Hercules JXD Technical Manual Download

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Summary of Contents for JXD

Page 1: ...This is a reproduction of a library book that was digitized by Google as part of an ongoing effort to preserve the information in books and make it universally accessible https books google com ...

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Page 6: ...W1 35 9 1706 TM 9 1706 WAR DEPARTMENT TECHNICAL MANUAL ORDNANCE MAINTENANCE HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS September 13 1942 1942 ...

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Page 8: ...st of references 320 INDEX 322 SECTION I GENERAL Paragraph Scope 1 1 Scope a General This manual is published for the informa tion and guidance of ordnance maintenance personnel and is one of several maintenance manuals on these vehicles It contains detailed instructions for removal disassembly inspection maintenance repair assembly and installation of the Hercules JXD gasoline engine and all its ...

Page 9: ... there will be a minimum of time lost for repairs Service maintenance by light and heavy maintenance units of the Ordnance Department has for its primary objectives supply technical inspec tion and corrective action and in general all repairs beyond the capacity of the using arms This work is accomplished either by unit replacement overhauling rebuilding reclaiming manufactur ing or any other nece...

Page 10: ...epair f Engine 1 Camshaft Replace 2 Connecting rods Replace 3 Connecting rod bearings Adjust and replace 4 Crankshaft Grind polish straighten 5 Cylinder Honeboring 6 Crankshaft main bearings Replace 7 Engine Rebuild replace 8 Flywheel Replace 9 Pistons Grind and fit 10 Piston pins Fit 11 Piston rings Fit 12 Piston assembly Replace 13 Timing gears Replace 14 Timing gear cover Replace 15 Valves Refa...

Page 11: ...ction of clutch 1 Test foot lever and make sure of proper mounting Examine return spring for wear or damage 2 Run vehicle to ascertain if clutch is smooth or jerky or slips in operation b Cooling system 1 Examine radiator and connections for signs of leakage clogging or damage 2 Inspect supporting bracket of fan and bushings and bearings 3 Look at water pump and casing for cracks and leaks and mak...

Page 12: ...resence of carbon 4 Check oil pressure for steady and normal reading with engine running g Fuel system 1 Inspect mounting and connections of fuel pump and check its operation Examine fuel tanks for leaks or damage 2 Examine carburetor and air cleaner Try all screws Inspect connections to accelerator and dash 3 Check fuel gage and switch h Lubrication system 1 Check oil pressure at gage 2 Check oil...

Page 13: ...es ground 4 Low or uneven compres sion 5 Motor overheats 6 Mixture too rich 7 Clutch slips 8 Brakes dragging c 1 Motor mountings loose or badly worn 2 Bad skip in motor 3 Ignition and timing too far advanced 4 Idle adjustment set too rich d 1 Circulation plugged in radiator causing cool spot in core 2 Radiator and block dirty retarding circulation 3 Ignition late 4 Brakes dragging 5 Clutch slippin...

Page 14: ... plugs 13 Flywheel loose f 1 Generator bearings worn 2 Water pump bearings bad 3 Lower fan pulley sprung or frame sprung so trun nion hits pulley 4 Broken ring or piston 5 Flywheel pan bent or dirt in flywheel pan hitting flywheel 6 Timing chain loose and rubbing case 7 Oil pan nuts in flywheel housing hitting against flywheel q 1 Piston ringgapslined up 2 Piston rings worn or car bon in ring groo...

Page 15: ... 1 Drive belt loose 2 Voltage regulator out of order 3 Generator not operating properly 4 Poor connections in circuit k Starting motion of vehicle k 1 Worn clutch linkage jerky or delayed 2 Worn or oil saturated clutch parts may also be out of adjustment 3 Play in universal joints 9 Tune up a General Best results are obtained in an engine tune up by using a systematic approach rather than a hit or...

Page 16: ...nspect it care fully for cracks and burned posts 6 Remove rotor clean contact point and make sure spring con tacts secondary terminal c Clean distributor points with a flat point file Inspect care fully and replace if cleaning does not remove pits and burns Never use emery cloth to clean points d Adjust points with feeler gage to provide 0 018 to 0 020 inch clearance Be sure that breaker cam is in...

Page 17: ... and connect gage hose to adapter tee outlet fig 193 Normal pressure should be between 21 2 and 4 pounds This gage is also used to check the vacuum condition in the vacuum pump Connect hose to pump inlet When motor is running this vacuum should pull from 8 to 10 inches 6 Remove sediment bowl and screen for cleaning c Inspect for worn parts and replace if necessary C Vacuum tests A vacuum gage is a...

Page 18: ... a burned valve a leaky valve or a head gasket leak 8 Slow movement low vacuum A low vacuum with a slowly moving needle might indicate late valve timing poor carburetor adjustment defective spark plugs poor ignition or gummy valve stems 9 Wide variations An oscillating needle over a wide range with the variation increasing with increased speed indicates weak or broken valve springs SECTION V CLUTC...

Page 19: ...rings packed with grease at assembly are used on the clutch shaft for the pilot and clutch release bearings SCREW CAP BCAXICD WASHER LOCK BECXIK MEMBER ASS Y LM CM 4137 SCA LM CM 4515 SCB M COVERPLATE ASSY LM CM 4348 RA PD 3235 FIGURE 1 Clutch assembly installed b Functioning Depression of the clutch pedal moves the clutch pressure plate away from the driven plate which is then disengaged from the...

Page 20: ...3517 OR SPRING LM C 3831 WASHER LM C 3568 LEVER LM C 3390 HUB LM C 3677 RA WASHER LM C 3569 BOLT LM C 3523 SPRING LM C 3522 WASHER LM C 3569 NUT LM C 3524 PIN LM C 3521 RIVET LM C 3006 NUT LM C 1404 PARTS WHICH WASHER LM C 1061 MAY BE USED WEIGHT LM C 3328 FOR BALANCE SCREW LM C 3329 BUTTON LM C 2085 SPRING LM C 3431 COVERPLATE LM C 4343 RIVET BMCXI CUP LM C 3437 N 5835 LONG MFG DIV N 5875 Nº 6358...

Page 21: ... facings O D I D Thick Total area Pressure plate O D Spring press 11 Trouble shooting 1 High carbon steel Woven or molded 12 inches 7 inches 0 137 inch 150 square inches 1212 inches 1 620 pounds maximum Probable remedy Symptoms and probable cause a Slippage 1 Worn facings 2 Clutch pedal riding floor board 3 Grease on facings 1 Replace driven member 2 Adjust pedal allowing about 34 to 1 inch free m...

Page 22: ...ly Replace if oil soaked 2 Replace 2 Insufficient cushion or dish in driven plate 3 Uneven release levers 4 Facings worn 5 Facings glazed 3 Reset on fixture 4 Replace driven member 5 Sand lightly with fine sand paper 6 Replace 6 Warped or grooved pres sure plate d Dragging 1 Grease on facings 1 Wipe off with solvent dry cleaning and sandpa per lightly Replace if oil soaked 2 Check on fixture 2 Rel...

Page 23: ...over Screw driver transmission Remove transfer case shift lever ball by unscrewing Remove six machine screws holding center floor plate and remove plate by lifting over transfer case shift lever b Disconnect propeller shaft 58 inch open end wrench 58 inch box wrench Remove four nuts bolts and lock washers holding propeller shaft to companion flange on transmission c Disconnect clutch release Plier...

Page 24: ... block and hook Put rope around and under transmission making certain that assem bly will be balanced in sling during removal in order to prevent injury to splined shaft fig 3 j Disconnect transmission bell 916 inch socket wrench housing from flywheel housing Remove 12 cap screws and lock washers holding bell housing to flywheel housing k Remove transmission None Using sling as a support push tran...

Page 25: ...der assembly 34 inch socket wrench Lands Place three lands on clutch rebuilder and center assembly on lands Place spider on clutch rebuilder shaft and compress clutch sufficiently to take spring pressure off cover plate Remove release lever nuts fig 6 Release clutch rebuilder and remove spider Lift off cover plate fig 7 d Dismantle pressure plate unit Pliers assembly fig 8 Hammer Lift out pressure...

Page 26: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 13 RA PD 7390 FIGURE 3 Transmission removal 19 ...

Page 27: ...ld be replaced 2 When pressure plate is discolored due to heat new pressure springs should be used as weak springs cause a slipping clutch NUT LM C 4345 1 COVERPLATE ASSEMBLY LM CM 4348 RA KA PD 8018 FIGURE 4 Clutch lever adjusting nut bur removal 3 A scored or rough pressure plate causes rapid wear of friction facings and should be replaced 4 Worn release levers cause poor clutch release and shou...

Page 28: ...of lever at this point If clear ance between release levers and inner edge of cover plate is less than RA PD 8019 PUNCH MARK PUNCH MARK FIGURE 5 Punch mark location 1 8 inch the future life of the facings will be very limited and they should be replaced by installing a new driven member assembly d Coverplate assembly 1 Should the windows in the cover plate be worn so that there is more than 0 005 ...

Page 29: ... friction facings f Lubrication As clutch shaft pilot and release bearings are packed and sealed at assembly no lubrication is necessary other than that of clutch shaft release bearing spline Apply a small quantity of oil engine SAE 30 every 500 miles in oil fitting on floor board SPIDER LOCK LEVER ADJUSTING NUT RA PD 8020 FIGURE 6 Clutch disassembly operation 15 Assembly Tools Hacksaw Pliers Clut...

Page 30: ...retainer Push retainer out with regular pin and insert cotter pin fig 9 Make sure slot in threaded end of yoke points outward to facilitate future disassembly Repeat for all levers PRESSURE PLATE AND LEVERUNIT ASSEMBLY LM CS 4347 co COVERPLATE UNIT ASSEMBLY LM CS 4349 RA PD 8021 FIGURE 7 Clutch cover plate assembly dismounted b Replace release levers Pliers Proceed as in a above using long release...

Page 31: ...nd lever bearing lugs fig 5 Locate pressure springs in their cups in cover plate Make sure PRESSURE PLATE AND LEVER UNIT ASSEMBLY LM CS 4347 SPIN ROD ILM C 3141 ISPRING TLM C 4346 LEVER ILM C 3390 ROLLER NEEDLE LM C 3077 SPIN COTTER BFAXICD IPIN ROD PLM C 3142 PIN COTTER BFAXICD BUTTON LM C 2085 YOKE ILM C 4344 INUT LM C 4345 RA PD 8023 SPRING LM C 3431 FIGURÐ 8 Clutch pressure plate and lever uni...

Page 32: ...OD LM C 3142 ROLLER NEEDLE LM C 3077 LEVER LM C 3390 RA PD 8025 FIGURE 9 Clutch lever bearing installation SPRING LM C 4346 YOKE LM C 4344 LEVER LM O 3390 SPRING LM C 3431 PLATE LM C 3594 BUTTON LM C 2085 RA PD 8022 FIGURE 10 Pressure plate lever unit assembly 25 ...

Page 33: ...l lever nuts stem end down and thread on until flush with the threaded ends of yokes GAUGE ROTATING STOP GAUGE PRESS CLAMP RA PD 8026 FIGURE 11 Clutch adjustment f Adjust height of levers Gage 34 inch socket speed wrench Rebuilder Weight Set clutch rebuilder adjustment gage at 21332 inches and slide it onto rebuilder shaft fig 11 Tighten each lever nut until lever just touches gage stop without ra...

Page 34: ...nd hammer fig 12 Should the LEVER SETTING TEST WEIGHT RA PD 8027 FIGURE 12 Clutch lever adjusting nut locking hacksaw cut on the nut line up with the slot of the stem make a new lock with punch and hammer at another point on the rim of the nut h Remove assembly from re Rebuilder builder Compress clutch assembly loosen and remove clamps Release spider and remove clutch assembly NOTE If clutch rebui...

Page 35: ... Place clutch in position and secure to flywheel with 12 cap screws and lock washers Tighten cap screws evenly so as not to bend cover plate NOTE Before clutch is reassembled clean and repack pilot bearing with grease general purpose No 2 Do not use excessive lubricant b Install transmission Chain block and hook Pinch bar Slide transmission under vehicle in approximately the correct posi tion and ...

Page 36: ...support bracket i Connect clutch release shaft Pliers lever to linkage Hammer Replace rod end pin and cotter pin holding release shaft lever to adjustable yoke j Connect rear propeller shaft 5 8 inch open end wrench 5 8 inch box wrench Set shaft in place and replace four nuts bolts and lock washers holding shaft to transmission companion flange k Replace floor board Screw driver Set floor plate do...

Page 37: ...ocks located in the radiator outlet pipe and in the left rear side of the engine block Vents sealed by plugs in the engine water outlet fitting and the water pump inlet fitting are provided for installing a heater a Functioning The pump circulates cooled water from the radi ator throughout the channels in water jacket and cylinder head The warmer liquid which rises to the top of the water jacket i...

Page 38: ... Connection c ylinder head H Valve s hut o ff J Support h eater hose K Hose h eater return L Clamp h eater hose M Gasket p ump to inlet connec tion Connection i nlet P Clamp r adiator hose Hose p ump inlet Ř T ube assembly radiator to pump HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 17 R QP NM L RA PD 10890 FIGURE 13 Cooling system i nstalled 31 ...

Page 39: ...e hose connections 1 Tighten all connections 2 Damaged hose connections 2 Replace damaged hose 3 Leaking water pump 3 Repack pump 4 Leaks in radiator core 4 Remove core and repair leaks 5 Loose or open drain cocks 5 Check and tighten 19 Fan and belt a Description fig 14 The six bladed fan assembly with pulleys is mounted on a bracket bolted to a pad on top of the timing gear case and is driven by ...

Page 40: ...R44 WI 311965 WI 311964 C67496 B156068 18 pounds 1 5 pounds V 6 Trouble shooting Symptom and probable cause Probable remedy 1 Overheating a Lack of water a Refill system 6 Fan belts loose 6 Adjust c Fan belts bottoming in pul c Replace ley d Broken belts d Replace 2 Overheated bearings a Lack of lubrication a Lubricate with proper lu bricant 6 Tight belts 6 Adjust belts to proper ten sion 3 Uneven...

Page 41: ...TM 9 1706 19 ORDNANCE MAINTENANCE SCREW FAN ADJUSTING 0 0 BRACKET ASS Y FAN MOUNTING FAN ASSY BELT FAN DRIVE HUB FAN PULLEY RA PD 10839 PULLEY FAN DRIVING FIGURE 14 Fan and belt assembly installed 34 ...

Page 42: ... 0 E GHj VOODO D C T A 0 0 0 0 Grease retaining 0 H Retainer roller bearing Washer J Gasket K Bearing roller fan hub rear L Hub fan pulley M Blade assembly N Plug pipe lubricating P Gasket Screw cap Q Washer lock R Bearing roller fan hub front S Washer roller bearing retaining ſNut slotted Roller bearing retainer T Pin cotterſ washer U Washer cork grease retaining V Washer spindle retaining RA PD ...

Page 43: ...rew driver 1 2 inch open end wrench Pliers 1 Remove fan assembly from 1116 inch open end wrench bracket Remove fan nut plain washer and shakeproof washer and pull fan assembly from bracket Then take washer off spindle 2 Remove blade assembly 12 inch open end wrench from fan pulley hub Remove four cap screws and lock washers that attach fan to hub and lift blade assembly from hub Gasket is shellack...

Page 44: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 19 RA PD 10891 STANFORD FIGURE 16 Loosening fan belts RA PD 10838 FIGURE 17 Fan mounting bracket removal 37 ...

Page 45: ...ainer cork washer and washer from spindle in order named and then drive rear bearing cone assembly from spindle RA PD 10834 FIGURE 18 Fan and bracket removal 7 Remove front and rear Soft metal drift roller bearing cups from fan hub Hammer Drive out front bearing cup and rear bearing cup from fan hub 38 ...

Page 46: ... Washer taining Q Bearing r oller f an pulley W Pin c otter b earing retaining D Screw f an adjusting J Spindle f an pulley R Hub f an pulley nut E Nut a djusting screw lock K Wire l ock r etainer S Bearing r oller f an hub front X Washer l ock b lade attaching F Washer l ock a djusting screw L Retainer r oller bearing T Blade assembly nut nut M Washer c ork grease retaining U Washer r oller beari...

Page 47: ...n turn adjusting screw handle to the left Adjust belts so that there is between 12 and 3 4 inch lateral movement of the belts halfway between the pulleys With the dual V belts very little tension is required to drive the fan and generator Belts that are adjusted too tightly will cause excessive wear and overheating of the fan roller bearing After adjustments have been made carefully check alinemen...

Page 48: ... end wrench Screw driver 12 inch open end wrench Pliers 1 Replace roller bearing cups Hammer Soft metal drift Insert front and rear bearing cups in fan hub and drive them in until they bottom against shoulder Pack bearing cups and bearings with grease and place bearings in cups RA PD 10892 FIGURE 20 Removing fan hub grease retaining plug 2 Replace rear roller bearing None retainers In order named ...

Page 49: ... inch open end wrench RA PD 10893 FIGURE 21 Inserting pressure grease fitting in fan hub Insert spindle in fan hub and replace washer castle nut and cotter pin Tighten this nut to give a loose fit with no end play and lock this adjustment with the cotter pin 5 Install fan blade assembly 1 2 inch open end wrench Place fan blade assembly with gasket on fan hub and install fan cap screws and lock was...

Page 50: ...e No Weight Hercules Impeller HM 40170 CS WI 316816 C65948 2 Replace and line up fan 34 inch open end wrench mounting bracket Slide mounting bracket into position on timing gear case pad and insert two attaching cap screws with lock washers Adjust bracket so that fan pulley is lined up with fan driving pulley and then tighten cap screws 3 Adjust fan belts 1416 inch open end wrench 34 inch open end...

Page 51: ...d pinned on the pump shaft A bearing on the pump cover is used for mounting the engine ignition distributor RA PD 10835 FIGURE 22 Installing fan belt 2 Functioning The water pump drive gear is driven from the engine camshaft gear by means of an idler gear which rotates the pump shaft at one half engine speed Water is drawn from the bot tom of the radiator by the rotation of the pump impeller and i...

Page 52: ... ischarge F Pump w ater a ssembly G Pipe assembly o il filter inlet H Cup g rease J Hose c ar heater K Connection p ump inlet L Hose p ump inlet M Clamp h ose N Pipe r adiator to pump P Screw a dvance control HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 20 N M RA PD 10894 FIGURE 23 W ater pump assembly i nstalled 45 ...

Page 53: ...16A RING H M 2 2168A GEAR H M 2 236A KEY W OODRUFF B GAX4D GEAR H M 2 2195B NOTE A SSEMBLE WITH 010 C LEARANCE GASKET H M 2 2164A PIN H M 1 4507A 圈圈圈 ORDNANCE MAINTENANCE PUMP W ATER A SSEMBLY HERCULES N 4 0170 C S ORDNANCE N C65948 WHITE Nº 3 16816 BUSHING H M 2 2175A PACKING H M 2 2166A BUSHING H M 2 2171B WASHER H M 4 024A KEY W OODRUFF B GAX3CC FIGURE 24 W ater pump assembly s ectionalized RA...

Page 54: ...etal hammer 1 Drain cooling system Pliers Open drain cock at lower left hand radiator hose connection 2 Remove distributor from Screw driver water pump Loosen spark control wire clamping screw and remove wire Re move distributor advance screw with two plain washers and spring washer and carefully lift distributor from its bearing so as not to move distributor shaft fig 25 3 Mark distributor shaft ...

Page 55: ... end wrench 34 inch open end wrench Remove four cap screws and lock washers from water discharge inlet pipe Then remove three cap screws and lock washers holding pump assembly to rear of gear housing fig 27 screws RA PD 10832 FIGURE 2 5 Removal of distributor assembly 48 ...

Page 56: ...with a brass hammer to free sleeve mounting from gear case before pump can be pulled out RA PD 10833 FIGURE 26 Indicating distributor timing position Arbor press d Water pump disassembly fig 29 Tools Screw driver 1 2 inch open end wrench Pliers Hammer Spanner wrench Punch Wooden mallet Vise 916 inch open end wrench 1 Remove discharge pipe and Screw driver hose assembly from pump Loosen hose clamp ...

Page 57: ... PUMP WATER ASSEMBLY WASHER LOCK BECXIK HM 40170 CS SCREW CAP BCAXIEC SCREW CAP HM 4625A WASHER LOCK BECXIM SCREW CAP BCAXICF WASHER LOCK BECXIK RA PO 8043 FIGURE 27 Water pump assembly removal 3 Remove water pump impel Hammer ler retaining pin Punch Vise Clamp impeller shaft in a vise and drive out impeller retaining pin 4 Remove water pump im Arbor press peller from shaft Place pump cover and sh...

Page 58: ...E HM 40064A CLAMP CMAX2A SA PUMP WATER ASSEMBLY HM 40170 CS PIPE HM 40690B GASKET WI A1949X CUP GREASE CLEX2B CONNECTION HOSE HM 44552B RA PD 8044 FIGURE 28 Water pump assembly dismounted 7 Remove grease retainers Pliers from pump shaft bearings Pull out washer retainer and apply grease water pump to retain ing washer from pump shaft bearing at front of water pump cover 8 Remove distributor drive ...

Page 59: ...ling pump use new gaskets on attaching flange and between cover and body 5 It is not necessary to remove the inlet elbow which is attached to the pump body by two cap screws unless the body casting has been damaged 6 Pack shaft bearing grease cup with grease water pump after installation f Water pump assembly fig 29 Tools 1 2 inch open end wrench Punch 6 inch open end wrench Hammer Screw driver Sp...

Page 60: ...ft H M 4 0172B 4 Key B GAX6B 5 Washer H M 4 024A 6 Gasket H M 2 21494 7 Cover assembly H M 1 0171CS 8 Screw c ap B CAXIBA 9 Washer l ock B ECXIH 10 Nut H M 2 2177A 11 Gland H M 2 1265A 12 Packing H M 2 2166A 13 Impeller H M 4 0165A 14 Pin H M 1 4507A 15 Gasket H M 2 2164A 16 Body assembly H M 4 5735CS FIGURE 29 W ater pump assembly e xploded view 53 ...

Page 61: ...retaining pin 8 Install pump cover as 1 2 inch open end wrench sembly Position gasket on pump body flange and place pump cover assem bly on body lining up punch marks on body and cover Then replace four attaching cap screws and lock washers 9 Connect discharge pipe and Screw driver hose to pump Slide elbow hose on water pump body outlet pipe and tighten hose clamp 10 Precautions In replacing distr...

Page 62: ...or bearing and on drive gear retaining pin are in line and slide distributor in mounting bear ing on pump cover so that slot in distributor advance arm is over arm retaining screw lug 4 Connect spark control wire Screw driver and secure distributor Insert spark control wire in swivel hole on advance arm and tighten clamping screw Then replace distributor arm advance control retain ing screw with o...

Page 63: ...ble remedy a Low or no generator output 1 Dry battery 1 Refill cells 2 Poor battery condition 2 Replace battery 3 Fully charged battery 3 None check output when battery is slightly discharged 4 Loose or dirty connections 4 Clean and tighten 5 Burned contacts on regula 5 Clean or replace contacts tor units check generator field condition 6 Grounded armature wires 6 Replace wires insulate ter or ter...

Page 64: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 23 RA PD 10950 FIGURE 30 G enerator and regulator i nstalled 57 ...

Page 65: ...If the output drops off with the field circuit disconnected at the regulator the trouble is isolated in the regulator Remove and check the regulator 3 Low battery and low or no charging rate This may be caused by a number of conditions Check the field and output circuits for loose connections Check for corroded battery terminals loose or corroded ground strap and frayed or damaged wires The high r...

Page 66: ...acket is screwed to the bottom of the frame and field assembly and to the side of the engine fastening the generator in place with the commutator at the rear and the pulley to the front in line with the engine fan Both head assemblies have openings and on the rear face of the drive pulley are vanes which force air through the generator from end to end to ventilate and cool it On top of the frame a...

Page 67: ...el 24 ARMATURE BALL BEARING 10000 00DRIVE PULLEY OILER AD000005 Tr ה ו ק ORDNANCE MAINTENANCE OlunDO0000 BALL BEARING 4000 door 000003 BRUSH SPRING FIELD COIL BRUSH ARM MOUNTING BRACKET BRUSH RA FSD 1865 FIGURE 31 G enerator assembly s ectionalized 09 ...

Page 68: ...ce brush d Replace spring e Clean commutator f Replace coil 9 Repair or replace h Repair or replace i Repair or replace c Open circuit due to worn brush d Open circuit due to broken brush spring e Open circuit due to dirty commutator f Open circuit in field coil 9 Short circuit or ground in commutator h Short circuit or ground in armature i Short circuit or ground at main terminal j Short circuit ...

Page 69: ...thin wall socket wrench 5 inch open end wrench Unscrew plug at top of generator field terminal shield housing fig 32 Detach upper terminal hex nut and plain washer Un screw conduit nut from field terminal housing Disconnect terminal wire in conduit and pull terminal out of housing assembly fig 33 2 Disconnect armature con 6 inch socket wrench duit Channellock pliers Unscrew condenser assembly from...

Page 70: ...hree cap screws and lock washers and one flathead screw holding bracket to generator d Generator disassembly fig 38 and Tools Screw driver Screw driver socket wrench 6 Fan belt or rope inch face Length of pipe 38 inch thin wall socket wrench 1 inch socket wrench 16 inch open end wrench Pulley puller 1 Remove cover band Screw driver Loosen roundhead machine clamp screw and remove band 63 ...

Page 71: ...ler Hold pulley with belt and pipe and unscrew hex nut at drive end of armature shaft fig 39 Take off plain washer and lock shakeproof washer Remove pulley and Woodruff key fig 40 3 Remove drive end head as Screw driver sembly Take out six oval fillister head machine screws and lock washers Remove head assembly from frame and field assembly and from arma ture shaft 64 ...

Page 72: ...9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 24 RA PD 10953 FIGURE 34 Removing generator armature condenser RA PD 10954 FIGURE 35 Unscrewing conduit nut from armature terminal housing 476794 42 5 65 ...

Page 73: ...TM 9 1706 24 ORDNANCE MAINTENANCE RA PD 10955 FIGURE 36 Removing armature terminal nut RA PD 10956 FIGURE 37 Generator assembly removal 66 ...

Page 74: ... and lock washers from end head Mark head assembly and frame assembly to facilitate reassembly and remove head assembly 7 Remove ball bearing from None commutator end head assembly Take out ball bearing plain washers felt washer and external tooth lock washer 8 Remove brushes and hold Screw driver ers Unscrew four roundhead machine screws with lock washers at ter minals of brush leads and slip bru...

Page 75: ... X 715 Washer lock BECX1D Nut AL X 794 W Screw AL 8X 118 RR Band assembly AL Washer lock GBG 24 BECX1E SS Frame assembly AL X Armature assembly GDJ 2084 AL GBJ 2031F TT Nut BBBX1B Y Spacer AL GBG 49 UU Washer AL MU 37 Z Retainer AL GBG 56 VV Washer lock AL X 1014 AA Washer felt AL WW Washer AL MU 36 GBG 58 XX Bushing AL GCY BB Screw BCGX2BF 28 Washer lock AL X YY Bushing AL GCY 27 196 ZZ Washer AL...

Page 76: ...ERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 24 Z AA 0 BB AD 000000000 AE AF AG AH AJ AK CC AC AB ZZ YY DD wow XX WW 9 VV ՍՍ ЕЕ 0000000 SS o FF GG НН JJ KK RRIO QQ PP NN RA FSD 1866B LL FIGUGE 38 Generator parts 69 ...

Page 77: ...TM 9 1706 IW 24 ORDNANCE MAINTENANCE RA PD 6491 FIGURE 39 R emoving generator pulley nut 70 ...

Page 78: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 24 RA PD 6490 FIGURE 40 G enerator pulley removal IL ...

Page 79: ...Thin socket wrench for removal of field terminal hexagon nut e Maintenance and adjustments 1 General The external cir cuit must be kept in good condition Defective wiring and loose or corroded connections at the battery starting motor ammeter and elsewhere in the circuit must be checked for and eliminated when found Loose or corroded connections in the charging circuit will cause high voltage whic...

Page 80: ...or down in a lathe removing only sufficient material to true up the commutator and remove rough ness and high mica Undercut the mica as shown in figure 42 The commutator should be inspected at least every 10 000 miles GT RA PD 10958 FIGURD 42 Undercutting armature commutator 4 Brushes a Check the brush spring tension by hooking a scale in the hole at the end of the brush arm and take reading as th...

Page 81: ...insulation Ball bearings should be thoroughly cleaned and repacked with lubricant All worn parts should be replaced 7 Tests If the generator is not performing according to speci fications and it has been checked and found to be at fault remove the cover band and check for sticking brushes If the brushes are seating satisfactorily and in good contact with the commutator remove the generator from th...

Page 82: ...ed from the gener ator and tested by connecting with brushes to a battery With test 110 VOLT LINE FLEXIBLE LEAD BULB INSULATED LEAD 11 TEST POINTS RA PD 10959 FIGURE 13 Test point assembly points connected to the terminals of a volt ammeter slowly rotate the armature checking between adjacent bars with the test points fig 44 Any open circuited coils will cause a full battery voltage read ing on th...

Page 83: ...ETER MAIN BRUSH INSULATED USE MILLIVOLT SCALE BATTERY RHEOSTAT KNIFE SWITCH RA PD 10960 FIGURE 44 Armature open circuit test 2 Install field coils and pole Screw driver socket wrench 16 shoes inch face Place coils in frame upper left lower left lower right and upper right in order named facing end with inspection openings Insert pole shoes in coils and fasten each with two flathead machine screws ...

Page 84: ...s on commu Screw driver tator end head assembly and con nect leads Lift spring arms and insert brushes into holders by hand Attach each lead to holders with one roundhead machine screw and lock washer 8 Install ball bearing in drive Screw driver end head assembly Insert felt washer and retainer against seat in end head Then install ball bearing gasket retainer and felt washer and secure bear ing r...

Page 85: ...tion Run a jumper lead between the armature and field terminals and then connect the generator across a 12 volt circuit At 12 volts the current draw should be 7 60 to 8 40 amperes Place band around frame over inspection openings and tighten with screw and nut g Generator installation Tools Screw driver Channellock pliers 9 16 inch socket wrench 33 inch thin wall socket wrench 34 inch socket wrench...

Page 86: ... to battery it is to charge This should always be done after any checks adjustments or repairs of generator or regulator 25 Regulator a Description fig 46 The regulator contains three assemblies the cut out which closes the charging circuit when the generator is charging and opens the circuit when the generator is not charging a voltage regulator and a current regulator which con nect and disconne...

Page 87: ...TM 9 1706 25 ORDNANCE MAINTENANCE L a i SCREW BCAXIBD NUT BBAXIB WASHER LOCK BECXIH RA FSD 1868 FIGURE 45 Voltage and current regulator installed 80 ...

Page 88: ...JUST BREAKING AIR GAP 060 T O 065 010 476794 12 6 047 TO 049 W HEN POINTS ARE JUST BREAKING HH 30 OHMS 015 49 7 OHMS 15 8 OHMS ТонМ 15 OHMS 81 80 OHMS HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 25 BATTERY ARMATURE GROUND BATTERY CAR FRAME GENER ATOR RA PD 40076 FIGURE 46 R egulator t ype VRH a nd generator wiring diagram ...

Page 89: ...he three terminals consists of an armature carrying contact points which are connected to the battery and controlled by an electromagnetic core on which are wound a few turns of relatively large wire making a current coil One end of this coil is connected to a fixed contact and the other to the armature of the regulator A spring attached to the armature of the circuit breaker normally keeps the fi...

Page 90: ...ing of thick wire in series with the armature of the generator and the current coil of the circuit breaker or cut out relay Additional resistance for the field windings of the generator are also present but are so arranged that as long as the contacts of both current regulator assembly and voltage regulator are closed this resistance is not effective 2 Functioning a When the engine has been starte...

Page 91: ...e coil on the magnetization of the core is continued When the battery voltage approaches its maximum it opposes the further flow of generator current through the current coil of the circuit breaker As soon as the generator stops or slows down to a point where its voltage is less than the battery voltage current from the battery flows through the current coil but in the reverse direction The curren...

Page 92: ...Ordnance No B167663 Manufacturer s No VRH 4102A White No 344909 Ground Negative Maximum current 55 amperes Radio shielded b Quick checks inspection of unit installed on vehicle If regu lator is thought to be faulty remove the cover make a close visual inspection of the following and make all possible corrections at once 1 Evidence of burning or abnormal high temperature at the coils contacts insul...

Page 93: ...nerator inoperative e Check and repair or replace f Low current regulator set f Check repair andadjust ting 9 Low voltage regulator set 9 Check repair and adjust ting h Damaged loose or broken h Check repair or replace regulator windings d Regulator removal Tools Screw driver 12 inch open end wrench Channellock pliers 1 2 inch socket wrench 58 inch open end wrench 1 Remove shield cover Screw drive...

Page 94: ... seal and remove two cover nuts and lock washers Lift off cover and gasket 2 Remove complete regulator Screw driver base assembly Take out roundhead machine screws and lock washers from corners of base assembly and roundhead screws with lock washers and plain washers connecting leads of circuit breaker and voltage regulator to ground Lift the complete base assembly 3 Remove three resistors un Scre...

Page 95: ...TM 9 1706 EE 25 DD u דח ma OWLOI 10 HH ORDNANCE MAINTENANCE NN JEZ 148421 BAT ММ RA PD 3293 LL F IGURE 51 Voltage regulator e xploded view 1 88 ...

Page 96: ...ver AL VRA 2 GG Gasket AL VRA 50 HH Nut BBAXIA Washer lock BECXIG JJ Screw BCOX2AE Washer BEBXIE Washer lock BECXIE KK Gasket AL VRA 51 Insulation AL VRA 52 LL Case with stud assembly AL VRA 1072 MM Resistor 80 OHM AL TC 51M NN Screw BCNXIFE Washer BEBXID Washer lock BECXID PP Resistor 30 OHM AL TC 51L QQ Nut BBBXIA Washer lock BECXIG RR Resistor 15 OHM AL TC 51J 4 Remove jumper between Soldering ...

Page 97: ...embly 11 Remove current regulator None adjusting screw and spring Unhook upper end of spring by hand from armature Remove adjusting screw nut and lift out adjusting screw and spring 12 Remove current regulator Screw driver armature assembly Extract two machine screws lock washers and plain washers and lift off armature assembly 13 Remove current regulator Screw driver support core and coil Extract...

Page 98: ...ssembly Lift out shunt coil assembly series coil and bottom insulation f Maintenance and adjustments 1 After any faults indicated by visual inspection have been corrected or ascertained and regulator continues to be defective remove the unit and use the following pro cedure to locate defects a Connect test lamp in series with battery Attach one of the test leads to BAT terminal and the other test ...

Page 99: ...open the contacts so as not to leave any lint between the contacts 3 After the regulator assembly has been disassembled or repaired and assembled again the armature air and point gap for the current regulator voltage regulator and circuit breaker should be adjusted as follows a Current regulator Using a test lamp set connect the lamp in series with the battery and test leads and place the test lea...

Page 100: ... top arms of the point brackets fig 55 4 After the above adjustments have been made proceed to make final regulator adjustments as follows a Mount regulator firmly and in same position as on vehicle 6 Connect regulator to generator and battery circuit RA PD 10971 FIGURE 52 Checking armature air gap with pin gage RA PD 10972 FIGURE 53 Checking contact point gap 93 ...

Page 101: ...TM 9 1706 25 ORDNANCE MAINTENANCE 昌 1000 AIR 許 UN GO RA PD 10973 FIGURE 54 Checking circuit breaker armature air gap RA PD 10974 FIGURE 55 Checking gap of circuit breaker points 94 ...

Page 102: ...y points Be sure that the armature and point bracket do not make contact i After adjusting install the regulator cover and again test the circuit breaker operation The voltage at which the circuit breaker closes should be 1 volt less than the voltage at which the regulator operates After this check make a final test by stopping generator and noting the maximum voltage reading when the gen erator i...

Page 103: ...tact point gap 0 010 inch minimum Pressure of contact points 7 to 8 ounces Operating voltages Allowable variation Plus or minus 0 15 volt Temperature F 60 70 80 90 100 110 120 Volts 14 51 14 48 14 45 14 39 14 36 14 33 14 30 Current regulator Armature air gap 0 047 to 0 049 inch meas ured when points are just breaking Contact point gap 0 010 inch minimum Pressure of contact points 7 to 8 ounces Ope...

Page 104: ...nt bracket assembly and solder securely 5 Install circuit breaker ar Screw driver mature assembly Place armature assembly in position so that front end is under frame support hook Secure assembly to frame by inserting one fillister head machine screw with lock washer and plain washer through each lead assembly terminal and armature support into frame 6 Install circuit breaker ad None justing sprin...

Page 105: ...rrent regulator coil top lead to front of base with machine screw flat washer and lock washer Connect bottom leads of current regulator and circuit breaker to gether with clip lock washer and nut at rear of base 12 Install resistor 1 Screw driver Secure one end of resistor to circuit breaker resistor bracket and the other end to current regulator resistor bracket with one machine screw lock washer...

Page 106: ...and lock washers Connect voltage regulator coil front lead in a similar manner to rivet at rear of base 19 Connect jumper to voltage Soldering iron and current regulator assemblies Solder ends of jumper to projections on insulated ends of contact springs of voltage and current regulator armature assemblies 20 Install three resistors on Screw driver bottom of riveting base Using two roundhead machi...

Page 107: ... on regu lator base feet and secure both to dash with cap screws lock washers and nuts 2 Connect generator field and Screw driver armature leads and filter lead to Channellock pliers regulator 5 8 inch open end wrench Insert leads through shield and connect them to respective regulator terminals with lock washers and fillister head machine screws Care should be taken when connecting filter lead un...

Page 108: ...he plugs and the coil and to metal inserts in the cap on top of the distributor The upper half and the lower half of the distributor are enveloped in radio shielding 27 Trouble shooting for system Symptoms and probable cause Probable remedy a Engine missing slightly or sluggish Conduit defective loose or Check and repair or replace short circuited 6 Engine backfires Crossed plug conduits Install i...

Page 109: ...nition coil and a condenser which is connected in the circuit at one end and grounded at the other end 2 Functioning a The ignition coil steps up or multiplies the voltage of the primary coil at the instant when this circuit is broken at the distributor to the high value needed for the electric discharge at the gaps of the spark plug The secondary voltage is as many times as great as the primary v...

Page 110: ...ections secondary circuit or either circuit grounded 6 Windings grounded inside 6 Replace coil casing c Short circuited turns in c Replace coil primary or secondary coil or high voltage break down in secondary d Damaged filter coil or d Replace filter assembly shorted filter condenser c Removal of assemblies Tools 34 inch open end wrench 33 inch socket wrench 5 16 inch open end wrench Screw driver...

Page 111: ...TM 9 1706 28 ORDNANCE MAINTENANCE RA PD 10977 FIGURE 57 Removing ignition coil and filter assembly RA PD 10978 FIGURE 58 Removing ignition coil from shielding 104 ...

Page 112: ...p periodically and inspect ignition coil terminals Keep high tension socket clean and dry to prevent arcing 3 If coil is thought to be faulty remove it from vehicle and test in coil tester or install new coil for comparison e Installation of assemblies Tools Screw driver 34 inch open end wrench 516 inch open end wrench 5 8 inch open end wrench 38 inch open end wrench 716 inch open end wrench 1 Con...

Page 113: ...as a bearing through which the main shaft projects at the bottom 6 The breaker plate assembly in the top of the base assembly is secured by screws to the rim This breaker plate carries the breaker screw point and the breaker arm which is supported on a pivot The arm is electrically connected to a post terminal in the side of the base assembly The primary of the ignition coil is also connected to t...

Page 114: ... Cap assembly AL IGB 1240 9 Washer lock BECXIE 2 Rotor assembly AL IGB 1239 10 Screw AL 8X 1004 3 Shield AL XA 551 11 Shield AL XA 552 4 Screw BCNXIFD 12 Washer lock BECXID 5 Washer lock BECXID 13 Screw BCNXIFB 6 Wick AL IG 495 14 Arm assembly AL IGB 2296 7 Condenser assembly AL IGW 3075D 15 Base assembly AL IGW 2123 8 Shield AL XA 553 16 Washer AL IG 90 107 ...

Page 115: ...it which extends through the rotor to the correct spark plug As the distributor rotates ignition is thus produced in the proper firing order 6 The direction of rotation of the distributor is clockwise when viewed from the top As the engine speeds up the governor advances the cam to make the ignition take place earlier in the stroke The purposes for which the manual adjustment of the distributor is...

Page 116: ...properly 6 Breaker contact points worn or defective c Condenser defective or dis connected 7 Timing incorrect or irreg ular Breaker cam loose or wobbly a Install new cam and stop plate assembly 6 Examine and replace breaker arm and screw point c Test connection or replace condenser Check governor weights springs and pivots Replace parts as needed 8 Engine knocks Breaker cam too far advanced Readju...

Page 117: ...one high voltage wire at a time and pushing it in proper position on new cap Hold both caps in same position 2 Disconnect spark control Screw driver Loosen clamping screw holding control to arm assembly and pull out control 3 Disconnect primary wire Screw driver Channellock pliers 3 inch open end wrench Remove distributor primary terminal shield by removing two ma chine screws Unscrew conduit coup...

Page 118: ...shers Dismount two shields 3 Detach rotor assembly from None cum Pull rotor assembly off upper end of cam and stop plate assembly 4 Remove terminal post and 3 inch open end wrench breaker arm assembly from base Remove remaining binding nut small lock washer plain brass washer shakeproof washer and insulating washer from terminal post and lift out breaker arm assembly Pull out terminal post carry i...

Page 119: ...104 N Shaft ass ably AL 1GW 2047 RF P Base assembly AL 1GW 2123 Q Cup grease R Washer AL 16 816A S Screw BCGX2BD T Arm assembly AL 16B 2296 U Washer lock BECXIG V Nut BBAX1A W Screw BCFX2DR X Washer AL 16 688A Y Washer AL 1G 687 Z Washer AL 1G 688 AA Nut AL 8X 163 BB Screw AL 1G 750 CC Insulation AL 1GB 21 DD Post AL 1GW 39 EE Washer AL 1GW 54 FF Bushing AL 1GW 38 GG Bushing AL CB 140 HH Washer AL...

Page 120: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 29 M N CC DD EES BB Y FF O GG AA HH JJ N KK 0 0 0 0 LL R X MM S T OO RA FSD 18638 W FIGURE 610 Distributor assembly exploded view 476794 42 8 113 ...

Page 121: ... gover None nor and cam assembly from base Lift drive shaft governor and cam assembly out of base assembly and slide thrust washer off shaft 9 Disassemble drive drive shaft Thin nosed pliers governor and cam Free governor springs from anchor lugs and remove cam lock spring ring Lift off cam and stop plate assembly from shaft assembly and remove governor weights 10 Remove grease cup from 716 inch o...

Page 122: ...it will go then release It should return with no drag or restriction Otherwise overhaul governor NOTE When moving the breaker cam forward to test governor it is best to remove the rotor If the cam is turned by grasping the rotor the key of the latter may break or chip Pliers may be used to grip breaker cam and shaft to hold the latter while moving the cam provided stout paper is placed in the jaws...

Page 123: ...l marking D C is in line with timing mark on flywheel housing No 1 cylinder is now in firing position e Position the distributor in mounting so that when gears engage the rotor metal strip will line up with No 1 spark plug contact in the distributor cap f Fasten distributor with screw two flat washers spring washer and nut to bracket on water pump 9 Loosen distributor clamp just enough so that the...

Page 124: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 29 RA PD 10986 FIGURE 62 Checking distributor point gap RA PD 10987 FIGURE 63 Adjusting distributor point gap 117 ...

Page 125: ... to 20 ounces Condenser capacity 0 20 0 25 mfd Advance 10 automatic Retard 6 manual f Assembly of distributor fig 61 and 2 Tools 14 inch open end wrench 716 inch open end wrench 38 inch open end wrench Screw driver Drift Thin nosed pliers Hammer 1 Replace bronze bushings in Arbor press base assembly Press bushings into both ends of shaft bore through base assembly Upper bearing hole should line up...

Page 126: ...rew about one third of the length Thread screw into threaded hole of lug on breaker plate assembly to binding nut 7 Replace breaker plate as Screw driver sembly in base assembly and re taining spring and hinge assem blies on outside of base assembly Insert breaker plate assembly into base assembly so that hole in center lug lines up with hole in base which is directly opposite terminal post hole S...

Page 127: ...ctly over terminal post Slip terminal of condenser onto terminal post 13 Install drive gear Drift Hammer Slip thrust washer onto shaft place gear in position on shaft and secure with pin Peen over end of pin End play of shaft can be changed by using different size thrust washers g Installation of assembly Tools 76 inch open end wrench 38 inch open end wrench Screw driver Channellock pliers 1 Mount...

Page 128: ... half shields and condenser shield attached by screws to the dis tributor base assembly and the upper half shield covering the cap of the distributor and secured by a screw and stud in slots on the lower half shields fig 60 6 The shields for the wires are in the form of metal conduits Each conduit encloses one of the wires and has a ferrule and an inter nally threaded coupling nut on each end By m...

Page 129: ...512 CONDUIT A SS Y T I 2 04 2 900 CONDUIT A SSY T I 2 04 3 800 GROMMET T I A 2 2840 T O COIL SHIELD A SSY T I B 2 7516 MARKER T I A 2 2714 ORDNANCE MAINTENANCE SPARK PLUG DISTRIBUTOR NO TERMINAL OVERALL LGH O F 1GNITION WIRE 1 274 LWIRE T I A 2 6742 2 2 9 2 2 3 3 3 NOTE CONDUIT ASSEMBLES DO NOT INCLUDE WIRE 4 4 5 5 31 3 36 4 39 424 50 į 6 6 RA PD 3247 DISTRIBUTOR TO COIL WIRE FIGURE 61 Ignition sh...

Page 130: ...65 Spark plug and shielding details c Removal and disassembly of shielding figs 65 and 66 Tools Screw driver 34 inch open end wrench 78 inch open end wrench 38 inch open end wrench 1 Remove upper half dis Screw driver tributor shield Loosen screw in side of shield Release cap from spring and hinge assemblies Turn upper half shield to free it from slots in lower half shields Lift upper half shield ...

Page 131: ...ch open end wrench 38 inch open end wrench 34 inch open end wrench Screw driver 1 Attach conduits V8 inch open end wrench 34 inch open end wrench 38 inch open end wrench Push in or connect wires at distributor cap ignition coil and spark plug upper shields and insulators Screw on hex nuts and coupling nuts at distributor cap and ignition coil Put lower shield on spark plugs when they are mounted w...

Page 132: ... ECXIE NUT B BKX2C CLAMPS TI A 20441 BRACKET T I A 27512 NUT T I R 15 3C HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 30 DISTRIBUTOR A SSEMBLY AL I GW 4 147 SCREW D ISTRIBUTOR ARM A L 1 G 7 50 RA PD 8037 FIGURE 66 R adio shielding i nstalled 125 ...

Page 133: ...RUBBER GASKET ASSEMBLY CONE SHIELD HIGH TENSION LEAD SUPPORT INSULATOR COUPLING NUT CONTACT SPRING ASSEMBLY SPARKPLUG SHIELD SPARKPLUG SPARKPLUG GASKET RA PD 3720 FIGURE 67 Spark plug with shielding installed inner end of the central stem by the spark gap The stem is sealed in the insulator and has a terminal on its outer end for connection with the high voltage shielded conduit leading to the dis...

Page 134: ...to give spark a Insulation broken at one a Replace plug end 6 Side electrode worn exces 6 Replace plug sively c Plug carbonized at inner c Clean plug end d Plug burned at inner end d Replace plug e Insulation swollen blis e Replace plug tered fused or broken f Electrodes showing signs of 1 Replace plug disintegration 9 Leak around insulator 9 Replace plug showing carbon streaks on outer part h Moi...

Page 135: ...nch on spark plug and screw it out of cylinder head fig 68 Remove lower shield and copper gasket PLUG SPARK WITH GASKET WI 363114 WI 309667 SOCKET WRENCH LEKU INSULATOR TI A 27487 SHIELD LOWER TI A 20315 PLUG AND SHIELD REMOVED 1 RA PD 8035 FIGURE 68 Spark plug removal d Maintenance and adjustments 1 After every 500 miles of operation the spark plugs should be removed and the following checks made...

Page 136: ...iring cylinder is shorted out a different rhythm is pro duced Remove shield cap and short out each plug Note the result on the operation of the engine If a cylinder is already missing no change will be noted when its plug is shorted out If a spark plug is thought to be faulty it should be removed and tested in a spark plug tester 3 After 10 000 miles of operation new spark plugs should be installe...

Page 137: ...NSULATOR TOP CARELESS HANDLING 2 SPLIT INSULATOR BENDING CENTER ELECTRODE 3 SIDE ELECTRODE WORN LOOSE PLUG OR TOO HOT 4 PLUG BADLY BURNED PRE IGNITION OR INADEQUATE COOLING RA PD 35726 FIGURE 700 Effects of operating conditions on spark plugs 130 ...

Page 138: ...1 5 STREAKED INSULATOR TOP BLOW BY 6 RUSTY BROWN COATING HIGH SPEED OR HEAVY LOAD 7 CARBON COATING RICH MIXTURE OIL PUMPING OR COLD PLUG 8 SOOT COATING PROLONGED OPERATION AT NO LOAD RA PD3 5720 FIGURE 700 Effects of operating conditions on spark plugs 131 ...

Page 139: ...TS 6 SLIGHTLY COLD D RY BLACK SOOT T OO HOT B LISTERED OR GLASSY ORDNANCE MAINTENANCE CORRECT INSULATOR COLOR L IGHT T AN TOO HOT A FTER PROLONGED OPER A TION AT HIGH SPEED OR UNDER HEAVY LOAD RA PD 3572A FIGURE 71 Effects of operating conditions on spark plugs 132 ...

Page 140: ...rk plug shields so that wire terminals enter insulators Insert lower ends of insulators into lower shields so that wire terminals engage upper ends of plug electrodes Screw shield coupling nuts onto lower spark plug shields SECTION IX ELECTRICAL STARTING MOTOR Paragraph Description 32 Trouble shooting 33 Removal of assembly 34 Disassembly of components 35 Maintenance and inspection 36 Reassembly o...

Page 141: ...TM 9 1706 32 2010 ORDNANCE MAINTENANCE 3 l o4 B O C MOTOR A SSY AL M AU 4 006 ADAPTER HM 2 2066A STUD W A 14047X NUT B BBXIC WASHER L OCK BECXIK RA PO 3292 FIGURE 72 S tarting motor i nstalled 134 ...

Page 142: ...GK 3 8 SCREW A L G T 2 0 WASHER L OCK B ECXIG BUSHING B Z A L M G 7 7A 100DDDDDDDDD 0 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 32 BENDIX DRIVE A SSY A L E BA 1 1 HOUSING A SSY AL P S 1 088 BUSHING B Z A L M G 7 7A BEARING A SS Y A L M AB 2 040A LABRUSH A SS Y A L M 2 1034 RIVET B MGXI BUSHING B Z AL M Z 4 0A PLATE E ND A SS Y A L M AB 2 002 SPRING A L M Z 1 9 HOLDER A L M Z 1 6 MOTOR S TARTING ...

Page 143: ...ture shaft and held in position by the doweled hex bolt which also secures the drive spring in position b Functioning When the battery circuit is closed to the motor by the starting switch the armature revolves and imparts movement through the drive spring to the assembly which carries the pinion gear The gear because of its inertia does not instantly rotate with the assembly Hence the drive assem...

Page 144: ...Repair or replace switch 3 Bendix gear jammed 4 Starting motor switch faul ty 5 Starting motor faulty 5 Remove and repair or re place starting motor 6 Remove starter and repair or replace drive 6 Bendix drive at fault 6 Starting motor cranks weakly 1 Battery weak 2 Loose or dirty connections 3 Commutator dirty 1 Recharge battery 2 Clean and tighten connec tions 3 Remove band and clean commutator w...

Page 145: ...tor forward and out of vehicle fig 75 35 Disassembly of components fig 76 a Bendix drive assembly Tools Screw driver Arbor press 5 8 inch open end wrench 1 Remove pinion housing Screw driver Remove two frame screws and lock washers from commutator head end of motor Pull off pinion housing assembly from frame and field assembly 2 Remove pinion housing end Arbor press bushing Press bushing out of pi...

Page 146: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 35 RA PD 10989 FIGURE 74 Starting motor removal RA PD 10990 FIGURE 75 Starting motor removal 139 ...

Page 147: ...aft assembly A L E BA1111 B Screw A L E D7807 C Washer l ock A L E B108 D Spring A L E B 8 705 E Head A L E B8503 F Screw A L E B7806 RA FSD 1862 G Washer l ock A L E B108 H Sleeve AL E B7819S J Spring A L E B8734 FIGURE 76 Starting motor B endix drive e xploded view 140 ...

Page 148: ...rushes Pull head assembly off frame and field assembly carrying remaining two brushes with it Knock out bushing 5 Remove pole shoes and field 16 inch screw driver socket coils Screw driver Mark position of field coils in frame Remove four round head ma chine screws holding pole shoes and field coils to frame and take out pole shoes Remove nut lock washer plain washer and insulating washer from ter...

Page 149: ...eeve AL EB78195 H Spring AL EBA8705 J Head AL EB8503 K Screw AL EB7806 washer AL EB108 L Bearing assembly AL 2040A M Bushing AL MG77A N Washer AL MU54 P Keyway BGAX8A Q Spacer AL MAB35 R Armature assembly AL MAB 2006 S Washer AL MU54 T Pole AL MAB29 U Screw AL GK38 V Brush AL MAU12 W Washer lock BECX1G X Screw AL GT20 Y Dowel AL MN21 Z Housing AL MAU2001 B A RA FSD 1861A FIGURÐ 770 Starting motor ...

Page 150: ...t AL 8X794 HH Screw AL X715 JJ Post AL MU28 KK Washer AL MU39 LL Bushing AL MAB85 MM Washer AL MAB31 NN Washer BEBX1BH PP Washer lock BECXIH QQ Nut BBBX1B RR Coil assembly AL MAU1009 lower left SS Terminal AL MAU14 upper left TT Coil assembly AL MAU1007 A upper left UU Coil assembly AL MAU1010A upper right VV Connector AL MAF59 WW Coil assembly AL MAU1008 lower right то оо оо оо о MM LL EE KK FF G...

Page 151: ...r make the fol lowing inspections 1 Check for worn intermediate and end bushings and replace if necessary 2 Check for broken or weak brush springs and replace when necessary see h below 3 Check terminal post for stripped threads Replace damaged post 4 Check and replace all damaged or cracked insulators 5 Check Bendix drive spring for weakness or distortion Replace faulty spring 6 Check Bendix driv...

Page 152: ...d switch terminal or fields RA PD 10991 FIGURE 78 Turning commutator 2 Failure to operate or low speed and torque with no current draw indicates a Open field circuit 6 Open armature coils Inspect commutator for badly burned bars With motor running at free speed an open armature will show excessive arcing at commutator bar which is open c Broken or weakened brush springs worn brushes high mica on c...

Page 153: ... check the armature for short circuit using a growler A thin strip of steel such as discarded hacksaw blade held in place over the armature core as the armature is turned in the growler will vibrate if a short circuit exists in the armature fig 81 Replace if necessary 6 Insulated brush holder test for ground Place one test prod on cover and other on insulated brush holder If lamp lights brush hold...

Page 154: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 37 RA PD 10975 FIGURE 79 Testing starting motor field RA PD 10976 FIGURE 80 Testing armature for ground 147 ...

Page 155: ... over field coil terminal add insulating bushing and thrust post through hole from inside of frame assembly Put insulation strip under upper and lower right coils along edge of openings in field and frame assembly Tighten four screws 4 Unite coils in series at drive Pliers end of field and frame assembly Soldering iron Use separate connecter for upper and lower right coils Join and solder all ends...

Page 156: ... on assembly and two additional brushes into remaining holders then set free ends of springs upon them Arbor press 10 Replace intermediate bear ing and bushing Press bushing into bearing and put bearing thrust spacer thrust washer and intermediate bearing assembly with bushing on armature shaft at drive end 11 Secure terminal post 16 inch open end wrench Apply insulating washer plain washer lock w...

Page 157: ...y into housing and tighten 38 Installation of assembly Tools 5 8 inch open end wrench 16 inch open end wrench a Mount starting motor on en 5 8 inch open end wrench gine Attach motor to flywheel housing with three studs three nuts and three lock washers b Connect motor to battery ca 16 inch open end wrench ble Remove one nut and lock washer from terminal post Attach ter minal of cable to post and s...

Page 158: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 39 RA PD 8104 FIGURE 82 G asoline engine compartment l eft side 151 ...

Page 159: ...TM 9 1706 39 A ORDNANCE MAINTENANCE RA PD 8105 FIGURE 83 G asoline engine compartment r ight side 152 ...

Page 160: ...ASSEMBLY WI 348746 PUMP FUEL AND VACUUM ASSEMBLY AC 1537105 MOTOR STARTING ASSEMBLY AL MAU4006 ADAPTER HM 22066A RA PD 8107 FIGURE 84 Gasoline engine dismounted right side in place by the starting crank jaw fig 87 The water pump is driven directly from the gear train and is mounted on the rear of the timing gear case fig 88 The distributor which is mounted on the water pump housing is driven by a ...

Page 161: ... 27512 DISTRIBUTOR ASSEMBLY AL IGW 4147 PUMP WATER ASSEMBLY HM 40170 CS RA PD 8106 FIGURE 85 Gasoline engine dismounted left side 4 The crankshaft is a drop forging and is both statically and dynamically balanced Seven cadmium nickel main bearings support the crankshaft The bearing caps are all drop forgings fitted with removable bearing shells 5 The pistons are made of an aluminum alloy and are o...

Page 162: ...CTING A SSEMBLY HM 4 0390CSY CAMSHAFT H M 4 5686A HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 39 FLYWHEEL H M 2 3705C PUMP W ATER A SSEMBLY HM 4 0170CS CRANKSHAFT H M 4 5853E PUMP O IL A SSEMBLY H M 4 5290CS BELL HOUSING H M 2 44270 RA PD 8111 FIGURE 86 G asoline engine s ectionalized s ide elevation 155 ...

Page 163: ...ed but readily accessible by the removal of the valve cover plate FAN ASSEMBLY SZ A 105005 BELT WI 311964 PULLEY WI 325753 JAW HM 40806A RA PD 8108 FIGURE 87 Gasoline engine dismounted front view 7 The camshaft is of the cast alloy type and is enclosed in the upper half of the crankcase It is mounted in four steel backed babbitt lined bearings of the continuous ring type The crankshaft to camshaft...

Page 164: ...MBLY HM 42310DS MANIFOLD EXHAUST AND INTAKE HM 43804E HEAD CYLINDER HM 459210 GEAR PUMP WATER HM 22195B GEAR CAMSHAFT HM 220498 000 GEAR IDLER HM 40135B GEAR CRANKSHAFT HM 22039B PAN OIL ASSEMBLY HM 40375D HM 421760 RA PO 8110 FIGURE 88 Gasoline engine sectionalized front elevation 157 ...

Page 165: ...H ASSEMBLY LM 5835 LM 5875 RA PD 8109 FIGURE 89 Gasoline engine dismounted rear view 10 The oil pump is of the two gear positive type having steel gears pressed on steel shafts The oil pump is bolted directly to the center main bearing web the suction tube extending into the strained oil compartment fig 90 The oil is raised from the strained oil reservoir and pumped into a channel drilled in the c...

Page 166: ...PASSAGES IN BLOCK I T 00 FE IM L U I CAMS HAFT HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 39 CRANKSHAFT CONNECTING ROD BEARINGMAIN BEARING OIL PUMP OIL PAN SCREEN LUBRICATING OIL DRAIN PLUG FIGURE 90 G asoline engine lubricat ing system RA PD 7529 159 ...

Page 167: ...rburetion 3 See section XI 4 Air cleaner restricted 4 Clean mesh element in gas line 5 Overheating 5 See section VI 6 Improper grade and viscos 6 Change to correct grade ity of oil b Poor compression 1 Valves worn 1 Grind valves 2 Valve seats worn or pitted 2 Cut new seats 3 Piston rings weak broken 3 Replace rings and correct stuck or worn cause of sticking 4 Tappets sticking 4 Clean guides 5 Tap...

Page 168: ...ves or broken 8 Air cleaner not clean al 8 Clean air cleaner mesh and lowing dirt to enter combustion sump chamber 9 Carburetor fuel mixture 9 Replace worn jets too rich d Bearing failures 1 Crankshaft bearing journal 1 Grind or replace shaft rough or out of round 2 Crankshaft oil passage re 2 Clean passages and line stricted 3 Bearings sprung 3 Replace sprung inserts 4 Bearings loose im 4 Adjust ...

Page 169: ... as required 6 Use genuine parts 7 Replace valve 1 6 Improper type valves 7 Valve head too thin caus ing hot sections 8 Valve seats too narrow 9 Lean mixture 8 Cut seats to correct width 9 Clean carburetor Check float adjustment 10 See section VI 11 Use good quality fuel 10 Overheating 11 Low grade fuel f Valves sticking 1 Improper valve clearance 2 Insufficient clearance be tween valve stem and g...

Page 170: ...orly seated 10 Replace rings 11 Overheating 11 See section VI 12 Oil ring slots clogged 12 Clean rings of carbon with carbon Replace if necessary 13 Excessive oil pressure 13 Adjust pump pressure i Low oil pressure 1 Improper oil 1 Use correct oil See TM 9 1705 2 Pressure regulating plung 2 Adjust correctly Oil er worn or clogged pressure 5 pounds at idling and at least 25 pounds at running speed ...

Page 171: ... Removal of assembly Tools Pail 5 8 inch open end wrench Pliers Channellock pliers 16 inch open end wrench 916 inch socket wrench Heavy duty square shank Thin screw driver screw driver 38 inch thin wall socket Length of rope wrench Hoist 34 inch open end wrench 6 inch box wrench 916 inch socket with speed 1 2 inch open end wrench handle Screw driver Length of 34 inch manila 34 inch socket wrench r...

Page 172: ...w driver nections Loosen clamps holding inlet and outlet radiator hoses and pull hoses loose from radiator e Remove radiator 34 inch socket wrench 78 inch socket wrench with uni versal attachment Chain hoist Disconnect radiator from cross member by removing holding stud nuts springs washers and pads Then disconnect stay rods at frame by removing nuts from stay rod bolts underneath car on the botto...

Page 173: ...TM 9 1706 41 ORDNANCE MAINTENANCE RA PD 6210 FIGURE 91 Radiator removal RA PD 10895 FIGURE 92 Battery compartment cover removal 166 ...

Page 174: ... throttle control rod to throttle lever and lower rod Then loosen screws holding choke and throttle controls at carburetor and pull out controls fig 94 k Remove pipe assembly 7 inch open end wrench check valve to inake manifold Disconnect flared tube nuts at check valve intake fitting and at intake manifold fitting and remove pipe assembly fig 95 1 Disconnect fuel feed line and 1 2 inch open end w...

Page 175: ...TM 9 1706 41 ORDNANCE MAINTENANCE RA PD 10896 FIGURE 93 Disconnecting battery terminal RA PD 10897 FIGURE 94 Disconnecting choke wire assembly 168 ...

Page 176: ...ding cover screws and remove cover Pull out high voltage wire from coil Remove nut holding low voltage wire to coil terminal and pull off wire fig 58 q Disconnect manual spark Screw driver control Loosen screw holding control wire to spark control arm and loosen clamp screw at bracket Pull out spark control r Disconnect armature conduit Channellock pliers with wire assembly at generator 6 inch soc...

Page 177: ... block Break oil filter return line assembly at flared tube fitting located between rear of block and filter U Remove temperature gage 5 8 inch open end wrench bulb assembly Loosen temperature gage bulb adapter nut at rear left side of engine cylinder head and pull out bulb from adapter fig 96 v Remove vacuum line assem 78 inch open end wrench bly from check valve to booster 34 inch open end wrenc...

Page 178: ... hoist in balanced place of rope and remove slack in rope by raising hoist hook Remove cap screws and lock washers holding transmission to engine bell housing fig 97 2 Disconnect engine supports Pliers 34 inch socket wrench 34 inch open end wrench 15 16 inch socket wrench 15 16 inch open end wrench Remove cotter pins from castellated nuts at rear support bolts and remove nuts bolts washers and rig...

Page 179: ... move engine straight forward until clutch assembly is free of splined shaft Guide engine out of car and place in stand or on blocks figs 99 and 100 RA PD 10900 FIGURE 97 Disconnecting engine bell housing from transmission 42 Removal of accessories Tools Screw driver 18 inch open end wrench 6 inch open end wrench 38 inch open end wrench Channellock pliers 1 2 inch open end wrench 34 inch socket wr...

Page 180: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 42 RA PD 10901 FIGURE 98 Disconnecting front engine support RA PD 7411 FIGURE 99 Engine removal 173 ...

Page 181: ...TM 9 1706 42 ORDNANCE MAINTENANCE BOLT BOLT 27 RA PD 10828 FIGURÐ 100 Gasoline engine mounted in stand 174 ...

Page 182: ...ellock pliers shielding 34 inch socket wrench Spark plug wrench Unscrew shielding nuts at all spark plug shieldings Remove cap screws holding shielding conduit support bracket to cylinder head and remove brackets and distributor cap and shielding assembly Remove spark plugs fig 102 c Remove generator assembly 34 inch socket wrench RA PD 10829 FIGURE 101 Distributor cap and shielding removal Remove...

Page 183: ...ASKET WI 363114 WI 309667 SOCKET WRENCH INSULATOR TI A 27487 SHIELD LOWER TI A 20315 PLUGAND SHIELD REMOVED RA PD40495 FIGURÐ 102 Spark plug removal Remove two cap screws and lock washers holding fan bracket to top gear case and lift off fan and bracket assembly fig 104 f Remove carburetor assembly 5 8 inch open end wrench Remove two carburetor to manifold stud nuts and lock washers and lift off c...

Page 184: ...starting motor as 16 inch open end wrench sembly Remove three nuts and lock washers holding starting motor and adapter to flywheel housing and lift off starting motor assembly and adapter fig 105 i Remove clutch assembly 16 inch socket wrench Loosen clutch cover plate cap screws one turn at a time to pre vent cover distortion until diaphragm spring pressure is completely released Remove cap screws...

Page 185: ... open end wrench Piston ring expanding tool Spark plug wrench Metal bar 5 8 inch open end wrench Pinch bar 1 2 inch open end wrench Pulley puller Fiber hammer 2 inch open end wrench 34 inch socket wrench Press Valve spring lifter Wood blocks Pliers 6 inch extension Valve rack Brass drift Screw driver a Drain oil from crankcase Pail 16 inch open end wrench Remove magnetic drain plug from bottom of ...

Page 186: ...sing and lower pan and gasket fig 107 c Remove oil pump 16 inch open end wrench Set Nos 3 and 4 crank throws at top dead center position and remove three cap screws and lock washers holding oil pump to main bearing web Turn pump one quarter turn counterclockwise and lift out pump assembly and gasket fig 108 See section XII for complete disassembly and servicing of pump d Remove exhaust and intake ...

Page 187: ...2 and lift out filler and breather extension pipe and cap assembly f Remove cylinder head 34 inch socket wrench Speed handle Loosen all cylinder head cap screws with a socket wrench and then use speed handle on wrench to remove cap screws fig 113 The oil filler and breather pipe clip will come off with its respective cap screw Lift off cylinder head and gasket g Remove valve covers 34 inch socket ...

Page 188: ...LINE ENGINE FOR SCOUT CARS 43 SCREW CAP BCAXIEB WASHER LOCK BECXIM PLUG DRAIN HM 11090 A HM 40375D SCA PAN ASSEMBLY HM 421760 SCB SCREW CAP HM 14770B SCREW CAP BCAXICB WASHER LOCK BECXIK RA PD 8047 FIGURE 107 Oil pan removal 181 ...

Page 189: ...TM 9 1706 43 PUMP O IL A SSEMBLY H M 4 5290CS ORDNANCE MAINTENANCE SCREW C AP WASHER L OCK RA PD 8046 FIGURE 108 O il pump i nstalled 182 ...

Page 190: ...6 STUD H M 1 4895A NUT HM 8 48A WASHER H M 1 388A 20 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 WRENCH MANIFOLD E XHAUST AND INTAKE H M 4 5804E RA PD 8097 FIGURE 109 Exhaust and intake manifold removal 183 ...

Page 191: ...TM 9 1706 MANIFOLD E XHAUST AND INTAKE H M 4 5804E lo43 SHARIFO LO P13 ORDNANCE MAINTENANCE GASKET H M 4 5805B RA PD 8103 FIGURE 110 E xhaust and intake manifold details 184 ...

Page 192: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 CLIP HM 45842A SCREW CAP HM 1048A WASHER HM 8191A RA PD 8098 FIGURE 111 Oil filler and breather pipe mounting details 185 ...

Page 193: ...9 1706 43 ORDNANCE MAINTENANCE CAP ASSEMBLY HM 40038AS PIPE OILFILLERBREATHER EXTENSION HM 45535B MOUNTING PAD GENERATOR BRACKET FIBRE HAMMER RA PD 8099 FIGURE 112 Oil filler and breather pipe removal 186 ...

Page 194: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 SCREW CAP HM 4118A SOCKET WRENCH HEAD CYLINDER HM 459210 O RA PD 8100 FIGURE 113 Cylinder head removal 187 ...

Page 195: ... centered on valve head as shown in figure 115 Press down on handle of tool until valve spring is fully compressed so that valve pin will be in the clear for removal Remove valve retaining pin and lift out valve Place valve in a rack suitably marked so that it can be put back in its proper place at assembly Proceed with all valves in the same manner NOTE It is advisable to rotate the crankshaft to...

Page 196: ...t position Remove cotter pins and castle nuts from connecting rod bearing cap bolts fig 118 Lift off bearing cap shell and shims Extreme care should be exercised in removing connecting rod assembly so that cylinder wall will not be scratched or gaged by connecting rod Place wooden handle of hammer against lower end of connecting rod and push until piston comes out of top of hole fig 119 Then pull ...

Page 197: ...TM 9 1706 VALVE E XHAUST H M 4 5810A VALVE I NTAKE H M 4 0107A 43 VALVE SPRING LIFTER PIN H M 4 0011A VALVE RACK 2 ORDNANCE MAINTENANCE PLIERS CLOTH RA PD 8052 FIGURE 115 Valve removal 190 ...

Page 198: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 SPRING VALVE HM 40008A SEAT VALVE SPRING HM 22013A 上 RA PD 8053 SCREWDRIVER ROD VALVE TAPPET HM 45812A FIGURE 116 Valve spring removal 191 ...

Page 199: ...TM 9 1706 43 ORDNANCE MAINTENANCE PILOT BAR RA PD 8054 FIGURE 117 Valve stem guide removal 192 ...

Page 200: ... 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 BOLT HM 22059A NUT HM 21056A SOCKET WRENCH CAP CONNECTING ROD BEARING 9M 40391B RA PD 8064 FIGURE 118 Connecting rod bearing cap removal 476794 42 13 193 ...

Page 201: ...TM 9 1706 43 ORDNANCE MAINTENANCE HAMMER NOTE POSITION OF HANDS PISTON HM 40120C RA PD 8065 FIGURE 119 Connecting rod and piston removal 194 ...

Page 202: ... NUT HM 21056A PIN COTTER BFAXICE SLOT ROD ASSEMBLY 40390CSY ROD HM 40390C SHIMS HM 40556A SCREW HM 22111A WASHER LOCK IBEAX3C PISTON HM 40120C PIN HM 22238A RING OIL REGULATING HM 3913A RING COMPRESSION HM 3813A RING COMPRESSION HM 42297A RA PD 8091 FIGURE 120 Connecting rod and piston assembly dismounted 195 ...

Page 203: ...ove piston pin clamp screw and lock washer from connecting rod and drive out piston pin as shown in figure 122 1 Remove starting crank jaw Pinch bar Hammer RING GROOVE RING EXPANDER RINGS HM 3813A RING HM 3913A RA PD 8092 FIGURE 121 Piston ring removal Place hammer handle between one of the crank throws of crank shaft and bottom of cylinder block to prevent crankshaft from turn ing Then place pinc...

Page 204: ...fig 124 Remove Woodruff key from crankshaft p Remove timing gear cover 916 inch socket wrench Speed handle Fiber hammer Pull off trunnion Remove cap screws and lock washers holding cover to engine block fig 125 Tap off gear cover and remove gasket figs 126 and 127 Pull off oil seal from crankshaft 9 Remove idler gear assembly None Pull out idler gear and shaft assembly by hand and remove cork wash...

Page 205: ...TM 9 1706 43 ORDNANCE MAINTENANCE BAR HAMMER JAW STARTING CRANK HM 40806A RA PO 8066 FIGURE 123 Starting crank jaw removal 198 ...

Page 206: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 PULLEY FAN DRIVE HM 45493B KEY BGAX3B WASHER HM 14734A CRANKSHAFT HM 45853D PULLEY PULLER RA PD 8067 FIGURE 124 Fan drive pulley removal 199 ...

Page 207: ...706 SEAL O IL H M 1 1137AS S CB 43 WRENCH COVER T IMING GEAR HM 4 0338D S CA HM 4 0341D S CB ORDNANCE MAINTENANCE SCREW C AP B CAXICF WASHER L OCK B ECXIK RA PD 8069 FIGURE 125 T iming gear cover removal 200 ...

Page 208: ...NGINE FOR SCOUT CARS 43 HM 40338D SCA COVER TIMING GEAR HM 40341D SCB PLUG FIBRE HM 14591A NUT LOCK BBCXID SCREW THRUST ADJUSTING HM 14595A SCREW THRUST ADJUSTING ASSEMBLY HM 14594AS RA PD 8084 FIGURE 126 Timing gear cover details 201 ...

Page 209: ... 22107A RA PD 8081 FIGURE 128 Idler gear group details r Remove camshaft None Note position of punch marks on camshaft and crankshaft gears before removing camshaft These marks must be in the position shown when engine is assembled in order to give correct valve timing With engine resting on top face of cylinder block the valve push rods will be down and will not interfere with removal of camshaft...

Page 210: ...oodruff key fig 131 U Remove flywheel assembly Diagonal pliers 34 inch socket wrench 6 inch extension Long handle Fiber hammer Wood block Anchor crankshaft with wooden handle of hammer Pull out cotter pins from flange bolt nuts and remove nuts fig 132 Re move hammer Loosen flywheel by bumping it near its outer edge with wood block through starter opening in front of face of bell housing while rota...

Page 211: ...TM 9 1706 43 ROD V ALVE PUSH A SSEMBLY H M 4 5812ASY ORDNANCE MAINTENANCE NOTE POSITION OF HANDS RA PD 8072 FIGURE 130 Valve push rod removal 204 ...

Page 212: ...GEAR H M 2 2049B CAMSHAFT H M 4 5686A WASHER H M 2 045A 0 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 43 RA PD 8096 OIL PUMP DRIVE GEAR I NTEGRAL KEY B CAX3CC NUT H M 1 1023A FIGURE 131 Camshaft group details 205 ...

Page 213: ...dowels from back side of flywheel carrying expansion plugs with them Then drive out bearing using wood block fig 133 W Remove engine bell housing 34 inch open end wrench Remove four cap screws and lock washers on outside of housing and two on inside of housing fig 134 Lift off flywheel bell housing and gasket 2 Remove bell housing oil seal Brass drift Hammer Drive oil seal out of bell housing y Re...

Page 214: ...d with its corresponding cap if no new shell is re quired Lift out crankshaft and timing gear assembly fig 136 Remove upper main bearing shells by pushing down with the hands on one end of each shell until it rotates in bearing web enough to get fingers under shell and then lift out shell fig 137 Mark shells in the same manner as lower shells CRANKSHAFT ALIGNING DOWEL HOLE FLYWHEEL HM 23705C GEAR ...

Page 215: ...holes in gear and pull off gear Remove Woodruff key GASKET HM 22065B BELL HOUSING HM 24427D 16 SCREW CAP BCAXIEC RA PD 8068 WASHER LOCK BECKIM FIGURE 134 Flywheel housing removal SOCKET WRENCH 16 SCREWCAP HM 40071A WASHER LOCK BECXA SCREW CAP HM400704 WASHER LOCK BECXUM RA PD 8073 FIGURE 135 Crankshaft removal 208 ...

Page 216: ...S 1 CEAR HM 220398 KEY BCAXXC POLTS HM 22104A CRANKSHAFT HM 45853D RA PD 8075 DOWEL HM 9642A FIGURE 136 Crankshaft SHELLS INTERMEDIATE BEARING HM 457118 SHELL BEARING CENTER HM 457098 EAR OR PROJECTION SHELLS REMOVED RA PD 8074 FIGURE 137 Main bearing shell removal 476794 12 14 209 ...

Page 217: ...TM 9 1706 43 ORDNANCE MAINTENANCE PILOT BAR GUIDE TAPPET HM 22089A O RA PD 8055 FIGURE 138 Valve tappet guide removal 210 ...

Page 218: ...ff all gaskets and clean all surfaces where sealing com pound has been used by scraping and washing with a suitable solvent b Inspection After parts are cleaned as explained above each part should be inspected and then covered to protect it from dust and dirt etc if it is to be used for reassembly Set all discarded parts to one side and mark in such a manner that they will not become mixed with th...

Page 219: ... fig 139 The meas urements should be made at the top of the cylinder bore preferably in the first 1 2 inch of top piston ring travel in several places around the inside circumference of the bore and again in several places near RO 36 10 RA PD 8120 FIGURE 139 Cylinder bore checking the bottom of the cylinder bore If the difference between the top and bottom measurements exceeds 0 008 inch the cylin...

Page 220: ...l dowel for damage and fit e Examine the two large flywheel centering dowels for fit Re place these dowels if they are too loose RA PD 8126 FIGURE 140 Checking timing gear backlash f Examine the crankshaft timing gear for excessive wear or damaged teeth Replace if necessary Timing gears should be checked for backlash before removal from engine fig 140 5 Pistons a Check pistons for cracks or excess...

Page 221: ... excessive wear of face Replace if any is evident c Inspect for wear of stem as determined by micrometer Replace if necessary see d below RA PD 10831 FIGURE 141 Alining connecting rod d Inspect for weak or broken valve spring Replace if necessary 8 Valve stem and valve tappet guides Inspect all valve stein and valve tappet guides in the upper crankcase If they do not check with the recommended fit...

Page 222: ...tion of stud and dowel holes If any elongation is evident replace flywheel c Check flywheel for balance Repair if necessary 12 Fiber plugs Check fiber plugs at ends of thrust adjusting screws in timing gear cover Replace badly worn plugs c Repairs 1 Carbon removal Whenever the engine cylinder head is taken off the carbon deposits should be removed from the inside of the head the top of the block a...

Page 223: ...linder bore as given in d below subtract approximately 0 002 inch for honing and this balance will provide correct setting for boring equipment 6 Clamp reboring tool over cylinder to be rebored after having centered the tool by lowering the cutter into the cylinder c Set cutter to the desired diameter as determined above and run cutter through cylinder d After boring to the desired diameter go thr...

Page 224: ... are in position on each side of main bearings 6 Grind connecting rod bearing journals in the same manner to a diameter which will provide proper clearance for the bearing shell of the nearest undersize when the three shims are in position on each side of connecting rod bearings 6 Resurfacing valve push rod screws If no new valve push rod screws are available the old screws can be reused by resurf...

Page 225: ...TM 9 1706 44 ORDNANCE MAINTENANCE T HANDLE SOCKET REAMER GUIDE TAPPET HM 22089A RA PD 8056 FIGURE 144 Valve tappet guide reaming 218 ...

Page 226: ...ntil a finished surface is secured fig 148 d Remove valve and clean compound from valve and valve seat e Test valve for perfect contact with seat in cylinder head by marking lines about 1 4 inch apart on face of valve with a lead pencil Insert valve in guide and give a one half turn to the right and a one half turn to the left If all pencil marks are removed the opera tion may be considered satisf...

Page 227: ...tes that a new ring gear is required it should be replaced as follows a Saw through and knock off old ring gear 6 Heat new ring gear so that it will fit into position on flywheel and allow it to cool shrink it d Service data See paragraph 75 RA PD 8122 FIGURE 146 Valve seat checking 1 220 ...

Page 228: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 44 RA PD 8058 FIGURE 147 Valve refacing 221 ...

Page 229: ...TM 9 1706 44 ORDNANCE MAINTENANCE SCREWDRIVER VALVE SPRING ON VALVE STEM RA PD 8059 FIGURE 148 Valve grinding 222 ...

Page 230: ...ng gear onto shaft over key Make certain that timing punch mark faces outward b Replace crankshaft and main 5 8 inch socket wrench bearing shells 34 inch socket wrench Speed handle Check crankshaft bearing on shaft while shaft is still out of vehicle so that piston drag will not be included Then place new upper bear ing shells in position in crankcase and lubricate These bearing shells are locked ...

Page 231: ... H M 4 05418 DOWEL FLYWHEEL HM 1 707A SCREW C AP H M 4 0071A 45 WASHER L OCK B ECXIL ORDNANCE MAINTENANCE SHIM C ENTER AND REAR BEARING H M 4 0551A RA PD 8076 DOWEL F LYWHEEL ALIGNING H M 4 642A FIGURE 149 Crankshaft replacement 224 ...

Page 232: ...them into place with a pilot bar and hammer Assemble push rods fig 151 and install them in their guides fig 130 Thoroughly oil push rods and guides e Replace camshaft timing Press gear Wood blocks 2 inch open end wrench Set thrust washer and Woodruff key in position on shaft and press timing gear onto shaft over key Make certain that timing punch mark faces outward Replace locking nut on shaft f I...

Page 233: ...INTENANCE TENSION WRENCH SOCKET RA PD 8077 FIGURE 150 Main bearing cap tightening ROD VALVE PUSH ASSEMBLY HM 45812 ASY ROD HM 45812A SCREW HM 2185A NUT HM 2186A RA PD 8060 FIGURE 151 Valve tappet or push rod group details 226 ...

Page 234: ...IMING PUNCH MARKS GEAR C RANKSHAFT HM 2 20398 GEAR C AMSHAFT H M 2 20498 GEAR I DLER ASSEMBLY HM 4 5375BS HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 45 C O RA PD 8082 FIGURE 152 C amshaft and idler gear replacement 227 ...

Page 235: ... PD 8083 Figure 153 Crankshaft oil seal replacement A SCREW HM 14595A B NUT BBCXID C PLUG HM 14591A FIBER BUTTON D GEAR COVER E STEEL PLUG IN SHAFT F NUT HM 11023A F HM 2045A G THRUST WASHER CAMSHAFT HM 4024A WATER PUMP RA PD 10908 FIGURE 154 Shaft end play adjustment 228 ...

Page 236: ...t NOTE Water pump shaft end play should be adjusted in the same manner at installation j Install fan drive pulley Hammer Place trunnion in position on timing gear cover fig 155 Then set Woodruff key in place on crankshaft line up pulley keyway with key and drive pulley onto shaft Replace special lock washer fig 156 k Install starting crank jaw Pinch bar Hammer handle FITTING CLDX5K TRUNNION FRONT ...

Page 237: ... Install engine bell housing 34 inch open end wrench KEY SLOT PULLEY HM 45493B KEY BGAX3B WASHER HM 14734A RA PD 8088 FIGURE 156 Fan drive pulley installation Shellac new gasket to front of bell housing Attach bell housing to crankcase with lock washers and cap screws Check clearance between oil seal and crankshaft flange fig 158 See par 44 d for correct clearance n Install flywheel Ball peen hamm...

Page 238: ...ooden handle of hammer Set castle nuts on flange studs turn them up tight and replace cotter pins Place new expansion plugs in large dowel holes and secure by tapping the center with ball peen hammer Drive clutch pilot bearing into flywheel fig 159 Remove hammer DRIFT SEAL OIL HM 3543A TIMINGHOLE BELL HOUSING A HM 244270 RA PD 8085 FIGURE 157 Bell housing oil seal replacement 231 ...

Page 239: ...9 1706 45 ORDNANCE MAINTENANCE FEELER GAUGE BRACKET W1 344927 L H WI 311969 R H SCREW CAP BCAXIEE WASHER LOCK BECXIM SCREW CAP BCAXIEC RA PD 8086 WASHER LOCK BECXIM FIGURE 158 Bell housing replacement 232 ...

Page 240: ...feeler the pull exerted to remove gage should read 8 to 12 pounds on scale p Install piston pins 16 inch socket wrench Vise Fit piston pins to pistons to a hand push fit at room tempera ture 70 F Set connecting rod in piston so that number on rod is opposite split side of piston Install pin through piston and rod so that notch in pin lines up with clamp screw hole in rod to prevent damage to threa...

Page 241: ...and just wide enough to be a light rolling fit each in its respective groove If ring fit is correct ring should re EYE RIBBON FEELER PISTON INVERTED HM 40120C RA PD 8090 FIGURE 160 Piston fitting to cylinder bore main suspended in groove as shown in figure 163 If ring is too wide reduce its width by lapping on a sheet of No 000 emery cloth placed on a flat surface See par 44d for ring clearance 23...

Page 242: ...ing bottom of a piston to square up ring in bore Check ring gup with feeler gage fig 164 See par 44d If gap is not wide enough ring should be filed using a fixture as shown in figure 165 Ends of ring should be squeezed together to file both sides to make ends parallel RA PD 10909 FIGURE 161 Testing tightness of piston pin in aluminum piston 235 ...

Page 243: ...TM 9 1706 45 ORDNANCE MAINTENANCE RA PD 10910 FIGURE 162 Connecting rod and piston alinement check 236 ...

Page 244: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 45 RING PISTON O PISTON RING GROOVES RA PD 8095 FIGURE 163 Piston ring groove checking 237 ...

Page 245: ...TM 9 1706 45 ORDNANCE MAINTENANCE PISTON RING FEELER GAUGE RA PD 8094 FIGURE 164 Piston ring gap checking PISTON RING FILE RA PD 7530 FIGURÐ 165 Increasing piston ring gap 238 ...

Page 246: ...in its lowest position Lubricate piston and bore thoroughly Compress rings with a ring compressor RING COMPRESSOR HAMMER HANDLE c u PISTON HM 40120C RA PD 8089 FIGURE 166 Connecting rod and piston replacement and slide piston and rod assembly into cylinder bore so that word front on piston faces front of engine fig 166 Remove ring compressor Insert upper shell into connecting rod and push piston d...

Page 247: ... until there is a barely per ceptible drag on the crankshaft when it is turned Use a new paper shim for each test Remove paper shim and replace bearing cap RA PD 10911 FIGURE 167 Connecting rod bearing shim installation tightening retaining nuts to required tension see par 44d Replace cotter pins and lock them securely Replace remaining pistons and connecting rods and adjust bearings in a similar ...

Page 248: ...t Place valve spring lifting tool in position with jaw of tool in position under valve spring seat and top of tool centered on valve head Press down on handle of tool until valve spring is fully compressed so that valve pin hole will be in the clear Insert valve retaining pin and remove valve spring lifter Proceed with the remaining valves in the same manner NOTE It is advisable to rotate cranksha...

Page 249: ...lace oil pump in position so that pump drive gear meshes with camshaft gear Install lock washers and cap screws attaching pump to main bearing web Use new gasket fig 108 y Install oil pan 16 inch socket wrench Speed handle 34 inch open end wrench 6 inch open end wrench Shellac new gasket to oil pan If gasket has shrunk soak in water before using Attach oil pan to block and flywheel bell housing wi...

Page 250: ...nch extension pipe Fiber hammer Tap oil filler and breather extension pipe into position in engine block and fasten to clip on cylinder head with cap screw and plain washer fig 171 ab Install exhaust and intake 5 8 inch open end wrench manifold With new exhaust and intake manifold gasket in position fasten exhaust and intake manifold to engine block by tightening 10 brass nuts and plain washers fi...

Page 251: ...TM 9 1706 BRACKET S HIELDING SUPPORT T I A 2 7512 46 TENSION WRENCH CLIP B REATHER PIPE H M 4 5842A SCREW C AP H M 4 118A ORDNANCE MAINTENANCE RA PD 8101 FIGURE 170 C ylinder head replacement 244 ...

Page 252: ...D GASOLINE ENGINE FOR SCOUT CARS 46 CAP HM 4003BAS SCREW CAP BCAX3B WASHER HM 8191A WASHER LOCK BECXIH CLIP HM 45842A PIPEHM 45535 TAP HERE EASY DRIVING FIT RA PD 8102 FIGURE 171 Oil filler and breather pipe replacement 245 ...

Page 253: ...prevent distortion of cover plate b Install starting motor as 16 inch open end wrench sembly CLUTCH DISC 13 PILOT BAR RA PD 10912 FIGURE 172 Clutch driven member installation Place adapter and starting motor in position on starting motor attaching studs and secure with lock washers and nuts fig 105 c Install fuel pump assembly 12 inch open end wrench 38 inch open end wrench Hold pump in position u...

Page 254: ...Y LM CM 4348 MEMBER DRIVEN ASSEMBLY LM CM 4137 SCA LM CM 4515 SCB RA PD 8029 FIGURE 173 Clutch cover plate installation Place fan and bracket assembly in position on top of gear case and secure with lock washers and cap screws fig 104 f Install water pump assembly 34 inch socket wrench and discharge pipe 916 inch open end wrench Use new gaskets between pump assembly and gear housing and be tween d...

Page 255: ...ock pliers Clamp distributor cap in position Twist distributor shielding clockwise to clamp it and tighten locking screw Clamp remaining conduits to cylinder head conduit brackets Attach spark plug con duits to respective spark plug shields with shielding nuts j Replace spark plugs Spark plug wrench Install new spark plugs with gaskets and their shielding in cylinder head fig 102 Care should be ta...

Page 256: ...h cap screws c With engine running in the test stand the following tests can be made as explained in paragraph 9 1 Vacuum test for engine performance 2 Exhaust test for adjusting carburetor 3 Oil pressure test and adjustment NOTE If time permits the engine should be thoroughly run in on test stand before it is installed in vehicle 48 Engine installation Tools Length of 34 inch manila 5 8 inch open...

Page 257: ...t and castle nut on left side and plain washers bolt spring and castle nut on right side Replace cotter pins in castle nuts and lock pins Bolt front trunnion to frame with cap screws lock washers and nuts fig 98 Remove rope sling and hoist from engine assembly c Connect brake vacuum boost 6 inch socket wrench er and bracket assembly Speed handle Raise booster and bracket assembly into position and...

Page 258: ...ing place it on armature post and secure with nut Fasten conduit to housing with conduit nut fig 35 Install condenser in housing fig 34 i Connect manual spark con Screw driver trol at distributor Insert wire through nut at spark control arm and tighten holding screw Fasten spark control holding clip to bracket with screw j Connect high voltage and 33 inch open end wrench low voltage wires at ignit...

Page 259: ...end wrench Force hose onto air cleaner outlet and place air horn over carburetor air inlet Tighten hose clamp at air filter and air horn clamp at carburetor fig 176 9 Connect heater inlet and Screw driver return hoses to engine outlets Force hoses onto water pump and cylinder head heater connections and secure with clamps Then clamp hoses to cylinder head hose brackets r Install left hand air funn...

Page 260: ...t Secure shutter side plates to body side plates by replacing holding screws and nuts Connect shutter control at lower right side of radiator w Install hood assembly 16 inch open end wrench Heavy duty square shank screw driver Length of rope Hoist Place hood assembly and top shutter louver in position on cowl and shutter assembly Replace bolts and elastic stop nuts securing rear of hood to cowl an...

Page 261: ...ered with a protector loom The air cleaner is bolted on the right engine side of the dash and is connected to the carburetor air intake horn by means of a rubber hose and clamps b Functioning The fuel pump forces fuel as required through the fuel filter and into the carburetor There it is properly mixed with air that has been cleaned by the air cleaner and drawn into the combustion chamber of the ...

Page 262: ...FILTER A SSY Z F 291X2 NIPPLE W I 3 80167 UNION W I V2521X PIPE A SS Y W I 3 48746 S TUD W I 3 68565 NUT B BBXID WASHER L OCK B ECXIL FGASKET W I A 24918X LINSULATOR W I 363727 CLEANER A SSY U A T 1 75 9497 S CREW CAP B CBXICA NUT B BBXIC WASHER L OCK B ECXIK CUP A SSY W I 3 57067 RA PD 3261 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 50 FIGURE 174 F uel system i nstalled 255 ...

Page 263: ...he engine compartment 1 Construction The carburetor air cleaner consists of two cylindrical sheet metal sleeves one inside of the other with an air space between the inner and outer sleeves The inner adapter sleeve contains the air filter hair the air outlet elbow at the top and a baffle plate attached to the bottom The inner sleeve is beaded in four places to center and attach the outer sleeve Th...

Page 264: ...WHICH DUST IS AT HIGH MOTOR WASHED SPEEDS RA PD 33314 FIGURE 175 Air cleaner assembly sectionalized 3 Specifications Make United Specialties Co Type Oil bath Ordnance No B167665 Manufacturer s No VA T175 9497 White No 347323 b Trouble shooting See paragraph 526 c Removal Tools 1 2 inch open end wrench Screw driver 6 inch open end wrench 1 Remove carburetor air 1 2 inch open end wrench horn and rub...

Page 265: ...er Remove four bolts nuts and lock washers from brackets and lift off baffle plate RA PD 10992 FIGURE 176 Carburetor air horn and hose assembly removal i e Maintenance 1 All connections between air cleaner and car buretor should be inspected at frequent intervals and should be kept tight 2 The oil bath cup should be inspected daily and kept filled with engine oil to the oil level mark indicated on...

Page 266: ...uts and lock washers 2 Install carburetor air horn Screw driver and hose assembly Slide air hose over cleaner outlet elbow and place air horn over carburetor air inlet Tighten hose clamp at air cleaner and air horn clamp bolt at carburetor 52 Carburetor a Description fig 174 The carburetor is a Zenith down draft type It is located at the right side of the engine and is bolted to the inlet manifold...

Page 267: ...to operation to supply additional fuel for maximum power d Power jet system The power and accelerating system supplies the extra fuel required for maximum power and acceleration during the periods of low intake manifold vacuum that occur at wide open throttle and low engine speed and momentarily when the throttle is opened quickly This extra flow of fuel continues only as long as the manifold vacu...

Page 268: ...icate 0 Z enith carburetor C arburetor sectionalized A Check valve H Idling fuel channel Q Main jet B Bowl drain plug J Idling jet R Well vent C Power jet valve K Idling air and fuel channel S Choke valve D Vacuum piston assembly L Power jet channel T Inlet fitting plug E Vacuum passage M Priming plug U Secondary venturi F Power jet N Main discharge jet plug V Venturi G Idling adjusting screw P Ma...

Page 269: ...ks at fuel filter c Tighten filter bowl Re place bowl gasket Tighten fuel lines fitting d Fuel leaks at carburetor d Tighten cover body screws Replace gasket c Carburetor removal Tools Screw driver 716 inch open end wrench 1 2 inch open end wrench 5 8 inch open end wrench Pliers 1 Drain fuel Screw driver Remove carburetor bowl drain plug and fuel filter bowl 2 Disconnect fuel line 1 2 inch open en...

Page 270: ...ct choke valve Screw driver control Disconnect choke control wire from choke lever and remove choke control tube from bracket fig 178 RA PD 10993 FIGURE 178 Carburetor control removal 8 Remove carburetor assem 5 8 inch open end wrench bly from inlet manifold Remove two stud nuts and lock washers securing carburetor to manifold Then lift off carburetor insulator and two gaskets from manifold fig 17...

Page 271: ...nipple 2 Remove carburetor fuel in 11 16 inch open end wrench let union Disconnect union plug and remove union assembly Then slide screen from plug and lift off washer fig 1810 3 Remove air intake body 1 2 inch open end wrench assembly Remove three body attaching screws and lock washers and lift off air intake body and gasket figs 1812 and 182 4 Remove bowl float axle Screw driver and valve Spread...

Page 272: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 52 RA PD 10994 FIGURE 179 Carburetor assembly removal 265 ...

Page 273: ... 1706 SA BA AZ AX AW AY AU AT ASAR O 52 O A P 8 BT BP BQ BR BS BN 3323 W E F 3 ORDNANCE MAINTENANCE G o l e BH BFBE o BK BL AD 2 M R w Y Z AB AC RA PD 8132 FIGURE 180 C arburetor assembly e xploded view 266 ...

Page 274: ... Z C R88 2 BA Jet i dling 2 C 55 11 AD V alve a ssembly Z C 81 3 B B V ent 2 C 77 14 AE W asher Z T 56 23 BC V alve Z C 41 9 AF S crew d rive Z T 73 15 Jet m ain 2 C 52 7 BD Screw Z C 138 61 AG Washer Z T 56 5 BE S crew Z T 888 6 AH W asher Z T 56 36 BF L ever a ssembly Z C 24 AJ B ody Z C 148 10A 138X5 AK W asher Z T 56 15 BG S crew Z T 8825 10 AL P lug 2 C 149 22 BH S top a ssembly Z C 25 98X5 A...

Page 275: ...t union removal Carburetor needle valve seat removal Carburetor throttle valve removal 6 Carburetor idle adjusting screw with spring removal PD 33306 3 Carburetor float removal Carburetor power and accel erating jet removal FIGURE 181 Carburetor disassembly 268 ...

Page 276: ... idling adjusting Screw driver screw with spring Unscrew idling adjusting screw and remove the screw and spring fig 1816 8 Remove float valve fuel Screw driver passage plug Unscrew and remove float fuel passage plug and fiber washer 9 Remove power and acceler Zenith tool No Z C 161 82 ating jet Unscrew and remove power and accelerating jet and washer fig 1810 10 Remove choke valve shaft Small punc...

Page 277: ...n shaft and slide out shaft 15 Remove main discharge 1 2 inch open end wrench jet Zenith tool No Z C 161 82 equivalent tool Screw driver Remove main discharge jet plug and washer fig 1839 Then unscrew main discharge jet and turn body over and jet will fall from hole fig 1833 16 Remove power jet check Screw driver valve and main jet Unscrew power jet check valve and main jet and turn carburetor bod...

Page 278: ...emoval PUMP CHECK VALVE MAIN JET O Carburetor choke lever assembly Carburetor pump check valve and main jet removal Carburetor main discharge jet plug removal 6 Carburetor power jet valve removal RA PD 33308 Carburetor main discharge jet removal FIGURE 183 Carburetor disassembly 271 ...

Page 279: ...ing screw on throttle control loose lever stop and slide both the stop and lever from the shaft 24 Remove throttle control Screw driver rod lever Loosen lever clamping screw and pull off lever from shaft 25 Remove throttle Stop Small drift lever Hammer Drive taper pin from throttle stop lever and remove lever and packing from shaft Carburetormaintenance 1 Inspection The carburetor should be remove...

Page 280: ...buretor throttle shaft removal c Inspect float for dents and leaks and float hanger pin for wear Replace if necessary d Examine float needle valve and seat If needle shows a groove on the seating surface replace both needle valve and seat e Inspect vacuum piston assembly as to fit in cylinder If worn and loose in cylinder replace complete piston assembly 476794 42 18 273 ...

Page 281: ... FIGURE 185 Carburetor throttle valve maintenance as a guide replace throttle shaft or plate If new plate shows a noticeable variation from the old one select another new plate to get one that fits very close to the scribed line when installed 6 All carburetor adjustments except idling are fixed and for this reason the carburetor should not give any trouble provided the regu lar cleaning and inspe...

Page 282: ...LAMP BRACKET H C HOKE CONTROL WIRE CLAMP ING SCREW J CARBUR ETOR K ROD END BALL JOINT ASSY 1 THROTT LE VALVE SHAFT LEVER M T HROTTLE VALVE SHAFT N T HROTTLE ROD P THROTTLE RETURN SPRING Q ACCELERATOR PEDAL ROD R ACCELERATOR PEDAL S CHOKE CONTROL T L OCK WASHER CONTROL BUTTON V L OCK NUT W T HROTTLE CONTROL E HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 52 B А Q R RA PD 7531 FIGURD 186 C arburetor c...

Page 283: ...n end wrench 12 inch open end wrench Zenith tool No Z C 161 81 1 Install throttle stop lever Small hammer Replace throttle stop screw and spring on stop lever Place lever on throttle shaft lining up taper pin hole Insert and drive home taper pin 2 Install throttle rod control Screw driver lever Place throttle control rod lever on hub of throttle stop lever and tighten throttle rod lever clamping s...

Page 284: ... check valve in their respective holes in bottom of bowl and screw them down to their shoulders fig 183 9 Install power jet valve Zenith tool No Z C 161 81 Place power jet valve in hole in bottom of well and screw home fig 1836 10 Install idling jet and well Zenith tool No Z C 161 80 or vent 346 inch open end wrench Screw driver Insert idling jet and well vent in their respective holes and screw d...

Page 285: ... and spread cotter pin 17 Install power and acceler Zenith tool No 2 C 161 25 ating jet Place gasket on power and accelerating jet and insert jet and tighten fig 1816 18 Install float valve fuel pas Screw driver sage plug Place gasket on fuel passage plug and insert plug in hole below fuel inlet union 19 Install float valve seat and 12 inch socket wrench float valve Screw float valve seat into bod...

Page 286: ... new gaskets one on each side of insulator place in sulator on inlet manifold flange Place carburetor assembly in position on manifold studs and secure with stud nuts and lock washers 2 Connect fuel line 12 inch open end wrench Connect fuel line from fuel pump to fuel filter inlet fitting with flared tube nut 3 Connect throttle control Screw driver Connect throttle control tube clip to bracket Ins...

Page 287: ...e provided to return throttle to closed position when the accelerator pedal is released or throttle hand control button pushed in e Removal and replacement of hand throttle hand choke accel erator pedal and linkage can be readily accomplished by referring to figure 186 f It is important that levers and linkage work freely and do not bind 54 Fuel filter a Description fig 187 The fuel filter is loca...

Page 288: ...te No 361787 b Trouble shooting See paragraph 52b c Fuel filter removal Tools 1 2 inch open end wrench 916 inch open end wrench 1 Disconnect fuel line fuel 1 2 inch open end wrench pump to filter Disconnect fuel line fitting flare tube nut at filter inlet elbow CARBURETOR ASSEMBLY Z 0 9232 RA PD 8008 FIGURE 187 Fuel filter installed 281 ...

Page 289: ...lter should be disassembled and cleaned when the carburetor is removed for inspection and when dirt or water is visible in the bowl Wash bowl and element with solvent dry cleaning allow to dry and blow out filter element with com pressed air 2 When cleaning filter head inlet nipple and outlet elbow check threads and replace if threads show signs of stripping 3 Inspect bowl gasket and replace if da...

Page 290: ...TM 9 1706 A E LBOW B NIPPLE C HEAD D E LBOW E G ASKET E LEMENT A SS Y G BOWL H B AIL HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 54 G H RA PD 3 3310 FIGURE 188 C arburetor fuel filter e xploded view 283 ...

Page 291: ...ter for the windshield wiper at low manifold depression The diaphragms which are made of a specially treated material are held between metal disks These disks also hold the diaphragm link rods which are attached to the rocker arm Coil springs are used to actuate the diaphragm on the re turn stroke of the rocker arm An air dome is used at the fuel pump outlet to eliminate surging of fuel delivered ...

Page 292: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 55 RA FSD 1850A FIGURE 189 Fuel pump sectionalized 285 ...

Page 293: ... intake manifold On the return stroke the diaphragm creates a suction in the chamber drawing air through the inlet passage from the windshield wiper When the manifold vacuum is greater than the vacuum created by the pump or when the windshield wiper is not in use the manifold vacuum holds the diaphragm in the upward position where it will remain inoperative until the manifold vacuum drops RA PD 33...

Page 294: ...wl gaskets if necessary 6 Tighten fuel pump inlet and outlet fittings Replace if threads are stripped c Tighten cover screws d Replace diaphragm a Tighten connections 6 Replace diaphragms c Loose fuel pump cover d Broken fuel pump dia phragm 2 Low fuel pressure a Air leaks in system 6 Fuel pump diaphragm out of order 3 Lack of fuel a Broken fuel pump dia phragm 6 Sticking fuel pump inlet and outle...

Page 295: ...m engine 1 2 inch open end wrench Remove two cap screws and lock washers that attach pump to its pad on engine crankcase fig 191 Then lift off pump two gaskets and the metal shim d Fuel pump disassembly fig 192 Tools Screw driver Hammer 5 inch open end wrench File Punch Long nose pliers 716 inch open end wrench 1 Remove vacuum chamber 716 inch open end wrench cover and filter screen Remove cap scr...

Page 296: ...TM 9 1706 HERCULES JXD GASOLINE ENGINE FOR SCOUT CARS 55 i PUMP FUEL AND VACUUM ASSEMBLY AC 1537105 SCREW CAP WASHER LOCK WRENCH RA PD 8000 FIGURE 191 Fuel and vacuum pump removal 476794 42 19 289 ...

Page 297: ...TM 9 1706 55 ORDNANCE MAINTENANCE O KK JJ B HHI O C LL GG 0 0 D 있 MM FF E ЕЕ 0 O WWW DO F G H н NN 1 co cc 00 K BB AA Z M um Y N X W V 019 T P Q R SL RA PD 3264A FIGURE 192 Fuel pump exploded view 290 ...

Page 298: ...y AC 1523779 GG Screen AC 1523802 HH Gasket AC 1523801 JJ Plate AC 1537195 KK Screw AC 1523829 Gasket AC 1523801 LL Retainer AC 1523803 MM Screw AC 855493 Washer lock BECX3E NN Gasket AC 1521953 00 Hair AC 1521553 3 Remove vacuum diaphragm None spring Lift out diaphragm spring and spring seat 4 Remove vacuum inlet and Screw driver outlet valve assembly Remove retainer screw and lift off retainer v...

Page 299: ...lled a Using a fuel pump analyzer connect the adapter tee into the fuel pump outlet line and connect the analyzer hose to the tee fig 193 Check the pressure at various engine speeds to duplicate actual operating conditions Normal pressure should be between 21 2 and 4 pounds 6 Connect adapter tee into fuel pump inlet line Connect ana lyzer hose to tee and run engine fig 194 The pump vacuum should b...

Page 300: ...uel diaphragm link Slide link spacer over links and place washers on each side of spacer KO RA PD 33312 FIGURE 193 Fuel pump pressure test Then hold them so that their holes are lined up place them in slot in rocker arm and insert link bushing Then place rocker arm spring on link spacer teat 2 Install rocker arm assem Center punch bly Hammer Assemble diaphragm links and spacer to rocker arm Place ...

Page 301: ...ng and spring retainer on diaphragm pull rod Place diaphragm in position on body flange and hook Pull rod over end of link If necessary use rubber band to hold links when hooking on pull rod fig 195 Break band and pull it out after assembly fig 196 5 Install fuel pump cover as Screw driver sembly Place cover assembly in position on pump body flange and replace 10 attaching screws and lock washers ...

Page 302: ...assemblies Position the valve retainer over valves and secure with retainer screw 8 Replace vacuum pump dia None phragm RA PD 8006 FIGURE 195 Fuel and vacuum pump assembly operations Place diaphragm spring on diaphragm pull rod with the large spring diameter resting against diaphragm Then place oil seal upper retainer leather oil seal washer and lower retainer on pull rod and turn 90 to lock parts...

Page 303: ...ce screen retainer on screen and position cover gasket and cover on body Secure with cap screw and gasket g Installation Tools 1 2 inch open end wrench 38 inch open end wrench 1 Attach fuel and vacuum 12 inch open end wrench pump to engine Using two new gaskets one on each side of the metal shim place on the pump flange and insert cap screws and lock washers through flange then place pump on its m...

Page 304: ...e opposite the camshaft Radial holes drilled from each crankshaft bearing take oil from the gallery and deliver it under pressure to the main bearings and through drilled holes in the crankshaft to the connecting rod bearings Another drilled passage from the gallery permits pressure lubrication of the idler gear shaft bushing The oil from the bushing travels through drilled holes in the shaft and ...

Page 305: ...oil filter 1 Replace filter 2 Sludge in oil lines 2 Remove and clean lines 3 Sludge in oil pan 3 Remove pan and clean 58 Oil filter a Description The engine oil filter is bolted on the dash at the left rear of the engine compartment 1 Construction The oil filter is of the extended area type A filter bag having an area several times that of the enclosing case is mounted over a supporting framework ...

Page 306: ...nch open end wrench RA PD 33315 FIGURE 197 Oil filter line removal Disconnect the oil inlet line inverted flared tube nut from the fitting at the top of the filter fig 197 and the oil outlet line inverted flared tube nut from the fitting at the bottom of the filter 2 Remove oil filter Screw driver Take out the two stove bolts and nuts from the filter clamping bands Then spread the bands apart and ...

Page 307: ...ances regardless of mileage Vehicles operating in dusty areas require replacements more often than those which do not encounter such conditions RA PD 33316 FIGURE 198 Oil filter removal 3 Under normal operating conditions the oil filter should be changed every 8 000 miles e Installation Tools Screw driver 716 inch open end wrench 1 2 inch open end wrench 1 Install oil filter Screw driver When inst...

Page 308: ...g and pressure adjusting screw The oil bypass holes and a venting hole are drilled in the boss The cover assembly which is bolted to the body assembly with six cap screws has a long boss with a cored passage for the oil intake and a threaded end to take the oil screen pipe 2 Functioning The oil pump is gear driven from the camshaft Oil pump pressure is automatically regulated through bypassing par...

Page 309: ...TTON HM 1385 A 720 SPRING HM 1347 A PISTON HM 22129 A SCREW CAP BCAX3K WASHER LOCK BECXIG SCREW CAP BCAXIAD WASHER LOCK BECXIG COVER HM 45171 B STRAINER ASS Y HM 45179 BS PUMP OIL ASS Y HERCULES N 45290 CS ORDNANCE Nº C72503 WHITE Nº 353055 RAFSD 3348 FIGURE 199 Lubricating oil pumps plan view 2 Adjust to proper pressure 2 Oil pressure relief valve not adjusted properly 3 Oil pressure relief valve...

Page 310: ...4 inch open end wrench STRAINER ASSEMBLY HM 45179BS GEAR HM 45266 A PIN HM 4809 A ATTACHING FLANGE NUT HM 1660 A NUT HM BBBXIB PUMP OIL ASSEMBLY HM 45290 CS SCREW CAP BCBXIBF RA PD 8048 FIGURE 200 Oil pump dismounted Remove 20 cap screws and lock washers holding oil pan to crank case and 5 cap screws and lock washers holding oil pan to flywheel housing fig 107 After these cap screws have been remo...

Page 311: ... the left Then lift off pump assembly and gasket fig 200 d Oil pump disassembly fig 201 Tools Pipe wrench Pin punch 716 inch open end wrench Hammer 34 inch open end wrench Small screw driver Pliers 1 Remove oil strainer from Pipe wrench pump Disconnect strainer pipe from pump inlet boss 2 Remove pump cover 716 inch open end wrench Arbor press 304 ...

Page 312: ...SPRING H M 1 347A 7 FITTING H M 1 885A 8 NUT H M 1 660A 9 NUT B BBXIB 10 SCREW C AP B CBXIBF 1 1 SHAFT H M 2 2124A 12 KEY B GAX4D 13 RING H M 4 387A 14 GEAR H M 2 2154A 15 KEY B GAX4D 16 SHAFT H M 2 2155A 17 RING H M 4 387A 18 GEAR H M 2 2154A 19 COVER H M 4 5171B 20 WASHER L OCK B ECXIG 21 SCREW C AP BCAX3K 22 SCREW C AP BCAXIAD 23 STRAINER A SSEMBLY H M 4 5179 B S 10 RA PD 8 049 FIGURE 201 O il ...

Page 313: ...r and press out shaft Then remove Woodruff key from shaft and slide off fiber thrust washer 6 Remove pump gear from drive shaft Pliers Screw driver Push shaft with pump gear from body and place in arbor press First press gear back on shaft about inch this will allow removing snap ring from groove in shaft Then press gear off shaft and remove Woodruff key 7 Remove pump idler gear Screw driver Pull ...

Page 314: ...p and inspect valve and valve spring 3 Before disassembly check gears for backlash and shaft for end play See section XIV for clearance End play can be reduced by grinding the pump body face with an abrasive compound on a flat surface SPECIAL T SOCKET WRENCH CROW FOOT WRENCH RA PD 33317 FIGURE 202 Oil pump pressure adjustment 4 After the oil pump has been disassembled clean all parts in solvent dr...

Page 315: ...ress gear on shaft far enough to allow snap ring to be replaced Reverse and press gear in position at end of shaft 2 Install idler gear on shaft Repeat above operation No Woodruff key is used on idler gear shaft 3 Install drive gear on shaft Arbor press Hammer Insert drive shaft with pump gear into pump body and place in press Then replace fiber washer insert Woodruff key and press gear in positio...

Page 316: ... Shellac new gasket on oil pan Position pan on crankcase and re place 20 cap screws and lock washers attaching pan to crankcase and 5 cap screws and lock washers attaching pan to flywheel housing 3 Replace oil in crankcase 16 inch open end wrench Screw magnetic drain plug into crankcase and fill with required grade and quantity of oil SECTION XIII PREPARING ENGINE FOR STORAGE Paragraph General 60 ...

Page 317: ...arts of the generator and starting motor except coils and windings if left in place on the engine must be coated with oil lubricating preserva tive medium These units then must be covered first with a piece of paper such as tar paper building paper or heavy wrapping paper treated with oil to make it waterproof or with oilcloth then if available burlap or canvas should be put on over the paper to p...

Page 318: ...mber g Government purchase number if purchased as a separate unit and not removed from a complete vehicle h Date placed in storage i Conditions as new stock rebuilt overhauled needs overhaul needs repairs of parts robbed of parts j If O K as new or rebuilt initials of inspector and date k Dates of subsequent periodical inspections and initials of inspectors l Any other information likely to be des...

Page 319: ...or a Generator Brush spring tension 64 to 68 ounces End play of armature 0 010 inch maximum b Regulator Carbon resistors four used Resistance R1 marked 80 76 to 84 ohms R2 marked 15_ 13 5 to 16 5 ohms R3 marked 30 28 to 32 ohms R4 marked 1 0 9 to 1 1 ohms Circuit breaker Resistance of volt a ge winding 49 7 ohms Armature air gap 0 060 to 0 065 inch Contact point gap 0 015 minimum Points close 13 0...

Page 320: ...arings 0 005 inch maximum With new bearings 0 0005 inch minimum to 0 001 inch maximum Breaker point gap 0 020 inch maximum Breaker arm spring tension 17 to 20 ounces Condenser capacity 0 20 to 0 25 mfd Advance 10 automatic Retard 6 manual b Spark plugs Gap 0 025 inch 74 Electrical starter Brush spring tension 42 to 53 ounces Torque tests No load speed speed with 4 800 rmp with 11 volts and 65 Bend...

Page 321: ...inch 0 020 inch 0 030 inch 0 040 inch Main bearing clearance 0 0025 to 0 0035 inch Torque wrench pull foot pound 70 Front and interior inch pound 840 foot pound 591 2 Center and rear inch pound 714 Shims 3 on each side 0 003 inch Flywheel and housing Flywheel run out 0 004 inch Concentricity of housing bore 0 010 inch Piston Diameter of piston at ring lands Refer to engine section Top land A 3 972...

Page 322: ... to 0 020 inch Ring and groove clearance 0 001 to 0 003 inch Oil ring Quantity 1 Type Butt joint heavy duty type Width 1 975 inches Gap 0 015 to 0 020 inch Ring and groove clearance_ 0 002 to 0 003 inch Connecting rod Center to center length_ 8 002 to 7 998 inches Lower bearing Replaceable type Lower bore 2 1350 to 2 1345 inches End float_ 0 005 to 0 0010 inch Connecting rod bearing lower Material...

Page 323: ...Seat angle Diameter head Length over all Stem diameter Guide ream Stem to guide clearance_ 2 0565 to 2 0555 inches 2 0565 to 2 0555 inches 2 0565 to 2 0555 inches 2 0565 to 2 0555 inches 0 0015 to 0 0025 inch foot pound 521 2 inch pound 630 Intake opens Intake closes Intake period Port diameter Exhaust valve Lash hot Seat angle Diameter head Length over all Stem diameter Guide ream Stem to guide c...

Page 324: ...mp Pressure at 1 000 rpni 35 to 40 pounds Gear backlash 0 008 to 0 010 inch Diameter Housing bore 0 5015 to 0 5005 inch Drive shaft 0 499 to 0 500 inch Idler shaft 0 5030 to 0 5035 inch Drive gear bore 0 498 to 0 499 inch Idler gear bore 0 5055 to 0 5045 inch Clearance between Drive shaft and housing 0 0005 to 0 0025 inch Drive gear to shaft 0 002 inch Idler gear to shaft 0 001 to 0 0025 inch Gear...

Page 325: ...es 77 Lubrication system oil pump Pump gears Type Steel spur gear Number of teeth 10 Pitch 10 Gear backlash 0 003 to 0 006 inch Pressure angle 30 Oil pressure 35 to 40 pounds at 1000 rpm Shaft end play 0 003 inch Pressure relief spring Free length 1916 inches Pounds pressure at 15 16 412 pounds inches SECTION XV 82 SPECIAL TOOLS AND EQUIPMENT Paragraph Clutch 78 79 Oil pump 80 Engine 81 Voltage re...

Page 326: ...0 Engine 1 38 inch thin wall socket wrench 1 tension indicating wrench 1 engine disassembly stand 1 piston ring gap filing fixture 1 pilot bar for valve tappet guide removal 1 pilot bar for valve stem guide removal 1 line reamer for camshaft bearings 1 valve rack 81 Voltage regulator 1 Fahrenheit thermometer 0 to 212 1 contact point file 1 0 040 inch pin gage 1 0 042 inch pin gage 1 0 047 inch pin...

Page 327: ...material OFSB 6 series Echelon system of maintenance TM 10 525 Fire prevention safety precautions and accidents TM 10 360 Maintenance and repair 3d and 4th echelon TM 10 520 Motor transport inspections TM 10 545 Storage of motor vehicle equipment AR 850 18 c Miscellaneous Hand measuring and power tools TM 10 590 List of publications for training FM 21 6 d Scout car matériel Scout cars M3 M3A1 and ...

Page 328: ...LES JXD GASOLINE ENGINE FOR SCOUT CARS e Transportation Military motor transportation Motor transport technical service bulletins The Army Motors monthly QMC motor trans port school TM 10 505 QMC QMC 476794 42 21 321 ...

Page 329: ...Description Disassembly Inspection Installation Maintenance Removal of assembly Repair Special accessories Trouble shooting Coil ignition Cooling system Data Fan and pump Inspection Repair 15 70 10 13 7 16 14 22 311 11 18 4 28 20 16 2 318 14 101 12 4 78 11 28 71 17 21 7 4 312 29 4 2 70 77 311 Data consolidated service Disassembly Clutch Engine stripped Regulator Starting motor Distributor Ignition...

Page 330: ... 80 47 40 172 243 248 164 223 310 150 177 249 211 309 313 319 248 160 Equipment special 78 82 318 65 17 21 28 54 310 29 101 280 51 53 49 256 280 254 Fan Belt tension Cooling system Filter Fuel system Carburetor Description Fuel Filter Pump Inspection Repair Service data Trouble shooting Tune up 54 55 7 4 280 284 5 3 318 254 10 76 50 9 24 Generator electrical Adjustments Assembly Construction Descr...

Page 331: ...cation system Starting motor Technical description Installation Clutch Engine stripped Generator Regulator Starting motor 7 7 73 7 69 6 7 7 7 7 7 4 4 313 5 311 4 5 4 4 5 5 4 16 28 48 24 25 38 249 78 100 150 App 320 56 7 297 5 Lists nomenclature Lubrication system Description Inspection Oil Filter Pump Repair Service data Trouble shooting 58 59 1 77 57 298 301 3 318 298 14 Maintenance Clutch Engine...

Page 332: ... Installation Maintenance Quick checks Removal Repair Service data Trouble shooting Voltage Removal of assembly Clutch Regulator Starting motor Repair jobs Allocation Fuel system Lubrication system 25 25 25 25 4 72 25 81 96 79 87 100 91 85 86 3 312 86 319 12 25 34 16 86 138 4 4 4 2 3 3 70 77 311 Service data Service maintenance definition Shielding Spark plugs 2 30 2 121 Ignition Storage preparati...

Page 333: ... Fan and pump 18 32 Fuel system 50 254 Generator 24 56 61 Ignition 27 101 Lubrication system 57 298 Regulator 25 86 Starting motor 33 137 Symptoms 8 5 Tune up Fuel system 9 10 Power plant 9 8 Vacuum tests tune up 9 10 Valve clearance tune up 9 10 Voltage regulator 81 319 Water pump Cooling system 20 43 Service data 71 312 A G 062 11 6 1 42 BY ORDER OF THE SECRETARY OF WAR G C MARSHALL OFFICIAL Chi...

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Hercules JXD, Technical Manual

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