Wisconsin Motors V465D Operating instructions

WISCONSIN
MODELS V465D
V41NID, V461D
REPAIR
~WISCONSIN
MOTORS, LLC

FOREWORD
Goodoperationanda plannedmaintenanceprogramas outlined in this manualare vital in
obtainingmaximumengineperformanceandlongenginelife. Theinstructions onthe following
pageshavebeenwritten with this in mind,to givethe operatora better understandingof the
variousproblemswhichmayarise, andthe mannerin whichtheseproblemscanbestbesolved
or avoided.
Theoperatoris cautionedagainstthe useof anyparts, other thangenuineWisconsinparts,
for replacementor repair. Theseparts havebeenengineeredandtestedfor their particular
job, andthe useof anyotherparts mayresult in unsatisfactoryperformanceandshort engine
life. Wisconsindistributors anddealers,becauseof their closefactoryrelations, canrender
thebestandmostefficient service.
THELIFE OF YOURENGINEDEPENDSONTHECAREIT RECEIVES.
The MODEL,SPECIFICATIONand SERIALNUMBERof your engine must be given when
ordering parts. TheMODELandSPECIFICATIONnumberare onthe nameplate. TheSERIAL
NUMBERis stampedeither onthe crankcaseor the engine’sidentification tag.
Copythe MODEL,SPECIFICATIONand SERIALNUMBERin the spaces provided below so
that it will beavailablewhenorderingparts.
MODEL SPECIFICATION
SERIAL NUMBER
Toinsurepromptandaccurateservice, the following informationmustalso begiven:
1. State EXACTLYthe quantity of eachpart andpart number.
2. Statedefinitely whetherpartsareto beshippedbyexpress,freight or parcelpost.
3. Statethe exactmailingaddress.

IMPORTANT
READTHESEINSTRUCTIONSCAREFULLY
All pointsof operationandmaintenancehavebeencoveredascarefullyaspossible,but if further
informationis required,sendinquiriesto thefactoryfor promptattention.
Whenwriting to the factory, ALWAYSGIVETHEMODEL,SPECIFICATIONANDSERIAL
NUMBERof the enginereferred to.
Starting andOperatinqNewEngines
Carefulbreaking-inof a newenginewill greatlyincreaseits life andresultin troublefreeoperation.
Afactorytest is notsufficient to establishthepolishedbearingsurfaces,whicharesonecessary
to the properperformanceandlonglife of anengine.Thesecanonly beobtainedbyrunninga
newenginecarefully andunderreducedloadsfor a short time.
¯ Besuretheengineis filled to theproperlevelwitha goodqualityengineoil.
¯ Forproperproceduresto follow whenbreaking-ina newengine,see’TestingRebuiltEngine’.
Thevariousbearingsurfacesin a newenginehavenot beenglazed,astheywill bewithcontinued
operation,andit is in this periodof "runningin" that specialcaremustbeexercised,otherwise
the highly desiredglazewill neverbe obtained.Anewbearingsurfacethat hasoncebeen
damagedby carelessnesswill beruinedforever.

IMPORTANT SAFETY NOTICE
Properrepair is importantto thesafeandreliable operationof anengine.ThisRepairManual
outlines basicrecommendedprocedures,someof whichrequirespecial tools, devicesor work
methods.
Improperrepair procedurescanbedangerousandcouldresult in injury or death.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE
Warninglabels havealsobeenput onthe enginesto provideinstructionsandidentify specific
hazardswhich,if not heeded,couldcausebodily injury or deathto youor otherpersons.These
labels identify hazardswhichmaynot beapparentto a trained mechanic.Thereare many
potential hazardsfor anuntrainedmechanicandthereis nowayto label the engineagainstall
suchhazards.Thesewarningsin the RepairManualandonthe engineare indentified bythis
symbol:
z WARNING
Operationsthat mayresult only in enginedamageareidentified in the RepairManualbythis
symbol: ,&CAUTION
WisconsinMotors,LLCcannotanticipate everypossible circumstancethat mightinvolve a
potential hazard;therefore,the warningsin this manualarenot all inclusive. If a procedure,
tool, deviceor workmethodnot specifically recommendedbyWisconsinMotors,LLC,is used,
youmustsatisfy yourselfthat it is safefor youandothers.Youshouldalso ensurethat the
enginewill not bedamagedor madeunsafeby the proceduresyouchoose.
IMPORTANT:Theinformation,specificationsandillustrations in this manualare based
oninformationthat wasavailable at the timeit waspublished.Thespecifications,
torques, pressuresof operation,measurements,adjustments,illustrations andother
items can changeat anytime. Thesechangescan affect the service given to the
product.Getthe completeandmostcurrent informationbeforestarting anyjob. For
parts, service, or information,contactWisconsinMotors,LLC,Memphis,Tennessee.

WARNING
Most sub-systemsused in conjunction with Wisconsin Motors, LLC, industrial engines
including(but not limited to) radiators, hoses,fans, fuel tanks,fuel lines or otherfuel system
components,batteries, electrical connectionsor other electrical components,clutches,
transmissions, hydraulic pumpsandgenerators, are not supplied by WisconsinMotors, LLC.
these items are providedby the manufacturerof the enditem in whichthe engineis used.
Someof the dangersassociated’with servicing such items are generally mentionedin this
manual;however,the appropriate handbooksandsafety instructions providedby the manufac-
turer of the enditem shouldalwaysbeconsultedprior to the undertakingof anyworkonsub-
systemsattachedto the engine, to avoid anyhazardsinherent to these sub-systems.
Readandobserveall individual safety warningsas youusethis manualto operate, service or
repair yourengine.
Alwaysexercise caution wheneve="workingwith an engineor any associatedsystem.
Injuries maybe causedby lack of care whenworkingwith, or near, movingparts, hot parts,
pressurizedsystems,electrical equipment,or fuel systems.
Alwaysweareye andhearing protection whenworking on or near engines.
Improperattire suchaslooseclothing, ties, rings, soft shoesor barefeet couldbehazardousand
should be avoidedwhenservicing engines.
Useor serviceof the engine(including the useof modifiedparts or materials)not in accordance
with manufacturer’sspecifications could damageyour engineor causepersonalinjury.
WARNING
Someequipmentandmaterials usedin the overhaul or maintenanceof an engine such as
machinetools, electrical equipment,compressedair, solvents, gasolineor other fuels maybe
dangerousandcan causeinjury. Alwaysobservesafety precautions.
iii

SAFETY PRECAUTIONS
¯Neverfill fuel tankwhileengneis runningor hot;
avoidthepossibility of spilled fuel causinga fire.
¯ Alwaysrefuel slowlyto avoidspillage.
¯Whenstarting engine, maintaina safe distance
frommovingparts of equipment.
¯ Donot start enginewith clutch engaged.
¯Donot spin handcrankwhenstarting. Keep
crankingcomponentscleanandfree fromconditions
whichmightcausethe crankjaw to bind andnot
releaseproperly.Oil periodicallyto preventrust.
¯Neverrun enginewith governordisconnected,or
operateat speedsin excessof 2400R.P.M.load.
Donot operateenginein a closedbuilding unless
the exhaustis pipedoutside. This exhaustcontains
carbon monoxide,a poisonous, odorless and
invisible gas,whichif breathedcausesserious
illness andpossibledeath.
Nevermakeadjustmentson machinerywhile it is
connectedto the engine,withoutfirst removingthe
ignition cablefromthe sparkplug. Turningthe
machineryover by handduring adjusting or
cleaningmightstart the engineandmachinerywith
it, causingseriousinjury to theoperator.
Precautionis the best insuranceagainst
accidents.
Keep this book handy at all times,
familiarize yourself with the operating instructions.
Model V465D
3-3/4" Bore m4" Stroke
177 cu. in. Displacement
ModelsV461D, V460D
3-1/2" Bore- 4" Stroke
154 cu. in. Displacement
2

CONTENTS
AirCleaner,Pre-Cleaner....................................................... 11,12
Alternator-- BeltDriven.......................................................... 34
Bearing-- CenterMain............................................................. 11
BreatherCap.............................................................................. 10
CarburetorAdjustment.............................................................. 12
CarburetorService
ZenithModel87A8........................................................ 35-37
ClutchAdjustment..................................................................... 18
ClutchPowerTake-off............................................................... 18
ClutchReductionUnit................................................................ 19
Compression-- Restoring.......................................................... 16
Cooling......................................................................................... 8
Dieseling,Anti-DieselValve..................................................... 10
DisassemblyandReassembly.................................................... 23
Accessories.......................................................................... 23
Camshaft.............................................................................. 30
CamshaftGear..................................................................... 30
CarburetorandManifold..................................................... 25
CenterMainBearing,Roller Type(OlderModels).............. 32
CenterMainBearing,ShellType......................................... 30
ConnectingRodandPiston.................................................. 28
CrankshaftandMainBearingPlate..................................... 31
CylinderBarrel.................................................................... 27
CylinderHead...................................................................... 27
CylinderShrouding.............................................................. 25
DistributorandAccessoryDrive.......................................... 24
EngineSupportsandOilPan............................................... 26
Flywheel.............................................................................. 23
FlywheelShroud.................................................................. 24
FuelPump............................................................................ 25
GearCover.......................................................................... 25
GearTrain............................................................................ 26
Generator............................................................................. 24
Governor............................................................................... 25
OilPressureReducingValve............................................... 32
OilPressureReliefValve...................................................... 31
OilPump.............................................................................. 26
IdlerGearandShaft.............................................................. 31
Piston................................................................................... 28
PistonRingandRodClearanceChart.................................. 29
PistonRings......................................................................... 28
ValveGuidesandSeatInserts............................................. 30
Valves.................................................................................. 29
RockerArmAssembly........................................................ 30
DistributorMaintenance............................................................ 14
ElectricWiringCircuits............................................................. 15
Electrical WiringDiagrams
DistributorIgnitionwithAlternator..................................... 34
DistributorIgnition withGenerator(OlderModels)............ 14
MagnetoIgnition................................................................. 15
FiringOrder............................................................................... 12
Fuel.............................................................................................. 9
FuelMixture.............................................................................. 20
FuelPumpandPriming............................................................... 9
GasolineStrainer....................................................................... 12
GeneralInformationandDesign.................................................. 8
Generator(OlderModels).......................................................... 15
GovernorAdjustmentandOperation......................................... 17
Horsepower................................................................................. 8
IgnitionSpark............................................................................ 16
IgnitionSystem.......................................................................... 12
Illustrations, Engine
Take-offView....................................................................... 5
FanEndView........................................................................ 5
SectionalViews.................................................................. 6,7
LubricationSystem.............................................................. 11
KeepEngineClean...................................................................... 3
Lubrication.................................................................................. 8
LubricationSystem................................................................. 8,11
MagnetoService
Fairbanks-MorseTypeFM-X4B7D..................................... 38
OilFilter.................................................................................... 10
Oil-- GradeofandServiceClassification.................................. 9
OilPressureandAdjustment...................................................... 10
Rotation....................................................................................... 8
RockerArmCovers................................................................... 17
SafetyNotice.......................................................................... ii-iii
SafetyPrecautions....................................................................... 2
SafetySwitch-- HighTemperature.......................................... 19
SolidStateIgnitionDistributors...................................... 12, 3940
SparkPlugs................................................................................ 16
StartingMotor-- Electric........................................................... 9
StartingandOperatingInstructions.............................................. 8
StartingandOperatingNewEngines............................................ i
StartingProcedure....................................................................... 9
StoppingEngine-- VaporLock................................................ 10
StorageofEngineforWinter..................................................... 21
TestingRebuiltEngine.............................................................. 23
Timing....................................................................................... 12
DistributorTiming............................................................... 13
MagnetoTiming.................................................................. 15
NeonLampTiming............................................................. 14
TimingInstructions.................................................................... 13
TimingMarks............................................................................ 13
Troubles-- CausesandRemedies............................................. 20
BackfiringThroughCarburetor............................................ 21
Compression........................................................................ 20
EngineStops........................................................................ 21
HighOilPressure................................................................. 21
Ignition................................................................................ 20
Knocking............................................................................. 21
LoworNoOilPressure....................................................... 21
Missing................................................................................ 20
Overheating......................................................................... 21
StartingDifficulties-- FuelMixture................................... 20
SurgingorGalloping........................................................... 21
Valves-- Grinding............................................................... 29,30
ValveTappetAdjustment.......................................................... 16
Warm-UpPeriod-- Overspeeding............................................ 10

KEEP EN( INE CLEAN
PREVENT OVERHEATING
This engine is cooled by a flow of air from a combi-
nation fan-flywheel, encased in a sheet metal shroud-
ing. The air is divided and directed by ducts and
baffle plates to insure uniform cooling of both banks
of cylinders. If dirt andchaff are allowed to accumu-
late in the cylinder shrouding or in the V between
cylinder banks, the flow of cooling air will be re-
stricted, creating an overheating condition, which
could result in costly repairs.
The rotating screen, illustrated in Fig. B, is recom-
mended for engines operating in dusty and dirty con-
ditions. The screen deflects foreign materials away
from the air intake opening and helps maintain maxi-
mumcooling efficiency. Keep rotating screen clean.
Even a small section of screen clogged up with dirt
will restrict the intake of cooling air enough to bring
about an overheating condition.
With reference to Figures A and B; follow these few
cleaning and maintenance instructions to insure trou- ’
ble free and satisfactory engine performance.
1. Cylinder head covers can be removed by releasing
snap clips and unscrewing wing nut. Clean out all
dirt and chaff from interior of shroud and from be-
tween fins of cylinders and heads.
2. Removedirt an,~ chaff from cylinder heat deflectors
at manifold ports.
3. Keep space between cylinder banks clean.
4. Replace this oil filter cartridge every other oil
change. If operating conditions are extremely dusty
replace cartridge every oil change. See Oil Filter
instructions, Page 10.
5. Rotating screen must be kept clean. Accumulated
dirt caked on screen will restrict cooling.
6. Read instructions on air cleaner regarding its care.
The entire air cleaner should be removed from the
engine at least once a year, and washed in a sol-
vent to clean out dirt gathered in the back fire
trap and filter element.
7. The collector type pre-cleaner must be emptied of
accumulated dirt frequently, depending on dust
conditions. Do not use oil or water in pre-cleaner,
this must be kept dry.
8. Do not allow shrouding to become damaged or bad-
ly dented as this will retard air flow.
Never operate engine with air shrouding removed.
Every 4 to 8 hours, depending on dust conditions,
check air cleaner and change oil. See Page 12.
Every 8 hourscheck crankcase oil level. Keep filled
to full mark on oil gauge saber, but no more. Every
50 hours drain crankcase and refill with fresh oil.
See Lubrication, Pages 8 and 9.
4
Fig. A
6
Fig. B

ROCKER ARM COVERS
OIL FILLER AND
BREATHER CAP
CYLINDER NU
VOLT AGE
IGNIT ION
GENE
PREoCLEANE
OIL BATH
AIR CLEANER
~
STARTING SO
STARTING MOTOR~
OIL FILTER
OIL DRAIN PLUG
MUFFLER
DISTRIBUTOR
ANTI-DIESE LING
SOLENOID
BUTTON
VARIABLE SPEED
~IOR CONTROL
PRESSURE GAUGE
- STARTER
SWITCH
fWHEEL SHROUD
FUEL PUMP
HEAT SHIELD
GASOLINE
STRAINER
PUMP
L GAUGE
SABER
-OPTIONAL-
OIL GAUGE AND
FILLER LOCATION
Fig. 1

IGNITION COl.
GENERATOR
VOLTAGE REGULATOR
DISTRIBUTOR
;CESSORYDRIVE ASSEMBLY
CARBURETOR~
GOVERNOR ASSEMB~
ANTI-DIESELING~
SOLENOID
FLYWHEEL
AIR SHROUD
CAMSHAFT
THRUSTPLUNGI
OIL
MAINBEAI:
IDLER
GOVERNOR:
ADJUSTING SCREW
~LEVER ~
/SPRING
LOCKNUT~
It.~,~_~
UEL PUMP
--CAMSHAFT
~-MAIN BEARING
HAND CRANK
FAN-FLYWHEEL DIL PUMP
SECTIONALVIEWSOF ENGINE
6