User Manuals: Ford LSG 875 Generator Set

Manuals and User Guides for Ford LSG 875 Generator Set. We have 1 Ford LSG 875 Generator Set manual available for free PDF download: Service Manual

Ford LSG 875 Service Manual

Ford LSG 875 Service Manual (174 pages)

LSG 875

Brand: Ford | Category: Engine | Size: 39.97 MB

Table of Contents

Safety Notice
4
Table of Contents
5
7.5 Liter Engines
5
Basic Engine
5
Section Title
5
Cylinder Heads
7
Cylinder Block
7
PART1 Basic Engine
7
Valve Train
8
Oil (Engine) - Health Warning
9
Lubrication System
9
Positive Crankcase Ventilation System
10
Compression Gauge Check
11
Camshaft Lobe Lift
11
Compression Test
11
Compression Test Conclusion
12
Hydraulic Valve Lifter
13
Crankcase Ventilation Regulator Valve Test
14
Positive Closed-Type Ventilation System
14
Crankshaft End Play
14
Flywheel Face Runout
14
Camshaft End Play
15
Timing Chain Deflection
15
- Exhaust Manifolds Cleaning and Inspection
  16
- Valve Rocker Arm Cleaning and Inspection
  16
Cleaning and Inspection
16
Intake Manifold
16
Push Rods
16
Basic Engine
21
- Main and Connecting Rod Bearings Cleaning and Inspection
  22
- Cylinder Block Cleaning and Inspection
  23
- Oil Pan Cleaning and Inspection
  23
- Oil Pump Cleaning and Inspection
  24
- Positive Closed-Type Crankcase Ventilation System Cleaning/Inspection
  24
- Cylinder Head Overhaul
  25
- Reaming Valve Guides
  25
- Refacing Valve Seats
  25
- Camshaft Repair
  26
  - Refacing Valves
    26
  - Select Fitting Valves
    26
- Valves
  26
- Crankshaft
  27
- Pistons, Pins and Rings
  28
- Cylinder Block/Refinishing Cylinder Walls
  29
- Push Rods
  29
- Repairing Sand Holes or Porous Engine Castings
  29
- Valve Rocker Arm
  29
- Valve Clearance Adjustment
  30
Overhaul
25
Adjustments
30
REMOVAL and INSTALLATION (Cont' D)
44
- Crankshaft Rear Oil Seal Removal and Installation
  45
- Oil Pan Removal and Installation
  45
- Oil Pump Removal and Installation
  45
- Main Bearings Removal and Installation
  47
- Connecting Rod Bearing Removal and Installation
  48
- Pistons and Connecting Rods Removal and Installation
  49
- Crankshaft Removal and Installation
  51
- Camshaft Bearings Removal and Installation
  53
- Cylinder Head Disassembly and Assembly
  54
- Oil Filter Removal and Installation
  54
- Piston and Connecting Rod Disassembly and Assembly
  55
- Cylinder Assembly Disassembly and Assembly
  56
- Cylinder Block Disassembly and Assembly
  56
- Oil Pump Disassembly and Assembly
  56
- Ignition System
  57
- Solid State Ignition Description
  57
- Description
  58
- Diagnosis and Testing
  61
- CLEANING and INSPECTION (Cont' D)
  74
- Adjustments and Repairs
  76
  - Breaker Plate and Sub-Plate Removal and Installation
    76
  - Breaker Points And/Or Condenser Removal and Installation
    76
- Prestolite Distributors (Marine and Irrigation Engines) Description and Operation
  76
- Bench Assembly
  79
- Major Repair Operations
  79
  - New Shaft and Gear
    79
  - Original Shaft and Gear
    79
- Mechanical Operation
  80
- Dwell Angle
  80
- Distributor Spark Advance Test
  80
- Centrifugal Advance
  80
- Fuel System
  81
- Fuel System Diagnosis and Testing
  82
- Fuel Pump Assembly Removal and Installation
  84
- Pressure and Capacity (Volume) Testing
  84
- Model 2300 2-V Carburetor Description
  85
- Carburetor Systems
  86
- Fuel Inlet System
  86
- Idle Fuel System
  86
- Main Metering System
  87
- Power Fuel System
  87
- Accelerating Pump System
  88
- Idle Mixture Adjustment
  89
- Erratic Engine Idle
  90
- Low Idle Speed Adjustment
  90
- Accelerator Pump Lever Adjustment/Accelerating Pump Stroke Adjustment
  90
- Fuel Level Float Adjustment - Dry
  90
- Fuel Level Adjustment - Wet
  91
- To Lower Fuel Level
  91
- To Raise Fuel Level
  91
- Accelerating Pump Diaphragm Removal and Installation
  92
- Carburetor Removal and Installation
  92
- Power Valve and Gasket Removal and Installation
  92
- Fuel Bowl and Gasket Metering Block and Gasket Removal/Installation
  92
- Fuel Inlet Needle and Seat Removal and Installation
  93
- Carburetor Disassembly and Assembly
  93
- Fuel Bowl and Metering Block
  93
- Main Body
  94
- Throttle Operating Shaft Housing
  94
- Carburetor Cleaning and Inspection
  95
- Carburetor Assembly
  96
- Throttle Body
  96
- Carburetor Exploded View
  99
- Model 4160 Carburetor Systems
  100
- Fuel Inlet System (4160)
  100
- Idle System (4160)
  102
- Main Metering System (Primary) (4160)
  103
- Power Enrichment System (Primary) (4160)
  103
- Accelerator Pump System
  104
- Integral Automatic Choke
  105
- Choke Systems
  105
- Electric Chokes
  106
- Hand Operated Chokes
  106
- Vacuum Systems Secondary Operation
  106
- Secondary Fuel Metering Systems
  106
- 4160 Carburetor Service Procedures
  108
- 4160 Carburetor Disassembly
  108
- 4160 Carburetor View
  109
- 4160 Carburetor Cleaning
  112
- 4160 Carburetor Assembly
  112
- Primary Fuel Bowl
  112
- Secondary Fuel Bowl
  112
- Main Body (4160)
  113
- Fuel Bowls and Metering Body
  113
- 4160 Carburetor Adjustments
  114
- Checking Accelerator Pump Lever Clearance/Choke Qualifying
  114
- Adjusting Secondary Throttle Stop
  114
- Secondary Diaphragm
  114
- Choke Unloader Adjustment
  115
- Curb Idle Adjustment
  115
- Erratic Engine Idle/Low Idle Speed Adjustment
  115
- Fast Idle Adjustment
  115
- Model 4160 Carburetor Exploded View
  116
- Idle Adjustment Procedure with Analyzer
  116
- Charging System
  118
- Alternator
  118
- Charging System Diagrams
  119
- Regulator
  120
- Charging System Application
  120
- Charging System Diagnosis
  121
- Normal Charge Indicator Light
  121
- Normal Charge Ammeter
  121
- Isolating the Problem
  121
- Capacity Test
  122
- Battery Testing
  122
- State of Charge - Maintenance-Free Batteries
  123
- Charging System Tests - Motorola
  123
- Ignition on - Engine Not Running
  123
- Field Draw Test - Ignition off
  123
- Ignition on - Engine Running at Fast Idle
  124
- Ignition on - Engine Running at Idle
  124
- Motorcraft
  124
- Base Voltage Test/No Load Test
  124
- General Charging System Test
  125
- Load Test
  126
- Over Voltage Tests
  126
- Under Voltage Tests
  126
- Regulator S and I Circuit Tests S-Circuit with Ammeter
  127
- S and I Circuit - with Indicator Light
  127
- Bench Tests
  128
- Rectifier Short or Grounded and Stator Grounded Test
  128
- Field Open or Short Circuit Test
  128
- Stator Coil Open Test
  129
- Stator Coil Grounded Test
  129
- Diode Test
  129
- Rotor Open or Short Circuit Test
  130
- Alternator Removal and Installation
  130
- Alternator Disassembly
  131
- Alternator Cleaning and Inspection
  133
- Alternator Assembly
  134
- Drive Belt Adjustment
  135
- Belt Tension
  135
- Starting System
  136
- Starting System Testing
  137
- To Jump Start (Negative Grounded Battery)
  137
- On Vehicle Testing - if Starter Cranks Slowly
  137
- If Starter Does Not Crank but Starter Relay Operates (Clicks)
  138
- If Starter Does Not Crank and Relay Chatters or Does Not Click
  138
- If Starter Spins (Humming Noise) but Does Not Crank Engine
  138
- Starter Load Test
  138
- Armature and Field Grounded Circuit Test
  139
- Armature Open Circuit Test
  139
- Starting System Bench Tests
  139
- Starter Cleaning and Inspection
  140
- Starter Removal and Installation
  140
- Starter Disassembly
  140
- Starting System Diagram
  141
- Starter Assembly
  143
- Starter Drive Replacement
  143
- Brush Replacement
  144
- Armature Replacement
  144
- Starter, Permanent Magnet
  145
- Jump Starting
  146
- Starter, Permanent Magnet Diagnosis and Testing
  147
- Check Starter Motor - Test a
  148
- Check Relay - Test B
  148
- Check Voltage at Remote Relay Start Terminal
  149
- Check Output Terminal Voltage
  149
- Bench Tests - Starter No-Load Test
  150
- Starter Motor Removal and Installation
  151
- Grounded Armature Test
  151
- Starter Solenoid Test
  151
- Starter Motor Disassembly and Assembly
  153
- Starter Motor Cleaning and Inspection
  153
- Starter Drive/Armature Replacement
  155
- Starter Specifications
  155
- Starting System - Special Service Tools
  156
- Governors
  157
- Mechanical Governor - Belt Driven, Description
  157
- Mechanical Governor Troubleshooting
  157
- Preliminary Checks of Mechanical Governors
  157
- Oil Level (Governor)
  158
- Belt Tension (Governor)
  158
- Throttle Control Rod (Governor)
  158
- RPM Adjustment/Spread Adjustment/No-Load Surge Adjustment
  158
- Draining and Filling the Cooling System
  159
- Coolant (Industrial)
  159
- Cooling
  159
- Cooling System Testing
  160
- Pressure Test
  160
- Thermostat Test
  160
- Cooling System Adjustments
  161
- Drive Belt/Belt Tension Adjustment
  161
- Thermostat Replacement
  161
- Cooling System Cleaning and Inspection
  162
- Specifications
  163
- Metrics
  168
- Nomenclature for Bolts
  169
- Bolt Strength Identification
  169
- Hex Nut Strength Identification
  170
- Other Types of Parts
  170
- Decimal and Metric Equivalents
  171
- English Metric Conversion
  172
- Torque Conversion
  173

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