Westerbeke 50 Technical Manual

TECHNICAL

MANUAL

WESTERBEKE 50

Marine Diesel Engine

Publication #23156

Edition Two

January

~r-.v-

'WESTERBEKE

WESTERBEKECORPORATION

~

MYLES 150

STANDISH

JOHN HANCOCK

1981

INDUSTRIAL

ROAD,

TAUNTON,

PARK

MA

02780-7319

TECHNICAL

MANUAL

WESTERBEKE 50

Marine Diesel Engine

Publication #23156

Edition Two

January

~r-.v-

'WESTERBEKE

WESTERBEKECORPORATION

~

MYLES 150

STANDISH

JOHN HANCOCK

1981

INDUSTRIAL

ROAD,

TAUNTON,

PARK

MA

02780-7319

IMPORTANT

THIS START-UP, OPERATION

DIESEL ENGINE. ENGINE'S

FAILURE

INVESTMENT

MANUAL

DEPENDABLE, READ KEEP KEEP

IT IT IT

TO

IS

THE

IN A SAFE HANDY

DO

SO

BUT

YOUR

WILL

INTRODUCTION

A DETAILED

AND

FOR

MAINTENANCE INFORMATION LONG

SAFETY

TERM

PLACE REFERENCE

INVITE SERIOUS

AS

GUIDE

OF

IT

CONTAINS

OPERATION.

!

AT

ALL

WELL.

TO

YOUR

TIMES

RISK,

THE

INSTALLATION,

WESTERBEKE

IS

VITAL

NOT

ONLY

MARINE

TO

THE

TO

YOUR

UNDERSTANDING

The

as

the above as

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camshaft,

reduction

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time

tamination essential.

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in

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ignition component both.

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Westerbeke

service.

ment

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mechanism

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closed

of

pistons, gear.

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operator

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engines.

diesel

method

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tting

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engine

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gasoline

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manufacturer

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service.

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description

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SYSTEM

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water,

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bends.

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be

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fittings

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8

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loop

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then

outlet

today

use

In

the

engine

backwards

hang

from

too

the

connect

components

to

be

a

flexible

and

the

a

most

into

much

engine

a

pipe

weigh

rigidly

exhaust

WAT(~

water

lift

installations

manifold

the

engine

weight

manifold.

nipple

about

connected

system.

DISCIo4ItR.G£

type

and

in

and

8

section

muffler

there

before

during

the

form

Generally,

a

pounds

to

each

must

the

cranking.

water

(4

be

WATEA.

WI

TH

1-3/""

such

is

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muffler

of

exhaust

jacketed

kg).

other

installed

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MUFF"LE:j

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dry,

it

than

as

is

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EXHAUST

the

SYSTEM

The

exhaust

engine

overhead.

All suitable possible.

Many cooled and vent

section

flexibility.

sagging,

Always possibly water

cannot

Otherwise, MEASURING

Back exhaust

The

line

engine

period.

1.

For

normally

WITH

STANDPIPE

system

manifold,

dry

portions

insulation

installations

of

bending

arrange

flow

back

spray

excessive

EXHAUST

pressure

and

should

Set-up

should

Pressure 1-1/2"

Max

WATER

must

usually

of

material

the

exhaust

Provide

and

the into directly

erosion

GAS

BACK

must

as

near

be

asperated

Test

PSI

JACKETED

be

the

use

flexible

adequate formation

rubber

the

PRESSURE

be

as

run

as

engines:

supported

using

exhaust

to

keep

line

hose

engine.

against

will

occur.

measured

possible

at

maximum

shown

Mercury

3"

Mercury

WATER

simple

surface

rubber because support

of

water

section

Also

the

on

to

below.

Test

!'4UFFLER..

LIFT

EXHAUST

"HYDRO-HUSH

or

suspended

metal

system

hangers should

temperatures

exhaust

of

the

for

the

pockets.

so

make

inside

a

the

load

sure

of

straight

engine

during

Water

'-3/~"

o.o~

__

...--,-_S-3/8"

,

1-1/2"

131710

OIA.

PH

SYSTEM

MUFFLER"

independently

secured

be

hose

ease

rubber

that

the

of

that

exhaust

for

installation

hose

water

entering

section

exhaust

the

Column

=

39"

WITH

of

to

the

wrapped

as

low

the

to

as

water

pre-

cannot

sea

piping.

of

the

manifold.

measurement

in

2.

For

turbo-charged

Pressure

0.75

Max

Test PSI

engines:

Mercury

1-1/2"

9

Test

Mercury

Water

=

Column 19-1/2"

Checking

1.

Exhaust

2.

Exhaust

3. partly

Measurement

for

normally

19.5"

The

Transparent

filled

for

Back

pipe

line

"A" may

asperated

turbo-charged

with

Pressure

flange

water.

plastic

not

engines

engines.

exceed

hose,

39" and

WATER

one strainer while

hose. collapse

the mits not be

leaks. be

FUEL

terne gel Copper necessary pump

should

installed Great

installed

against

installed

type

filter

injection

the be

dependable

and

installed,

certainly

started

CONNECTIONS

Seacocks

size

the

Water

outlet

the

use

of

bronze.

run

dry.

TANK

Fuel

plate.

coated

provided

be

care

A

primary

is

As

the

injection

connected

To

care

greater

should

vessel

lines

In

any

under

and

engine

street

The

neoprene

AND

tanks

to

or

galvanized

to kept

above

should

so

dirt

between

available

is

fitted

pump

fuel

insure

supply

are

because

cause

for

the

and

mount

and

to

strainers

than

be

is

can

case,

suction,

the

to

elbows

Use

FILTERS

may

If

made

prevent

will

minimum

the

be

that

water

fuel

the

on

and

has

lift

pump,

the

satisfactory

of

especially

fouling

first

the

of

the

at

sea.

be

copper

use

exhaust

be

moved

in

sealing

impeller

be

of of

fuel

the

raise

engine

taken

air10cks

entering

filter

fuel

from

the

a

pump

the

top

clean

dirt

time.

should

inlet

type

a

section

between

system.

slightly

suction

compound

in

fiberglas,

fibers

tanks

tank

(6

the

overflow

of

left

above

the

replaceable

important

of

fuel

feet

level, to

ensure

of

tank

list

engine

has

a

the

operation,

diesel

anywhere

the

thread

which

tubing

the

piping. the

from

being

it

are

the

and

of

between

capacity

is

tank

fuel.

injector

be

of

the

of

may

or

wire-wound,

of

flexible

hull

This

when

at

sea

should

the

from

can

that

eliminated

fuel.

water

the

accessor element.

piped

or

at

inlet

All

all

(raw)

monel,

be

certain

contaminating

eng

the

maximum).

be

fuel

the

in

as

near

a

For

the

in

full

the

be

withdrawn

and

takes

it

connections

not

ine

utilized

the

collecting

excess

to

diesel

time

the

nozzles

up is pipe

water

aluminum,

be

level

tank.

fuel

and

lift ies.

fuel

the

this

when

fuel

flow

sea

water

reinforced

hose

engine

vibration

being

and

pump

that

the

used.

as

The

If

a

in

system

precautions

pump.

The

lift

of

fuel

top

engine

reason,

the

lines

when

type

pump.

for

that

and

re-a1igned. fittings

to

prevent

should

plain

the

that

interior

fuel

It

the

amount

tank

this

type

secondary

tank

as

the

fuel

is

should

A

recommended

pump

required

and possible. must

cleanliness

fuel

or

engine

at

least

cleaning

rubber

will

between

and

per-

should

never

steel

system.

is

lift

of

lift

already

position.

correctly

taken

fuel

and

should

have

tank

will

The

not

Do

air

or

is

not

be

the

by

a is is

FUEL

PIPING

We

recommend

copper

tubing

together

10

with

suitable

fittings,

both

for longest

the

pieces connectors. eng

ine

joints

should

be

Keep

temperature,

The should copper

The rubber

fuel

always

tubing

final

hoses.

supply

The

free

fuel

to

line

obtainable

shut

be

of

pressure

lines

eliminate

piping

be

securely

is

secured

connection

and off

the

as

far

leading

by

the

to

avoid

valve

fuel

leaks.

as

"vapor

anchored

means

to

return

in

oil

possible

locks".

from

the

type,

the

of

eng

line. use

line

from

tank

to

prevent

copper

ine

of

and

should

Run

unnecessary

between

it

is

exhaust

to

the

chafing.

straps.

be

the

tubing

fuel

important

pipe

eng

ine

through

in

fittings

tank

that

for

minimum

compartment

Usually

flexible

the and and all

the

ELECTRIC

The

meter

PANEL

Westerbeke

wi

th

required, panel Each

ground

are

instrument

and

ELECTRICAL

Most

connectors.

running.

supplied, ments.

Starter

possible

to

low

tial

it

use

is

the

amperage

loads

essential

charging

"alternator

Starter

discharge

Carefully

diagrams.

use

the

following

#1 #1/0 #2/0 #3/0

a

built-in

except

a

voltmeter,

may

be

EQUIPMENT

Westebeke

Never

'Carefully

especially

batteries

to

avoid starter

or

(from

current

output

batteries

(Diesel

follow

Plan

installation

all-electric

for

is

lighted.

mounted

eng

make

voltage

batteries

are

intermittent.

lights,

to

have for splitter".

starting).

cable for for for for

hourmeter.

the

Skipper

water

where

ines

or

follow

those

should

drop

refrigerators,

a

this

must

the

be

recommended

sizes: distances distances distances distances

panel

mechanical

temperature

The

all-electric

visible.

are

supplied

break

all

instructions

relating

be

located

through

for

other

complete,

by

means

of

a

so

the up

to

up

to

up

to

up

to

utilizes

Tachometer

gauge

It

pre-wired

connections

to

fuse/circuit

as

long

services

In

cases

radios,

separate

of

type

which

wire

battery

8

feet

10

feet

13

feet

16

feet

panel.

is

close

leads.

where

a

sizes

is

an

cables

and

~il

panel

normally

while

on

the

It

unless

there depth system second

permits

shown

close

electronic

are

Mounted

pressure

is

isolated pre-wired.

and

wi

the

wiring

breaker

to

the

is

bad they are

sounders,

and

alternator

a

high

in

to

the

no

th

plug-in

engine

diagram

require-

engine

practice

require

substan-

to

provide

rate

the

engine

tacho-

longer

on

the

gauge.

from

etc.),

wiring

and

is

as

or of

MECHANICAL

the knob a

Morse

tion lever. full

clutch

Any

The

recommended

run

at

posi

the

type

transmission

by

a

The

throttle

control

bends

CONTROLS

tion

pilot

and

station.

lever

flexible,

single-lever

range

with

in

the

practice

controlled

at

the

control

sheathed

in

one

control

pilot

type

neutral

lever

is

The

lever

and

cables

to

have

by

throttle

station

may

cable

gives

position.

throttle

11

the

a

sheathed

lever

by a sheathed

be

connected

and

clutch

controlled

and

The

control

should

be

stop-run

cable

should

throttle

two-lever

with

gradual.

lever

to

be

cable.

to

by

a

connected

the

pilot

a

Morse

control

type

the

other.

End

loaded

push-pull

statype

with

provides

sections

to to

at

engine

are

completed, that, forward,

i~

on

stop-run

Some fuel the

solenoid

W58

when

the

lever

models

and

transmission

the

transmission

neutral

respective

on

or

the

check

and

the

do

not

an

W52.

the

reverse,

detent.

fuel

require

electric

must

be

installation

control

the

Check

injection

a

stop

fuel

securely

lever

control

the

pump

cable

pump.

for

full

at

lever

throttle

for

because

Examples

mounted.

travel,

the

pilot

on

control

full

travel.

of

the

they

After

making

station

transmission

lever have

such

models

linkages

sure

is

and

the

either

are

in

a

12

PREPARATION

The

the

crankcase

fOllow

engine

these

for

FOR

FIRST

is

and

recommended

the

first

START

shipped

fluid

time.

OPERATION

"dry"

from

procedures

•••

the

transmission.

with

lubricating

carefully

oil

Therefore,

before

drained

be

sure

starting

from

to

the

1.

diesel

under

Select

2. TYPE Transmission

Engine

tain

If

the

dipstick

on

the

3.

tion is

expelled.

Fill

after

the

water

inch

4. plates effort

Remove

lubricating

Maintenance

an

approved

Fill

A

transmission

additives

the

V-drive

Fill

only

of

after

surge

engine

top

Ensure and that

the

Section

oil

level

is harmful

engine

with

housing.

fresh

has

and

battery

may

oil

for

grade

reverse

not

is

the

water

opening

tank

run

may

replace

battery

is

be

required

filler

to

an

fluid.

of

this

recommended

to

equipped

recommended

all

to

within

for

have

filler

water

fully

cap

the

approved

from

gear

manual

some

cooling

petcocks

a few

dropped.

charged on

and

highest the

to

the

Do

transmissions.

with

one

minutes.

cap.

level

the

fill

mark

lubricating

listing

highest not for

because

a

V-drive,

lubricant

system

and

inch

If

is

at

so

first

oil

on

and

overfill.

details.

it

with

plugs

of

If

so,

least

that

start.

sump

the

oil.

continue

mark on

can

fill

specified

a

50-50

until

the

top.

trapped

refill

3/8"

it

is

with

dipstick.

Do

the

foam,

to

the

antifreeze

all

Check

air

tank

above

capable

heavy

not

to

use

dipstick

Refer

and

it

full

on

the

entrapped

is

to

within

the

of

duty,

See

table

overfill.

it.

to

can

mark

data

solu-

this

level

released,

battery

the

extra

with

the

con-

on

tag

air

one

5.

Fill

oil

is

recommended. The

ferred

recommended

wire

grade FUEL

upon

correctly.

this line,

pressure,

system servicing.

because

NOTE:

screen.

6.

Fill

of

water

SYSTEM

The

fuel

very

pressure

then

and

In

consequence,

whenever

fuel

of

I f

there

procedure

grease

pump

injection

high

fuel

Relatively

and,

this

therefore

any

tank

its

is

cup grease.

pressure

if

air

it

part

with

use

higher

no

is

to

on

system

tiny

any

acts

fuel

is

of

clean of lubricant

filter

pour

the

sea

of a compression

during movements air

as

injection,

essential

the

diesel

No. 1

in

the

water

is

a

cushion

system

is

the

fuel

the

of

present

that

fuel

permissible

content.

filler

through

pump,

injection

the

inside

and

from

has

being

all

been

oil~

of

the,

a

funnel

if

present,

ignition

stroke

pumping

prevents

achieved.

air

opened

No. 2

but

No. 2

fuel

engine

plungers

the

is

high

bled

for

diesel

tank,

of

200 mesh

with

to

function

pressure

the

from"

repair

fuel

is

pre-

the

a

good

depends produce correct

the

or

13

BLEEDING

PROCEDURES

BY

MODEL

1.

Initial

a. grade b. diesel engine.

the may c.

than

tanks

The

above

restarting

WESTERBEKE

1.

with

the

bleed mounted on

the

bubbles

the

bleed

2.

With

securing

Engine

Insure

of

Fill

fuel

manual

prove

Turn

one

being

procedures

engines

W7

AND

use

screw

one secondary lift

flows

screw.

a

5/8

the

that

diesel

any

To

priming

futile

the

tank

used. are

stopping

WPD4

of

a

or

pump

from

open

injector

Start-up

the

fuel.

large

that

primary

is

attempt

lever

or

require

fuel

selector

insure

basic

due

GENERATOR

5/16

fuel

two

box

turns

filter

priming

this

end

point.

wrench

line

(Engine

fuel

installed

to

fill

on

that

for

to

(3600

wrench

on

(Bleed

lever,

to

the

stoppage

tank

(s)

filter/water

any

the

engine

a

considerable

valve

fuel

all lack

initial

of

RPM)

or

common

the

bleed

Stop

loosen

injector

is

between

large

to

"On".

returning

engine

fuel.

(Figure

outgoing

point

until

pr

iming

one

due

filled

separator

the

primary

mounted

amount

1)

screw

side

A).

and

to

two

(Bleed

to

lack

with

fuel

filter

fuel

Systems

is

going

start-ups

driver,

of

with

fuel

gently

turns

point

the with

of

the

firm

free

B).

of

fuel) proper

clean

tank

using

lift

priming.

with

to

or

open

engine

strokes

of

tighten

the

and

pump

more

the

for

the

air

nut

Decompress head.

the full the

and

engine

open.)

engine

tighten

dures.

WESTERBEKE WEO

15

(Figure

1.

Open fil lift

the

ter

pump

flows

2.

On

the Point switch.

3.

the

Stop On

5/16 in

pump.

pr

priming

the

bleed

Step

)

Crank

W30

1-2

from

fuel

B).

iming

control

2.

the stop until

the

(Figure

4),

banjo

turns

priming

this

This

Open

lever and

screw.

(Note:

eng

the

eng

lever

(4KW:

fuel

5/8

W80 & BR

bolt

(Bleed

point.

inj

ection

may

this

tighten

cover

ine

use

nut

2),

on

lever,

one

bleed

Open

Bypass

with

over

is

the

spurts

W40

30

top

Point

Stop

pump

be

or

the

of

this

the

with

in

the

defeat

by

and

proceed

& WPOlO,

(Figure

of

bleed

priming

body

mounted

two

until

bleed

the

inj

screw

this

lever

run

the

A).

until

turns

fuel

ection

bleed

on

the

starter.

position

nut

with

l2~,

5), engine

Wi

th

and

is

a

on

a

(do

free

screw.

one

to

point

the

top

and

while

and

line.

normal

15

W120 & BR

mounted

firm

fuel

free

tighten

5/16

manifold

not

remove

of

pump

two

(Bleed

turns

on

of

(W7:

the

cranking.)

starting

(Figure

45

secondary

stroke

of

the

bleed

with

air

bubbles

the

ensure

throttle

Stop

(Figure

on air

bolt.

screw

it)

Point

and

W30

cylinder

cranking

proce-

3),

the

bubbles

a

pressure

and

flows.

C)

proceed

inj

ection

that

is

Crank

W50

5)

fuel fuel

(Bleed

with

is

as

&

a

14

4.

5.

W50

injection

Point

with

the position, free

of

bleed with

a

attaching

full

the

open

engine

injector

and

proceed

D)

on throttle

air

screw.

5/8

line

the

crank

flows

wrench

nuts

and

over

with

pump

at

the

at

injector

full

the

from

the

engine

with

each normal

only.

open

engine

this

loosen

base

the

injector.

starting

line

and

over

point.

one

of

stop

starter

Open

banjo

the

with

to

each

control

until

Stop

procedures.

the

bolt

engine

the

Stop

two

injector

in

fuel

cranking

5/16

bleed

one

stop

starter

cranking

turns

and,

the

spurts

or

the

run

and

two

lever

until

and

injector

with

position,

by tighten

screw

turns

in

clear

tighten

the the

(Bleed

and,

the

fuel

this

line

throttle

crank

nuts

the

run

and nut

WESTERBEKE These

1.

2.

units Turn Start

the

WESTERBEKE

1.

Open

the

secondary

(Bleed

oper

ated primer and

tighten

2.

With

bleed

times.

The

injection

system

3.

pump Loosen

inj

is

ector

wrench.

the

engine

and

nuts

injector

and

W13, 4.4KW, W21, 7.7KW, W27,

are

self-bleeding.

ignition

the

engine

W58 & WTO

bleed

fuel

Point

until

pr

A).

iming

fuel

the

screw

This

primed

to

following 20

screw

filter

pump.

free

bleed

A

primes pump when

the

ON

position

normal

(Figure

on

one

This

of

the

7)

to

fuel

Wi

t.h

air

top

screw.

tightened,

the

injection incorporates the

eng

ine

inboard

two

filter

the

flows

pump

is

required.

the

four (Bleed Place

over

lines.

proceed

injector

Point

the

throttle

with

line

B)

one

the the

stop

normal

attaching

to

in

starter

cranking

starting

11.lKW,

starting

turns

palm

from

pump

a

feed

running:

two

the

and

wait

procedures.

side

using

is

equipped

of

this

the

hand

which

pump

nuts

turns

full

open

until

tighten

procedure.

W33, 12.5KW

15--20

of

seconds.

the

engine-mounted

a

10mm

with

your

hand,

point.

primer

is

self-bleeding.

which

thus,

at

with

no

the

a

keeps

external

base

16mm

position

fuel

spurts

each

(Figure

box

a

pump

Stop

several

the

open

and

by

of

the

6)

wrench

hand-

this

pumping

more fuel

lift

of

each

end

crank

the

nut

four

Figure

1

15

Figure

2

Figure

3

Figure

6

Figure

4

5

16

Typical

Figure

Mechanical

Lift

pump

7

Fuel

PREPARATION

1.

Check

2.

3.

4.

5.

below Check

Check See Check

the

that

electrical

and

turn

6.

Check

FOR

water

top

the

engine

the

transmission

there

to

see

on

the

seacock

STARTING

level

of

in

the sump

is

fuel

that

connections

the

power

and

expansion

tank

oil

fluid in

the

starting

are

at

the

ensure

when level.

level.

the

properly

battery that

cold.

tank

tank.

and

battery

it

It

should

the

fuel

is

made,

all

disconnect.

is

open.

be

shut-off

fully

circui

l~

to

is

charged,

ts

in

2

in.

open.

all

order

STARTING Most

Westerbeke

starting

1.

Check position.

2.

place

3.

Press

4.

While

"ON" and

to

turn than start system

5.

If

and step

THE

aid

to

the the

holding

or

fuel

20

rather

the

preheat

4.

ENGINE

to

see

throttle

"Preheat"

"Run"

solenoid the seconds.

is

activated

engine

(COLD)

marine

ease

that

in

the

position.

or

keyswitch

Some

that

the

fails

for

an

diesel

the

starting

"stop"

in

the

button

"Preheat"

This

electric

to

the

units

keyswitch

by

fuel

to

start

additional

engines

lever

fully

in

and

button

"Start"

may

pressure.

of

open

hold

activates

fuel

pump

be

and

in

20

15

are

your (if

engine

installed)

position.

for

in,

turn

the

if

position

equipped

in

these

seconds,

to

20

equipped

when

15

to

the

panel

so

equipped.

and

with

cases

release

seconds,

with

cold.

is

in

20

seconds.

keyswitch

gauges,

hold

a

for

pushbutton

the

start

then

a

cold

the

"run"

to

lights

Continue

no

more

electrical

switch repeat

the

to

6.

As

preheat

immediately.

CAUTION: start. ween

the

starter STARTING

I f

the

place

the

starter

soon

Do

Allow

start

motor

THE

eng

as

button

not

a and

ENGINE

ine

is

throttle

above,

the

eng

and

crank

rest

period

cycles.

the

(WARM)

warm

in

eliminating

ine

starts,

return

the

engine

of

Starter

backfilling

and

the

has

partially

at

the

more

least

damage

of

only

preheat

17

release

throttle

than

twice

may

the

been

open

the

20

occur

exhaust

stopped

position

step.

start

to

seconds

the

system

switch

the

"idle"

cranking

by

overworking

for

and

when

period

is

possible.

a

short

and

position

trying

engage

the

to

bet-

the

time,

the

NOTE:

before

gear

Always again

or

starter

be

sure

re-engaging

pinion

may

that

the

be

damaged.

starter

plnlon

~

otherwise,

has

stopped

the

flywheel

revolving

ring

,/

Ensure correct.

Extended

should

NEVER

start

under

your

qualified

WHEN

1.

ENGINE

Check

not IS

2.

Check

iwthout

3.

Recheck subsequent and necessary fill

as

that

be

the

use

of

avoided

any

electr

the

to

circumstances

engine.

Westerbeke'marine

STARTS

for

normal

continue

seconds

Sea

to

of

starting

Water

delay. Crankcase

to

an

check

the

crankcase

to

add

engine's

necessary.

cold

prevent

If

oil

run

Flow.

Oil.

oil

internal

Check

ical

starting

your

presure

engine

the

Look

change to oil

connection

aid

damage

use

to

or

engine

mechanic

immediately

if

oil

engine.

for

water

After

oil

the

or

level.

new

compensate

oil

passages

level

each

to

beyond

the

allow

will

check

pressure

engine

installation,

This

for

day

the

aid.

your

upon

at

is

the

and

of

cold

the

time

anyone

not

start,

engine.

engine

is

exhaust

has

run

important

oil

that

oil

operation.

starting

to

not

outlet.

3

stop

filter.

periods

use

then

starting.

present

or

4

the

as

it

is

required

aid

stated

ether

have

within

Do

this

minutes,

engine may

Add

oil

is

to

a

Do

be

to

4.

Recheck

to

a

engine

into

Check

S.

Recheck cooled.

filled

operating

top

WARNING:

must

be advisable slowly felt. Press and

6.

counter-clockwise

Leave

the

continue

Warm-up

but l30-lS0·F. transmission

transmission

transmission.

Transmission

fluid

after

forward

fluid

Expans

for

of

tank.

The

released

to

protect

the

cap

turning

Instructions.

at

reduced

change

or

running

and

level

one

each

ion

(This

the

applies

first

temperature

system

is

gradually

the

cap

in

downward

until

speed,

If

necessary,

in

neutral

in

neutral

Fluid new

installation.)

for

several

into

day

Tank

Water

after

time.)

of

l7S·F

pressurized

if

the

hands

until

this

position

against

it

can

As

soon

until

takes

level.

reverse,

of

operation.

cooling

and

filler

against

the

be

as

water

engine

at

1000

(This

minutes

then

Level,

Stop

engine

add

when

overheated,

cap

escaping

resistance

until

spring

lifted

possible,

temperature

can

RPM.

longer

applies

In

at

add

if

engine

system water

is

of

all

to

clear

off.

get

be

and

tends

only

such

800

RPM

fluid

a

case, with

as

is

has

after

to

steam

pressure

within

be

the

been

it

and

the

removed.

and

turn

safety

is

the

safety

boat

gauge

warmed up

Warming up

to

overheat

subsequent

stop

one

shift

necessary.

fresh

water

drained

has

one

reached inch

pressure

It

the

stops

released.

stops

underway,

indicates

with

the

'or

of

is

cap

is

the the

the

18

7.

Reverse shifting

will

carry

Operation.

gears.

full

engine

Always

However,

load.

reduce

when

the

engine

transmission

to

idle

is

speed

engaged,

when

it

NOTE:

lever overcenter

STOPPING

1.

2.

3.

4.

5.

The

must

position Idle

pate If

position the the

Turn

they shuts position.

Close

SAO

be

locking

THE

ENGINE

shift

the

engine

some

equipped

until injection run

position

off are

the

equipped

off

the

transmission

held

of

the

seacock.

in

mechanism.

lever

for

the

heat.

with

the

pump.

to

keyswitch.

fuel

the

2

a

engine

avoid

with

supply

reverse

in

to

stop

After

a

requires

neutral.

4

minutes

lever,

stops.

the

difficulty

Some

fuel

when

that

position,

pull

This

engine

models

solenoid

the

keyswitch

to

when

do

when

since

avoid

the

stops

stops,

not

or

backing

it

boiling

knob

the

return

restarting

use

electric

is

down,

has

and

flow

the

fuel

turned

no

and

hold

the

stop

the

positive

to

in

of

fuel

control

engine.

lever pump to

the

shift

dissi-

this

at to

as

which

OFF

6.

Disconnect

OPERATING PRECAUTIONS

1.

2.

3.

4.

5.

6.

7.

Never occurs,

DO cylinder

Keep Do Never

dequate Keep Keep

and

injection

run

NOT

intake

not

Race

the

dirt

as

put

head,

run

oil

engine

power

eng

ine

extensive

cold

block

silencer

engine

a

Cold

circulation.

fuel

in

system

clean.

fuel

to

for

water

at

Engine

and

cause

is

system

extended

internal

or

free high

accessories

reduced.

with

in

an

manifold.

from

RPM

as

Handle

more

battery

per

iods

damage

overheated

lint,

without

internal

clean.

it

wi

trouble,

when

can

etc.

clutch

damage

th

extreme

switch.

be

caused.

engine.

can

and

excessive

It

engaged.

occur

care

service

overheating

can

crack

due

because

life

to

of

the

ina-

water

the

8.

Do long

in

not

allow

enough

engine

fuel

to

allow

stoppage

to

run

air

requiring

low,

to

because

enter

system

19

fuel

the

injection

bleeding.

intake

may

be

system,

uncovered

resulting

9.

Do

not following load. heavy this

it.

metal

is

High signal ficulty, operating.

be

alarmed

a

sudden

This

is

masses

to

run

temperature

alarm

against

temperatures

stop

caused

near

engine

if

temperature

after

by

the

at

idle

reading

restarting.

will

quickly

gauges

engine

release

combustion

for

a

short

after

If

return

has

of

chamber.

a

stop

there

show a

been

residual

period

does

is

to

normal

high

operating

heat

Prevention before not

no

functional

when

reading

at

from

stopping

necessar

engine

full

the for

ily

dif-

/

is

20

TEN MUST RULES

IMPORTANT

•••

for

your

ALWAYS

NEVER

-

1.

2.

3.

4.

5.

-

6.

7.

8.

9.

10.

safety

Keep Use Check

190· Close out. Investigate

Race Run

Break

Use

in

Subject

run

this

only

cooling

or

all

the

cotton

a

galvanized

it

if

and

Manual

filtered

less.

drain

any

engine

fuel

waste

the

black

your

handy

water

cocks

oil

in unless pump

container.

engine

smoke

IMPORTANT

engine's

and

fuel

or

oil

temperature

and

leaks

neutral.

the

seals.

fluffy

to

prolonged

comes

dependability.

read

and

refill

immediately.

gauge

check

cloth

from

it

whenever

frequently

with

shows

for

overloading

the

lube

exhaust.

oil

water

proper

cleaning

in

to

doubt.

level

make

before

oil

or

IMPORTANT

daily.

sure

starting

pressure.

store

continue

it

fuel

is

to

21

PERIODIC ATTENTION:

After

you

make

operation.

Note: first of

this

the

25

manual

you

have

following

Transmissions

to

30

hours

for

MAINTENANCE

taken

checks

of

details.

delivery

right

generally

operation.

of

your

after

require

Refer

engine, the

first

fluid

to

the

it

is

important

fifty

change

Transmission

hours

after

section

of

that

its

the

FIFTY Do

1. bolts.

2. nuts clearance.

3.

the reverse transmissions.

4. and

s.

oil

6. and

7. clamps, vee ticular engine tings. alignment.

HOUR

the

following:

Retorque

and

Check

forward

Change

oil

Check

leaks.

Check

inspect

Check

belt

and

band

filter.

connections,

tensions,

mounts

CHECKOUT

the

adjust

adjust,

drum

on

manual

engine

for

cooling

These

fuel

Correct water

for

attention

engine

(INITIAL)

cylinder

rocker

valve

if

assembly

lubricating

and

if

system

level.

loose

etc.

could

bracket

necessary,

and

SAO

and

lubr

icating

necessary.

for

fittings,

nuts,

Pay

to mount cause

head

rocker

the

SA-l

oil

leaks

bolts,

par-

loose

fit-

mis-

DAILY Do

1.

2.

3. dipstick.

4.

5. dipstick

SEASONAL

Do

1. proper

2.

3.

4.

5. Refer Overfill.

CHECKOUT

the

following: Check Check

Check

Turn

Check

the

following:

Check

tension. Check Change

Replace Fill

to

the

sea

water

lubricating

down

fluid

with CHECK-OUT

gener

water

oil

sump

Specification

See

level

grease

proper

ator

level

in

lubricating

with

Note.

water

cup

level

fluid.

(MORE

,

sump.

diesel

strainer,

in

cooling

oil

on in

OFTEN

alternator

in

battery. See

oil

lubricating

page

if

system.

level

water

transmission.

Note.

filter,

in

pump,

IF

POSSIBLE)

and

for

proper

22

Figure

one

sump.

sea

oil

has

if

to

been

Fill

used,

Fill

water

2.

See

highest

quantity

installed.

to

highest

one

full

to

highest

pump "V"

Note.

mark

of

turn.

on

oil.

mark

belts

dipstick.

Do

on

for

Not

CAUTION:

changes instances

6. oil

as required

Add

Start

filter

it

oil

may

The

has

been

cause

engine

gasket

be

to

as

necessary.

use

known

complete

necessary

fill

of

and for

the

different

to

cause

oil

run

leaks.

eng

to

See

for

add

ine'

Note.

brands

extensive

starvation.

3

or

4

Check

oil

s

internal

oil

to

of

lubricating

oil

minutes.

sump

compensate

oil

level.

passages

sludging

Stop

for

oils

and

engine

This

the and

during

may

and

is

important

oil oil

in

many

check

that

filter.

oil

is

IMPORTANT IT

IS

MANDATORY

TOTAL

IS

7. that air dirty correct reducing

8.

9.

10. water cleaned

11.

12.

13.

Section END

1. pressure

2. needs

may

3.

make.

4. down with

5. or

6. to

7.

8.

Turn

9. preventing

10.

11.

12.

13. of

14.

OPERATING TIME

REACHED

Clean

does

filter

conditions,

Check Check

Wash

or

Replace Replace

Change

OF

SEASON

Drain

Remove

replacing.

occur

Fill

(Refer

Start

and

High

Carefully

some the

this

other

Seal

engine

Remove

Replace

engine

Top Leave

Change

Wipe

Change

manual

Disconnect

NOTE

BEFORE

Air

not

depends

time

bore

engine sea primary

sediment,

more

secondary

air

the

of

this

fresh

cap

and

zinc

between

fresh

engine.

drain

Detergent

the

injectors

slowly

off

fuel

water

fuel

engine

fluid

THAT

END

Filter

require

on

the

periods

wear, water

frequently.

fluid

SERVICE

to

lubricating

seal

suitable

exhaust

as

injectors

system

for

battery

thereby

for

pump

filter

filter.

manual

water

opening

rod

The

dissimilar

water

Cold

When

Lubricating

air

possible.

over tank formation

filters

with

in

details.

THE

REACHES

OF

if operating

for

loose

fuel

in

(usually

zinc

Weather

outlet

and

completely

full

a transmission.

CHECKS

150

SEASON. supplied.

cleaning.)

seasonal

replacing

extending

bolts,

for

leaks.

bowl

filter

the

transmission.

for

details.

cooling

all

water

located

rod

metals.

cooling

temperature

oil.

intake

medium.

at

spray

with

compression.

before

coat

and

new

by of

of

store

3,

4 ,

HOURS.

(Most

The

conditions;

frequency

the

nuts,

and

will

system

Precautions.)

opening

oil

condensation. fuel.

putting oil

screen.

and

element.

system

take

gauge

Remove

Oil.

the

into

sealing

so

that

or

in

secondary

in

Insert

with

most

the

grease.

Refer

fully

5

AND

IN

SOME

models

time

filter

etc.

heat

and

cylinders.

per

therefore,

should

life

If

oil

Refer

by

removing

petcocks.

exchanger)

care

accessible

no

of

new

antifreeze

indicates

replace

waterproofed

washer

air

engine

to

the

charged

6

BE

ATTENDED

INSTANCES, THIS

have

iod

will

of

the

filter

fuel

any

zinc

under

space

back

Transmission

an

for

under

be

increased.

greatly

engine.

bowl

filter

to

the

electrolysis

if

of

l7S·F, filter.

location

each

remains,

in

condition.

air

replacing

Transmission

and

necessary.

a

shut

adhesive

service.

TO

silencer

extremely

assist

contains

need

surge

see

reputable

engine

Fill

as

injector.

thereby

Section

Before

WHEN

TOTAL

the

The

in

be

tank

if

it

that

sump tape

.

close

23

storing be

treated

15.

Check

the

battery,

to

alignment.

prevent

the

battery

corrosion.

terminals

Recharge

and

cable

battery

connectors

every

30

should

days.

24

LUBRICATING OILS

Lubricating offer modern

an

improved

operating

peratures. These

oils Specifications also course,

conform

also

COMPANY

American

BP

Canada

Chevron

Cities

Oil

Service

Co.

oils

Ltd.

Co.

are

standard

conditions

meet

MIL-L-2l04B

to

these

suitable.

Co.

American

Motor

BP

RPM

service

Oil

CITGO

available

of

performance

such

the

requirements

(API

specifications,

BRAND

Supermil

Oil

Vanellus Vanellus

DELO

Multi

Oil

Extra

for

as

Service

Range

Westerbeke

to

sustained

of

CC).

but

are

0·/4S·F

10W/30

meet

the

Any

not

S.A.E.

lOW lOW

lOW

Diesel

the

high

U.

listed

4S·/80·F

engines

requirements

speeds

S.

other

and

Ordnance

oils

here,

DESIGNATION

OVER

20W/20 20W/20

10W/30

20W/20

which

are,

30 30

30

of

tem-

of

80·F

Continental Co.

Gulf

Oil

Corporation Mobil Shell Sun Texaco,

Oil Oil

Oil

Company

Inc.

Oil

Company Company

CONOCO Gulflube

X.H.D. Delvac Shell Subfleet Ursa

Oil

TRACON

Motor

1200

Rotella

MIL-B Extra

OIL

Oil

Series

T

Duty

Oil

lOW

20W/20

1210 1220

lOW lOW lOW

20W/20 20W/20

20W/20

30

1230

30 30 30

2S

YOUR NOTES

26

ENGINE OVERHAUL

p

The

following information ing

characteristics

systems

and

cluded sembly suitably service

necessary

only

are instructions

and

by

such

sections

relating in

the

disassembly,

equipped

rebuilding

procedures

facilities.

of

for

and

contain

to

the

rework the

staffed

facilities.

should

detailed

proper

major

engine.

and

guidance

marine

be

undertaken

components

A1

operat-

In-

reas-

of

engine

The

Additional

included

manual. Any

replacements

genuine

Westerbeke

operating

in

the

characteristics

Operation

should

parts.

Section

be

made

of

only

are this

with

A2

GENERAL SPECIFICATION DATA

ENGINE - Diesel 1.8 litre

..••...................

Type

Number

Bore Stroke Capacity

Injection

Valve operation Compression ratio Torque (gross)

of

cylinders

.......•

'

..............

..•...................

..........•.....•.•.•

order

................

...............

................

.•.....•.....

.............

Crankshaft

Main journal diameter

Minimum regrind diameter Crankpin journal diameter

Minimum regrind diameter Crankshaft end-thrust

Crankshaft end-float

..........•..

Main bearings

type

Number and

..............

Length: Front, centre and rear

Intermediate

Diametrical clearance Undersizes

.... ' ..............

Connecting rods

Type

....•..................

Length between centres

Big·end bearings

.••.••..•..............

Type

Length

.....................

Diametrical clearance Undersizes

..................

Gudgeon pin

Type

...•••.................

Fit in piston

Fit

in connecting rod

Diameter (outer)

.................

.•.............

Pistons

..•••.•................

Type Clearances:

Top land Bottom

Bottom

Oversizes

..................

land

....•...........

of

skirt

.............

...................

Piston rings

Compression:

Type: Top

,Width

Fitted gap:

•...•....•..•....

Second

..............

....................

Top

.....•........

Second

to

Ring

groove clearance: Top

Oil control

Type

....................

Fitted

gap

.................

to

Ring

groove clearance

...........

........

..•......

•...........

•..•.......•

...........

......•....

.....•......

...........

Second

.......

.. . •..

...

..

18V----D

4

.

3.16 in (80.26

3.5

109.8 in

.

1,3,4,2

.

Overhead

21.47:

. .

79'lbf

2.1262

.

2.1162

. .

1.8759

1.8659

Taken

in

(88.9 mm)

ft (10.92 kgf m)

on

mm)

3

(1799 cm

by

3

push-rod

)

1

at

2,400 rev/min

to

2.1270 in (53.992

to

2.1170 in (52.742

to

1.8764 in (47.64

to

1.8664 in (47.39

thrust washers at centre main

bearing

0.001

to

0.0055 in (0.025

.

5 Steel backed lead indium

to

1.120

0.760

0.001

. .

0.010 in (0.25 mm)

1.130 in (28.45

to

0.770 in (19.30

to

0.0027 in (0.03

to

to to to

Horizontally split big-end, plain small end

6.220

to

6.222 in (157.9

to

Steel backed lead indillm

.

0.775

to

0.001

0.785 in (19.68

to

.

0.010

0.0027 in (0.03

in (0.25

mm)

to to

Fully floating with circ1ip location

.

0.0001

to

0.0003 in (0.002

clearance

.

0.0002

to

0.0009 in (0.02

to

clearance

to

0.9998

1.0000 in (25.39

Aluminium alloy, solid skirt, with open

combustion cavity

.

0.0171

0.0137

.

0.004

.

0.020 in and 0.040 in (0.51 mm and 1.02

to

0.0211 in (0.43

to

0.0172 in (0.35

to

0.005 in (0.10

to to

to

0.13 mm)

mm)

Chrome-faced Tapered, cast iron alloy

.

0.0771

.

0.012

0.009

.

0.0025

.

0.0015

. . .

to

0.0781 in (1.96

to

0.017 in (0.30

to

0.014 in (0.23

to

0.0045 in (0.06

to

0.0035 in (0.04

Slotted scraper

0.012

to

0.0015

0.017 in (0.30

to

0.0035 in (0.04

to

0.43 mm)

to

0.35 mm) to to

to

0.43 mm) to

to

54.012 mm)

to

53.762 mm)

to

47.65 mm)

to

47.40 mm)

0.139

mm)

28.70 mm)

19.55 mm)

0.07

mm)

158.0 mm)

19.93 mm)

0.07 mm)

to

0.007 mm)

0.04

mm)

to

25.40

mm)

0.57 mm)

0.44

mm)

1.98 mm)

0.11 mm)

0.09 mm)

Camshaft

Journal diameteIS:

Bearing liner inside diameter (reamed

after fitting): Front.· Centre

Rear Diametrical clearance End-thrust End-float

Rocker gear

Rocker shaft diameter Rocker bush inside diameter (reamed in

position)

.•..................

...................

••...................

...................

Front Centre Rear

•..........

......••.......•...

..................

.•..........

...........

.........

..•......

.

1.78875

1.72875

1.62275

1.79025

.

1.73025

1.62425

0.001 Taken on locating plate

.

0.003

.

0.624

.

0.6255

to to to

to

0.002 in (0.02

to

0.007 in (0.08

to

0.625 in (15.85

to

1.78925 in (45.43

1.72925 in (43.91

1.62325 in (41.22

1.79075 in (45.47

1.73075 in (43.95

1.62475 in (40.26 to

to

0.6260 in (15.89

to

45.44 mm)

to

43.93 mm)

to

41.23 mm)

to

45.48 mm)

to

43.96 mm)

to

40.27 mm)

0.05 mm)

0.18 mm)

15.87 mm)

to

15.90 mm)

A3

Tappets

Valves

Valve guides

Valve springs

................•......

Type Outside diameter Length

Seat Head diameter: Inlet Stem diameter: Inlet Stem Valve lift: Inlet and exhaust

Valve:

Length: Inlet and exhaust Outside diameter: Inlet and exhaust Inside diameter (reamed after fitting):

Fitted height above spring seat: Inlet Interference fit in head: Inlet and

Free length

Fitted length . . . . . . . . . . . . . . . . . .

Load

Load Number

...

angle: Inlet

to

guide clearance: Inlet

Stand down

Inlet and exhaust and exhaust

exhaust

at

fitted length

at

top

of

..............

','

••...•..•........

....••..........

Exhaust

..........•.•......

• . . . . . . . • . . . . . . . . . .

of

working coils

•..••........

.•.....•.•...

Exhaust

.....••......

Exhaust

.••••.........

..•..........

................

............

lift

.•.•..•.......

..••.•....

.•.•.•....

......

Exhaust

.......

....•....

.........

...

Bucket

.

0.8125 in (20.65 mm)

1.495

to

1.505 in (37.97

45° 45°

1.434

to

1.207

0.3428

0.3422

.

0.0008

.

0.0014

.

0.384 in (9.75 mm)

0.0445

2.22

0.5635

0.3441

0.55

.

0.0005

1.92 in (48.77 mm)

1.44 in (36.57 mm) 821bf

.

1421bf (64.4 kgf, 631 N)

.

4Ya

1.439 in (36.42

to

1.212 in (30.64 to to to to

to

in

(56.39 mm) to

to

0.56 in (13.9

to

(37.19 kgf,

to

364

to

14.2

N)

0.3433 in (8.71

0.3427 in (8.69

0.0020 in (0.02

0.0026 in (0.03

0.0505 in (1.13

0.5640 in (14.31

0.3448 in (8.74

0.00175 in (0.01

38.23 mm)

36.55 mm)

30.78 mm)

to

8.73 mm)

to

8.70 mm)

to

0.05 mm)

to

0.06 mm)

to

1.28 mm)

to

14.33 mm)

to

8.76 mm) mm)

to

0.04

mm)

Valve timing

Timing marks

Rocker clearance: Running

Inlet valve: Opens

Exhaust valve: Opens

Lubrication

System System pressure: Running

Oil pump

Oil filter

Oil pressure relief valve

Relief valve springs: Free length Load

...•..................

at

........•.......•

Timing

..•.....••.....

Closes

...•..•........

Closes

.....•..............

........•.•..........

fitted length

Fitted length

...........

.••.........

.••..........

.......

........

..........

....

...

..

Dimples

0.017 in (0.43 mm) cold

.

0.024 in (0.61 mm) 8° B.T.D.C.

42° A.B.D.C.

.

60° B.B.D.C. 12° A.T.D.C.

Wet sump, pressure fed

.

Between

pressure

Rotor Full flow; disposable cartridge 50lbf/in2 (3.52 kgf/cm

.

3 in (76 mm)

.

2.156 in (54.77 mm)

.

15.5

on

flywheel

type

to

16.51bf (7.0

timing wheels, marks on

idle

will

and

running

vary

2

)

to

7.4 kgf, 69

from

type

speed

45-85

to

73

the

psi.

N)

A4

FUEL SYSTEM

Fuel injection

Type Injection timing

Fuel lift

Fuel injectors

Nozzle Nozzle holder Opening pressure . .

Main fuel filter

Type

Heater plugs

Champion

pump

...........•.........

pump

type

....................

.............

......•..........

..•....•.........

................

type

.......•.........

......•...........

. . . . . .

...........

..........

TORQUE WRENCH SETTINGS

Cylinder head Rocker bracket Manifold Big-end Main bearing set screws Flywheel bolts Timing cover bolts: ~ in

Rear plate bolts: Camshaft

Crankshaft Idler gear Cylinder side cover set screws Rocker cover

.

Sump bolts

. Oil filter

Oil

pump Oil release valve Starter Clutch

to Fuel lift Injector nozzle Injection Injector nuts

Injection Water

pump pump

Water Alternator Thermal

nuts

....•...•...•......

...•.....•..........

..•................

fe-

-&

nut

...................

bolt

.................

hub

bolt

nuts

....•................

adaptor

nuts

........•..........

motor

bolts

flywheel

pump

nuts

nut

pump

nuts

...................

pump

driving flange bolts pulley set screws.

pulley

transmitter

•..••.•.........

..............

............

...........

fe-

in

...........

in

.............

in

.............

....•.••........

...............

................

domed

nut

....•...........

......•.........

•....•..........

...............

..............

................

nut

.............

..............

........

set

........

..•....

screws

..

C.A.V DPA

.

18° A.C. Mechanical C.A.

.

BDN.OSPC.6651

.

BKB.35SD.5188

135 Atm

.

C.A.V.

.

FS5836B130

AG32

1bf

75

.

25 15

35

.

75

40

.

14

.

30

.

20

.

30

.

65

.

75

30

.

4

.

4

6

.

30

16

.

45 35 25

12

.

50

.

18

.

12 10

.

17

.

18

.

27

.

16

B.T.D.C.

V.

Pintaux

ft

kgfm

10.4

3.5

2.1

4.8

10.4

5.5

1.9

4.1

2.8

4.1

9.0

10.4

4.1

0.5

0.8

4.1

2.2

6.2

4.8

3.5

1.7

6.9

2.5

1.7

1.4

2.3

2.5

3.7

2.2

Nm

102 34 20 47

102

.54

19

41

27

41

88

101

41

5

8

41

22

61 47 34

16

68 24

16 14

23 24 36 22

TRANSMISSIONS

Type Type Short Paragon Warner Propeller

ENGINE

COOLING

SAO

Westerbeke/Paragon

SAOV

with

Profile

Hydraulic

rotation

MOUNTS

Type

.•.•.••••..•..•••.••••.•

SYSTEM

Type

•..•••..•••..•..••••.••••

Thermostat

Water

Capacity

RVIOS

Sailing

Setting

(Fresh)

Vee

Gear

is

left

...••..•.••

..•.•••

Manual

Drive

hand

except

Warner

Flexible

Centrifugal

82C

(180F)

7

Quarts

1.91

Adjustable

Pump,

to

1

Thermostat

FUEL

INJECTION PUMP HUB

Remove and refit 12.10.26 Fuel injection pump gear I

to

and 12

Removing

1 Remove

12.65.14.

2 Remove the injection pump, see

19.30.07.

3 Remove the four bolts from

injection pump driving flange.

4 Withdraw the driving flange and

collect 5 Withdraw 6 Remove the injection pump drive oil

feed pipe. 7 Remove the countersunk screw from

the injection pump hub. 8 Remove the upper bolt from the chain

vibration damper. 9 Remove 10 Remove the hub gasket. 11

Remove

hub. Refitting

I 2 Reverse

13

Ensure

located in its groove in the splined

bore

flange. 14 Fit one

its groove in the injection pump hub,

and position

mm) peg through the timing hole in

the locating plate and

hole in 15

Fit the second locating half plate and

then

the driving flange timing hole with the

peg.

16 Fit and tighten the driving flange bolts

to ensure from

bolts with their lock plates. 17 Fit the timing chain, see 12.65.14, 18 Fit the injection pump, see

18 12.10.25

the

timing chain, see

the

two locating half plates.

the

injection pump gear.

the

injection pump hub.

the

oil pipe union from the

the

procedure in 5

that

the

of

the injection pump driving

of

the locating half plates

it

by inserting a n in (5.5

the

gear.

fit

the driving flange, engaging

10

Ibf

ft

(1.4

that

the

peg can be withdrawn

timing hole and lock

circlip

into

kgf

to

5

to

II.

is

correctly

the timing

m,

14 Nm);

19.30.07.

the

to

the

OIL

PUMP

3

9

/'

/ 3

z~

SHe

"'53

Remove and refit

Oil pump

Removing

1 "'A'

2 Drain the sump. 3 Disconnect the oil cooler pipe from

the

4 Release the oil pipe

gearbox mounting plate and move the oil pipe aside.

5 Remove

6 Remove the oil strainer and gasket.

7 Remove the three oil pump securing

nuts.

8 Withdraw the oil pump and its drive

shaft.

9 Withdraw the drive shaft from the oil

pump.

10 Remove the oil pump gasket.

Refitting

II

Reverse the procedure in 1 tightening the oil pump securing nuts to

TAPPETS

Remove and refit 12.29.57 Camshaft 1

Service tool: 18G 694 Removing

1

NA

2 Drain the sump.

3

<NA

4 Remove

camshaft gear, see 12.65.12. 5 Remove the camshaft locating plate. 6 Remove the fuel lift pump. 7 Remove the rocker cover and gasket. S Slacken evenly and remove the eight

nuts retaining the rocker shaft

brackets. 9 Remove the locking plate from the

rocker shaft rear bracket. 10 Remove the

the shim under each centre bracket.

II

Withdraw the push-rods and retain

their order for refitting.

DRIVE

LH

side

the

161bf ft (2.2 kgf

to

the

SHAFT

of

the crankcase.

sump.

17 and

timing chain and the

~·ocker

12.10.30

12.60.26

clip.

from the

to

10,

m,

22 Nm).

20

to

32 12.13.02

shaft assembly and

~AJ(~

/c'

~Lo

:

@

18

.(Ii~"~

0 •

fl)

o 0

0 •

17

~I

.---J

,

~t"~

--WLI

f~

5NC"30

>

U1

~

0)

I 2 Lay 13 Withdraw the dipstick.

14 Remove the sump. 15

16

17 18 Withdraw the tappets and retain their

Refitting 19

20 21

22 23 Fit the dipstick. 24

25 26 Fit the rocker shaft assembly, noting:

27 28 Fit 29

30 31

32 33 Run the engine for a minimum

the

engine

on

cylinder head slightly downwards.

Remove the oil pump and its drive

shaft.

Rotate

the camshaft tappets away from their cams. Withdraw

order for refitting.

Fit towards Fit the camshaft. Fit the oil tightening the retaining nuts

ft

Fit the sump. Place

position. Fit

a Ensure b Fit the locking pia te c Tighten

d Tighten the rocker bracket nuts

Fit the fuel lift pump. Fit the camshaft gear, timing chain,

and timing gear cover, NOTE: Do pulley in position. Adjust the valve rocker clearance, see

12.29.48. Fit the rocker cover and its gasket.

the

tappets with their open ends the

cylinder head. pump

(2.2 kgf

m,

the

the push-rods.

both

under bracket. 75 Ibf ft

the sequence shown, using 18G

694

to

25 Ibf ft (3.5 kgf

the

camshaft locating plate.

its side with

to

position all

camshaft.

and

its drive shaft,

22

Nm).

engine in an upright

that

the

shim

centre brackets.

the

cylinder head nuts

(l0.4

kgf m, 102 Nm) in

to

reach

the

m,

not

see·12.65.12.

leave the crankshaft

NA

or

75lbfft

I 5 mins and

1

of a turn

(lO.4kgfm,

miles, 8 km slacken the cylinder head nuts approximately sequence shown before retightening them

to in the sequence shown. Check the valve rocker clearances.

the

to

16 Ibf

is

fitted

to

the rear

tool

centre row.

34

Nm).

of

on

return

in the

102 Nm)

14

CAMSHAFT BEARINGS

Remove

Service tools: 18G 55

123 18G 123 T, 18G 123 AB, 18G 123 18G 123 AD, 18G 124 124 18G 134 CQ, 18G 284, 18G

284

Removing

to

I

2 Drain the sump.

3

4 Remove the 5 Remove the flywheel. 6 Remove

7 Remove the bolts securing

8 Remove the two 9 Remove the alternator.

10 Remove

II

5

I 2 Remove the timing chain and

13 14 Remove 15

16 Remove the two bolts securing

and

refit 12.13.13

B,

18G 123

C,

18G 124 F, 18G 124

AC, 18G 694, 18G 1108, 18G 1195

E,

18G 123 F, 18G 123

NA

the

retainer. adaptor

plate

off

the

injectors and pump.

Remove the injection pump drive oil

feed pipe. camshaft gear, see 12.65.12.

Remove the camshaft locating plate. Remove the bolt securing each front

mounting bracket front mounting plate

crankshaft rear oil seal

plate and pull the

its two locating dowels.

the

high-pressure pipes from

the

chain vibration damper.

2 5

A,

18G 123

A,

18G 124

adaptor

to

the crankcase.

to

the crankcase.

12

A,

18G

L,

AC,

B,

18G 134,

A,

the

gearbox

adaptor

18G 18G

the

H,

284

plate gaskets.

17 Lift

18 Remove 19 Withdraw

20

21 22

23 Remove the rocker shaft assembly,

24 25 Remove the cylinder head nuts.

26 Lift

27 28

29 30

31 32

33 Lift 34 Withdraw the connecting rod 35 Rotate 36 Withdraw the camshaft.

37 Withdraw the tappets and retain their

"38

39

40

off

the

front complete with injection pump, front mounting brackets, chain tensioner stop-pin,

Release the dipstick

cylinder head tube Disconnect and remove No. I heater plug.

Remove

noting the locking plate

bracket and

centre bracket. Withdraw

their order for refitting.

NOTE: inserts may

head as it

refitted in their original positions.

Remove Lay the engine

cylinder head face slightly downwards.

Remove Remove the oil

shaft.

Remove

bearing halves.

Remove

bearing halves, using tools 18G 284,

18G

the

piston assemblies. tappets away from their cams.

order for refitting. Remove the camshaft front bearing liner, using tools 18G 124 A and 18G 124 F Remove liner, using tools 18G 124 A and 18G I Remove the camshaft centre bearing liner, using tools 18G 124

C,

and

chain tensioner shoe.

the

fuel lift pump.

the

from

the

rocker cover and gasket.

the

off

the

cylinder head.

The

drop

is

the

cylinder head gasket.

the

sump.

the

big-end bearing caps and

the

284

A,

and 18G

out

the

bearing and

the

camshaft

as

shown.

the

24 B as

shown.

and

18G 124 H as shown.

mounting

dipstick.

crankcase.

the

main bearing caps and

crankshaft and remove

tube

nut

and withdraw

shim

push-rods, retaining

combustion chamber

out

of

lifted; they MUST be

on

its side with

pump

and its drive

284

thrust

washer halves.

to

position all the

camshaft rear bearing

plate,

from

the the

on

the

A,

18G 124

rear

each

the

and

under

the cylinder

AC.

IBGI24F

,

INC49BC

IBGI24B

i

INC497C.

IBGI24C IBGI24H

INC496E

Refitting NOTE: When fitting each new bearing liner ensure

that

its oil holes are lined up with

those in the crankcase.

41 Fit a new camshaft front bearing liner,

using tools I

SG

124 A and ISG 124 F

as shown.

42

Fit a new camshaft rear bearing1iner, using tools 18G 124 A and 18G as

shown.

i

24

43 Fit a new camshaft centre bearing

liner, using tools C,

and ISG 124 H

ISG 124

as

shown.

A,

ISG 124

NOTE: Lightly lubricate the arbor before

to

assembling the cutters and pilots

Feed the reamers very slowly and keep

it.

the

cutters dry.

Keep the reaming. .

44

45

46 Ensure that the oil holes

cutter

flutes clear

of

swarf during

Ream the front and rear bearing liners using tools

ISG 123 E (in position arbor), position

1 23

AC Ream the centre bearing liner, using tools 123 F (in position

ISG 123

and

ISG 123

'6'

on

as

shown.

ISG 123

AD

A,

ISG 123

'10'

on

AB,

ISG 123 B (in

the

the arbor), and ISG

A,

18G 123 T, ISG

'9'

on

the

arbor),

as shown.

of

the

L,

bearing liners are still lined up with those in the crankcase.

47

Thoroughly clean all swarf from

the

cylinder block and crankcase.

4S Fit the tappets with their open ends

towards the cylinder head.

49

Fit the camshaft.

50 Fit the connecting rod and piston

assemblies with the combustion cavities using tool

the R.H. side

ISG

55

A.

of

the engine,

on

5 I Fit the crankshaft main bearings, and

thrust washers (grooved side towards

to

the crankshaft)

52 Fit

the

main bearing caps, noting:

the crankcase.

a Caps Nos. 2 and 4 are each

stamped with their number.

the

b Fit caps 2, 3 and 4 with

word

'FRONT' towards the front

of

the engine.

c Using a straight-edge, align

cast

t,he

front and rear bearing caps with

of

the front and rear faces

the

crankcase.

B

18GI24C

18GI24H

d Tighten the main bearing bolts

75 Ibf ft

(l0.4

kgf

53 Check the crankshaft end-float against

the figure in DATA, and fit alternative

if

thrust washers

necessary.

54 Fit the big-end bearings and caps,

ensuring that the connecting rod and cap markings are aligned.

55

Tighten the big-end nuts (4.S kgf

m,

47

Nm).

56 Fit the oil pump and its drive shaft,

tightening the retaining nuts

m,

22

fit

them

Nm).

to

the front and rear

ft (2.2 kgf

57

Soak the cork sealing strips in engine oil, then main bearing caps.

58 Fit the sump.

m,

102 Nm).

to

INC495C

I

INC494£

INC493E

35 Ibf ft

to

16 Ibf

to

18GI23AC

18G

123AD

59 Position the front mounting plate

assembly on the engine and locate it by fitting the camshaft locating plate bolts and the chain tensioner retaining

screw.

Fit the two bolts

60

mounting plate Fit the two bolts

61

mounting brackets Fit the chain vibration damper.

62

Fit the camshaft locating plate.

63 64

Fit the camshaft gear, timing chain,

to

the crankcase.

to

secure

to

the crankcase.

secure

both

the

front

and timing gear cover, see 12.65.12.

NOTE: Do not leave the crankshaft pulley in position.

to

65 Reverse the procedure in 18

noting:

a Fit the cylinder head gasket with

the

face

marked

27,

,

'TOP'

uppermost.

b Ensure

that

the combustion chamber inserts are fitted flush with the cylinder head face.

c Leave the cylinder head nuts

finger tight until the rocker shaft assembly has been fitted.

d Tighten the cylinder head nuts

to

75 Ibf ft (10.4 kgf m, 102 Nm) in

the sequence shown, using tool

18G 694

to

reach

the

centre row.

INC492E

18GI23F

18G

123T

INC49tE

e Tighten the rocker bracket nuts

to

25 Ibf ft (3.5 kgf

f Adjust the valve rocker clearance,

see 12.29.4S.

to

g Apply Loctite

the

the dipstick tube.

66 Reverse the procedure in 4

noting: a

Use

tools 18G 134 and 18G 134

CQ

to

b

fit the new rear oil seal.

Use

tool 18G

11

OS

to seal 'when fitting the adaptor plate.

c Tighten the adaptor plate bolts

30 Ibf ft (4.2 kgf NOTE: Fit the two longer bolts in the two

top

m,

holes.

m,

34 Nm).

bottom

to

protect the

41

Nm).

of

II,

to

»

"'"

l:-

eo

d e

67

Fit

the

DATA

Camshaft

in

position): Front

Centre

Rear Crankshaft Thrust

.....................

washer thicknesses

Tighten

to

Tighten

Ibf ft (5.5

....................

the

oil seal

20

Ibf

ft

(2.8

the

engine.

bearing inside diameters

...................

end-float

kgf

........

retainer

kgf

m,

flywheel

m, 54 Nm).

..•...•....

CONNECfING RODS AND

PISTONS

Remove Service Removing

I

2 Drain 3 Drain 4 Remove

5 Disconnect 6 Release

7 Remove 8 Remove

9 Remove

10 Withdraw II 12 Remove

and

refit

tool:

18G

55 A

NA

the

sump.

the

cooling system.

the

12.29.02. the

L.H. side

the

gearbox

the

oil pipe aside.

halves. piston assemblies.

Mark

for reassembly. pins

and

connecting

cylinder head gasket, see

the

of

the

oil mounting

the

sump.

the

big-end nuts.

the

big-end caps

the

pistons

the

circlips

separate

rods.

oil

cooler

the

crankcase.

cooler

pipe clip from

plate

connecting

and

connecting

and

the

pistons from

27

Nm).

bolts

(reamed

.

12.17.01

pipe from

and

bearing

rod

the

gudgeon

bolts

to

40

. . .

move

and

rods

the

68

Run

the

engine for a

slacken approximately t of a turn sequence them

to Nm) in the

valve

1.79025

1.73025

1.62425

0.001

0.0885

0.091

0.0935

12

to

to to to

0.0055

0.093

1.79075 in

1.73075 in

1.62475 in

0.0905

0.0955

I 5 mins

the

cylinder head

shown

75

Ibf the rocker

ft

sequence shown. Check

clearances.

in (0.03

in (2.25

in (2.31

in

(2.37

~

13a

minimum

before

(10.4

(45.47 (43.95 (40.26

to

0.14

to

2.36

to

and

on

return

in

retightening

kgf

m,

to

45.48

to

43.96

to

40.27 mm)

2.30

mm),

mm)

2.43

and

mm)

13a

4NC09lA

of

nuts

the

102

mm) mm) mm)

Refitting

13 Reverse

noting: a Assemble

b

c Use d

If

14

have crankshaft by the

IS

If

limits given in DATA, fit suitable alternative piston(s) from available. NOTE: pistons in height grade.

16

Tighten (4.8

17 Reverse

DATA

Piston

the

connecting combustion hole side

If

new

piston ensure correct,

the Fit assemblies with cavities

engine.

the

which each

cylinder

piston

kgf

stand-proud

that

see 12.17.10.

tool piston the

connecting

on

connecting

been

and

block

stand-proud

It

is

an

the

big-end

m,

47

the

procedure

the

of

18G 55 A

rings.

the

renewed,

measure

piston

not

engine

Nm).

in 8

pistons

rods

cavities

the

connecting

rings are being used

the

ring gaps are

to

rod

the

R.H. side

rods

or the

stands

face

at

T.D.C.

is

necessary for

to

be

nuts

in I

on

combustion

rotate

outside

of

to

with

the

rods.

compress

and

piston of

piston(s)

amount

proud

the

range

the

same

35

Ibf

7.

12, the

the

oil

the

of

the

ft

0.013

to

0.021 in

(0.33

to

0.53

mm)

CONNECTING RODS AND PISTONS

Overhaul 12.17.10 Connecting rods 1 Pistons 1

I

2 Drain 3 Drain

4 Remove the cylinder head gasket, see

5 Remove and separate 6 Remove

7 Check

S Fit

DATA Connecting

Maximum out-of-parallel

Connecting

Clearance Inside diameter (reamed

Piston rings

Fitted

Ring

to

NA

the

12.29.02.

rods and pistons, see 12.17.0

the

unworn

against

necessary, increase the

end

of

the

piston rings, noting:

a Fit

spring first, ensuring latch pin enters spring.

b Fit

gap

pin.

c Fit the second ring with

'TOP'

rod

little-end

rod

on

gap:

Top

compression Second compression . Oil

control

to

groove clearance:

Top

compression Second compression Oil

control

to

9 and 12

sump. cooling system.

the

part

the

the ring(s).

the

ISOo from

uppermost.

alignment

..................

bush

gudgeon.pin

5 and 10

the

rings from

jJiston ring gaps, in

of

figures'

oil control ring

oil

........

................

the

both

control

the

after

............

..........

the

cylinder bore, in DAT gap(s)

expander

of

to

12

connecting

I.

pistons.

ends

ring with its

big-end and

........

fitting)

.

an

A.

If

by

filing

expander that

the

of

the

latch

the

word

..

CRANKSHAFT

Remove Gearbox Flywheel I

~r1I'·

O;=II~~

J~LJ~

) B

9 Check

against

10 Check the gudgeon pin clearance in

the connecting rod bush (see DATA).

If

bush, noting:

a Position b Finish-ream

II

Ensure alignment DATA.

12 Reverse

.

0.004 effective mandrel length

.

0.0002

1.0002

0.012

0.009

0.012

.

0.0025

.

0.0015

.

0.0015

o~

the

piston ring groove clearance

the

figures in DATA.

the

clearance

and oil grooves towards the top.

dimension given in DATA.

the

in per inch

to

0.0009

to

1.0007 in (25.41

to

0.017 in (0.30

to

0.014

to

0.017 in (0.30

to

0.0045 in (0.06

to

0.0035 in (0.04

to

0.0035

is

excessive, renew

the

bush with its hole

the

that

the

is

within

procedure in I

(0.004

in

(0.02

in (0.23

in (0.04

bush

connecting

the

figure given in

cm per

to

0.04 mm)

to

25.42 mm)

to

0.43 mm)

to

0.35 mm)

to

0.43 mm)

to

0.11 mm)

to

0.09 mm)

to

0.09

to

cm)

5.

mm)

4NCQ1,

to

the

rod

Service tools:

IIOS

Removing

I

2 Remove 3 Remove 4 Remove 5 Lift 6 Remove 7 Remove

S Pull

9 Remove

10 Remove

Refitting II

12 Reverse

and

NA

off

gearbox

the

locating dowels.

plate.

Fit

the

face

of

ISG 134 and ISG 134 CQ.

noting: a

Use tool ISG oil seal when fitting plate.

b Tighten

30lbfft NOTE: Fit in

c Tighten the oil seal retainer bolts

to

d Tighten

Ibf ft (5.5 kgf

REAR

refit 12.21.20

adaptor

to 8 and

ISG

134, ISG 134 CQ, ISG

the

gearbox.

the

dllllller

the

flywheel securing bolts.

the

flywheel.

the

oil seal retainer.

the --bolts securing

adaptor

the

two

the

oil seal from

new oil seal flush with

the

adaptor

the

procedure in I

the

(4.2

the

two

20

Ibf ft (2.S kgf

the

OIL

plate 12.53.03

IS

plate.

plate

off

adaptor

the

top

plate gaskets.

the

plate, using tools

II

OS

to

protect

the

plate bolts

kgfm,

41

two longer bolts

holes.

m,

flywheel bolts

m,

27 Nm).

54 Nm).

SEAL

12.53.07

its

two

adaptor

the

rear

to

adaptor

Nm).

to

the

10,

the

to

40

S,.,C

~18A

l>

CD

CRANKSHAFT

Check

and

1

NA

2 Check

dial gauge against pulley limits given in DATA, change thrust

following paragraphs. 3 Drain 4 Release thtl. oil

5 Remove

6 Remove

7 Remove 8 Remove

9 Remove

10 Slide

11

12 Reverse

DATA Crankshaft end-float Thrust

the

gearbox oil

pipe

shaft.

main bearing cap.

thrust crankshaft.

the washers them. Select a the

correct

noting: a

Fit grooved crankshaft.

b

Fit 'FRONT' of

washer thicknesses

END-FWAT

adjust

the

crankshaft

bolt.

If

end-float is

washers as described in

sump.

mounting

aside.

the

washers from

around

set

the

pipe

plate

sump.

oil

pump

two

bolts

centre

bottom

upper

halves

the

crank

of

thrust

end-float

procedure

thrust

washers

sides towards

main bearing

mark

engine.

..............

main bearing cap.

(see DATA).

towards

12.21.26

end-float using a

the

crankshaft

outside

clip from

and

from

halves

the

of

and

washers

in 3

cap

..........

move

its drive

the

centre

of

cap

the

thrust

remove

to

with

the

front

the the the

the the

the

or

give

10,

their

the the

»

...

o

33

SNC4778

c Tighten

bolts 102

d Ensure

correct bearing

e

Tighten nuts

Nm).

.

0.001

to

.

0.0885

0.091

0.0935

to

0.0055

0.0905

0.093

0.0955

to

75

Nm).

that

after

cap

the

to

16

in (0.03

in

in (2.31

in

the

main bearing

Ibf

the

tightening

bolts.

oil

Ibf

ft

to

(2.25

to

(2.37

ft

(lOA

end-float

pump

(2.2

0.14

to

2.30

2.36

to

2.43

the

securing

kgf m,

mm)

kgf

and

cap

m,

is

main

22

CRANKSHAFT

Remove

Service tools: 18G 134, 284,

Removing

1

2 Drain 3 Remove 4 Remove

5 Remove 6 Remove

7 Remove

8 Remove

and

18G284AC,

NA

the

the the the

off

the

plate

its

the

retainer. adaptor

plate

refit

18G

sump.

engine.

daMper

flywheel.

crankshaft

bolts

and

two

locating dowels.

two

adaptor

18G

1108,

securing

pull

12.21.33

134

CQ, 18G

18G

1195

rear

oil seal

the

gearbox

the

adaptor

plate gaskets.

9 Remove

10

Disconnect from

II 12 Remove

13 Remove 14 Remove

IS Remove 16 Remove 17 Lift

18 Withdraw 19 Remove

the

Remove

feed pipe. camshaft gear, see

mounting front

mounting

off complete mounting stop-pin,

the

alternator.

the

injectors.

the

the the the

bracket

the

the with

and

the

high-pressure pipes

injection

timing chain and

camshaft locating plate. chain vibration damper. bolt securing each

two

front

brackets, chain

chain tensioner shoe.

dipstick.

sump.

pump

12.65.12.

to

the

crankcase.

bolts securing

plate

to

the

mounting

injection

pump,

drive oil

the

front

the

crankcase.

plate,

front

tensioner

20

Remove

shaft.

21

Remove the big-end bearing caps and bearing halves. NOTE: rotated, be careful not to apply any force which could cause damage piston touches a valve.

22 Remove the main bearing caps and

bearing halves, using tools 18G 284 and 18G 284 caps if necessary.

23 Lift

the bearing and thrust washer halves.

24

Remove the crankshaft gear.

25 Remove the crankshaft keys and lift

off

Refitting 26 Fit the shim(s}, keys and gear

crankshaft.

27 Fit the crankshaft, main bearings, and

thrust washers (grooved side towards the crankshaft)

28 Fit

a Caps Nos. 2 and 4 are each b Fit caps 2, 3, and 4 with

c Using a straight-edge, align the

d Tighten the main bearing bolts

29 Check the crankshaft end-float against

the figure in thrust washers

30 Fit the big-end bearings and caps,

ensuring that the connecting rod and cap markings are aligned.

31

Tighten the big-end nuts to 35 Ibf ft (4.8 kgf

DATA Main

journal diameter Crankpin diameter Clearance in bearings Uournals and crank-

pin} Undersizes Uournals and crankpins} Crankshaft end-float

Thrust washer thicknesses

the

oil pump and its drive

If

the crankshaft has

AC

on

the front and rear

out

the crankshaft and remove

the

shim(s}.

to

the

main bearing caps, noting: stamped with their number. word 'FRONT' towards the front

of

the engine.

front and rear bearing caps with the front and rear faces crankcase.

751bfft

.••.......••.••..•......

m,

(l0.4

OAT

47

crankcase.

kgf m, 102 Nm).

A,

and fit alternative

if

necessary.

Nm).

.............

.•.•.•....•.....

..•••..........

..........

to

the

of

.....

if

the

cast

the

32 Fit the oil pump and its drive shaft,

tightening the retaining nuts

ft (2.2 kgf m, 22 Nm).

33 Soak the cork sealing strips in engine

be

a

to

.

oil, then fit them main bearing caps.

34 Fit the sump.

35 Fit the dipstick.

36 Position

assembly on by

fitting the camshaft locating plate bolts and the chain tensioner retaining screw.

37 Fit the two bolts to secure the front

mountig plate

38 Fit the two bolts

mounting plate

39 Fit the chain vibration damper.

40

Fit the camshaft locating plate.

41

Fit the camshaft gear, timing chain, and timing gear cover, see 12.65.12. NOTE: pulley in position.

42

Reverse the procedure in 4 to noting: a

b

c Tighten the adaptor plate bolts

d Tighten the oil seal retainer bolts e Tighten the flywheel bolts

2.1262 to

1.8759

0.001

0.010 in (0.25 mm)

0.001

0.0885

0.091

0.0935 to 0.0955 in (2.37

00

Use

tools 18G 134 and 18G 134

to

CQ

Use

tool seal when fitting plate.

30 Ibf ft (4.2 kgf

NOTE: Fit the two longer bolts

in the two top holes. to

20

Ibf ft (5.5 kgf m, 54 Nm).

2.1270 in (54.01

to

1.8764 in (47.64

to

0.0027 in (0.03 to 0.07 mm)

to

0.0055 in (0.03

to

0.0905 in (2.25

to

0.093 in (2.31

to

the

front mounting plate

the

engine and locate it

to

the crankcase.

to

secure

to

the

not

leave the crankshaft

fit

the

new rear oil seal.

18G 1108

Ibf

ft (2.8 kgf

to

161bf

front and rear

both

crankcase.

to

m,

41 Nm). .

m,

to to

0.14 mm)

to

2.30 mm),

2.36 mm) and

to

2.43 mm)

front

protect

the

adaptor

27 Nm).

to

54.03 mm)

47.66 mm)

OIL

PUMP

Overhaul

Dismantling I Remove the oil pump, see 12.10.30. 2 Remove the cover from the pump

body. NOTE: The dowels.

3 Remove the rotors from the pump

body.

Inspection 4 Clean the components. 5 Fit the rotors

the chamfered end

at

the closed end

6 Check the end-float

outer rotors.

7 Check the

diametrical clearance. 8 Check the rotor lobe clearances. 9 Renew the pump assembly if

II,

the

to

40

clearances exceed the figure given in

Reassembling 10 Lubricate all components with clean

engine oil.

II

Reverse

ensuring that the

with its chamfer

the body.

DATA Outer rotor end-float Inner rotor end-float Outer

rotor

clearance

Rotor lobe clearance

cove.r

is

to

the pump body with

of

the body.

outer

rotor

or

end-floats in 6

the

procedure in I

outer

at

the closed end

.••.•.........

to

•••.••...••..........

.••.• ~ ..•......

pump body diametrical

...••..••.....•

12.60.32

located by two

the

outer

rotor

of

the inner and

to

pump body

to

OAT

A.

is

to

fitted

rotor

the

3,

of

8

0.005 in (0.13 mm)

0.010 in (0.25 mm)

0.006 in {0.15

~

'HC4MA

~lIIl

mm}

»

~

»

....

I\)

ENGINE PLATE

Remove

Removing

I Remove

2 Remove 3 Remove

4 Remove

5 Disconnect 6 Disconnect 7 Disconnect 8 Disconnect 9 Disconnect

FRONT

MOUNTING

GASKET

and

refit

the

camshaft gear, see 12.65.12.

and

move

heater

plugs.

the

injection

the

injection

from

the

timing chain

the

camshaft locating plate.

the

chain vibration damper.

the

alternator.

the

wiring harness aside.

the

supply

the

fuel

pump.

the

fuel supply pipe from

pump.

the

injection

16

thermal

return

stop

pump.

16

12.25.10

and

transmitter

lead from

pipe from

control

the

cable

10 Disconnect

injection

lever.

II

Remove the injection feed pipe.

12 Disconnect

from

13 Remove

securing the front moullting plate the

14 Lift

crankcase.

complete mountings, chain tensioner stop-pin, and

the

throttle

pump

the

injectors.

the

off

the

with injection

chain tensioner shoe.

high-pressure pipes

two

bolts

front

mounting

cable from

and

pump,

IS.,

16 NA 17'/

the

drive oil

washers

to

plate,

front

18 Remove

gasket

Refitting 19

Fit

20

Position assembly by bolts

screw.

21

Reverse noting: a With

b When

22 Bleed

the

front

the

front

mounting

the

front

on

the

fitting

and

the

pump through movement

connected, control

the

engine

the

camshaft

the

chain

tensioner

procedure

the

throttle

ensure

that

throttle

the

fuel system, see 19.50.07.

lever its full range by

the

stop

ensure

has sufficient travel

mounting

plate gasket.

mounting

and

locate it

locating

retaining

in I

cable

connected

the

injection

is

operated

throttle

control

that

cable

the

plate

plate plate

to

pedal.

stop

CYLINDER LINERS

Remove

NOTE: bores up

liners can be fitted (see DATA).

Pilots should be made

given, from case-hardening steel

case-hardened.

The

from

hardened

550°C

DATA Cylinder block

Bore:

Cylinder liners n

Outside Bore:

and

refit

If

the

is

such

to

accept oversize pistons, dry cylinder

pilot extension should be

55-ton

(l020°F).

Standard Oversize maximum

To

Standard Oversize

condition

that

they

hardening

in oil,

diameter

and

.•...............

cylinder liner)

accept

cylinder

...........

(machined

(maximum)

cannot

to

and

then

.........

12.25.26

of

the

cylinder

be cleaned

the

dimensions

tempering steel,

tempered at

(without

liner

after

fitting)

........

and

made

.

16,

of

" M

~

J\I

f>

Pilots

Pressing-out pilot:

is

Pressing-in pilot:

Pilot extension:

3.1595

0.040

3.2615

3.2645

3.1595

.

0.020

Q

to

3.1606

in (1.02

to

3.2620

to

3.2660

to

3.1606

in (0.51

· t 1

"'~4ft'

A.

3.25 (82.55'

B.

3.

(80.19

C.

1.75 in

D.

0.75

E.

34

F. 3.625 in G.3.312in(84.14mm)

H.

3.133

(79.58

J. 1.25 in

K.0.75in(l9mm)

L.

0.015

M.

14.50 in

N.

0.875

P.

0.625 in

Q.

0.625

R.

Two mm)

S.

34

T. 1.25 in (31.75

in

(80.25

mm)

in

(82.84

in

(82.92

in

(80.25

mm)

8:~

0·13 0'00

0'000

IS

7

-0'005

:"g:r:

(44.45

in

(19

in B.S.

W. (92.07

, 0'000

-0'005

:::g:r:

(31.75

in

(0.38 (36.83

in

(22.22 (15.87

in

(15.87

flats I in across

in B.S.W.

to

80.28

to

82.86

to

82.96

to

80.28

in

mm)

in mm)

mm)

thread

mm)

in mm)

mm)

em)

mm) mm) mm)

(25.4

thread

mm)

mm) mm)

=&

I;g)

CYLINDER HEAD GASKET

Remove and refit

Service tool: 18G 694 Removing

I

NA

2 Drain the cooling system. 3 Disconnect the hoses from the water

outlet elbow.

4 Disconnect the breather

cylinder side cover.

5

NA

6

Disconnect the lead from the thermal

7

transmi tter. Disconnect the supply lead from the

8

heater plugs.

9

4

C!)

H I

15

~~

~

~i

~

Disconnect the spill rail and return pipe from the injectors and lay the

spill rail aside.

10

Remove Nos. 3 and 4 injector pipes.

II

Remove Nos. Remove the oil dipstick.

12 13

Release the dipstick tube from the cylinder head tube from the crankcase.

14

Disconnect and remove No. I heater

plug.

Remove the rocker cover and gasket.

15

Remove the rocker shaft assembly,

16

noting the locking plate bracket and the shim under each centre bracket. Withdraw the push·rods, retaining.

17

their order for refitting.

Remove the cylinder head nuts.

18

Lift

19

20

off NOTE: The combustion chamber inserts may drop out

as

head refitted in their original positions.

Remove the cylinder head gasket.

I and 2 injector pipes.

nut

and withdraw the

the cylinder head.

it

is

lifted; they ·MUST be

12.29.02

hose from the

on

the rear

of

the cylinder

Refitting 21

Reverse the procedure in l noting:

a Fit the cylinder head gasket with

the

face

uppermost.

b Ensure that the combustion

chamber inserts are fitted flush with the cylinder head face.

c Leave the cylinder head nuts

finger tight until the rocker shaft assembly has been fitted.

d Tighten the cylinder head nuts

75 Ibf ft (10.4 kgf the

sequence shown, using tool

18G 694

e Tighten the rocker brackets nuts

to

25 Ibf

f Adjust the valve rocker clearance,

see 12.29.48.

g Bleed the fuel system, see

19.50.05.

h Apply Loctite

22 Run the engine for a minimum

the dipstick tube:

slacken the cylinder head nuts approximately sequence shown before retightening them

to

Nm)

the

75 Ibf ft (10.4 kgf

in

the sequence shown. Check

valve rocker clearances.

marked

to

reach

ft

(3.5 kgf

to

I 5 mins and

1

of

m,

the

In,

the

a turn in the

12

5

to

20.

'TOP'

on

of

return

m,

to

in

of

102

102 Nm) centre row.

34 Nm).

bottom

~

....

Co)

~

....

~

CYLINDER HEAD

Overhaul

Service tools: 18G 27, 18G 29, 18G 45,

18G 167, 18G 167

C,

18G 174, 18G

174

C,

18G 174

I Remove the cylinder head gasket, see

A,

18G 167

1741\,

D,

18G 284, 18G

12.29.02.

2 Remove the three remaining

plugs from the cylinder head.

3 Remove

284, and 18G

4 Remove

the

injectors, usinl: tools 18G

284

the

P.

two sealing washers from

each injector position.

5 Remove

cylinder head

6 Remove

the

heater hose from

•..

the

manifolds and gasket.

7 Mark the combustion chamber iriserts

for refitting jn their original positions.

8 Remove

inserts,

through

9 Push

their

10 Remove

the

combustion

if

necessary using a soft drift

the

injector holes.

out

the

injector heat shields and

sealing washers.

the

water

outlet

gasket.

II

Lift

out

the

12

Remove components, using NOTE: Seals are fitted valve guides.

13

If

the DATA), press direction

14

To

fit new valve guides, press from until they

thermostat. the

valves and their

tool

valve guides are worn (see

them

of

the

valve seats.

the

top

of

the

protrude

stated in DATA. Protrusion

measured from

guide

to

bore for

15

Ream new valve guides

the

bottom

valve spring.

top

given in DATA.

16 Check

the

cylinder head face for

flatness and, if necessary, reface

cylinder head without reducing its

depth

below

the

figure given in DATA. NOTE:

The

combustion inserts must be faced level with cylinder head

o

12.29.19

B,

18G 167

18G 174

B,

284

heater

chamber

elbow and its

18G

45.

to

the

out

in them

cylinder head

by

the

amount

of

the

of

the

counter

to

the

chamber

18G P

the

inlet

the

in

valve

size

the

is

17

If

necessary, reface the valves

angle given in DATA, removing

18

minimum

If

the

of

material.

necessary, recut the valve seats in

cylinder head, using

the tools: a 18G 27 Handle. b 18G 174 DPilot. c 18G 174 A Glaze breaker for inlet

seats.

d 18G 174

Cutter

for inlet seats.

e 18G 174 B Top narrowing

for inlet seats.

18G 174 C

Bottom

cutter

narrowing

for inlet seats.

\'J{)

to

the the

following

cutter

g 18G 167 A Glaze breaker for

exhaust seats.

h 18G 167

18G 167 B

Cutter Top

for

exhaust seats.

narrowing

for exhaust seats.

k 18G 167 C

Bottom

cutter

narrowing

for exhaust

seats.

19 Lap 20 Check

21

the

valves

onto

tool 18G 29.

the

figure in DATA.

valve stand-down against

their seats, using

If

excessive, even with a new renew

the their seats. Renew

valve seat insert(s) and

the

valve springs

if

stand-down

va1ve

they

as specified in DATA.

22

Renew

the

sealing washers

injectors.

the

23 Renew

sealing washers for

injector heat shields;

24

Reverse

the

procedure in I

to

DATA

Depth

head

after

refacing

Cylinder

Valve guides

Inside diameter (reamed after fitting) Protrusion counterbore)

(from

.................

bottom

Valves

Seat angle Stand-down Stem

..............•.....

..•.....•......•...

diameter: Inlet

Exhaust

............

..•.......

Valve springs

Free length (approximate) Load when compressed

(36.58 mm)

....••.•...•.....

to

........

1.44 in

cutter

fitted,

are

for

12.

cut

not

the the

of

is

3.16 in

0.3441

0.550

.

45°

0.0445

.

0.3428

0.3422

.

I

it

82 Ibf (37.195 kgf,

(80.26

mm) minimum

to

0.3448 in (8.74

to

0.560

in (13.97

to

0.0505 in (1.13

to

0.3422

to

0.3427 in

in (48.75 mm)

in (8.71

(8.69

364N)

to

8.76 mm)

to

14.22 mm)

to

1.28 mm) to'8.73 to

8.70

mm) mm)

VALVE CLEARANCE

Check and adjust 12.29.48

Checking

I Remove the rocker cover

2 Check, and

clearance between the rocker arms and valve stems against the figure in DATA, working in the following order: Check: No. I valve with

3

" 5 4

2 7

" S " I

,,6

4 " 5

" 7 " 2

DATA Valve rocker clearance (cold)

ROCKER

Remove and refit

Service tool: ISG 694

Removing

I

NA

2 Drain the cooling system. 3 Remove the rocker cover and gasket.

Slacken evenly and remove the eight

4

nuts retaining brackets.

5 Remove the locking plate from

rocker shaft rear bracket.

6 Remove

the

shim under each centre bracket.

if

necessary adjust, the

No.8

" 6

,,3

SHAFf

the

ASSEMBLY

the

rocker shaft assembly and

ana

gasket.

valve fully open.

12.29.54

rocker shaft

the

4

2,

I

be...j

Adjusting

Slacken the locknut.

3 4 Rotate the adjusting screw

clearance.

5 Hold the adjusting screw against

rotation and tighten the locknut.

6 Fit the rocker cover and gasket.

0.017 in (0.43 mm)

3

4HC104A

to

set the

'SNC

.,7

Refitting 7 Reverse

noting: a Tighten the cylinder head nuts

b Tighten the rocker bracket nuts c Adjust the valve rocker clearance,

S Run the engine for a minimum

slacken the cylinder head nuts

approximately sequence shown before retightening them

Nm) the

ROCKER

Overhaul 12.29.55

Service tools: ISG 226, ISG 226 A Dismantling

I Remove the rocker shaft, see

12.29.54.

2 Remove the split pin from each

the rocker shaft.

Slide the components

3 4 Remove the locating screw from

rocker shaft rear bracket and remove

the bracket.

5 Remove

Inspection

6 Clean the oilways

7 Examine the rocker to valve contact

faces for wear, and renew the

rocker(s)

S Renew

they are worn

damaged.

Press

9

tools

Reassembling 10 Press in new rocker bushes, using tools

ISG 226 and ISG 226

that in

DATA

Rocker shaft diameter Rocker bush inside diameter (reamed in

position)

the

procedure in I

75

Ibfft

. the sequence shown, using tool

ISG 694

to

see 12.29.4S.

to

in

valve rocker clearances.

out

ISG 226 and ISG 226

the

positions shown.

(10.4 kgf m, 102 Nm) in

to

reach

the

251bf

ft (3.5 kgf

115

mins and

t

of

a turn in

75 Ibf ft (10.4 kgf

the sequence shown. Check

SHAFf

the

bush

.....•....••••.......

ASSEMBLY

off

adjuster screws.

of

the rocker shaft.

if

necessary.

rocker adjusting screws

or

if

the

worn rocker bushes, using

joint

A,

and oil groove are

..••...•••.•..

to

centre row.

rn,

34

Nm).

on

return

rn,

end

the

shaft.

threads

A.

and ensuring

to

of

the

102

of

the

are

6,

13b

I~Q~

2 4 . 2

II

if

I 2 Burnish-ream the bush 13

0.624

0.6255

PM·

6

W\I1

I

~Q

I

~

t.

Drill a hole in the bush, through the hole in the using a 1.95 mm drill.

dimension given in DATA. Reverse noting: a The locating screw engages the

larger opposite holes.

b The

are fitted inside the plain washer at each end

to

0.625 in (15 .S5

to

_

I

6 INC

top

of

the rocker barrel,

the

procedure in I

of

the two diametrically

doubl&ocoil

of

the shaft.

0.6260 in

(l5.S9

to

6 12

MIt

spring washers

15.S7 mm)

to

13b

I

Q~Q.II

.1

....

_10311

to

the

to

5,

15.90 mm)

»

...

U1

OIL

PRESSURE RELIEF VALVE

Remove and refit Service tool: 18G 69 Removing

.1

INA

2 Remove the valve cap washer from

rear

of

3 Withdraw the spring from

4 Withdraw the valve

Refitting 5

6 Renew the spring 7 Reverse the procedure in 1

DATA

Relief valve spring:

Free length

Load when compressed to 2.16 in

the L.H. side

crankcase.

18G 69.

If

the valve plunger seating correctly, lap the plunger its seating, using tool 18G 69. lapping fails renew the plunger and ensure that new plunger seats correctly.

specified in DATA.

.......•.•.••...•..

(54.77 mm)

of

plunser, using tool

is

to

correct

if

.••.••.••.•..•...

12.60.56

the crankcase.

pitted,

or

the

it

is

to

4.

is

fault,

not

the the

not

onto

If

the

as

TIMING GEAR COVER

Remove and refit 12.65.05

Service tools: 18G ·98

134

BD

Removing

I

lNA

2 Slacken the alternator mounting boIts

t~~~)

Qg)i&m-;l

4

3 in (76 mm)

15.5

to

16.51bf (7.0

-..."

to

7.4 kgf,

I

~

INC

oue

69

to

73

N)

and remove the fan belt.

3 Remove the

pulley.

4 Remove the crankshaft pulley, using

tool 18G 98

5 Remove the timing gear cover and

gasket.

6 Remove the oil seal from the timing

cover.

Refitting 7 Fit the new oil seal

cover, using tools 18G 134 and 18G

134

8 Fit the timing gear cover and gasket,

9 Fit the timing gear cover boIts in the

10 Reverse the procedure in I

BD.

using the crankshaft pulley centralize the oil seal crankshaft.

following illustrated positions. Position Bolt size

fa-

A

B

1\

l'lOTE: An 'bolt. C

1\ 1\

D

Y..

E F

Y..inxlY..in(31.75mm)long

tightening the crankshaft pulley boIt to

751bf

A.

in x I % in (44.5 mm) long in x 2 in (50 mm) long

'0'

ring

in x 2 in (50 mm) long in x

2Y..

in x

in (57 mm) long

1%

in (44.5 mm) long

ft (10.4 kgf

OIL

A,

18G 134, 18G

. water pump

to

the timing gear

on

is

fitted on this

m,

102

Nm~

SEAL

to

the

4,

»

...

0)

~~-~;;

J

-,

TIMING CHAIN AND GEARS

Remove and refit 12.65.12

Timing chain tensioner

1 to 14, 16 to 19, 34 to

and

43

to Timing chain 1 to 14, 16 22,29

Service tools: 18G 98

134

BD

Removing

I

NA

2 Drain 3 Slacken the alternator mounting bolts

and remove the fan belt.

4 Remove

pulley.

5 Remove the crankshaft pulley, using

tool 18G 98

6 Remove the timing gear cover and

gasket. 7 Remove the crankshaft oil thrower. 8

If

slacken the camshaft

18G 98

9 Rotate the crankshaft until

marks are positioned as shown.

10 Hold the chain tensioner and chain

together by hand and remove

tensioner retainer screw.

11

Lift away the chain tensioner.

47

to

41, and

the

cooling system.

the

A.

the camshaft gear is to be removed,

A.

43

to

A,

40,

12.65.28

to

47

12.65.14

18G 134, 18G

water pump

nut

using tool

the

timing

the

o

~~

1--\.

~f?11

-I

~;;~

},

39

29

/

!.~

.

.;;:~

"56

C

A

30

SHe

1 2

If

the chain tensioner shoe is to be

renewed, remove the circlip from the pivot pin and lift

13

Remove the idler gear bolt.

14 Lift away the idler gear and its hub.

NOTE: The idler gear hub

by a roll-pin dowel.

15

Remove the timing chain. 16 Remove the camshaft 17 Remove the crankshaft gear.

Refitting

18 Fit the camshaft gear and secure it

with its nut.

I 9 Check the camshaft end-float against

the figure in DATA.

excessive, remove and renew

20 Fit the camshaft gear and crankshaft

gear

to

21

22 Position the injection pump gear with

23 Position the camshaft gear and

24 Fit the timing chain and place the

25 Adjust the position

26 Fit the idler gear bolt and tighten it

DATA

Camshaft end-float . . . . . . . . . . . . . . . .

Timing gear alignment

their shafts. Place a straight-edge across the face

of alignment; the crankshaft gear face should be rearward by the amount stated in DATA. remove shims behind the crankshaft gear to set the alignment possible

its timing hole o'clock and insert a through the hole the engine front plate.

crankshaft gear with their timing marks in the positions shown.

idler gear (without its hub) in position on

without rotating the gears, to permit the idler gear hub chain slack between the idler and its adjacent gears. NOTE: The idler gear hub by a roll-pin dowel.

30

the gears and check their'

to

the chain.

lbf

ft (4.1 kgf

off

the shoe.

is

nut

and·gear.

If

end-float

the

camshaft locating plate.

the DATA figure.

camshaft gear

If

necessary, add or

as

at

approximately 7

* in (5.5 mm) peg

to

engage the hole in

of

the chain,

to

be fitted. without

is

m,

41

Nm).

...•.•.•...•.•

located

tooth

near as

located

to

27 Fit the chain tensioner shoe and

circlip

to

28 Fit the spring, pressure block, and

centre pin body. Compress the the compressed position.

29 Fit the pressure lever

tensioner with the lever of tensioner body will contact the engine front plate when fitted.

30 Fit the retaining screw through the

pressure lever and tensioner body.

31

Fit the compressed chain tensioner

is

and tighten its retaining screw.

32 Rotate the centre pin

the tensioner.

33 Ensure that the timing marks are still

correctly positioned.

34 Remove the peg from the injection

pump gear.

35 Tighten

(9 kgf m, 88 Nm).

36 Fit the crankshaft oil thrower with its

dished side towards the gear.

37 Renew the timing gear cover oil seal,

using tool 18G 134 and 18G 134

38 Fit the timing gear cover and gasket,

using the crankshaft pulley centralize the oil seal crankshaft.

39 Fit the timing cover bolts in the

following illustrated positions.

Position Bolt size A B NOTE: An bolt C D E F

40

Reverse the procedure in I tightening the to

0.003

to

Crankshaft gear

ward

the pivot pin.

to

the chain tensioner

centre pin 180

the tensioner body, i.e.

the

camshaft

·rw

in x I * in (44.5 mm) long

-A.

in x 2 in

'0'

*in

x 2 in (50 mm) long

* in

)(

2U.

U.

in x I * in (44.5 mm) long

U.inxlU.in(31.75mm)long

75lbf

ft (10.4 kgf

0.007 in (0.08 to 0.18 mm)

of

0.005 in (0.13 mm) rear-

camshaft gear

~ringand

nut

(50

mm) long

ring

is

in (57 mm) long

crankshaft pulley bolt

m,

retain the

to

the chain

legs

to

65 Ibf

on

rotate

forward

release

to

1800 to

fitted on this

102 Nm).

the

ft

BD.

to

the

5,

»

....

.....

HYDRAULIC TYPE ONLY

,..

....

00

FUEL FILTER ELEMENT

Remove and refit

Removing

1

Support

the 2 Detach the filter base. 3 Remove the element, using a twisting

motion. 4 Remove the seals from the filter base

and Refitting

5 Clean the filter base. 6 Reverse the procedure in

a new element and seals. 7 Bleed

the filter base and unscrew

centre bolt in

filter head.

the

fuel system, see 19.50:07.

the

19.25.07

filter head.

I

to

4,

using

INJECfION

Remove Ti'lliUg -

1

to

Service tools: Removing

I Slacken

and

2 Remove

3 Disconnect the fuel return pipe from

the

4 Disconnect the fuel supply pipe from

the

5 Disconnect

from

6 Disconnect

injection

7 l>isconnect

preSSIre

8 Remove the injection

return spring.

9 Remove Nos. 3

10 Remove Nos. I

II

Remove the three nuts and washers

securing the injection

withdraw the injection engine. NOTE: anchor return

12 Withdraw the injection

bar.

13

Remove the injection

14-

20

PUMP

and

refit

check

and

16

and

21

AMK

the

remove"the fan belt.

the

injection injection pump.

the

injection

pump

adjust

to

38

9990,

alternator

alternator.

pump.

the

stop

pump.

the

throttle

"

the

lead from

ulte.

and and

The

lower

bracket for

spring.

IIA

nut

19.30.07

19.30.01

MS

67 A

mounting

control cable from

pump

4 injector pipes.

2 injector pipes.

pump

also secures the

the

pump

the

stop

pump

from

stop

gasket.

bolts

cable

the

fuel

lever

and

the

lever

torsion

~~

Refitting

21

Rotate

the spline in the

22 Insert timing pin AMK

timing hole in plate.

sump

23 Maintain a light pressure

pin normal direction timing pin engages the injection the 8 o'clock from

crankshaft until

the

12

o'clock

The

hole

flange

and

rotate

flywheel.

pump

the rear. "

injection

on

The

pump

position.

the

gearbox

is

situated below

the

RH side.

the

crankshaft in the

of

rotation

the

master spline in

drive should

position when viewed

SN::46S

the

master

drive

is

in

9990

into

the

adaptor

the

on

the

timing

until

now

be

the the

in

timing hole in

24

Assemble tool on its knurled screw.

25 Insert the assembled

injection engaging

splines.

26

Slide centre injection

the

27

Apply gentle clockwise (viewed from

the check

mark)

with

necessary, scribe a new mark.

28

Remove

29

Remove timing pin

30

Fit

drive gear hub.

31

Fit

flange

32

Position the injection shaft

with

33

Fit

the

GENTLY splines with

34

Push

position anchor

35 Progressively tighten the three

pull

position, ensuring

marks are aligned.

36

Reverse

37

Bleed

the

long

MS

67A

the

2040 position

pump

the

body

bar

until

pump

centre

bar

rear) pressure

that

on

the

scribing guide

tool

the

injection

the

torsion bar in

on

the

so

that

on

the

injection

end

of

the torsion

engage

the

injection

as

possible

bracket, washers, and nuts.

the

injection

on

the

fuel system, see 19.50.07.

scribing guide

to

the

tool and

position

injection

with

the

drive gear

MS

engine. its master spline lines

the

pump

procedure in I

tool

on

of

the

body

drive gear hub. Lock

the

knurled screw.

to

scribed line (timing

of

67A.

AMK

pump

drive flange. pump

drive shaft over bar

the

drive flange splines.

pump

and

pump

that

and

body,

lock

the

pump

tool

engages

the

hub

the

9990.

gasket

to

pump

and VERY

drive shaft

as

fit

the

fully

the

drive flange

of

set

it

with

into

the

engine,

drive

along its

the

tool

and

lines

up

tool.

to

the

the drive

drive

up

far

into

spring

nuts

to

into

timing

to

10

it

If

LIFT

PUMP

Remove

Removing

I

2 Disconnect 3 Plug

4 Remove

5 Remove

Refitting 6 Reverse

7 Bleed

LIFT

Overhaul

DismantlinR 1 Remove

2 Scribe a reassembly mark across 3 Remove 4 Remove

5 Remove

6 7 Remove

8 9 Lift

10

11 12

Reassembling 13 Renew

14 Reverse

and

refit

NA

pump. tank.

washers.

the

supply

the

fuel system,

the

two

pipes from

pipe

securing nuts

lift

pump

proced ure in I

PUMP

the

lift

pump,

body

joint

flanges.

the

domed

ring.

separate

the

If

them

Press

rotate

If renewed, carefully retainer.

Lift

If

be renewed, secure vice mounting arm

worn noting:

a

the

filter.

the

pump.

the

out

the

out

the

If

renewed, ensure

spring

original.

top

valves require renewing, lever

out

carefully.

the

valve gaskets.

the

it

through

the

diaphragm spring.

diaphragm

the

seal.

rocker

and

tap flange

and

its

any

or

damaged.

the the

is

cover

securing screws

and

diaphragm downwards,

90°

rod

withdraw

arm

the

face

to

dislodge

components.

components procedure

diaphragm spring

of

the

same

19.45.09

from

the

and

gasket.

to

5.

se.e

19.50.07.

19.45.16

see 19.45.09.

and

bottom

and

seal is

or

rocker

of

in 1

that

colour

halves

withdraw

the

linkage is

arm in a the the

which are

the

sealing

to

pump

rocker

to

as

lift fuel and

the

and

of

it. be

seal

to

12,

new

the

is

3

17

'ccCO~-=--""

3~

4

_----0--'

7~<§>-7

8

~

b

If

the

valves are renewed, enS\lre

that

they

the

in.

NOTE: an

arrow

correct

The

on

the

are fitted

directions

inlet

pump

port

to

is

indicated

body.

operate

and

staked

in

by

~

CD

FUEL

SYSTEM

Bleeding 19.50.07

l>

I\)

o

NOTE: be

necessary

and

2,

the

filter

1.

Slacken

filter

priming

screw

2.

Slacken the

when

air

3.

Slacken switch the air

4.

Slacken governor fuel bubbles,

5.

Slacken high-pressure

with

when screw screw.

6.

Continue to the screw

screw.

7.

Slacken two with

the

bubbles,

After provided

expel

renewing

to

bl~ed

is

dismantled.

the

bleed

head.

lever

is

free

the

union

fuel bubbles,

bubbles,

fuel

high-pressure

the

adapter.

fuel

the

flowing

the

full

the

is

the

throttle

fuel

feed fuel

air

flowing

air

housing. leave

air

throttle fuel free

cranking any flowing free

flowing tighten

that

Operate

and, of

pipe. flowing

tighten

bleed

tighten

bleed

from

the

bleed

banjo flowing

of

air

of

union

in

the

fuel

the

fuel

the

engine

screw

the

when

air

bubbles,

nut

at

Operate

from

the

screw Operate from

air

trapped from air

from both

the

Operate

the

bleed

bolt.

in

bubbles,

the

bubbles,

nut pipes.

the

full

the

screw

bleed

screw

the

from

engine

the

at

both

union

filter filter

has

at

banjo

lift

the

fuel

the

nut.

on

the

bleed

screw.

on

the

screw

on

Operate

full

the

in

the

governor

the

Operate

run

pipes

nuts.

element as

described

not

been

fitting

pump

by

flowing

tighten injection the

lift

union the

lift

the lift

slack. the

run high-pressure

tighten with

governor

tighten injector

position

fuel

pump

screw

injection

pump

is

injection the

position

the

housing

the

is

free

it cranked in

means

from

the

screw.

pump

pump,

free

pressure

and

is

free

until

of

starter

the

bleed

starter

and

the

bleed

end

of

starter

and

of

will

the of

the

end and

of

when

of

pump

air

pump

and

bleed

motor

when

bleed

any

motor

when

air

only

in

1

while

fuel

its

of

the

motor

8.

9.

C

2_-K-~~~

C:2

Start

firing

Note:

If

difficulty

take

valve exhaust the

engine

to

prevent

2

~=l

C)~~~

~-~~

~7~7~7

and

starting

be

with

to

allow

closed

sea

open

the

it

or

repeat

occurs, to

water.

the

sea

pump

the

on

system

.'

engine all

must

starts, damage

cylinders in

to

run

step 7 if

the

prevent

Immediately water

and

engine.

until

sea

filling

intake

it

is

necessary.

water

of

when

valve

inthe

INJECTORS

Remove

Service tools: 18G 284, 18G

Removing

I

2 Disconnect 3 Disconnect 4 Remove 5 Withdraw 6 Remove

Refitting 7 Fit

8 Reverse

9 If

and

refit

INA

injectors. from the

injectors.

18G

each injector position.

two injector position, fitting washer

tightening

121bfft

more

removed,

starter

the

high-pressure pipes.

the

injectors.

the

nuts

the

284

and

the

two

new sealing washers

as

shown.

the

the (1.7 than

crank

motor

.

spill rail from

high-pressure pipes

and

injectors, using tools

18G

284 P if

sealing washers from

procedure

injector securing

kgf

m,

16 Nm).

two

injectors have been

the

and

bleed at least

19.60.01

284

P

the

washers securing

necessary.

to

each

the

smaller

in I

to

5,

nuts

to

engine with

two

the

of

20°

~

I

cu.

4~

5~

6~1

INJECTORS

Overhaul

Service tools: 18G 109

1091::;,

18G 210, 18G

I Remove 2 Mount 3 Remove

washer.

4 Remove

5 Remove 6 Lift 7 Remove

using

8 Renew

of

9 Renew

straight.

10 Clean

18G

II

Reverse-flush 18G

the

the the

out

the

tool

the

weakness

the

487. 109 A and

the

18G 210.

nozzle and valve, using kit

A,

18G 109

388,

18G

injectors, see

injector in

cap

spring cap spring.

spindle.

nozzle

spring if it shows any sign

or

distortion.

spindle if it

the

tool

nut

and

nut

is

not

nozzle, using tools

18G 109

E.

fiq

7

5NC480

19.60.08 B,

18G

487

19.60.0

I.

18G

388.

and

sealing

shim.

and nozzle,

perfectly

12 Renew

pintle clearance allows more

shown.

If

13

valve seats

DATA.

14 Check

in DATA.

I 5 Reverse

tightening the nozzle

(6.9

16 Test

specification given in DATA, using

tools

17 Fit

DATA

Auxiliary hole Needle lift Nozzle seat angle Valve seat angie

Testing

TEST

Auxiliary 135 Atm

Spray

Main

Seat tightness 100

Back-leakage 160

Final setting 135

* Add 5

the

nozzle assembly

than

20°

necessary, restore

kgf

the

Atm

to

the

needle lift against

the

m,

68

and

set

18G

109 A

injectors, see

diameter

...•.•..•..........

NOZZLE

TO OPEN

when

setting

when

the

procedure

Nm).

the

injectors

and

19.60.0

..............

...............

Atm

135

Atm

to

170

Atm

Atm*

new injectors

if

an

checked

the

nozzle

angles given in

in 2

nut

to

18G

109

..•........

SET

AT

SET

the

angle

and

the

figure to

50

Ibf

to

the

B.

I.

ADAPTOR (18G

109

TO OPEN AT

220

- -

-

- - -

or

after

of

as

7,

ft

0.2 mm

'.

0.70 59°

. .

B)

Atm

0'

60°

0'

STROKES

MINUTE

fitting new springs.

to

0.75

mm

PER

60

140 Spray free

-

REQUIREMENTS

Spray free Slight core permissible.

Slight

Dry nozzle

seconds at

Initial pressure 160 Atm.

Time for pressure drop

from 150 be between 6 and 140 seconds

of

core

90

to

distortions.

permissible.

after

10

Atm pressure·

100 Atm

to

!

»

III

...

SERVICE TOOLS

All Service Tools mentioned in this Manual

must be obtained direct from manufacturers :

Messrs

V L Churchill & Co. Ltd.

PO Box London Road Daventry Northants

England

No.3

NNll

4NF

the

tool

18G SSA

Piston Ring Compressor

18G

109 A

Injector Machine

Nozzle Testing

18G 123 B

18G 123 E

l>

N

~

Cal1L'lhaft Cutter

~."

Cal1L'lhaft Cutter

Liner

Liner Reamer

Reamer

18G 27

18G 29

18G4S

Valve Seat Cutter and Pilot Handle

18G

29

Valve Grinding-in Tool

Spring Compressor

Valve

18G 69

18G

98

18G99"

18G

99

Oil Pump Release Valve Grinding-in Tool '

A

Starting Nut Handle

Clutch Assembly Gauging

A

Fixture

18G

109 B

109 E

IJijector Nozzle Testing Adaptor

~

Injector Nozzle Reverse Flush - Adaptor

~

18G 123 F

18G 123 L

18G 123 A

/-

~

a-~""""

Camshaft Cutter

Liner'

Reamer

~

Camshaft Liner Reamer Pilot

Camshaft Liner Reamer Basic Tool

18G 123 T

18G 123

18G 123 AD

AB

AC

Gl)""

Camshaft Liner Pilot

Reamer

~t

Camshaft Liner Reamer

Pilot

~

Camshaft Liner

Pilot

~

Camshaft Pilot

Reamer

Liner Reamer

18G 124 B

18G 124 C

18G

124

@

Camshaft Remover Adaptor

@

Camshaft

Rem Adaptor

@

F

Camshaft R e Adaptor

18G

124B

Lin

/Replacer

..

,,"

over / Replacer

mover / Replacer

Lin

..

""

Liner

e r

18G 134

~

U

BD

Timing

Replacer -

~-

CQ

Crankshaft Rear Oil Seal

Replacer - Adaptor

Case

Adaptor

•..

~~

Oil Seal

18G 167 C

18G 174

18GI74A

/JM\,,"

Valve Cutter -

Seat

Bottom

Narrowing

~."

Valve Seat Finishing

~

Valv Seat Glaze Breaker

laG 174-'

Cutter

'V

0~

18G 124 A

18G 124 H

f'

Camshaft Remover/Replacer - Basic 18G Tool

Liner

134

~

18(i

120tH

Camshaft Remover / Replacer Adaptor

...,......

~

Bearings Replacer - Basic

and

Liner

lfiG

134

Oil Seal 18G 167 B

Tool

18G 167

Q)".

Valve Seat Finishing

~

Valve Cutter -

laG 1618

Seat

Top

Cutter

Narrowing

18GI74B

18G 174 C

~

/JM\,,"

lP.(,

17~[

-

Seat

Top

Seat

Valve

Cutter

Valve

Cutter -Bottom

Narrowing

l>

N

Co)

18G

174

D

Valve

Seat

Cutter

Pilot

18G

~

laG

284

A

Main Bearing Cap Remover

-

284A

Adaptor

18G

487

Injector Nozzle Cleaning Kit

18G

636

6,

...

Transfer Pressure -

Adaptor

~

N

.Jio

18G

210

18G

226

18G

226

18G 284

O?,

I

njector

Spanner

l Valve

A f Remover/Replacer

Impulse

Tool

Rocker

Extractor

Nozzle

Bush

Nut

laG

284

- Basic

18G

284

P

ector

Adaptor

Remover

I

nj

~

18G

284

AC

Main Bearing Cap Remover

-

Adaptor

18G

~~~

18G

284

388

~

AAF

Crankshaft Remover -

~Q

~

Injector

Fixture

,,,,,

..

,,

Spigot Bush

Adaptor

lflG3AA

Dismantling

18G

633

A

634

~

635

Protection

D.P.A. Assembly Base

Assembly Box

Hydraulic

Spanner

Drive Shaft

Cap

18G

B

Assembly

Automatic

637

638

6?

639

640

Head Protection

~

Automatic Protection

Rod

Advance Gauge

Locating

Cap

Advance Plug

Cap

Fitting

'\

)

18G 641

18G 643 A

18G 646

18G 647

Assembly

Spanner

Drive

Plate

~"

Metering Protection

Valve Pinion

Cap

~

Torque Spanner Socket

6Y.

Assembly Cap

18G 651 Drive

~."

18G

653

A

Relief Valve Timing Adaptor

18G

655

A

Drive Adaptor

Shaft Holding

Plate Screw

Tool

Torque-

18G 691 A

18G

694

1004

18G

~

Pilot Guide

A

Cylinder Head Crowfoot Wrench (Special)

- Alternative Tool 18G

186

1004

Circlip Pliers - Small

Nut

694

L;;J

18G

1195

AKM

9990

MS67A

1

Clutch Plate Centralizer

Timing

Injection Timing Gauge

t::=ID

HS6,.

18G

648

Universal Flange Marking

A

Gauge

18G 656

690

18G

Maximum Fuel Adjusting

Probe

P::

End

Plate Adjuster

18G

1108

Crankshaft Rear Oil Seal Protector Sleeve

»

I\)

(II

OTHER OVERHAUL

Q.l

CONTENTS

MARINE

COOLING

TRANSMI

ENGINE Activation Activation

vati

Acti

SS Type

SAl

and

SAl

and

Paragon

Warner

ELECTRICAL by

Keyswitch (1980 onwards)

by

Fuel

on

by

Lube

SYSTEM

IONS.

SAO

Hydrau1

(EXTERNAL)...................

• . . . . . • . . . . . . . . . . . . . . . . . . . . . . . S

Manual..........................................

SAO

Clutch Adjustments

SAO

Reduction Units

P-21

Series,

i c

.........................................

SySTEM.............

Pressure

Oi 1 Pressure..........................

Hydraulic

.•••.•.............•..........

.......................•...

......•.......................

............•..............

SECTION

Q

...•..............•

R

PAGE

Q.2 Q.4

Q.

6

S. 9 S.21 S.23 S.29 S.

35

Short

Profile

Sailing

Gear

.....................••.•......

S.41

Q.2

SECTION Q

MARINE ENGINE ELECTRICAL SYSTEM

ACTIVATION

Thjs system beke

engines beginning tially accomplished the is by The key position.

Voltage fuel solenoid or fuel plied, the

Models

tric key lift by

The breaker located near the time excessive current flows. the breaker will resettable before the engine will operate again.

activation

key

switch.

required.

depressing the preheat

engine switch to the right-most

ignition

fuel

switch.

pumps

pulling a stop cable.

circuit

is

maintained to the instruments,

and

to other

which

pump

or

BY

KEY

SWITCH

is

supplied

of the

by

the

No

The

engine

cranked

position of the have

a fuel solenoid or

may

Models

no

fuel solenoid are stopped

is

protected

trip.

breaker,

on

most

May.

ignition

oil

by

lift

electrical

be

turned

with mechanical fuel

This

and

1980.

circuit

position of

pressure switch

is

preheated

push

turning the

momentary

pump

devices via

key

off

by a circuit

starter.

is

a manually

must

be

electrically

button.

Wester-

Essen-

is

if

sup-

switch.

elec-

via the

Any

circuit

reset

CAUTION that engine are

devices cannot water.

The engine's

on

the wiring diagram shipped with the

engine.

diagram

- the builder/owner

the instrument panel, wiring

latest

and

installed

come

information regarding your

electrical

Be

sure to study all

the notes thereon.

so

in contact with sea-

system

must

that

is

this

electrical

included

ensure

and

wiring

Q.3

WATtR

TtMPT.

~IT'H

@

~

i

..L.

- I

= @ =

tt"\. Of=lTIONAL -

W ALARM

Olt.

PR!S!.URe

@SWITCH

'¥----~

~I

' I

I

e

I

f'UEL. SOL..

I

l.

___

../

WI

j

...L..

(w~a

RI

NG

®.5U

W.T.5ENDER

ONL.V)

DIAGRAM.

NOT!-

D

NOT

ACTIVATION

USED

OC"

ORN

••

RN

@

ALTERNATOR

BY

KEYSWITCH

~

1 Z

VDC

"

SECTION Q

SCHEMATIC

BATTERY

@

PRE-ICAT

DIAGRAM.

&AT'TERY

ALARM

A ---;@---

@.

@

@)

M'TU,,"

o.

P,

sw.

'@----

•.

T.SW.

NOT

@SEENOTE-a

0.P.5ENDER

USED

I PRE-HEATER

ON

OON

PUR

®

PRE-HEAT SOL..

'12

$EE

__

I-~_.w:lli_r"""

".

NOTE-A

_ +

W T

Q.4

MARINE ENGINE ELECTRICAL SYSTEM

ACTIVATION

(Push

Button

This

six

cylinder January very

simple separate engine

Starting

of

the

starting

Once

sure

developed the

fuel pressure to

the

alternator

instruments.

When

sure

drops

removes

When

heating

separate

a NOTE:

installation breakers,

Responsibility"

supplied

BY

FUEL

Start)

system

1975. switch

alarm

start

motor

the

injection switch.

alarm

the

voltage an

device,

It

is

as

with

PRESSURE

is

supplied

Westerbeke

Basically,

and

eliminates position

system,

is

accomplished

push

button

to

crank.

engine

in

the Voltage

system

for

engine

and

the

from

engine

the

push

button. important includes

described

on

your

engines

when

is

running,

low

pump

operates

(if

supplied)

excitation

is

stopped,

fuel

pressure

these

is

supplied

device

that

fuses

under

the

wiring

engine.

on

all

the

system

the

to

activate

supplied.

by

which

pressure is

then

and

devices.

with a pre-

is

energized

your or

"Ownership

diagram

four

beginning

is

need

operation causes

fuel

side

a

fuel

applied

and for

fuel

switch

engine

circuit

for

the

pres-

and

a

of

to all

by

ACTIVATION BY FUEL PRESSURE

(PUSH

BUTTON

STARn

Q.5

• EO

@

~

I"+~--I-~il'-::::,(

L.

___

_

.

,-

"

, .

~

·

• °

·

.

,-

~

.

.-

,0

<

.-

@

~

~=====:::;LJI2~

~ED

"$

G-P

\ ®

~

<

.-

.

o

S~NDE~

(~,

OPfiONA

;

ALARM

I

START

5w

PANEL.

C---------,

I:)TA.RT 5W

1-

I 1

ASSEMBLY

PREH[""

~

L

0

,.

0

.

«

.

•

r------------l

p"j:i I

: I

L--...:~--_>,A~--;:,i'!":/;CO;:',

I

I I

I @

I

I 11(-,1; t &I

i

I I

I i

l:~;t:~-J1.l

:)W'I

1

J@

I

-

......

;-""'",.

- +

u"

I·

I

I@-

.5TARTER

..

V;~-OTMTA-~';SE:'~\J

r-------

[o~.E-®®®®

1",1

~JI..HQ.W

I

:<1

I

I I

I

1

: @

t STAR1 ER

I

:

I I

I _ I

L

___________

---,

i

~L'-'G.S

(J':,)

'.~

:

I I

An

.ATT

I

..J

CHART

FOR

STARTER

MOTORS

,------------,

r~'E'@@®®

~I

(,.~:.PLLC.~

I I

, I

1

I

I I

L.

____________

@IL

i

~

I

J

,:.r,C)

HEATERS

r-

---

41

I

,·1

I

'~I

I

I I

I

I I

I

L

__

Drawing

---

------,

'

'0'

6

.,T~RT£R

_________

No.

19201

"'"

"£'

MTT

I

I I

J

Q.6

Marine

ACTIVATION

(Keyswitch

This cylinder to

January Putting tion

energizes plied). position

Turning

tion

operates

the

engine.

switch

When

voltage

excitation ever

the sure

removes

When heating arate

When electric a

separate panel. NOTE: stallation breakers,

ponsibility" with

your

Engine

BY

LUBE

Start)

system

Westerbeke

1975.

the

start

Returning de-energizes

the

is

released

the

engin~

is

supplied

and

engine

an

engine

device,

push

button

an

engine

stop

push

It

is

includes

as

engine.

Electrical

OIL

PRESSURE

is

supplied

diesels Operation switch

an

alarm

the

start

the

starting

Upon

voltage

described on

starting,

to develops

to

all

stops,

is

it

is

at

is

solenoid,

button

important

fuses

the

wiring

on

produced

is

in

the

system

start

the

switch

the

instruments.

loss from furnished

energized the furnished

it

at

that

under

switch

alarm.

to

motor

the

Run

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alternator

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is

the

your

or

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diagram

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all 4 and

prior

very

Crank

position.

oil with a pre-

with energized key

simple.

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posi-

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devices.

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sup-

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posi-

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starts

start pressure,

When-

pres-

panel. an

switch

engine

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Drawing

No.

15245

I

Q.8

YOUR NOTES

COOLING SYSTEM (EXTERNAL)

1.

DESCRIPTION:

Westerbeke marine diesel engines are

equipped with fresh water cooling. Transfer of heat

~ater

1n tion to

to sea water

a heat exchanger, similar in func-

an

automotive

water flows through the tubes of the

heat exchanger while fresh water

flows water with the

around and

fresh water never

result

water passages in the engine stay

clean.

2.

Heat well

. .

1S

absorbed

flow

culating

from

.

FRESH

WATER

rejected during combustion,

as

heat developed

is

created

pump.

the engine through a fresh water cooled exhaust manifold, a heat exchanger, in and

returns to the suction side of

most

the fresh water The

flow

is order in every a cold engine, flow vented Some

to the heat exchanger

by

the closed thermostat.

amount

to prevent overheating in the exhaust

manifold.

As thermostat begins to full

flow

of engine fresh water thru

the external cooling system.

from

engine fresh

is

accomplished radiator.

the tubes.

The

sea

mix

that

the cooling

CIRCUIT:

by

friction

by

the fresh water

by

a fresh water

The

fresh water flows

cases

circulating

an

oil

pump.

not necessarily in

model. most

When

starting

of the external

is

of by-pass

the engine

is

warms

open

maintained

up

allowing

Sea

as

whose

cir-

cooler,

this

pre-

up,

the

SECTION R

charge of the sea water heat exchanger sea water passing through the tubes of the heat exchanger, the sea water

tran~mission

and

1f sea water cooled. Ultimately,

oil

cooler

the sea water enters a water wet

exhaust system, the type of exhaust system in use. the case of water

flow

larger

is

divided

engines the sea

ing the exhaust systems portion and exhaust

is

dumped

a portion

system~

directly

is

used

Full sea water entering the exhaust system create unnecessary exhaust pressure.

4.

SEA

WATER

The.s~a

pos1t1~e

pump

wa~er

dlsplacement.

w1th neoprene impeller. flexible curved

vanes

cam

PUMP: pump

is

a nonferrous housing

The

which

plate

within the impeller housing, producing the On

no

account should dry. impeller

There

and

should

always

impeller cover gasket

aboard.

5.

SEA

WATER

The

~ol!owi~g

and

lnd1cat1ve only. Specific

t~ons

w1th

where

your replacement impeller.

PUMP

IMPELLER

instructions

applicable

pump

inlet.

may

if

most

prior

so

to

cool

self

It impeller

wipe

pumping

this

may

to the

After

enter a

present

injected, popular

In

to

enter-

that

a

overboard

the

flow

would

back

priming

is

a rotary

and

and a

has

against a

action.

pump

be

run

be

a spare

REPLACEMENT:

are general

instruc-

be

packaged

3.

SEA

WATER

The

sea water positive displacement neoprene pump

(gear

cases).

water

sea

directly

cock

CIRCUIT: flow

pump

in

Normally

from

and

sea water

is

created

certain

the

pump

the

strainer.

special

draws

ocean

by

a

inpeller

sea

via the

Sometimes a transmission oil cooler, or pehaps suction side of the sea water

Generally devices water priming water flows

a V drive will

it

is

better

on

the suction side of the sea

pump

as

possible to preclude

difficulties.

directly

be

piped

to

have

Usually sea

from

the

on

pump.

as

dis-

the

few

Remove

a.

the

front

cover taking care

to salvage the gasket.

b.

Remove

straight

the

done

the impeller

outwards,

pump

shaft.

with a

pair

by

parallel This of

pliers

plied to the impeller

c.

Coat and mounts

d.

Carefully align the impeller

way,

the replacement impeller

the

chamber

into

which

with grease.

or other locking

pulling

to

is

best

ap-

hub.

it

key

mechanism,

R.2

with the

all the

shaft.

Take

care the impeller blades same

direction

and

e. Inspect the front cover for

A

f.

g.

6.

worn

mately

it gency stamped seal i'mpel1er

Reinstall the new

Be for sea water the engine. indicates be This gated immediately or the from

ENGINE

front cover should

be

replaced.

can

be

reversed

measure, but not

markings

between

the cover

blades.

end

gasket.

doubly

sure to

flow

The

priming

situation

new

impeller will

that

the

itself

must

overheating.

FRESH

WATER:

Sometimes

as

an

would

cover with a

check

when

absence

pump

properly.

be

damage

result

that

bend

in

trailing.

wear.

ulti-

emer-

when

break the

and

the

quickly starting

of

flow

may

not

investi-

to

8.

THERMOSTAT:

Generally thermostats are of One

is

simply a opens ture has is stat an head. 1980 hole

and

closes

rises

and

a by-pass

a disc

which

on

moves

internal by-pass passage within the

Both

onward, punched

choking

as

falls.

device

the engine tempera-

The

mechanism.

the

bottom

of the thermo-

downward

types of thermostats,

have through

a 0.06" diameter

them a by-pass while the engine up.

This

prevents overheating in the exhaust manifold during engine The

hole thermostats design

When

that

strike

is

critical

must

be

and

equal

characteristic.

replacing a thermostat, it

is

rotated

so

as

the thermostat housing, pro-

two

types.

which

second

Usually to close

type this

off

from

to serve

is

warming

as

warm-up.

replacement

in

this

be

sure

to not

jections inside the head, temperature senders or temperature switches

which

may

be

installed

close to the

thermostat.

It

is

preferable to

50%

with a This

precludes the necessity of drain-

ing

coolant in the winter. Since

antifreeze-water mixture.

fill

your engine

most antifreezes contain preservative agents of

one

kind

or another, rusting within

is

the engine

minimized.

freeze mixture boils

Also

at

a higher

the

anti-

temperature than water, giving cooling system

When pressure vacuum

7. It

the fresh water the engine. become all phere to bleed entrapped

engine

coolant, the full time al cooling

pockets of to the ant

"head

draining the engine,

created

FILLING

is

very important to completely

cap

room.

first

by

THE

It

II

to

relieve the

draining.

FRESH

WATER

system is

normal

open

before

for

trapped in various passages

high

points

must

be

opened

air.

is

started

system

after

may

filling

look

until the thermostat opens.

when

at

water

fill this

flows

circuit

air

can point. time.

through the exter-

for the

be

Be

first

exposed

sure to

the

SYSTEM:

fill starting air

to

so

to

atmos-

When

an

with

deceptively

At

this

time,

and

rise

add

cool-

A thermostat er

operation

of cold water

checked

by

placing

and

then raising the

it

in a

for prop-

pan

can

be

temperature of the water to a boil.

The

thermostat should ably (with travel 1/4" - 1/2")

and

open

on

the order of

be

fully

notice-

opened

when

the water is boiling.

ENGINE

9. Lubricating oil carries heat

the engine bearings surfaces.

oil

lube through the engine oil cooler, to the oil

The

oil cooler engine fresh water or

10.

TRANSMISSION

LUBE

The

pump,

pump.

OIL

COOLER:

away

and

other

oil circulates

friction from

through the engine,

and

may

be

OIL

COOLER:

cooled by

either

sea water.

from

the back

by

Certain transmissions require oil cool-

In

ing.

oil cooler

these cases, the transmission

is

usually cooled

by

sea

water. Normally

after

sea water enters

this

cooler

exiting the heat exchanger, but

not always.

R.3

Note:

Drawing

TWO

is

indicative only. Specific

PASS

MANIFOLD

models

may

vary in detail •

.---

TO

EXHAUST

5YSTE/v1

PUMP

FRESH WATt':?

R.4

Note:

SURGE

TANK

FRESH

WATER

PUMP

Drawing

SINGLE

is

indicative only. Specific

PASS

EXHAUST

MANIFOLD

models

--

may

~

H

EXCHANGER

-..

I

~~--~M

vary

in

i\lER

BOARD

J"

~

C c::I

detail.

FROM

<J:l

SEA

COCK

FROM

COCK

RAW

WATt:.R

PUMP

SEA

OIL

FILTER

I -

0

-~-

HYDRAULIC

....

-

Q1b

---"""III.."'

GEAR/

COOLER

• •

> >

....

- - • -

I"-'-..-L

'lL"t:X.P

'If

FRESH

USED

I

t:l

RAU

RAW

WATER

ENG'NE

ON

L Ie

GEAR

ONLY·

01

L

HYD-

TRANSMISSIONS

SECTION S

S.8

YOUR

NOTES·

S.29

I.

SPECIFICATIONS

A.

Description

MODEL

P21L P22L P23L P24L P25L

B. Model and

Serial

PARAGON

Chart

REDUCTION

DIRECT

1.

2:1

2. 5: 1

3:1

Numbers

P-21

5: 1

SERIES HYDRAULIC

RATIO

DIRECTION

ALL AS

THE

OF

LEFT

VIEWED

OUTPUT

THE

MISSION

OF

TRANS-

ROTATION

HAND

FROM

END

Each

the of

a

serial

name

the

reverse

transmission.

~~

P2 - Gear.

Size

gear

number.

plate,

1 -

has a model

These

located

MODEL

DIRECT DRIVE

number

numbers

on

the

AND

and

are

on

housing

SERIAL

MODEL

P21- L 5J-1234

Direct

Drive

L -

left

REDUCTION

P

23

L

GEAR

MODEL

5J-5678

AND

Hand

NUMBER

SERIAL

Rotation

AND

Unit

SERIAL

CHART

NUMBERS

5J-1234

-

Transmission

Serial

No.

~

P 2 -

Gear

Si

ze

2 )

3 ,

: \

.

Redu Gear

Si

ze

ction

--------=:::::---------

1. 5: 1

2 0

2.5:1

3.0:

. •

-1

1 .

·t

\

Reduction

Gear Ratio

L

..

Left

Hand

Rotation

Unit

5J-5678

-

Trans-

mission

Seriol No.

S.30

II.

INTRODUCTION

Transmissions

operation transmission pressure separated

Translllission engage a forward

and dependability in

system

from

have

is

self-

engine

oil

been

designed

contained, having

and

oil

supply

lubricating

under

or

pressure

reverse

drive.

for

marine

completely

oil

is

smooth

use.

The

an

oil

systems.

used

to

The

for-

ward

drive arrangement, a

reverse train. cooled core, water. with Gear model Section I,

The

transmission

through a sep&.rate

which

Paragon

either

reduction

identification

under

is

through a multiple

while the

clamp

is

in

transmissions

direct

"SPECIFICATIONS".

reverse

band and

oil

turn

cooled

drive

ratios

numbers

external

or

and

disc

drive

utilizes

planetary

is

circulated

oil

cooler

by the engine

are

furnished

reduction

corresponding

are

gears.

listed

clutch

gear

and

in

III. INSTALLATION

A. The

B.

C.

installation

use

when the removed installed, is

to be adapted

ment

It

is mission tion

this

of

the engine output end wise

rotation

the engine A

letter transmission trated indicates use engine.

The

the engine in the following

1.

Insert transmission

engine

2.

Place so matching

housing flange.

for

to a

marine

important

rotations

of

rotation

manual

rotation

and a

in Section I, "SPECI FICA TIONS",

whether

with a

hydraulic

adapter

the

that

instructions

original

servicing

or

when the

engine.

that

of an engine

as

the

crankshaft

of

the of the engine counterclockwise

is a left "R"

or

serial

right

transmission

two

3-1/2"

transmission

the

studs

holes

below

transmission

and

transmission

as

non-original

the engine and

are

matched.

direction

as

viewed

transmission. A clock-

is a right

hand

rotation.

"L"

appearing

number

the

transmission

or

left hand

is

manner:

studs

mounting

plate.

go

in the

holes

against

through

are

has

been

must

be

unit

equip-

trans-

The

direc-

is

defined in

of

rotation

from

hand

rotation

on the

plate

transmission

illus-

is

rotating

attached

in opposite

in the

the

studs

two of the

for

re-

the

of

for

to

4.

Install

washers

housing flange into the engine

plate.

and tighten the two

with

mission

D.

The pling propeller mission, consequent engine, and boat hull

To align the coupling, move the

shaft,

the

transmission

propeller

mission tact.

contact

in ference.

faces

the pOint.

tion the engine and

by loosening the engine

adding either

move the engine

runout

faces

bolts coupling

together.

bolts,

E.

Connect the oil

mission.

and tighten

through

Remove the

lockwashers

housing flange.

transmission

must

be

carefully

shaft

in

order

damage

with

attached

shaft

coupling flange

The coupling flange

throughout

The

total

should not

If

the runout

or

removing

end of the engine.

or

to align the coupling flange

laterally.

and

recheck

before

Connect the coupling flanges with

lockwashers,

bolting the coupling flanges

cooler

four

the

3-1/2"

through

and

propeller

aligned

is

connected

to

avoid

to the

during

coupling' flange,

so

that

coupling flange and

their

runout

exceed

exceeds

attached

shims

sideways

Tighten

the

and

the

nuts.

lines

bolts

with

transmission

adapter

studs.

remaining

the

shaft before

to the

vibration

transmission,

operation.

propeller

toward

the

faces

are

in

faces

support

alignment

should be

entire

or

.002", repOSi-

to

circum-

gap

between

.002"

transmission

bolts

raise

or

If

necessary,

to

adjust

engine

to

support

the

lock-

Install

bolts

trans-

cou-

the

trans-

and

of

the

trans-

con-

at

any

and

lower

the

of

the

trans-

3.

Slide the toward the enters

engine

transmission

the

engine

shaft

at

the

the matching

vibration

so

that

front

of

the

splined

dampener.

along

the

the-

spline

transmission

hole in

studs

on

the

F.

Connect the cockpit control page 5. valve

control

valve

Place

lever

shift

station

lever,

in

control

to the

shown in

the

transmission

the

neutral

cable

from

transmission

Figure

control

position

the

on

and

adjust the in

the

control

positions

transmission

The move fully into

when the hand

IV.

OPERATION

the

shaft

cockpit

transmission

control

neutral

hand

several

lever

control

forward

lever

control

station

position.

to

forward

times

valve

control

is

cable Move

while

valve

or

moved into

length

hand

the

and

observing

lever

reverse

until

lever

is

cockpit

reverse

the

motion.

should position forward

or

reverse exactly hand

G. Remove

on

Type A

the transmission

Starting

lever

page

dipstick.

Procedure

position,

to

the

neutral

is

in

the

oil

dipstick,

5,

and fill

transmission

Replace

housing.

and should

position

the

neutral

shown

the

transmission

fluid to

the

when

position.

in

the

mark

dipstick

return

the

Figure

with

on

in

the

Principle

The are sure.

the

transmission

external

returned, distribution valve

closed

When

forward

li

vered which planetary discs pling in

reverse control oil

under piston. the case, from to

revolve shaft of

the neutral from band stationary.

of

Operation

transmission

operated

An

maintains

until the

the'

moves

nnd

lever The

reverse

preventing

moving but allowing the

in a

engine.

pOSition,

entering

piston

by

internal

oil

cooler.

still

tube and

r;ontrol

position,

to the

to

reverse

case

the

direction

drive

to the

pressure

reverse

band

to

drive

direction

With

the

:md the

the

then

forward

transmission

gear

oil,

under

oil

pressure lever

oil

multiple

clamp

gear

is

engaged by is

around the

pressurized

clutch

and

type

under

The

transmission

pressure,

relief

pressure

under

disc

the

case

revolve

of engine

reverse

delivered

piston

the

planetary

the ()utput

opposite

the

control

propeller

reverse

oil

under

oil

pump

pressure,

valve.

by

reaches

is

shifte1

pressure

clutch

together.

as a solid

rotation.

shifting

position,

to the

moves

planetary

or

to

the

lever

oil

is

piston

or

shaft

drives

pres-

delivers

to

oil

to

the

The

relief

remaining

60

PSI.

to the

is

piston,

discs

cou-

so

that

reverse

to

clamp

gear

case

gears

propeller

rotation

in

prevented

reverse

remains

the

is

oil

deand

The The

the

1. Always miSSion boat suddenly

2. When the engine to and oil to

ON TRANSMISSION OIL LEVEL CHECKED BEFORE ENGINE, CHECKED.

Start

3. in NEUTRO\L, and allow up to

4.

Shift

REVERSE

stall

FORWARD mission engine.

It

speeds the long and boat. EMERGENCY

higher

recommended

start

the engine with

in

NEUTRAL to avoid moving

forward

idle

for

a few

check

if

the

SUBSEQUENT START-UPS, THE

is

800 RPM,

the

transmission

necessary

mark

the engine

operating the

when the

recommended

the

on

NOTE

WHEN

again,

temperature.

transmission

as

desired.

transmission

or

REVERSE,

in NEUTRAL

below 1000 RPM, and

or

life

of the engine,

engine

speeds,

practice.

or

is

first

moments. to

bring

the

transmission

RUNNING

ENGINE OIL

with

If

before

that

idle

engine

the

trans-

back.

started,

Stop

the

MAYBE

the

enginetowarm

into FORWARD

the engine should

place

shifting be done

range,

transmission,

shifts

but

this

allow

the

engine

oil

level.

oil

level

dipstick.

THE

IS

transmission

is

shifted

the

trans-

restarting

preferably

to

may

be

is

not a

the

it

Add

up

or

to

the

at in

pro-

at

8.32

V.

MAINTENANCE

A.

Lubrication The Models P200, P300 and P400

missions dent of the engine

The

units

splash

recommended Type

transmissions

The quantity of oil depends upon the angle

installation,

of model. The level the

mark checked tory

operation.

When filling

after

running that the oil

are

self-contained

lubricating

are

lubricated

from

A", commonly

an oil change, check the level

its

own

is

in automobHes.

as

on the

periodically

for

the

for

a few

cooler

"Transmission

well

must

dipstick

first

minutes and the

units,

by

pressure

oil.

The type of oil

used

for

as

the reduction

be maintained

and should be

to

ensure

time

or

to make

various

indepen-

systems.

automatic

satisfac-

refilling

certain

passages

trans-

and

Fluid,

after

by

at

are

full.

If

on the of

level oil engine.

The oil in the changed under number oil tions. bottom of the

reduction

B. Adjustments

No

WARD

reverse sate reyerse

dipstick

the

transmisSion.

should be

level

is

every

normal

of

changes

Drain

gear

adjustment

drive

band

for

lining band

necessary,

to

checked

checked,

100

conditions. However, the

hours

varies

plugs

reverse

housing.

is

multiple

is

self

wear,

adjustment

refill

ensure

transmission

that

with

necessary

proper

The

transmission

each

time

before running the

hours,

or

can

be run between

theoperatingcondi-

are

located

gear

housing and the

for

disc

clutches,

adjusting

so

that

is

to

each

to

no

the

mark

operation

oil

the engine

should be

season

at

the

the FOR-

and the

compen-

external

necessary.

COUPLING

FLANGE

OIL

TO

COOLER

C. Trouble Shooting

Chart

S.33

PROBLEM

GEAR INOPERATiVE

Drive

with

or

Shaft

selector

reverse.

does

valve

not

operate

in

forward

POSSIBLE CAUSES

1.

Low Oll

Pressure.

AND

METHODS OF CORRECTION

a.

Low oil supply. Add lubrication.

b.

Faulty

Oil

obstruction and

c.

Plugged oil Clean

d.

Oil

oil gauge. Replace gauge.

gauge slow

bleed

lines

pressure

to

in

oll

gauge

oil gauge

lines

or

passages.

relief and sticking. Remove Clean

valve and valve

e.

control cloth

Defective seal

valve housing with

to

free

valve,

pistons

rings.

and oil

Replace

f. Defective oil pump. Check

and

replace

if

necessary.

oll,

register,

line.

passages.

valve

relief

bore

or

replace.

distributor

seal

refer

air

Clean

scored

valve.

in

crocus

rings.

for

to

or

wear

2.

3.

High Oil

Reverse engaging Gear

Cage.

Temperature

Band not

Planetary

a.

Low oil supply. Add lubrication.

b.

Low

water

Add

v'ater,

c.

Plugged Clean

d. Collapsed

inlet

e.

Air

line~

f.

Raw

raw

screen.

or

hose.

leak

in

Replace suction

watar

damaged. Replace

g.

Clogged

or

Remove and

a.

Reverse

band lining

Replace lining.

b. Defective

Replace

reverse

"0"

level

in

cooling

and

check

water

inlet

diSintegrated

Replace

cooling

pump

hose.

water

impeller

impeller.

dirty

oil

cooler

clean

worn

piston

ring.

oil,

for

line.

refer

system.

leaks.

screen.

water

suction

worn

element.

out.

"0"

ring.

to

or

4.

Failure

Assembly.

5.

Failure Gear.

of

Planetary

of Reduction

Remove for defective

gear

defective

or

case

or

damaged

Remove reduction check

for

defective

Replace defective

assembly,

parts.

gear

assembly

or

damaged

or

damaged

and check

Replace

and

parts.

S.34

PROBLEM

GEAR

DRAGGING

Drive

forward

Selector position.

GEAR

SLIPPING

ENGAGE

With

Selector

or

reverse

Shaft

or

Valve in

rotates

reverse

neutral

OR

Valve in

position.

either

with

SLOW

forward

TO

POSSIBLE

1.

Defective Clutch

2.

Defective Clutch Spring.

3.

Binding in Assembly.

1.

Low Oil

CAUSES

forward

Plates.

forward

piston

Planetary

Pressure.

AND

Release

METHODS

Forward

sticking. Remove clutch

OF

clutch

CORRECTION

plates

warped

plates

replace.

Forward

broken

a.

clutch piston

or

weak. Replace

Bearings

in

gear

and

case.

release

gears

worn

Replace

spring.

excessively

necessary

parts.

b.

Input shaft

bearings

worn

causing misalignment of input shaft.

See

Replace

"Gear

necessary

Inoperative~'

parts.

(1).

and

spring

excessively,

INTERNAL

LEAKS

AND

EXTERNAL

2.

Worn

forward

Plates.

3.

Reverse engaging

1.

Water

in Lubricating

Oil.

2.

Excessive Engine

Crankcase

Flywheel Housing.

3.

Oil on

Exterior

Marine

4.

Loss

of Oil

Transmission.

Clutch

for plates.

Band not See

Gear

Case~

a.

Oil

in

Defective front end plate

or

Replace

of

Gear.

a.

b.

from

a.

Remove

wear

"Gear

Hole in

water

Replace oil

b. Oil

and

Oil seeping for

Defective oil

Check seal.

forward

clutch

excessively.

Inoperative".

oil

cooler

to

seep

cooler

gaskets.

replace.

oil

seal.

from

too high

oil

rear

seal.

for

defective

replace

element

into

oil

element.

breather.

level.

end

plates

and check

clutch

(3).

permitting

compartment.

Check

oil

gaskets

seal.

Check

oil

seal.

Replace

gaskets

and

WARNER HYDRAULIC

S.35

DESCRIPTION

Engines hydraulic

gear The

of clutch, and control

tained

necessary

provide

operation. for

the

input direction. provide obtained

Oil

cent which operates to

provide

regulator.

From

directed to

the ings lubricant

parts ing is reverse

are

direct

assemblies.

direct

a

all

speed

pressure

requiring

whenever

and

positive

drive

planetary

a

reverse

pres

valve.

in a cast

forward,

forward

of

shaft

quieter

with

type

is

keyed

at

screened

the

through

bushings

is

it

conditions.

also

sure

shafts

A

the speed, Helical

pump,

regulator

should

VVesterbeke

furnished

drive

transmission

gear

regulator

All

iron

direct

operation.

output

operation

spur

is

provided

to

transmission

and

lubrication.

present

the

in

forward,

set,

clutch,

of

these

housing

and

reverse

drive

shaft

but

gearing

gearing.

the

oil

valve

the

proper

anti-friction

at

front

be

noted

Four-107

with

VVarner

and

reduction

consists

a

forward

an

oil

and

are

along

connectors,

and

neutral

ratio

in

by

drive

to

the

pump

is

In

reverse,

is

equal

the

opposite

is

used

than

the

gear

shaft

input

pressure

the

circuits

A

required

is

that

neutral

flow

pump,

rotary

con-

with

to

used

to to

can

be

cres-

of

and

speed

oil

is

bear-

of

turn-

supply

and

be

shifted

the

letter"

is

located poppet if

the

ball

is control or

repositioned, remote lever both

directions.

transmissions

Gear. LUBRICATION

The transmission to system. important automatic

Type PROCEDURE

VVhen

should full tity the turned

short

including

PROCEDURE

electrical

properties

the

"A"

TRANSMISSION

mark

of

installation.

LEVEL

to

F"

in

ball.

shift

permanently

lever

does

proper

filling

over

time

The

lever

is

control

not

Therefore,

that

transmission

be

used.

be

added

on

oil

depends

at

in

the

point

on

the

its

proper VVarranty

poppet

changed

or

and

have

This

equipped

shift

of

are

extremely

function

the

FOR

VVITH

the

until

the

dipstick.

engine

order

cooler

FOR

where

case

removed,

if

transmission

sufficient

control.

the

recommended

FILLING

transmission,

upon

The

to

and

CHECKING

casting,

position

spring

in

any

linkage

does

with

oil

of

the

it

is

fluid

OIL

it

the

unit idle fill

cooler

is

not

used

extremely

reaches

The

speed

all

it

covers

and

by

the

cancelled

and/

or

if

the

manner,

between

shift

travel

apply

VVarner

important

hydraulic

angle

should

circuits,

OIL

to

in

the

oil,

(ATF),

oil

the

quan-

be

for

piping.

in

of

a

The

unit

has

of

oil.

Both coaxial, for and flange shaft.

CONTROL The

transmission

the

installation

the

for

position

with

output

seals

input

connecting

LEVER

and

the

shaft

of

the

when

to

prevent

output

input

of a drive

provided

to

POSITION

control

in

shafts

shaft

the

forward

escape

are

splined

damper,

with

propeller

lever

should

a

on

The mediately sufficient

transmission

on assembly case

need

until

face

oil

level

the

dipstick

need

to

determine

only

the

cap

surrounding

The

periodically

and

transmission

oil

should

after

oil

be

or

to

should

shutting

added

assembly.

not

inserted

assure

level

plug

be

to

be

threaded

the

rests

the

should

added

be

checked

off

again

to

the

The

oil

into

oil

filler

proper

if

im-

engine

bring

full

level.·

the

on

be

oil

necessary.

and

mark

dipstick

into

case

the

sur-

hole.

checked

level,

the

It

S.36

CHANGING

It

is

recommended sion After

oil

be

draining

removable thoroughly the

mended

REDUCTION

The

transmission

oil

reduction conjunction The

reduction planetary input

It

is

tions

suitable

prevent

when pulsion. operation

the

boat rotate, culated oil

pump heating may

result

peller

gear

revolutions.

recommended using

locking

rotation

the

boat

If

and

causes

lubricating

through

is

and

shaft

OIL

changed

oil

cleaned

(ATF)

GEAR

gear

with

the

gear

set

a

reduction

of

is

not

the

marine

the

the the

not

in

damage

unless is

prevented.

that

once

from

screen

before

with

Type

"A".

BOX

box

direct

box

which

to

a

that

device

the

propeller

under

forward

propeller

oil

will

gear

operation.

to

the

rotation

the

transmis-

each

the

unit.

should

refilling

the

operates

drive

consists

reduces

fixed all

installa-

gear

or

brake

direct

gear

motion

not

because

marine

of

season.

the

recom-

unit.

of

the

ratio.

have

shaft

pro-

is

not

shaft

be

cir-

the

Over-

gear

the

pro-

be

in

a

to

in of to

Except forward neutral

1000

rpm

engine.

in

to at

or

an

emergency.

reverse

engine

to

prevent

marine

gear.

shift

drive speeds damage

from

through

below

to

the

S.41

1.

1.1

SHORT PROFILE SAILING

Description

Brief

description

The

Short

driven,

servo-operated

effort

for

single-lever

Bowden The

torque

preventing

thus The

transmission

overall

strength, improved

The

transmissions

restricted

Profile

mechanically

for

gear

cable.

transmission shock

ensuring

dimensions.

corrosion-resistant

sea

to

Sailing

operated

multiple-disc

changing,

remote

loads

maximum

units

water

oil

resistance

are

level

Gears

making

control

capacity

from

protection

are

The

gearbox

immersion-lubricated.

checks

are

equipped

helical

clutch

exceeding a predetermined

characterized

aluminum and

requires

the

transmission

via a rod

of

the

of

the

castings

optimum

(see

"Maintenance").

gearing

linkage,

clutch engine.

by

are

alloy,

adhesion

with a positively

system.

only

low

made

chromized

Maintenance

GEAR

minimum

suitable

Morse

is

exactly

value

weight

of a highof

paint.

The

or

and

for

is

rated,

and

small

AIR

VENT

HOLE

LEVER

NING

SCREW

5.42

1.2 Gear casing of

The rotating parts divided

ing ribs ensure good heat dissipation and mechanical rigidity.

An casing. The

oil

into

filler

two

screw

filler

the HBW transmission are accomodated in

halves in the plane

with

dipstick and

screw

is

provided

of

the vertical axis.

an

oil

drain plug are screwed

with

a breather hole.

Amply

an

oil-tight casing

dimensioned cool-

into

the gear

The shaft

side

1.3 Gear The transmission

forged low-carbon alloy steel. The multi-spline driving shaft connecting the trans-

mission

The driven shaft (propeller side) flange.

of

sets

for

actuating the multiple-disc clutch extends through a cover on the

the

gear

casing.

is

with

equipped

the engine

with

is

hardened

shaved, casehardened'helical

as

well.

of

the transmission

is

fitted

gears

with

made

of

a forged coupling

S.43

1.4

Multiple-disc clutch including operation - power train

is

The engine torque

applied rotation and, in shifting position A engaged via

In shaft (36)

clutch

the guide

discs

sleeve

(59)

shifting position B

via

intermediate

(51

(see

external disc carrier (57), the guide

to

the

input

shaft (36) in the specified direction

(see

item 1.2), via

and 52)

to

the

to

the external disc carrier (57) and from there

output

shaft (66).

item 1.2), the torque

gear

(26),

gear

(65), clutch

sleeve

(59) and the

gear

is

transmitted

- Function The transmission

clutch system mounted on the The thrust force required

clutch discs balls which,

uses

a positively driven, mechanically operated multiple-disc

for

is

provided

by

the rotary movement

by a servo

output

shaft.

obtaining positive frictional engagement between the

system. This essentially comprises a number

of

the external disc carrier,

inclined surfaces provided in pockets between the guide disc carrier and in this manner exert axial result, the transmittable

Due

to

applied. tion

of

the

cannot

exceed

the clutch

the cup springs (48) supporting the clutch disc stack

range

of

axial travel

a predetermined value,

is

limited.

friction

torque

of

the external disc carrier (57), the thrust force

pressure.

are

thus proportional

so

that

the torque transmission capacity

The thrust force and,

(44), the

discs

output

sleeve

frictionally

from

the input

(51

and 52)

to

shaft (66).

are

urged against

and the external

to

the

input

and

of

the

of

as

a

torque

a limita-

of

sleeve

(60)

is

The actuating

initiate the shifting operation, the actuating axially actuating

by

a shifting

sleeve

(60)

fork

is

held in the middle position

sleeve

until

the arresting force

moved automatically

has

by

the spring-loaded pins, while the

external disc carrier, which follows this movement, forces exerted

by

the clutch discs, and the shifting operation

scribed above.

Input

36

(60)

been

is

rotated

by

spring-loaded pins. To

need

merely

be

displaced

overcome. Then the

by

the frictional

is

completed

Output

as

de-

5.44

1.5 Shaft beari Both the

input

bearings.

The intermediate bearings.

ngs

and

gear

the

output

shafts are carried in amply dimensioned taper roller

and the movable

gears

are carried in sturdy needle roller

\

1.6

Shaft

seals

External sealing

The running surfaces on the shafts are casehardened.

1.7 Lubrication The transmissions

with

splash

of

the

input

are

immersion-lubricated. The bearings are generously supplied

oil and oil mist.

and

output

shafts

is

provided

by

radial sealing rings.

2. Installation

2.1 Delivery condition

For

safety

shipment.

reasons,

The

shaft.

~~e

actuating

gearbox

lever

is

mounted

NOT

filled

on

with

the

oil

for

actuating

S.45

2.2

2.3

Before leaving prescribed ATF oil. acts as a preservative and provides

1 year if

Painting

Before painting

the

factory, each transmission

The

residual oil remaining in

the

units are properly stored.

the

gearbox

the

gearbox,

reliable protection against corrosion for

take

care

to

remove any oil films by means

able agents (e.g. HST safety cleansing fluid).

Always cover both

shafts before painting. Make certain

screw

is

Connection

A

torsio-elastic transmission and

to

loads.

the

not

closed by

of

protect

Radial

running surfaces and sealing lips

that

the

paint. Indicating plates should remain clearly legible.

gearbox with engine

is

play

damping

to

compensate

the

input

should

plate

shaft

be

between

for

from

at

is

the

minor

external

least

subjected

the

of breather hole

the

to

a test run with

transmission after draining

the

radial sealing rings

on

engine

alignment

forces

and errors

and

O.Smm.

the

at

least

of

suit-

on

oil filler

2.4

Suspension To

protect

made for

The

oil drain plug

2.5 Position The

inclination

manently exceed an angle of

The gearbox can also be

Interchange

of

engine-gearbox assembly in

the

gearbox from detrimental stresses and loads, provision should be

elastic suspension

of

the

of

-gearbox

the

in

of

the

oil dipstick and

of

the

engine-gearbox assembly

gearbox should be conveniently accessible.

the

boat

gearbox unit

20

mounted

in

degrees (see illustration).

with

the

boat

the

direction

the

output

oil drain plug

of

the

shaft

in

this case.

in

the

shafts should

in

the

upward position.

boat

or

not

craft.

per-

S.46

2.6 Operation Gear changing requires

lever remote control. Upon loosening the retaining screw,

illustration) can

or

rod linkage). Make certain

cover plate (9): The control cable

in the neutral position

The shifting travel, the neutral position and end positions A and B should be outer and

A larger amount

However,

which, in turn, would mean premature wear, excessive heat generation and

ing damage.

of

gearbox

be

moved

the

minimum distance between lever and cover should be 0.5 mm.

or

rod should

as

30

mm

for

of

lever travel

if

the lever travel

only

minimum

to

any position required that

the lever does

be

arranged at right

of

the

lever.

measured at the

the

inner

pivot is

in no way detrimetal.

is

shorter, proper

effort.

pivot

point.

o

The gearbox

for

not

angles

point

of

gear

engagement might

Minimum shifting movement

is

suitable

the

actuating lever

the

control elements (cable

contact

the

to

the actuating lever

the actuating lever, between

at

least 35 mm

for

single

(see

actuating lever

for

the

be

impeded

result-

Clamping screw

tightened

of

18 Nm

to

torque

to

be

Oil drain plug

Oil dipstick and oil filler screw

17 mm width across flats

A

8

Min.

distance

actuating lever 0.5 mm

of

S.47

The position to

ensure equal lever travel

When

installing the gearbox, make certain

restricted movability

sheaves,

guide

2.7 Engine-gearbox compartment Care

should

3.

3.1

Operation

Initial operation Fill the gearbox

oil

level

of

be

should

the cover plate underneath the actuating lever

from

of

the Bowden cable

too

small bending radius, etc.

taken

that

the engine-gearbox compartment

with

oil

of

the recommended grade

be

the index mark on the dipstick

neutral position

Casi

ng

su

rface

to

that

shifting

or

rod linkage,

A and

is

(see

items

(see

illustration).

is

factory-adjusted

B.

not

impeded

by

unsuitably positioned

is

properly ventilated.

4.1

e.g.

and 4.2). The

by

Correct readings up

200 inclination in direction

To

check the oil level, just insert the dipstick, do

hex screw

of

shafts

with

the dipstick after the oil level check.

to

Oil

level

Dipstick

--::~~~~Jlrr~~~~A~TF'

Type A

or

not

screw in. Retighten the

Dexron

II

S.48

3.2 Operating temperature The max. permissible temperature

3.3 Operation Shifting

ing be shaft and fixed

Gear changing should ruption). The multiple-disc clutch permits cluding sudden reversing at

3.4 Operation Rotation

or will

Locking

ing

is

cam. The completion

influenced

anchored in a river,

have

of

is

possible

of

the transmission oil

of

gearbox

initiated

without

of

the propeller

no detrimental effects on the gearbox.

the propeller shaft

by

a cable

by

external control. The actuating lever

by

means

be

load

as

by

engaging the

or

rod linkage

of

the

gear

changing operation

of

a retaining screw.

smooth,

without

well

top

as

not

too

speeds

load,

idling

by

an

additional brake

reverse

via

slow, and continuous

gear

in the event

e.g.

while the boat

of

the engine

gear.

is

130

0e.

the actuating lever and

is

automatic and cannot

is

mounted on

(without

changing at high engine rpm, in-

of

danger.

is

sailing, being towed,

with

the propeller stopped,

is

not

required. since lock-

an

actuating

inter-

actuat-

3.5 Lay-up periods

If

the transmission

filled

pletely

shaft and the

3.6 Preparation

Drain

level

with

output

for

the

transmission

with

oil

re-use

the

is

not

used

of

the

same

flange

by

prescribed

for

means

of

periods

grade

of

all

oil

oil.

of

more than 1 year

to

prevent corrosion. Protect the

an

anticorrosive coating

and

refill

to

it

the

should

if

be

input

required.

proper

com-

4. Maintenance

5.49

4.1

4.2 Oil quantity

4.3

Transmission oil To

ensure trouble-free operation

type.

Under no circumstances

sulphite. We

recommend commercial Automatic Transmission Fluid

or

Dexron

BW

5 approx 0.4

H HBW 10 approx 0.6 H

BW

20 approx 0.8

Use

the index mark on the dipstick

Oil level checks

Check oil Always

the

level

use

II.

oil is

the

level

the

same

of

the clutch, only

should the oil contain any additives

Itr Itr Itr

as

a reference.

in

the

transmission

index

oil

mark

grade

on

the

when

dipstick

topping

use

oil

daily.

up.

of

the recommended

such

as

molybdenum

(ATF),

Type A

Correct

(see

item

3.1)

.

4.4 Oil Change

vals

4.5

4.6

Checking the Bowden cable The Bowden cable

The minimum lever travel from the neutral position

(O-A = O-B) Make certain rod linkage

OVERHAUL

Disassembly mended. be

center.

change

the oil

of

at least 1 year.

that

for

If

done

by

for

the first time after about 25 hours

or

rod linkage

or

rod linkage should

should

these

easy

of an

the overhaul

be

35 mm

minimum

movability

transmission

Westerbeke

or

for

values

(see

or

an

be

the outer and 30

are

item 2.9).

in

repair

authorized

of

operation, then at inter-

checked at shorter

to

operating positions

mm

safely reached. Check the cable

the

field

is

needed,

Westerbeke

time

intervals.

for

the inner pivot point.

is

not

recom-

the

work

should

service

or

SERVICE BULLETINS

SECTION V

The

updated service

proper

systems.

You

and

Bulletin

or

following

should

make

overhaul.

Bulletins

information

procedures

functioning

familiarize

sure

(s)

whenever

that

about

which

of

you

your

contain

your

yourself

consult

eng

various

are

eng

ine

supplementary

components

important

and

with

the

requires

its

the

appropriate

and and

to

the

support

subjects

service

127

V2

SERVICE BULLETIN

DATE: MODEL:

SUBJECT: Connecting Pressure Sensing

6/15/69

All

Engines

Oil

pressure sensing devices, never reason the

be

connected

is

simply

fittings

used

the engine loses

Such

pressure sensing devices

directly

that

its

continued engine vibration causes fatigue of

to

make oil

pressure

connected to the oil gallery using oil hose.

Any

fittings

used

Devices

to

such

to

any

oil

such

a connection.

and

must

an

to connect the

BULLETIN NUMBER:

Oil

Galleries

as

senders

gallery of

If

and

an

engine.

these

switches,

The

fittings

20

must

fail,

very quickly seizes.

be

bulkhead

mounted

and

appropriate grade of lubricating

hose

to the gallery

must

be

of steel or malleable iron.

purpose .

Brass

must

not

be

used

fo"r

this

'..~j

PIN:

11967

J. H. WESTERBEKE CORP.

AVO"

",O«Ie.",'A'

NIt«,

CA.'.: " ••

AIIOII, MAee.

TCOIt~,

AVO"·

o.~

•.

r.'.Il:

·'.17/

•• -••••

...

-7700

SERVICE BULLETIN

V3

/.-",

DATE: MODEL:

SUBJECT:

5/6/74

All

marine

Exhaust

When

engine sea water

stream

strikes

Proper design of exhaust inlet strike

system

be

positioned

a surface

water stream should

inlet In

fittings

addition to the

tageous to divide the sea water exhaust The

system

remainder proportion of the sea water can

only

be

generators

system

failures

is

fed into

a surface, erosion

either

a water jacketed or ~ water injected

to prevent

so

that

directly.

be

as

big in diameter

above

so

that

is

normally piped directly over the side.

determined

design considerations,

only a portion of

by

and

marine

engines

an

exhaust

may

this

problem

the entering stream of sea water

Also, the velocity of the entering sea

low

as

possible

as

possible.

flow

trial

flow

and

to

at

pass error.

excessive exhaust temperatures with the

BULLETIN

system

cause premature

so

that the full

failures.

NUMBER:

{lIwet)1I

requires that the sea water

does

which

is

achieved

it

is

by

usually

having

advan-

the point of entry to the

it

enters the exhaust system.

The

proper

through the exhaust

The

goal

is

least

amount

of sea water.

system

to prevent

69

not

PIN:

19149

J. H. WESTERBEKE CORP.

AVON

'NDU.TR'AI.

CA.I..:

,.AR",

Mi

AVON,

••

TCOR,.,

iliA

AVON·

•••

02322·

T.I..1C:

'8f71

.2-4444

588-7700

V4

SERVICE BULLETIN

DATE: MODEL: SUBJECT: Non-Interchangeabil

In

recen't years

May

All

29,

we

1974

have

purchased

manufacturers.

In

no

case

manufacturer.

sender varies

Thus

it

may

by

becomes

the

In

gauge

some

of

cases the wiring of

manufacturer.

important,

one

when

replacement sender, to order a

manufacturer

Ammeters

is.

are

electrically

interchangeable.

STEWART-WARNER 2"

OIA

CASE

Ammeter

11581

ity

between

gauges

manufacturer

Manufacturers of

and

senders

be

used

either

ordering a replacement

matched

set

or to

VOO 2 3/8"

OIA

CASE

11931

from

BULLETIN

Gauges

four

di

NUMBER:

and

Senders

fferent

with the sender of another

or

both

know

the

gauge

or ordering a

conclusively

FARIA

2"

OIA

CASE

16550

and

who

NOVOX

2"

OIA

19165

72

the

CASE

Oil

pressure

Oil

pressure sender

Water

~Ja

ter

temp. temp.

Adapter ri

stall

2"

ng

dia

gauge

gauge sender

to i

gauge 2 3/8" dia panel cut-out

Wiring

diagram

SND~B+

n-

in

11544 11542 11545 11543 16023

and

S8

GND

~

#44

B+

11914 11916 11913 11915

LAMP

__

-.

.....

GND

Also S8

#36

...

__

SND

AMP-

16548 16551 16549 16552 16023

and S8

#44

LAMP'"

19166 19167 19168 19169 16023

and

S8

#44

LAMP+

SND~B'"

see

~

(;ND

SN

....

_·,...

(;ND

B+

PIN:

19190

J. H. WESTERBEKE CORP.

AIION

INDUSTRIAL

PARK,

CABLE:

AIION,

WESTCORP,

MAS.S.

AIION·

02322·

TELEX:

(517}

.2-4444

588-7700

SERVICE· BULLETIN

V5

DATE: MODEL: Four-9l,

SUBJECT:

An

anti-stall engines. beneath are a

complete

This

the

August

27,

1975

W-30 ; W-50

Proper

pumps

device

air

bleeding procedure for hydraulically

incorporating

is

device

is

vent bleed screw.

assembly

incorporated

located

incorporating parts #1,

gram.

The

anti-stall

with

the

upward

top

movement

engine deceleration.

device

end

has

a spring

of the fuel injection

of the metering valve to the fuel cutoff position, during rapid

Rapid

deceleration or rapid retarding of the

without this device installed

stoppage. It

should sary to bleed

be

noted

the

here that

bleed

screw

an

on

would

under

#5

shown

(If

fitted

engine

on

top

In

loaded

normally

normal

with

thi s

anti-stall

fuel injection of the fuel

fact,

the bleed

pump

(metering valve) preventing rapid

cause

which

#2,

pump

and

comes

engine

bleeding procedures,

on

the

diagram.

BULLETIN

type

pump)

governed

fuel injection

device

pumps

fitted

governor housing,

screw

#3

and

as

shown

anti-stall

in direct contact,

stalling

it

is

NUMBER:

to the

on

the dia-

throttle and/or

only

neces-

76

Four-91 just device

However, bleed

if

screw

excessive

#1

in the

air

entering the injection

diagram

during the fuel loosening or tightening the bleed is

to

loosen to prevent ing procedure

wise

during bleeding the result will

controlled If

the adjustment of the

a replacement

1.

2.

3.

the bleed

it

from screw

by

retarding the

pump,

Loosen body

(#2)

the locknut

screw

turning

#2

shown

the procedure for resetting

to

be Set engine idle Turn

the

anti-stall

and

upsetting the adjustments.

in the

throttle.

anti-stall

(#3)

unscrewed

speed

with

device

perceptible increase in the idling speed.

with

wrench

4.

Accelerate the engine to

and

tighten locknut (#3).

rapidly to the idling position.

maximum

RPM

to idling

RPM indication that the device should

engine

stalling

pump

makes

pump

bleeding procedure,

screw

one

#1,

two

is

to

hold

diagram

be

device

is

excessive engine

has

wrenches

the

anti-stall

inadvertently turned in or clock-

been

disturbed or

it

is

as

sufficiently to enable the

two

complete idling stop body

(#2)

turns. screw

(#4)

clockwise until there

Now

maximum

speed

has

occur, this is

no Should

exceed

been

load

RPM

and

the period of return

three seconds, this

screwed

an

in

indication that the device

it

necessary to

should

device

If

during the bleed-

RPM

which

follows:

anti-stall

to

800

hold

device

return the

too

far.

be

used.

cannot

when

RPM.

is

body

throttle is

However,

when

One

body

#2

be

installing

device

a barely

(#2)

from

an

PIN:

19329

J. H. WESTERBEKE CORP.

AVON

INDUSTRIAL

PARK,

CABLE:

AVON,

WESTCORP,

MASS.

AVON·

02322·

TELEX:

(8171588-7700

112-

........

V6

has should

CAUTION: because into the

loosened

housing

the "threaded

governor

or turned

may

not

Use

become

been

be

made

extreme

housing.

through

necessary .

SERVICE

screwed

in far

BULLETIN

accordingly. .

caution boss"

when

that the

It

is

not

tighteniny the locknut or the bleed

over-torquing, replacement of the

#76

conlt.

enough.

assembly

an

In

either case, re-adjustment

is

screwed

into

integral part. Therefore,

is

pressed

if

complete

screw

it

is

governor

On

all

prewired engines dating

been

relocated to the opposite side of the fuel injection

PN19329

8/27/74

•

from

early

1975

onwards

bleed

pump.

screw

(#5)

has

Page

2/2

DATE:

SERVICE BULLETIN

May

19,

1980

BULLETIN

V.7

NUMBER:

82

MODEL:

SUBJECT:

MODEL

W-7, & WPD4 W-13 W-21 W-27 & 11 W-33 W-30 W-40, & WPD-l0-15 W-50

All

Battery

& 4.4

& 7.7

Recommendations

KW KW

KW

BATTERY

RECOMMENDATIONS

AMPERE

60-90

90-125 90-125 90-125 90-125 125-150 125-150 125-150

HOURS

VOLTAGE

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C. W-58 & WTO-20 W-60

&WBO-20 W-80 & 30KW W-120 & 45

The

ampere

KW

hour

KW KW

range

shown

125-150 150-170 170-200 200

is

minimum.

minimum

There

is

no

real

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.

maximum.

PIN: 20442

J. H. WESTERBEKE CORP.

AIION

INDUSTRIA&.

PARK,

CAS&.E:

AIION,

WESTCORP,

IIfASS.

02322

AIION·TE&.E/(:

. (ts.71

112-

588-7700

••••

V.8

SERVICE BULLETIN

DATE: MODEL:

SUBJECT:

September

All

Heat

Many molded

There by

It inside of the

heat exchangers supplied

rubber

have

the

improper

is

absolutely essential

end

been

cap

according to the

In

any

cases of engine overheating

it

should

be

checked

troubleshooting.

4,

1975

Exchanger

cap

occasions positioning of

be

positioned over the baffle of the heat exchanger,

drawing

Rubber

to

facilitate

on

that

below.

End

Cap

on

our various products incorporate a

inspection of the tubes.

which

engine overheating

this

the

rubber

molded

where

end channel

such

BULLETIN NUMBER:

has

been

cap.

running across the

a rubber

end

cap

for proper positioning along with other routine

caused

is

used,

84

PIN:

20684

J. H. WESTERBEKE CORP.

AVON

'NDUsrR'AL

CA.L.:

"AR",

w.srCOR",

AVON,

MASS.

02322·

A.,Olt·r.L.1C:

'.,71

.2-4444

5

••

-7700

SERVICE BULLETIN V.9

DATE:

MODEL: SUBJECT: Alternator

April 4,

All

GENERAL two

from

lates other.

DESCRIPTION:

batteries

a single

each

Charging

1983

Marine

to alternator

battery

of discharge). bility It

of a rotary switch for selecting

also assures

battery. INSTALLATION:

1.

2.

Mount in system.

Be

splitter

an

air

sure to

stream

Install

alternator. the

alternator

3.

4.

5.

6.

Connect Connect Connect When voltage if

desired,

the

one

the other

the

splitter

8/10 volts less than usual.

output terminal instead of the regulator terminal.

BULLETIN

NUMBER:

Engines Output

be

rates are in proportion to the

This that

use

In

alternator splitter

by

Splitter

The

splitter

recharged

so

that

method

and

as

large

discharging

precludes the necessity,

ships services cannot drain the engine

on a metal

if

available.

with cooling fins aligned

is

a solid brought to the as

120

amp

one

which

state

and,

will

battery

device

same

ultimate voltage

at

the

have

no

effect

batteries'

and

is

which

same

voltage even to

be

allows

time, iso-

on

the desira-

charged.

starting

surface other than the engine, preferably

Do

not

install

near engine exhaust

vertically.

a wire size appropriate to the output of the associated

full

power

to the

splitter

side terminal to splitter is

installed,

connecting the regulator wire

systems

and

number from

the

4 wire

splitter

is

output terminal to the center

one

battery (s)

side terminal to the other

both

batteries

This

will see a charging

voltage

drop

directly

recommended

to the

batteries.

splitter

..

battery(s).

can

be

to the

alternator

87

the

(state

from

terminal.

regained,

PIN:

TEST

INFORMATION:

When

the engine

is

not running, the side minals should read the voltage of the respective battery. splitter

With minals should read the regulator or

should read zero voltage.

the engine running

and

same

somewhat

less.

alternator voltage

The

which

center

charging, the side

should

splitter

be

the voltage of the

terminal should read .82

volts higher than the readings of the side terminals.

J. H. WESTERBEKE CORP.

AI/ON

INDueTRIAL

20745

,.AR/(,

CA.L~;

AI/ON,

WtEeTCOR,.,

MAee.

AI/ON·

02322·,ef7} 5 ••

T~L~1C:

splitter

The

center

splitter

Continued

-7700

.2-4444

ter-

...

V.10

This unit BY

..

PASSING

from

alternator bypassing the both

of charge.)

is

SPLITTER:

batteries

sealed for

In

by

connecting

splitter

unless they

maximum

the event of

itself.

r---+-o.

life

either

This should not

are~

and

S?LITTER

I

A

PN20.6S4

2 (.;..-

and

is

fai1ure~

splitter

will

,).--+-.......e

.......

remain

POWER DISCONNECT

SWITCH

_ ..... 0

not repairable.

batteries

terminal

be

done

at,

POWER

may

#l

or

simultaneously for

the

same

DISC.

8+

STARTING

BATTERY(S)

-

8

+

.5ERVI

BATTERY(S)

CE

-o-

be

charged

#2

to terminal

voltage

SW.

......

~

directly

A,

(state

.sTARTER

-

SHI P',s

SERVICE

LOADS

-

SEE NOTE

DRWG

NOTE: and

engines, the regulator wire should

reconnected to the provide

On

regulator terminals,

Jl

Alternators

an

equivalent voltage drop.

20

70

I

which

such

OUTPUT

terminal

have

as

an the

isolation diode

Motorola

be

removed

as

shown.

units from

The

between used

the

REG

diode in the

their

with

terminal

-

output

most

WESTERBEKE

splitter

and

will

DATE:

SERVICE BULLETIN

Apri

1 28,

1976

BULLETIN

V.ll

NUMBER:

92 MODEL: SUBJECT:

Given gized, the

neg. (8-) terminals

Assuming gized

If

O.K.

the gauge, or with the sender. If

defective

All Troubleshooting

a presumably

first

there

and

perform the following

is

faulty

step

12

Water

is

to

of

the gauge.

volts

gauge

check

as

1. Disconnect the sender wire gauge

2.

Connect the sender terminal see this

both of the

and

the

either

of and

reads zero, the

if

the

gauge

situation.

above

problem

the

should

gauge lies

above

be

gauge

reads

tests

either

replaced.

Temperature

and

Oil

Pressure

Gauges

indication with the instrument panel ener-

for

12

VDC

between

the ign.

(8+)

and

required, leave the instrument panel ener-

steps:

at

the

normal

full

are

reading for

at

the

scale,

positive,

with the conductor

tests

is

negative, the

gauge

gauge the

the

and

this

to

normal

gauge

from

gauge

see

if

the

situation.

ground

and

reading

is

undoubtedly

the sender to

is

probably

for

Assuming

the

gauge

is

O.K., preoceed

the sender to the sender terminal

Check

isolated

(both plus

that

ground

the engine block

terminals

and

minus) the

ground

is

connected to ground.

and

if to the block. If

the sender

to

gauge

is

probably defective

conductor

as

at

follows.

the

gauge

Check

for

continuity.

the conductor

Some

the

battery

is

connected to the

side will not necessarily

is

O.K.

and

the engine block

and

should

be

replaced.

starters

be

connected

is

from

have

starter

grounded,

PIN:

21616

J. H. WESTERBEKE CORP.

AVON

INDIJSTRIAL

CABLE:

PARI<,

WESTCORP,

AVON,

MASS.

AVON·

02322·

TELEX:

(fS'7}

92 -........

588-7700

V.12

SERVICE BULLETIN

DATE: MODEL:

SUBJECT:

If speed, the reverse be If

The is

mission service dealer. To

On pad. should stop fewer

June

22,

1976 All Adjusting

the boat

moves

very careful the boat

goes

Paragon

P200

forward

band

may

not

to get reverse

backwards

when

be

when

Series

the gear

Reverse

is

out of adjustment.

band

too

in neutral,

following adjustment procedure should only

not possible to obtain the service of

an

Adjust: the outside

Under than

left its forward

one

washer

side of the gear there

head

are 1 to 3 washers.

boat

movement.

nor

more

than three.

But

Remove

under

BULLETIN

Band

in neutral

When tight it

or

may

be

carried out

authorized

is

a bolt in the

one

NO

circumstances

at

proper adjusting,

it

will

too

tight.

Paragon

washer.

NUMBER:

idle

burn

out.

when

it

trans-

mounting

This

use

93

PIN:

21683

J. H. WESTERBEKE CORP.

AI/ON

'NDuaTR'AL

PARIC,

CABLE:

AI/ON,

WE.TCORP,

"A.a.

02322

AI/ON-TELEX:

-

(8171

588-7700

.2-4444

~~.

! \

DATE:

SERVICE BULLETIN

September

9,

1976

BULLETIN

V.13

NUMBER:94

MODEL:

SUBJECT:

All

Fuel

Pressure

Overleaf installation

Switch

is

a parts

of the fuel pressure switch

engine products.

Installation

list

and

an

illustration

used

showing

on

most

the proper

of our

PIN:

21564

J. H. WESTERBEKE CORP.

AVON

INDUSTRIAL

CABLE:

PARK,

WESTCO"P,

AVON,

If

ASS.

AVDN·

01131111·

TELEX:

(8171

.11-

588-7700

••••

FUEL

(ON

INJECTION

PUMP.

EN~INE)

9 I

19/87

8'/9442.

7

/~320

~

11383

5

1I~/5

4

/9321

.3

/9185"

2

1f}261

I

19204

ITEU PART

NO.

I

flE..t'

"O"Rlr'IIt::;

FUEL

PLUG

'0"

ADAPTER

COPPeR

SCReW

HD.

;::-t..~T

WASHER

PRESSURE

RINt;

ASs')"

DESCRiPTION

OAT.

1"'1

".VISION

SCREW

l1"O.D.

9/1"

Wt4SHee

(Bl.eCD)

".CO"D

SWITCH

O.

D.

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.

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rUTHID"

lete

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-7,

WESTERBEKE

AVON.

rUW'NG

NUMm

MA.

21

CORP.

02322

7 4 3

MAD.

IN

U_

•.

A.

SERVICE BULLETIN

V.15

DATE: MODEL: SUBJECT:

7 July

All

Domesti c Hot

80

Rei

ssued

Water

Heaters

PRINCIPLE The

heater allows installation the heater

freshwater The

only potential disadvantage of a

due

either

as

models

is

full

water

is circuit.

to a

W58, W80,

connected in

flow

for

series maximum

also avoids several potential

in

parallel

restrictive

W120),

with

heater design, a large engine water

or a combination of both.

Installation

The

shorter the length of piping to

elevation of the heater should assure no

higher than the engine pressure cap.

this

at

any

heel angle, then the optional

to

be

the highest point of the

with the engine's freshwater

heat

either

c~rcuit.

transfer

pitfalls

to the heater.

of

installations

the engine's by-pass or

series

and

that

installation

from

the heater, the

the top of

If

the heater

remote

fill

its

must

tank

BULLETIN

circuit.

its

is

flow

better.

internal coil

be

higher than

must

be

NUMBER:

This

The

series in

which

internal

restriction

(such

The

is

installed

95

Piping to the engine the engine. convenient

Study

ing

inlet. want steam to

Since the heater

ient Some

in water

between

the engine

so

If

trapped

method

that

trapped

air

of

bl~eding

and

can

the attached sketches. A convenient place to

circuit

the

point of the

is

This

is hottest come

between

also the

water

from

is

circuit

the thermostat housing

hottest

available,

the faucets.

in

series

can

engine/heater combinations require

parallel

flow

with the heater. This

for cooling

capability.

of "by-pass" nipples in these

MODEL

W30

'----

SENDURE

W40 W

50

1/2" 1/2"

1/2"

___

\0158

HaQ

l.-Hm

heater should air

will

rise

to the

that

air

rise

automatically heater,

is

a necessity.

continuously

from

then a petcock or other

interrupt

outlet

water available.

it

is

possible for scalding water or

and

the exhaust manifold

CAUTION:

with the engine cooling water,

also

be

interrupted for heater

that

a "by-pass" nipple

is

required to maintain

The

table

below

shows

an

the

situations:

HEATER

ALLCRAFT

NPT

l{p'L_

IJPT

1/2" 1/2" 1/2"

NPT NPT NPT

from

the heater

the heater to

the engine cool-

While

most

owners

even

any

other conven-

installation.

be

installed

adequate fresh

minimum

diameter

RARITAN 3/8" 3/8" 1/2"

NPT NPT NPT NPT

3/4"

3f~NPT

3/4"

~IPT

PIN:

21814

Please see sketches

on

overleaf.

J. H. WESTERBEKE CORP.

AVON

INDUSTRIAL

CABLE:

PARK,

WESTCORP,

AVON,

MASS.

OZ3ZZ -(.f7/

AVON -TELE

1C:

8Z

5.8-7700

- ~~~~

Westerbeke 50 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual