 1 8 x 1 3 4 Radiator Drain Coupling 1 8 Pipe 90 6 494 66 6 66 SOREWS NUTS AND BOLTS DESCRIPTION 5 16 x 1 2 54 Mach Screw Radiator Side Panel 5 16 Lockwasher Radiator Side Panel 5 16 x 5 8 Rd Mach Screw Radiator to Top Bracket 5 16 Lockwasher Radiator to Top Bracket 5 16 Hex Nut Radiator to Top Bracket 1 44 x 1 2 Hd Mach Screw Radiator Grille 1 4 Lockwasher Radiator Grille 10 24 x 1 1 2 Rd Hd Mach Screw Radiator Hose Clamp 10 Square Head Nut Radiator Hose Clamp 8 Lockwasher Radiator Base 5 3 8 S A E Cap Nut
68. ating hours grind valves each 1000 to 2000 operating hours clean spark plugs each 200 operating hours and change crankease oil each 100 to 200 operating hours When sane Army 80 octane fuel aviation 100 octane fuel other fuel containing more than 2 cubic centimeters of lead gallon change the crankcase oil each 50 operating hours When using such highly leaded fuels it may be necessary to remove carbon and grind valves each 100 to 200 operating hours clean spark plugs each 50 operating hours and replace them each 100 to 200 operating hours If carbon is removed every 100 to 150 operating hours the periods between valve grinding jobs usually can be considerably lengthened When using leaded fuels inspect the engine more often and give it the more frequent service required 0 mn enm 4 H PE GENERAL INFORMATION THE PURPOSE OF THIS BOOK This instruction book is furnished so that the operator may learn of the characteristics o the plant thorough study of the book will help the operator to keep the plant in good condition so that it will give efficient service n understanding the plant will also assist the operator in determining the cause of trouble if it occurs KEEP THIS BOOK HANDY Such simple mistakes 85 use of im proper oil improper fuels or the neglect of routine servicing may result in fail
69. be taken if the not to be used for an extended period rust miren d cause Serious harm 5 Preparation for Storage Drain the fuel from the tank and filter Run the plant until it stops This will remove the fuel from the line and the carburetor Drain 11 the oil from the crankcase s Drain the liquid from the cooling system or add anti freeze sufficient to protect against freezing Remove the spark plugs and pour 1 4 pint of S A E Ao lubricating oil into each cylinder Replace the plugs Cover 811 exposed rustable mechanical parts with a thin coating of grease Clean the commutator and brushes Wipe with a Pine lint free cloth Cover but do not coat any of the electrical parts Plug the exhaust opening so mositure cannot enter the valves pistons or cylinders Cover the plant so dirt and dust cannot settle on it Every two or three weeks turn the engine over few times to redistribute the oil film over the ring surfaces the plant has batteries store them in a warm spot Check them periodically and recharge them 2 gix to twelve weeks when Withdrawal from Storage 1 I 3 4 5 6 pu ul 8 9 30 di Remove all protective coverings from the plant Wipe off all traces of the grease Drain the fuel system of any water or sediment which may have accumulated Check all the fue
70. d to connect the tank to the engine If a larger x tank is desired underground tank may be used if the plant ES is to be permanently installed suggested tank is shown on the next page but check the underwriters instructions before making this installation The lift from the tank to the plant SUE should never be greater than 6 feet nor longer than 25 feet un s less a separate fuel pump is used Be sure that the tank is well vented System Flexible exhaust tubing and an automotive type muffler come with the plant If the exhaust line passes thru wall Shield the wall by passing the tubing thru amp metal aci 3 Iron pipe be used in place of the flexible tubing but ab least 12 of the tubing should be inserted between the pipe and ja the plant Increase the size of the tubing or pipe one size for every Six feet in length if the line is to extend over 10 feet All exhaust connections must be tight and free from leaks bon monoxide fumes are poisonous and extremely dangerous Be 2 ANS gt especially careful if sub ground level installation is used Ew because carbon monoxide is also heavier than air The exhaust Line should downward from the plant If it must be pitched upward a condensation trap should be installed close to the plant Any type of fitting which will collect the condensation of moisture in the
71. ding 225 ixternal Short Circuit 3 Reversed Shunt Field Open Circuit in Shunt Field 3 ALTERNATING CURRENT GENERATOR ASSY COMMUTATOR INNER TOR RING 3 uus nt FLYWHEEL Lock WASHER FLYWHEEL NUT BALL BEARING 7 PRESSED WITH ENCLOSED SIOE iH TOWARD ARMATURE CAUTION CRANKSHAFT TAPER MAST BE CLEAN AND FREE MARKS OBTA TRUE RUNNING ARMA 7 BEARING COVER STING 538 1 WITH HACKSAW BLADE GROUND AS SHOWN GRINO SIDES WIDTH OF MICA 0 TEST LAMP FOR TESTING GROUNDS OPENS SHORTS ETC 57 CANDLE VOLT BULBS WITH 12 VOLY EATERY USE 6 VOLT BULBS WITH 8 VOLT BATTERY CAUTION ween TING BRUSHES USE SAND PAPER WIDER THAN BRUSH USE 00 SANOPAPER NEVER USE EMERY CLOT OR EMERY PAPER REPLACE ANY BRUSH WORN TO 34 OR LESS M 77 GENERATOR SERVICE GENERAL The generator consist of two assemblies the armature which is the rotating part of the generator and the frame assem bly which is the stationary part of the generator fhe frame is a steel ring with two or four field coils and pole shoes bolt to the inside The brush rig assembly located in the genera tor end bell is also part of the frame assemb
72. dio Shielded Coil to Distributor High Tension Cable Ignition Coil Shield 4990 50 Ignition Coil Shield Outlet Nipple Coupling Nut Spark Plug Shield Assembly Ignition Coil Shield Clamp Lead Coil To Stop Circuit 1 Coil To Battery 1 Lead Coil To Distributor Not Illustrated Shield Suppressor Not Illustrated Tube Suppressor Shield Not Illustrated Lead Coil to Distributor Not Illustrated SOREWS NUTS AND WASHERS DESCRIPTION 10 32 x 1 1 4 Hd Mach Screw 10 32 Plated Hex Nut 10 Split Lockwasher 0686 0 Int Ext Tooth Lock Washer 4 BATTERY DESCRIPTION Cable Battery to Plant Positive 36 Long Cable Battery to Plant Negative 36 Long Battery Connector Cable 6 3 4 Long Battery Hydrometer 009 Battery Fuse Clip tese DET RET ERE OH OTE Battery Fuse 50 OTERO EEE HOD HEE HERD Battery 1761 Grant 6 EACH 65 25 5 50 25 75 85 85 35 38 25 75 1 60 50 35 35 10 PRICE EACH 02 01 01 01 PRICE EACH 90 0 75 15 12 00 65 PRICE E 070
73. djust the gap to 019 LAS Remove the covers from the ee and the spark plugs heads Remove the carbon from the electrodes EE Reset We eroe trode gap at 025 e RT 1 Generator Inspect dis commutator nd collector rings and clean then 7 1 dirty Use lint free 62800 brushes ride 656137 in the holders and make good contact SIX MONTES INSPECTION Every six months go over ali of the weekly and monthly maintenance and in addition remove the gasket plate and gasket from the rear of the gen rator Clean out all the hardened grease from the generator ball bearing Repack the bearing with not over tablespoonful of approved ball bearing grease p Never use ordinary cup grease Replace the gasket and cover Check all electrical 0 including main line dise check khe and replace worn to 5 8 If the plant has batteries clean the contact tighten the connections cover them with petroleum jelly Check all nuts bolts and screws Vibration may Loosen them impairing the 5 efficiency of the plant Tighten any that 18055 Check all hose connections Replace any hose that ds weak or Leaking Flush the radiator and engine with en water SORE aasawa Saw a a aR eg ec
74. e 8 Excessive Carbon 3 Worn Pistons or Rings 50 Valve Timing incorrect Weak Valve Springs Hot Spot in Cyiinder Head Inferior Fuel by the spark being advano Nu COMPRESSION RINGS AD ADJUST CLEARANCE WITH CYLINDER AND VALVE SERVICE SHEET VALVES VALVE SPRINGS CYLINDER HEAD GASKET 1 VALVE SPRING WASHERS e VALVE x SPRING 8 LOCKS OIL RING 7 PISTON PISTON PIN LOCK RING A eu PISTON PIN TO INCREASE PUSH IN TO PULL OUT SECURELY AFTER ADJUST THICKNESS GAUGE TON ON POSITION OF THE COMPRESSION STROKE BOTH VALVES MUST HE CLOSED SETINFAKE VALVE 008 SETEXHAUST VALVE O19 VALVE CLEARANCE CHECK 31 XEARLY ENGINE SERVICING Bach year if the RE 45 used under normal conditions the accumulated hours of operation will total 2500 or more After every 2500 to 3000 hours the engine should be given amp thorough checking over the valves should be ground the carbon removed and the pistons piston rings valves bearings etc should be carefully checked Valve 07 07 by thorough eleaning of carbon is one of the most frequently reouired service operations in a modern gasoline engine As the plant during the years service has ordinarily been used to an extent comparable to 4000 to 5000 miles in an automobile the increased e
75. e Shakeproof 05 10 32 x 7 8 Rd Hd Mach Screw DO Jumper Strap iQ Brush Guide End 05 10 32 3 8 Rd Mach Screw Spider End 05 10 32 Outside Shakeproof Lockwasher Brush 006 u 05 10 32 Outside Shakeproof Lockwasher Spider ind Flat Brass Washer Brush Guide End Flat Brass Washer Spider 05 3 8 Lockwasher Gen Adapter 0 Stud 05 3 8 SAE Nuts i WT Gus 5 7 16 Generator Frame Support Stud pos NS 75106 PART NO 14124 1412B 44128 14121 141406 1414D 14224 1426 1428A 1430 1431 1438 1483 1513 1517 3522 15534 1554 1566 1630 1646 3300 5301 5302 5303 5304 5305 12795 127954 5937 8739 8740 8743 10750 19414 10420 10615 12820 12821 12822 12823 75105 45 CONTROL PARTS E BS PRICE DESCRIPTION EACH Charge Rheostat Assembly 2 Ohm Model J Ohmite 2 50 Charge Rheostat Knob 6 18 Resistance Unit Wire 10 Turns 250 W 12 Volt D C 70 Charge Ammeter 10 0 10
76. e eese i Maintenance Daily e e HE cun Nc t Weekly 99996 99 99 69 46 686 5 6 66 Monthly Maintenance boos tenes checks Six Months General Trouble CAUSES Accessory Service ve mr ET RR Air A Automatic 05 0182 i 42 Spark PLUGS 568 688 Distributor 6096 9998 999699 099 949 0606656969 9 9 6 6 09 666 Battery Care and Governor Internal 7759 SESS es VEN E T Governor External Type s Fuel PUNmD 4 646 649 069 96 P BOR E TABLE OF CONTENTS CONT D SUBJECT Engine Service Diagnosis 5 ee eee 99 65 9 9 99 6 6 99 69996 5 5 9 Engine Disassembling 1 8 Valve OrindlhSoke w AA cb Adjustment E Edu ad DI i a 8
77. e level 3 gn above the top of the plates not fill MS the top of the battery Check the charge condition with a hydrometer If the reading is below 1250 specific gravity increase the EEE rate if above decrease the charging rate Eleotri nt Inspect all electrical connections Be sure that they are clean MAINTENANCE MONTHLY MAINT TANCE Each month or after 200 hours of operation check the following points in addition to those covered in the regular weekly servicing Lubrication Drain the crankcase while the engine is warm ponies the plug refill with amp quarts of new oil of the proper grade and viscosity Check the oil level in the fan hub and oil if necessary sure that the filler plug is tight 5 Place a drop of Light oid on the following carburetor throttle shaft bearings choke shaft bearings and governor link dp Clean the air cleaner element drain the oil cup and refill witi engine oil of Same grade that used in the crankcase 0 Ignition If the plent has magneto ignition remove the cover fion the magneto and inspect the breaker points Clean the 01 with fine stone 0 the 6 014 016 On plants having battery ignition remove the cover from the distribut r cl an the points crank the engine until the pones open end a
78. e seats The exhaust valve seats be removed and replaced if too badly burned or cracked Usu ally a pitted valve seat can be restored to good condition by using reamer designed for that purpose all carbon from around the valve seats and the top of the cylinders Put a thin coating of a medium grade of valve grinding compound on the face of valve Slip a thin coil spring over the valve stem and insert the valve stem in the guide Using a valve grinding tool rotate the valve back and forth against the seat The spring prevents too much pressure and assures easy removal 55 s M YEARLY ENGINE SERVICING After several cycles back and forth lift the valve and turn it so different surfaces of the valve face and seat will be touch ing tepeat the rotating process until bright silvery band the width of the valve seat extends all around the valve face amp nd the valve seat shows hig gh polish new compound when ever it loses its cutting properties Remove the valve and vipe all traces of the grinding compound from the valve and valve seat Using a soft pencil draw marks across the valve face iieinsert the valve and rotate it against the seat If the pencil marks are erased a gas tight fit has been secured but if not repeat the grinding process until each valve will pass this test After all the
79. eaner to Radiator 868826 as Cleaner Air TORE 9909909299 Breather Crankcease 0 0 9990090099099695 Inverted Elbow 400 x 4 Weatherhead Air Cleaner 1 0101 Stret Elbow 1 8 Pipe Thread Weatherhead SCREWS NUTS AND BOLTS DESCRIPTION 1 4 x 1 Rd Mach Screw Clamp Screw 1 4 Square Nut Clamp S rew ea 1 4 Wing Nut Air Cleaner Stud 10 24 x 1 1 2 Rd Hd Mach Screw Radiator Hose Glamp eecosovevosacvecbesoe 30 Square Hd Nut Radiator Hose Clamp FUEL TANK AND FITTINGS DESCRIPTION Fuel Supply Tank Complete Round 5 Gal Fuel Tank Fuel Tube Base Complete Round 5 Gal Fuel Tank Tube Gasket 6969906466 Fuel Tank Tube with Fuel Supply Tank Square 5 Gal Manual Plants Only 9 Fuel Tank Brackets for 5883 Fuel Par Fuel Valve Drain and Outlet to Carburetor Reservoir 9090059996 Tank Mounting Gasoline Line Support Gasoline Line Clamp Two Way Valve for Fuel Flexible Fuel Line 42 Long with 1 4 Invert ed 69969 60
80. ed Connecting rods are drop forged steel with replaceable steel backed babbit liners The crankshaft is also drop forged Main and camshaft bearings are steel backed babbit The main bearings are pressed into bearing plates bolted to the crankcase and line reamed The camshaft bearings are pressed in to the crankcase and then line reamed Two types of governors can be f rnished With one the governor mechanism is an integral part of the camsnaft timing gear With the other an industrial type governor is bolted to the front gearcase and is driven by the camshaft gear Neither type should require any servicing or adjusting unless they have been 92 ed with or the engine has been disassembled The downdraft carburetor is equipped with needle valves The choke is either manual or automatic In the latter case the automatic element is mounted on the carburetor choke valve shaft and controlled by a thermostatic coil actuated by an electric element The air cleaner mounts on the carburetor intake and draws air thru conduit to the front of the radiator connec tion between the crankcase ventilator and the air cleaner draws oil fumes back into the engine thru the carburetor where they help lubricate the upper cylinder walls and valves Spark plugs and high tension cables are selden to prevent ra dio interference Ignition current is supplied either from battery thru coils and distributor or from a 08 driven fro
81. ed Motors Service Branches and Authorized AC Service Stations who are prepared with parts and fixtures for repairing all types of pumps There are some service operations on this fuel pump that can if necessary be done without referring to the service station and these are tabulated on the reverse side of this sheet In some instances trouble is attributed to the fuel pump which in reelity is caused by some other condition These should be carefully checked to avoid the needlesa replacement of fuel pumps 27 THE AC FUEL Hints cont d LACK OF FUEL AT THE CARBURETOR n Check as follows DEM HERMES 7 Cause 5 Gasoline tank empty Refill Leaky tubing or connections Replace tubing and tighten all pipe connections 5 at the fuel pump and gasoline tank PERPE Bent or kinked tubing Replace tubing 2 7 E pss _IH V Glass bowl loose Tighten thumb nut making certain that cork gasket lies flat in its seat and not broken Dirty screen Clean the screen Make certain that cork gasket is properly seated when reassembling 760655 valve plug Tighten valve plug secueely replacing valve plug gaske
82. ernating Current Generator Assembly ee 95 99 9 9999996999 68688 of Commutator and Brush8S 4 Wiring Repsir Parts Illustrations Engine 0 Engine 846668801188 ce ce 5 6 9 65 9 9 6 99 6 96 9 6 6 6 6 9 6 9709999 9 6 9 9 999 9669998 66 29 30 33 34 34 34 35 36 45 46 48 55 Cross Bee ion View enne s s of Book 0 4 2 in front of the fan SPECIFICATIONS MECHANICAL DETAILS Engine A four cylinder four cycle L head water cooled engine is used in this Two blocks of two cylinders each are mounted at a 909 angle from one another common crankcase The cylinder bore is 3 the stroke 2 1 4 the piston displace ment 77 8 cubic inches and the compression ratio 5 1 2 to i Due to the V design the engine develops 14 5 horsepower within amp n overall length but slightly longer than a two cylinder engine with half the power Cylinder heads and cylinders reuoveable The crankcase can gt be separated from the cast iron oil and mounting base Inspection plates are located on either side of the crankcase Cast iron three ring 2 compression and 1 oil control pistons are us
83. factorially and the entire system is more efficient The location should be such that the air not dirty or extremely humid If Xhese conditions can not be avoided the plant should be inspected more often Also take any preventive or corrective measures necessary Sub ground levels are to be avoided because of dampness poor air circulation and possible coll ection of dangerous exhaust gases leaking from the line If the plant is to be permanently mounted a base should be built and the en closure should be at least 10 feet square If it is to be operated as a port able unit sub base should be provided and th plant protected against extreme exposure to the elements If installed aboard a mobile vehicle the compartment must be as large as penis and sufficient ventilating provided VENTILATION This is an important factor as any gasoline engine generates 2 great deal of heat which must be dissipated Overheating will reduce the effi ciency and may cause damage to the plant The air that circulates must be clean Otherwise it will deposit the dirt on the plant This will act as 8 blanket and reduce the cooling so that the plant will overh at The plant should be imata Lad at least 24 away from any wall or air circulation barrier If the plant is mounted in an enclosure air intake and discharge openings should be provided They should be at least 1 1 2 times the size of the radiator The ai
84. fficiency and savings in operating costs will more than make up for the and labor invested inspection plates are provided on both sides of the engine case By removing these plates and inserting a trouble lamp in to the crankcase practically all of the wearing parts can be inspected by sight or by feel to determine the extent of the ser vicing needed making this inspection first and estimating the extent of repairs beforehand necessary parts and gaskets can be ordered from the factory so the plant will not be out of operation for more time than the actual servicing requires We recommend that the following parts plus any additional parts which inspection has indicated needed should be on hand 1 complete set of engine gaskets to include cyiinder head gaskets 2 cylinder head cap gaskets 2 2 cyiinder base gaskets 2 intake manifoid gaskets 2 water inlet gaskets 2 exhaust manifold gaskets 2 water outlet gaskets 1 carburetor flange gasket 2 inspection plate gaskets 1 valve tappet cover gasket 2 A complete set of radiator hoses 3 A set of piston rings 4 assortment of valves valve Springs locks ete sufficient to replace any warped or burned valves broken springs or worn guides that may be discovered To disassemble the engine for valve or piston service follow the outlined procedure Disconnect ail main lines or batteries o the pinos Drain the wa
85. g Oil Base 3 8 Pipe Plug Cyi Water Outlet Temperature Guage Hole ee eee ee 666 92 68 set 99 6 6 01690 866 PRICE EACH 05 05 05 7 05 05 95 5 05 2 95 05 05 05 05 05 05 05 05 05 05 05 305 05 05 O5 05 05 05 05 05 677 2 05 7 DES M GM IM anb NO 2268 5729 5740 574Y 572 5743 5745 5746 5747 5748 5756 5757 5758 5882 122174 12219 12220 12221 QUAN USED N PS 09 09 P PS E 66 ENGINE ACCESSORIES PARTS RADIATOR DESCRIPTION Radiator Hose Clamp csccscccccccscnsvcescncccsccssceesserenesced Radiator Filler Cap Oniy 660 6669969996 ESHER ER Radiator Top Casting bevoosoccestutot hnoehoeteontseteciesst anuavev Radiator Grille 664249994549 Radiator Base Casting 2996 0099999990 Radiator Side Panel HEH HEY Radiator Core amp nd Tank Assembly eT 86 8 6 Radiator Base Stud Long 3 8 10 5 16 Radiator B
86. gine up to a certain point Remove the radiator from the engine With this removed the can be unbolted and removed from the oil base The gearcase is also exposed and can be Temoved to service the gov ernor or the timing gears Examine each part as it is removed and decide which must be replaced which need adjustment ana which just need cleaning Replace any parts of which there is doubt as it is poor economy to use a part worn to an extent that replacement would be necessary before another servicing should be due Replace all worn or scared pistons pins and rings The cylin ders can be honed or bored to an oversize diameter and larger pistons be furnished by the factory Have this work done in competant properly equipped shop or if this is not practi cal new cylinder blocks using standard sized parts be ob tained New connecting rod bearing inserts be installed to restore proper bearing clearance unless the bearing journal sur faces have become seared or rough The main engine bearings are not adjustable but should seldom if ever need replacement If necessary the old bearings can be punched out of the case and new bearings can be set in sure that the oil groove in the babbited bearings heads in a direction opposite to the rotation of the shaft The bearings must then be line reamed to the proper size Two oil seals are used Both are of leather
87. k the handle will be pulled from your pranp While cranking ihe plant partially close the choke valve 18 cold temperature completely lose the choke to obtain a rich fuel mixture average temperature or when the engine is warm only slight choking will be required Avoid too Eins mixture or flooding of the carburetor If the engine does riot start repeat the process If it Will not start after several attempt check the ignition System fuel supply position of the fuel shut off valve etc With a new plant or one which has not been used for some time several cycles of crank ing may be necessary to bring fuel to the carburetor When the engine has started vary the choke adjustment CM engine has warmed up Gradually open the choke valve until the full open position is reached with the engine running setisfactor ily El ctric Start Plants Press the start button and hold it for about 5 seconds and then release it repeat this procedure until the plant starts allowing about 10 seconds between attempts If the plant does not start after several attempts check the fuel ignition systems automatic choke is mounted on the car buretor and no manual choxing is necessary an emergency if the electric start system fails to start the plant or the starting batteries are low the piene may be start ed in the same manner as the Manual Plants Chec
88. k the panel controls if any to see that the engine is operat ing satisfactorily After the engine is warm close the electri cal disconnect switch to connect the load Check engine operation periodically During the first 10 hours of operation when the plant is new or has just been run the plant at not _ over 1 2 load STOPPING THE PLANT stap the pla bs press the Stop button on the nt or at 8 remote control station Hold this button down until the engine has completely Stopped ar fn an emergency if the stop button fails te works the plant can 06 stopped by closing the fuel shut off valve at the gas tank 7 The engine will continue to run until the fuel in the carburetor bowl has been nearly used up and will then stop for want of fuel Use this method to stop the plant or the last dime if the is to be moved to new location ll uuu Pn REIE CIE 5 ET 78 ABNORMAL OPERATING CONDITIONS COLD WEATHER fuel The fuel tank should always be kept full to prevent con densation within the tank Under extremely low temperature Strain the gasoline thru chamois skin to remove all particles of ice or water Check all filters and screens periodically clean thoroughly each time Lubrication Keep the temperature PT the plant as high as possible Crankease Run the plant until the engine is warm and then drai
89. ket Sia RE Ra 10 32 Inside Shakeproof Lockwasher Governor Arm to 10 32 Inside Shakeproof Lockwasher Governor Arm Ball Joint 10 32 Hex Nut Governor Arm Ball Joint Cotter Keys Governor Link to Ball Joing OIL G UGE ASSEMBLY DESCRIPTION 011 Pressure special Double Ell Weatherhead Tube Size 5 16 x 1 4 1 8 Pipe Thread EXTERNAL GOVERNOR ASSEMBLY DESCRIPTION Governor 6 6 6 6 6 6 9 8 8 7 Governor 4 Governor Idler GOAL 69 5 69 6 6 6 6 Governor Gear Shaft 4 60 9 9 6 9 Governor Gearcase 60413 6 4 Governor Spring Carburetor to Governor Link Governor Ball Joints wo wo a Pow amp PRICE EACH 20 720 0 5 15 65 15 40 1 15 20 2129 PRICE EACH 05 95 95 95 05 05 05 05 PRICE 70 4017 inve
90. l lines to be sure that are M d that the connections tight Replace the filter bowl gasket Fill the fuel tank and open the shut off Fill the cooling system use anti freeze if necessary Check tighten all electrical connections Inspect and clean the spark plugs Clean the breaker DS in the magneto distributor Adjust them Zt Turn the engine over times with the spark plugs lt removed This will remove the oil in the cylinders and fill the fuel lines and carburetor Check the tension of the fan belt Readjust if needed and add oil to the level in the 88 hub When batteries used check the condition nect them to the plant Nu Replace the spark plugs and start the plant in the usi 1 manner Fill the lubricating system with the proper grade of oil 4 tug 2 E E ES ETS MOS 340438 DRILNVIS 3136 KIVI NOANO NO LOH SWISNZONOA ISA HIVA Dy SUISA N92 v 3ST SHSSNSONO2 D LON M MR 7 2 2 04 2 428SANOD F 34443904 0223300602 L ge ONIONS ING
91. lubrica tion overheating or defective rings d Engine overheated due to poor ventilation Troubles peculiar to electric start plants only 1 Plant does not cranks Discharged starting batteries b Loose battery connections Open circuit in control box 2 Battery run down a Open circuit in wiring b Charge relay not closing c Voltage regulator relay not functioning pro perly cuts down charging rate before the batteries are fully charged d Dead cell in battery e Lack of water 3 Battery will not take charge tes m internal short in Open circuit in charging control winding 5 18 Battery plates 454 Ct 7 A T a xu 4 Y ACCESSORY SERVICE SHEET GAUGE 1 OIL LEVEL SHOULD BE MAINTAINED BETWEEN FULL AND LOW MARK NEVER ALLOW TO DROP BELOW LOW MARK AUTOMATIC CHO USED ON FULL AUTOMATIC MODELS CONTROL BOX DISTRIBUTOR OIL GAUGE BELL HOUSING BAND CONTROL BOX POINT GAP SET AT O20 MANUAL FUEL N gt zr DO PRESS STARTER PUMP TO FILL 12 E CONTINUOUSLY CARBURETOR WHILE STARTING Wi P5 INTERMITTENTLY FOR PERIODS OF ABOUT
92. ly and it is not necessary to separate these when removing the generator from the engine Ordinarily most generator troubles can be checked and corrected without disassembling the generator by removing the band around the generator end bell When this band has been removed there is ample room for replacing the brushes or brush springs or for checking the various parts of the generator The most common reason for a generator failing to produce cur rent is an external short on the main line or in the control or outlet box Disconnect all wires leading from the generator run a test lamp across the output of the generator while it is running If the test lamp lights the external circuit must be checked for amp short circuit or amp loose connection but if it fails to light the generator is at fault snd steps must be tak en to locate and correct the trouble Check the brushes to make sure that they ride freely in their holders end that there is sufficient spring tension on all the brushes Check the wires leading from the brushes If every thing appears to be normal disconnect all batteries or main line vires from the plant Raise the brushes in their holders until the springs slip down the sides of the brushes and keep them from making contact with the armature Disconnect the D C field wire and proceed as outlined in the following paragraphs using the tests which apply to the generator to be te
93. m the D C Generator winding A valve is mounted on the choke shaft and is off center in the body When the engine is cranked and the air passes from the cleaner to the carburetor the off center position of the choke shaft allows the valve to be push ed open slightly by the air stream working against the tension created by the thermostat on the shaft During the period while the engine is warming up to normal oper _ ating temperatures the small choke shaft knob sheel locat at its outer end will indicate the choke valve is oscillat ing rapidly the engine reaches normal temperature the cillation will cease and the choke valve will be open With the engine cold turning the choke knob to the left counter clockwise should result in the carburetor being completely choked lmproper operation of the choke assembly will be indicated by hard starting or irregular running during the warm up periods A proper adjustment of the assembly can be made by loosening the small screw clamping the thermostat housing to the carbure tor choke shaft boss and rotating it in a clockwise direction when looking at the choke knob to decrease the air mixture or counter ci ockwise when looking at the choke knob to in crease the air mixture to 8 position where it will give the results indicated in the foregoing paragraphs Re tighten the clamp screw securely after the proper adjustment has been made SPARK PLUGS The spark
94. m the camshaft gear type oil furnishes pressure lubrication to tne main and connecting rod bearings Spray fron the ends of the bear ings lubricates the pistons valves and other wearing parts An oil drain is located in the base A bayonet type oil level gauge extends thru the right hand inspection e 011 capacity 3996 quarts The cooling system is of the thermal syphon type having a capa city of 17 quarts The fan is four bladed and nas an oil lu bric ted hub which is driven V belt at 1 1 10 times engine Speed Air is discharged or pushed out over a radiator located i SPECIFICATIONS ELECTRICAL DETAILS Generator The generator is a standard four vole self excited alternating current type with the frame bolted to an adapter ring on the engine crankcase arusture is coupled to the 1 40661 by metal disk type coupling which serves a solid drive mem and at the same time accommodates ony misaligreent between the engine and the generator The rear main crankshaft pearing supports the lorward end of the armature and tne outboard end is carried in grease sealed ball besring Both alternating ana direct current are Windings for both types of current are wound on the same armature shaft and pole pieces The direct current is token from an oversized com mutator and the alternating current from large brass collector rings by carbon orushes The direct
95. mperature rise CONTROLS Manual Plants These plants are equipped with for start ing push button for stopping Ignition is furnished by a gear driven magneto with an impulse coupling to insure easy start inge The carburetor is manually choked 266686 Control Plants These can be started electrically by by pushing a button either at the plant or at a remote control station which can be set up at any point within 250 feet of the plant Ignition may be either of the magneto or the battery distributor type An automatic choke properly controls the mix ture of fuel and air entering the carburetor Stop buttons also located at the plant and at the remote control station In case the batteries are discharged or if for any reason the plant will not start when the button is pushed hand crank is furnished Py which the plane can be started manu ally 5 2 1 extremely cold weather the temperature of the enclosure can be controlled by INSTALLATION The proper installation of the plant is absolutely necessary for satisfactory and continuous service Location ventilation and temoerature are among the main factors to consider LOCATION The plant should be located centrally with respect to the electrical equipment it is to operate This allows the use of small size current carrying wires a result there is less voltage loss the equipment 5 more sat is
96. n the oii 6 quartg of S A E 10 oil with one quart of kerosene or any other suitable diluent Fill the crankcase and run the engine for at least 10 minutes to be sure the 041 has circulated to all parts of the motor Never di lute an oil heavier than 5 20 nor add Kerosene alone Diluted oil must be drained after 50 to 60 hours of operation and replaced with new mixture oil must be warm before it drained Under extreme low temperatures dr amp in the oil more of ten to remove water condensation Air Cleaner Clean and refill the air cleaner with oil of the same viscosity as that used in the crankease if the oil tends to congeal or frost forms to restrict operation of the cleaner rinse the cleaner element in gasoline and replace it dry Cooling System Radiator Flush thoroughly Engine Flush thoroughiy und separately from the engine doses Check all hoses and replace them if necessary Tighten all hose clamps _ Gaskets Inspect all gaskets especially the gaskets if necessary Tighten all nuts Fan Belt Inspect the fan belt Adjust or repiace it Anti freeze Use an available anti freeze of a standard type Aleohol Giycerine or Eltylene Glycol types may be used Prepare the mixture according to the manufacturers instructions Never mix two types of anti freeze together the solution to the cooling system but leave room for expa
97. nd the carburetor Then replace it and oil the moving parts such as the throttle and choke arms COOLING The cooling system should be thoroughly flushed io if available a cleaning agent should be used for the radiator Ins pect the condition of the hoses and if necessary replace them Check the tension of the fan belt and see that the hub is well lubricated GOVERNOR ADJUSTMENT See the Accessory Service Section for the gt operation of the governor before making any adjustments The n proper operation is essential for correct engine speed and gen erator output 84 2 EARLY ENGINE SERVICING RUNNING When a reconditioned plant is first started little or no load should be connected during the first several hours of operation This will allow the new and reconditioned parts to wear in without ex cessive wear and prolong their life It is advisable after such 8 run in period to go over each of the nuts and bolts especially those holding the cylinder and cylinder head and retighten them Also remove the valve tappet cover and recheck the clearances readjust them if necessary THE FOLLOWING IS A TABLE OF CLEARANCES FOR BEARINGS AND OTHER PARTS OF THE ENGINE AND SUGGESTED METHODS FOR CHECKING THEM MINUMUM MAXIMUM TESTING DEVICES Valve Tappet Clearance Intake 7 7608 770108 fhickness Gauge Valve Tappet Clearance Exhaust 010 012 Thickness Gauge Valve Seat Width A11 3 64 1 16
98. nsion of the Licuid when heated Check the level daily especially when temperature changes are frequent and add anti fr eze to main tain the strength of the solution Never use kerosene or distillate for an anti freeze Such liauid will not satisfactorily cool the engine and will allow overheating with resultant wear on the engine parts With inflamable liquids the danger of fire is also increased Electrical System ignition Inspect the spark plugs and breaker points per iodically Keep them cleaned and adjusted pro perly Batteries Batteries must be kept fully in low temperatures Discharged batteries will freeze and become damaged beyond repair at about 209 p Never add water to amp cold battery The water might freeze before it became mixed with the electrolyte Store low or discharged batteries 19 in warm place until they be recharged ABNORMAL OPERATING CONDITIONS HIGH TEMPERATURES 7 Fuel Never fl the fuel tank bil when the weather is extremely warm Gasoline is very to expand and overflow full tank creating amp possible fire hazard lubrication Keep the oil level at the full mark on the gauge Maintaining a lower level is dangerous the engine will run hot Maintaining higher level can be equally dangerous as the oil may foam and as a result the parts which are 007 spray lubricated would receive no oil
99. olished Blackening of all the bars indicates an incorrect brush position Blacken ing of groups of bars at regular intervals may be due to the same cause or to poor contact Blackening at irregular intervals in or number of bars plus excessive flashing when the plant is un der load indicates an open circuit in the windings Use a lint free cloth to keep the commutator grean 44 Before installing the frame onto the crankcase remove the bear ing at the rear of the generator and clean the bearing sur face in the frame and the bearing on the armature shaft Line firm even contact with the commutator or collector rings Always before attempting to start the engine turn it over slowly for several revolutions to be sure that the armature is not binding GENERATOR SERVICE Over a period of time the copper bars will wear down to the level of the mica insulation The mica is harder than the copper and will form ridges which will cause the brushes to jump make poor contact and be very noisy noisy brushes always an dication of a rough commutator It will be necessary to re turn the commutator as described above to correct this condition Never use lubricant on the commutetor or use of amp ny lubricant will increase commutation difficulties and REGE the brushes REASSAMBLING THE GENERATOR Keassembly is made by reversing the proced
100. plugs used in this plant are Champion 6 030 They should be removed cleaned and gap set to 025 to close inspection should be to determine by the condition of the porcelain and spark electrodes if the plugs Should be replaced rule replacements should be made after 1500 to 2000 hours of operation The new plugs should be of the comparable make and type Visual Tests of spark plug operation Iy 2 If the insulator is light brown operation is satis factory If insulator is a dead white color plug is too hot or mixture too lean If insulator has dull sticky deposit plug is too cold or mixture too rich If insulator has shiny black deposit plug is too cold or engine is pumping oil lf electrodes are burned piug is too hot or poor fuel has been used 2 hot plug has a large e the insulator exposed to burning gases cold plug has amall area of the insulator exposed to the burning DISTRIBUTOR Plants using battery ignition have an Auto Lite 4115 distributor This is gear driven by the camshaft An oil cup amp t the base is provided for lubrication The distributor oil ing and breaker points should be checked according to the Service page 22 Breaker pont clearance is 025 to 030 Qm Vor ACCESSORY SERVICE 10 CARE BEND ATTENTION With an
101. r become damaged ARMATURE The armature is made of of a stack of perforated disks or laminations pressed onto a shaft Wire is wound on this stack and the ends are connected to copper bars or rings On direct current generators there are only the bars called commutator from which direct current is drawn On alternating current gen erators there are both the bars commutator which supply direct current for exciting the alternator field coils and rings known 1 collector rings which supply alternating current Separate windings used for the bars and rings but both windings are wound on the same shaft Always handle the armature carefully and do not allow it to roll around 1 can be easily damaged by rough handling The commutator on the armature is probably the most frequent Source of generator trouble If it is dirty from brush wear clean it with kerosene If it is rough or pitted the armature must be mounted in a lathe and the commutator turned until smooth It will then be necessary to shave or undercut the insula tion amp bout 1 32 below the level of the copper to allow the brushs to ride on the copper bars without interference Polish the com mutator carefully and be sure that there are no metal particles in the cuts If the plant should be started with metal particles between the bars the armature windings would burn out The commutator should maintain a p
102. r inlet should be as close to the plant as possible Both types of openings should be shielded with a screen louvres A thermal ventilator in the form of a cupola or stack can be built into the roof to provide normal air circula tion when the plant has shut down Additional ventilation precautions must be bh when the plant is mounted aboard vehicle Usually the compartment is small so that more openings have to be provided These can be directly above the cylinders opposite the fan or in the floor closing off the openings and allowing the heat of the plant to heat the room Normal temperatures can thus be maintained When used as portable unit some type of wind barrier or temporary walls should be used to keep the plant at the correct operating temperature MOUNTING BASE If the plant is installed permanently on a base it should be high enough from the floor to allow easy access to all of the parts and to guard against damage which may be caused by bumping the plant with other objects The base should be frou 9 to 12 high The plant should never be bolted solidly to any foundation Shock mountings provided to prevent vibration from the PROPER INSTALLATION amp Ds MOUNTING BASE US PROPER INSTALLATION PROPERLY INSTALLED ELECTRIC PLANT FOR PERMANENT INSTALLATION SHOULD BE
103. rator to supress radio interference 42 GENERATOR SERVICE odo ghee EON GENERATOR DISASSEMBLY If 09 tests have shown that the field coils or armature need servicing or replacing the generator must be removed from the engine and the armature dis connected from the engine crankshaft If there is fuel tank mounted on the generator it must be removed Likewise any con trol box installetion mounted on the generator shouid be taken off and set aside plants which have a starting sheave at the rear of the generator loosen the set screw and pull it off the armature shaft taking care not to lose the key which 628 jt to the shaft 0 REMOVING THE FRAME FROM ThE ENGINE Ali generators are carried on a turned diameter at the rear of the crankcase After any accessories which were mounted on the generator have been ed the frame itself can be separated from the engine by loosen ing and removing the bolts which hold it in place and drawing it off over the armature If it should stick when unbolted well directed blow with a hammer and punch at the inner rim will loos en the frame from the adapter ring Use great care when drawing the frame over the armature Never allow the frame to touch or rest on the armature the weight of the frame can bend or distort the armature shaft enough to make it unserviceable BRUSH RIG It is not necessary to remo
104. rted islbow 400 x Pressure Gauge 9 e 9 wv 9 25 1 50 20 EACH 7 3 00 05 3 25 75 2 1275 95 24 00 75 10 E 7 NES 2 Sci ie 345 GENERATOR PARTS 212 1004 Spring Brush Not lustre used PRIOE PART NO m DESCRIPTION EACH 513 Armature Hub Drive Dise 35 572 Armature Hub Drive Disc Nut Lockwasher 05 1269 Ball Bearing Grease not illustrat d 045 2014125 Armature Assembly 5055 Armature Ball Bearing 77306 5 35 5060 Armature Drive and 1 2 00 5062 Armature Hub Drive Dise TP 75 5064 Armature Drive Hub 1 10 5065 Armature Drive Washer 11 32 ID x 3 4 OD ec MC es 210A1086Generator Frame Assembly with Field Coils 5102 Governor Frame Thru Stud 4 used 35 5105 Pole Shoe Assembly 7 1 2 5000 Watt i A USOT ADD 5106 Frame Illustrated 24 00 222 1096 Generator Field Coil wd 5116 Generator Field Coil Only not illustrated Ce uc 5140 Generator Frame Adapter 4 30 UM 5142 Generator Adapter Ring Stud 6
105. s Blow the jet out with air to clean it Never use a wire to scrape the jet or the size might be changed When re placing the jet be sure that the small fibre gasket is place beneath the head of the jet AIR CLEANER The air cleaner is of the oil bath type mounted on the carburetor intake A flexible hose to the radiator allows clean air to be thrown into the carburetor The cleaner is also connected to the oil filler tube from which it draws all oil fumes back into the engine where they help to lubricate the valve stems and upper cyl inder walls The filter so operates that dirt and dust are de posited directly in the oil or accumulate on the Screen from which they drain into the oil The air stouid be serviced each time the oii is changed in the crankcase If dust conditions are severe or there is than 1 2 of accumulated dirt in the oil cup service it more often Remove the cleaner pour out the old oil and clean the dirt out of the cup Dip the cleaner element in kerosene to clean the screen and allow it to dry Fill the oil with clean oil of the same grade as that used in the crank case replace the cleaner tighten securely 1 9 ACCESSORY SERVICE AUTO TOMATIC CHOKE The automatic choke consists of a thermostat mounted directly on the choke butterfly shaft of the carburetor and operated by a nichrome heating element obtaining current fro
106. sted All Onan generators produce direct current but only those rated as amp lternating current generators need be given kids additional tests for that type of generator TESTING FIELDS FOR OPEN CIRCUITS Connect one end of a test lamp wire to one field wire and the other end to the other field wire The test lamp should light if the field coil wir ing has not been broken If it fails to light the winding or circuit is open and new 21616 coil set must be installed However if the break is in wire connecting two coils the connection can be resoldered and the plant will again operate TESTING FIELDS FOR GROUNDS Connect one end of the test lamp wire to one field wire and the other end to a clean surface on the generator frame If the lamp lights a field coil is ground the field coils must either b replaced Temperature changes cause metal to ez or 01 Varying degrees of expansion between the iron in the frame and pole pieces and the copper in the wiring of the field coils can cause a chaf ing which may over long period of time wear thru the ins la tion protecting the field coils and allow the wires to touch the frame The electric current which should go to magnetize the pole c pieces will be side tracked no magnetic field will be set up and 00086007 no current vill be produced 41 i _ GENERATOR SERV the pole pieces c
107. sy 5 00 Side Outlet Elbow 1 4 Std Special Housed Model Va o 1 50 Reducing Bushing 1 1 4 to 1 Special Model 1 15 Pipe Nipple 1 x 4 Special Housed Model see ECKE RN eae eee 20 Pipe Nipple 1 1 4 x 29 Special Housed Model 00 20 1 25 Pipe Elbow 1 1 4 x 459 Special Housed s Model 1 4 6 0 Pipe Tee 1 1 2 Spec Housed Model Only ii Close Nipple 1 1 4 Spec Housed Model Only 2i Reducing Elbow 1 1 2 to 1 1 4 x 909 Housed Model 6 Asbestos Wrapping 2 ide Spec Housed Model Only per ft 1C 20 NUTS AND BOLTS TEES PRICE DESCRIPTION EACH 5 16 Lockwasher Outlet 05 5 16 S A E Nut Exhaust Qutlet 0 5 16 x 1 Hex Hd Screw Exhaust Tube p to LARA 2268 5911 5918 5951 10657 12121 W 3400x2 QUAN USED N PART NO 649A 6498 650 6508 6514 5848A 5878 5905 5913 5914 5915 5917 19466 19469 W730 W3400X2 AIR CLEANER DESCRIPTION Radiator Hose Clamp 2 To Air Cleaner Air Cl
108. t if necessary Dirty or warped valves Remove valve plug and valves Wash valves kerosene damaged or warped replace them Examine valve seat to make certain there are no irregularities which prevent proper seating of valves Place valve in valve chamber assemble valve plug and spring making certain that spring is around the lower stem of the valve plug properly Use new gasket under valve plug if necessary MAX FUEL LEAKAGE THROUGH VENT HOLE IN BODY Check as follows Cause _ Nec Worn punctured diaphragm Replace diaphragm Loose diaphragm nut or defective pull rod gasket 20 LEAKAGE OF FUEL AT THE DIAPHRAGM Check as follows P Cause Loose cover screws Tighten cover screws alternately and securely Also check inlet and outlet pipe connections ee FLOODING OF CARBURETOR _ Check as follows Cause Carburetor needle valve not seating Check carburetor for proper adjustment IMPORTANT When the above remedies do not correct the condition replace with a new fuel pump sending the old fuel pump to the nearest AC service station for repairs ene xs x 4 5 o re 5
109. ted Oil Passage 5 Insufficient Oil Pres Bearing Sprung or Loose sure Journal Hough or Out of Round 6 Improper Lubricant Lack of Oil 7 Improperly Fitted Bear ing c8 Dirt 29 NP 0 2 s 4 1 3 2 3 Li 2 3 Pinging or Spark MOSK is usually caused ed too far ENGINE SERVICE DIAGNOSIS Burned Valves and Seats Spark Plugs Fouled or Dirty Sticking Valves improper Valves Valve Head Too Thin Valve Seat Too Narrow Overheating Scared or Dirty Stems Excessive Carbon Gum Content of Fuel Excessive Bearing Clear Worn Oil Pump Insufficient Oil Stop Wire Grounded Defective Coil Low Power Source insufficient Tappet Clearance Weak or Broken Springs 7 Incorrect Valve Timing 6 Late ignition Timing 9 Excessive Carbon Deposits 10 Sticking Valves Incorrect Tappet Adjustment 4 Insufficient Clearance in Guide 5 Weak or Broken Springs 6 Too Great insufficient Oil Pressure improper Lubricant Relief Valve Stuck ance Oii intake Sereen Clogged Excessive Oil Dilution 7 Defective Ignition Breaker Sticking 6 Breaker Points Pitted 7 Defective Condenser 8 Point Setting Incorrect 9 Leak in System Popping Spitting or Spark Knock 2901 Adjustment 6 improper Carburetor Adjustment 7 Insufficient Valve Clearanc
110. ter from the cooling system Remove the radiator hoses and the water inlets and out lets If there is a temperature guage disconnect it first 4 if an external governor is used remove the oii 1466 ds tween the crankcase and the governor 5 Disconnect the governor arm from the Carburetor And Td move the governor if an external type 6 Remove the fuel line ieading to the carburetor 7 Disconnect the air cleaner from the breather tube and from the air inlet hose Remove the cleaner 8 Remove the carburetor choke and intake manifold 2 52 Ir RADIATOR CAP RADIATOR TOP HOUSING 1 8 RADIATOR GRILLE RADIATOR CORE RADIATOR SIDE PANEL RADIATOR WATER INLET 71 CYLINOER WATER OUTLET i lt D FAN SUPPORT ARM CONNECTING LINK GOVERNOR OG T PT ARM 10 CARBURETOR s FAN BELT ADJUSTING STUD 2624 INTAKE MANIFOL n vestes FAN BELT ADJUSTING a 525256050 25 5 5954 STUG LOCK NUT i EXON X XXX b LY posed S P lt gt a SEAT INSERT 25255000 5 225 5
111. the factory This warranty does not include or cover standard accessories used such as carburetors magnetos fuel pumps etc made by other manu facturers Such accessories have separate warranties made by the respective manufacturers Repair or exchange of such accessories will be made by us on the basis of such warranties d This warranty is in lieu of all other warranties expressed or implied j EBERT RATED EIU 496 2 OF CONTENTS SUBJECT Specifications I 1 Engine 151643 5535559969 5 59 6 9 669 6 6996 9 6 66 96 96 6 6 96 8 6 Generator Deteils ee ee eee ee ae Controls ecce 9966 6996 6 96 66 669 99 889 6 Installation of Power Unit LOCACLON 60h 9 8 9 6 8958 6 6 46 0 9st 0 6 TOR 6 0 6 6 de e de YentilatioD i se d 4 Mounting Bage 4 969 5 5 96 9 69 6 96669 Fuel 9992352555 54559 56 8 6 9 696 6 6 6 54 6 6 9 6 6
112. trols the charg ng rate to the batteries PROPER STARTING The proper method of starting any self starting switch is not to down continuously on the start button but to intermittently close the start button for period of about five seconds and release for a second or two Then if the plant does not continue to run press the start button the second or third time holding each time for about five seconds until the plant continues to operate M STOPPING CYCLE When the Stop Button at the plant lt a remote start stop seth is pressed the ignition secondary circuit is grounded thereby causing a feilure of ignition and stopping the engine SERVICING It is not necessary to provide any regular servicing for the control system However it is advisable to inspect the Start Relay contacts occa sionally to determine whether they burned or pitted in operation If _this is found to be the case the contact points should be cleaned 5 with 00 sonipopsra 1 EMERGENCY STARTING If the A n batteries do not have sufficient 0 crank the engine jt may 6 started by hand whether the ignition is battery or magneto hand crank is provided and this is inserted into the crankshaft at the front end of the i prank 5 pu but do not spin the crank MAINTENANCE 1 is important that certain inspections
113. ure of the plant at a time when it is urgently needed It is suggested that this book be kept near the plant so that it may be referred to when necessary SERVICE trouble occurs and the operator is unable to determine the cause after a thorough study of the book or if he is unable to determine what repair parts are required the manufacturer will upon request PA nish any advice needed When asking for advice be sure to state the Model Serial and Generator numbers of this plant This information is absolutely necessary and may be obtained from name plates on the plant Be sure to give all other details available MANUFACTURER S WARRANTY The manufacturer warrants each new engine or electric plant to be free from defects in material and workmanship Under normal use and service our obligation under this warranty is limited to the replac ing of part without charge which within ninety 90 days after delivery to the original user shall be returned to us or our authorized service station with transportation charges prepaid and which our ex amination shall disclose to have been defective 1 Our liability in case of defective workmanship material or any costs incurred in remedying any claimed defective condition in any unit or such unit having been repaired altered or which installation and service recommendations have not been complied with is limited strictly to the proper adjustment authorized by
114. ure used in disassembly BE SURE THAT ALL PARTS ARE CLEAN Before installing the armature grease the end surface to keep it from rusting while in service check the rear main bearing oil seal to be sure it is functioning properly up the notch in the bearing with the pin in the frame install the frame over the armature carefuliy tighten the bolts that hold it gradually and alternately Never pull one down tight until the others are nearly tight Repack the ball bearing with ball bearing grease only and replace the gasket and cap BRUSHES The brushes must move freely in their holders and make keep an extra set hand and replace any brush that wears to 3 8 in length or less See the illustration on Care of Commu tator and Brushes for proper method of seating brushes to the commutator Brush spring tension must Measure tension with the brush spring to point where the top of the brush is even with the top of the brush holder Install new if the tension is unequal PS x all the accessories which were mounted on the generator and the plant will be ready to be put into operation However or striking against the pole pieces The armature would be spoiled if such condition exist when the quens is start 46 _ ds 2 3 Ae 2 6 iO 41 STORAGE B Certain precautions must
115. ve the brush rig assembly from the generator end bell when disassembling the generator If it should have been removed accidentally or for servicing line up the mark on the rig with the indicator point on the frame when reinstalling it Unless the brush rig is in the pro per position excessive arcing of the brushes heating of the generator armature and field windings and low voltage produc tion will result POLE SHOES The pole shoes are made up of laminations of spec ial electrical steel stacked and riveted together and bolted to the generator frame They to be removed only in order to remove the field coils When replacing pole shoes be very care ful that all surfaces are An accurate clearance must be maintained between the pole shoes when assembled in the genera tor frame and the revolving armature Any dirt between the pole shoe and the generator frame would change this clearance and possibly cause damage to the armature Use lock washers with the botes and be sure that they are securely F ET and amp t the forward end by the rear main erankshaft bearing On smaller generators the armature shart is tapered and fits into a tapered surface in the crankshaft The armature shaft is hollow and a drawbolt runs from the crank shaft to a nut at the outboard end of the armature shaft which E clamps the two securely together
116. y plants using batteries certain periodic care and atten tion is necessary to increase the iife and efficiency of the batteries Always follow the battery manufacturers recommenda tions if handy If not use she following 10 11 13 level of the electrolyte about to 3 8 above the top of the plates dd only distilled water to the electrolyte Clean battery terminals by using a solution of soda and water Apply coating of petroleum jelly to prevent corrosion When connecting batteries together be Sure that the positive 4 post of one battery is connected to the negative post of the other battery When connecting batteries to the plant make certain that battery positive 4 post is connected to the positive terminal on the plant and that a battery negative post is connected to the negative terminal of the plant Heversing these connections would discharge ruin the batteries The average amp mpere charging rate should be approximate ly one twentieth 1 20 of the Ampere Hour Capacity of the batteries When the battery is discharged it can be charged faster but with a nearly charged battery the rate should be reduced Remove the vent caps while charging the batteries un less the caps are marked otherwise When charging batteries make certain that the internal temperature of the batteries does not rise over 1109 F if the temperature nears 110 F

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