I-49

INSTRUCTIONS

for

ENGINE THROTTLE CONTROL MODIFICATION

from

FULL ELECTRIC-HYDRAULIC CONTROL

to

MECHANICAL AND ELECTRIC-HYDRAULIC CONTROL

GENERATOR SETS

SPECS 5210 and VAR. 1 SPECS 5219 and VAR. 1

MOTOR GENERATOR DIVISION HOBART BROTHERS CO&IF"

TROY, OHIO 45373

U.S.A.

10-8-70

TABLE OF CONTENTS

Introduction

PAGE

1

Electric-Hydraulic Governor Modification

Preparation for Modification

Location of Equipment Inspect Modification Kit

Kit Components for Tractor-Mounted Unit (S-5219 and Var. 1)

Kit Components for Self-Propelled Unit (S-5210 and Var. 1)

Modification of Tractor-Mounted Unit (S-5219 and Var. 1)

Modify Governor Control Box Assembly Modify Rear of Instrument Panel Modify Terminal Board on Control Box Support Modify Actuator Linkage Install New Manual Control Linkage Install Hand Throttle Control Cable Inspection Start-up after Modification

Modification of Self-Propelled Unit (S-5210 and Var. 1)

Modify Governor Control Box Assembly Modify Rear of Instrument Panel Modify Terminal Board on Control Box Support Modify Actuator Linkage Install New Manual Control Linkage Install Hand Throttle Control Cable Modify Accelerator Linkage Inspection

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2 2

3

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k 6

10

19

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19

20 20 20 20 20 27

'i.

LIST OF ILLUSTRATIONS

FIGURE NO.

1

2

3

4

5

6

7

8

9

10

ll

I2

13

14

15

16

17

TITLE

Original Electric Governor Control Box Assembly, All Models

Modified Electric Governor Control Box Assembly, All Models

Rear View of Instrument Panel

Control Box Support Terminal Board for S-5219 (Tractor-Mounted units)

Original Throttle Linkage

Modified Actuator Linkage

Throttle Linkage Installation

Carburetor Throttle Linkage

Hand Throttle Control Installation Drilling Dimensions

Solenoid and Control Cable Linkage

Control Box Support Terminal Board for S-5210 (Self-Propelled Units)

Floorboard Assembly

Electric Accelerator Linkage

Floorboard Mounting Hole Locations

Clevis Mounting Hole Location

Accelerator Linkage

Accelerator Linkage Installed

PAGE

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7

8

9

11

12

14

15

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18

21

23

24

25

25

26

28

ii.

1. Introduction

These instructions provide information for modification and conversion of engine speed control devices which were original equipment on ground power units, S-5210 and S-5219. Originally the hydraulic governor was controlled electrically for both generate mode and mobile operation of the self-pro- pelled unit. The modification provides mechanical speed control for mobile operation while retaining electric control of the hydraulic governor for power generating mode of operation. Since the tractor-mounted generator set, S-5219, may be installed in the self-propelled unit, S-5210, and generating unit from S-5210 may be mounted on a tractor, interchangeability must be retained and both units (S-5210 and S-5219) must be modified.

2. Electric-Hydraulic Governor Modification

Some knowledge of the engine throttle system is required to understand the modified governor linkage and the new mechanical control hook-up. The engine is equipped with two butterfly type throttle valves. In addition to the valve which is conventionally located in the carburetor throat, another valve is located in a water jacketed valve body which is mounted below the carburetor, between the carburetor and intake manifold. For identification purposes and to avoid confusion, we shall refer to the lower, water jacket valve as the auxiliary throttle.

Originally the auxiliary throttle was locked in wide-open position by a cap- screw and nut (Figure 5, items 13 and 12), and only the carburetor throttle was functional. The hydraulic actuator (9) was connected to the carburetor throttle lever by a rod (15) and ball joints (10 and 16). Engine speed for both generate and mobile operation was controlled entirely by the hydraulic actuator which received its positioning signals frcm the electric-governor, control box during "generate" operation and from an accelerator operated rheostat during mobile operation. Throttle linkage was arranged and con- nected in such a manner that the weight of the actuator lever (7) and throttle rod assembly would force the throttle to CLOSED (idle) position when the actuator was not receiving a signal from the control box, or the accelerator rheostat. By use of a toggle switch and relay, control of the actuator (and throttle) could be switched from the generate mode, using the governor control box to control engine speed, to mobile mode, using the accelerator rheostat for speed control.

The modification utilizes both throttles for engine speed control. The auxiliary throttle is connected to the hydraulic actuator for generator speed control. The carburetor throttle is coMected through special linkage to manually operated controls. A hand-operated control cable, mounted on the control box, is used on S-5219. A longer cable, connected to the accelerator pedal, is used for S-5210. To allow the auxiliary throttle to become functional, the carburetor throttle must be OPEN. Like- wise the carburetor throttle is functional only when the auxiliary throttle is OPEN. For the purpose of holding the carburetor throttle OPEN (to allow the auxiliary throttle to operate in generate mode), the movable core (F'g. 8, item 5) of a solenoid (6) is mechanically connected in the throttle 1 r&age. I:

1.

When the "generate-drive" switch is placed in GEN position, the coil is energized and will hold the carburetor throttle linkage in OPEN position, once it is placed there either by pulling on the hand throttle control (for S-5219), or by depressing the accelerator pedal (for S-5210). When the generate-drive switch is in DRIVE position, no holding current is supplied to the throttle solenoid and spring action holds the carburetor throttle in CLOSED position. Thus the auxiliary (governor) throttle is rendered non-functional. Naturally, at this forced idle speed the governor system is signaling for higher engine speed, therefore the actuator will hold the auxiliary throttle wide-open so the carburetor throttle will be functional up to engine governed speed of 2400 RPM. The actuator lever and throttle,linkage is assembled in such a manner that its weight forces the throttle into WIDE-OPEN position when the engine is stopped. This allows the carburetor throttle to be functional for starting purposes.

3. Preparation

A. Location of Equipment

Locate and position the unit to be converted where adequate lighting, and power for driving hand tools is available.

B. Inspect Modification Kit

Make certain you have the proper kit for the unit being converted.

kits are identified as follows:

Throttle Modification Kit for Tractor-Mounted Units (S-5219 and Var. 1). Throttle Modification Kit for Self-Propelled Units (S-5210 and var. 1).

Unpack the kit and identify all parts. Check against packing list to be certain all required parts are available to do the job.

2.

Kit Components for Tractor-Mounted Units (S-5219 and Var. 1)

1 - Cable assembly, hand throttle 1 - Knob, hand throttle 1 - Linkage assembly, hand throttle 1 - Grommet, rear panel 2- Screws, l/4-20 x l/2 (stop bracket mounting) 2- Nuts, l/4-20 (stop bracket mounting) 2- Lockwashers, l/4 (stop bracket mounting) 1 - Threaded rod, governor linkage 1 - Bracket, cable stop 2 - Terminals for RED and GREEN potentiometer lead (No. 400456-2) l- Wire lead, BR-GRN Term C-3 to B-8 (36 inches) 14-F

Wire lead OR-GRN Term c-6 to solenoid (60 inches) 14-F 4' 1 Terminals'for 14-F leads above (No. 406456-2) l- Loom (96 inches) 8 - Plastic ties 1 - Hose, "Oildex" l/2 in. x 16 in. long.

5. Kit Components for Self-Propelled Units (S-5210 and Var. 1)

1 - Cable assembly, hand throttle 1 - Knob, hand throttle 1 - Linkage assembly, hand throttle 1 ... Grommet, rear panel 2- Screws, l/4-20 x l/2 (stop bracket mounting) 2- Nuts, l/4-20 (stop bracket mounting) 2- Lockwashers, l/4 (stop bracket mounting) 1 - Threaded rod, governor linkage 1 - Bracket, cable stop 2 - Terminals for RED and GREEN potentiometer leads 1 - Wire lead, BR-GRN Term C-3 to B-8 (36 inches) 14-F 1 - Wire lead, OR-GRN Term c-6 to solenoid (60 inches) 14-F 4 - Terminals for 14-F leads above l- Loom (96 inches) 8 - Plastic ties 1 - Hose, "Oildex" l/2 in. x 16 in. long 1 - Cable assembly, accelerator 1 - Spring, accelerator return 1 - Cotter pin, yoke 1 - Bracket, accelerator cable mounting 3- Screws J l/4-20 x 3,‘4 3 - Nuts, l/4-20

( (

accelerator bracket and spring mounting) accelerator bracket and spring mounting)

3 - Lo&washers, l/4 (accelerator bracket and spring mounting)

3.

..-..C_ . .._ -_ ..,. ,c _ -,.,_._ _.___,.~i.. _ ,-,. ,._- ~._=- - ..i-- a-s-. ___ _.._e -- -^^_;-m.- _._--.-,.--- - - -- - --

During modification of the unit, it will be necessary to remove certain wire leads and electrical equipment which are either not required, or are replaced.

E: (1) Instructions for disconnecting or removal of wire leads are contained throughout disassembly procedures. All terminal boards are illustrated, and identified by a letter "A", "B", etc. Terminals on each board are then identified by a number 1, 2, 3, etc. It is important to remember that terminals are numbered from LEFT-to-RIGHT, on horizontally mounted boards, and from BOTTOM-to-TOP on vertically mounted boards. For example, a terminal referred to as Fig. 1, B, 3, would be the THIRD terminal from the LEFT (or BOTTOM) on terminal board

6. Modification of Tractor-Mounted Unit, S-5219 (and Var. 1)

' r

"B", located in FIGURE 1.

Most wire terminals are "ring" type. They require complete removal of the terminal screw (or nut) for detachment from a terminal board or electrical component. ALWAYS RElNSTALL terminal screws (or nuts) after a lead has been disconnected, to prevent loss, and lost time looking for a replacement.

A. Modify Governor Control Box Assembly

Refer to Figure 1. All items are identified by item name.

CAUTION: DISCONNECT SOURCE OF 12-V DC POWER BEFORE COMMENCING MODIFICATION.

(11

(2)

(3)

(4)

(5)

Remove six self-tapping screws and lift off governor control box cover. Figure 1 illustrates box with cover removed.

Disconnect all leads from terminal board "A".

Unsolder and disconnect all wire leads from the top (terminal end) of the switching relay. Two leads (RED and GREEN) removed from terminals no. 5 and 7 will be reconnected later to terminal board "B".

Both the switching relay and termfnal board "A' may now be removed. Use a 5/16 in. open end wrench to reach behind mounting board and remove relay attaching nut and washer. Lift off relay with drive speed potentiometer attached. Use the same wrench to hold terminal board "A" attaching nuts and remove board attaching screws. Send relay and terminal board to stock.

Disconnect leads from terminal board "B" as follows:

(a) Disconnect short BLACK lead from terminal "2" and discard.

1

4.

Mounting Board

Drive Speed Setting Potentiometer

\

Switching Relay

\

Reverse Polarity

Diode\ Electric Control

Box----G

"A" Terminal Board

Governor Speed Setting /Potentiometer

"B" Terminal Board

Original Electric Governor Control Box Assembly All Models

Figure 1

5.

(b) Remove terminal screw 8. Disconnect BROWN AND YELLOW lead and WHITE AND YELLOW lead from this terminal. Tape ends of these leads. Remove and discard the lead assembly, contain- ing a diode, which will be f'reed when screw 8 is removed. The other end of this lead was disconnected from terminal board "A" in step (2) above. ILEAVE THE OTBER LEAD ASSEMBLY, CONTAINJXG A DIODE, CONNECTED BETWEEN TERMINALS 8 AND 1.

(c) Disconnect (and discard) leads frm terminals 10 and ll,

(6) Identify the RED and GREEN leads unsoldered from terminals 5 and 7 on the switching relay and attach a terminal (No, 400456-2) to each. Connect the RED wire to terminal B-10. Connect the GREEN wire to terminal B-11. See Fig. 2.

(7) Later, a new wire will be connected to terminal B-8.

B. Modify Rear of Instrument Panel

See Figure 3.

(1) Remove control box access cover from left side of box.

(2) Disconnect BROWN and GREEN lead at lower terminal 3 on terminal board C.

(3) Disconnect ORANGE and GREEN lead at lower terminal 6 on terminal board C.

(4) Tape ends of both leads disconnected above.

(5) Connect a new BROWN and GREEN lead (36 in. long) at lower terminal C-3. Protect with loom, Route the lead as convenient, following existing looms and connect to electric governor control box, terminal 8, on terminal board "B" Figure 2. Band the lead with plastic ties as necessary to hold in place.

C. Modify Terminal Board on Control Box Support

See Figure 4.

This terminal board is located on the left side of the control box support frame, just forward of the hinged, plexiglass terminal cover.

(1) Disconnect leads at terminal board in accordance with BEFORE and AFTER illustration Figure 4. These are "push-on, pull-off" type quick-disconnect terminals. Removal of these leads from the loom and harness in which they are routed is NOT recommended.

6.

Governor speed setting potentiometer

Electric control box

Reverse polarit diode

"B" terminal board

onnect GREEN to terminal 11

Connect RED to terminal 10

Leave YELLOW connected to terminal 9

New BROWN-GREEN lead connected to terminal 8

Modified Electric Goveraor Control Box Assembly All Models Figure2

t 7.

Rear View of Instrument Panel Figure 3

8.

BEFORE Modification

AFTER Modification

Control Box Support Terminal Board for S-5219 (Tractor-Mounted Units)

Figure 4

(2) Tap@ ends, then tape leads together and secure so there is no possibility of "shorting".

D. Modify Actuator Linkage (See Figure 5)

(1) Remove and discard capscrew (13) and locknut (12). Check operation of the throttle valve. It is assumed that the valve will be Itsticky" and difficult to operate, because it has been locked in open position for a long time.

NOTE : Apply a liberal amount of penetrating oil to both throttle shaft bearings. If this does not free the valve, it may be necessary to remove the auxiliary throttle body (5) and clean thoroughly.

The valve MUST operate freely.

(2) Remove throttle rod assembly by removing nut (1) from ball joint (16) and unscrewing ball joint (10) screw from lever (7).

(3) Disassemble throttle rod assembly and save ball joints (10 and 16) and locknuts (11). Discard rod (15).

(4) Assemble ball joints (10 and 16) and locknuts (11) on a new rod (ll inches long). Adjust ball joints on the rod to approximately 1.3-5/16 inches from center-of-ball to center-of-ball.

(5) Move actuator lever toward the rear to full-speed position. Loosen lever clamping screw and nut (8), and slide the lever off the ser- rated, actuator shaft.

Attach one ball joint of the new rod assembly to the AUXILIARY throttle lever (14). (The carburetor throttle lever (4) will be used for manual control.) Use a l/+-inch lockwasher on the joint attaching screw. Attach the other ball joint to the free actuator lever. Mount the joint in the second threaded hole from the end. Use a l/b-inch loclswasher here also. Position the rod assembly and lever toward the rear of the engine so that the auxiliary throttle lever (Fig. 6, item 1) is against the throttle stop (2), in HWIDE- OPEN" position. Slide the actuator lever (4) on the actuator shaft in the position required for assembly. Its position~is dictated by the 13-5/16-inch long, rod assembly (3). Clamp the lever (4) on the actuator shaft with nut and screw (Fig. 5, item 8). The combined weight of rod (Fig. 6, item 3) and lever (4) will hold the auxiliary throttle lever (1) in full open throttle position. The rod and lever should be in the approximate position as shown in Figure 6. Make certain that the linkage is free and be sure it will move from throttle "CLOSED't to "OPEN" positions without binding.

10,

16

15

14

13

12

Ill.

10

9

1. Nut, ball joint attaching 9* Hydraulic actuator 2. Choke lever 10. Ball joint 3. Carburetor 11. Locknut 4. Carburetor throttle lever 12. Locknut 5. Auxiliary throttle body 13. Screw 6. Screw, nut and washer 14. Auxiliary throttle lever 7. Actuator lever 15. Rod 8. Clamping nut and washer screw, 16. Ball joint

Original Throttle Linkage Figure 5

11.

1. Auxiliary throttle 2. Lever stop pin 3. Rod assembly 4. Actuator lever

Modified Actuator Linkage Figure 6

2

I

12.

E. Install New Manual Control Linkage

(2)

(3)

(41

(5)

(6)

(7)

03)

(9)

Remove two screws and nuts (Fig. 5, item 6) which attach the air cleaner mounting band to the mounting bracket. Save this hardware for mounting the throttle linkage assembly.

Disconnect vacuum hose at the top of the "Oildex" crankcase filter and at the intake manifold elbow.

Position the throttle linkage assembly (Fig. 7, item 2) on the air cleaner mounting bracket (l),, so that the throttle rod (4) is toward the front. Align mounting holes and secure the linkage assembly with two capscrews, nuts, and lo&washers (3) removed in step (1) above.

Loosen clamping screw in carburetor throttle lever (Fig. 8, item 2). Reposition the lever on the throttle shaft so that it is pointing upward, and toward the front at approximately 15 degrees from vertical (see Figure 8). Tighten clamping screw.

NOTE : Do not disturb the idle adjusting lever (Fig. 8, item 3).

Attach the ball joint (Fig. 8, item 1) to the throttle lever (2), with a l/4-28 nut and lockwasher.

Remove nut (10) and washer (11) from Flo-matic valve housing and attach spring mounting bracket (strap) (7) in end hole. Hook spring (8) in fifth hole from free end of bracket. Other end of spring should be hooked in clevis pin (4) to serve as a retainer for the pin.

Reinstall "Oildex" vacuum hose. It may be necessary to turn the manifold connection elbow (9) slightly counterclockwise to route the hose so it will not interfere with linkage.

Actuate linkage (solenoid core, and throttle rod) to be sure it will move freely from IDLE position to FULL THROTTLE position. Adjust linkage by unhooking spring, removing clevis pin, loosening locknuts and using the clevis or clevis eye to shorten or lengthen 'linkage as required.

Install throttle stop bracket (Fig. 10, item 9) to the solenoid mounting bracket. Two mounting holes, located just to the rear of the solenoid, are provided. Mount the bracket with the slot toward the air cleaner. Align holes and attach with two, l/4-20 capscrews and nuts.

NOTE : This bracket is non-functional on S-5219. It is used to secure the end of the hand throttle cable when the unit is used in self-propelled S-5210.

13.

1. Air cleaner mounting bracket 2. Throttle linkage assembly 3. Attaching screws, nuts and lockwashers 4. Throttle rod

Throttle Linkage Installation Figure 7

14.

1 2 4 5 6

10 XL-

1. Ball joint 2. Carburetor throttle lever

ge ;;.3E (strap)

3. Idle speed adjusting lever 9: Elbow 4. Clevis pin 10. Nut 5. Solenoid core 11. Washer 6. Solenoid coil

Carburetor Throttle linkage Figure 8

(10) Route an ORANGE-GREEH lead (60 inches long) between the solenoid (Fig. 10, item 8) and terminal board "C", Figure 3. The lead should be protected by loom. Follow the routing of other leads and cables and secure the lead with plastic ties as required. Connect to terminal no. 6 on terminal board C, Fig. 3, and to the fourth terminal from the left on the solenoid, Figure 10.

F. Install Hand Throttle Control Cable

This installation requires hole drilling in the control box front and rear panels.

(1)

(2)

(3)

Locate throttle control mounting hole in control box front panel. See locating dimensions in Figure 9. Drill (or cut) 2l/32 inch diameter hole.

CAUTIOM: EXERCISE CARE TO AVOID MGNG WIRING AHD COMPONENTS BEHIND THE PANELS.

Locate mounting hole in rear panel in accordance with dimensions in Figure 9. Cut a z-1/8 inch diameter hole. Install rubber grommet in the hole.

Install throttle control cable assembly.

(4 (b)

(4

(d>

(4

w

k>

Remove round knob handle.

Remove the g/16-18 nut from the panel mounting end of the cable assembly.

Install the handle end of the cable assembly through the rear panel hole and route through the front panel mounting hole.

Install nut removed in step (b), and install knob handle. Tighten the mounting nut behind the front panel.

Mount the free end of the cable housing in the outside slot of the mounting bracket (Figure 10, item 6), so that a locking nut (7) is on each side of the bracket.

Be sure there is a locknut (4) on the threaded end of the cable (5). Loosen locknut (2) and start threading the adapter (3) onto the cable (5). When threads are well started, twist the knob handle to thread the cable (5) into the adapter (3) several threads.

Operate the throttle linkage with the cable handle, to be certain the throttle can be opened fully by pulling the handle outward. and 7).

Adjust linkage as required. Tighten locknuts (2, 4, Tighten the housing securing nuts (7) so that the

position of the cable housing in the bracket is not changed.

I

r

1-/ FRONT PANEL- FRoNTvlJm

7 I 0 z

Q

REAR PANEL -REARVIEW

Hand Throttle Control Installation Drilling Dimensions Figure 9

17.

- .-- .-.. -- -.--1.-- --- ------ .----

12 34 5 6 7

1. 2.

1: Z: ;I: 9.

Lead connection terminal (fourth from LEFT) Locknut Adapter Locknut Threaded cable end Cable housing mounting bracket Cable housing locknuts Throttle holding solenoid Throttle cable "stop"

Solenoid and Control Cable Linkage Figure 10

G. Inspection

Check all modifications to make certain all instructions have been followed.

(1) Check all linkage to be sure it is free and operating properly.

(2) Check wiring and connections to be certain there are no short circuits or loose connections.

H. Start-up after Modification

(1)

(2)

(3)

04

(5)

(6)

(71

(8)

(9)

(10)

Be sure all switches are OFF, or in pre-start position.

Connect the source of 12-V DC power.

Start the engine in the normal manner, with generate-drive switch in DRIVE position.

Check operation of the hand throttle control. It should control engine speed as desired. Return engine to idle speed.

Place generate-drive switch in GEN position. The engine should continue to idle.

Pull hand throttle handle outward to full-speed position, and release. The engine should operate at governed speed, and the sole- noid should hold the carburetor throttle linkage in f'ull-open position.

Adjust governed engine speed as required (2400 RPM).

Place generate-drive switch in DRIVE position. The solenoid should release the carburetor linkage and allow it to return to idle position.

Adjust idle speed as required (650 RPM).

Reinstall governor control box cover and main control box access panel.

7. Modification of Self-Propelled Unit, S-5210 (and Var. 1)

Many modification instructions for the tractor-mounted unit are exactly the same for the self-propelled unit. When instructions already given above for S-5219 are the same for S-5210, they will be referenced. When different or additional instructions are required, they will be given below.

A. Modify Governor Control Box Assembly

See paragraph 6, A (1) thru (7) above for instructions.

B. Modify Rear of Instrument Panel

Follow procedures as instructed in paragraph 6, B, (1) thru (5). '

19.

C. Modify Terminal Board on Control Box Support

Instructions for modification are the same as those given in paragraph 6, C, (1) thru (2) above, except use Figure ll instead of Figure 4 for BEFORE and AFTER illustrations.

NOTE: It is not necessary to tape the five leads disconnected from the upper row of terminals. These leads will be removed later when modifying the floorboard.

D. Modify Actuator Linkage

Instructions for modification of this linkage are exactly the same as those given in paragraph 6, D, (1) thru (6) above.

E. Install Hew Manual Control Linkage

These instructions are the same as those contained in paragraph 6, E, (1) thru (10).

F. Install Hand Throttle Control Cable

These instructions are identical to those contained in paragraph 6, F, (1) thru (3) (d). When step (d) is completed, proceed as follows:

(1) Mount the free end of the cable housing in the NSIDE slot of the mounting bracket (Figure 10, item 6), so that a locking nut (7) is on each side of the bracket.

(2) Position the l/b-inch locknut on the threaded cable so that it is on the RIGHT side of the throttle stop bracket when the 'threaded cable is placed in the slot. Thread another locknut (l/4-28) onto the cable and use both locknuts to clamp the cable end in the bracket slot.

NOTE: The accelerator cable will be connected to the carburetor throttle linkage later.

G. Modify Accelerator Linkage

The accelerator pedal originally operated electrical equipment for control of engine speed. This equipment must be removed and replaced by mechanical controls. Proceed as follows:

(1) Refer to Figure 11. The five upper wires, previously disconnected from this terminal board, lead to the accelerator control box located on the floorboard. They are enclosed in a protective loom their entire length. Remove plastic ties and cable clamps as required to free the loom and wires from the terminal board (Fig. 11) to the floorboard. (Other clamps may be removed when the floor- board is removed.)

20.

(2)

(31

(41

(5)

03)

(7)

(8)

(9)

(10)

w

02)

(13)

(141

Remove four attaching screws and lift off the gearshift "boot".

Remove fifteen attaching screws (one screw attaches the master cylinder inspection cover), and lift out the floorboard assembly. (The parking brake should be applied for easiest removal.)

Place the floorboard assembly "up-side-down" on two wooden or steel stands, or "horses". See Figure 12.

Unhook and remove return spring (Figure 12, item 2).

Remove four attaching screws, nuts, and washers, and remove cover (1) '

Refer to Figure 13 and remove all cable clamps (9) which attach leads and loom to floorboard.

Disconnect clevis (5) by removing cotter pin (7) and clevis pin (6). Loosen locknut (4) and remove clevis (5). Save the clevis and clevis pin for later use.

Remove the two nuts, washers, and screws which attach the rheostat mechanism (1) to the floorboard, and remove the complete assembly including wire leads, etc., and the actuating rod assembly (3).

Remove the two stop-screw mounting brackets (8 and 10) by removing attaching nuts, washers, and screws (two for each bracket).

Drill two, s/16-inch diameter holes in the floorboard in accordance with dimensions given in Figure 14. !Fhese holes are for mounting a control cable bracket.

Use existing 5/16-inch hole which is approximately 4 inches from the side and 2-3/8 inches from the front for mounting a spring attaching screw.

Drill a l/&inch diameter hole in the cable actuating arm (Figure 14) in accordance with drilling instructions in Figure 15.

Refer to Figure 1.6 and mount the cable support bracket (4) as shown in the illustration. Use two of the screws, nuts, and washers which were previously used to mount the rheostat assembly cover.

Use another cover mounting screw, nut, and washer to attach one end of the new spring (11) to the floorboard. Hook the other end in arm (10).

Reinstall floorboard assembly and secure with fifteen screws.

Position gearshift "boot" and secure with four screws,

-._ _ -__ i_ __ r .,.

1. Cover 2. Spring 3. Floorboard

Fhorboard Assetily Figure 3.2

t

6

8

1. Rheostat mechanism assembly 6. Clevis pin 2. Bracket (not part of installation - Cotter pin

for test purposes only) i: Bracket 3+ Actuating rod 9. Cable clamp 4. Locknut 10. Bracket

5, Clevis 11. Cable assembly

E%ec%ric Accelerator Mechanism Figure 13

t

24.

Ly spri~n~~~;~;~ arm "Up-side-down" View of Floorboard

Mounting Hole Locations Figure14

OIA

Control cable actuating arm

Clevis Moun%ing Hole Location Figure 15

25.

6

-7

-8

1, Spring attaching screw 2, Cable housing lOCknU%

Cable housing z: Bracket

Cable threaded end 2: Locknut

7. Clevis 8. Clevis pin 9. Actuating arm 10. Return spring arm 11. Return spring

.Accelera%or Linkage Figure 16

26.

(17)

(18)

09)

(20)

(211

(22)

(23)

(24)

Route the flexible control cable from housing mounting bracket (see Figure 10, item 6) to the floorboard bracket (Figure 16, item 4). DO NOT "KINK" OR DAMAGE THE CABIX HOUSING.

NOTE: Use a floor jack or hoist to raise the vehicle for easier access to the underside of the floorboard.

Refer to Figure 10, and mount the cable housing in the "outside" slot of the mounting bracket (6) so that a locking nut (7) is on each side of the bracket.

NOTE : The hand throttle control cable housing should be mounted in the "inside" slot of the bracket (6) and the cable end mounted in the cable "stop" bracket (see Para. 7, F, (2)).

Thread adapter (3) onto threaded end of cable (5).

NOTE : This may be accomplished easier by removing clevfs pin (Figure 8, item 4) and rotating the solenofd core assembly (and the adapter).

Tighten locknut (Figure

Refer to Figure 16, and cable (5).

10, item 4) and reinstall clevis pin.

install clevis (7) on threaded end of

Place cable housing (3) (2) on each side of the

in bracket slot (4) with a locking nu% bracket.

Adjust clevfs (7) on cable (5) so that when the clevis is placed on actuating arm (9), the clevis pin (8) may be easily installed through the clevis (7) and arm (8).

NOTE : The return spring (10) must be holding the accelera%or pedal in idle (up) posi%ion and the return spring (Fig. 8, item 8) must be holding the carburetor throttle linkage in idle position when tne clevis adjustment is made. S

Install a cotter pin in the clevis pin (8) and tighten locknuts (2 and 6).

H. Inspec%ion

Check the complete installation to make certain nothing has been over- looked (see Figure 17).

(1) Operate the accelerator. The cable and linkage should operate smoothly. If binding is presen%, check the control cable routfng to be sure there are no abrupt bends in the cable. I% is permissible to bend the mounting bracket (Figure 16, item 4) slightly 5.f bifding is suspected a% the cable end.

27.

Accelerator Linkage Installed (View of floorboard from underside, looking forward)

FQure 17

28.

(2) Depress the accelerator pedal fklly. Throttle linkage should be pulled "to wide-open" position. Release accelerator pedal. Throt- tle linkage should return to idle at once.

(3) Reinstall governor control box cover and main control box access cover.

t

29.

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