Westerbeke 6.5KW, 8KW, 11KW Technical Manual

TECHNICAL

WESTERBEKE

4

CYLINDER

MARINE GASOLINE

GENERATOR SETS

TWG SERIES

MANUAL

jr-.v-

6.5KW, 8KW, 11KW

Publication # 34645

Edition Two

November 1987

'WESTERBEKE

J WESTERBEKECORPORATION

•

MYLES

150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

TECHNICAL

WESTERBEKE

4

CYLINDER

MARINE GASOLINE

GENERATOR SETS

TWG SERIES

MANUAL

6.5KW, 8KW, 11KW

Publication # 34645

Edition Two

November 1987

~r-.v-

'WESTERBEKE

WESTERBEKECORPORATION

~

MYLES

150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

TAUNTON,

PARK

MA

02780-7319

SAFETY PRECAUTIONS

The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator.

The

above symbol is used in the manual to warn

serious personal injury or loss

of

life.

of

possible

CAUTION

The above symbol is used in the manual to caution personnel of

possible damage to equipment.

Read

the manual carefully and thoroughly before attempting to operate the equipment. Know when dangerous conditions can exist and take necessary precautions to protect and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and moving and hot parts serious personal injury or death. Follow recommended proce-

dures carefully. Always operate bilge blowers for at least five minutes before

starting a gasoline-fueled engine; ensure no gasoline fumes are present before starting.

• Prevent Electric

Shut off electric power before accessing electrical equipment.

are

potential hazards that could result in

Shock

personnel

• Use Extreme Care When Handling Engine Fuel (A

constant danger

Do

not fill fuel tank(s) while the engine is running.

Do

not smoke or use

fuel tank.

• Do

Not

Alter

or

Be

sure all fuel supplies have a positive shutoff valve.

Be

certain fuel line fittings are adequately tightened and

free

of

leaks.

Make sure a fire extinguisher is installed nearby and is properly maintained. tinguishers rated ABC applications encountered in this environment.

of

explosion

an

open flame near the engine or the

or

fire exists)

Modify the Fuel System

Be

familiar with its proper use.

by

the

NFPA

are appropriate for all

Ex-

• Use Extreme Care When Servicing Batteries

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a which can be ignited cigarette, cigar, or pipe. flame near the battery being serviced. Shut off all electrical

equipment in the vicinity to prevent electrical arcing

during serviCing.

by

electrical

Do

highly-explosive gas,

arCing

or

not smoke or allow

by

a lighted

an

open

Use

insulated mats whenever working on electrical equip-

ment. Make sure your

shoes), and keep your skin surfaces dry when handling electrical equipment.

Remove wristwatch and jewelry when working on electrical equipment.

Do

not connect utility shore power to vessel's except through a ship-to-shore switch. Damage to

is not done.

Be extremely careful when werking

ponents. High voltage can cause injury or death.

clothing is dry, not

vessel's

double-throw transfer

AC

generator may result

damp

(particularly

AC

on

electrical com-

• Exhaust Gases Are Toxic

Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists.

Be

sure the unit and its surroundings are well-ventilated.

circuits,

if

this

• Ayoid Moving parts

Do

not service the unit while the unit is running;

tion arises in which

operating adjustments, parts and hot exhaust system components.

Do

not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts or sleeves, rings, necklaces, or bracelets that might be caught

moving parts. Make sure all attaching hardware is

Keep protective shields and guards in their respective place at all times.

Do

not check fluid levels or drivebelt tension while the unit

is operating.

Do

not work

ly

incapacitated

on

it

is absolutely necessary to make

use

extreme care to avoid moving

properly tightened.

the equipment when mentally or physical-

by

fatigue.

if

a situa-

in

TABLE OF CONTENTS

INTRODUCTION INSTALLATION OPERATION

................................................................... 4

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

MAINTENANCE ENGINE TABLE TABLE

TECHNICAL

OF

TIGHTENING

OF

STANDARD DISASSEMBLY ENGINE ENGINE LUBRICATION COOLING

INSPECTION

ASSEMBLY

SYSTEM

SySTEM

................................................................ 3

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

DATA

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

FOR

OVERHAUL.

TORQUES

TIGHTEING

AND

REPAIR

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

TORQUES

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

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

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

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

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

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

14 18 21 28 29 30 35 47 60 66

GOVERNOR

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

CARBURETOR

DC

ELECTRICAL

DC

WIRING

AC

GENERATOR LAY-UP SERVICE

DIAGRAM·

AND

RECOMMISSIONING

BULLETINS

AND

FUEL

SYSTEM

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

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

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

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

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

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

73 75 78 79 89 98

101

1

IMPORTANT

Product technical and and Westerbeke, dingly, tesy CONTENT

software

data,

parts

price

specifications

is

provided

and

service.

OF

SUCH REPRESENTATIONS TIMELINESS LIABLE CONNECTION SUCH

For

SOFTWARE.

example, Westerbeke's blocks, cal

components, ported Westerbeke Westerbeke's dated

and no

Westerbeke's

in

advance,

software

FOR

fuel

by

until

OR

COMPLETENESS

ANY

WITH,

components

products

systems

their

must

own

suppliers,

are

after

PRODUCT

of

all

kinds,

operator's

lists,

and

provided

not

within

to

Westerbeke

tiESTERBEKE

SOFTWARE,

WITH

TYPE

OR

ARISING

RESPECT

OF

and

pumps and

manufacturers depend product

longer

on

software.

accurate.

of

frequently

such

SOFTWARE

such

and

workshop

other

from

Westerbeke's

customers

CANNOT

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THEREOF,

DAMAGES

OUT

OF,

and

sub-assemblies

supplied

components,

other

products)

with

such

which

not

changes

software

Westerbeke

reflected

take

NOTICE

as

brochures, manuals,

information,

sources

control

BE

RESPONSIBLE

NO

INCLUDING

AND

OR

THE

by

WILL

INJURY

FURNISHING

others

transmissions,

are

their

own

for

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software

changes

rarely

in

place.

drawings,

parts

instructions

other

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FOR

WARRANTIES

THE

ACCURACY,

IN

NO

EVENT

INCURRED

OR

USE

incorporated

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engine

electri-

generally

software,

the

design

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has

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supplier's

lists

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THE

OR BE

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and

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Westerbeke between

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Westerbeke

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editions

products

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currency

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of

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time

and

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the

Westerbeke

most

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documen-

products,

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on

but

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or

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consulted

INTRODUCTION

This tion, gasoline important

manual

maintenance,

engine

to

A. Read B. C. Keep

Understanding

The

gasoline

lar

to

the

gasoline

tical

in

line, distributor, lubrication controlled. engine

used maintenance engine vity system, assembly engine able

treatment

in

his

are

proper

cooling

and

driven

service.

the

is

a

overhaul

driven

the

unit's

it.

Keep

it it

the

Gasoline

engine

overhead

horizontally

system

It

to

that

with

follows

drive

any

automobile.

ventilation,

system

thorough

generator

What

unit

receives

basic

guide

generator.

dependability

in

a

safe,

handy

for

Driven

driving

in

camshaft

mounted,

fresh

therefore

our

generator

intelligent

The

and

generator

testing

capable

we

as

in

to

the

and

troubleshooting

The

information

and

dry

place.

reference

Generator

the

AC

generator

your

automobile.

chain

camshaft

water

to

cooled

a

requires

operator

most

important

maintenance

end.

have

the

resulted

of

many

manufacturer

field.

installation,

service

at

all

times.

The

dr i ven.

driven.

engine

great

extent

the

would

factors

of

the

Care

in

thousands

cannot

That

part

start-up,

of

your

contained

life.

is

-in many ways cylinders

Solid

Pressure

block.

that

same

give

to

fuel at a

system,

the

factory Westerbeke of

hours

control

is

up

opera-

Westerbeke

within

simi-

are

ver-

state

type

Thermostat

the

gasoline

preventative

the

unit

gasoline

longe-

ignition

during

gasoline

of

depend-

is

to

you.

is

the

Ordering

Whenever part List). of

description

Be

the

generator Westerbeke quently

not

Parts

replacement sure factory

made

and

to

include

and

packaged

to

the

part

its

same

parts

are

number

the

engine's

model

parts,

specifications

needed,

(see

number.

because

always

separately

serial

Also,

"will

as

include

number be

sure

fit"

original

the

furnished

along

to

with

insist

parts

equipment.

complete

Parts

that upon

are

fre-

3

Forward

INSTALLATION

Since

(Power

The

Yacht

purpose

generator

Inspection

The

properly

These

are accepting be

opened visible vering tents

made

agent

of

damage.

J.

H.

Westerbeke

Rigging

The

Rope lifted have fore,

by means

been

auxiliary

CAUTION: lifting lifting

The used litle bility

is

at

of

crankshaft

In

some

the

regular lowered If

the

opening

some

extent, cooling equipment should

be entering replaced

In

cases

upwards

must parts

be done

that

generator.

the

-

of

into

an

of

Equipment

generator

crated.

usually

shipment

and an

or

concealed

to

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shipment

any

discrepancies.

Claims

and

Lifting

generator

or

chain

designed

Slings

eyes

in

must

general

amply

a

strong

time

accidents

pulley.

cases

horizontal

endwise

the

piping,

should

taken

openings.

once

the

where

or

generator

very

the

yachts

Sailing

this

in

which

Yacht),

section

environment

is

shipped

Accessory

packed

from

in

the

inspection

damage

sign

nReceived

against

for

loss

or

Corporation.

is

fitted

slings

of

tackle

to

slings

carry

are

must

should

attached

not not

significant

not

be

in

rule and

it

in

see

by may

moving

and

firmly

that

avoiding

be

position.

through

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extremely

outside

manifold,

a

small

clearances

filters,

be removed by a

to

avoid

unit

it

The

has

is

end

damage

parts

been

necessary

upwards,

carefully

lifting

sling

these

details

is

to

aid

that

items

the

from

are

same

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our

transportation

made

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in

the

This

damage

for

noted,

damaged

packing

is

must

----

with

lifting

be

attached

to

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full

required

be

so

short

sheer

excess

stress.

of

generators

fixed

it

is

firmly

haste.

necessary

It

hatchway

restricted,

by

mounting

competent

to

any

which

positioned.

to

the

to

avoid

bear

against

generators

on

the

not

be

factory shipped crate

company,

concealed

you

condition

list

your

protection

be made

eyes.

to

this

weight

or

desired.

as

10·

from is

in

place.

supported.

Do

to

lift

may

be

which

it

the

removal

lugs,

exposed

have

hoist

attachment

the

due

are

installation

installer

detrimental

securely

in

separate

as

the·

generator.

damage.

should

n

•

and make

to

the

eyes

sling.

of

the

to

place

Strain

the

vertical.

to

see

that Move

not

the that

lift engine

the

cannot

is

possible

of

etc.

mechanic

parts

been

the

removed

generator

of

possibility

to

the

installed

in

placing

mounted and

small

the

crate

require

Also

sure

against

carrier,

and

The

lifting

generator

the

on

the

all

the

Eliminate

from

in

engine

be

made

to

the

alternator,

This

and

special

to

lifting

of

weight

also

to

vary.

it.

boxes.

Before

should

If

either

the

deli-

check

note

loss

not

the

engine

1

there-

generator generator

equipment

engine

possi-

the

front

other

must

larger.

reduce,

accessory

avoid

should

front

slings

damage

of

vary

our

con-

is or to

eyes

a

than

be to

care

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end

to

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4

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competent

Extreme

is

wiser

people

caution

that

special

knowledgeable

and

care

rigging

in

cannot

the

be

work

be

handling

stressed

done

of

heavy

enough.

by

experienced

equipment.

and

Generator

The

through vibration are

the

in

generator

mounting

Mounting

complete

soft

from

each

centers.

-

generator

flexible

the

generator

to

its

Location

isolator

mounting

unit

mounts

to

the rail

platform.

is

rails.

to

mounted

that

Three

be

used

These

on

prevent

in

holes

lightweight

the

1/2

inch

properly

are

transfer

bolt

secur

on

15

rails

of

holes

ing

inch

The

vapor above. vicing

sideration platform

support

it

at

The vessel engine end.

generator

location

areas

It

should

and

on

the

all

angles

generator

it

cylinders

Heat

efficency

and

away

repairs.

as

well.

which

generator

is

installed.

from

should

be

the

of

vessel

set

and

the

and

be

from

being

properly

Access

The

location

generator

and

securely

needs

is

of

generator

longevity.

such

splashed

ventilated

for

is

operation.

fresh

Air

prime

is

importance

end

that

major

should

mounted

hold

cool

needed

must

5

it

by

and

repairs

the

air

is

dry

bilge

accessible

be

properly

should

mounting

in

whatever

for

be

removed

and

above

water

should

ventilated.

be

strong

rails

location

combustion

cooling

to

or

for

be

fastened

the

insure

low-lying water minor

given

enough

in

wi

thin

generator

proper

from sercon-

The

to to

the the

Air

Reguirements

(Minimum

Values)

Model

6.5

KW

8

KW

11

In

confined

compartment

air

should

Unwanted

compartment.

Sizing

The should be

worked

An ticular and

run.

as

3 - 5

proper

be

inventory

attention

times

Determine to

handle

by

means

be

directed

hot

installed,

out.

(The

its

the

this

load

compartments

of

AC

at

air

sized

should

generator

otherwise

of

the

vessel's

to

motor

amperage

draw

normal

average

with

reserve.

Engine

40 40 53 fresh

or

DC

the

generator

loads

of

running

AC

load

cu.ft./min cu.ft./min cu.ft./min

cool

air

blowers

end

be

to

allowed

maintain

compromises

AC

loads

that

a

the

motor

amperage.)

of

the

vessel

should

and

necessary

bell

to

the

when

should

generator

when

starting

be

opening.

exhaust

average

loading

be

will

and

size

Generator

cu.ft./min

200

cu.ft./min

220

cu.ft./min

250 brought

ducting.

vessel

will

made

paying

have

can

be

the

into

This

from

load

have

par-

to

start

as

much

generator

the

to

Model

6.5-614

4.9-514

8.0-614

6.0-514

11.0-614

8.5-514

Exhaust

All

the

engine engine healing, Special

tight

System

exhaust

is

backing

attention

and

(60 (50

(50

exhaust

not

free

Hertz) Hertz)

hertz)

Hertz)

(60

Hertz)

systems

running,

of

CARBON

manifold

down,

must leaks.

115/230 115/230

should

when

from

be

following

made

MONOXIDE

Volts

be

such

and

cylinders

the

to

insure

WARNING EXHAUST

vessel

seas

GAS

that

the is

is

or

the

IS

DEADLY.

entry

prevented

under

any

other

system

Amps

56/28 43/21

70/35 52/26

94/47 74/37

of

sailor

is

water

into

while

power,

conditions.

secure

the

and

6

Exhaust System

IWARNINGI

CARBON MONOXIDE EXHAUST can cause unconsciousness and is potentially lethal. on monoxide inhalation

or

o Dizziness

GAS

IS

DEADLY. Carbon monoxide is a dangerous gas that

poisoning are listed below.

o Vomiting

Some of the symptoms

or

signs of carb-

o Intense Headache o Muscular twitching o Weakness and sleepiness o Throbbing in temples

All

exhaust systems should be such that the entry of sea water into the engine's exhaust manifold and

cylinders

ing down, from following seas

is

prevented while the engine is not running, when the vessel is under sail

or

any other conditions. Special attention must be made

or

power, healing, back-

to

ensure that the ex-

haust system is secure and tight and free of leaks.

The sea water supply thru-hull sea cock fittings

to

tings should not be used, as they tend

encourage siphoning.

must be of the flush-hull type. High-speed scoop type fit-

When a water lift type exhaust

system is used, the exhaust muffler should be mounted as close to

the engine as practical. The

exhaust discharge should always drop downward into the

exhaust muffler. Loops in the

exhaust

hose

between

the

water-injected exhaust elbow

and the water lift muffler should

be avoided as these will trap and

hold water.

For installations where the ex-

haust manifold/water-injected

exhaust elbow is at

or' below the

vessel's water line, provisions

to

must be made

or

break

supply

a vent in the sea water

hose

jected exhaust elbow

install a siphon-

to

the

water-in-

to

stop the

flow of raw water through the

raw water cooling system, filling

the

exhaust

and

engine cylinders when the engine is shut down. This sea water supply

hose must be looped above

the water line and the siphon-

break

or

vent installed in the high

point of the loop above the water

or

line. This siphon-break

vent

7

&uer-ator

Above

Wabr

line

must used,

when

always

the

must

engine

be

have

above

the water line at

its vent

is

hose

or tube

shut down to allow air to enter through this vent

all

angles

routed

Exhaust Back-Pressure The

exhaust minimal Exhaust erator sive

back-pressure will affect the engine's performance

discharge

run

to prevent

baCk-pressure

is

put into

service.

hose

must

excessive

should

be

(Refer

be

of

adequate

exhaust

checked

back-pressure. before

to the illustration.) excesthe generator's power output. To

measure manometer, ing

gauge a tapped tapped for a 1/4-inch

the engine's back-pressure, either a mercury

has

hole

a water

to be

in

used.

its

exhaust

column,

If the generator

elbow,

NPT

fitting.

or another

one

pressure

set

must

of

vessel

so

as

to

size

to a

measur-

does not

be

drilled

operation to

be

above

and

gen-

and

have

and

the water

and

prevent

line

and

prevent

siphoning.

to

remain

siphoning.

The

vent,

when

empty of water

Exhaust Elbow

Exhaust

Measure while measured lowing

Excessive the of the be exhaust tem

manifold haust hold haust

the engine's back-pressure at the

the generator

by a

gauge

is

under a

instrument,

speCifications:

3

inches 39 22 11/2

exhaust

limited since

between

in

systems

of mercury

inches

ounces

of water

psi

back-pressure

hose,

discharge

these

system

the engine's

and

the water injected

elbow

must

the

heat.

must

(0.104

in

a water column

can

fittings, water pockets,

hose.

will

create

must

be

separate

exhaust

be

insulated

Dry

stack type

be

attached to

full

kg/cm

be

caused

The

flow restrictions

ex-

to

ex-

the generator engine's exhaust

manifold by connector be

properly supported

lated

to prevent water entry into the

engine's

must

be

the engine's

means

pipe.

of a flexible

This

system

and

must insu-

cylinders. Provisions

made

for the discharge of

cooling

sea

water.

load.

should

2

)

use

from

exhaust

Back

pressure,

not

exceed

(.099

kg/cm2 at

by a

small

and a high

of

elbows

any

other engine's

r

loin

elbow

as

the fol-

0

4

C)

diameter

volume of water

and

fittings

and

contribute to

exhaust

in

the

exhaust system.

'

......

c--!M

hose, a small

in

the

exhaust

discharge hose's routing back-pressure.

Dry portions of the

'

II

muffler,

system

sharp

due

to the length

The

generator's

exhaust

bends

should

sys-

in

8

Dry

Stack

Exhaust

Fuel System

The

generator must

primaryfilter/Water separator. at or above the generator with the fuel

tank's top must running. supply line into the engine through the carburetor, position or not

This

erator's engine be erator buretor

manually-operated service

vice shut-off The

Guideline.

This

(anti-siphon) shut-off

operationable from the generator's start/stop

is

located above the

remains

valve

two illustrations that follow

These

have

its

own

fuel

supply line;

DO

NOT

tee

fuel

supply lines to the engine's carburetor routed below the

have a means

installation procedure helps

seat

properly, or

valve

is

started, orwhen it

fuel

above the top

shut

located at the

illustrations show basic

of shutting off the

should can

tank(s), whereby the routing of the

-off

the

be

electrically-operated

is

shut

level

of the

valve

should

fuel

connection to the generator.

were

taken

off another engine's

guard fuel

line rupture

down.

panel

fuel

from

fuel

system

in

other

words,

fuel

to the generator's

against the possibility of gasoline siphoning through this

should

A manually-operated

tank,

be

the carburetor float

between

(with

or from

do not require this (anti-siphon) shut-off

located

the

between

Coast

layouts that incorporate anti-siphon protection.

it

must

have

its

fuel

supply.

manual

the

vessel's deck. I nstallations

Guard

Installations with the

engine

needle

the

engine

valve

fuel

supply line to the generator's

the

fuel

publication Fuel. System Compliance

and

override) to

can

also

pickup at the tank

own

when

valve

fuel

open

be

installed

pickup

the

stick

tank.

when

where

tubes

fuel

level

engine

in

the

and

the

valve.

and

tank(s)

of

is

open

should

the

and

the not

gengen-

car-

A

ser-

FUEL

LINE

TOP

LEVEL

FUEL

TANK

All

fuel

lines

shoule

be

supported every

The

fuel

tank's vent

fuel

tank(s). Moisture must not

be

12 -14

should

ALWAYS

TOP

LEVEL

routed

inches.

be

ABOVE

FUEL

TANK

---'

NO

ANTI-SIPHON

and

supported to

Use

located

be

allowed to accumulate

-

--

OPERATED

NOT

ACCEPTABLE

as

few

connections

so

that its discharge route cannot allow water to enter through to

TOP

--

DEVICE

VALVE

prevent

LEVEL

--

OR

ELECTRICALLY

HEEDED

leaks

from

as

possible.

in

the vent's

--

vibration

line.

and

chaffing.

The

line

should

the

9

~

___

ANTI-SIPHON OEVICE OPERATED

-

---

FUEL

-

STOP

--

OR

ELECTRICALLY

VALVE

;:;;L-;::;-

T;;;

LEVEl~

FUEL

/

LINE

BELOW

ANTI-SIPHON VALVE

FUEL

TANK

TOP

FUEl

LINE

TOP

~

NOTE:

LEVEL

ANTI-SIPHON DEVICE STOP

VALVE

60ES

BELOW

The

use

these may tax the

DEVICE

AT

FUEL

TANK

LEVEL

ABOVE

FUEL

AT

POINT

FUEL

of check valves instead of a solenoid shut off valve is not recommended,

fuel

lift pump's ability to draw trap dibris under their seat which inhibits the valve's cracking pressure

is

recommended that

It generator's engine to

an

approved filter/separator

help remove contaminants

lift pump and carburetor.

FUEL

OR

ELECTRICALLY

WITHORAWAL

TANK

FUEL

OR

ELECTRICALLY

WHERE

TANK

TOP

is

too high, it may cause vapor lock.

TANK

LINE

TOP

FUEL

LEVEL

TOP

LEVEL OPERATED

FITTIN'

ANTI-SIPHON DEVICE

I

OPERATED

BELOW

FUEL

LEVEL

DISTRIBUTION LINE

TANK

OPERATED

fuel

through a check

valve's ability to close.

be

used

in

the

fuel

before the

FUEL

the

STOP

OR VALVE

FUEL

valve.

In

addition, if a check

fuel

supply between the

fuel

reaches the engine-mounted

ELECTRICALLY

as

Check valves can

fuel

tank and the

fuel

IWARNINGI

Gasoline leakage

in or around the generator compartment

is

a potential cause of fire and/or

explosion. Repair leaks promptly and ensure that the compartment

is

properly ventilated.

10

Cooling System

The

generator's engine

the heat exchanger's cooling

positive displacement rubber impeller

is

fresh water cooled by

medium.

Sea

pump.

an

water

is

Afterthe

engine-mounted heat exchanger.

pumped through the heat exchanger by a belt-driven,

sea

water cools the fresh water that circulates through the heat

sea

water

is

exchanger, the

discharge, carrying with it the heat

engine's fresh water The

engine's fresh water coolant

system.

then injected into the exhaust

removed

is

circulated by

from the

means

of

a belt-driven, centrifugal type metal impeller pump

on

mounted coolant's temperature

the side of the engine. The fresh water

is

thermostatically controlled. A

plastic fresh water system coolant recovery tank is sup-

each

plied with recovery tank

engine.

be

It

installed

is

recommended thatthis coolant

and

used.

COOLANTIIECOVEJIYTAIIIC

Sea

water

is

used

as

DC Control Circuit

is

This circuit

PART

183).

designed

No modifications

assure that the installation of the generator set

installed be

Electrical System Characteristics

The

in

compliance with the above Coast

the cause of injury.

generator

is

and

manufactured

may

be

in

made

started by a conventional,

compliance with United States Coast

to it by the installer or

and

any remote start panels or remote instrument

Guard

Standards. Failure to observe these requirements could

separate

cranking motor which includes a self-contained, positive-engaging starter solenoid. Battery recharging capacity 50

Amps output capacity. A circuit

all

solenoid, protects

subsequent wiring.

momentary toggle switches are

and

reliable

The

choke

ventional breaker points.

in

a marine environment, no

is

automatic

and

electrically operated.

An the ignition system should the engine's approximately milliamps

the generator

amounts to about necessary to during normal operation. be

unattended for many months, the two to stop this slight drain tery switch providing

second

to

mounted control

(.025

is

be

2175. or 1/4th of

This shutdown consumes

an

connected

18

to

Amp-hours

concerned with this slight discharge

If the generator

is

to first turn off the

12

volts to the generator

remove

the ignition

panel.

An

used

breaker,

to start

located within 7 inches of the battery connection to the starter

This

circuit breaker

and

stop the generator

relays

have

been

The

ignition system

overspeed shutdown switch shuts off the generator set by grounding the out

rpms

reach,

25

Amp)

at

all

times once

its battery.

in

fuse

As

this only

a month, it

set

easiest

main

set,

on

the generator-

is

were

ways

un-

to

batand

optional remote start

COOLANT

user.

It

is

provided by

is

manually resettable.

set.

To

incorporated

in

is

electronic

RECOVERY

Guard

is

the installer's responsibility to

Standards

TANK

(33

panels

an

alternator with approximately

Three

manually-operated

keep

the control circuit simple

this electrical design.

and

does not

require

B AMP

IGNITION

CFR

are

con-

FUSE

11

panel is available LED which lights when the engine runs at approximately 600 rpm. The purpose operator ning. An optional remote instrument panel is available, which includes starting controls. This panel also includes a water temperature gauge, oil pressure gauge, battery voltmeter, operating hourmeter and start-stop control switches.

to

for

controlling the generator from a remote location. Remote start panels include a green

release the starter toggle switch in addition

of

the LED is

to

continue indicating that the generator set is run-

to

alert the

REMOTE

DC

Circuit

The two-pole ON switch is operated pole provides a source B

+

to gize the starter switch when the generator is running. If starting the generator at a remote location, release the START switch when the green LED tinue holding the ON switch until oil pressure is sufficient the

normal B + path

generator is running until someone again operates the ON switch first. Should the generator shut down from an overspeed condition, the overspeed circuit is done

procedure.

Description

the start switch and

to

crank the engine. If you are starting the generator at the generator set, release the START

by

simply depressing the STOP switch momentarily and then proceeding with the normal starting

is very important that the overspeed shutdown always be installed and functioning. Any

It tampering with the overspeed shutdown

be a cause

to

run away.

of

injury should the generator's belt-clriven governor fail and cause the generator

START

of

B +

to

bypass the protective shutdown switches, the START switch is pressed

lights, but continue depressing the ON switch. After releasing the START switch con-

to

the ignition system. Note that it is

PANEL

to

bypass the protective shutdown switches during starting. The second

to

the START toggle switch. While continuing

to

close the oil pressure safety switch, providing

now

impossible

must be reset before attempting

IWARNINGI

module, which would cause it

REMOTE

to

hold the ON switch,

to

energize the starter while the

to

GAUGE

PANEL

to

provide

to

restart the generator. This

malfunction, could

ener-

To STOP the generator, depress the STOP switch, which opens the normally closed B + path on the ON and START switches. The STOP switch must be held open until the generator comes Remote start panels may be connected tween the

T1

and T2 connections at the panel connection terminal board.

to

the generator set as indicated. A jumper has

12

to

a complete stop.

to

be removed be-

When

installing the optional remote start

the installer's responsibility to comply with

Generator AC Load Connections

ALL

115

VOLT

CURRENT

THE

LOWEST

LOADS

FLOWING

AMPERAGE

MUST

IN

ANY

RATING

BE

DIVIDED

OF

THE

ON

IWARNINGI

panel

or the optional remote instrument

U.S.

Coast

CAUTION

UP

AND

THREE

THE

LEGS

GENERATOR'S

Guard

CONNECTED

(G1,

Standards

G4,

G2/G3)

DATA

33

CFR

IN

SUCH A MANNER

DOES

NOT

PLATE.

panel,

PART

EXCEED

it

183.

THAT

is

rating

the

The

cover

generator

of

connections

This

4

lead binations wire,

or

wire.

All

be

connected 115 volt to

the

115

volt

devices

230

For

half

of capacity leads from

G4

Gl

and

230

nected

to

generator

CAUTION: LOADS AND MANNER

IN

ANY

(GI,

EXCEED RATING

the

of

is

wi

the

for

a

th

of

generator.

generator

115

single

vol

115

115/230

volt

to

one

sources

must

volt

all

the

may

and

source.

115

generator's

be G2/G3

G2/G3.

Volt

rated

Gl

loads

and

capacity.

ALL

MUST

BE

CONNECTED

THAT

G4,

THE

ON

OF

G2/G3)

THE

CURRENT

THE

LOWEST

data

or

230

tage

volt,

devices

of

and

be

all

connected

volt

taken

and

are

G4

at

115

DIVIDED

IN

THREE

DOES

AMPERAGE

DATA

plate

The

mounted

volt

phase,

com-

two

three

must

the

two

230

loads,

rated

from half

confull

VOLT

UP

SUCH

A

FLOWING

LEGS

NOT

PLATE.

gives

generator

AC

the

voltage,

set

control

output~

wir

panel

4WIRE

1.

WHEN THE ELECTRICAL SYSTEM REQUIRING

~'-----1

z

w

a:

:)

....

<t

::E

~'------I

2. WHEN THE ELECTRICAL SYSTEM REQUIRING 120V.

~'-----i

z

o z

~

w

a:

:)

I-

<t

::E

~'------;

ONLY

120 VOLTS:

OR

amperage

ing

120/240 VOLTS:

decal

shows

the

IS A TWO

IS

A THREE WIRE TYPE

and

located

electrical

WIRE TYPE

NEUT.

LEG

230

hertz

on

V

12-1

Shore Power Connections If the installer connects shore power into the vessel's

POWER/OFF/SHIPS

GEN,

center position-off transfer switch

AC

circuit, this must

as

shown below.

be

done by means of the

CAUTION

Damage to the generator can result if utility shore power and generator output are connected at the

same

time. This type of generator damage is not covered under the warranty; it

installer's responsibility to ensure that

Generator

~

i

:z

=L..

______

t

I

L

____

-(-<J) ~\

r-----\Q)

I ,

I

/,.--

NOTE:

__

all

DIAGRAM WIRE.

SY_S-,TEM OTHER

....

~-

/

...

AC

connections are correct.

SHOWS

128-VDLT

USE

DOITED

HOT

LEGS.

CONNECTIONS

SYSTEM.

LINES

FOR

THREE-WIRE

FOR

----,

I

L_L2

Ship'S

LOAD

TWO-

THE

SHIP-TO-SHORE

(3

POLEI

PN

328B8

(48

AMPS/POLE)

PN

32B89

(8B

RMPS/POLE)

PH

32818

(125

AMPS/POLE)

PN

32133

(288 AMPS/POLE)

SWITCH

is

SHORE

the

GeneralOr

N

GI'

-

I--

L---+--Ir---+W

~

Shore

)

_____

~-~Dl

DIAGRAM WIRE.

WITH

..::B..::.O"-AT~S

/"--

......

,

4'·

);,

....

,

,-+---,

SHOWS

120-VOLT

CONNECTIONS

SYSTEM

THREE-WIRE.

YSTEM.

FROM

120-VOLT

FOR A TWO-

THE

GENERATOR.

NOTE:

"

I

-_

....

" /

..--

....

/

'\

\

L---.L1

Neutral

ir-~;-~ro==:::'n~/;"';~:~~:~~:f'N:H:T:)

:Z~

t (GRN)

Power

l2

Ship's

Note

~~.,:

NO

equipment

Ship·to-Shore

Load

240-V0It

Shore Power Switch Connection Diagram

PH

(411

PH

(BB

PN

(125

PH

(21111

Switch

(3

328BB

AMPS/POLE)

3211119

AMPS/POLE)

32919

AMPS/POLE)

32133

AMPS/POLE)

POle)

12-2

IMPORTANT

RULES

Important

Always

1.

2.

3.

4.

5.

6.

7.

ventilate

start

Keep Check Check

Avoid

when When

the

this

engine engine

moving

servicing

working

shock. Do

not

wear

Disconnect

equipment. Use

properly

Beware be

a

product

To

of

deadly.

protect

regularly

the

generator

generator. manual

coolant

lubricating

parts,

front

on

jewelry.

electrical

insulated

exhaust

Carbon

of

combustion

yourself

and

repair

Important

handy

level

keep

of

electrical

gas

leaks.

monoxide

from

any

compartment

for

reference before

oil

belt

engine.

power

tools

from

this

exhaust

each

level

before

guard

equipment,

before

and

equipment.

Carbon

is

a

colorless

a

gasoline

gas,

inspect

leaks

before

whenever

day's

each

in

place.

beware

working

monoxide

engine.

the

immediately.

attempting

in

use.

day's

of

on

exhaust

and

exhaust

Important

doubt.

use.

Remove

electrical

odorless

only

gas

gas,

system

to

can

8.

9.

10.

Do

not

Allow

applying

Maintain ment.

overload

the

generator

heavy

your

the

generator.

engine

loads.

generator

in

to

a

warm

dry,

up

well

and

stabilize

ventilated

before

environ-

13

OPERATION

Preparing

The

coolant

generator

drained recommended for

the

first

1.

Remove

2.

fill as

Use Fill

and

the

specified

a

the

fresh

and add centration water

the

air lower housing.

the

Engine

procedures

time.

the

engine

good

brand

fresh

water.

rust

of

cooling

bleed

rear

engine

from

oil

in

water inhibitors

antifreeze.

system,

petcock

portion

for

the

fill

oil

the

of

Follow

Initial

is

engine.

carefully

cap

sump

with

Engine

oil

having

cooling

remove

or

of

Start-Up

shipped

before

from

the

Specification

an

system

the

antifreeze

if

needed.

To

the

remove

the

cylinder

dry

with

Therefore

attempting

the

engine

proper

A.P.I.

with

properly

manifold

the

lubricating

be

sure

to

rocker

amount

of

section

Spec.

a

of

mixture

manufacturer's

Do

not

fill

1/8

head

NPT

the

cap

plug

near

to

follow

start

shaft

lubricating

of

this

SE

or

SE-CC.

of

anti-freeze

instruction

use

an

engine's

and

open/remove

found

the

oil

and

these

the

engine

cover

and oil

manual.

over

con-

fresh

at

the

thermostat

Mix

your

fold

filler

antifreeze

neck.

solution

14

and

slowly

pour

it

into

the

mani-

of petcock/plug tinue the base. and operating system.

filler level recovery engine system tank

3.

Check 120 control Insure vent

metal

leads

While

the

cylinder

filling

coolant

Once

antifreeze

TOp

the

neck

between

is

and

AC

or

240

panel

these

shorts

box

against

filling

opening,

the

level

the

temperature

system

pressure

the

tank

rises

shut

working.

add

antifreeze

electrical

volt

cover

connections

and

are

routed

chaffing.

observe

head

system

is

engine

solution

off

ADD

down

Monitor

connections

output.

for

that

the

open

and

when

close

at

the

approximately

is

started,

added

(170-190·

with

cap.

and

as

and

the

Fill

MAX the cools.

mark. engine

engine

mixture

An

AC reference are

secure

any

leads

through

bleed

coolant

petcock/replace

filler

1/2

this

as

needed

F),

and

antifreeze

the

coolant

Observe

is

This

coolant

as

needed.

to

the

wiring

schematic

when

and

routed

grommet

ted

petcock/plug

begins

neck

and

inch

level

as

air

mixture

that

run

will

indicate

level

generator

making

properly

through

holes

to

flow

the

from

should

the

is

expelled

recovery

and

via

output

is

these

insulated

the

to

out

the

plug.

manifold

the

be

engine

and

the

level

lowers

the

this

affixed

connections.

control

protect

at

the

of

filler

monitored

reaches

from

install

tank

when

recovery recovery

leads

to

the

back

this

Con-

until

neck

to

in

to

pre-

panel

the the

a the the

for the

AC

4.

5.

6.

7.

Connect tion

points

Always

swi

tch control these holders

F

ill

the

regular)

The

This

pump activated using the

carburetor

during

NOTE:

which

Raw

water using tion

can

Connect

that

they

DC

starting

on

connect

should

panel

connections.

after

fuel

• engine

can

by

depressing

the

electr

system

The

the

choke

generator

supply should

a

good

grade

collapse

the

engine

are

the

engine.

be

in

removed

the

connections

tanks

has

be

used

ic

electr

priming.

may

of

hose

tight

battery

the

ground

the

from

Reinstall

with

mounted

to

the

pump

ic

choke

Reconnect

have

will

be

wire

having

to

the

and

there

leads

OFF

position

their

a

good

on

pr

ime

ON

for

this

to

operating.

connected

reinforced

exhaust

lead

have

it

the

switch

to

be

soft

is

securely

last.

respective

the

been

grade

a

12

eng

purpose

prevent

after

readj

to

wall

system.

no

likelihood

to

The

and

fuses

the

in

made.

of

gasoline

volt

ine'

s

in

the

unplug

activation

the

system

usted

the

engine

hose.

contruction.

Check

the

starting

three

holders

their

electric fuel

control

the

for

Sea

of

an

tagged

fuses

(unleaded

system.

panel.

"+"

of

is

primed.

the

sea

water

all

exhaust

connecbattery

in

when

making

respective

fuel

pump. I t

When

lead

the

choke

climate

water

pump

pump suc-

connections

leak.

the

or

is

on

in

CARBON

Check

leaks

the

and

exhaust

correct

MONOXIDE

system

carefully

them.

EXHAUST

15

GAS

once

IS

DEADLY.

the

engine

is

started

for

Starting

(Ventilate

to

start

1.

Depress

2.

Depress and

3.

If switches. 1

and

the

crank

the

2.

Generator

the

Generator

engine).

the

ON

the

engine

Check

switch

START

engine

fails

Engine

Compartment

(black),

switch

over

to

for

fuel

to

start

and

(white).

start

in

and

choke

.

for

5

minutes

hold

This

it.

20 - 30

operation.

it.

will

seconds,

prior

engage

release

Then

to

attempting

the

repeat

starter

the

two

steps

When

1.

2.

3.

NOTE:

Starter cranking with

When

the

raw

Generator

the

continue

is

to

allow

switch

Check NOTE:

a

cold

Allow

Check

to

for

There

engine.

the

AC depressing eng

ine

water

coolant needed. galleries has

been system plastic

and

water

generator

to

maintain

raw

output.

stops

This

and

expelled

up

fully,

remote

overheating

there

which

Engine

hold oil

the

pressure

water

will

This

engine

the

STOP

completely.

level

is

to

the

recovery

is

may

Starts

engine

ON

the

flow

be

some

will

to

Once

swi

(initial

replenish

filter.

from

replace

a

possibility

back

switch

to

ignition

being

hunting

subside

run

and

engine

tch

Check

the

tank.

and

up

damage

into

starts,

depressed

build

circuit.

discharged

warm

is

(red).

start).

oil

Coolant

fresh

pressure

of

release

up

and

evident

once

up

warmed

Keep

eng

ine

that

is

water

can

filling

the

for

activate

the

sump

is

needed

cooling

cap

occur

engine.

the

5 -

with

when

governor

(initial

up,

switch

oil

Add

now

oil

filling

and

the

START

10

the

initially

shut

to

replace

system.

add

from

exhaust

excessive

system

switch

seconds.

the

oil

pressure

exhaust.

starting

warms

up.

commissioning).

engine

down depressed level

and

coolant

internal

air

Top

coolant

to

and

This

by

until

fresh

as

oil

that

the the

WARNING:

the

engine

is

removed removed coolant. clockwise Carefully

to

bleed

the

off

safety

the

cap.

NOTE:

will

drain

The

slowly

Depress

off.

cap.

Check

Coolant

fresh

is

running

with

until

release

stops

plastic

into

Again

Always

recovery

the

and

the

pressure

and

manifold

water

and

eng

ine

the

hands

presaure

resistance

press

rotate

fill

recovery

tanks

cooling

hot.

hot,

Any

it

are

cap

of from the

the

cap

counterclockwise

the

tank

system

level~

mounted

when

the

16

system

time

is

protected

slightly

the

cap

down,

full

above

pressure

is

the

manifold

advised

and

safety

and

allow

now

before

add

as

the

under

from

rotate

more

to

needed.

manifold

cap

pressure

that

escaping

stops

system firmly

remove

replacing

is

the

it

cap

counter-

are

pressure to

and

fill

removed.

when

cap

be

hot

felt.

clear

lift

the

cap

To

prevent manifold

this,

to

the

pinch

plastic

off

recovery

the

clear

plastic

tank.

hose

running

from

the

Restart

4.

(Check

50

gradually.

Stopping

1.

Remove

2.

Allow

stabilize

3.

Depress completely.

data

hours),

the

all

the

generator.

tag

avoid

Generator

the

AC

engine

temperature.

the

STOP

for

light

load

to

run

switch

Check

rating).

loads.

from

for

(red)

the

Vary

the

generator.

5

minutes

AC

output.

During

the

and

hold

generator

loads.

to

dissipate

until

Load

the

break

the

engine

generator.

in

(first

generator

heat

and

stops

NOTE:

Prolonged cranking intervals without the engine starting can result in filling the exhaust system attached water pump

ing. This sea water can enter the engine's cylinders by way once the exhaust system supply sive engine cranking needed of

mind.

Starter overheating

to

is

pumping sea water through the sea water cooling system during crank-

thru-hull shutoff, drain the exhaust muffler, and correct the cause for the exces-

sea water entry

and

damage

the engine with sea water coolant. This may happen because

fills. Prevent this from happening by closing the sea water

to

is

not a warrantable issue; the owner/operator should keep this in

can

occur from

CAUTION

obtain a start. Engine damage resulting from this type

excessive

cranking.

of

the exhaust manifold

17

sea

MAINTENANCE

Daily

1.

Check Keep dipstick.

2.

Check

tank.

3.

Periodically

inch

governor

4.

Visually

faults.

Fifty

Change

1. oil oil

for generator must SE-CC. Retorque

2. down

Adjust

3. Clean

4. Check

5. exchanger. needed. scrape exchanger clean

6.

deflection Clean

7. engine

Remove on

loose. spillage base.

A new

be

is

Check

8. bolts

9.

Check

security that

wiring

Checks

deflection

Hour

filter.

with

have

bolts

(engine

Check

the

)

installed

removed

(before

the

oil

the

(Maintain

action,

look

Correct

Service

the

an

the

is

an

the

warm).

and

regap

zinc

clean.

from

belt

filter

mounted

the

base

hose for

security

all

and

there

on

the

initial

level

of

level

eng

ine

the

remove

between

engine

over

as

Check

engine

Use a good

SAE

number

area

operating.

API

cylinder

(engine

valve

spark

anode

Clean

If

zinc

Check

for

zinc

exchanger.

tensions,

at

widest

screen

electric

base

(Be

when

hex

by

nut

careful

removing

sealing

each

and

reinstalled.

clamps,

electrical

proper

is

no

generator

oil

coolant

belt

needed.

lube

in

spec.

warm).

and

is

zinc

pieces

span.

found

placing

gasket

time

fittings, and

chafing

daily

in

the

between

level

guard

widest

cooling

the

engine

oil

and brand suitable

which

The

of

head

the

oil

SE

holdclearances plugs.

in

heat

replace

flaking,

end

and

3/8

-

1/2

in

fuel

a

and

twisting

of

gasoline

the

#34706

the

pump

nuts

tightness.

connections

insulation

or

that

start-up)

lube

the

in

and span.

and

of

or

as of

inch

base

pump.

wrench

pump must

base

and

for

and

of

the

wiring

oil

upper

the

between

check

Belts

alternator

generator

of

it

running

sump

and

plastic

ADD

belt

will

with

lower

coolant

and

MAX

tensions,

stretch

charging.

for

to

and

the

marks

when

any

Magnet

Seal ing Gasket

from

dipstick.

on

recovery

cold.)

3/8

-

1/2

affecting

visible

it.

the

18

10.

11.

12.

13.

14.

15.

Inspect Remove

Clean

it

moves

Adjust

located

Check

inspect bell. Clean

the

and

clean

and

lube

freely

carburetor

on

the

security

electrical

the

carburetor

exhaust

linkage

with

choke of

system

air

screen

between

no

choke

cover

cooling

connections

inlet

that

inlet

binding.

if

lower

fan

filter.

it

on

governor

needed.

right

inside

and

components

is

secure

carburetor.

and

The

inboard

generator

and

tight

throttle.

choke

side. end

inside

(no

Insure

index

bell.

generator

leaks).

that

mark

Visually

end

is

Seasonal

1.

Change operation

2.

Clean inlet

3.

Check cally

4.

Check

5.

Check bolts

6.

Clean

7.

Check water the

8.

Clean operation

9.

Check A. B. C.

D. E.

10.

Torque

hours

11.

Check

as

12.

Check 500 be

Servicing

engine

the

filter

the through belt for for and and/or

condi

cooling

coolant

the

ignition

Clean Check

Adjust

Check Clean

cylinder

of

engine condition sea

needed.

generator

hours

replaced.

lube

or

once

fuel

filter

screen

zinc

anode

the

tension,

wear~

loose

replace fittings,

coolant

replace

tion

circuit.

and

replenish

carburetor

or

more

circuit

rotor

and

engine

carburetor.

coil

and

gap

operation.

of

water

thereafter.

oil

a

season,

in

season,

3/8

circulating

primary

and

strength

air

frequently

cap.

timing.

plug

spark

head

holddown

sea

pump

for

brush

and

whichever

screen

the

carburetor

the

clean

-

1/2

as

needed.

clamps,

Strengthen

should

inlet

every

leads. plugs.

water

internal

rig

initially

Brushes

oil

filter

in

main

the

engine

and

inch

deflection

electrical

hoses

fuel

of

antifreeze

filters.

the

screen

as

needed.

300 -400

bolts

pump

impeller

wear.

worn

every

occurs

electr

every

replace

for

good

the

mixture

coolant

every

hrs.

and

at

to

1/2

100

first.

ic

300

heat

it

between

connections,

condition. mixture

become

adjust

and

Replace

500

hours

inch

hours

fuel hours.

exchanger

as

needed.

as

needed.

300

hours

valves

replace

pump

and

in

of

pump

and

periodi-

widest

nuts

in

the

discolored.

of

every

as

needed.

components

then

length

engine

the

span.

and

fresh Drain

engine

500

every

should

End

of

Season

1.

Check strength needed. the

system

2.

Inspect exchanger.

3.

Clean

engine

against

Operate

the

filter

Service

fresh

and

condition

Clean

screen

recheck.

(Winterization)

water

freezing.

the

engine

of

the

or

replace

in

engine

coolant

Drain

to

insure

zinc

it

mounted

19

as

anode

needed.

antifreeze

and add

complete

#11885

electric

mixture

additional

circulation

in

the

(Keep

spares).

fuel

for

mixture

engine

pump.

proper

as

through

heat

4.

5. 6A.

NOTE: Clean

Change

Flush

Electric

carburetor

engine

the

antifreeze against

lubrication raw mixture

freezing.

fuel

inlet

water

pump

filter

oil

circuit

through

base

the

gasket

screen. and

oil

with

raw

#34706

filter.

fresh

water

must

water

circui

be

and

t

to

replaced.

then

run

protect

an

it

NOTE:

the

circuit

6B.

Fogging

mixture

intake fogging stalling faces amount two

or

plugs

missioning.

7.

Remove dition. recommisioned.

8.

Check

9.

Insure and added instructions.

10.

Lubricate

governor

11.

Remove

Feed

the

and

the

is

engine

drawn

screen

oil

with

into

three

as

it

these

into

and

this

each

complete

Close

the

impeller

Do

not

alternator

fuel

tanks

conditioners

at

that

the

arm.

the

s.tarter

raw

supply

into

and

spray

the

coating

oil. spark

will

off

reinstall

and raw

are

as

time

linkage

motor

water

it

with

should

the

mystery

carburetor

the

Remove

plug

revolutions.

need

to

the

from

the

water

full

well

according

between

and

circuit

an

antifreeze

be done

raw

water

oil

inner

cylinder,

the

hole

be

and

cleaned

carburetor

sea

water

it

in

pump and, as

when

carburetor

to

the

clean

out

as

of

the

circuit.

or

while spark

turn

Loosely

and

air

pump

the

pump

drive

filling,

the

conditioner

carburetor

and

lubricate

a

bucket

mixture.

last

a

commercially

the

of

engine

piston

plugs

the

and

engine

reinstall

gapped

intake

with

and

until

belts.

gasoline

conditioners

throttle

the

to

both

the

antifreeze

Remove

available

is

and

valve

spray

over

the

prior

an

to oily

inspect

the

engine

stablizers

should

manufacturer

drive

flush

the

air

running,

sur-

a

small

by

hand, spark

recom-

rag.

its

con-

is

be

and

the

pinion.

IS

12.

13.

NOTE:

Remove

motor. Check

belts

spares this

over need

kit

lay-up, Generator winter vent

it

lay-up

freeze

to a warm

DC

the

engine

replacing

and

order

such

eng

ine

period

damage

location.

power

come

as

filters

starting

should

to

and

items

the

engine

see

r~GOmmissioning.

not

if

on

and

battery,

be

in

battery.

prior

external

hand

zincs.

if

a

full If

or

left

not,

to

items

Check

that

on

state

removing

such

over

were

board of

charge

it

is

wise

-

the

as

your

used

dur

to

starter

hoses

basic

during

ing

to

remove

or

this

pre-

20

ENGINE

TECHNICAL

DATA

Type Number

of

Bore

6.5

and

cylinders and

stroke

and

llKW

Total

6.5

piston

&

SKW

llKW

Compression

6.5

and

llKW

Valve

system

Timing Intake Intake

,opens

closes Exhaust Exhaust

arrangement

SKW

displacement

ratio

SKW

6.5

&

opens closes

SKW

Gasoline, Four

cylinders

vertical

70.0 (2.76

77.0 (3.03

1071 1490

mm x 69.6

in

mm x SO.O

in

CC CC

9.2:1

9.0:1

Single

overhead

driven

15·

BTDC

44·

ABDC

53·

BBDC

6·

ATDC

four

type

x

2.74

x

3.15

(65.4 (90.9

cycle

in

mm

in)

mm

in)

cubic cubic

cam

line,

inches) inches)

(OHC)

chain

Valve

timing Intake Intake

opens

closes Exhaust Exhaust

Compression

Standard Limit Limit

of

cylinders

Valve

clearances

Valve Cam

side

llKW

opens closes

Pressure

difference

Intake

Exhaust

Intake Exhaust

between

(engine

warm)

15·

BTDC

sS·

ABDC

sS·

BBDC

15·

ATDC

12.0 300

9.0 300

2.0

0.25

0.30 O.lS

0.22

kg/cm

RPM

kg/cm2 (12S

RPM

kg/cm

mm mm

mm

2

(2.S

(0.010 (0.012 (0.007 (0.009

(170

lbs/in

lbs/in2)

in) in) in) in)

lb/in2)

2

at

21

Cylinder

Height Warp Grinding

head

limit

90.5

0.15

0.20

mm mm mm

(3.563 (0.006

(0.008

in) in)

in)

Valve

Seat

Standard Wear

Seat

Exhaust

Seat

Exhaust

Valve

Standard Wear

Guide

Valve

Valve Minimum

Valve

Free

Valve

seat

sinking

limit

Angle

Intake

Width

Intake

guide,

stem

limit

inner

stem

Intake

Standard Wear

Exhaust

Standard

Wear

head

Intake Exhaust

Intake

(marg

spring

length

Intake

Standard

Wear

spring

valve to

diameter

limit

diameter

face

and

valve

in)

and limit

(Dim

"L")

and

guide

diameter

angle

exhaust

head

squareness

of

valve

exhaust

constant

valve

clearance

thickness

limit

spring

39.5

1.5

mm

45·

41)·

1.4

mm

1.4

mm

0.018 (0.007

0.20

8.063 (0.3174

8.080 (0.3161

7.980

8.025 (0.3159

7.975

35.95 (1.4154

30.95 (1.2185

45·

1.0

mm

1.51

43.3

42.0

2.925

mm

(1.555

(0.059

(0.055 (0.055

-

0.053

-

0.0021

mm

(0.0079

-

8.083

-

0.3182

-

8.045

-

0.3167

mm

(0.3142

-

8.045

-

0.3167

mm

(0.3140

-

36.05

-

1.4193

-

31.05

-

1.2225

(0.0394

mm

(0.059in)

mm

(1.705

mm

(1.654in)

kg/mm (164

in)

in) in)

mm

in) in)

mm

in)

mm

in) in)

mm

in) in)

mm

in)

mm

in)

1b/in)

Rocker

Bore Clearance

arm

in

and

rocker

in

rocker

arm

rocker

Standard

Wear

limit

arm

shaft

22

19.0

-

(0.7480

0.020 (0.0008

0.10

mm

19.033

-

0.074

(0.0039

mm

0.7473 mm

0.0029

in)

Camshaft

Camshaft Camshaft

Standard Wear

Camshaft

Front Center

Wear Camshaft

(oil

Front Center

Oil

clearance

Cam

lobe

6.5 Standard Wear

llKW

Standard

Wear

run-out end-play

limit

journal

and

limit

bearing

clearance)

and

height

&

8KW

limit

Intake

limit

rear

of

rear

Intake

and

diameter

journal

clearance

limit

and

exhaust

0.30

0.02 (0.001

0.20

41.949 (1.6515

41.919 (1.6504

0.05

0.035 (0.0014

0.065 (0.0026

0.15

44.119

43.919

44.114

43.914

mm

-

mm

(0.0012

0.18

-

0.007

(0.008

-

41.965

-

41.935

(0.0020

0.076

-

0.106

-

(0.0059

mm mm

mm

1.6522

1.651

mm

0.0030 mm

0.0042

(1.7401 (1.7291

(1.7337 (1.7258

in)

in) in)

mm

in)

mm

in) in)

in)

in) in)

Connecting

bearing Length

Maximum Piston Clearance

and

Connecting

Standard Wear

Connecting

clearance

Standard

Wear

Available

bearing

Crankshaft

rod

(center

allowable

bore

between bore

rod

limit

rod

(Oil

limit

undersize

and

run-out

and

to

side

journal

main

connecting

center)

twist

piston

clearance

clearance)

connecting

bearings

bearing

rod

135.95 (5.352

Less

per

19.948 (0.7854

-0.015 (-0.0006

0.11 (0.004

0.3

0.024 (0.0009

0.10

0.25

0.50

0.75

Less

than

100

-

mm

than

-

136.05

-

5.356

mm

-

19.961

-

-0.040

-

0.262

-

0.010

(0.012

-

0.048

(0.0039

(0.010 (0.020 (0.030

0.04 (3.9370

0.7859

-0.0016 mm

in)

mm

0.0019

0.03

mm

in)

mm

in)

in) in) in)

mm

(0.0016

in)

(0.0012

in)

23

Connecting

Standard Wear

limit

Grinding

Main

bearing

Standard Wear

limit

Grinding

Main

journal

Standard

Available

Crankshaft

Standard End

play

Available

rod

journal

limit

journal

limit

bearing

undersize

end

play

limit

oversize

diameter

clearance

main

thrust

bearing

39.940 (1.5724

0.05

0.75

mm mm

49.938 (1.9661

0.05

0.75

mm mm

0.023 (0.0009

0.25

O.sO

0.75

0.10

mm mm mm

-

(0.0039

0.30

0.25

0.50

0.75

mm mm mm mm

-

39.956

(0.002 (0.030

-

49.956

(0.002 (0.030

-

0.042

(0.010 (0.020 (0.030

0.15

(0.0118 (0.010 (0.020 (0.030

1.5734

1.9668

mm

0.0017

mm

0.0059

mm

in) in) in)

mm

in) in) in)

in) in) in) in)

in)

Cylinder

Limit

block

Cylinder

6.5 11

Maximum Maximum

Oversize

6.5

llKW

Piston

at l8mm groove

6.5 llKW

Piston

6.5 11

Wear

block,

of

distortion

top

bore

& 8

KW

Standard

cylinder difference

cylinder

&

8KW

diameter

90·

to

(0.709

&

and

& 8

KW

Standard

limits

piston

surface

diameter

KW

Standard

piston

in)

8KW

cylinder

KW

Standard

and

of

cylinder

bore

taper

in

cylinder

bore

(Diameter

axis

below

oil

clearance

piston

measured

and

ring

bore

0.15

mm

70.00 (2.7559

77.00 (3.0315

0.09

0.15

0.25

0.50

0.75

1.00

0.25

0.50

mm mm

mm mm mm mm

mm

69.944 (2.7537

76.954 (3.0297

0.036 (0.0014

0.026 (0.0010

0.15

mm

(0.006

70.019

-

77.019

-

(0.0035 (0.0059

(0.010 (0.020 (0.030 (0.040 (0.010 (0.020

-

69.964

-

76.974

-

0.075

-

0.065

(0.0059

2.7567

3.0323

2.7545

3.0305 mm

0.0030 mm

0.0026

in)

mm

in) in)

in) in) in) in) in) in)

mm

in)

in) in)

~

in) in)

24

Piston

ring

Top Second Oil

scraper

Piston

ring

Top Second Oil

scraper

Clearance

and

ring

Top Second Oil

scraper

Wear

.

Piston

limit ring

Top Second Oil

scraper

Wear

limit

Oversized

6.5

&

11KW

Piston

Interference

boss

Pressure

in

groove

thickness

between

groove

end

piston

8KW

diameter

to piston

gap

fit

install

width

piston

rings

in

a

piston

boss

ring

available

piston

1.22 (0.048

1.52 (0.0598

4.02 (0.1583

1.17 (0.0461

1.47 (0.0579

none

0.03 (0.0012

none

0.15

0.2 (0.008

0.3 (0.012

1.0

0.25

0.50

0.75

1.00

0.25

0.50

19.976 (0.7865

o -

(0 -

500 -1,500

(1,102

-

1.24

-

1.54

-

4.04

-

1.19

-

1.49

given

-

0.07

-

0.07

given mm

-

0.4

-

0.04

-

-0.9

-

mm

(0.039

mm mm mm mm mm mm

-

0.024

0.0009

-

0.050

-

(0.0059

0.016

mm

0.035

(0.010 (0.020 (0.030 (0.040 (0.010 (0.020

19.988

-

3,307

mm mm

0.0606

mm

0.1591

mm

0.0469

mm

0.0587

mm

0.0028

mm

0.0028

mm

in)

0.7869

mm

in)

kg

in)

in) in)

in)

in) in) in)

in) in) in) in) in) in)

mm

in)

1b)

Flywheel

run-out

25

0.20

mm

(0.008

in)

Lubricating

Oil

Pump

Type

Oil

pressure

1800 700

RPM

Outer

rotor

Standard Wear

Clearance

Standard Wear

Rotor

end

Standard Wear

Pump

shaft

Standard Wear

Free

length

Sprocket

pressure

System

RPM

limit

between

limit

drive

method

at

(idle)

and

float

and

relief

to

engine

pump

.

rotor

body

gear

install

speed

body

lobes

clearance

valve

pressing

on

clearance

spring

pump

shaft

Full

Trochoid

1.75 (25 - 35

.7

(10 - 25

0.20 (0.0078

0.35

0.03 (0.0012

0.25

0.04 (0.0016

0.15

0.02 (0.0008

0.10

45.5 700 -

Forced

-

1.75

mm

pump

2.50 lb/in

lb/in

0.294

(0.0134

0.12

(0.0098

0.10

(0.0059

0.056

(0.0029 (1.791

1300

kg/cm

0.0116

0.0047

0.0039

0.0022

(1543 - 2865

kg/cm

mm

kg

lb)

2 2

2

) 2

)

in)

Oil

Filter Type Oil Oil

Lubricant

pressure capacity

Temperature

Engine

oil

switch sump

Oil

(C')

(F')

and

brand

-30

-20

(normally

filter

meeting

-20

-10

o

open)

A.P.I.

20

o

Full

close

3.7 (3.3

spec

40

10

flow,

4.5-6.8

liters

Imp.

SE

20

60

spin

(3.9

quarts)

or

SE/CC

30

80

on

cartridge

kg (10 -

quarts)

40

100 120

15

50

lb)

26

Cooling

Fresh

capacity

Fresh Metal

shaft

Raw

(measured

Water

closed)

System water

6.S

&

8KW

llKW

water

impeller

water

6.S

&

pump

pump 8KW

llKW

temperature

circuit

coolant

approximately

pump

press

flow

at

exchanger

fit

rate

switch

to

pump

1800

RPM

discharge)

(normally

4.7

liters

6.6

liters

Belt

driven

1200 - 1300 positive neoprene

displacement

impeller

type

2S.3

26.

Opens

ltr/min

S 1

tr/min 9S·C

(S

quarts)

(7

quarts)

centrifugal

kg

(264S - 2866

belt

(6.7 (7

gal/min)

(20S·F)

type

lb)

type,

.drive

Fuel

System

Carburetor

Air

filter

Choke

Throttle

Fuel

Fuel Fuel

pump

flow

pump

Engine

rated

6.SKW 8KW llKW

Electrical

Type Alternator

Starter

Ignition Spark Spark

Ignition

Distributor

Ignition

leads

Resistance Resistance

(R X 1000)

Resistance

leads

Coil

control

(free

lift

fuel

comsumption

KW

output

System

system plug plug

gap

firing

timing

coil

(R X 1)

insulation

flow)

capacity

(Engine)

at

and

of

primary

of

secondary

of

high

at

full

approximate

order

1800

high

RPM

tension

coil

t~nsion

resistance

(R

plug

X

Single Metal Mechanical Belt

driven

cally

Engine

12

volt

self

contained

(cleanable)

0.8

ltr/min

1.8

m (6

4.16

4.73

6.0S

12 12

ltr/hr ltr/hr ltr/hr

volt

volt regulator, 12

volt,

Spark

0.80

1·-

14·

±O.OS

3 - 4 - 2

BTDC

Solid

type

1)

0.8

ohm

80

ohm

ohm/inch

410 10 megohms +

barrel

screen

linked

speed

pulsating

ft)

-

negative

-

SO

solenoid

plug

+1·

state

+0.2 +10

-

downdraft

12

volt

governor,

to

throttle

1800

filter

(0.84

(1.10 (1.2S (1.60

amps

belt

type

mm

driven

ignition

(0.031

breaker

activated

mechani-

arm.

RPM + SO

type-with

screen

qt/min)

gal/hr) gal/hr) gal/hr)

ground

internal

mounted

+0.002

assembly

RPM

in)

27

Generator

Type

Ratings

6.5KW 8KW llKW

Cooling

generator

6.5KW 8KW llKW

(standard)

air

requirements

end

for

Four

inherently limiting, stationary rings, 1800 50

115/230

60

115/230 60 115/230 60

5.66

6.23

7.80

pole

RPM

Hertz)

Hertz, Hertz,

Hertz,

cu cu cu

revolving

regulated,

rectifier

field,

single

operation

volts, volts,

single

volts,

single

m/min (200 m/min (220 m/min (250

bearing

56/28

single

70/35

94/47

armature

excited,

AC

(1500

phase phase phase

cu cu cu

self

slip

design.

amps amps

amps

ft/min) ft/min) ft/min)

,

for

Cylinder Manifold

Intake

Exhaust Main Connecting Camshaft Crankshaft Flywheel Backplate Spark

Timing

Oil Oil Oil

Thermostat

Fresh Generator Drive Drive

bearing

plugs

chain

filter

pan

pump

water disc

disc

head

caps

rod

sprocket

pulley

cover

housing

pump

cooling

to

armature

to

flywheel

bearing

nut nut

fan

TABLE

caps

nut

OF

TIGHTENING

TORQUES

11.0

Tighten

7.8

1.9

6.6

3.0

7.0

8.3

7.0

1.5

1.9

0.7

1.9

1.

3.5

6.9

2.5

kg-m

-

9 -

-

8.2

2.6

2.3

7.1

3.5

8.0

12.0

9.0

10.0

2.3

3.1 by

1.2

3.1

7.6

2.8

lb-ft 56 -

14

-

14 48

- 51 22 - 25 51 80

- 87 60

-

51 11

- 17

14

-

hand

5 - 9 14 14 - 22 14 - 22 25 50

-

18 -

59 19

17

58 65

72

22

55 20

28

TABLE

OF

STANDARD

HARDWARE

TIGHTENING

TORQUES

\

,_/

Unless stated otherwise

hardware.

Grade4T

6mm

bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

Grade6T

10mm bolt head/nut 12mm 12mm bolt head/nut 12mm bolt head/nut

Grade

10mm bolt 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

bolt head/nut

6mm

bolt head/nut

8mm bolt head/nut

10mm

bolt head/nut

7T,

8Tand

6mm

bolt head/nut

8mm bolt head/nut

8.8

head/nut

for

a specific assembly, use the following torque values when tightening standard

Pitch

1

1.25

1.5

1.25

1.5

1.75

1.5

2

1.5

2

1

1.25

1.5

1.25 (ISO)

1.5

1.75

1

1.25 1,25

1.5

1.25 (ISO)

1.5

1.75

1.5

2

1.5

2

(ISO)

Ib-ft

2.9 -

5.1

7.2 - 11.6

13.7 - 22.4

13.0 - 21.7

25.3 - 39.8

21.7 - 36.2

32.5 - 50.6

36.2 - 57.9

34.0 - 55.7

54.2 - 79.6

51.4-

10.8 - 15.9

21.7 - 32.5

19.5 -

36.2 - 57.9

36.2 - 50.6

34.7 - 49.2

28.9 - 39.8

26.8 - 37.6

54.2 - 75.9

50.6 -

43.4 - 61.5

57.9 - 86.8

72.3

68.7 -101.3

108.5 - 166.4

101.3 -159.1

76.7

4.3 -

6.5

30.4

5.8 - 8.7

14.5 - 21.7

65.1

-108.5

kg-m

0.4 - 0.7

1.0 - 1.6

1.9 -

3.1

1.8 -

3.0

3.5 - 5.5

3.0 - 5.0

4.5 - 7.0

5.0 - 8.0

4.7 - 7.7

7.5-11.0

7.1

-10.6

0.6 - 0.9

1.5 - 2.2

3.0 - 4.5

2.7 - 4.2

5.0 - 8.0

5.0 - 7.0

4.8 - 6.8

0.8 - 1.2

2.0 - 3.0

4.0 - 5.5

3.7 - 5.2

7.5 -10.5

7.0 - 9.0

6.0 - 8.5

8.0 -12.0

10.0 -15.0

9.5

-14.0

15.0 - 23.0

14.0 - 22.0

Grade 5 capscrew

1/4 UNC 1/4 UNF

UNC

5/16 5/16 UNF 3/8

UNC

3/8 UNF

7/16

UNC

7/16 UNF

UNC

1/2 1/2 UNF

29

11

9 -

11

- 13

18 - 20

21

- 23 28 - 33 30 -

35

44-

49

50 - 55

73

68 -

80

73 -

1.2 - 1.5

1.5 - 1.8

2.5 - 2.8

2.9 - 3.2

3.7

-4.6

4.1

- 4.8

6.1

- 6.8

6.9 - 7.6

9.4-10.1

10.1

-11.1

Removal

1.

Remove

2.

Shut

3.

Unbolt

4.

Drain exchanger

off

all

and unit all

AC

and

disconnect and remove lubricating

system.

DISASSEMBLY

DC

power

connections

fuel,

to

the

oil

FOR

OVERHAUL

raw

water

overhaul

and

coolant

from

and

shop.

the

unit.

exhaust

from

connections.

the

engine

and

Generator

1.

Disconnect leads

tag

tions. from one

2.

Support and bell

fan

3.

Remove

4.

Remove holder

the

the each

to

help nections Examine

to

1/2

Removal from

engine

from

engine

and mark

Unbolt

generator

assembly.

unbolt

cover

and

the

brush

rear

the

exposing

generator

each

individually

electrical

respective

brush

is

insure

on

the

each

inch

brush

in

Engine

wiring

connections,

harness

control

of

generator

rig

assembly.

br

ush

and

connections

brush

removed.

keeping

correct

and,

length,

panel

the

fan.

from

resecure

holder

the

replace.

harness connec-

panel

as

engine

end

cooling

its

to as

This

is

con-

holder.

if

worn

5.

6.

Remove

the

4

bolts the the

with

and

the

may

the

exhaust

bellhousing

and

outer

engine

the

generator bellhousing.

aid

armature

rear

be

support

pulled

lockwashers

of

shaft,

off

housing.

7.

When

tor

clear

,housing

of

the

carefully

screen

and remove

holding

housing

a

puller

attached

carefully

bearing.

the

bearing

armature

off

and/or the

from

the

to

draw

In

some

armature.

30

to

the

cases

shaft

shaft,

the

end

generator

the

along

manually

bearing

outer

rear

with

slide

support

housing

support

the

web off

bearing

generator

genera-

NOTE:

end

S.

Unbolt

supporting

drive

housing

9.

Remove

assemble

10.

Remove

related the heat tested repair needed.

Rest

as

damage

the

disc

securing

the

hoses

rear

exchanger

at

shop

the

armature

the

through

exhaust

and

heat

of

generator

to

the

field

and

drive

armature.

the

bolt

bellhousing

bosses.

manifold

inspect

as

needed.

exchanger

and mounts from

the

eng

ine.

cleaned

a

local

or

radiator

replace

housing

coil

windings

disc

Then,

and

Have

and

as

on

its

assembly

cocking

clearing

may

the

hoses

not

result.

from armature,

the

as

on

the

flywheel,

draw

generator

a

unit.

inner

its

outer

Dis-

11.

12.

13.

14.

15.

.

16.

17. IS.

Remove circuit Examine

replace

Remove

belt

Remove

the breaker

starter

as

sea

and

governor

bracket.

Remove 12 mounting

Remove

intake

carburetor,

manifold.

Remove mounting

Remove Remove

bellhousing,

fresh

starter

assembly.

needed.

water

mounting

volt

bracket

ignition

bracket.

water

motor and

and

repair

pump,

bracket.

and

alternator

• fuel

coil

flywheel

circulating

or

drive

mounting

and

pump

and

pump.

Belt Tension

3/8-1/2 Inch

Deflection

Longest

Span

at

19.

20.

Remove Remove

thermostat

oil

pressure

tee.

This

cleaning,

should

inspection

leave

the

housing

switch,

basic

and

repair

and

thermostat.

oil

engine

as

31

pressure

block

needed.

sender

assembly

and

for

oil

manifold

dissassembly,

Disassembly

1.

Remove

2.

Rotate chain disassembled. gear

3.

Loosen

the

numerical

figure.

Make

few

turns

4.

Remove and

camshaft

5.

Remove valves.

6.

Remove of

a pressor removed

sequence

of

the

so

cover.

cylinder

sure

the

suitable

tool.

for

the engine

engine

that

Disassemble

order

bolts

at

a

rocker

with

cylinder

valves

each

Engine

rocker

crankshaft

the

Remove

head

are

time.

shaft

drive

valve

Make

are

cylinder.

Block

master

the

shown

loosened

head

wi

th

spring

cover

link

chain

the

bolts

in

assembly

gear.

with

the

com-

sure

kept

and

so

as

is

master

in

the

a

aid the

in

baffle

to

position

in

a

tensioner

link

assembly.

position

from

to

separate

the

camshaft

that

front

the

it

can

chain.

drive

be

timing

7.

8.

9.

10.

11.

Remove Remove

pulley cover.

Remove assembly

Remove

bear

ing necting from

the

fully

the

block.

NOTE:

together.

needed.

Press

that for

disassembled

each

the

and

the

and each

cap

rod

engine

forcing

Keep

out

the

cylinder.

engine

front

lube

drive

and and

it

rods Number

piston

oil

sump. crankshaft

timing

oil

chain.

connecting.

remove piston

block

out

by

the

and

them

pistons

gear

pump

rod

the,.~on

assembly

care-

top

of

caps

as

with

and

piston piston

pin rings

setting

are

tool.

kept

in

sequence

Make

sure

32

12.

13.

Remove

main

Remove

bearing

washers.

bearl

.

baring

the

inser

aln

th7n~

e

cap

puller.

crankshaft

ts

and

c

ap

thrust

with

main

33

34

ENGINE INSPECTION

AND

REPAIR

NOTE: for Before matter Since and

to Do num.

Checking

1.

Replace leaks,

2.

Measure

along specifications,

Before

indications

checking,

(pieces

the

other

ensure

not

use

Cylinder

the

gas

the

washing

cylinder

engine

against

cleaning

Head

cylinder

leaks

extent

areas

of

parts

or

shown

grind

the

water

wash

gasket,

head,

are

damage.

solutions

head,

cracks.

of

in

the

cylinder

leaks,

each

dust, cylinder

made

warping

the

surface

gas

part

oil,

of

that

if

it

figure.

head

leaks,

to

remove

carbon,

head

aluminum,

will

has

(flatness)

If

or

replace.

cover,

be

any

the

and

block,

damage

any

scale,

timing

handle

harmful

damage,

on

warping

r

5t

aight-etlgs

or

adhered

the

check

cracks.

etc.)

chain

them

to

such

lower

is

foreign

carefully

the

alumi-

as

surface

more

them

cover

water

than

Height Warp Grinding

Checking

Valve

Measure clearance or

both.

Clearance

of

limit:

Guide

the

exceeds

cylinder

limit:

clearance

limit:

0.15

the

head:

mm

(0.006in)

0.2

mm

between

specified

0.20

(0.0079

mm

90.5

(0.008

limit,

in)

35

the

mm

(3.5630in)

in)

valve

replace

and

the

guide.

guide

or

If

valve,

the

Measuring Check

the

diameter

Method

difference

of

the

#1:

between

valve

stem.

the

inner

diameter

of

the

guide

and

Measuring

Check

the

NOTE:

the

valve

Separate

Measure

Method

valve stem

at

a

#2:

deflection

from

the

position

side

valve

near

to

with

side.

from

the

a

mounted

the

valve

valve guide.

dial

seat

indicator

before

by

moving

measur

ing.

Replacing

1.

Remove valve

2.

Knock opposite chamber

installer.

3.

Place guide opposite chamber

installer.

NOTE: valve of

the

side.

4.

Install valve pusher.

the

Valve

the

guide.

the

guide

side

with

a

clip

and

drive

side

with

The

guides

the

guide

valve

of

a

valve

on

of

the

shape

differs

on

valve

with

Guide

seal

out

toward.the

the

new

it

in the valve

of

the

seal

a

valve

from

combus~~n

the

guide

valve

from

the

combustion

guide

intake

from

that

exhaust

on

the

seal

36

Checking

1.

Check

damage. grinder.

2.

If stem

3.

Check exceeds

Valve

the

is

the

contact

Minor

valve

dented,

the

stem

valve

limit,

surface

or

rough

is

replace

stem

replace

worn,

the

diameter

of

the

surface

damaged,

valve.

with

the

valve.

valve

may

bent

face

be

repaired

or

the

a

micrometer;

and

end

valve

with

surface

if

seat

a

the

valve

of

wear

for

the

4.

Valve

Intake Exhaust

Check· head Replace cified

Minimum

thickness:

1.Omm Limit

diameter: Intake: Exhaust:

stem

the

(margin)

if

limit.

(0.00394

of

diameter

valve:

thickness

and

less

than

valve

reduction

7.980 (0.3142

7.975 (0.3140

7.980 (0.3142

7.975 (0.3140

the

head

in)

mm mm

limit:

mm

in)

mm

in)

of

valve

diameter.

the

spe-

in

in) in)

Checking

1.

Check corrosion

if

2.

Check

replace

length

following

Valve

the

or

necessary.

the

is

dimensions.

Free

length

Spring

valve damage

spr

less

ing

and

if

limit:

spring

replace,

length

the

than

(1.654

42.0

for

and

free

the

mm

in)

37

3.

Check spr

ing.

limit,

the

replace

squareness

If

it

with

of

exceeds

a new

valve

the

one.

Checking

1.

Check

the If correct

When

0-0.5 dard,

When

0.5-1.5 dard, adjust standard between and

Squareness

than

100

mm

Valve

the

valve

it

exceeds

it

Dimension

39.5 the

mm

replace

the

mm replace the

the

cylinder

3

mm

(3.937

seat

protruding

stem

the

as

follows.

"L"

mm

(1.555

dimension larger

the

dimension

larger

dimension

by

adding

lower

head.

limit:

(0.118

in)

length

(dimension

specification,

(standard):

in)

"L"

than

the

valve.

"L"

than

the

the valve "L"

some

spring

Less

in)

per

"L").

becomes

stan-

becomes

stan-

and

to

the

washers

seat

of

tOO/Oll9

When

standard,

2.

Check a.

b.

c.

NOTE:

Refacing Reface

the

for

Apply

seat Insert

on Check

position

is

Valve

in

the

dimension

replace contact

a

contact

the

not

Do

not

and

following

thin

the

valve

if

the

of

the

centered,

rotate

Valve

"L"

both

the

between

coat

face.

into

seat.

valve

recut·

the

Seat

order:

becomes

valve

the

of

Prussian

the

seat

contact

and

valve.

more

and

valve

contact

surface

than

cylinder

and

Blue

guide

face.

1.5

valve

(or

and

face

If

the

mm

head. seat

Redlead)

press

contacts

the

valve

larger

as

follows:

on

fit

contact

seat

the

and

than

valve

center

position

valve.

the

38

1.

Reface

the

valve

with

a

valve

grinder

to

the

specified

angle.

2.

Valve

Reface contact

NOTE:

tacts

the

Valve Valve

CONTACT WIDTH

1.4

mm,/

~~~··~··-~~~~_a.~.~~~n~~~~_~~~~~

face

the

valve

between

Reface

center

seat

angle:

seat

the

position

valve

with

valve

45·

and

seat

of

a

valve

taking

the

valve

angle:

width:

I~ON

,

...

TACT

POSITION

..

~

..

1.4

seat

seat.

care

valve.

Intake

mm

(0.055

cutter

that

in)

90°----...

while

the

1.4

checking

valve

Exhaust

mm

seat

(0.055

EX

the

con-

in)

3.

Reface compound.

4.

Measure

5.

Adjust

between

Checking

1.

Check

cracks.

2.

Check open.

3.

Check

exceeds

the

dimension

the

Rocker

each

to

If

the

dimension

the

lower

Arm

component

If

necessary,

see

any

clearance

the

limit,

Clearance

valve

and

that

clogs

between

and

nLn.

nLn to

spring

Shaft

part

the

oil

are

between

replace

valve

seat

of

replace

passages

found,

the

rocker

the

and

the

with

remove

the

rocker

arm

seat

standard

cylinder

rocker

of

rocker

and

with

arm

a new

the them

arm

arm shaft:

IN

a

good

by

adding

head.

assembly

one.

rocker

or

replace.

bore

bushing

arm

and

valve

some

for

and

shaft.

lapping

washers

damage

shaft

If

or

are

it

Standard: Limit:

0.020

0.10

-

mm

0.074 (0.0039

39

mm

(0.0008

in)

-

0.0029

in)

Checking

1.

Check damage repair block.

2.

Check

sages

the clogged, air

3.

Check distortion. limit, cylinder

Cylinder

the

or

to

and

cylinder

remove

or

a

wire

the

repair

block.

cylinder

cracks.

replace

see

coolant

block

cylinder

If

Block

that

with

probe.

it

or

block

If

necessary,

the

cylinder

oil

passages

are

open.

compressed

block

exceeds

replace

for

pas-

of

If

for the the

Warp

Check

4.

the necessary, replace

Measure

5.

bores in

micrometer.

difference and limit,

limit:

for

cylinder

the the

at

the

figure

minimum

rebore

Standard

Maximum

Inner

0.15

scratches

repair

cylinder wear

six

(The

between

diameters.)

the bore

11

KW:

6.5

& 8

difference

diameter

mm

(0.006

or

walls.

by

block.

on

the

positions

with

wear

the

cylinder.

diameter:

77.0

KW:

error

burns

bor

ing

cylinder

an

is

maximum

-

77.019

70.0 in

in)

shown

inside

the

If

the

-

bore:

of

each

on If or

wear

mm

70.019

0.15

cylinder:

is

(3.03l5

mm

X_X'IS

more

-

3.0323

(2.7559

(0.0059

0.09 or

the thrt/$! direotion

than

the

in)

-

2.7567 in)

mm

(0.0035

more

specified

in)

Select cylinder

oversize

bore.

Oversize

*for

6.5

pistons

& 8

pistons

KW

only

according

available:

40

0.25

0.50 *0.75 *1.00

to

the

mm

mm mm mm

maximum

(0.010 (0.020 (0.030 (0.040

in) in) in) in)

wear

on

the

Checking

1.

Check on

2.

Measure groove,

the

Piston

the

pistons

external

the

at

in

place).

carefully

piston

right

and

circumference

diameter

angles

with

replace,

of

the

18

mm

the

piston

if

severe

piston

(0.7087

burns

are

in)

under

location

found.

or

scratches

the

(but

oil

ring

without

3.

Check

18

mm

(0.7087

Standard

6.5

& 8

11

KW:

the

clearance

Clearance

111)

piston

KW:

limit:

diameter:

69.944 (2.7537

76.954 (3.0297

between

0.15

-

69.964

-

76.974

-

2.7545

3.0305 the

piston

mm

(0.0059

mm

in)

mm

in)

and

in)

cylinder

wall.

Checking

1.

Check cracks, replace,

2.

Measure Replace

NOTE:

cylinder

is

Piston

about

the

burning

if

the if

Push

with

2

Rings

piston necessary. piston

it

exceeds

a

ring

a

piston

inches

surface.

End

gap

limit:

or

ring

from

1.0

rings

wear

end

the

into

until

the

mm

(0.039

for and

gap.

limit.

the

it

block

in)

41

3.

Measure

tween

groove

the

•

the

side

piston

clearance

ring

and

be-

ring

. NOTE:

around

of

Checking

1.

Check

rod

cracks

replace

2.

Check bends alignment

ment

using gradual replace

Measure

the

ring

Side

Connecting

the

small

or

the

or

is

a

pressure

the

total

groove.

clearance

0.15

mm

clearance

Rod

side

end

of

and

damage.

connecting

twists

with

fixture.

necessary,

press

and

connecting

the

clearance

circumference

limit:

(0.006

limit:

the

connecting

large

If

end

necessary,

rod.

rod

a

suitable

If

realigncorrect applying

to

the

rod.

rod

in)

0.15

for

by or

a

mm

(0.006

in)

twist

t:h"a/e

~

3.

Check play

feeler figure. limit, rod

or

Permissible

the

with

connecting

a

dial

gauge

If

replace

crankshaft.

End

play

deflection:

indicator

as

shown

it

the

limit:

rod

in

exceeds

connecting

0.3

(0.012

mm

side

or

the the

in)

0.04 (0.002

a

mm

per

in

per

100

4

mm

in)

42

Checking

1.

Check carefully worn,

2.

Check clear If

the grinder undersize

Connecting

the scored the

ance

it

exceeds

crankpins

and

Rod

connecting

and

replace

or

flaked.

connecting

with

a

the

with

use

bearings.

Bearing

rod

bearing

if

it

rod

bearing "plastigauge". limit,

with

a

correct suitable suitable

is

NOTE: rod torque.

Checking

1.

Check or replace

2.

Check sages open. remove

or

Tighten

cap

Cap

Bearing

Crankshaft

the

other

the

to

of

If

them

a

suitable

bolts

to

tightening

clearance:

Standard:

Limit:

crankshaft

damage.

crankshaft.

see

that

the

any

clogs

with

wire.

the

connecting

the

specified

torque:

0.024

0.10

mm

for

If

necessary,

the

crankshaft

are

compressed

cracks

oil

3.0

-

0.048

(0.0039

pas-

are

found,

air

-

3.5

mm

in)

kg-m

(0.0009

(22

-

25

0.0019

Ib-ft)

in)

3.

Check

If the grinder undersize

NOTE:

journals to

the

it

exceeds

crankshaft

and

Measure

the

crankshaft

cr

main

at

ankshaft

the

with

use

bearings.

the

two

points

limit,

a

with

diameter

axis,

for

correct

suitable suitable

(the

as

wear.

of

front

shown

43

each

and

in

the

of

rear

figure.

the

crankpins

portions)

Rt=O.l46/0.157"(.J,

Rz'O.l26/0.142"(J.2tJ/J,6Imm)

at

90

"tP,99mm)

and

degrees

main

Standard

Main

49.938 (1.9661-1.9668

Journal

-

49.956

mm

in)

Crankpin

39.940 (1.5724-1.5734

-

39.956

mm

in)

NOTE:

points.

a.

b.

Undersize

When

shaft,

uR"

The diameters

the

grinding

as

crankshaft

table

0.254

0.508

0.762

grinding

finish

shown

are

above.

in

the

as

49.690 (1.9528-1.9534

49.440 (1.9430-1.9436

49.190 (1.9332-1.9338

the

place

figure.

processing

shown

-

crankshaft,

crank-

of

in

49.705

49.455

49.205

mm

in)

mm

in)'

mm

in)

take

39.690

.

(1.5598-1.5604

39.440 (1.5500-1.5506

39.190 (1.5402-1.5408

care

of

-

39.706

-

39.456

-

39.206

the

mm

in)

mm

in)

mm

in)

following

4.

5.

Check

If

it

with

Check

wi in the bearing bearing.

NOTE:

should

machine

a new

Maximum

th

a

the

limit,

End

the

exceeds

0.05

the

dial

figure.

with

play

Any

be

shop.

crankshaft

one.

done

the

limit,

allowable

mm

crankshaft

indicator

If

replace

an

oversized

limit:

crankshaft

by

alignment.

replace

run-out:

(0.0020

end

as

it

exceeds

the

0.30

(0.0118

grinding

a

qualified

in)

play

shown

thrust thrust

mm

in)

~l~

Ilpnr~lJli!]ftfl

~II'::

~'~r!!!

::",,"'l1U;:I!i'

=!>

An~

W

I I

! f

: .

44

Checking

1.

Check and

scored

2.

Check with exceeds main crankshaft main

Main

replace

bearings.

Bearing

the

main

or

flaked.

the

main

a

"p1astigauge".

the

journals

ground

bearing

if

bearing

limit,

by

it

correct

having

for

carefully is

worn,

clearance

If

the the

undrsized

------

it

NOTE:

cap

torque.

Checking

1.

Check

wear necessary.

2.

Measure

exceeds camshaft.

Tighten

bolts

Cap

tightening

Bearing

Standard: Limit:

Camshaft

the

or

Limit

camshaft

damage

the

of

the

to

clearance:

run-out.

1imi

runout:

main

the

torque:

and

t,

bearing

specified

0.023

0.08

for

replace

rep],.ace

(0.0012

mm

cracks,

If

0.03

6.6

-

0.042 (0.0031

the

mm

in)

if

it

-

7.1

mm

kg-m

(0.0009

in)

(48 -51

-

0.0017

1b-ft)

in)

3.

Measure

replace

limit.

Cam

6.5

11

the if

Lobe

& 8

KW

cam

the

Height:

KW

lobe

wear

height

exceeds

and

the

45

Standard

44.119

(1.7401

44.114

(1.7337

mm

in)

mm

in)

Limit

43.919

(1.7291

43.914

(1.7258

nun

in)

nun

in)

4.

Measure

wear locations front limit

on

the

and

is

exceeded.

extent

journals

(direction

back).

of

uneven

at

A

and

Replace

four

B,

if

Checking

1.

Check

and

2.

Replace a. b. c.

Uneven

Diameter

(standard):

Front

41.949

Center:

Flywheel

the

replace,

the Heat Remove Heat

plate make directed

wear

and

(1.65l~

flywheel

ring

the

or

sure

limit:

of

journal

rear:

-

41.919

and

if

necessary.

gear

ring

new

in

that

toward

-

Ring

ring

an

(0.020

41.965

1.6522

-

41.935

Gear

for

by

with

gear

oven.

the

0.05

mm

in)

damage

the

a

torch. by

to

Before

chamfered

engine.

mm

in)

mm

(1.6504

or

wear

following

striking

250 -300·C

slipping

-

1.651

on

ring

procedure:

its

circumference.

(480

it

side

of

in)

gear

-

onto

the

tooth

570·F)

the

ring

2

A

~B

surface

on a hot

flywheel,

gear

is

NOTE:

cause

Checking

1.

Check

Excessive

premature

Chain,

for

Chain

wear

heat

failure

Adjuster

or

may

of

damage

destroy

the

Blade,

ring

46

Damper

and

original

gear.

replace

and

heat

Sprocket

any

treatment

faulty

and

parts.

ENGINE

ASSEMBLY

Take

A.

B.

c.

D.

E. F.

G. H.

the

following

Make

Be

used During assembled

tion

bearings

Apply

that

and

I f

them Use Tighten cified Use Refrain

sure

careful

on

in

lubr

moving

are

there

correctly

new

liquid

that

not

various

assembly,

in

relation

and

bearing

icating

parts,

not

subject

are

gaskets,

the

torques

from

bolts

sealants

using

precautions:

all

parts

to

mix

engine

recheck

their

mating

for

using

proper

to

the

oil

when

to

assembly.

lockwashers,

and

tape

to

nuts

assemblies.

clearances

engine

caps.

to

assembled

binding

mar

ks

nuts

a

reliable

when

sealants.

be

and

bolts.

order

block,

moving

or

scr

ibed

o-rings,

on

important

torque

required

assembled

Metric

and

facing

e.g.,

parts

on

the

excessive

dur

ing

etc.

wrench.

on

are

and

insure

in

pistons,

dur

ing

engine,

tension.

disassembly,

parts

nuts,

thoroughly

S.A.E. parts

the

correct

piston

assembly.

rotate

of

engine

bolts

and

cleaned.

bolts

are

being direcrings,

Insure

or

slide

reference

to

spe-

gaskets.

are

47

8J

2

6

7

10

3

5

'----11

CJ

i

l...

1

~

4

~

13

1.

Piston pin

2.

Piston ring

3.

Piston and connecting rod

4. Connecting rod bearing

5.

Thrust washers

6.

Main

7.

Crankshaft

8.

Oil seal

9.

Thrust washers

10.

Main

bearing

48

11.

Main

bearing cap

12.

Side

seal

13.

Connecting rod bearing and cap

14.

Oil pump

15. Timing

. Adjuster blade rocket . Chain

16

C:;:h~'~~;;;;;-------

ch

:;:am and sprocket

am and sp

30

18.

17

19

• 1 pan

17

da:m~-----------

T"

O~l

:~:per

mg chain cover

16

20.

End

pl-=at-e-----

21.

Flywheel

22.

Crankshaft pulley

49

33--------4

26--------,

25--------...

~f)

@

........

y--27

I

M

®

f!J

~

//A'----24

23. Valve

24.

Cylinder head

25. Bolt (cylinder head - timing

chain cover)

26.

Camshaft

27. Rocker

28.

29. Locknut (camshaft sprocket)

arm

Cylinder head bolt

50

30. Chain adjuster

1.

Assemble

necting following setting

the

rods

procedure.

tool.

pistons

according

and

Use

con-

to

piston

the

2.

a.

Assemble

figure.

b.

Apply

external piston

c.

Set

d.

Press

top piston cified lower

the pressing

-1500 I f 500 -

piston

rod.

Assemble

suitable

engipe

pin.

special

as

shown

fit

end

bot

kg

the

1500

piston

as

oil

circumference

tool

in

the

by

pressing

of

installer.

is

in

position

of

gu

ide

tom

of

block.

load

(1100 -3300

load

is

kg,

or

replace

rings

ring

expander.

shown

to

and

piston

figure.

The

the

spe-

when

touches

The

is

500

lbs).

other

than

connecting

using

in

the

of

the

a

a.

b.

Install and

mark Set

ring in

the

top

on

the

in

both

rings)

the

open

the

figure.

rings

with

top

surface.

end

positions

(second

of

each

shown

"R"

51

3.

Insert stamped

(engine

the

on

piston

the

front).

into

piston

is

Use

the

cylinder

facing

a

suitable

Top

block,

toward

ensuring

the

piston

Second

cra·nkshaft

ring

that

"F"

pulley

compressor.

mark

end

4.

Insert block ports

5.

Install

being

6.

Crankshaft. Be

settles

insur

are

directed

careful

in

main

the

place.

bearings

ing

properly

upper

outward

that

the

bear

thrustwashers

the

thrustwashers

on

ing

the

oil

aligned.

(crankshaft

with

thrust

do

·r"'-~·

the

not

groove

side).

drop

as

in

the

washer

crankshaft

52

7.

8.

9.

10.

Rear

Install

with

being Insert

Main

oil

seal.

the

groove

directed

lower

bearing

lower

outward.

main

caps.

thrustwashers

in

the

washer

bearings.

11.

12.

NOTE: cap

with arrow the

front Tighten NOTE:

Cap

Insert that

the either side

of

Match

the

mark

of

the

Make

bolt

the

hole

toward

cylinder

the

"Cap

should

the

main

sure

tightening

side

in the

main

No.",

point

engine. bearing

the

crankshaft

seal,

seal

is

inside

block.

bearing

and

the

towards

cap

bolts.

torque:

ensuring

pointed or

out-

rotates

6.6 -7.1

smoothly

kg-m (48 - 51

after

installing.

lb-ft)

13.

Connecting

NOTE: surface bearing Insure proper

ly

rod

Apply

of prior that

matched

caps.

engine

the

to

the

rod.

14.

Connecting

rod

cap

Tightening

oil

connecting

installing.

rod

to

caps

the

bolts.

torque:

onto

proper

3.0

the rod

are

-

3.5

53

kg-m

(21.7

-

25.3

lb-ft)

15.

16.

Install drive shaft

Timing

the

chain

and

chain

oil

on

pump

and

pump

both

the

sprocket.

sprockets.

with

crank-

the

17.

18.

19.

a.

b.

c.

Timing Timing Timing

Match

the

(shiny chain of

with

the

Install sprocket ensur

ing

assembled

timing

Match

marked sprocket. and

sprocket wire, position chain

is

and

not chain chain chain

ring

link)

the

crankshaft

the

on

the

not

to

position

chain

the

link

and

other

to

Tie

together

so

the

of

camshaft

changed.

adjuster

damper.

front

cover.

plate

of

timing

sprocket.

crankshaft

crankshaft,

change

of

sprocket.

the

camshaft

the

assembled

the

timing

sprocket

blade.

mark

mar k

the the

shiny chain

wi

th

20.

21.

22.

23.

NOTE:

Cut

ends.

Tightening

Oil

pan.

Backplate.

Tightening Flywheel. NOTE:

Install rotating Install

After

torquing,

mounting

Tightening

Front Apply

crankshaft

sealant

it

the

bolts.

off

any

torque:

the

to

properly

tabwasher

bend

torque:

pulley.

to

the

excess

1.9

7 -

flywheel

align

and

one

8.3

threads

portions

-

3.1

10

kg-m

by

the

mounting

tab

-

9.0

of

crankshaft

of

kg-m

(51

placing

mounting

bolts.

against

kg-m

the

cover

(14 -22

- 72

it

Ib-ft)

on

bolt

a

flat

(60 -65

pulley

Ib-ft)

the

holes.

of

Ib-ft)

bolt

gasket

crankshaft

each

and

at

both

of

torque.

and

the

54

24.

25.

Tightening

Valves. Assemble cylinder

spring

lifter

Cylinder

the head

head.

torque:

valves

with

and

pivot.

11.0

in

a

-

the

valve

12.0

kg-m (80 - 87

lb-ft)

26.

27.

a.

position

the

b.

c.

position

Install the chain

Camshaft.

a.

Slide

sprocket

making

chain the

b.

position

the

Rocker

shaft

install

the

that offset rocker

that

rocker

there

between

arm

of

block.

head

cover.

the

sure

and

sprocket

cylinder

assembly.

the

valve

arm

is

adjusting

the

exhaust

the

head

the

cylinder

capscrew

into

timing

on

the

timing

are

the

camshaft

head.

rocker

shaft.

1

mm

(.039

the

center

valve

gasket

head.

through

the

timing

chain

camshaft

position

mark on

correct.

arms

Insure in) of

screw

stem.

on

of

on

of the and

IN

8

28.

Cylinder NOTE:

bolts

head

Tighten

in

the

bolts.

the

order

figure.

Tightening

7.8

torque:

-

8.2

(56 - 59

29.

Check

the

oil

clearance

"plastigauge".

NOTE: oil

Make

clearance.

Limit

sure

of

camshaft

cylinder

shown

kg-m

lb-ft)

head

in

(when

bolts

oil

head

the

cool)

between

are

clearance:

55

the

camshaft

properly

torqued

0.15

and

mm

cap

after

(0.0059

with

checking

in)

a

30.

Install

the

camshaft

drive

sprocket

washer

and

nut.

31.

32.

Tightening

Check

(clear

thrust exceeds replace

Limit

Timing Install

the

timing

to

the

a.

Push

body with

7.0 (51 -58

the

ance

between

plate).

the

of

0.20

chain

the

chain

following

the

completely

the

torque:

-

8.0

camshaft

If

specified

thrust

camshaft

mm

tension

chain

cover procedure.

sleeve

kg-m

1b-ft)

sprocket the

plate.

(0.008

adjuster.

adjuster

and

end

limit,

end

play:

according

into

lock

hook.

play

and

play

in)

on

the

it

b. NOTE:

installed, by chain engine and

tically,

to

33.

Distributor. a.

b.

Install

the

which

the

Turn

the cylinder center stroke.

mark

matches the

Apply

to distr the toward high

After

the

action

is

cranked

sleeve

thus

camshaft

the

piston

of

on

timing

engine

the

o-ring

ibutor

rotor

tension

the

chain

the

of

actuated

projects

applying

drive

crankshaft

reaches

the

Make

the

top

chain

shaft.

No.

1

adjuster.

adjuster

is

the

when

once

or

chain.

in

top

compression

sure

crankshaft

mark

cover.

oil

sparingly

fitted is

spark

lead

terminal.

released

timing

the

twice

automa-

tension

until

No.

dead

that

the

(T)

on

the

Insure

pointing

plug

is

1

on

56

34.

35.

c.

Insert distributor camshaft. be

Adjust Technical

Adjust

installed

engine

Data

the

valve

the

timing

Section.

distributor

shaft

This

fits

groove

correctly

according

clearance.

shaft

into

is

to

the

by

the

offset

camshaft.

to

turning groove

so

it,

on

the

distributor

specifications

ensuring

the

rear

in

end

the

that

of

can

Engine

the the

only

a.

b.

36.

Thermostat. NOTE:

thermostat at mostat block. housing.

Adjust

#1

and

#2

with

top

dead compression cylinder.

Rotate

and

adjust

valves.

Valve

Cam

Be

sure

with

12

o'

clock.

body

Install

the

#3

the

side

is

valves

and

the

piston

center

stroke

.

crankshaft

the

side

to

the

inboard

the

intake

of

remaining

0.25

0.18

position

bleed

Insure

thermostat

exhaust

#1

and

at

the

of

the

No.

360·

Intake

mm

the

hole

ther-

of

the

1

(0.010 (0.007

valve

in) in)

0.30

0.23

Exhaust

mm mm

valve

(0.012 (0.009

in) in)

36.

Oil

filter.

NOTE:

sparingly

oil

filter

Apply

filter

fully

to

engine

the

and

by

hand.

oil

o-ring

tighten

of

an

the

57

38.

Rocker

39.

Oil

40.

Fresh

41.

Bellhousing.

42.

Ignition

43.

Intake

cover.

manifold

water

coil

manifold.

tee,

pump.

and

oil

pressure

bracket.

sender

and

switch.

44.

Carburetor

45.

Alternator

46.

Governor.

47.

Sea

48.

Starter

49.

Heat

50.

Exhaust

Armature

51.

Tightening

and and

water

pump.

motor

exchanger

manifold

Tightening

and

Tightening

Drive Drive

torque: fuel bracket.

and

torque:

drive

torque.: disc

disc

pump.

circuit

disc

assembly.

armature:

to to

flywheel:

1.9

2.6

breaker.

hoses.

and

-

kg-m (14 - 19

hoses.

kg-m

2.3

6.9

-

2.5

-

(14 -

7.6

2.8

lb-ft)

17

kg-m kg-m

lb-ft)

(50 (18 -

55 20

lb-ft) lb-ft)

52.

Generator NOTE:

is

53.

Exhaust

54.

Generator

55.

Generator

Tightening

56.

Generator

57.

Mounts and

58.

Control

housing.

Be

sure

in

place.

screen.

brushes. fan.

fan

rails.

panel

bear

torque:

cover.

and

ing

wiring

seats

3.5

kg-m (25

harness.

properly

58

and

lb-ft)

that

the

bear

ing

lock

59.

Adjust

n

nv

10

kg

For

new

For

used

nVn belt

belt

(22

belt:

belt.:

deflection

lbs)

tension.

force: 9 -

11

(0.35

-

10 -12

(0.39

-

mm

0.43

mm

0.47

exer

ting

\ .

in)

59

Operation

LUBRICATING

SYSTEM

The The

When

lubricating

engine filter. lubricating

sump.

the

open

thereby

the

)

J

)

j

,

)

/

oil

The

oil

points

oil

keeping

pressure

relief

system

forced

passes

in

valve

the

is

a

pressure

out

exceeds

of

through

the

in

oil

engine

the

oil

the

oil

pressure

feeding

pump

oil

filter

and

specified

pump

within

then

and

system

is

passed

and

returns

pressure,

returns

its

using

through

then

to

the

to

specified

to

an

the

oil

lube

oil

pump.

the

oil

various

oil

pushes

pan,

range.

60

Checking

1.

Check correct normal

2.

Check daily

3.

Make

nFn and

mark,

Engine

for

as

Oil

any

needed.

maintenance

eng

ine

prior

sure

to

that

nLn marks

replenish

eng

oil

engine

the

up

ine

oil

Tightening

and

is

level

usage.

oil

of

the

to

the

leakage.

the

responsibility

with

the

Add

is

higher

dipstick.

nFw mark.

of

Should

fittings

lube oil

as

than

If

oil

needed.

the

found

leakage

and

bolts

of

the

dipstick

mid

point

lower

be

is

considered

owner.

at

least

between

than

detected,

once

the

nLa

NOTE: of lack Gauges engine

Maintaining

the

engine

of

and

oil

responsibility Engine

oil All Oil

Troubleshooting

Trouble

Oil

leak

adequate

alarms

pressure.

of

capacity:

(including

Sump

the

proper

eng

owner/operator.

oil

are

is

the

provided

Monitoring

the

owner/operator.

filter)

Oil

System

possible

1.

Loose

oil

hose

Oil

block

pan

leakage

2.

ine

oil

level

Any damage

responsibility

to

warn

of

engine

liters

3.7 liters

3.0

Cause

drain

to

cylinder

is

to

of

against

operating

1.

Tighten

2.

or

the

responsibility

the

engine

owner/operator.

loss

gauges

(3.9 (3.3 (3.2 (2.6

u.S.

Imp.

u.S.

Imp.

Remedy

or

securing

replace

due

of

proper

is

quarts) quarts) quarts) quarts)

replace.

pan

gasket.

to

the

belts

Damaged

3.

timing

or Damaged

4.

cylinder Loose

5.

oil Loose

6.

pressure sender

chain

rocker

or

filter

or

loose

cover

or

loose

head damaged

damaged switch

61

gasket

or

3.

Replace bolts.

Tighten

4.

Tighten

5.

6.

Tight~n

or

tighten

replace.

Low

(unit

Trouble

Oil

Pressure

shut-down)

Oil

1.

Low

2.

incorrect

Possible

leaks oil

level

Cause

or

grade

1.

2.

Refer Add

oil

level

Remedy

to

above.

to

proper

or

change.

Checking

1.

Remove and

pressure

2.

Electrically

sure

Oil

Pressure

the

connect

gauge

switch

3.

4.

5.

6.

7.

with

oil

pressure

a

mechanical

instead.

jump

the

connections.

Faulty

oil

switch

Clogged

strainer

Worn oil valve

Faulty

or

pressure

spring

electrical

circuit

Mechanical

sender

oil

pres-

pressure

oil

filter

pump

fatigued

relief

Gauge

oil

3.

Test

Remove and

4.

filter.

Remove and

5.

Remove and

6.

7.

Check repair

and

circuit

as

replace.

replace

clean.

replace.

and

needed.

oil

3.

Start 1800 warm

4.

Measure less check

Oil

NOTE:

requirements

the

RPM

and

up.

the

than

the

lubricating

pressure:

Insure

engine,

allow

oil

the

1.75 (25 - 35

proper

and

the

operate

engine

pressure.

specification,

system.

-

2.5

kg/cm

PSI + 5

oil

A.P.I.

is

Spec.

at to

If

2

+

lb/in

being

of

.7

kg/cm

2

)

used

SE

or

2

that SE/CC.

meets

temperature

62

Disassembling

Oil

Pump

Disassemble

1.

Cover

2.

Cotter

3.

Plunger

4.

Outer

in

5

assembly

rotor

the

following

7

order.

6

4

1

3

2

5.

Sprocket Remove porting pressing

6.

Shaft

7.

pump

Checking

1.

Examine

a. b.

2.

Check

gauge.

the

and

inner

body

Oil

Pump

the

Pump

body

Plunger

the

clearance

If

the

Clearance

sprocket

shaft

rotor

following

and

worn

or

clearance

limit:

by

assembly

parts

cover,

damaged.

between

0.25

sup-

and

out.

and

deformed

the

exceeds

mm

replace,

or

lobes

the

(0.010

if

damaged.

of

the

limit,

in)

necessary.

rotors

replace

with

both

a

feeler

rotors.

63

3.

Check

the

outer with clear replace body.

the

a

feeler

ance

clearance

rotor

exceeds

the

and

gauge.

rotor

pump

the

between

body

If

limit,

or

pump

the

4.

5.

Clear

Check rotors. edge

across

measure

the wi clear

th

rotor

a

ance replace shaft, rotor

and

Clearance

Then,

place clearance exceeds

it.

0.35

the

feeler

the

inner

the

ance

rnrn

end

Place

the

clearance

and

gauge.

exceeds

drive

pump

0.15

a

straight

between

limit,

limit:

(0.014

float

a

pump

straight

the

gear,

rotor,

body. limit:

rnrn

(0.0059

the

in)

of straight body

between

I f

limit,

drive outer

edge

straight

correct

the and

edge

the

in)

across

the

edge

pump

the

cover

pump

and

cover

cover.

by

grinding

and

If

measure

the

or

replace

the

cover

Clearance

6.

Check plunger

the

relief

and

Spring

45.5

7.

Clean

the

pick

limit:

fatigued free

rnrn

up

valve

spring.

length:

(1.791

strainer.

0.15

for

rnrn

worn

in)

64

(0.0059

in)

Assembling

the

Oil

Pump

Assemble

NOTE:

surface pressing

the

NOTE: Make

outer

in

the

Press

becomes

pressure

sprocket

Pressing

rotor

reverse

the

flush

or

shaft,

pressure:

sure

and

inner

order

dr i ve

is

less

that

of

gear

with

the

than

or

both.

700 -1300

when

rotor

face

disassembling.

onto

the

end

the

surface

specified

kg

assembled,

toward

pump

(1540

the

~https://manualmachine.com/

shaft

of

the

value,

-

2860

tally

outside

until

shaft.

replace

lbs) marks

(cover

,~4-I~

the

on

OUTER

ROTOR

INNER

ROTOR

TALLY MARKS

end

If

the

either

both

side).

Reinstall

the

pump

in

the

engine.

65

Description

COOLING

SYSTEM

Westerbeke Transfer by

a

heat Sea water with

water

flows

the

clean.

Fresh Heat

tion, water a

the cold vented to up, fresh

Sea

Water

rej

fresh

suction

engine,

prevent

the

water

Water

is

circulating

water

by

mar

ine

of

heat

exchanger,

flows

around

result

Circuit

ected

dur

absorbed

cooled

side

most

the

closed

overheating

thermostat

through

Circuit

generators

from

through

the

that

ing

combustion,

by

the

pump.

exhaust

of

the

of

the

thermostat.

begins

the

engine similar

the

tubes.

the

cooling

fresh

The

fresh

external

in

the

external

are

fresh

in

tubes

The

water, fresh manifold,

water

exhaust

to

open

cooling

equipped

water

function

of

the

sea

water

as

well

whose

water

a

circulating

flow

Some

amount

manifold.

up

wi

th

to

sea to heat

and

passages

as

flow flows heat

to

exchanger

the

allowing

system.

fresh

water

an

automotive

exchanger

fresh

heat

is

from

pump.

heat

of

bypass

As

full

water

is

water

in

the

developed

created

the

engine and

When

exchanger

is

the

flow

cooling.

accomplished

radiator.

while

engine

never

by

fresh

mix

stay

fr

ic-

by a fresh

through" returns starting

is

pre-

maintained

engine

of

warms

engine

to

a

The

sea impeller ocean

via directly exchanger heat

exchanger, system, of

larger

exhaust

Full

Sea The

sea

Water

sea rotary impeller wi

thin account impeller

water

pump.

the

from

sea

the

engines,

systems

water

Pump

water

pump

has

the

should

and

flow

Normally

sea

the

water

the

most

popular

so

flow

pump

with

flexible

impeller

this

impeller

is

cock

discharge

inlet.

sea

the

sea

that

would

is

self

a

non-ferrous

vanes

housing,

pump

cover

created

the

and

water

type

water

a

portion

create

priming

be

gasket

pump

sea

After

of

which

run

by

a

draws

water

of

the

passing

enters

exhaust

flow

is

used

unnecessary

and

housing

wipe

producing

dry.

aboard.

posi

ti

sea

strainer.

sea

a

water

system

is

divided

to

positive

and

against

a

There

ve

displacement

water

Sea water through

injected,

in

prior

cool

exhaust

displacement.

a

neoprene

pumping

should

directly

pump

the

use.

the

back

a

curved

always

water

to

tubes

to

entering

exhaust

pressure.

impeller.

action.

then

the

wet

In

cam

be

neoprene

from

the

flows

heat

of

the

exhaust

the

case

the

system.

It

is

The

plate

On

a

spare

a

no

66

Fresh

1.

2.

Water Drain Remove pump

adjusting

3.

Remove

4.

Remove

Pump

coolant

strap coolant belts

Removal

from

engine

drive

and

hose

mounting

belt

pivot from

pump

block.

by

bolt.

pump

to

loosening

to

manifold.

engine

block

the

and

12

volt

remove

alternator

pump.

Checking

1.

Check necessary.

2.

Replace

3.

Examine

Sea

Water

The

following instructions impeller.

1.

Remove

2.

Remove pump the

3.

Coat with

Fresh

for

pump pump

Pump

where

the

shaft.

impeller

the

replacement

grease.

Water

water

if

abnormal

and

Pump

leaks.

impeller

Impeller

instructions

applicable

front

cover

impeller

This

hub.

Replace

noise

for

Replacement

are

gasket.

by

pulling

is

best

impeller

or

damage

general

may

be

straight

done

and

cover

bearing

and

packaged

with

the

gasket,

and

replace

indicative

outwards,

a

pair

chamber

squeak

with

of

into

cover

is

present.

if

necessary.

only.

your

parallel

pliers

which

or

pump

Specific

replacement

to

the

applied

it

mounts

as

to

4.

Carefully wi the

5.

Inspect

mately

measure, tween

6.

Reinstall

7.

Be

the by

immediately

th

the

same

doubly

engine.

priming

the

align

shaft.

direction

the

be

replaced.

but

cover

the

sure

front

not

end

The

itself

or

to

damage

heating.

the

Take

and cover when

and

cover

check

absence

properly.

impeller

care

trailing.

for

Sometimes

stamped

the

impeller

with

quickly

of

to

the

-keyway,

that

wear.

it markings

a new

flow

This new

67

all

A

worn

can

blades.

gasket.

for

sea

indicates

situation

impeller

or

the

be

other

impeller

front

reversed

would

water

that

must

will

locking

cover

as

break

flow

the

be

result

mechanism,

blades

should an

emergency

the

when

pump may

investigated

from

bend

ulti-

seal

starting

over-

in

be-

not

Sea

1.

2.

3.

Raw

Water

Pump

Remove

inlet

connections Loosen

bolts

belt. Remove

mounting

Pump

Removal

and

outlet

on

pump

mounting

nuts

Disassembly

for

and

hoses

proper

pump

bolts

connected

assembly.

to

support

and

lift

to

nipples

bracket

pump

from

on

and

engine.

pump.

remove

Note

drive

Disassemble

4

in

the

following

order.

1.

Impeller gasket

2. . Impeller

3.

Drive

4.

Bearing NOTE:

bearing

5.

Cam

and

6.

Small

7.

Large

8.

Bearing

9.

Small

10.

Bearing

11.

Drain

cover

(Ref.

and

pulley

housing,

Shaft

housing,

screw retaining retaining

housing

retaining

(Ref.

plug

and

with

20 -

key

and

#17

(Ref.

ring ring

(Ref.

rings

7) dowels

graphite

24)

(Ref. key screws

18 -19)

(Ref.

and

withdrawn

bearing

14 -15) and

(Ref.

8) (Ref.

(Ref.

16) lockwashers

through

and

seal

6)

from

shaft

5) 12 -13)

68

bushing,

the

assembly.

(Ref.

and

5 &

screws,

front

9)

bearing

of

(Ref.

lockwashers

the

pump

5 -

10)

with

and

the

NOTE:

Drive

pulley

not

shown. Thermostat The

head

1.

2.

3.

4.

S.

Drain

thermostat

Checking A

thermostat

pan of

boil.

1/4

of

cold

The

n

-

Thermostat

Removal

is

to

the

distributor.

the

coolant.

the

hose thermostat thermostat. housing

Thermostat

can

water

thermostat

1/2")

and

Installation

mounted

from

cover

gasket.

be

checked

and

then

should

be

fully

inside

a

thermostat

housing

for

raising

open opened

housing

housing and

bolts.

proper

the

operation

temperature

noticeably

when

on

the

to

(with

water

heat

back

of

exchanger.

by

placing

of

the

travel

is

boiling.

the

water

on

cylinder

it

in

to

the

order

a a

1.

Install a

new

both

sides

NOTE: vent

at the

2.

Replenish

the are

Engine It

is fresh should

hole

the

thermostat

engine

no

Coolant recommended

water

be instructions. in

the

antifreeze

Filling

and

in

housing

with

Insure

in

12

o'clock

the

leaks.

cooling

used.

Rust

Draining

reverse

gasket

that

the

is

coolant

and

check

that

system.

The

used.

order

the

thermostat

position

installed.

that

an

mixture

and

scale

Fresh

using

coated

cement.

small

when

and

start

there

antifreeze

An

Ethylene

should

inhibitors

Water

on

is

be

System

mixture

-

Glycol

according

should

be

used

base

to

in

antifreeze

the

manufacturer's

added

if

the

not

engine

only

found

Draining system block,

system

should

manifold

coolant:

be

opened

and

Two

to

drain

exchanger.

points

fresh

69

on

the

water

engine

coolant

fresh

water

from

the

cooling

engine

POINT

the

engine

#1:

Drain heat

petcock

exchanger.

located

on

the

right

inboard

side

of

Filling

1.

Replace cock

2.

Open 1/8

3.

Fill neck or until

4.

Start

S.

With

install level tank.

be

POINT

fresh

system

on

air

pipe

system

on

open

coolant engine

engine

is

Add

found,

#2:

water with

inlet

heat

hose

exchanger.

bleed

plug).

with exhaust plug,

and add

at

pressure

between

coolant

investigate

Remove

circulating

coolant:

to

petcock

appropr

manifold.

close

is

petcock

1/4

coolant

operating

cap.

MIN

and

as

the

fresh

at

thermostat

iate

When

-

1/2

inch

temperature,

Add

coolant

MAX.

needed.

cause

before

hose

pump.

water

antifreeze

coolant

or

replace

from

to

maintain

Monitor

Should

connected

circulating

housing

flows

plug

filler

level

fill

to

plastic

coolant

an

further

to

the

pump

(early

mixture

"from

and

neck.

at

manifold

recovery

level

extreme

engine

inlet

and

close

models

through

bleed

continue

filler

neck.

completely

tank

from

loss

of

operation.

of

the

pet-

remove

filler petcock filling

and

until

recovery'

coolant

Exhaust Removal

complete

1.

Drain

2.

Remove

3.

Loosen

4.

Loosen

assembly

S.

Remove

Exhaust

1.

Remove Clean

2.

Remove

3.

Remove plates. each

Manifold

of

the

assembly

the

engine the and remove

and remove

to

the

Manifold

the

and

inspect

exhaust

water

Be

for

proper

Removal

exhaust

in

the and

exhaust

the

cylinder

manifold

Servicing

exhaust

nipples,

connectors

sure

replacement.

manifold

following

cooling

connection.

all

hose

the

nuts

head.

from

the

elbows

for

cracks

elbows

from

to

note

from

the

manner.

system

connections

and

cylinder

from

the

and

the

proper

defects.

plugs

ends

eng

of

all

to

bolts

head

lower

of

location

ine

should

coolant.

the

manifold.

attaching

as a complete

surface

of

Replace

from

the

manifold.

manifold

and

be

done

the

manifold

unit.

the

manifold.

as

needed.

and

the

arrangement

as

end

a

of

70

4.

Examine needed.

all

parts

for

defects,

corrosion

and wear and

replace

as

Exhaust

1.

If be Do nuts

2.

If

a.

,

b.

c.

d.

e.

Manifold

the

manifold

replaced

not

reuse

to

the

manifold

Loosely fold

using

Gradually ment

Torque

Reassemble sure suitable to

8 - 10

Reinstall using

Reconnect

Installation

was removed

on

the

cylinder

the

gaskets~

proper

of

to

attach

all

use

gasket

specification

has

been

the

new

gaskets.

tighten

the

10 - 12

the

end

new

cement

disassembled,

elbows

each

parts.

lb-ft.

plates,

gaskets

lb-ft.

the

exhaust

"Locktite-Anti-Seize

all

hoses,

as

an

head

in

install

(10 -

to

Do

not

fitting

This

connectors

and

such

as

connections

n

on

replacing

assembly

the

reverse

new

ones

12

follow

the

cylinder

use

any

to

make

should

coat

the

"High

and

the

threads.

them

as

and and

lb-ft).

the

gasket

sure

be

done

on

gasket

Tack".

plug

needed.

left

order

torque

steps

head

of

in

the

surfaces Torque

into

intact,

of

removal.

the

bolts

below.

and

the

sealant.

proper

three

manifold.

the

manifold

it

can

mani-

alignsteps.

with

nuts

or

Be

a

f.

g.

Adjust

nV·

(22

belt

lbs)

For

Refill Pressure

"V"

Belt

deflection

force:

new

used

belt:

the

system

test

Tension

exer

9 -

(0.35

10 - 12

(0.39

system

ting

11

mm

-

0.43

-

with

mm

0.47

coolant

and

10

in)

check

kg

as

detailed

for

above.

leaks.

71

Cooling

System

Troubleshooting

Coolant

1.

leak using

iST255. the

2.

Overheating Water

Trouble

leaks:

in

the

commercially

Follow

leak.

(Fresh

System)

It

cooling

instructions

2.

3.

1.

2.

3.

possible

is

recommended

system

available

Leaking

cap

Faulty

coolant

tank

Insufficient coolant

Loose

water

or pump

belt

Faulty

Cause

that

the

pressure

with

the

pressure

plastic

recovery

broken

drive

thermostat

that

when

system

tester

tester.

2.

3.

1.

2.

3.

Remedy

trying

be

pressure

such

Locate

Test

and/or

Check

with

replace.

and

nections

tank.

Replenish check

for

loss.

Adjust

Remove

or

and

to

as

the

and

above

tighten

or

replace

coolant cause

replace.

locate

tested

STANT

correct

unit

of

a

con-

and

3.

Overheating Water

System)

(Raw

4.

Faulty

switch

5.

Scale

in

6.

Faulty

pump

1.

Loose

water belt

2.

Faulty

pump

3.

Clogged

exchanger

4.

Scale

overheat

and

cooling

circulating

or pump

raw

heat

in

sediment

system

broken

drive

water

exhaust

raw

4.

Remove

5.

Flush

system changeri coolant.

6.

Remove

1.

Adjust

2.

Check

for

impeller.

replace

3.

Remove

clean

4.

Remove

and

engine

and

or

raw

wear,

as

exchanger,

and

elbow

replace.

cooling

heat

replenish

replace.

water

defective

Repair

needed.

flush.

and

ex-

pump

or

clean

Other raw engine.

causes

water

of

circuit

Examine

eng

ine

supplying

the

overheating

coolant

off

circuit

72

may

for

be

to

the

possible

caused

raw

from

water

faults

pump

contributing

in

the

on

the

faults.

GOVERNOR

Governor The

governor engine speed

determines

NOTE:

span belt when

The

governor

frequency

(Generator

Governor Operate

perature

NOTE:

adjust before

Description

RPM

under

Belt with tension

worn,

will

output

Data

Adjustments

the

generator

before

If

the

proceeding

is

belt-driven,

varying

the

tension:

22

lbs

for

frayed

maintain

from

Plate)

attempting

the

governor

linkage

Hertz

3/8 pressure proper or

cracked.

no

set

at

with

mechanically

conditions

and

voltage

-

1/2

applied

governor

engine

load

an

the

to

bring

adjustment.

is

severely

no

load

adjustment.

of

inch

operation.

RPM

full

the

to

generator

output

deflection

to

belt

to

within

rated

unit

out

obtain

operated

of

the

at

outer

Replace

3

Hertz

load

up

of

adjustment,

a

safe

and

load.

generator.

center

face.

of

the

to

operating

output

maintains

The

of

engine

widest

Maintain

drive

belt

generator

generator.

tem-

manually

voltage

There

are

illustration.

1.

Increase/Decrease

This

to

set

the

eng arm arm should the

throttle

the

engine Insure freely

joint

per

ly graphite pose.

joint

lube

joint.

three

)

adjusting

the

no

ine.

between

and

be

adj

is this and

connectors

lubr

lube

Disconnect

and

to

the

adjusting

bolt

load

(The

the

throttle

usted

full

not

linkage

that

icated.

for

apply

inside

Speed

is

used

speed

linkage

governor

lever

to

hold

open

when

running.)

moves

the

are

ball

pro-

Use

this

the

pur-

ball

graphite

of

the

points

of

on

the

Bumper Screw

Carburetor Throttle Lever

governor.

Hunting/Regulation

Adjustment

Increase/Decrease Speed

(Refer

to

the

73

2.

Hunting/Regulation

If

variation

great,

adjust

hub.

3.

The

Bumper This NEVER

increase/decrease

If

the

spring

Screw

screw

turn

it

increases

in

this

governor

away from

is

used

the

engine

eye

surges

to

bumper

no

load

speed

bolt

speed

between

to bolt

under

the

lever

remove a no

screw

into

speed.

draw

may

load,

hub.

the

adjust

load

the

no

load

spring

need

to

(Check

surge

governor

and

closer

be

adjusted

this speed

ONLY.

far

full

load

to

the

as

eye

bolt

adjustment.)

enough

is

lever

well.

to

so

too

move

that

Governor

1.

Periodically arm

Maintenance

and

NOTE: governor/throttle

2.

Governor NOTE:

3.

Change To

change

fill

with

throttle

Free

oil Do governor

level

3

ounces

lubricate

movement

capacity

not

overfill

oil,

plug

of

lever.

operation.

oil

every

remove

and

10/30

linkage

Use a graphite

of

this

- 3

ounces

governor.

governor

drain

engine

2000

all

arm

linkage

tlO/30

hours

from

oil.

attaching

lubricant

arm

motor

of

operation.

engine

Reinstall

Replace

is

important

oil.

and

plugs.

points

or

remove

on

engine

at

governor

equivalent.

for

proper

oil

fill

and

fill

74

Carburetor

CARBURETOR

AND

FUEL

SYSTEM

The

screened

The mixture).

accept

Any

carburetor

air

carburetor

The

no

adjustment.

adjustment

intake

has

warmed up and no

Electric The

electric

choke

NOTE: and

The

choke

Adjust

rotating

ENRICH

average

Choke

choke

automatically

Some

on

choke is

adjusted

the

of

choke

cover

choke.

70·F

is

filter

two

other

to

the

load

once

hunting

with

by

clockwise

The

room

a

single

(cleanable).

metering

fast

idle

on

uses

no

the

a 12

the

will

load

with

running

mixture

generator.

engine

be

the

loosening

to

choke

temperature.

barrel

jets,

volt

present

on

the

engine

the

LEAN

is

down

one

jet

is

jet

should

heating

starts

generator.

three the

initially

draft

of

set

and

when

off

cover

choke

set

which

at

the

be

done

element

is

running.

the

generator

and

at

securing

and

at

type

is

with

adjustable

factory

with

which

room

temperature.

a

and

the,

opens

is

started

engine

screws

counterclockwise

the

factory

for

metal

(idle

will

the

and

to an

The

choke

ambient

The

choke

side.

CAUTION: operation.

NOTE: system mounted prevent unplug priming

may

need

temperature

index

mark

The

Initial servicing,

fuel

unwanted

the

12

and

readjustment

of

the

is

located

choke

engine

prime

pump

by

activation

volt

reconnect

area

the

on

housing

start

the

engine

depressing

(+)

lead

it

the

will

up

of

at

after

at

engine

is

choke

operating

cover

normally

(commissioning)

fuel

the

system control carburetor's

electric

priming

commissioning

in.

get

panel

lower

hot

by

right

dur

or

using

ON

after

switch.

electric

to

choke

start

during

the

for

ing

the

inboard

eng

ine

fuel

engine

To

choke,

this

engine.

75

Air

Intake Screen

Electric The

engine

supplies

during

filter

Remove

the the as

be

hex

bayonet

needed.

installed

removed

WARNING:

at

Take

filter smoking, sources when

tilation system.

Fuel

fuel

engine

screen

the

nut

and

engine

care

servicing.

Pump

mounted

to

the

operation.

is

contained

base

and

by

twisting

-fittings.

A new

each

base

time

reinstalled.

Shut when

to

off

servicing

catch

elements.

open

of

flames,

fire

when

electric

engine

placing

Clean

gasket

the

fuel

00

NOT

sparks

near

the

Insure

servicing

A

in

its

a

it

loose

the

134706

pump

service

fuel

when

fuel

proper

fuel

pump

carburetor

cleanable

base.

wrench

from

screen

must

base

valve

system.

opening

allow

or

any

other

system

ven-

the

fuel

on

is

76

Troubleshooting

the

Fuel

System

1.

Hard

2.

Flooded

Trouble

starting

possible

1.

Faulty

2.

Fuel

~.

Fuel

4.

Faulty

adjustment

1.

Carburetor

needle or

2.

Float

leaking

3.

Float

gasket securing loose

check

pump

idle

valve

damaged

in

carburetor

chamber

damaged

screws

Cause

jet

float

open

or

are

1.

2.

3.

4.

1.

2.

3.

Check

and

operation.

Check correct

Check and

clean

screen.

Adjust

Clean

needle

Repair

float.

Replace

tighten

Remedy choke

fuel

type.

pump

filter

idle

or

replace

valve.

or

gasket screws.

adjustment

supply

operation

jet.

the

replace

and/or

and

3.

Poor

at

generator

perform~nce

speed

1.

Main

2.

Carburetor

filter

3.

Fuel clogged

4.

Air

screen

jet

clogged

pump

intake

dirty.

clogged

inlet

filter

1.

Remove and

2.

Remove and

3.

Remove and

4.

Remove and

clean. clean.

clean.

77

DC

ELECTRICAL

SYSTEM

Safety

Information

This

united

tions

States

may installer's generator are

installed

Failure

Circuit

Description

The two

down

B+

switches

to

the

While switch switch

and

is starting generator start

switch

Continue

tinue

holding pressure viding

the impossible until

one

circuit

be made

responsibility

set

to

observe

pole

start

continuing

to

operated

at

the

is

running.

when

depressing

the

is

sufficient

normal

to

again

is

Coast

Guard

and any

in

compliance

these

ON

switch

during

toggle

bypass

to

generator

the

ON B+

energize

operates

designed

Standards

to

it

remote

requirements

starting.

switch.

to

hold

the

cause

If

starting

green

the

switch

to

close

path

to

the

and

by

the

to

assure

start

with

is

operated

The

the

ON

protective

the

set,

LED

ON

after

release

shines.

switch.

releasing

the

ignition

starter

ON

switch

manufactured

(33

CFR

installer

that

panels

the

or

above

could

to

bypass

second

switch

to

shutdown

starter

to

the

at

a

remote

It

oil

pressure

system.

while

first.

PART

the

remote

Coast

be

the

pole

provide

crank

start

is

the

in

183).

or

user.

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Westerbeke 6.5KW, 8KW, 11KW Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual