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Wisconsin V460D, V461D, V465D Repair Manual

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Wisconsin V460D, V461D, V465D Repair Manual WISCONSIN MODELS V465D V41NID, V461D REPAIR ~ WISCONSIN MOTORS, LLC FOREWORD Goodoperation and a plannedmaintenance program as outlined in this manualare vital in obtaining maximumengine performance and long enginelife. Theinstructions on the following pageshave been written with this in mind, to give the operatora better understandingof the various problemswhich may arise, and the mannerin whichthese problemscan best be solved or avoided. Theoperator is cautionedagainst the use of any parts, other than genuineWisconsin parts, for replacementor repair. Theseparts havebeen engineered and tested for their particular job, andthe use of any other parts mayresult in unsatisfactoryperformance and short engine life. Wisconsindistributors anddealers, becauseof their close factory relations, can render the best andmost efficient service. THE LIFE OF YOURENGINE DEPENDS ON THE CAREIT RECEIVES. The MODEL,SPECIFICATION and SERIALNUMBER of your engine must be given when ordering parts. The MODELand SPECIFICATIONnumber are on the nameplate. The SERIAL NUMBERis stamped either on the crankcaseor the engine’s identification tag. Copy the MODEL,SPECIFICATION and SERIALNUMBER in the spaces provided below so that it will be availablewhen ordering parts. MODEL SPECIFICATION SERIAL NUMBER To insure promptand accurate service, the following informationmust also be given: 1. State EXACTLYthe quantity of eachpart and part number. 2. State definitely whetherparts are to be shippedby express,freight or parcel post. 3. State the exact mailing address. IMPORTANT READ THESE INSTRUCTIONSCAREFULLY All points of operationand maintenance have been covered as carefully as possible,but if further informationis required,send inquiries to the factory for promptattention. Whenwriting to the factory, ALWAYSGIVE THEMODEL, SPECIFICATION AND SERIAL NUMBERof the enginereferred to. Starting and OperatinqNew Engines Carefulbreaking-in of a newengine will greatlyincrease its life andresult in troublefreeoperation. A factory test is not sufficient to establishthe polishedbearing surfaces, which are so necessary to the properperformance and long life of an engine.These can only be obtainedby runninga newengine carefully andunder reduced loads for a short time. ¯ Besure the engineis filled to the properlevel with a goodquality engineoil. ¯ For properprocedures to follow whenbreaking-in a newengine, see ’Testing Rebuilt Engine’. Thevarious bearing surfaces in a newengine have not beenglazed, as they will be with continued operation,and it is in this periodof "runningin" that specialcare must be exercised,otherwise the highly desired glaze will never be obtained. A newbearing surface that has oncebeen damagedby carelessnesswill be ruined forever. IMPORTANT SAFETY NOTICE Properrepair is importantto the safe andreliable operationof an engine.This RepairManual outlines basic recommendedprocedures, some of whichrequire special tools, devicesor work methods. Improperrepair procedurescan be dangerousand could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warninglabels havealso beenput on the enginesto provideinstructions andidentify specific hazardswhich, if not heeded,could cause bodily injury or deathto you or other persons.These labels identify hazardswhich maynot be apparentto a trained mechanic.There are many potential hazardsfor an untrainedmechanic and there is no wayto label the engineagainst all suchhazards. These warnings in the RepairManual and on the engineare indentified by this symbol: z WARNING Operationsthat mayresult only in enginedamage are identified in the RepairManual by this symbol: ,&CAUTION WisconsinMotors, LLCcannot anticipate every possible circumstancethat might involve a potential hazard;therefore, the warningsin this manualare not all inclusive. If a procedure, tool, device or workmethod not specifically recommendedby Wisconsin Motors, LLC,is used, you mustsatisfy yourself that it is safe for you and others. Youshould also ensurethat the engine will not be damagedor madeunsafe by the proceduresyou choose. IMPORTANT:The information, specifications andillustrations in this manualare based on informationthat wasavailable at the time it waspublished. The specifications, torques, pressuresof operation, measurements,adjustments, illustrations and other items can changeat any time. Thesechanges can affect the service given to the product. Get the completeand mostcurrent informationbefore starting any job. For parts, service, or information, contact WisconsinMotors, LLC, Memphis,Tennessee. WARNING Most sub-systems used in conjunction with Wisconsin Motors, LLC, industrial engines including (but not limited to) radiators, hoses,fans, fuel tanks, fuel lines or other fuel system components,batteries, electrical connections or other electrical components,clutches, transmissions, hydraulic pumpsand generators, are not supplied by WisconsinMotors, LLC. these items are provided by the manufacturerof the end item in which the engine is used. Someof the dangers associated ’with servicing such items are generally mentionedin this manual; however,the appropriate handbooksand safety instructions provided by the manufac- turer of the enditem should alwaysbe consulted prior to the undertakingof any work on sub- systemsattached to the engine, to avoid any hazards inherent to these sub-systems. Readand observe all individual safety warningsas you use this manualto operate, service or repair your engine. Always exercise caution wheneve="working with an engine or any associated system. Injuries maybe causedby lack of care whenworking with, or near, movingparts, hot parts, pressurizedsystems, electrical equipment,or fuel systems. Always wear eye and hearing protection whenworking on or near engines. Improperattire suchas loose clothing, ties, rings, soft shoesor bare feet could be hazardousand should be avoided whenservicing engines. Useor service of the engine(including the useof modifiedparts or materials) not in accordance with manufacturer’sspecifications could damageyour engine or causepersonal injury. WARNING Someequipment and materials used in the overhaul or maintenanceof an engine such as machinetools, electrical equipment,compressed air, solvents, gasoline or other fuels maybe dangerousand can causeinjury. Always observe safety precautions. iii SAFETY PRECAUTIONS ¯ Neverfill fuel tank while engneis runningor hot; Donot operateengine in a closed building unless avoidthe possibility of spilled fuel causinga fire. the exhaustis piped outside. This exhaustcontains carbon monoxide, a poisonous, odorless and ¯ Alwaysrefuel slowly to avoid spillage. invisible gas, whichif breathedcauses serious ¯ Whenstarting engine, maintain a safe distance illness andpossible death. from movingparts of equipment. Nevermake adjustments on machinerywhile it is ¯ Donot start enginewith clutch engaged. connectedto the engine,without first removingthe ¯ ignition cable from the spark plug. Turningthe Do not spin handcrank whenstarting. Keep machinery over by hand during adjusting or crankingcomponents clean andfree from conditions cleaning might start the engineand machinerywith which might causethe crank jaw to bind and not it, causingserious injury to the operator. releaseproperly. Oil periodically to preventrust. ¯ Neverrun engine with governordisconnected, or Precaution is the best insurance against operate at speedsin excessof 2400R.P.M. load. accidents. Keep this book handy at all times, familiarize yourself with the operating instructions. Model V465D 3-3/4" Bore m 4" Stroke 177 cu. in. Displacement Models V461 D, V460D 3-1/2" Bore- 4" Stroke 154 cu. in. Displacement 2 CONTENTS AirCleaner, Pre-Cleaner ....................................................... 11,12 GeneralInformation and Design .................................................. 8 Alternator-- BeltDriven .......................................................... 34 Generator(Older Models) .......................................................... 15 Bearing-- CenterMain ............................................................. 11 GovernorAdjustment and Operation ......................................... 17 BreatherCap .............................................................................. 10 Horsepower................................................................................. 8 CarburetorAdjustment .............................................................. 12 IgnitionSpark ............................................................................ 16 Carburetor Service IgnitionSystem .......................................................................... 12 ZenithModel 87A8 ........................................................ 35-37 Illustrations, Engine ClutchAdjustment ..................................................................... 18 Take-offView ....................................................................... 5 ClutchPower Take-off ............................................................... 18 FanEnd View ........................................................................ 5 ClutchReduction Unit ................................................................ 19 SectionalViews .................................................................. 6,7 Compression-- Restoring .......................................................... 16 LubricationSystem .............................................................. 11 Cooling........................................................................................
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