Westerbeke FOUR-230 Technical Manual

TECHNICAL

MANUAL

WESTERBEKE

Marine Diesel Engines

MODEL FOUR-230 70hp MODEL

SIX-346

115hp

Marine Diesel Generators

MODEL WPDS30 MODEL WPDS45

Publication

Number

30kw 45kw

13315

jr-.v-

Issue

Date

Edition

June

2

1.1975

'WESTERBEKE

J WESTERBEKECORPORATION

•

MYLES

150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

TECHNICAL

MANUAL

WESTERBEKE

Marine Diesel Engines

MODEL FOUR-230 70hp MODEL

SIX-346

115hp

Marine Diesel Generators

MODEL WPDS30 MODEL WPDS45

Pu

bl i cat

Issue

ion

Date

Number

June

30kw 45kw

13315

1,

1975

~r-.v-

'WESTERBEKE

J WESTERBEKECORPORATION

•

MYLES

150

STANDISH

JOHN HANCOCK

Edition

INDUSTRIAL

ROAD,

TAUNTON,

2

PARK

MA

02780-7319

INTRODUCTION

/

This

manual Westerbeke to

be

a

guide

diesel The

nism case.

it

diesel

has

engines.

is

essentially

its

crankshaft

the

same

system. The

diesel handling and forms

in

and

their

the

functions

Therefore. preventive give the filter

to a gasoline

fuel.

elements

maintenance

lubricating

contamination

Another designed lubricating

important

specifically

oil

describes

Model

for

engine

sort

engine

firing

place

it

follows

at

(i.

is

the

SIX-346

those

closely

the

is

of

does

its

and

concerned

resembles same. one

of

valves.

differ

fuel.

is a single

of

both.

to a great

as

that

engine.

the

e..

factor

and

time

water.

for

The

cooling

periods

sediment.

is

diesel

rec0mmended.

operation. FOUR-230

with

the

Its

cylinders

the

same

camshaft.

from

the

Carburetor

adjustment

Marine

the

gasoline

general

pistons.

gasoline

and

component -the

extent which most

that a diesel

any

intelligent

important

systems.

specified

etc.)

the

use

of

"High

engines

and

Diesel

operation

engine

are

arranged

type

as

connecting

engine.

ignition

Fuel

systems

Injection

and

factors

Replacement

is a must

in

the

fuel

Detergent"

continued

and

maintenance

Engines.

and

maintenance

inasmuch

above

that

of a gasoline

rods

however.

engine

careful

are

proper

of

fuel

and

frequent

system

diesel

use

of

and

is

designed

of

as

the

mecha-

its

closed

crank-

engine;

and

lubricating

in

the

method

are

done

away

Pump -which

requires

the

operator

maintenance

and

lubriCatiilg

checking

is

also

essential.

lubricating

the

same

brand

the

these

of

with

per-

same

would

of

for

oil

of',--"

Unremitting many

ever.

thousands

is

the

you. Whenever

numbers on

the

with

nameplate

Example:

SIX-346

FOUR-230

care

treatment

service

engine

and

of

hours

parts

model

affixed

Marine

attention

of

service.

the

product

are

ordered.

and

to

the

Diesel

at

the

will

number.

exhaust

Engine

or

Engine

factory

What

the

receive

always

The

manifold.

No.

57PS/

No.

have

resulted

manufacturer

in

service.

give

engine

complete

model

1641 / 20801

38PS/

1641/39101

in

an

engine

cannot

This

description

and

number

control

part

capable rests

and

is

stamped

of

how-

with

part

2

TABLE

OF

CONTENTS ENGINE INSTALLA ENGINE GENERAL I

NSTALLA

IDENTIFICATION

TION

DESCRIPTION

DATA

TION OPERATION MAINTENANCE COOLING FUEL

SYSTEM

ENGINE

HYDRAULIC

TRANSMISSIONS GENERATOR VOLTAGE

REGULATOR & POWER

DRAWINGS

CONNECTIONS

DIAGRAM

4-5 6 7-8 9-12

13-18

19-23 24-27 29-32

33-4OB

41-71

73-92

94-117

118

MANUAL

STARTER

DISCONNECT

(ROTARY

SWITCH)

119-125

3

ENGINE

IDENTIFICATION

ENG

I N E

IDE

NT I FICA T ION

5

RATIO

150'1

2.04:1 ?S2:1

3.CO:1

:DIM

°A"

DIM

161.18 i 4.50 cuB

14.50

'61.50

'525

61.50

5,25

11.56

!

1

'"0fc'5f

iI

RAPIUS

9.I,2RL.

,-

·8"

r

IOFFSET

I 1.30

: 2.10

~-

.85

1.90

______

i 1

INSTALLATION

__

--------~1.25

___

.1

__

_

DRAWINGS

~.a,NL.U\

w'~Jm~

.

~+-~---

CONN.

1---

11:

E,t,I~JNE

'~rLEX

MfG

i

FO~

~.

B9LTS

LAG~~~_R.E;.~~

CENTERS

--OB

,._-

RATIO

1.50:1

2.04:1

2.52:1

3.00:1

~_

~iJP$

lli-:

DIM.

"A"

DIM."S"

4.50

5.25

QV:LL_~T

FA~

OFFSET

.85

1.30

1.90

2.10

51.56

51.87

.WAT,ER

L

-.A:5.12~IRE

T

R=--IV

DIPSTICK Q'J

EITHER

CAN

BE

SIDE.

-----I

SIX-346

1---

_________

-----------·A''----------.I

6

....

~-----.30.62-----.j.

.45.50-"'-''''R'''C'''T.....!l'''R'eyV-''-

___

.8'

----I

FOUR-230

FLEX

MOUNTING

.EQR..~

BOLTS

T

OR

CENTERS

LAG

SCREwS

ENGINE

DESCRIPTION

ENGINE

DESCRIPTION

The Four-230 direct stroke stroke

injection. units

units

"Right side" seen

means

from

CYLINDER

The

cylinder

is

a

one

detachable

lower

end

CYLINDER

The valves.

tors;

around The

it

the

air

valve

is

induction exhaust opposite The cylinder

the

rods The

ter

valves

head

medium

and

inlet

than

the

shrouded

induction.

Westerbeke

Marine

and

respectively.

hand

the

flywheel

BLOCK

piece

wet

liners.

by

synthetic

HEAD

cylinder

rocker

completely

ports

manifold sides

of

are

and

of

the

tappets

valves

exhaust

to

assist

Diesel six

four

side"

side

AND

block

casting.

rubber

AND

head

gear

and

injector

manifold

are

the

set

vertically

are

operated

rocker

from

are

larger

valves

Six-346

engines

cylinder.

or

"left

of

the

engine

end.

CRANKCASE

and

crankcase employing

sealed

at

0

VALVES

carries

and

water

jacketed

sleeves.

and

mounted

cylinder

through

gear,

the

camshaft. in

diame-

and

air

swirl

and

are four four

hand

as

their

rings.

the

injec-

the

on

head.

in

the

push-

are

on

fitted

(Six-346

shaft mounted the

TIMING

drive tion is means idler the camshaft drive

PISTONS

connecting

pins.

to

the

engine

vibrations.

In

rear

main

GEARS

A

train

the

camshaft

pump.

mounted

of a separate

gear

on

and

gears.

AND

The

pistons

and

a

on

transmits

the

rods

are compression The

piston

greater and

top

compression

is

chromium

wear

extended

resistance.

LUBRICATING

The

suction

the

dipstick

may

tube

be

oil

removed

front

only)

A one-piece bearing.

AND

of

gears

and

The

camshaft

the

steel

crankshaft

the

fuel

PISTON

are

by

fully

equipped

and

one

life.

OIL

SUMP

sump

extension

tube)

from

by a suction

of

the

to

absorb

lip

type

housing

TIMING

is the

hub

the

injection

PINS

attached

floating

scraper

ring

inserted

rapid

is

fitted

(combined

which

crankshaft

crank-

oil

seals

CASE

utilized

fuel

injec-

drive camshaft and

nut.

drive

to

both

pump

to piston

with

three

on

to

seating.

with

the

pump.

seal

to

gear

by

An

from

the

ring.

each

give

a

with

oil

CAMSHAFT

The

camshaft

crankcase, crankcase the

front.

bearing. trolled camshaft timing

bores which Camshaft

by a thrust

shoulder

gear.

CRANKSHAFT

The engine able engine main

thrust thrust ing.

crankshaft

is

mounted

main

bearings.

is

mounted

bearings

of

the

washers

A

torsional

running

with

runs

in

the crankshaft on

the

vibration

is

mounted

directly

the

exception

in a white-metal

end-float

plate

and

the

for

on

seven

and

on

five

the

is

between

camshaft

the

Six-346

replace-

Four-230

replaceable

crankcase.

is

taken

front

main

damper

in

bear-

the the

con-

the

End

by

of

is

LUBRICATING

The driven shaft.

bearing pressure

rotor-type

from

is

mounted

cap

relief

body.

Oil

through

From

through housing

From is

fed

oil

cooler Drillings oil

to

and

camshaft

across

is

a

the

an

attache.:!

the

outlet

under

from

the

strainer.

pump

external

to

crankshaft

SYSTEM

the

front

and

incorporates

valve

drawn

the to

side pressure the

the

bearings.

front

oil

on

from

to

oil

the

of

main main

of

pump.

of

the

front

gear-

crank-

main

an

in

the

pump

the

oil

filter

oil

is

sump.

pump.

passed

via

crankcase.

the

filter. through oil

gallery.

gallery

main

bearings

and a drilling

the

crankcase

oil

a

oil

the

feed

7

ENGINE

DESCRIPTION

feeds lubricate oil cates

ings to from gudgeon

the the rocker

of the pressure front The lubricated

shafts~

chamber guide

oil

jet

screwed

the

train

From

oil

is

the

big-end

the

pins

An

external

main

cylinder

brackets

the

rocker

intermediate

rocker

and

provides

lubrication.

to

the

idler

the

fed

crankshaft

and

gallery

shafts

relief

bearing

by

oil

Discharged

rockers

the the to

the

FUEL

pump hand driven

rated advance injection engine

and

push-rod

tappets

sump.

INJECTION

A

distributor

is

flange

side

of

by a splined

An

automatic

in

the

or

according

speed.

The

engine

relief

and

the

retard

by a mechanical

porated

speed top engine

of

in

the

control the

fuel

stop

idler

gear

into

this

of

timing

crankshaft

through

bearings.

cylinder

pipe

through

head

to

and

the

shafts.

is

valve

rocker

oil

from

mist

the

oil

from

valve

tunnels

cams

before

SYSTEM

type

mounted

cylinder

shaft. device

fuel

injection

the

speed

type

fuel

injection

lever

pump

being

together

lever.

gear bearings.

drilling

gears.

main

the

crankshaft Oil

lubricates

walls.

feeds

oil

drilling

intermediate

hollow

Oil

pressure

controlled

fitted

surfaces

the

in

the

necessary

the

drains

and

lubricates

returning

fuel

injection

on

the

block~

is

incorpopump

point

to

changes

is

controlled

governor

pump~

located

shaft

to

An

lubri-

bear-

splash

the

from

in

centers

in

by

on

the

bracket.

are rocker rocker

valve

down

right

and

to

of

fuel

of

incor-

the

on

with

an

a

The

atomisers located cylinder They flanges

INDUCTION

die-cast side filter

EXHAUST

is

fitted cylinder direct but ing

COOLING

water

to

water

on

the

head

are

retained

secured

The

induction

aluminum~

of

the

is

fitted

MANIFOLD

A

water

to

head.

contact circulates the

coolant

SYSTEM

Two

methods

cooling

customers

is

circulated

in

MANIFOLD

cylinder

cooled

the

by a centrifugal

this

water

heat

exchanger

ELECTRIC

Twelve

is

fitted

The

is

mounted

engine~

front

sion

is

able

link

The

is

fitted

engine

is

to

the

12

and

end

of

adjusted

and

flange on

in

accessible

in

SYSTEM

volt

volt~

on

is

the

pivot

the

(fuel

right

an

hand

accessible

in

with

nuts.

manifold

on

the

head~

in

this

manifold.

exhaust

left

hand

with

in

an

The

water

the

outer

exhaust

expansion

of

indirect

are

available

requirements.

round

type

turn

or

cooled

keel

water

cooling

electrical

engine.

55

ampere

the

left

hand

belt

driven

crankshaft.

by

means pin.

mounted

right

hand

position.

injectors)

side

of

position.

the

head

is

made

right

and

an

manifold

side

is

not

jacket

form-

tank.

according

the

engine

pump

by

either

pipes.

equipment

alternator

side

from Belt

of

an

adjust-

starter

side

are

the

by

of

hand

air

of

the

in

gases

fresh

Fresh

and

of

the the

ten-

motor

of

the

a

A

fuel type fitted hand

and

on

side operated camshaft.

8

lift

pump equipped the

cylinder

of

the

by

an

of

for

hand

block

engine.

eccentric

the

diaphragm

priming

on

The

from

the

pump

is

left

is

the

GENERAL

DATA

Types

Bore

Stroke

Capacity:

Compression

Torque:

Cylinder Thickness Piston

face

Piston Piston Gudgeon

Connecting

Crankshaft

Rear

thread

End

"¥ashers):

.

Six-346

Four-230

Six-346

Four-230

Six-346

Four-230

liner

of

to

bore

at

bottom

ring

Remainder

ring

Remainder

pins:

Fit

in

piston

to

small-end

rods: Length Permissible

big-

and

Big-end

clearance

Connecting

side-clearance

Little-end

wrapped

and

Journal

Crankpin Undersizes

Bearing

clearance

oil

seal

clearance

float

(controlled

Four-230

Six-346

ratio:

.

bore

liner

clearance

of

groove fitted

gap

.

between

out

small-ends

bearing

rod

bush

type)

main

diameter

to

crankshaft

cover

.

" .

diameter.

shims

(on

skirt)

clearance

bush

centres

of

parallel

to

crankpin

to

crankshaft

. .

(bi-metal

inner

bearings:

to

oil

by

thrust

GENERAL

. • .

thrust

.

clearance

.

of

diameter

journal

return

DATA

Six-346 Four-230

3.

937

4.

724

345. 3 cu. 231

16.8:

16.8 255

174

3.7401

·003 .0055

.0095

·002

·014

·011

·0005

·00025

.

0005 8·185 '0001

effective

.

·0015 .008

1·37525

34.944

3·2495

2·6245

-·015 (-.381

·002

·0070 all

·006

.006

in.

cu.

1

: 1

lb. lb.

to

and

to to

to

.004

to

·020

to

·016

in. in. to in.

to

.012

to to

in.

to

.004

to

round.

to

·010

to

.013

(115

(70

(100

(120

in.

ft

(35~

ft

(24.06

3.7409

·005

·007 .011

(·013

in.

to

8·187

per

mandrel

·0030

to

1·37575

mm.

3·250

2.6250

-·030

mm.,

·0085

HP @ 2600

HP

@ 2500

mm.

).

mm.

26

kgm) @ 1750 kgm) @ 1400

in.

(·076

in.

('139

in.

(.24

in.

(.051

in.

(·36

in.

(.279

mm.)

(.006

mm. ) clearance

.0013

in.

inch

in.

(.2

in.

(207·90

(.0001

(.04

to

in.

).

in.

(82·54

in.

in.,

-·762

in.

(·05

in.

(0178

in.

(.15

in.

(015

rpm)

).

(95.00

to to

to

and

to

·28 .102

·51 .406

to .127

.18

mm.).

interference

(.013

to to cm.

length.

to

·08

.3

mm.).

(34·931

to

(66.66

-.045

mm.,

to

to to

·10 to

.25

.33

to

in.

-1-143

mm.).

. 216

mm.). mm.).

rpm. rpm.

95·02

mm. mm.). mm.). mm.).

·033

207·95

per

mm.).

to

82·55

66.67

mm.

mm.).

).

to

.

mm.).

cm.

mm.).

mm).

mm.).

).

) "

9

GENERAL

DATA

Camshaft

Bearing

No. 1 (bush)

(finished

End-float Cam Timing

Cylinder

Valve Valve

Valve

lift:

Backlash

Number

Idler

Thickness

Oil

Valve

Inlet

Exhaust

hot

or

(finished

seat seat

stem stem

lift:

and

bearings:

to

camshaft No. 1 (bush) Remainder

inner

in

position)

(controlled

gears:

of

teeth: Crankshaft Camshaft

Fuel

Idler

feed

cold.

gear gear

jet

head

timing:

valve:

angle face

to

injection

gear

bush in

position)

bush

of

idler

diameter

and

Opens Closes

(cylinder

width

guide rocker

. . • •

diameter

gear.

gear

pump

inner

to

shaft

gear

valve

Six-346,

Four-230,

Opens Closes

clearance

clearance:

•

by

thrust

.

gear

diameter

.

clearance thrust

mechanism

with

with . .

head

and

.

-

plate)

washer

'021

·019

valve)

•

in.

.0015 .

00275

1.9995 (50.787

·002

•

261

.004

25.

50.

58.

1·125

·001

·068

·062

(.53

mm. ) rocker

in.

('48

2-1/20 B. 42-1/20 A. 37-1/20

7-1/20

0

45

·055

·001 .013

.430

to

to to

to

·012

in.

to

·006

to

.002

to

·070

in.

(1.59

mm.)

A.

to

·070

to

·0025

in.

(.33

in.

(10·92

·0040

·00475

2.0010

to

50·825

in.

(6.63

in.

1·1255

in. in.

rocker

T.

D. C.

B.

B. D.

T.

D. C.

in.

mm.).

in.

(.038

in. in.

(.051

mm.

(.102

in. (·025 (1·73

mm.).

clearance

D. C.

C.

(1.40

in.

(·025

mm.).

to

(.0698

mm.

).

to

.305

).

to

.152

(28.575

to

.051

to

1·78

clearance

to

1·78

to

·064

.102

to

mm.).

to

mm. mm.).

mm.

mm.)

·1206

mm.)

28· 588

).

mm.

•

mm.).

•

mm.)

).

Valve

Free Fitted

Load

Rocker Rocker

Six-346

Four-230,

Tappet Flywheel

springs:

length.

length

to

(valve

to

rocker

spacer

to

To

fit

flywheel

compress open)

•

gUide

and

.

shaft

sizes:

between

and

between"

rockers.

starter

heat

to

fitted

clearance

each

bracket

each

clearance

ring:

ring

to

length

rocker

. .

pair

.

to

(Six-346). (Four-230)

•

of

Inner

1·8

in.

(45.

72

mm.

1.594

40 . 001

·243

·290

·8055

.0005

2750C.(5270F. 3500C.

lb.

to

to .8055 (6017 20·46

to

in.

(40.487

(18· 14

·002

·250, to

.8125

to

6.35,

to

20·64

.297

to

·8125

to

·0023

(6620F.)

kg. in. .340

in.(7.37

(·025

in.

8·64

mm.

in.

)

mm.)

)

(.013

) 2· 25

1·

(47·625

90

to

·051

to

·343,

to

8.71,

).

to

7·53

(20·46

to

Outer

in.

875

lb.

and

20.64

·058

(57015

in.

(40·82

mm.).

and

mm.)

mm.

mm.)

kg.)

mm.

).

mm.)

)

10

GENERAL

DATA

In.iection

Add 5 atmospheres fitting

Injector

Oil

pump:

Driving

End-float

Backlash

gears

Pump

thicknesses

Number

dri

Main

Rocker

Oil

oil Spring Spring

Load

length

Spring

Spring Load Diameter

pressure

Idling Normal

capacity:

Six-346 Four-230

pressure

new

securing

shaft

body

ven relief

free fitted

to

compress

gear

free fitted

to

speed

running

.

to

the

opening

springs~

bolts

to

pump

of

pump

between

. . .

to

bearing

. . .

of

teeth

gears

valve:

.

oil

compress

of

(engine

.

on

.

length

relief length

length

ball

speed

to

allow

.

body

rotors

driving

cap

driving

. . . . .

spring

valve:

.

to

fitted

.

hot):

.

clearance

. . . .

and

shim

and

to

fitted

length

for

settling

driven

175

pressure

144

·0025

·0020 .004

·002

46. 2-17/64

2

in. 11 3/4

5/8

3

·236 10

35

11. 5 qts. 8

atmospheres.

when

of

the

components.

lb.

in.

(·063

to

·0045

in.

(.102

and

·003

in.

(50·8

lb.

12

oz.

in.

(19

in.

(15·9

oz.

(85

gm.

in.

(6

to

15lb./sq.in.

to

60

lb./sq.

qts.

setting

(1. 7

mm.)

in.

mm.

in.

(57. 6

mm.

).

(5·33

mm.).

).

mm.

(2570 p

new

kg.

(·051

).

(.051

mm.).

kg.

).

in.

0

s

injectors

m.)

maximum

to

.114

and

).

(·7

to

1·05

(2·46

to

·076

4.22

or

mm.

mm.).

kg./cm.

kg./cm

).

2

)

2

)

COOLING Water

Thermostat:

TORQUE

Cylinder Crankshaft

Main

Big

Main

pump:

Fan

hub Impeller Impeller

clearance

Opening

Bellows

Fully

Bellows

head

bearing

end

bolts

bearing

SYSTEM

pump

to

pump

vane

temperature:

type

open

WRENCH

temperature:

type

nuts

pulley

bolts

(Four-230)

studs.

spindle

to

impeller

.

•

SETTINGS

.

nut

(Four-230)

.

fit

.

housing

·0015

·0010

·010

77 940 C.

I,

3~

1,200

720

600

to

interference.

to

interference.

to

·021

to

800

(2010 F.).

200

lb.

080

lb.

000

lb.

in.

lb.

in.

·0028

·0023

C.

in. in. in. in.

in. in.

in.

(·25

(170

(13· 8 ( ). (34. (13· 8 kg.

(8· 3

kg.

(7·0

kg.

(·04

(·03

to

1760 F.

kg.

56

m.). m.).

to

kg.

to to

·53

m.).

·07

·06

mm.).

).

mm.) mm.

Cold Hot

)

11

GENERAL

DATA

Main

bearing

Slotted

'Nyloc' Connecting Exhaust

Valve

manifold

rocker 5/16 3/8

in. Flywheel C.

A.

V.

starter

C.

A.

V.

'distributor' Cam Transfer

ENGINE

a_tit:

t:OIIdititHII

nuts:

type

rod

bolts

bracket

in.

diameter

bolts

advance

pump

•

• • • •

nuts

(Six-346) (Four-230)

•

.

bolts:

• . . . . . . .

motor

injection

screw

pinion

•

stop

pump:

nut

rotor

RECOMMENDED LUBRICANTS

CaIftI

...

MoIIII

1,000 1,200 700 350 600

180

350

I,

40 400

65

SIleO

lb. lb. lb.

lb. lb.

200

to

lb.

lb. lb.

lb.

50

in.

in. in. in.

in.

BP

in.

lb.

in.

(11' 5 kg.

in.

(13'8

(8.

(4

kg.

(6·

(2·

(4

kg.

(13· 8

ft.

(4· 6

(. 75

.....

1

kg.

91

1

kg.

(5· 6

kg.

m.).

kg.

m.).

kg.

to

m.).

m.). m.).

m.).

7· 0

kg.

.....

m.).

rw.

.....

-

Above

32°

C.

(90°

F.) Castrol Essoftect

CIlI30

-32°

C.

(90" F.)

to-12°

--12°

C.

down

to-ISO

Below-IS·C.

-In

particular condition prevailinl

concemed.

down

C.

(10°

F.)

(10°

F.)

C.

(0°

addition to the lubricants listed

Castrol Essofteet CIlI

Castrol CIlIIO HDX

F.)

Castrol

CIl

TRANSMISSIONS

Hydraulic

Vee

HDX30

20

HDX20

Essoftect Delvac

lOW

Esso

Extra Mobiloil Shell Winter Filtrate Sternol

down

AND

Motor Oil

5W/20

we

approve the

to

-ISO

VEE

C.

5W/20

Transmissions

Drive

Delvac

1130

Delvac

1120

1110

5W/20

UIe

F.).

of

Below

(0°

DRIVE

-

Shell

1l0teDa

Oil

30

Shell

Ilotella

Oil2O/20W

Shell

1l0teUa

Oil

lOW lOW

Special

Motor Oil

or

SheD

Super Motor

Oil 5W/30

the appropriate multiJrade oil, supplied

-ISO

C.

Automatic

Heavy

VaneDus

S.

SAE30 Diesel

Vanellus Filtrate

S.

SAE20 Diesel

VaneDus

S.

SAE

(0°

F.)

usc a 5W/20

Transmission

Duty

lOW

Filtrate Panther

30

20

Filtrate Panther

Diesel

5W/20

oil

or

Motor

30

Panther

20

10

WW

Multiarade

5W(lD

by

the above compuiel, for the

the curreat practice

Fluid

Oil

SAE-30

of

Type

F1eetol

HDX30

Fleetol

HDX20

Fleetol

HDXIO

Q5-3O

the COUDtry

'~"

12

INSTALLATION

FOREWORD

It

is

not

the advise on well lation ing included

boatyards

the

generally

developed

of

engines.

outline

because explaining ponent, cautions tionship operation details ha

ve a periodic

of

the

to

of

the

operator understanding conditions procedure

INSPECTION

The

engine mounted crated. shipped usually

upon

Accessory

in

packed

Immediately

ment

should accidental any

possible equipment. shipment company, and damage

an

the inspection

made. concealed the

delivering

in

damaged protection such carrier,

FOUNDA

A

towards

the

of deflect engine may rough support

damage

good

engine. rigid

have

seas.

not

TION

engine

the

nor

weight

to

the

purpos e of

and

well

procedures

However,

of

general

it

the

functions

reasons

be

watched

the

installation

the

engine.

installation

check

should

to

for

in

OF

is

shipped

heavy a

have

ensure

the

engine

servicing

SHIPMENT

skids

separate

with

upon

be

damage

arrival,

inspected

in

shortage·

Before

from

the

crate

If

damage

is

agent

condition."

against

loss.

must

to

J.

H.

FOR

ENGINE

bed

satisfactory

The

engine

construction

twist

take

or The

when

the

under

bed

engine

this

section

engine

installers

understood

for

the

procedure

is

valuable

of

each

why,

and

the

There

which

and

of

which

a

thorough

good

operating and the

from

the

and

properly

equipment

small

the

engine

the for

transit

in

parts

accepting

transportation

should

for

either

be

concealed

visible

noted,

to

sign

''Received

This

Claims

be

made

Westerbeke

contributes

operation bed and

subjected

position

the

effects

must

firmly

in

and

instal-

follow-

com-

pre-

rela-

to

the

are

should

the

correct

engine.

factory

box,

crate.

ship-

possible

and

for and any

opened

or

require

is

your

for

to

the

Corp.

much

must

be

neither

the

boat

not

only

exact

to

is in

is

of

to of

position within inch has

to

the

propeller propeller in

the

bolts

In

fiberglas

similar

hulls

glassed allows firmly and

transmitted

The a

pair

should will

through

require which

but

one

or

of

this

position

withstand

shaft,

engine

and

engine

hulls,

wooden

be

formed

to

the

hanger

in

wood,

temptation

of

be

resisted.

allow

to

a react

engine

the

firm

fiberglas

Job. RIGGING

The rings, be

lifted chain rings of a tackle The to

carry therefore required

The to

see amply place. time ported. dents from against distort

In

some

lift

the

horizontal

engine

AND

engine

designed

slings

and

lifting

the

or

general

that

strong

Move

and

Eliminate

by

avoiding

the

this

the

cases

engine

must

is

without

should

the

attached

rings

auxiliary

desired.

rule

see

propeller

with

coupling.

position.

through a small

be

made

larger.

must

two

the

which

to

and

finally

bed.

we

stringers

hull

bolts

thus

vibration.

to

install

vibrations

hull.

foundation

if

they

LIFTING

fitted so

that

damage.

engine

to

have

full

weight

in

all

equipment

and

the

engine a little

that

possibility haste.

crowbar,

it

may

in

other

be hatchway

keep

the

thousandths

at

all

times.

forward

is

applied

the

thrust

to

the

recommend

as

in

and

fitted,

securely.

to

be

reducing

the

engine

"angle

Such

construction

Flexible

are

to

with

be

lifted this

two

the

engine

attached

by

short

been

of

the

slings

moving

engines

firmly

it

is

firmly

Do

coupling,

as

be

necessary

than

the

It

may

be

lowered

which

If

the

opening

engine

of

an

It

push

to

of

the

bearing

engine

that

wooden

then

This

installed

noise

on

irons"

to

pass

mounts

against

do

their

lifting

may

Rope

to

or

the

means

sling.

designed

engine,

are

not

is

used

fixed

is in

at

sup-

of

acci-

not

lift

or

pry

you

may

to regular that

the

endwise

cannot

is

a

13

INSTALLATION

extremely reduce

clearances water etc. be

and

avoid the have have to

tank,

This

removed

special

damage

entrance

been

position

opening In

case engine reverse tachment

carefully damage weight

special

someone in

the

handling

ENGINE

restricted

to

some

such

filters,

accessory

by a competent

care

to

of

made.

removed

as

soon

has

been

it

is

either

gear

of

to

may

passed.

necessary front

end

slings

avoid

the

come.

rigging

experienced

of

BOLTS

it

extent

as

equipment

should

any

exposed

dirt

The

should

as

end

upwards

must

the

parts

work

heavy

is

possible

the

cooling

mounting

mechanic

be

where

openings

parts

be

returned

the

restricted

to

hoist

upwards

be

done

possibility

on

which

It

is

be

done

and

competent

machinery.

outside

piping,

lugs,

should

taken parts

which

the

very

best

to

or

the

or

at-

of

the

if

by

the

key

be shaft fit

ly,

keyway

If

over expanded boiling peller

the

but

it

and

the

side

should

ir.

seems

the

water.

coupling

the

shaft,

by

pendicular of

the

propeller

PROPELLER The

type

with

to

fit

tests.

engine,

gear

the

To

and

ratio

application

and conditions, propeller

to

reach

throttle.

by

actual

which its This

properly

coupling.

of

the

not

hub

difficult

heating

The

must

to

the

shaft.

size

and

utilize

to

achieve

it

is

will

full

can

trials

fitted

The

keyway,

touch

of

the

to

fit

the

coupling

it

face

be

center

of

propeller

must

based

the

full

desirable

permit

rated

be

determined

of

the

both

key

very

the

top

coupling.

the

coupling

can

in

a

pail

of

the

exactly

line

or

be

selected

upon

power

ideal

loading

to

the

speed

pilot

on

model.

to

the should close-

of

the

be

of proper-

axis

varies

boat

of

the

use

engine

full

only

a

It

is

recommended bolts through Lag

their

every

the

nuts

tighten to

permit bolt as a stud and

of

the

screws

hold

time

lag

bolt

on

top

the

itself

the

appropriate

engine

the

stays

and

wood

removal. PROPELLER

Each

fitted necting

engine. machined ward

long

shou'ld The fit

have

order

Westerbeke

with a suitable

the

The

for

end

of

straight

be

coupling

on

the

shaft

to

be

to

get a fit.

engine

are

less

on

the

they

are

stays

of

the

lag

down

engine

in

position

the

bond

is

not

COUPLING

propeller

coupling

accurate

the

propeller

keyway

removed

should

and

scraped

that

bronze

size

flexible

preferred

wood

moved,

in

position

bolts

or

to

be

between

weakened

Diesel

coupling

shaft

is

very fit.

and any

from

be a light

the

shaft

down

It

is

important

be

mounts. because

is

weakened

whereas

and

are

loosened

moved

at

all

the

engine

for

carefully The

shaft

this

should

or

hanger

used

the

used

..

The

tlmes

bolt

by

its

con-

to

the

for-

has

burrs

end.

drive

not

filed

that

to

is

in

a

ALIGNMENT

The exactly shaft. used be hull extent

is

It

the vals they

engine

to

flexible

will

than

launched

is

therefore

engine

and

may

aligned No build a boat

to

change

alignment

to

appear.

Misalignment

the

propeller troubles other

bearing will,

of

the

which

causes.

wear,

in

many

hull

fastenings.

will

have it

is

propeller

exactly

therefore

shaft

straight.

One

particularly

misalignment

OF must

matter

some

is

usually

and

operated

very

correct

between

shaft

are

It

rapid

cases,

by

A

ma.y

ENGINE

be

with

what

it

will

extent

its

shape

realized

important

at

frequent

any

the

is

blamed

will

create'

shaft

reduce

loosening

bent

the

propeller

same

necessary

itself

annoying

be

properly the

propeller

material

be

found

and

the

to a greater

when

in

the

to

errors

engine

the

cause

often

excessive

wear

the

effect

that

be

perfectly

result

leakage

and

is

to

boat

it

water.

check

inter-

when

and

of

on

B:nd

hfe

hull

shaft

and

the

of of

14

INSTALLATION

transmission

seal. of parts,

that

While

leakage

one

alignment

prescribed. The

engine

the

bed

and jacks the without flanges

best

or

shims

couplings

using

meet

not

to

foundation

alignment

determined. N

ever the in tunity It

is fuel all Take

boat

the

and

the

attempt

on

water

to

assume

best

water usual

plenty alignment anything The shaft forward easily cates

together

of

the

parallel

less

alignment

can

into

and

that

at

propeller

within

However,

tolerance per

inch

of

In

making ment, be ment

tested each degrees test peller ment

held

of

will

on

the

in with with

four

between

also

half

its propeller alignment the

engine

each The

checked

90

degrees

engine

after

oil

through

it

is

possible

to

be

caused

should

always

is

be

within

supported

until

can

be

force

evenly

drill

bolts

has

a

land.

and

the

foundation

until

been

final

The

have

its

to

do

the

alignment

tank

about

equipment

of

time

and

do

not

than

is

correct

be

slipped

the

counterbore when a feeler the

flanges

all

points.

coupling

0.001

the

must

coupling

the

engine

one

position

the

maximum

not

O. D.

final

half

propeller

positions,

each

check

coupling

shaft.

coupling

should

half

coupling

is

Then,

in

be

from

alignment

the

boat

the for by

first

moved

on

the

two

brought

and

so

all

around.

the

approximate

alignment

boat

had

final

water half

in

making

be

satisfied

perfect

backwards

gauge

come

The

two

in.

if

exceed

check

coupling

and

coupling

rotated

position.

whether

in

exact

keeping

one

position

checked

to

full

the

should

has

rear

this

oil

type

defective

check

the

limits

around

on

screw-

halves

together that

the

It

for

the

accurately

with

should

an

be

oppor-

form.

with

the

full

and

on

board.

this

with

results.

when

the

and

very

indi-

exactly

halves

should

be

possible.

allowable

0.001

for

in.

align-

should

the

align-

coupling

90

This

the

pro-

align-

the the

rotating

position

one.

re-

been

of

is

in

service

for necessary will no because at

the have It

longer

first,

some

may

usually

the

but

time

engine

probably

even

at a further The

up boat land the strain both cases

_

by WATER

coupling

and

the

is

to

boat

on

when

the

these

hauled

the

strains.

CONNECTIONS

Seacocks the

full

flow equal pump

to

the

(see strainer may the

Water or

be

withdrawn

vessel

lines

reinforced use a section will

not

collapse

the

hull

before

to take

engine being should sealing

it

up

to

realigned.

be

compound

prevent

impeller

should

never

EXHAUST

Exhaust

line siderably for

the

particulCLr

requirements

line

and water.

into

with

arranged

or

the

one

to

three

the

alignment

be

found

in

alignment.

work

was

because

to

take

bed

its

and

absorbed

be

necessary

period.

should

bolts

removed

out

or

water.

often -puts

the

shaft

it

is

being

shaft

and

has

strainers

type

inlet

and pipe

installation

should

be

for

is

at

sea.

can

be

either

rubber

of

flexible

under

inlet

enters

and

the

vibrations

be

moved

All

of

bronze

at

air

leaks.

in

the

sea

be

run

SYSTEM

installations

and

each

are

to

a

minimum

so

that

condensation

engine.

There

weeks

remade.

that

the

This

improperly

the

boat

final

engine

some

to

always

whenever

moved

The

flexibility

a

very

or

the

coupling

moved.

actually

should

of a size

of

the

drawing).

of

the

type

cleaning

copper

hose.

In

hose

suction)

engine

exhaust

and

permit

Slightly

pipe

and

or

brass.

all

connections

The

(raw)

water

dry.

must

job.

be

The

provide

of

restrictions

sea

water.

cannot

should

and

engine

is

done

has

taken

shape

stringers

moisture

re-align

be

opened

from

severe

In

some

been

be

at

least

sea

water

which

while

tubing

any

case

(hose

between

and

outlet

line

so

when

fittings

neoprene

pump

vary

con-

designed

general

an

outlet

get

back be

if

It

is

not

and

the the

of

or

bent

of

The

that

as

the

it

is

Use

to

rain

a

15

INSTALLATION

considerable the

exhaust discharge makes driven steep better

Avoid

line

which obstruct avoid

Brass wet

exhaust tion gas

of will

Cast

it

in

drop

than

any

or

salt

iron

end.

very

depression

the

sharp

copper

cause

recommended The

exhaust large flange

To to ably 12 and

as

the

(refer

insure

hull

use a flexible

of

stainless

in.

overall

installed possible. be

installed asbestos should brackets the

covered.

be

to

manifold installations exhaust tion ease

Provide rubber bending,

of

hose

the

of

installation adequate

hose

and

pockets. Always

into a

--rlser exhaust possibly

FUEL Fuel

plain

glass tain prevent

fuel

arrange

the

rubber flange

flow

TANK

tanks

steel

-fiber

that

the

fibers

system.

or

fall

manifold

This

difficult

far

followed

a

straight

would

flow

of

bends.

systems,

water

or

wrought

for

line

engine to

Installation

vibration

threaded

as

close

This

flexible

with

properly

eliminate

flange

use

for

the

exhaust

to formation

that

hose

sufficiently

so

back

AND

should

or

terne

is

also

interior

from It

in

the

line

flange

slope

for

water

by a wave;

by a long

gradual

or

trough

fill

with

exhaust

is

not

acceptable

as

the

and

diesel

rapid

deterioration.

iron

the

exhaust

must

be

exhaust

doesn't

section

steel,

no

at

to

the

section

no

bends

The

exhaust

supported any studs.

flexible

water

line

because

and support prevent

water

section

that

water

into

FILTERS

preferably

plate;

suitable.

is

gel-coated

contaminating

is

not

necessary

between and

in

the

pipe

to

and

slope

slope.

to

water

gas.

Also

combina-

exhaust pipe

line.

at

least

manifold

Drawing).

transmit

prefer-

less

than

each

engine

should

and

pipe

strain

Many

rubber

cooled

sec-

of

flexibility.

for

sagging,

for

water

discharge

is

behind

below

cannot

the

engine.

be

reinforced

Be

cer-

the

be

a

is

the

and

for

is

as

end

as be by

on

the the

the

of

to

the

to

mount

as

raise

amount

(6 already

can

care fuel that

cautions

entering A

lecting the

the

fuel

the

of

feet

being

installed

be

utilized should system

airlocks

the

primary

type

fuel

tank

fuel

lift

be

taken

fuel

should

recommended

the

list

of

optional

fuel

between

injection

filter

the pump

element. As

the

fuel

lift excess pump, tank of

and

the

of

that

the

should

tank

overflow

possible. ELECTRICAL

Starter close avoid It

is a bad

batteries

boat

batteries

to

the

voltage

unless

practice

for

intermittent. are

substantial refrigerators, etc. , it separate charging auxiliary power engine. type discharge

Carefully wire

(Fig. battery battery

is

take

which

size

1). is

cable

essential

system,

current

generator

Starter

(Diesel

follow

shown

Plan

close

above

lift

pump

from

should

be

maximum).

above

in

this

taken

is

are

to

correctly

eliminated

against

fuel.

filter

and

type

be

the

of

installed

fuel

is

extras.

is

fitted

fuel

lift

and

has a replaceable

pump

has a capacity

required

is

be

connected

or

as

near

EQUIPMENT

should engine drop

through

to

other

these

In

are

cases

loads

radio,

to

and

to

driven

off

at

the

batteries

permit

a

starting).

the

in

tlle

wiring

the

installation

to

the

sizes

as

the

engine

provided

the

tank.

kept

If

engine

position.

ensure

level

will The

minimum

a

tank

level

Great

that

the

installed

and

pre-

dirt

and

water

the

water

col-

between

lift

pump.

available

on

the

pump

by

the

piped

to

the

be

situated

as

possible,

long

use

the

services

light

where

from

depth

from

The

main

engine

and

the

injection

the

fuel

to

the

top

leads.

starter

in

the

or

very

there

lights,

sounders,

have a complete

to

provide

this

high

from

front

must

from

of

be

rate

the

of

recommended

diagrams.

so

the

engine

and

use

indicated.

is

it

so

A

in

as

to

an-

a

of

16

.@

'ALAR

SPARE

ro

START

DErAIL

~

A

....

ET!R

+12VDC

--.

.....

..

,I

T81-1

@

S5

SWITCH.

T82-. 55

SOL,RELAV

~,

ENGINE WITH

MOD£L

TWO-TERMINAL

STARTER, fOR

OTHER

SEE

ENCOINES,

~

,

4-107 DETAIL

DWG

~

"A"

NO . .17309

.'

:.

~1.-

-1.:.=1=-:-.:1==

, ---

.,.,

T8Z

@IQP,

S[(NQT[-

IW,T,

@

: I

2

1 . 1 1 I

ENGINE

NEGATIVE

GROUND

CRllo,p,

q

,~:'N:®I

'8

----

F5

r.;:..

~

~I

... 1 ...

l"9

...

'

I

8ATTERY RETURN

MODEL

4-236.4-91,4-231,4-154,4-2.106.

TER"INA~

5TARTER

(INTEGRAL

-10

I

j

--,

I

II

TO

SENDERS

OPG'T82-3

WTG:

=ll

i:I.~,I~

l_J

NOTE:

BATTERY

'1

FOR '1/10 ''1/0

'J/O

OISTANa

FOR

OISTANa

FOR

DISTANCE

FOR

DlSTANa UPTO

!fADS

I

UP

TO 8 H.

UP

TO

UP

TO

i

10 13 16

H. FT. FT.

T82-4

!!£AR

NOTES:

L THIS DRAWIN,"

PANELS USIN<; FARIA USE

2,SEND£RS

@

3

DETAIL

VIEW

-,!!P~c;AL

12889

FOR

(501,

SEE

MOTOROLA

6-346

..

ENT

50LENOID)

~TO+12VDC

CASE RETURN CONNECTION

T82-2

RH'JRN

-DC T82-5

ENGAGE

NE<;ATlVE

oB'

!~I:''''A

_~,~C;!,

IS

FOR

USE

ON

OIL

PANELS WITH V.D.O, GAUGES,

S02)

ARE

INSTALLATIoN

CONTROL

IS.

WATER

COAUGES,

I WIRE 1I00Y RETURN TVPE.

INSTRUCTIONS.

"

Fig.

WIRING

1

DIAGRAM

INSTALLATION

PREWIRING

1.

Pre-Wiring

Pre-wiring

wiring

alternator, starter connecting

and

temperature switch harness interconnecting key

switch meet Chief elimination minimum

ALL

Marine ammeter, and ments negative

panel protected

salt

2.

This

existence low installed at ble the panel. and

for

alarm switch

be

switch,

turn

ELECTRIC

oil

should spray. Factory

System

alarm

oil

the

alarm

low

compatibility

de-energized

off

includes

of

solenoid,

terminal

panel,

and

panel

or

exceed

advantages

installation

instruments

water

pressure

are

back

grounded.

from

(Optional)

of

high

pressure,

on

factory.

to

being

The

oil

system

at

the

should

the

alarm.

AND

regulator,

of

Installed

system,

pressure

OPTIONS

the

switches

electric

engine

cables

and

wiring

PANEL

gauge. lighted,

be

mounted

direct

water

your

It

indicate

part

high

with

is

energized

key

switch

the

following

instrument

harness.

ABYC

of

temperature

Westerbeke

consists

water

by

installation starting

blocks,

separate

panel

between

all

electric

Standards.

prewiring

mistakes

time.

used

The

vented

The

Engine

is

of

switches the

operator

instrument

so

contact

to

indicate

temperature

designed

of

either

the

key

temperature

engine.

by

panel

the

same

and

devices:

motor,

senders,

pressure

key

wiring

The

two

engine,

panel

are and

include

gauge

instru-

and

that

it

with

Alarm

the

and

diesel

an

audi-

failure,

switch

are

set

The

the

key

and

can key

wish

is

or

to

position, wire push-pull to

starter throttle type ble

sheathed

transmission Transmission

lever three

Forward Reverse be

connected flexible by

Morse Morse throttle range lever control

control

Any

bends

be

gradual and mounted. pleted, travel, transmission station reverse, transmission detent and

detent throttle lever travel.

Throttle

Max~Idle

and

or

flexible

knob

button

lever

on

the

positions

(R).

sheathed

control

control,

in

the

Morse

with

transmission

After

check

making

is

(F)

against

control

on

fuel

controlled

sheathed

at

pilot

or

connected

at

pilot

cable.

control.

Control:

transmission

(F),

Type

neutral

the

in

and

in

the

(R)

Control

--"

Neutral

This

to

the

cable

lever(s).

lever

control

one

other.

the

control

end

the

installation

sure

control

forward,

control

is

stop

against

lever

injection

station

key

switch

station

Refer

with

control

pilot

and

gives

with

position.

provides

lever

sections

must

linkages

that

lever

on

its

pin,

stop

pump

by a Bowdoin

cable

to a Morse

by a flexi-

The

housing

detents

(N),

lever

station

controlled

The

clutch

full

and

cables

be

neutral,

respective

(N)

pin.

and

to

adjacent

and

below

control

has

and may by

single

throttle

The

two

clutch

throttle

should

at

engine

securely

are

com-

for

when

at

pilot

on

detent,

Check

stop-run

for

the

to

for

and

full

the

and

the

full

a

CONTROLS

Throttle The

engine levers which

side

The the

18

control

fuel

supply

speed on

top

is

mounted

of

the

recommended

stop-run

and

to

is

controlled

of

the

engine

lever

stop-run

the

engine

fuel

injection

on

the

(refer

practice

loaded

control:

by

and

two

right-hand

to

Fig.

is

to

the

small

pump

2).

have

run

__

~LJI_~,~

~Ir,=?

_.

~

Fig.

2

CI.OJ'j,,!.:.,,·I·'~l

<:::::>

FUEL

~

INJECTION

,

PUMP

OPERATION

Page

PREPARATION

BLEEDING

TO

START WHEN TO

STOP OPERATING COLD

WEATHER

THE

ENGINE.

ENGINE

PRECAUTIONS

FOR

STARTS

STARTING

FUEL

SYSTEM

• •

. . . . . . .

ENGINE

. . .

AFTER

INSTALLATION • 20

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

. . . . . . . . .

PRECAUTIONS

•

. · . . . . . . .

..

20

21 21

22

19

OPERATION

Preparation installation. "dry". drained

that

from transmission. cedure before

should starting

time.

1.

Remove

filler

cap

and lubricating the

dipstick. listed to filler

2. 3/4 sion)

sion).

in

use

it.

cap.

Remove

in.

hex

or

and

"General

filler

transmission mark

3. and and/ Weather inch cap. and

on

dipstick.

Remove fill

tank.

or

antifreeze

Precaution")

of

top

Ensure

heat

closed.

4.

Ensure level plates. that that

is

it

may

at and is

start.

5.

Fill

Diesel

ble

but

its

higher

NOTE: filler

mended through wire

6.

Open fuel System.

fuel

Fuel

No. 2

lubricant

If

of

the

procedure

a

strainer.

valves

system.

"

for

starting

The

is.

engine

with

the

The

be

checked

the

engine

fill

oil

to

the

Select

an

Data"

Do

not

overfill.

transmission

fitting

fill

(Paragon

plug

housing

fluid

(Warner

Type

Do

expansion

with

of

fresh.

tank.

cylinder

exchanger

storage

least

battery

capable

be

required

tank

Oil.

is

3/8

is

of

with

No. 1

preferred

content.

there

fuel

is

tank.

is

funnel.

refer

in

with

fuel to

engine

is

lubricating

crankcase

following

methodically

for

lubricating

sump

with

highest

approved

and

breather

transmistransmis-

with

Automatic

"A"

not

overfill.

tank

clean

(refer

to

within

Replace

block

petcocks

battery

in.

above fully the

charged

extra

on

No. 2 is

permissi-

because

no

filter

the

to

pour

a

fine

line

"Bleeding

after

shipped

pro-

the

first

diesel

mark

grade

continue

Replace

to

high

filler

water

to

"Cold

filler

drain

water

battery

effort

the

first

clean

in

recom-

the

mesh

and

bleed

Fuel

oil

and

oil

on

cap

one

tap

are

so

of

the

fuel

BLEEDING One

possible

ing

to

start. eration the of

Before insure of

fuel

supply

1. ing

is

system.

the

system

bleeding

that

in

is

turned

Slacken the

fuel

that

there

secondary

the

priming

on

the

fuel issues air

NOTE: driving mum

from

bubbles.

If

the

lift. obtain a full priming be complete

2. side ated plate. lever. bubbles.

3. back behind lift

pump flows bleed

4. end

5. sion may

6.

control

7.

position

lever.

turned

revolution.

Slacken

of

the

directly

Operate

and

tighten

Slacken

of

the

throttle

priming

free

screw.

Slacken

of

each

IMPORTANT:

shift

start

when

Ensure

is

in

Advance

(for

THE

FUEL

cause or

erratic

air

in

which

is

the

tank

on.

the

bleeder

injectors

fuel

filterhead.

lever

lift

pump.

the

bleeder

tighten

the

engine

fuel

lift

it

will

pumping

and

with

the

air

fuel

injection

above

the

when

fuel

the

fuel

injection

of

air

the

union

of

the

lever

corr..pleting

fuel

STOP/RUN

full

run

throttle

maximum

of

may

case

will

the

an

adequate

and

(refer

p'ump

not

the

starter

bleed

the

lift

flows

bleed

air

bleed

lever.

bubbles

high

Position

in

neutral

position. to

SYSTEM

the

engine

have

"bleeding"

be

necessary.

system.

that

screw

return

to

note

when

screw.

bleeder

camshaft

is

on

be

possible

stroke

engine

motor

screw

pump.

pump

free

screw.

screw

pump

Operate

and

when

tighten

nuts

at

pressure

transmis-

as

Step

push-pull

maximum

fuel

flow).

fail-

accel-

entered

first

supply

the

fuel

secur-

pipe

to

Operate

below)

fuel

oil free screw.

cam

maxi-

with

the

should

one

on

the

situ-

name-

priming

of

air

on

cover.

the

fuel

the

injector

pipes.

engine

8.

open

of

to

20

B.

Turn tion. free

and

of injector union. this

procedure

throttle TO

START

1.

Position

2.

Position

full

run

3.

Advance

(to

obtain

starting).

4.

Turn

tion

and

starts.

Immediately

5. tion

throttle

NOTE: motor 15

seconds. stop engine

cranking

should lutions charged

fuel.

The

cranking indicates battery

start.

check

a.

tank

and

b. throttle pump

are

c.

and

at

gaskets

d. injectors System". doesn't injectors.

key

switch

in

sequence

air

bubbles

If

to

pipe

engine

idle

union.

speed.

ENGINE

shift

fuel

position.

throttle

maximum

key

switch

hold.

(See

Release

note

upon

to

idle

Never

operate

continuously

If

engine

for

start

of

the

crankshaft

and

the

motor

the

battery

is

charged

fuel

Ensure

engine

Ensure

control

in

Check

the

is

levers

their

for

of

fuel

the

Determine

refer

Steps

issue

bleed

4 from complete

to

START

when

issues

tighten

should

start

immediately

lever

to

stop-run

to

fuel

to

for

START

when

below.

)

starting.

setting.

the

for

more

has

not

15

seconds.

within a few

if

engine

is

turning

is

charged.

and

engine

system

fuel

as

valve

open.

stop-run

on

the

full

run

leaks

in

filters.

if

fuel

is

to

"Bleeding

to

B.

If

union

system.

posi-

fuel

from

each each

during

move

neutral.

control

maximum

easier

posi-

engine

posi-

cranking

than

started.

The

revo-

battery

receiving

over

fast

If

doesn't

follows:

between

and

injection

positions. fuel

lines

reaching

Fuel fuel nuts

oil

to

is

a

oil

at

WHEN ENGINE

1.

Check

for

water

without

ing

System.

2.

Check

Normal

10

to

15

at

operating

3.

Recheck engine subsequent installation.

the

crankcase

important

add

oil is

required

oil

passages necessary. of

operation.

4.

Recheck

(This change a

case.

for

several

one

shift

reverse.

5.

Check mal 190

6.

operating

o

F.

Recheck

level.

system

Stop

engine operating add

water

quired

the

at

delay.

)

Oil

oil

pressure

psi.

speeds.

Crankcase

has

run

to

as

to

compensate

to

Check

applies

or a new

stop

minutes

into

then

temperature

(This

has

been

after

temperature

and/

to

within

exhaust

when

stop

and

Transmission

only the

tank.

WARNING: when be is

overheated

released

to

be protect stearn

and clockwise safety

stops

The

gradually

removed.

the

hands

turn

until

is

STARTS

Sea

Water

outlet.

(Heat

Exchange!'

Pressure

is

idling.

for

3

an

oil

the

engine

oil

level.

it

may

fill

the

oil

be

engine

filter.

oil

subsequent

installation.)

engine

at forward add

oil

temperature

expansion

applies

drained

engine

of

or

antifreeze

one

system and

the

It

against

the

cap

i.he

resistance

felt.

Leave

OPERATION

Flow.

Look

Do

Cool-

immediately

approximately

35

to

60

Oil.

After

or 4 minutes.

change

and

or

check

This

necessary

for

the

oil

I s

internal

Add

oil

level

as

each

Oil

to

after

BOO

rpm

and

one

necessary.

gauge.

is

tank

after

and

refilled.)

has

170

to

Level.

an

In

such

running

Nor-

below

water

cooling

reached

IBO

as

inch

if is

of

is

pressurized

pressure

the

filler

advisable

top

must

escaping

slowly

counter-

of

the

cap

this

psi.

the

new

is to

that

as

day

oil

with

into

o

F.

re-

of

cap

to

the

in

21

OPERATION

this

position leased. against stops. be

lifted

7.

Warm-Up

as

possible

and

run

BOO

to gauge 50

psi. indicates with

Press

the

and

continue

off.

the

900

indicates

and

170

clutch

necessarily

B.

Avoid

9.

Reverse reduce ing

gears.

mis

sion

engine TO

STOP

1.

Move

2.

Position NarE:

dissipate

prolonged

engine

is

load.

ENGINE throttle

Idle

heat

down.

3.

Position control

tion the

NOTE:

to

stop.

functions

injectors.

Key

push-button

and

hold

until

4.

Turn

key

OPERATING

1.

Never

periods

occurs can

be

when

as

caused.

until

spring

the

all

cap

to

pressure

clear

turning

Instructions.

engage

engine

rpms.

the

at

reduced

until

forward

approximately

water

to

in

long

temperature

IBOoF.

neutral

time).

takes

idling.

Operation.

to

idle

speed

However.

engaged.

lever

shift

engine

when

it

will

to

lever

to

for a few

gradually

fuel

push-pull

Control

by

stopping

switch

switch.

engine

switch

panel . with

depress

stops.

to

OFF

PRECAUTIONS

run

engine

excessive

extensive

internal

is

downwards

the.

safety

until

it

As

clutch

speed

oil

pressure

35 gauge

(Warming

an

Always

when

the

shift-

trans-

carry

idle

position.

neutral.

minutes

before

shut-

(stop-run)

in

stop

posi-

fuel

flow

STOP

push

button

position.

for

extended

overheating

damage

re-

can

soon

of to

up

un-

full

to

4.

Do

not

without

5.

clutch

Never internal of

proper

6.

Keep clean.

7.

Keep with dirt

extreme

in

fuel service factor.

B.

Do

because

long

fuel

enough

system.

stoppage.

9. Do gauges sudden

not

show a high

stop operating by

the

release

the

heavy

bustion

is

period

to

chamber.

run

before perature necessarily starting. difficulty. return

to

operating. COLD

1.

WEATHER

Precautions freezing is

to

be weather reputable suitable

corrosion

engines

perature type

Glycol

use

anti-freeze

Base

alcohol

run

engine

engaged.

Race

d.amage

oil

circulation.

the

a

can

engine

Fuel

care

cause

interruptions

not

allow

fuel

intake

to

allow

resulting

be

alarmed

reading

after

under

metal

load.

of

residual

masses

Prevention

engine

at

stopping

reading

after a stop

signal

If

there

temperature

normal

PRECAUTIONS against

should

left

by

make

be

exposed

adding

and

taken

inhibitor.

are

equipped

thermostats.

with

should

solutions.

at

high

Cold

occur

and

Engine

due

accessories

Clean.

because

more

than

fuel may

air

water

trouble

any

to

be

uncovered

to

in

if

temperature

following

engine

This

heat

near

idle

for a short

it.

High

alarm

is

against

no

functional

will

when

engine

damage

if

the

to

inclement

an

anti-freeze

incorporating

with

high

a

permanent

an

be

used.

rpm

to

lack

Handle

and and

other

run

low.

enter

the

engine

has

been

is

caused

from

the

com-

for

this

tem-

does

not

re-

quickly

engine

As

these

tem-

Ethylene

Do

not

as

it

a

is

by

of

a

2.

DoNot heated head.

3.

Keep lint.

22

engine.

block.

etc.

Put

or

intake

Cold

It

Water

can

manifold.

silencer

in

crack

free

an

over-

cylinder

from

2.

Draining

pressure

open

the clockwise) cylinder housing.

Cooling

cap

drain

on

block.

from

tap

right-hand

expansion

(turn

to

Remove

tank

and

counter-

side

of

flywheel

3.

Filling

mine

capacity

(including

fill

cooling amount degree

within tank. Start and

one

Ensure

engine

when normal engine

and

Cooling

keel

pipes

system

of

antifreeze

of

protection

inch

to

temperature

operating

add

System.

of

cooling if

with

and

from

drain

circulate

gauge

temperature,

coolant

installed)

the

water

required.

the

top

tap

is

antifreeze

indicates

as

necessary.

Deter-

system

and

correct

for

the

to

of

the

closed.

stop

OPERATION

NOTE: solution off

tester

4.

often,

to

remove sation wise

The

must

with

anti-freeze

when

Fuel

filters

particularly

all

separated

this

may

flow.

-

strength

be

maintained

in

doubt).

must

the

moisture

from

freeze

MAINTENANCE

of

the

anti-freeze

by

topping

if

necessary

be

the

and

checked

primary

and

the

fuel,

stop

more

filter

conden-

other-

the

(use

fuel

POST-DELIVERY PERIODICAL FILTER

MAINTENANCE

ATTENTIONS

PRESERVATION PREPARING

THE

CHECKOVER

.

OF

LAID-

ENGINE

UP FOR

MAINTENANCE

.

ENGINE

RETURN

TO

SERVICE

Page

24

24 24

26

27

23

MAINTENANCE

POST-DELIVERY

After a customer

his

engine.

interests.

the

engine

first This

25

checkover

following

1.

Renew

lubricating

it

that a general

be

to

50

points:

sump

oil

has

is

advisable.

carried

hours

should

filter.

CHECKOVER

in

lubricating

Maintenance-Lubricating

2.

If

necessary.

adjust

speed.

3.

4. the

Check Check

correct

external

cylinder

torque

nuts

clearances.

5.

Check

leaks.

6.

Check

and

inspect

7 .

Check

8.

Carry

performance

and

for

fuel

rectify

cooling

system

alternator

out

test

of

engine.

and

if

necessary.

system for

taken

checkover

out

service.

comprise

Refer

Oil

slow

for

head

and

nuts

check

lubricating

leaks.

belt

to

check

delivery

in

his

after

oil

to

"Filter

Filter". running

tightness.

are

valve

water

level

tension.

general

of

own

of

the

and

to

oil

Every

lubricating

100

ReneN

Hours

sump

oil

filter.

lubricating

(Refer

Maintenance -Lubricating

Clean Check

Clean Clean

protective

air

intake

alternator

fuel

filter

battery

coating

filter.

belt

water

terminals

to

terminal

nectors.

Check

level

of

battery. Every

fluid. hex breather out

Fill sion dipstick.

NOTE: filler

FILTER

300

Hours

Renew Renew

final

transmission

Remove

fitting.

fitting

of

housing

fluid

with

Type

Do

not

Warner

plug.

MAINTENANCE

or

Once a Season

fuel

filter.

breather

Ins

ert

pump

opening

into a waste

Automatic

"A"

to

overfill.

Transmission

oil

to

"Filter

Oil

Filter.

tension.

trap.

and

electrolyte

lubricating

cap

3/4

hose

and

pump

container.

Transmis-

high

mark

and

")

apply

con-

in

in.

in

fluid

on

has

9.

Check

tightness.

10.

Check

and

wiring

11.

Check

peller Thereafter

be under

shaft

in

accordance

11

Periodical

maintenance

PERIODICAL KEEP

ENGINE

Daily

Check Check Check Check Check

sea cooling oil oil fuel

engine

all

for

engine

mounting

electrical

tightness

alignment

coupling.

with

Attentions

ATTENTIONS

CLEAN

water

strainer.

system level level

level

in in

in

bolts

connections

and

chafing.

to

periods

those

water

should

11

•

level.

given

sump. transmission.

fuel

tank.

for

pro-

Air

Filter

The

filter

time

depends therefore. time

period

for

cleaning correct will wear

greatly

thereby

engine. To

clean

follows:

1.

Unscrew

the

air

move

2.

filter.

The

blowing

side clean

to

the

period

on

under

of

100

should

maintenance

assist

extending

the

air

the

thumb

filter

to

its

element

compressed

the

outside.

element

for

cleaning

operating

dirty

hours

conditions,

be

decreased. of

in

reducing

recommended

the

filter

screw

manifold

may

be

air

Do

not

by

any

the

conditions.

air

life

proceed

securing

and

cleaned

from

the

attempt

other

means.

air

the

The

filter

bore

of

the

as

re-

by

in-

to

24

A

strong

of

the

outside

paper

corrugations. damaged dirtl

replace

light

element

will

reveal

or

shows a large

element.

directed

and

viewed

any

If

into

the

from

damage

the

element

deposit

inside

the

to

the

is of

MAINTENANCE

Fuel

It oil

Oil

is

essential

free

Filters

from

Provided

trouble fuel

1.

trap must being be

taken

washed

should

system. The

first

in

the

not

poured

out

in replaced. filler be strainer

2. A

of

the

poured

or a piece

primary collecting installed fuel checked

A

recommended

lift

between pump.

and

Westerbeke.

to

water

clean

be

filter

filler

be

removed

into

every

fuel o ill

If

there

fuel

through

fuel

or

separating

cleaned

use

clean

or

contamination.

fuel

oil

experienced

should

of

the

fuel

the

tank.

500

hoursl cleaned

and

is

no

tank

the

a

of

chamois.

filter

type

the

fuel

The

filter

every

type

is

available

diesel

is

usedl no

with

be a gauze

tank;

when

fuel

It

should

immediately

filter

fuel

fine

of

the

in

should

gauze

water

should

tank

and

should

100

hours.

from

fuel

the

this

is

the

be

the

be

'9r---7

~

...

---9

-"""'---10

l

1----11

Fig. 3

Main

I.

Centre bolt.

2.

Washer.

3.

Filter head.

4.

Sealing plug.

5.

Copper washer.

6.

Non-return valve.

fuel filter

components

7.

Sealing ring.

8.

'0'

9.

Element.

10.

Sealing ring.

11.

Filter base.

ring.

3.

The

secondary

is

mounted right ment every

of attention. proceed

of and

filter

"0"

the

a.

the

filter b.

ring c.

side

type

300

fuel as

Unscrew

filter

Remove

base

from

Wash

of filter

hours

To

follows:

element.

kerosene.

d.

Install

sealing

rings

order I above.

fuel

to a bracket

the

engine.

and

must

lJ.nless

warrants

remove

the

center

head

and

detach

Discard

the

sealing

and

the

sealing

filter base

and

new

head. of

••

a··

filter

ring

filter

on

It

be

the

more

filter

(Fig.

the

is

an

replaced

condition

regular

element

bolt

on

the

element.

ring

in

clean

element

in

reve

3)

front

ele-

top

base

from

and

rs

e

Lubricating The

importance

cannot

time

l

replacement

period

element of

oil

very

long engine. secured hand

side

replace

1.

Run

2.

Remove

of

the

hoses

3/8

l

tube a

waste

in.

and

Oil

be

stressed

specified

of

and

the

is

used

life

can

The

to

its

of

the

filter

l

engine

dipstickl

and

I.

D.

hose

pump

container.

Filter

of

clean

lubricating

too

highly.

(100

the

spin-on-type

use

of

the

during

be

oil

obtained

spin-on-type

filter

head

cylinder

proceed

until

oil

is

and

flllmp

suppUedl fit

over

the

oil

from

If

hours)

filter

same

brand

changesl a

from filter

on

the

block.

as

follows:

hot.

with

the

dipstick

sump

oil

the

for

the

is

left

To

aid the

into

25

MAINTENANCE

3.

Place polyethylene canister,

a

bag

and

drip

counter-clockwise filter.

4.

To

replace

on

the

filter

in

position

the

gasket

then

advance

5.

Fill Lubricating mark

Oil

6.

on

Capacity

Start operating checking engine

down,

with

and

contacts

one-half

sump

Oil"

dipstick.

engine,

temperature

that

filter

and

PRESERVATION

When diesel several some afforded suffers

Just the air water

a

engine

before

fuel

space

craft

months,

measure

the

engine

no

ill

hauling

tank

remains,

formation

pan

under

completely

turn

filter,

oil.

hand

to

remove.

tighten

spin

coat

Place

the turn.

with

being

the

used,

Do

Six-346 Four-230

run

joint

add

oil

OF

LAID

which

is

effects

it

to

of

is

be

is

to

during

advisable

protection

ensure

(laying

completely,

thereby

or

filter

over

on

or

filter

Discard

the

gasket

the

filter

'~pproved

not

until

head;

to

high

overfill.

11. 5 Qts.

8.0

Qts.

until

is

as

powered

laid

normal

reached,

tight.

required.

UP

ENGINE

up

Shut

by

for

that

storage.

up)

top

off

so

that

preventing

condensation.

a

be

it

no

Fill

Sump: detergent high fill.

mark

Refer cants, " and of

oil.

Sump

Fill

Capacity

Transmission: Automatic "A",

to

high

overfill. Drain

sure open on next

Filling the ing

system

Cooling

cap

drain

right

to

flywheel

hand

Cooling

capacity

keel

with anti-freeze of

protection inch tap

Remove of zinc The

trolysis

should Replace

from

is

closed.

heat

rod

zinc

the

exchanger

in

be

plug

Fill

diesel

on

always

lubricating

dipstick.

to

"Recommended

use

Six-346

Four-230

Transmission

mark

on

System.

from

tap

expansion

(turn

counter-clockwise)

side

housing.

System.

of

cooling

pipes

the

and

if

correct

water

required,

top

of

tank.

hex

screw

the

plug

rod

takes

the

salt

checked

with

every

new

sump

with

Do

the

same

Fill

housing

Fluid

dipstick.

Remove

of

cylinder

Determine

system

inl?talled)

amount

for

the

to

within

Ensure

plug

and

determine

needs care water

of

system

three

rod

if

necessary.

high-

oil

to

the

not

over-

Lubri-

brand

11. 5

Qts.

8.0

Qts.

with

Type

Do

not

pres-

tank

and

block,

(includ-

and

fill

of

degree

one

drain

from

side

replacing.

anyelec-

and

months.

if

Start ating engine

Remove

the

3/8

tube

engine

temperature

down.

dipstick,

hoses

in.

1.

and

pump

into a waste Remove

Insert fitting and

pump

sion. Remove

Filter: and remove. gasket advance

26

pump

opening

(Warner

Place

turn

contacts

filter

breather

the

and

filter Hand

and

run

and

pump

D.

hose

the

container.

hose

to

oil

gear

Replace

a

drip-pan

counter-clockwise

tighten

the

one-half

until

and

is

reached,

with

normal

supplied,

over

oil

from

cap

3/4

through

bottom

out

of

the

has a filler

Lubricating

filter

adapter

turn.

the

dipstick

the

in.

fitting.

breather

of

housing

transmis-

under

until

face

oper-

shut

aid

fit

the

sump

plug.

Oil

filter

the

then

of

to

NOTE: must when

Start

operating ensure tion cedure forward below transmission

)

lated. mating

After add

dipstick. transmission, high

All

have

replaced Engine.

proper

of

anti-freeze.

and

800

Also

surface

shutdown

lube

oil

mark

threaded

sealing

compound

to

prevent

Run

temperature

mixing

exercise

reverse

rpm

to

fluid

check

for

check

if

required

Check

lubricating

add

on

dipstick.

screw

leakage.

engine

is

of,

until

reached,

and

During

transmission

several

ensure

is

new

that

properly

lube

leakage.

oil

level

to

high

fluid

if

required

Check

on

threads

circula-

this

the

oil

in

mark

fluid

fittings

normal

to

pro-

in

,cycles

new

circu-

filter

sump,

on

in to

level

of

MAINTENANCE

anti-freeze add

anti-freeze

within·

one

solution

inch

tank. To

sea

ensure

water

that

cooling

anti-freeze through exhaust input

the pipe

through-hull Disconnect its

a

separate nection with 50

its

percent

(the

other

length

same

approximately engine.

Immediately anti-freeze Before

end

anti-freeze

Remove connect Drain

plug

section.

hose

and

exhaust

(if

installed)

Replace

solution from

any

sea

will

solution

system

outlet

hose

from

of

I.

D.

end

anti-freeze

two

solution

of

hose

is

uncovered.

from

secure

pipe

at

drain

in

expansion

if

required

top

of

expansion

water

should

and

as

follows:

fitting

the

Attach

hose as

left

not

freeze.

expelled

seacock. seacock and

to

this

hose

removed)

be

in a container

and

gallons.

check

at

in

connection

for

exhaust

container

stop

engine.

and

original

by

removing

the

water

plug.

tank.

to

in

the

an

run

at

the

Close

secure

con-

water.

Start

flow

outlet.

rehose. drain

cooled

at

of

of of

4. into

5.

6.

Connect circuit.

Open Bleed

batteries.

valves

fuel

in

fuel

system.

"Operation -Bleeding

fully

line.

Fuel

charged.

refer

System".

to

Remove filter. Carefully a

waterproof

other

Seal

Change Close

air

refer

seal

suitable

the

exhaust

and

all

seacocks.

Disconnect charged

storing nals treated

battery

If

winterization

notify

ized

the

and

to

yacht

and

in

cable

prevent

every

should

PREPARING

RETURN

1.

Clean

TO

external

filter. to

"Filter

air

adhesive

medium.

clean

all

batteries

a

cool

battery.

connectors

corrosion.

30

days

is

performed

yard

that

not

THE

SERVICE

Clean

Maintenance.

intake

tape

outlet

fuel

filters.

and

location.

the

battery

when

engine

be

run.

ENGINE

parts

of

air

intake

opening

or

at

transom.

store

Before

termi-

should

Recharge

in

storage.

by

owner.

is

winter-

FOR

the

engine.

"

with

some

fully

be

2.

Remove

intake

3.

Remove

haust

and

install

outlet.

adhesive

air

adhesive

tape

filter.

tape

from

air

ex-

27

COOLING

SYSTEM

GENERAL. HEAT KEEL DRAIN FRESH

THERMOSTAT

EXCHANGER PIPES

COOLING

WATER

To

Remove

To

Dismantle

To

View

To

Reassemble

To

Install

To

Remove

To

View

To

Install.

and

.

SYSTEM

PUMP.

Pump

Overhaul

. .

Overhaul

• •

'.

COOLING

SYSTEM

Page

29 29 29 29 29

•

29

30 30 30 30

30 30

ALTERNATOR

SEA

WATER

To

Remove

To

Dismantle

ELECTROLSIS COOLING

SYSTEM

V

BELT

PUMP

Pump

CONTROL

TEST

ADJUSTMENT

.

31 31

31

32 32 32

28

COOLING

SYSTEM

1.

General

The

Westerbeke Marine with cooling heat

lized

has

2.

a

system.

exchanger

to

circulated

Heat

Transfer

(closed

water

is changer, radiator; water,

fresh tion, tion which

into

cooled block

not

water.

as

well

is

absorbed

flows

the

and

centrifugal

ings

in

the cylinder sponding where

through

sion The

openings

the

tank

engine unrestricted raw

water

the

fresh This sea sea

through transmis

raw

by a powerful

water

the

sion) exchanger, The

heat

dual

away frictional lubricating oil

pressure flow the

of

raw

cooler.

Six-346 diesel fresh

engines

water

or

cool

the

fresh

round

Exchanger

of

heat

from

system)

circuit

accomplished

similar

it

differs

air,

Heat

as

rejected

heat

by

from

heat

exchanger,

discharged

cylinder

fresh

water

bores'

connect

in

fresh

water

thermostat

and

the

circuit

is

indirectly

fast-flowing

which

water

absorbs

via

is

pump,

dual

oil

and

is

discharged

oil

cooler

from

the

surfaces

oil

which

pumps

water

through

and are

(closed

With

keel

this

pipes

water

the

water

the

by a heat

to

an

because

cools

developed

the

expansion

into

head

by pump.

jacket

the

cylinder

then

into

repeats.

cooled

the

heat picked neoprene and

after

cooler

through

above

bearings

by is

circulated

and

cooled

COOLING

Four-230

equipped

circuit)

system

are

after

jackets.

fresh to

the

automobile

salt

the

engine's

in

combus-

by

fresh

water,

where

the

engine

means

Open-

around

with

corre-

passes the

expan-

by

stream

heat

exchanger.

up

from impeller

passing

(engine

the

overboard.

conducts

and

the

flow

by

the

tubes

uti-

it

water

sea ex-

(raw)

fric-

tank

it

is

of

the

head,

out

the

of

from

the

and

heat

other

of

by

the

of

a

SYSTEM

3.

Keel

When simplified changer fresh drawn dual

oil

ted

by a centrifugal where cylinder jacket, tank

and returns cooled hull.

4.

Drain

To

drain remove open

drain

on

right next water

Two

drain

of

the

raw

water

water.

5.

Fresh

The of

gal "V" To

water

pump

the

-belt

Re

Loosen nator the

and der

to alternator swing

block Remove nuts the

securing

impeller water impeller

Pipes

keel

pipes

version

system

water

from

(closed

the

cooler,

it

is liners to

the

exhaust

to

the

by

the

Cooling

fresh

expansion

tap

hand

to

flywheel

drain

taps

exchanger,

and

Water

is

which

cylinder

from

move

the

its

Pump:

set mounting

alternator

to

release

the

housin~,

pump,

housing

are

of

described

system)

keel

pipes

movement

type

circulated

and

cylinder

combination

manifold, keel

sea

water

System

water

tank

(turn

counter-clockwise)

side

of

housing

tap

on

are

installed

the

center

Pump

circulated

is

mounted

block

the

crankshaft.

bolt

securing

bracket.

adjustment

toward

tension

belt.

the

Remove

water

and

noting

the

gasket.

used,

the

which

heat

above,

circuit

through being water

around

head

expansion

and

pipes

that

outside

cooling

filler

cylinder

and

heat

exchanger.

on

forward

tap

for

by a centrifu-

on

the

and

driven

the

strap

the

of

the

pump

withdraw

pump

is

ex-

the

assis-

pump,

the

water

finally

are

the

system, cap

and

block

fresh

bottom

tap

for

fresh

front

by

alter-

Slacken

bolts

cylin-

the

belt.

four

body

the

body

a

is

a

to

29

COOLING

SYSTEM

Disconnect from the housing

cylinder

To a.

water

the

impeller

six

bolts

and

block.

Dismantle:

Withdraw

pump

tor. b.

Extract through body, ing

the

and

assembly

body. c.

Withdraw spindle, move

To

view

a.

Check sembly bearing

b.

Check

pulley

the

hub,

using water

and

for

seals

spindle

destroyed. c.

Inspect

and

wear.

To

Reassemble:

Reassembly cedure

"To

following: a.

Ensure

coincides

the

pump

b.

Assemble

impeller

Figure

To

Install

Reverse

body.

to

4

the tensioning be

pressed

the

center

the

inlet

housings.

and

remove

its

joint

the

pulley

spindle,

the

bearing

hole

in

the

drive

the

rearwards

the

impeller

an

extractor,

seal.

overhaul:

the

spindle

wear

and

are

that

the

and

the

water

is a reversal

Dismantle",

that

the

with

the

dimensions

lubricating

pulley

procedure

the

drive

in

one

in.

of

its

vertical

and

by-pass

Unscrew

the

impeller

washer

using

hub

an

from

retaining

top

of

the

spindle

and

out

from

and

bearing

ensure

in

good

condition.

interference

impeller,

has

not

seal

for

of

the

noting

hole

in

the

hub

given

''To

Remove",

belt

so

that

(25.4

mm.)

run.

'hoses

the

extrac-

clip

pump

bear-

of

the

and

re-

as-

that

the

of

the

on

the

been

damage

pro-

the

bearing

hole

and

in

the

in

it

can

at

Fig. 4

Water

pump

assembly

"

..

·731

to

·738

in.

B

..

3-670

to

c'

..

·010

to

6.

Thermostat

A

thermostat thermostat tront fresh

of

water impedes water

has ture

into

reached a predetermined

in

the the

the

housing

the

cylinder

vides a more

(18·57

3-700

in.

·021

in. (·25 to

is

cylinder pump. circulation

expansion

rapid

engine. Normal

170

to

To

Remove:

a.

Drain

b.

Disconnect

the

outlet

c.

Release

remove

thermostat d.

Lift

operating

1900F (77

the

cooling

pipe.

the

outlet

housing.

out

the

to

the

two

thermostat

housing.

dimensions

to

18·74

·53

to

mm.).

94-00

mm.).

(93-22

installed

mounted

head

The

thermostat

of

tank

block

and

warming

temperature

870C).

system.

outlet

set

pipe

mm.).

in

on

above

the

fresh

until

tempera-

so

up

of

hose

from

bolts from

from

the the the

it

pro-

the

is

and

the

its

30

To

a. it

View

in

Test

water

and

the

temperature.

should

start

1760F (77 at

2010F (940C). open or the No

the

b.

outlet

To

The

between

it

sticks

thermostat

attempt

thermostat.

Clean

pipe

Install:

installation reversal Remove" between the

water

7.

Alternator

The ment of

the

at

their

moving

the sion below. faults to

"FAULT

a.

.

the

purpose

is

to

alternator

the

cylinder

of

the

Other

should

Referring

alternator

the

release

b. on it

block, in

c. when up, pressed center

NOTE: is will

alternator

the

Using a hard

the

alternator

away

from

thereby

the

belt.

The

belt

securing

the

long in

by It

is

always

cause

belt.

Overhaul:

thermostat

and

heat

The

to

open

and

BOOC),

If

the

given

in

the

fully

should

the

and

of

Fit

be

joint

thermostat

of

the

a

new

thermostat

outlet

pipe.

V

of

Belt

the·

maintain

and

maximum,

alternator

block

belt.

to

Proceed

specific

be

diagnosed

DIAGNOSIS. "

to

Fig.

securing

with

set

bolt

hand

sufficiently

the

side

taking

should

be

bolts

run

of

1

inch

normal

important

run

taut

slip

and

by

immersing

up~

checking

thermostat

between and

be

the

valve temperatures,

open

be

made

face

of

thermostat

procedure

joint

housing

Adjustment

following

the

performance

fresh

and

in

water consists

relation

adjust

as

performance

by

5 ,

slacken

bolt

(A).

one

(B)

hand

and

pressure,

of

the

up

any

slackness

adjusted

are

finally

the

belt

(25

mm.)

thumb

that

as

rapid

the

any

wear

pressure.

slackness

the

val

ve

1 70

and

fully

open

does

position~

not

renewed.

to

repair

the

water

housing.

is

a

"To

gasket

and

adjust-

pump

of to

the

ten-

detailed

referring

the

Support

and

nut

(C).

press

to

swing

cylinder

so

that

locked

can

be

at

the

fan

belt

of

the

B. ·Sea

The prene timing

by

sea

the

Water

water

impeller

gear

timing

self-priming. To

Remove

pump

Uncouple

and

set

drain.

inlet

nections.

Unscrew

pump

the

away

cover.

Remove

case

Replace

gasket

cover.

pump procedure. pump ing

and

gear

compound

screw. NOTE:

The

completely

"Cooling

System

COOLING

Fig. 5

Fan

belt adjustment

Pump

pump

and

case

cover

gear

Pump:

screw

and

four from

between

by

reversing

Use

new

case

when

sea

water

free

of

Check.

SYSTEM

contains

is

mounted

and

train.

The

on

underside

outlet

capscrews,

timing

pump

gasket

cover.

replacing

system

air

leaks.

"

a

is

pump

hose

and

gear

and

the

between

Use

drain

must

Refer

neo-

on

the

driven

is

of

con-

lift

case

gear

above

seal-

set

be

to

31

COOLING

To

Dismantle: Remove Remove

means need

of

not

Remove dri

ve

end

A

suitable

the

shaft,

peller

end

Remove from

Clean,

that

inside

inspect

show

SYSTEM

cover

and

impeller

suitable

be

removed.

the

large

of

pump.

press

seal,

of

pump.

the

retainer

pump

damage

from

may

and

body.

and

or

cover

pump

pliers.

retainer

be

seat

ring

replace

wear.

gasket.

shaft

Drive

ring

used

to

out

and

any

by

key

from

drive

the

im-

bearing

parts

10.

Cooling

The

fresh

must

Air

in

be

the lubrication pump

To leaks, from of air bubbles water the or

neoprene

check

disconnect

the

water.·

bubbles

cooling

pump

a

pump

indicate

impeller,

neoprene

installed.

System

and

raw

(salt)

completely

system

and

shorten

impeller

the

raw

the

and

Run

the

engine

in

the

an

system

Test

water

free

will

water

outlet

insert

discharge.

air

leak

which

rubber

of

air

reduce

the

sea

life.

system

water

it

in

and

in

can

exhaust

muffler

systems

leaks.

pump

water

hose

a

bucket

watch

Any

the

raw

damage

line

for

if

Reverse impeller

or a good Replace Secure

pump

reversing

9.

Electrolysis

Located exchanger detects

resulting tions parts

and

of

electrode once

a rapidly, nections or

sandpapering Normal water

should

the

procedure

with a thin

grade

cover

the

of

with

to

timing

procedure

Control

on

the

left

is a zinc

stray

electrical

from

faulty

corroded

the

electrical

should

month

all should

life

and

terminals

be

of

the

be

above,

coat

water

new

gasket.

gear

'To

rearside

electrode,

currents

ground

terminals

circuits.

be

checked

if

it

and

cleaned

and

electrode

at

least

coating

of

glycerine

pump

grease.

cover

Remove.

of

the

heat

which

often connecin

other

This

at

least

disintegrates

ground

by

con-

scraping

tightened.

in

3

months.

by

"

salt

NOTE:

than

one

Do

not

minute.

run

engine

for

more

32

FUEL

SYSTEM

The

principal delivering are

as follows:

Fuel Fuel Fuel Pump. Injection

The

fuel

lift

the

fuel

quantities,

injection

the

In

from fuel

and

nozzles. Two

operation.

fuel

the tank to the

oil

filter;

finally

conditions

components

the

fuel

Filters. lift

Pump.

nozzles.

pump

pump,

and

nozzles.

system the

then

the

fuel

oil

"lifts"

which

at

conveys

appropriate

norma

engine

the

injection

are

FUEL

of

the

to the

the

Secondary

essential

fuel

I course

is

firstta pump

engine

from

intervals,

INJECTION

equipment

cylinders

the tank to

it

in

measured

to the

of

the

fuel

the

Primary

fuel

oil

filter;

and

injection

for

efficient

for

SYSTEM

Fuel Pump.

The

fuel

Its

working

limits,

or

its

its accuracy of before

When pump,

This

pump

Where

referred

and

the

entry

working

making

the

requesting

the

can

gallery

service

be

to the

pump

sure

pump

is

parts

mishandling

of

the

parts

type

may

of

operation. that the

is

information

and

obtained

above

is

required,

fuel

an

instrument

are

made

in

any

smallest

reached.

number

from a plate

the inspection plate.

pump

particle

damage

Hence the

fuel

is

the

manufacturer's

of

to

extremely

shape

it

and

thoroughly

regarding

should

matter

precIsion.

fine

or

form,

of

dirt

inta

diminish

importance

filtered

the fuel

be

quoted.

fitted to. the

should

be

agents.

First, because the fuel compression, pended

Second,

perfectly

Fuel

Given

of Attention,

ted

refers apparatus.

The

The fitted to the

side

engine A

fuel

dirt,

should

these conditions,

potential

towards

to the

Fuel

lift of

the

camshaft.

hand

from

it

must

sand

that

the

fuel

clean state.

be

filtered

engine

therefore,

the section

care

Lift

Pump.

pump

primer

is

tappet

engine

is

the tank has

and

reaches the

troubles

should

and

of

the

inspection

and

fitted

at

oil

be

clean,

other

before

ninety

would

be

of

this

upkeep

diaphragm

is

driven

for

use

any

ignites

foreign

entering

time

by

heat

free

from

matter.

fuel

pump

the tank.

per

cent

at

be

eliminated.

earnestly

handbook

of

the

filtering

type.

cover

on the off-

by a cam on the

if

the

supply

failed.

of

sus-

in a

least

direc-

which

It

of

is

Ini

ection Nozzles.

Injection nozzles and cylinder head

The cylinder washer

nut

When

cylinder

type the and should

is

to resu It.

It

is

when

been

Make from

head

nuts.

connection

head

between

and

the recess in the

putting

head,

of

copper

cylinder

the

always

the nozzle

removed

sure

the

head, the faces

corresponding

be

perfectly

advisable

the

cylinder

with a two-bolt

between

is

made

the

the nozzle

care

washer

holder

for

any

old

head

holders

lower

should be taken

clean

to

reason.

washer

or

are

attached to the

flange

the nozzle

with

a special

face

of

cylinder

holders

is

face

fit a new

is

replaced,

nozzle

head.

used. of

the

of

the nozzle cap

if a leak-proof

copper

has

been

holder.

and

two hex

holder

the nozzle cap

in place in the

that

The

copper

after

and

copper

only

this

recess in

washer

jOint

washer

having

removed

To lift oil.

use this

pump,

primer,

filters

and

pump

fuel

by

pump

hand

are

until

full

pipes,

of

fuel

The j oint

loose

fit

this

is

such an

washer

for

the

should injection Important

be an easy, but

nozzle,

feature

and

that

it

is

only

not

because

wash-

33

ers especially

used and none

ordinary

an

The

nozzle Before tighten ing down it should be ascertained that

the

nozzle

that

the

fuel pipes can be fitted

them.

made other.

spark plug type washer be used.

holders

for

can

holder

the puspose should

Under

no

conditions should

now

be fitted in place.

is

correctly

without

placed and

bending

be

Trouble. in Service.

The

first

symptoms

usually

headings:

I.

2. Knocking in one (or

3. Engine

fall

Misfiring.

overheating.

in one

of

or

more

injector

more

cylinders).

nozzle

of

the follOWing

trouble

Fuel Pipes.

No

two

of

the

pressure pipes

pump

this in Place in position the

injection nozzle unions to check that the

square

bend

When fitfing the pipe, natively a little then

If the pipe

as

make a

When changing an injection nozzle. move

end,

pipe.

to the injection nozzles

mind

when replacing.

pipe

at both ends.

the pipe to square

the

other.

is

square to the unions

described

the pipe

leaving

above.

good

entirely.

the

Do

at a time.

no

joint.

other

to

notfitone

it

with

tighten

force

No

force should be used.

Never

tight.

from

are

alike. Keep

the fuel

end

the

other

the unions

first

one

at

will

be needed to

take

off

Never

pump

always

Maintenance.

Injection no!zles should be taken

nation

val the operates.

When good maintained cient every

at

regular

should be

different

combustion conditions in the

and

the

if

the nozzles

1000 hours.

intervals. How long this

is

difficult

conditions

fuel tank

in

first

class

to advise. because

under

and

order.

are

tested twice

out

which the

filtering

it

for

engine

system

is often suffi-

the fuel

and

pipe

fits

and

then

union.

alter-

end and

each end

re-

only

one

bend the

exami-

inter-

engine

are are

yearly

or

4. loss

5. Smoky exhaust (black).

6.

Often the trouble pipe union engine This nozzle to the engine

the

pipe union nut. the

constant, this denotes a

The

from

outwards, on its pipe, and the unions retightened. After

pipes (to starting). the engine should be

nozzle sprays into the

at once

unduly

side,

complete unit should be replaced (See Fig.

The

clean

tion cap on the nozzle

of

tenance bench. .

Great

from

working

the skin with ease.

of

power.

Increased fuel consumption.

particular

may

be

nut

on each nozzle in turn, with the

running

will

prevent

engine

complete

the

slackening the unions

or

faulty

greaseproof

getting into contact with the spray,

revolutions.

unit

cylinder

avoid

if

the spray

"wet"

care should be taken to

or

the injection nozzle

unit

pressure

nozzle

determined

at

approximately

fuel being

cylinder,

engine

should then be

head and turned round, nozzle

the possibility

is

"streaky"

then

being

paper

for

will

cause the

or

nozzles causing

by releasing the

1,000

pumped

If after slackening a

revolutions

faulty

air,

nozzle.

of

the

when

in

order.

or

"dribbles"

securely

or

rag with the protec-

attention on the main-

through the

thereby

other of

turned

it

will

If the spray

obviously

prevent

oil

to

rev/min.

altering

remain

withdrawn

injection

the

engine

until the

be seen

to

one

then the

I 10).

wrapped

the hand

as

penetrate

is

in

the

Nozzles unless a nozzle tester is nozzles

With

condition

the less attention the nozzles so there which the

so much,

never

should

are

the cooling system

and

their

effiCient life. In this connection, since

is

no

performance

it

runs with

not

be

removed

available

on hand

other

pays the user to see

for

replacement.

absolutely

item

any

of

the nozzles

maintained

clean fuel

of

the

of

the

34

for

checking

or

in

are

will

need, and

equipment

engine

that

the

out

depends

of

spare

good

used,

upon

engine

order.

Fig. 110-Nozzle Spray Paltern

FUEL

4 sucking noise should be heard.

SYSTEM

Fig. Da.l

Fuel

lift

pump components

Pivot pin.

Delivery valve.

I.

2.

Filter gauze. 10.

3. Sediment chamber. U.

4. Inlet valve.

Inlet port.

S.

Rocker arm spring.

6.

7. Rocker arm.

Camshaft eccentric.

8.

9.

Link.

Pun-rod.

Hand priming lever.

12.

Diaphragm spring.

13.

Diaphragm.

14.

Outlet port.

IS.

Section Da.I

DESCRIPTION

The fuel lift pump

is

operated

by hand priming lever permits pumping a supply testing purposes.

When the lift pump output

jection pump requirements the fuel in the pumping cham-

ber holds the diaphragm against the pressure

diaphragm spring, and the connecting link allows an idling movement

the contact between the rocker arm and the eccentric thus

eliminating noise.

OF

THE

FUEL LIFT

is

mounted on the crankcase and

PUMP

an eccentric on the engine camshaft. A

of

fuel for

is

greater than the fuel in-

of

the

of

the rocker arm. A spring maintains

In

a similar manner seal the delivery side (marked charge the pum

'OUT') and press the rocker arm inwards to

ling chamber with air.

of

If

the pump

is

in good condition the air in the pumping chamber should be held under compression for two

or

three seconds. Finally repeat this test, but immediately the pumping chamber is

charged with air immerse the pump in a bath

of

clean paraffin and inspect the diaphragm clamping flanges for signs

of

air leakage.

Lubricate the rocker arm and the rocker arm pin with clean engine oil and after replacing the pump bleed the fuel

system

Section Da.3

DISMANTLING AND REASSEMBLING

THE

FUEL

Scribe a mark across the pump body joint flanges for

guidance when reassembling.

Remove the set bolt,

sealing ring, and lift off the filter gauze.

Unscrew the set screws and separate the two halves

the pump body.

Remove the two screws and withdraw the retaining plate, inlet and outlet valves, and valve gasket from the upper half

of

the pump body.

Press the diaphragm downwards and turn it clockwise

through an angle

of

90° from the connecting link. Withdraw the diaphragm and its return spring from the lower half

Remove the rocker arm pin retaining clips and with-

LIFT

PUMP

detach the dome cover and its

of

to release the diaphragm pull-rod

of

the pump body.

Section Da.2

REMOVING AND REPLACING

FUEL

LIFT

PUMP

Disconnect the two fuel pipes from the body

pump, unscrew the two set bolts securing the pump to the

crankcase and withdraw the pump and its joint washer.

Before replacing the pump. which

is

foregoing procedure, the pump should be tested. In the

of

absence

special test equipment the pump may be tested

as follows:

Immerse the pump in a bath

of

clean paraffin and flush

it through by operating the rocker arm six to eight times.

Remove and empty the pump; seal the suction side pump, placing a finger firmly over the inlet union (marked 'IN')

and operate the rocker

removal

of

the finger from the inlet union a distinct

arm

several times. Upon

THE

a reversal

of

the

Fig.

Da.2

Diaphragm assembly diagram

I.

Pump mounting flange.

:!.

Initial position of diaphragm locating tab.

3.

Final position

tab.

of

diaphragm locating

35

FUEL

SYSTEM

Section Da.4

Main fuel/ilter C01'lf/HJMllIS

1.

Centre bolt.

2. Washer.

3. Filter head.

4. Sealing plug.

Copper washer.

S.

6. Non-return

valve.

).---11

7. Sealing ring. S.

'0'

9.

E1el1lCDt.

10.

SeaIiDa

II.

Filter

rinI.

base.

ring.

DESCRIPTION

The

main fuel filter

a resin impregnated paper as the filtration medium.

The main parts lower plate assembly; clamped between which canister containing the filter element.

'0'

An boss its clean side.

The air bleed point, which filter, is connected provides continuous air-bleeding ation.

ring located in an annular groove in the centre

of

the filter head seals the dirty side

OF

THE MAIN FUEL FILTER

is

of

the cross-flow type employing

of

the unit are a die-cast head

of

the filter from

is

on

the clean side

to

the fuel injector leak-off pipe

of

the filter during oper-

is

a metal

Section Da.5

REMOVING AND REPLACING THE MAIN

FUEL FILTER

Disconnect the fuel pipe the filter head.

Remove the two bolts

and

bracket

The installation removal' procedure.

Bleed the fuel system

withdraw it from the

of

and

leak-off connections from

and

nuts securing the filter to its

engine~

the fuel filter

is

a reversal

and

of

a

the

and

the

draw the pin spring,

Detach the spring from the priming Reassembly is a reversal

noting the following.

(I)

flanges are true. They may be lapped to restore

(2) Check

surface does not exceed

(3) The rocker

body; the body.

(4) Locate the diaphragm return spring in the dia-

the diaphragm downwards through

(5) When assembling the two halves

ensure

flange leaving

securing screws diagonally.

(6) Test the

to

r~lease

and

connecting link.

Ensure

their flatness.

phragm lower protector washer phragm into the

pull-rod with the connecting link.

before dismantling coincide. by means

arm phragm

that

this

11

o'clock position (see Fig;

an

that

apd

the

towards the

at

pump

the rocker arm. distance washers,

of

the foregoing procedure

the diaphragm

the wear

arm

pin should be a

may

be restored by peening the holes in

pump

angle

of

90°

the marks scribed

of

the rocker arm, level with the

secure

the

two halves

screws finger-tight. Push the rocker

pump

the

bottom

as described in Section

and

on

the rocker arm working

'010 in. (·25 mm.).

tap

and

body with

and

turn

to

engage the diaphragm

on

Hold

of

body

to

of

its stroke

lev~r.

pump

mounting

fit in the

insert the dia-

its.

locating

Da.

2).

Press the

it anticlockwise

of

the

pump

the

joint

flanges

the diaphragm,

the

pump

position the dia-

and

tighten the

Da.

2.

36

pump

tab

in

body

joint

body,

Section Da.6

DISMANTLING AND REASSEMBLING

MAIN FUEL FILTER

Unscrew the bolt from the centre and detach the

Remove the filter element, using to

release the element from the head casting. Withdraw the three sealing rings from their locations in the head bottom

ment, in petrol

using a new element fitted with its strengthened rim uppermost.

plate.

Thoroughly clean all components, excepting the

Reassembly

bottom

and

is

plate from the filter.

allow them

a reversal

of

and

sealing rings.

of

the head casting

a twisting movement

to

dry.

the foregoing procedure,

The

THE

element is

Section Da. 7

DESCRIPTION

The

fuel injectors each comprise two

nozzle

and

the nozzle holder, which axially by a nozzle nut. nozzle

and

the nozzle holder are lapped

pressure seal.

The

nozzle is spaced holes and

positioned nozzle valve is accurately lapped give the closest possible fit within which freely.

The retains the spring is located in the opening pressure

at

nozzle holder contains a spindle

the

nozzle valve

OF

THE

FUEL INJECTORS

are

The

mating faces

of

the long-stem type, having

an

angle

of

20°

from

the

to

give a spray

of

cone

into

on

its seat.

an

adjustable

the nozzle is 'let.

main

parts,

clamped together

of

both

to

ensure a high

four

equally

nozzle centre line

angle

of

140°.

the

nozzle

body

it

will operate

and

spring which

The

upper

end

cap

nut

by which

and

ele-

the

The

to

of

FUEL

SYSTEM

Fig. Da.18

FUll

Injector

I.

Cap Dat.

2.

SpriD.

cap

3. SpriD, plate.

4.

SpriDJ.

5.

Joint

6.

Feed-pipe

Lubrication

and

valve returns this fuel

Section De

REMOVING Disconnect the injector feed pipe union

injector leak-off unions.

Remove the two set bolts securing the injector

cylinder head

DUt.

washer.

UDioD.

is

by back leakage

a leak-off connection

to

the fuel tank.

•.

8

AND

and

withdraw the injector, using tool

7. Nozzle holder.

S.

SpiDdle.

9.

Nozzle

10. Needle valve.

II.

Nozzle body.

of

on

REPLACING

DUt.

fuel past the nozzle

the nozzle holder

AN

INJECTOR

nut

and

all the

to

18G491 A.

If

the injector is

its inlet union, using sealing

Thoroughly clean the copper sleeve in the cylinder head. ensuring face.

Place the injector tighten the securing bolts, using set

to

the figure given in

Connect the fuel feed pipe

that

to

all

be stored for

carbon

in

position in the cylinder head

'GENERAL

any

length

cap

18G 216.

is removed from its

torque

and

wrench 18G 537

DATA'.

leak-off unions.

of

time seal

bottom

the

and

Mount screw the injector cap nut, washer. spring

Using spanner 18G 210, remove the nozzle nut and nozzle, taking care not nozzle body.

~OTE.-Each

sembly and

Thoroughly clean the injector components, using clean-

ing kit 18G 487 when dealing with the nozzles.

nozzle body scoring

lery. the spray holes with fitted to the probing tool.

the nozzle tip towards the inlet connection. Connect the adaptor the nozzle the internal passages.

be softened in the following manner:

added detergent by dissolving 2 oz. (56 gm.) soda of ies in the liquid, bring it for Take

because per may be roughened, making it impossible for the injectors to

them in running water, watering oil such as Shell Ensis oil by draining

the injector in dismantling fixture 18G 388, un-

and

remove the copper joint

Cn~crcw

plate, spring,

shOUld

Using the brass wire brush. remO\'e all carbon from the

and scratches, and for blueing due

Clean

out

and

the valve seat, using the brass scrapers,

Assemble the nozzle body into

to

testing machine 18GI09 A, (See Fig. Da.25) to clear all loose

Where the carbon build-up is particularly

Prepare a

in

I pint ('57 litre)

an ordinary washing detergent. Place the nozzle bod-

a minimum

care

not

jf

the percentage

cent. the surface

be serviced correctly.

Remove the nozzle bodies from the solution. wash

the spring cap nut and remove the

and

spindle.

to

let

the valve

nonle

body

and

always

and

nozzle valve. Examine the valve for

the internal feed passages. the annular gal-

10

per cent. solution

of I hour

to allow the water

be

kept together.

an

appropriate size cleaning wire

adaptor

of

water

to

the boil,

and

not

of

caustic soda rises above

of

the nozzle bore

and

then immerse them in a de-

254.

or

compressed air.

drop

out

valve

are a mated as-

to

overheating.

and

18G

109

and

reverse-flush

carbon

hard

of

caustic soda with

of

and

add

i oz. (14 gm.)

and

allow it

more

than

I!

to

evaporate

Remove the surplus

and

sealing face

too

of

the

clear

E with

from

it may

caustic

to

boil hours. much.

an

IS

Section

As cleanliness is essential when work is being carried the injectors.

Da

•.

9

DISMANTLING

THE

in the case

of

injection

AND

REASSEMBLING

INJECTORS

pump

dismantling, absolute

out

on

Withdrawing

Fig. Da.19

an

injector. using tool

l8G

491 A

37

FUEL

SYSTEM

Fig.

Da.21

Cleaning the

car-

bon from the fuel

galiery

Fig.

Da.23

C I e

ani

n g the

seat

valve

Fig.

Da.20

Clearing the feed

channel bores

Fig.

Da.22

Decarbonizing the

dome cavity

and torque wrench 18G 'GENERAL DATA'.

Reassemble the spindle, spring, and spring plate, and fit the spring cap copper joint washer.

Test and set the injector as described

372

set to the figure given in

Do

not overtighten the nozzle nut.

nUL

and the injector cap nut with its

in

Section Da.

10

Section Da 10

TESTING AND ADJUSTING

THE INJECTORS

To

Lest

or

adjust the injectors it testing machine Calibration Fluid 'C', which the operator, should be used

WARNING.-Wben an injector is

boles

ill

the nozzle should always

operator.

Before removing

close the check

prevent damage. which may result from a sudden drop in

pressure.

Checking and adjusting the nozzle opening pressure

Connect the injector to the testing machine, open the check valve and operate the pump lever. Note the reading on the pfl:ssure gauge at the instant the nozzle sprays.

If

the pressure adjust the spring cap nut until the correct injection pressure

is

obtained.

Check the tightness sure that the copper joint washer Cbecking the nozzle spray

Close the check valve to cut out the pressure gauge and operate the pump lever ute. There should be four equal sprays from the nozzle, evenly distributed, and each spray should persist for about 6 in.

18G

109

A.

in

an

injector from the testing machine,

valve

to the pressure gauge

is

incorrect

of

the injector cap nut and make

at

the rate

(15

cm.) without any visible core

is

necessary to

and an oil such as Shell

will

not affect the skin of

the machine.

being

tested the spray

be

turned away from the

in

(see

'GENERAL DATA'),

is

in position.

of

60

strokes per min-

use

order to

or

jets

of

Fig.

Da.24

C 1

ear

i n g the

spray holes

The carbon may now be removed, using cleaning kit

18G

487

as already described.

To reassemble the injector, thoroughly wash all the injector components the nozzle body and valve in a bowl fluid and assemble them under the liquid. The valve should fit easily and without any tightness.

Mount the nozzle holder in fixture the mating faces perfectly clean assembly in position on the nozzle holder. Fit the nozzle nut and tighten carefully, using spanner 18G 210

in

clean calibration fluid. Immerse

of

clean calibration

18G

388,

of

the nozzle holder

and

undamaged, and place the nozzle

and

nozzle body are

make sure

38

Reverse /lushing an injector mochine Shown

18G 109 A and adaptor 18G 109 E.

inset is

II

sectioned adaptor with

In

poation.

nouJe.

.'

rt:~

~

using telfing

1M

no_

~

FUEL

After

30

seconds lapping time withdraw the nozzle,

clean the lap, and examine the conical lap tip. There

be a mat surface where the lap has been in contact with

nozzle seat, and

the

mat surface circumferential ring cate the extent

The lap should be refaced, as already described, after

every

badly worn nozzle seat it may be necessary

time.

Wip\! Recharge the tip nue lapping until the seat When the scat appears satisfactory after a few seconds lapping with a freshly ground lap, charge the lap with

fine lapping paste

mat surface the lapping operation the lap should be cleaned examincd after every

Thoroughly clean the nozzle by 'reverse-flushing' as described in sed air. Make a final inspection the microscope.

Examine the conical valve face under the microscope for scoring and pitting. The most critical conical face

is

face defined with edge' anywhere on its diameter. The reason for this is ensure a high pressure, fuel the nozzle valve valve face should be refaced on the nozzle grinding and lapping machine.

Ensure that

the refacing angle is set for the nozzle valve (see

'GENERAL

Mount the conical tip in the same way as already dcscribed for the nozzle body lap.

Remove only the absolute minimum ficient to change the colour otherwise the needle lift there should be no sparks grinding-wheel when carrying out this operation.

The operation glass, the point face away from the grinding-wheel.

In the event nozzle body, due guide surface

Mount machine, using a suitable very small quantity surface lapping collet, supplied with the machine, over the rotat-

will probably be narrow

I-fr

minutes

the lap stem clean and recoat it with tallow.

is

produced over the entire seat. Throughout

Section Da. 9 ,

part

of

and

formed. This angle

no

that

DATA').

the valve in the lathe

of

the nozzle valve in the lapping chuck

of

the valve. Start

in

the early stages

in

the middle. These markings indi-

of

the wear on the nozzle seat.

of

lapping time,

of

the lap with lapping paste and conti-

is

free from

and

continue lapping until a smooth

30

seconds

and

the valve face

the parallel stem

'rounding'

and

seat.

the grinding-wheel is dressed correctly

is

best observed through a magnifying-

of

focus being the surface

of

the no:ale valve being a tight fit in the to

slight distortion

the valve, it is possible

of

is

shoul~

or

wear breaking the 'knife-

proof

If

wear is evident the conical

of

will

be affected. As a guide,

or

adaptor

fine lapping paste

the

SYSTEM

will

of

lapping this

or

have a bright

but

in the case

to

scorc:s

and grooves;

of

lapping time.

dry

out

with compres-

of

the nozzle seat under

of

the nozzle valve

the angle formed by the

on

which the conical

be sharp

line-contact between

the machine

of

material; suf-

the valve face

audible hiss from the

of

or

deposits on the

to

restore

chuck,

machine

and

to

and

of

reduce this

and

clearly

and

reface

is

enough,

the conical

the

of

the

apply a

the

guide

thread

the

to

fit.

ing valve. Oscillate the collet over the valve guide surface and

after every the valve correctly fitting nllve should body under its own weight when lubricated with fuel oil.

After attention valve seat face on the nozzle valve, check the nozzle valve lift (needle lift) against the figure given in DATA'.

a

by lapping the joint face

lapping plate.

Wben lapping tbe nozzle

takeD to pressure joint witb the nozzle holder and must therefore

be

9

al"oid

true and

Reassemble the injector as described

and

test and adjust it as described in Section Da.

IO

to

15

seconds

and

test it for correct fit in the nozzle body. A

to

the nozzle body valve seat

If

the needle lift

tilting tbe nozzle, as this face makes a high

at

rigbt angles to the nozzle axis.

is

of

lapping time clean

just

slide into the nozzle

excessive it may be restored

the nozzle body on a surface

face, extreme care should

in

or

to

the

'GENERAL

be

Section

Da

10

39

FUEL

Fig. Da.26

Reassembling an injector, and spanner 18G

unatomized fuel.

or

leaks

test to locate the cause.

Checking the pressure tightness of seatings

the pump lever slowly until a pressure

pheres is obtained. Hold this pressure for then check the nozzle tip for is permissible. pressure for paper below the nozzle tip. The diameter on

Checking the back-leakage

atmospheres the pressure to a new nozzle the time taken should A nozzle which has been in service will show a faster pressure drop but as this does not seriously affect engine performance a nozzle may be considered serviceable until a time factor

dribble occur wipe the nozzle dry and repeat the

Open the check valve, wipe the nozzle dry, and depress

60

the paper should

Depress the pump lever slowly until a pressure

210 with torque wrench 18G 372

If

the spray

If

in doubt, maintain the

seconds while holding a piece

not

is'

obtained, then check the time taken for

drop

from

of

less than 5 seconds

using fixture 18G 388

dryness-slight

exceed

150

to

SYSTEM

is

not correct,

tin.

(13

100

atmospheres.

be

12

is

recorded.

or

of

160

10

seconds and

dampness

160

atmospheres

of

the wet spot

mm.).

to

30

if any

atmos-

blotting-

of

160

For

seconds.

Select a suitable lap from those supplied with the grind-

ing and lapping machine. The bore diameter varies

is

slightly from one nozzle to another, and it

fits

choose a lap which ner as the the valve seat ping.

Mount the lap lapping machine nozzle body The lap should across the surface l)f the grinding-wheel, feeding-in the lap very cleaned up. Inspect the lap under the nozzle microscope to ensure that its ground surface appears rough the grinding-wheel should be dressed.

Fit the lap into the lapping chuck

apply a coating

for lubrication purposes. Apply a very small quantity lapping paste to the tip paste does not extend to the top

NOTE.-If the guide surfaces clearance between the nozzle body and valve

increased and the nozzle

seniceable.

Start the machine and carefully slide the nozzle over

the rotating lap. Oscillate the nozzle on the lap, short strokes,

engaging the nozzle seat with the lap

stroke. The nozzle seat for more than pressure applied to the nozzle should be light. Excessive pressure will cause grooving

nOlLle

in

SC;Jt

be

gradually until its conical surface

any lapping paste is allowed to get between

at

lap should not remain in contact with the

the nozzle body

valve. This

the body with the body bore after lap-

in

the lathe

and grind the conical tip to the correct

angle as given

passed slowly backwards and forwards

of

tallow to the guide surface

of

a rate

will

ensure concentricity

of

th.!

nozzle grinding and

in

'GENERAL DATA'.

is

smooth.

of

the lap, taking care that the

of

the cone.

the lap and the nozzle body, the

will

probably

of

20

to

30

five

seconds

of

the nozzle seat.

necessary to

in

the same man-

of

is

entirely

If

the surface

of

the machine and

of

the lap

of

will

be

made

UD-

in

very

strokes per minute.

at

the end

at

a time and the

of

each

!

Section Da

RECLAIMING

If

after dismantling, cleaning and testing, as described

in

Sections Da. 9 and Da.

be unsatisfactory,

nozzle providing it has been found satisfactory when

'Checking the back-leakage'.

To recondition a nozzle the use lapping machine is required. A nozzle microscope is also necessary for inspection during the reclaiming process.

11

INJECTOR

10

it

is

usually possible to recondition the

of

the nozzle body

NOZZLES

an injector

of

a nozzle grinding

is

found to

and

40

and

valve

Fig. Da.27

An

injector assembled to machine J8G 109 A ready

for spray testing

D.

P.

A.

TEST

DATA

FUEL

SYSTEM

Pump

Type:

Engine:

BASIC

PUMP

Mechanical Light Rotation

load

(looking Governor Governor

Roller Plunger

TEST

Fit

Where

15

to

diameter

PROCEDURE

auto-advance

marked

seconds Shimming A

0.5

mm removed. screw

Test

fully

No.

3248880A FOUR-230

SPECIFICATION

governor.

advance

link

control

roller

device

on

drive

length

spring

dimension

6. 5

measuring

thus

use

before

of

Light

shim

No

taking

Load

is

fitted

further

retracted. Description

3248889A

with

Anti-stall

end) -Clockwise

52.5

mm

No. 2

50.

mm

30

seconds

reading.

Advance

to

the

shimming

± 1

hole

37

mm

device

Device.

piston

is

device

mm

nominal

control

and

set

glass

cap

necessary.

R.

arm

scale

draining

on

assembly.

P.

M.

and

No. 2

to

zero

time

and

This

Throttle

idle

Requirements

hole

before

allow

must

and

throttle

lever

commencing

fuel

to

settle

NOT

be

maximum

link

test.

for

speed

1

2

3

4

NOTE:

5

6

7

Priming Transfer

Transfer Transfer

on

tests 5 and

metering

Delivery

Advance

Delivery

pump

pressure pressure

valve

setting

check

vacuum

6.

To

adjuster

obtain

on

the

100

max.

100

100 1250

required

end

of

1250

degree

the

Fuel

Note

(406

allowed

11

48 kg/cm

governor

Fit

tool

delivery time

mm)

60 lb/in2 (0.8 to

60

lb/in2 (3.4

2

)

of

shut-off

to

pump. delivery off

lever

Advance

zero.

With

shut-off

external.adjustment

1-3/40 to

With

shut-off adjustment average

6.8

cc.

from

to

reach

Hg.

Max.

secs.

kg/

advance

use

housing.

lever

Obtain

6.0

to

6.8

adjustment.

indicator

lever

2-1/40

advance

lever

as

at

(5)

delivery

to

all

injectors.

16

in.

time

2

cm

to

min.

)

4.

2

the

adjustment

average

cc

by

shut-

Note-

must

as

to

and

be

show

at.

(5)

obtain

external

(6)

6.0

set

to

8

Advance

check

1250

With

shut-off advance

to

lever

be

3-1/20 to

fully

closed.

4-1/20.

40A

FUEL

SYSTEM

Test

No.

9

lOMax.

11

12

13

14

15

Description Back

.

Throttle

leakage

lever

fully

closed

fuel

delivery

Max.

fuel

delivery

check Cut-off

Shut-off

operation.

lever

closed

Throttle . operation Throttle

Fuel Governor

lever

delivery

setting

closed

check

R.P.M. 700

700

100

200

1700 1950

Requirements

5

to

50

cc

for

cycle.

Set

to

8.

2 ±

between

0.8

cator

Average

than

Average

1.

5

Screw and

exceeding Record

Set

lines

cc.

Note -Advance

must

delivery

average

delivery

cc.

back

lock

to

average

throttle

0.8

adjustment mum No stop

average

line

screw.

to

exceed

100

stroke

O. 1 cc.

not

to

show

zero.

to

at

(10)

not

anti-stall

give

delivery

cc.

delivery.

by

maximum

screw

to

delivery

2.5

time

Spread

exceed

indi-

be

not

minus

to

exceed

device

not

speed

give

maxi-

of

1.

cc.

less

1.

0

5

cc.

Lock

cc.

16

17

Fuel

delivery

Timing

check

1700

With

throttle

average

than

0.4

average

cc.

Using set

indexing

scribe

delivery

outlet

line

set at

'V'

tool

on

housing

as

to

(14)

(30

to

at

(15)

be

not

minus

ats

pressure)

860 and

flange.

less

408

ENGINE

DIESEL ENGINE

Page

Camshaft -removing Connecting

Dismantling

Removing Crankshaft Cylinder Cylinder Decarbonizing. Diesel

External Internal

Diesel

External Internal

Engine

Flywheel

Injection

rod

and

replacing

and

main head -removing liner -removing

Engine·

Engine

sandwich

and

pump

FOUR-

components

SIX-346

components

plate -removing

starter

drive

and

replacing

piston

reassembling

bearings -removing

230 .

ring -removing

.

and

•

replacing

and

and . .

replacing

and

replacing

.

·

69

•

61 62

61

.

•

70

• 56

• 63

·

60

43

44 46

• 49

•

50

•

52

.70

70

69

Dismantling Removing

Injector

Oil

pressure

Oil

pump

Dismantling Removing

Rocker

Dismantling Removing

Timing Timing Timing

Dismantling Removing

and

reassembling.

and

replacing

sleeves -removing

and

shaft

gear gear gears

relief

strainer

assembly.

case -removing case

valve

.

and

reassembling

and

replacing

and

reassembling.

and

replacing

cover -removing

.

and

reassembling.

and

replacin~

•

and

•

• and

•

replacing

.

replacing.

and

replacing

·

69

·

69

•

61

• 55

.54 .54

.54

55

•

55

• 55

• 67

•

.64 .64

66

65

41

Valve Valve

grinding.

•

guides -removing

and

replacing

•

59

58

Valve Valve Valves

Valve

rocker seat

inserts

timing

clearance

• 55 60

58

• 67

42

F 0 U R -

23

0 -LITRE DIESEL ENGINE

(Longitudinal Section)

43

FOUR-230·

DIESEL ENGINE EXTERNAL

COMPONENTS

178

.179

III

~

....

r,)

~1I4

113

_ P

'V

~_

-34

~

.IS.! r _rO;!'

-

~~~-192

,u

190

109

;9--189

~

'

~

•

44

FOUR-230

DIESEL ENGINE EXTERNAL COMPONENTS

No. Description

I.

Cyllnder

2.

Main

3.

Main

4.

Main

rear).

5.

Dowel

6.

Stud

7.

Stud

Nut

8.

9.

Washer

10.

Main

I I

Crankshaft

12. Dowel

13.

Dowel

14. Dowel

15.

Dowel

16.

Front

17.

Locating

18. Seloc

19. Oil gallery

20.

Washer Oil gallery

21.

22.

Washer

23.

Oil gallery plug (tapped).

24.

Washer

25.

Water

26.

Washer

27.

Water

28.

Water

29.

Cylinder

30.

Cylinder Cylinder

31.

32. Shim Washer

33.

34.

Adaptor

35.

Washer

36.

Rear

37. Bolt for plate.

Spring

38.

39.

Ioint

40.

Screw-cover

41.

Spring

42. Sandwich plate.

Ioint

43.

44.

Bolt-plate

Spring

45.

46. Valve

47.

Joint

48.

Bolt-tappet

49.

Washer

SO.

Timing

block.

bearing

for for

for

bearing

for

main

stud.

for

nut.

cap

(intermediate).

cap

bearing

bearings.

thrust

for

flywheel housing.

for

cylinder

for

injection

for

rear

camshaft

washer

gallery plug (brass).

gallery gallery

for

cover

washer

for

half

bearing.

screw

for

screw.

plug

plug.

plug

plug. plug. plug.

(front

(brass).

plug

for for for

for

core liner. liner sealing ring. block

water

drain

tap.

for

drain

drain adaptor.

plate

and

tap.

for

cover

plate.

plate to block.

washer

for

sandwich plate.

to

tappet

for gear

cover. cover

bolt.

case.

block.

for

cover.

washer

tappet

for

(front).

(centre

cap

washers.

head.

pump

of

timing case.

bearing.

and

(steel).

plug.

drain

oil seal.

bolt.

screw.

bolt.

to

block.

cap.

(short).

(long).

bracket.

rear).

tap.

and

No. Description

5

I.

Ioint

for

timing

52.

Bolt--timing

block.

53.

Spring

54.

55.

56.

57.

58.

59.

60. Spring washer

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

washer

Dowel

for Timing Joint

gear

for timing

Crankshaft

Bolt-timing

block.

Bolt-dynamo

cover

to

block.

Bolt-timing

Nut

for

Spring

Front

Timing

loint Screw-blanking

bolt.

washer

lifting plate.

cover

for

Spring washer

Oil feed jet Bolt-lifting

gear

case

for

timing

gear

case cover.

gear

oil seal.

case

bracket,

for

bolt.

gear

cover

for

nut.

blanking

blanking plate.

plate

for

screw.

for

timing gears.

plate case. Spring washer

71.

72. Engine front

73.

Bolt-support

ca~e

74.

75.

76. Spring

77.

to block.

Bolt-support

and

case.

Steady Outrigger bearing for idler

for

breather

washer

for

bolt.

support

bracket, cover

bracket

for

bolt.

shaft. Ioint

for

78. Screw-bearing

79.

80. Spring washer

81.

Dynamo

82.

Dynamo

83. Bolt

84.

Nut

85.

Spring

Dynamo

86.

87.

Bolt-bracket

Spring washer

88.

89.

Oil delivery pipe.

90.

Joint-delivery Ioint-delivery

91.

92.

Bolt-delivery

bearing.

adjusting link. bracket-front.

for

steady.

for

bolt.

washer

bracket-rear.

to IImmg covcr.

for

screw.

for

nut.

to cylinder block.

for

pipe pipe

pipe

(short).

case.

to

bolt.

case cover.

and

cover

case

to

plate.

to cover.

to

cover

bracket.

to cover

pipe.

bolt.

to

block.

to

pump.

to block

cylinder

to

and

cas·e.

and

grar

No. Description

93.

Bolt-delivery

(long). Tab

94.

95. Bolt delivery pipe

96.

97.

98.

99.

100.

101.

1O:!.

103. Blanking plug.

104.

105.

106.

107.

108. Oil level indicator.

109.

110.

II

I.

112. Bolt

113.

114. Spring washer

115.

116.

117. Engine

118.

119.

I

:!O.

I:!

I.

1

:!:!.

I

~3.

124.

125.

washer

Tab

washer Oil strainer. Ioint

for Oil sump. Gasket

Washer Washer

Drain

for

plug.

for

Bolt-sump

Spring

washer

Plain

washer

Guide

tube

Breather

Clip

Nut

Cylinder Gasket

pipe.

for

clip.

for bolt.

head. for rear

Joint

for

Stud

for

Nut

lifting plate.

for

stud.

Spring washer

Injector sleeve.

Cylinder

Nut

for

Core

stud.

plug (steel).

pipe to block

for

bolt.

for

bolt.

oil strainer.

sump. drain

plug ..

blanking plug.

to block.

for

bolt.

for

indicator.

breather

for

nut.

cylinder head.

lifting plate.

lifting

plate.

for

nut.

head stlld.

126. Plug (brass).

127. Air inlet

1211.

loint

129.

Bolt-manifolJ

130.

Bolt-manifold

IJ

I.

Spring

132. Plain

133.

Throttle loint

134.

135.

Stud

136.

Nut

137.

Spring

139.

Exhaust

140.

Joint

141.

Stud

14~.

Nut

manifold.

washer

for

washer

unit (Venturi).

washer

for

throttle

for

stud.

washer

manifold.

washer

for

manifold.

for stUd.

manifold.

to head (short). to head (long).

for

bolt.

for

throttle

unit.

for

nut.

for manifold.

to

bolt.

pipe.

bolt.

pump.

unit.

No. Description

143. Spring washer

146.

Thermostat.

147.

Thermostat

148.

Ioint

141).

150. Spring washer for bolt.

151. Plug

152. Fibre washer

153.

154.

155.

156. Spring washer

157.

158.

151).

160. Plug

161.

162. Rolt

163.

164. Plain washer

165. Bolt

166. Spring

167.

168. Relief

169. Relief valve ball.

170. Relief valve spring.

171. Scat

I n. Plug

173. Plain

174.

175.

176.

177.

1711.

17!).

180. Stlld for

III

I.

182.

183. Oil liller

187. Oil feed pipe to rockers (lower).

188. Oil 18lJ.

IlJO.

11)1.

19:!.

I'H. (Jnion

t'l4.

for thermostat body.

Bolt-body

for

Water

outlet

loint

for water outlet pipe.

Bolt-outlet

body.

Rocker

rcar). Rocker

Rocker mediate).

for

Wa~her

for

Spring washer

for

wa~her

Plain

wa~her

valve body.

for

wa~her

Tab

wa~hcr

Overnow

Wa~her

Wa~hcr

Valve

roder

('a'iket

Hand

nut

ribre

washer for nut.

fe~d

for Washer for pin (small). Washer

Tab

wa~her

for

Wa,hcr

for

nut.

body.

to cylinder head.

thermostat

for

body.

plug.

pipe.

pipe to thermostat

for

shaft bracket (front and

shaft

shaft bracket (inter'

intermediate bracket.

for plug.

bracket.

intermediate bracket.

relief valve spring.

relief valve body.

pipe

for

fo~

for

rorker

for stud.

COl

bolt.

bracket

for

overnow

overnow pipe (large).

cover.

for

bolt.

for

bolt.

plug.

pillg.

for

relief val",·.

(centre).

pipe hillaI/).

rocker covcr.

eO\'.r.

p.

pipe to rockers (upper).

feed pipe banjo. for pin (large).

for pin.

oil gauge pipe.

for

IInion.

ti

~

FOUR-230

DIESEL ENGINE INTERNAL COMPONENTS

~124

-

_;7

I'--~

2/-·

II~

3<-

~.-~

~

-:,....

;i"

-~

,

_,

, -

-

'~,_4

, , -

~~_~

@"

5

. ,:\;:j

21.

2~343_e

,.~

14--fI1

15-

, 24

~

~·~t

~

22

3Se

~(j~

3.

W~

...:..

S-ij

~~I

35

- I

33

==

11-:

39--

fi

~g

30

'/

121

FOUR-230

DIESEL ENGINE INTERNAL COMPONENTS

No. Description

I.

Compression ring (taper sided, chrome face).

2.

Compression ring (taper face).

3.

Scraper ring (slotted).

4.

Piston.

5.

Gudgeon pin clip.

6.

Gudgeon pin.

7.

Small end bush.

8.

Connecting rod.

9.

Hollow dowel.

10.

Connecting rod bolt.

II.

Tab

washer for bolt.

12.

Big-end bearing.

13.

Crankshaft.

14.

Inlet valve thimble.

15.

Inlet valve oil seal.

16.

Inlet valve guide.

17.

Thimble locating dowel.

18.

Inlet valve key.

19.

Valve spring collar.

20.

Retainer for collar.

21.

Spring clip for retainer.

22.

Inlet valve.

23.

Exhaust valve oil seal.

24.

Retainer for exhaust valve oil

seal.

25. Exhaust valve guide.

26.

Exhaust valve.

27. Inner valve spring.

28.

Outer valve spring.

29.

Valve rocker shaft.

30.

Plug for shaft.

31. Shaft locating screw.

No. Description

32. Spring washer for screw.

33.

Plain washer for screw.

34.

Valve rocker spacing thick.

35. Valve rocker spacing thin.

36. Valve rocker.

37.

Valve rocker adjusting screw.

38.

Lock nut for screw.

39.

Push rod.

40. Tappet.

41. Camshaft.

42.

Key-hub

to camshaft.

43. Camshaft locatin'g plate. Bolt-locating

44.

45.

Spring washer for bolt.

plate to block.

46. Camshaft gear hub.

47. Camshaft gear.

48.

Bolt-camshaft

49.

Washer for bolt.

50.

Locking

51.

Tab

washer for nut.

nut-hub

gear to hub.

to camshaft.

52. Idler gear shaft.

53.

Idler gear.

54.

Idler gear thrust washer.

55.

Key-gear

56.

Key-pulley

57.

Oil pump driving gear.

58.

Crankshaft timing gear.

59.

Oil thrower.

to crankshaft.

60. Distance piece.

61. Crankshaft pulley.

62.

law-starting

Tab

63.

washer for jaw.

handle.

washer-

No. Description

64. Injection

65.

Injection

66. Locking

pump

nut-hub

driving gear

driving gear.

pump drive shaft.

67.

Tab

washer for nut.

68.

Bolt-driving

69. Injection

70.

Injection

71.

Key-driving

n.

Key-hub

73.

Drive shaft bearing (large).

74.

Cover plate for bearing.

75.

Cover plate retaining screw.

76.

Drive shaft bearing (small).

gear to hub.

pump

drive housing.

pump

drive shaft.

flange to drive shaft.

to drive shaft.

77. Drive shaft oil seal. 7S.

Drive housing end cover.

79.

Screw~nd

cover to drive

housing.

SO.

Spring washer for screw.

S!.

loinl-drive

ca~e.

8:!.

Screw-drive

housing to timing

case.

83.

Spring washer for screw.

84.

Driving flange.

85.

Screw-driving

flange to dog

flange.

S6.

Spring

wa~her

for screw.

87.

Plain washer for screw.

88.

Dowel

screw-driving

dog flange.

89. Spring washer for screw.

90.

Plain washer for screw.

91.

Driving flange clamping bolt.

92.

Tab

washer for bolt.

93.

Nut for bolt.

hUb.

to injection

flange to

No. Description

94.

Spring washer for nut.

95. Coupling dog flange.

96. Coupling insert.

97.

Coupling pump

9S.

Oil pump driven gear.

99.

Nut-oil

flange.

pump gear to oil pump

shaft.

100.

Split pin for nut.

101.

Oil pump rotor

I 02.

Key~il

103.

Oil

104.

Adjusting

pump

and

pump

gear to shaft.

body.

shim~il

shaft

bearing cap.

105.

Oil

pump

cover.

107.

1.0S.

loint-relief

Bolt-relief

valve to pump.

valve body to oil

pump.

109.

Washer for bolt.

110.

Oil relief valve body.

III.

Oil relief valve seat.

112.

Oil relief valve.

113.

Oil relief valve spring.

114.

Oil relief valve plug.

115.

Tab

washer for plug.

116.

Screw-cover

to oil pump bod y

(short).

117.

Screw-cover

to oil pump body

(long).

118.

Bolt-cover

119.

Spring washer for bolt and screw:

120.

Flywheel.

121.

Dowel-flywheel

122.

Bush for crankshaft.

123.

Shims for starling jaw nut.

124.

Bolt-flywheel

to oil pump body.

10 crankshaft.

to crankshaft.

assembly.

pump

to

~

'I

48

SIX-346

.....

11111111

...........

1111

.. I II

I'" I ..................

DIESEL ENGINE

~.I

__

.~.+.~.I~.+I

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

___

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

~

·

I

:

·

:

f

:

i

·

I

!

i

i i

:

f

:

I::

·

.~

·

:

....

~

·

i

~

:

l::s

-

~

::s

.~

~

.5

~

co

~

M

I

~

Cll

f

:

!

I

·

i

N

~

i

I

·

i

••

,'111'1'

III

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

'111

11"11'111'

49

~

••••

•••

·'.,'

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

11,

•• ,

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

++++4"'1""1,

•••

,.,

"'4

~

\lIZ

;~

'''''

III

.,~

~~

r"

2

#-lIlI

~

•

.'-4

I

SIX -346

Fig.

£.4

Engine-external components

f

I

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

i

I

!

i

j

I

!

t

t 51. Lifting

t 54.

I

I 57.

: 58. Rody for Ihermo_lat. 130. Stu'" for : 59. : : 61.

I 62. Spring

: 63. : 64. : 65.

t 66.

"

t 73. Plug

I I

In

j

_u_u~~~uu~~

1

••

111

•••

J.

Cylinder

2.

3.

4.

5. Dowel---<:ylinder

6.

7.

8.

9.

10. II.

12. Il.

14. IS.

16.

17.

18.

19.

20.

21. Shi.n

22.

23. Sandwich pia Ie. head. 176a.

24.

25.

26.

27.

28. Valve

29. Vah'e lIui

30.

31.

32.

33. Inlel valve. 105.

34.

15. Valve

36. Valve

37.

38.

39. Spring clip

40. Oil sc.1 fnr

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52. NUl

55.

56. Spring

60

•.

67.

68. Valve. rocker. 140. Spring washer

69.

70.

71.

72.

74. Locating screw 7'.

76.

77.

78. sUfcport

block assembly.

Dowel-injection Dowel-sandwich Dowel-timinl

Camshafl

Localinl Sprinll washer Core

Plug-brass-for Wa,her

Plug-for Core

Plug-for Joint

Union

Washer Cylinder

Sealing

Drain

Washer

Joint

Sel

Spring

Cylinder

Inj":lor

Core

Joinl-copper·-for

Exhaust

Cullar

Thim"le

Seal

bearinl

screw

disc

for

oir

plug-steel-for

oil

for

Pluf

for

oi

for

liner.

rinl

lap

for

drain

for

..

boll

for

wuher

head

guide-exhausl.

...

e-inlet.

slee'·e. 102.

plug-square

vah·e. 106. Hollow dowel spring-inner. spring-ouler.

for

Relainers

Relainer f,'r oil .eill. Localirgpeg Decom"r

Siud Slud-exhausl Slud-.alve Gaskel Slud-short·-for Stud-long-for

Jninl Nut

Thermo.lat. Joint

ScI Plu!! for

CIA

Waler Joinl Set Spring

Spacing Adjuslinll screw

Locknul

Shaft

Spring Supporl

rocker

Support

oaloe. 109. NUl for .Iu..... 190.

for

f".

inner

....

--rear

for cylinder

and

for

pia Ie. 126. Set

for

plate. 127.

w.\her

for

Ihenooslat

holt

fnr

thermoslat

wa,her

washer

ou,let

for

waler

bolt

for

washer

wa.her

for

valve rockers. 147.

for

valve

washer

bracket-fronl

.ha'\.

bra"ket---<:enlrc-for

brackel

rocker

..................... -......

p.ump

support

plate. 80.

case-rear

head. 80a.

bush. 81.

for

bush.

for

screw. 82. Valve

water

..

IIery. 83.

water

plug. 85. Joinl---<:over

..

IIery I in.

waler

gallery l in. gas. 88. Valve lIear em·er. 168.

(No.

12). 89. Oil filler

..

uge pipe. 90.

plug

(No.

14)

(rubber)

for

cylinder block. 94.

tap.

drain

lap.

ndwieh plate.

sandwich plale. cylinder head. 178.

fur

sandwich plate.

and

valve guides assemhly. 99. Plain washer

hea.... 10J.

core

coll.r.

for

relai"t".

valve. 112. Vacuum

inltl

voloe. 114.

for

Ihimble. 115.

valve

spring-inlel.

",

screw. 117.

cover·plalt.

manif.,M. 119.

rocker

cover. 120.

he.d.

cylinder head. 122. cylind.r head

rear

Ihermustal

studs.

cover-plate. 125. Set

for plate. 128.

bo"'y.

""dy.

for sel bolt. 134.

for

plug.

pipe.

oUllel pipe.

water

oullel

for

sel holt. 139.

for

valve

for

valve rocker. 145. Hlanking

adjusting

rocker

shaft. 148.

for

rocker

for

localing screw.

(plain)-interrnediato-

~~.:..

........

braekel.

half.

lallery.

gas

circular

head. 86.

gallery. 87.

and

union

[(No.

liner 93. Air manifold. 171.

plUI. 104. Plain

head. 121.

body.

pipe. 118. Sel boll---<:over

rocker

screw. 146.

shaft

and

____

16). 92.

(thick). 141. Oil seal. 222.

rear

-for

rocleer

shaft.

•• _ ••••••

KEY

TO

FIG. E.4. ENGINE-EXTERNAL COMPONENTS ...... -

;9.

Support

bracket

(driUed)

for

rocker

Set

(A

S.t Sprinlwasherforsetboh(j\

81a.

Sprinl Push-rod.

84.

Cover Sel

Spring

Gasket

91.

Nut

Washer Stud

95.

Joinl-air

96. Sel

97.

Sel

98.

Sel

100. Spring washer

101. Venluri Joint-venluri

..ocknul-venluri

Spring

107.

Stu.I·-,h"rt

108.

Slu

110. Split pin for nuls. 191.

III.

Vacuum

Ill.

Exhaust Slud Joinl

116.

Nut Casing-limingchain-re.r

118. J"int---<:asinglo cylinder block. 19').

Sel Dowel-liming

121. Spring washer Guide Pad

124. Rivel

Spring Tensioner

129.

Chain

Ill.

Sel bolt

1l2.

NUl

IlJ.

Tab Timing

U5.

Uftinl

\l6.

Cover

1l7.

Joint---<:over SCI

Joinl--blanking Set Spring

149.

Distance

ISO.

ScI

IS\.

Sprinl

152. Oil filler. 210.

153. Oil filter elemenl. 2)1.

154. Oil filter

~~:

..

~:~~~::~~~~:'~~~~"",

shaft. boll-support in.). boll-supPOrt

washer for set

tappel.

for

push-rods. 164.

10

bolt-cover

for "alve

for

~oh-ohort-air

boll-lon8-air

...

-lonll-for

for

holt--<asing

for

holt-Guide

screw-guide

for washer

bolt-cover

screw-blanking

boll

cylinder block. 165.

10

washer

for

cap.

for vah'e gear cover. 170.

~ear

llibre)

for

air

manifold. 174.

manifold

boll-mediuRI-air

for

bolt;.

for

control

unil (C.A.V.).

hI

washer-venluri

washer-venturi

for

-for maIO bearing caps. 189.

pipe-,hort. pipe-long.

manifuld. 194.

exhausl

for

hracket

for

whtel

for

manifold. 195.

..

hau't

e,hausl

manif"ld.

to

case

fur

and

guide bracket. 204.

pad.

hrackel

braC~tll(l

wa,her

for

for timing chain. 209.

for ,ensioner. 210.

chain

tensioner

for

"hain

stud.

for

stud chain. plale-fronl.

liminll

to

casing. 218.

to

for

plale

for

plate

washer

for

piece

for

di.,ance

washer

for

,askel.

intermediate-

brackets

to

cylinder

brackets

10

cylinder

in.).

bolt

cylinder block (short). 166.

scI bolt. 167.

e,"cr. valve

gear

10

cylinder head. 175.

manifold

bohs.

air

manifold. I

II'

air

manifold. 184.

10

to

main

bedfing

main bearing

manifold (pipe,.

cylinder hlock. 200.

to

cnver.

sct

Nit.

"ad

for

to

bolt.

an

(in

lensioner. 212.

and

case-fronl

ca.ing.

and

casing

set bohs. [hlnck. 221.

fronl

cover. 22J.

10

plale

sct screw. 226.

front cover. 227

piece. 228.

set

""It.

[\lin.).

II

in.). 161.

cove.

nu'.

10

c)'linder 176.

manifold

10

cylinder 179.

[h.ad.

air

manif".....

air

manifolJ.

c"ps.

ca"s

half.

liminl

chain. 201.

cylinder hlock. 206.

qlinder

block. 207.

...

screws. 208.

cylindtr

hlock). 211.

holt. 214.

half. 217.

to

cylinder 220.

fronl

cover. 224.

10

fronl

cover. 225.

156.

157.

head

158.

159.

head

160.

162.

163.

169.

171.

172.

10

P7.

180.

181. IH2.

Sl.

1"'. I

S6.

187.

188.

192. 19J.

191\.

191. 19R.

~Ol.

202.

20S.

21

J.

21~.

211i.

2111.

229.

232.

•••

",~~"

Set

Plain washer Spring Oil luhricallon. 237. Oil I'in for Joint Joint T.b Oil

Pin for Wa_her 1

al"o CIi" Oil Blanking Washer

Ora JoiDl Joinl--<um" Sel SCi

Plain washer Spring

Oil'

fuel

I1rackel Set holt Spring Set Overflow pipe for injection

"in Wa,her "'eady

h."rrulc f(lr

Dri"ing

E,hauster.

Rolt Srring 1 iming

Hul' Se, I

0.1 f"cd

Rilnill

lI.njo

("

nil'

SCI Speing \\"a,her for holt. 280.

~1uJ-e",hau\lf'r

NUl fllr

S,'ring

Front Set Sel holt

Spring

Fuel filler 288.

\'Iemenl for filter. 289.

JIlin. (.)r cover. 290.

Sel

Plain wash.:, fur set

S"ring

Fuel

le;.k-on

9rackel

Sleady

Oynamn.

"ulle)"

IIracket f,'r

Set

Spring

Boll-brackets

Nul

S"ring

Set

Plain

Adjustin.

Bracket

"

bolt-filter

pipe-on

pipe-oil

wasber

pipe-in

washer

sump.

in plUI

hoh-short-sump bolt-long-sump

rod

screw-inJectinn for

••

,\

holt f,'r cli". 279.

hol,-

boll-filler

holt-rear

for

to

cylinder block. 2J4.

..

or

set bolt. 215.

washer

for

set bolt. 2J6.

cylinder

head

for

rocker

gallery

to

pipe

on

han;o

of washer washer for

for pipe. 243.

washer

injection

f."

fIn

'It

wa,h<r for pins. 277. f"r

pipc·-Iift pi"e--fiher

screw-dynamo

washer

pipes. [head. 218.

for

pin.

rin.

for

pin.

liminll

banjo

for

washer

for

f"r

for fuel

washer

banjn

for pin. 264.

fnr overflow pipe. 265.

coupling

exhausler.

,,,

.. h ..

chain

-huh plpe-".mp

pin-pil'f' pin·-pipe

nil f

stud.

...

a.her

.up"ort

.Iong

-,h.)fl

",asher

w3\her

pipe-au.iliary.

fur fuel filter 297.

plale

for

washer

boh.

washer

for

use

of

pipe. [lion.

pin. 241.

for

pin. 242.

plug. 245.

plug. 246.

for

sump. for plug. 249. to

crankcase.

10

to

for

sel bolt. 251.

for

SCI

bolt. 254.

oil levol.

pump.

r"el injeclion

inje~tion

for

sel bolt. 259.

pump

of

pipe. 263.

ovrr"ow

(lipe. 266.

...

" injeclion

Ii"

holl. 270.

gear.

wheeL 272.

to

chain

wh

to

exhauster. 274.

to

rlthau,h:r.

10

sump.

.....

pi"e. 278.

to

timing

for

.tud.

hradet.

- for hra,·"et. 28S. fnr

hradel.

for

IlUll', 287.

10

bracket.

holt.

for set

h"h.

pump

10

injection

for fuel filter. 298.

dynamo.

dynamo-rear.

dynamo

brackel

for

sel

boh.

to

dynamo.

for

boh.

nange

for

set screw.

link

for

dynamo.

dynamo-fronl.

___

...

___

"ylinder

for

"hain

lubrice- 240.

"rankcase.

pump. pump

hrackel.

to

hra"kel.

pump.

..

l. 271.

chain

casing. 281.

filter. 294.

pump.

I,'

cylinder 301.

[block. 304.

to

adjustinl

[Iinlc.

._

••

___ • __

...

----

2J9.

244.

247.

250. 2S1.

252.

2~S. 2~6.

257.

258.

261.

262.

267.

268.

2611.

275.

276.

282.

283. 2R4.

286.

291.

292.

293.

295.

296.

300.

101.

302.

105.

306.

107.

108.

309.

310.

311.

_

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

Boll

for

dynamo

bra"kel

to

timing Spring washer Fuel cylinder. Fuel

cylinder. I

Fuel cylinder. Fuel "ylinder. • Fuel cylinder. : Fuel aamp Bolt Nut Sprinll

Starler.

Distance

.Slud-starter

Nul Spring A

nchor Pin-slrap Pin-tapped-for Screw-pin Strap lIanjo pin Fihre Clip Clip Distance Main Banjo pin Washer

Fuel injector.

Se,

h.,1t for injeclor. Sprinl Banju Uanjo p.pes. , Adaplor Copper SCI Spring washer

I'lain washer for boll. Adaptor Copper

Rody-relief

Ball-relief Spring

Seal Plug for Packing waoher Tah Overflow Washer-small Washer-.large Joint--exhauster

Pin-plain-for

Spacing Orain Steady Grommet Cylinder Joinl

Bolt for hlankinll pia Ie. , Valve Nut

Wafer

Washer Set screw for oil pipe Guide Spacing washers Plug-hra

Plug Washer

W!:::

~~~:~

for

pipe-injection pipe-injeclion pipe-injeclion pipe-injection pipe-inicetion pipe-injeclion

for for for

washer

for

washer

for

washer for for

leak-ofT pipe. I

for

washer

pin-leak-ofT

pin-long-for

washer

holt-fucl

waoher for

for

f"r

washer for body. I

lap

for

cover

for

drain

IUN

for

.~~~~.~::~~

holt. icover.

pump pump pump pump pump

fuel pipes. [cylinder.

clamp.

bolt. :

piece-slarter

stud.

for

10

(No.

starter. i

for

pipe. pipe-oillallery

piece

for

pin. :

for

fur

fuel oil filter.

valve. I

ball.

sprinll.

"ody.

pipe

washer

lube.

drain

for

block

blanking

venl pipe. i

cover

plug. :

for plug. :

assemhly

...

intermediate

for plug. :

}~~

~~I~t'

pump

for

bolt. :

10 sandwich pIa Ie.

10

clUI"b housinll.

for

stud.

starter

strap.

anchor

pin. :

.trap.

254)

to

hanjo

of

pipe

for

banjo

pin.

for

pipe-short.

for

pipe-auxiliary

for

valve.

fm

holt>-for

drain

blanking

vent

to

clip. :

sct bolt. ,

10

fuel filler. t

banjo

for

adaptor.

filler

support

""It.

adaplor.

for

""dy.

relief valve.

hoie-·

for

banjo.

banjo. !

to

timing

starter

slrap.

for

valve

rocker

lap

tube. I

tap

tuhe.

pia Ie. t

platc. i

pirt'.

on

cylin';., I ••

for

dip-rod.

for

luide.

rocker

...... -.... -....

chain

to

No. I

to

No.

to

No.

10

No.

10

No.

to

NO.6,

(No.

2901. •

to

pump.

cylinder head

of

leak-ofT i

leak-off

[fuel filler. :

bra"kel

["yrinder

b"'ck

chain

c3,ing. ,

(thin).

ad.

brad

..

et. :

-.-.-.J

2

3 4 , :

10

to

'I

, :

i

I

:

1

I

:

i

I

"

•

:

i

'J

i

c.n

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

~

121

119

a

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

-_.

--

~~

-U

2~.

2

L

__

Fig.

E.5

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

,

..........

,

......

~~~~~.~

..

~I

componenu

.........

-

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

DIESEL ENGINE

Fig.

Aa.4

Checking the oil pump drive backlash

Section Aa.6

REMOVING AND REPLACING

OIL

PUMP AND STRAINER

Remove the sump. Unscrew the two set bolts securing the oil delivery

pipe to the cylinder block.

Remove the nuts securing the oil pump to the front main bearing cap and withdraw the pump. complete with delivery pipe. oil strainer. and pressure relief valve. noting the shims between the bearing cap and oil pump.

To

replace the oil pump. reverse the above procedure

and

fit

a new gasket to the delivery pipe flange. Tighten the oil pump securing nuts to the figure 'GENERAL DATA' using torque wrench

Check that the backlash on the oil pump drive gears

is as

given in 'GENERAL DATA' and. if necessary. adjust the backlash by means of the shims between the oil pump and main bearing cap.

The oil strainer can

Checking the oil pump rotor end-float

be

removed with the oil pump

Fig. Aa.5

mE

18G

given

372.

in

B

Fig.

Aa.6

Check the oil pump rotor lobe clearance with the rotors ill positions A alld

are

for

the maximum clew·ance

still

in

situ

hy

ullscrcwlIlg

the oil

~uction

pipe

flange

B.

The dimensions given

tht:

two

set

holts

to

the

oil pump.

whidl

secure

Section Aa.7

DISMANTLING AND REASSEMBLING

TBE

OIL

PUMP

Disconnect the delivery pipe. oil strainer, and pressure

relief valve from the oil pump.

Remove the gear and key from the end of the pump

shaft.

Unscrew the set bolts, separate the oil pump cover from the with inner and outer rotors.

Thoroughly clean and inspect ponents.

Check the rotor end-float and driving shaft ance against the figures given in 'GENERAL DATA', Excessive rotor end-float can be remedied

the pump body face.

Measure the rotor lobe clearance Fig. Aa.6.

Reassemble the oil pump procedure, noting that the chamfered end of the outer rotor should be fitted towards the bottom of the rotor pocket. During reassembly smear all working parts with new engine oil.

body, and remove the pump shaft complete

aU

the dismantled com-

clear-

by

lapping

as

illustrated

by

reversing the dismantling

in

DIESEL ENGINE

Adjustillg the valve 10 rocker clearance

Section As.8

OIL

The

pressure

on

the

outlet

towards

move washer,

plunger

check

tion versal

renewthe the

the

Release

the

oil and

Examine

for

the

in

"GENERAL

When

of

mounting

Fig.

Aa.7

PRESSURE

RELIEF

relief

flange

front

the

of

the

of

the

locking

pressure

valve

wear

spring

the

seat

valve

or

against

DATA."

reassembling,

the

dismantling

body

plug

locking

flange

gasket.

valve

oil

engine.

washer

relief

from

score

..

,-0

-p

VALVE

is

pump,

pI

ug,

cover.

seat

marks,

the

specifica-

which

procedure,

washer,

A4588A

mounted

facing

and

re-

locking

and

the

and

is a re-

and

bracket set bolts. 'GENERAL

bolts.

Adjust the valve rocker clearance (Section

and replace valve rocker cover.

Start the engine and inspect the rocker cover joint

for oil leaks.

then reset the torque wrench (see

DATA') and tighten the i in. diameter

Aa.H)

Section Aa.lO

DISMANTLING AND REASSEMBLING

THE

ROCKER

Unscrew the set bolts from the centre rocker bracket and separate the rocker shafts from the centre bracket.

Remove the rockers and distance collars and the remaining brackets from the rocker shafts. and unscrew the blanking plug from the end of each shaft.

Release the tab washer from the oil relief valve pipe on the front intermediate bracket and unscrew the relief valve from the bracket.

Remove the plug from the relief valve body and with- . draw the spring. spring seat. and relief valve ball.

Clean all the dismantled components. paying

tar attention to the oilways.

Inspect the components and check them against their

specifications in

When reassembling. which

mantling procedure. smear all moving parts with new

engine oil. renew the tab washer and copper gaskets on the oil pressure relief valve. and so that it ensure rectly

that

pOSitioned

'GENERAL

is

directed down the push-rod tunnel. Also

the rocker shaft distance collars are cor-

(see

SHAFT

DATA'.

is

a reversal

'GENERAL

ASSEMBLY

of

fit

the drain pipe

DATA,).

drain

particu-

the dis-

Unscrew center rocker

rocker

shafts

the

set

bracket

from

the

bolts

and

center

from

separate

bracket.

the the

Section As.9

REMOVING AND REPLACING

THE

ROCKER

Remove the valve rocker cover.

Slacken the rocker adjusting screws until all pressure

is relieved from the valve springs.

Remove the set bolts

the cylinder head and lift

Refit the rocker shaft assembly to the cylinder head

with all rocker adjusting screws fully slackened. Using torque wrench 18G 537 set to the figure given in

'GENERAL

DATA'

SHAFT

securing the rocker brackets to

off the rocker shaft assembly.

tighten the

ASSEMBLY

/r

in. diameter rocker

Section

The clearance between tile ends of the valve stems and the valve rockers gauge.

Crank the check the clearance fully closed.

To a screwdriver and slacken the locknut (Fig. Aa.7). Rotate the adjusting screw until the clearance between the valve stem and rocker is DATA'. it

in position with the locknut. and then re-check the

clearance.

Check the remaining rocker clearances

As.ll

VALVE

adjust the clearance. hold the adjusting screw with

Hold the adjusting screw against rotation. lock

ROCKER

is

FOUR-230

engin~

until No. g valve of

No. 1 valve. which will now be

CLEARANCE

checked by means

is

fully open and

as given in

by

of

a feeler

'GENERAL

reference.

55

DIESEL ENGINE

to the following table:

No.1

valve (ex.)

3

"

5

"

2

..

8

"

6

"

4

..

7

"

valve

The

periodically

" "

" " " "

"

(in.) (ex.) (in.) (ex.) (in.) (ex.) (in.)

rocker

at

the

with

No.8

..

"

..

" " "

"

clearance

intervals

valve

6

"

4

"

7

"

I

"

3

"

5

"

2

"

recommended •

fully open.

"

..

" "

"

" "

should be

SIX-346

Crank the engine until No.

check' the clearance

fully closed.

To

adjust the clearance. hold the adjusting screw with a screwdriver Rotate the adjustina screw until the clearance tho valve stem and rocker DATA'. Hold the adjusting

it in position with the locknut. and then

clearance.

Check

to the following table:

Check

the remaining rocker clearances by

and

adjust No.

..

"

,.

The

valve

be

checked

recommended.

Section

stat

thermostat

bracket

h.12

REMOVING AND REPLACING

Drain Remove

housing. Remove

from

of

and slacken the locknut (Fig. Aa.7).

I valve (ex.) with No.

7

..

9

..

2

..

5

..

10

..

12

..

6

..

4

..

II

..

8

"

3

"

rocker

periodically

THE

CYLINDER

cooling

hoses

the

housing

cylinder

12

valve is fully

No. 1 valve. which

is

u Jiven in 'GENERAL

screw

against rotation. lock

(in.)

..

system.

..

(ex.)

..

(in.)

.. ..

(ex.)

.. ..

(in.)

.. ..

(ex.)

..

(in.)

..

(ex.)

..

(in.)

..

(ex.)

..

(in.)

..

clearance

at

the

BEAD

connected four

bolts

and

heads.

engine

wiD

re-check

12

valve fully open

6

4

11

8

3 I

7

9

2

5

10

intervals

to

checked

opeD

and

now

be

betweeD

the

referenm

..

"

should

.thermosecuring

lifting

Remove

water

exchanger

cooler. hose dual

bracket

engine. pansion manifold

lift

rocker entrance

wiring

leak off the

intake Remove

cylinder NOTE:

in nozzle face

tain

Fig.

Aa.8(B)

cylinder

only,

amount Remove off

be used as a wedge between the cylinder head and block. A suitable method of removing the cylinder head is to place a sling round the exhaust manifold studs on one side, and round two high-tensile ,i-in. bolts screwed into the air inlet manifold bolt holes the other side. When lifting the head a direct pull should

cylinder head gaskeL

pump

Remove

Disconnect

from

Remove

oil

Disconnect

tank/

Remove

away

Release

feed

Remove

bracket

Disconnect

off

all

pipes

entry

Remove

manifold

intake

Remove

The

position

tips

of

the

damage Working

Aa.8

then

in

the

cylinder

On no account should a screwdriver

be

given to lift it evenly

Unscrew the two locating dowels and remove the

water

and

water

and

side

the

cooler

and

exhaust

the from with

the

pipe.

of

dirt.

the

unions

of

dirt.

the

head.

injectors

in

protrude

head

.

(A)

for

the

head

unscrew

the

cylinder

hose

heat

exchanger,

hose

the

dual

the

two

move

exhaust

expansion

the

heat

two

to the at

and

six

manifold.

the

in

for

six-346,

nut a quarter same

head.

water

of

heat

bolts

to

the

cooler

manifold.

_cylinder exchanger

"T"

connection

Seal

bolts

the

fuel

injectors

bolts

to

cylinders

injectors

should

cylinder

below

and

are

the

order

the

each

order

head

pipe

ends

cylinder

pipe

injectors.

up

between

oil

cooler,

exchanger.

securing

engine

away

tank/

securing

unions to

securing

head

the

liable

four-230,

slacken

nut a further

until

nuts

-

or

the studs.

fresh

at

pump.

heat

discharge

lifting

from

head,

attached.

to

from

not

shown

of a turn

ex-

exhaust

and

in

prevent

head.

Seal

prevent

head.

be

left

as

bottom

to

sus-

each

loose.

and

similar tool

UNF. set

the

and

the

lift

at

in

or

on

56

Check the cylinder head joint face for flatness.

a straight-edge.

If

there is any doubt as to the condition of the

it

cylinder head gasket. one fitted. plain side downwards.

Replace the remaining components by reversing the removal procedure. tightened in the order shown in Fig.

Adjust the valve rocker clearance as described in

Section

speed

retighten the

Fig.

Aa.ll.

Bleed the fuel system

Start the engine and allow

until

it

is thoroughly

Stop the engine. remove the valve rocker cover. and

cylinder head nuts in the order shown in

Aa.S.

should be discarded and a new

The cylinder head

of

air

it

to run

DUts

Aa.S.

at

a fast idling

should be

warm.

uSlng

Recheck described

Fig.

Cylinder

the

valve

in

Section

Aa.8A

head

tightening

rocker

Aa.

clearance

11.

(FOUR-230)

nut

slackening

sequence

and

as

Using spanner 18G

to tighten the cylinder head nuts

Fig. Aa.9

396

and torque wrench

18G

372

Fig.

Cylinder

tightening

Aa.

head

8B

(SIX-346)

nut

slackening

sequence

and

57

DIESEL ENGINE

Fig.

Aa.JO

Compressing the valve springs. using

Recheck the valve rocker clearance as described in

Section

Aa.ll.

tool18G

Section Aa.13

REMOVING Remove the valve rocker shaft assembly (Section

Aa.9).

Drain the cooling system Remove the cylinder head (Section Aa.l2).

Detach the spring clips from the valve spring collar retainers. Compress each set of valve springs. using tool18G retainer. Release the compressing tool and remove the valve spring collar. oil seal. and retainer (exhaust valve only), valve springs. and the exhaust valve. draw the thimble from the inlet valve stem. detach the valve key from its slot in the inlet guide and remove the inlet valve. Remove the inlet valve oil seal from inside the thimble.

Clean the valves and guides. removed from the guides by dipping the valve stem in petrol the guide until it the valve guides should be renewed (Section Aa.15).

Inspect the valve faces and seats. and recondition them as necessary (Section Aa.l4).

Check the valve springs against the specification in

'GENERAL springs are square with

A new oil seal should be fitted to each valve during reassembly to avoid the loss of oil tightness which will result from re-fitting the old seals. that the seals are more easily fitted if they are soaked in engine oil before use.

lubricate

oil and replace the valves. which are numbered,

106

AND

REPLACING

and remove both halves of the spring collar

or

paraffin and moving it up and down in

is

free.

If

excessive wear

DA TAt and ensure that the ends of the

thp.

spring axis.

the valve stems and guides with new engine

THE

The

carbon can be

It

will be found

106

VALVES

With-

is

disclosed

in

their

I

~

I A

I'll

,

,I

Fig. Aa.11

Engine (A)

original positions inlet valves top of the valve stem

locating peg. Insert the valve key into position in the inlet guide slot and replace the thimble complete with oil seal. Fit the inner and outer valve springs, the exhaust valve oil seal (chamfer downwards) and

retainer. and the valve spring collar. Compress the valve springs with tool collar retainers. Release the compressing tool and

replace the spring clips on the collar retainers.

Check that the valve head 'stand-down' below the cylinder head face 'GENERAL

is

excessive,

'stand-down' being excessive with new valves.

valves

Fit the valves with their top faces standing down below the cylinder head joint

valve components showing the locating

on the inlet valve and the chamfered bore

of

the exhaust valve oil seal

(B)

in

the cylinder head. Position the

80

that the small flat (Fig.

is

in line with the valve guide

18G

106, and refit the spring

is

in accordance with the figures in

DATA.'

fit

seat inserts as described in Section Aa.l6.

If

the valve head 'stand-down'

new valves. and in the event of the

Fig. Aa.12

face

shown inset

Aa.ll)

to the dimension

fiat

on the

fit

new

58

DIESEL ENGINE

Fig.

Aa.13

Grinding·in a valve, using tool18G

29

Section As.14

V

ALVE-GRINDING

If

only slightlY pitted the valve faces and be reconditioned by grinding-in with tine grmdmg compound. Smear the valve face compound and lap the valve on to Its

semi-rotary motion, with tool 18G 29. is

not

complete until a dull, even,

blemish is produced on both the valve face and seat.

After cleaning away all traces

can

the valve seating marking blue to the valve face about

one

tum completely reproduced on lapping, using oil only, is recommended.

When the valve faces and seats cannot be corrected

by lapping the valves should be refaced to the .correct

be checked

on

its seat; the marking should be

ligh~ly

mat

surface, free from

of

grinding compound

by

applying a spot of

and

rotating the valve

the

valve seat. A tinal

sea~s

~aD

with

gri~ding

s~at,

usm~

ThIs operatlon

angle (see

machine. and the valve seats recut, using tools 18G 27.

18G 28. 18G

18G 174 A. 18G the glaze-breaker to prepare the seat surface and recut the seats, removing only as little metal as is necessary to ensure a true seat. Restore the seats to their correct width (see cutters. Finally. already described.

'GENERAL

28

A. 18G

174

'GENERAL

lap.

DATA')

28

B.

~8G

DATA')

the valves onto their seats as

on a valve grinding

B. 18G

174

28

C. and

by using the narrowing

Section As.IS

REMOVING

THE

Remove the valve rocker shaft assembly (Section Aa.9). Drain the cooling system; Remove the cylinder head (Section Aa.12) and the valves (Section Aa.13).

Drive the valve guides out

using tool 18G

port

end_

New valve guides should be driven into position with

tool 18G 228 until the shoulder on the guide is flush

a

against the cylinder head. When titting the inlet valve guides ensure that the locating peg slot in the valve guide shoulder is in line with the locating peg in the cylinder head before driving the guide into position.

Finish ream new valve guides, using tool 18G 229A, then ensure the valve guide bores. recutting the seatings if necessary

(Section Aa.14).

Replace the remaining components by reversing the

228

that

AND

REPLACING

VALVE

inserted into the guide from the

the valve seatings are concentric with

GUIDES

of

the cylinder head.

C. 18G 174.

180230.

Use

Badly pitted tools

18G

valve

27, 18G 28,

l8G 174, l8G 174 A,

Fig.

Aa.14

seats should

18G

28

A,

l8G 28 B.

18G

174 B, l8G 174 C, and

be

re/aced, using

18G

28 C,

18G

230

Fig.

Aa.1S

Driving a valve guide into position, using tool

18G 228

59

DIESEL ENGINE

=.-.

-.

-: -...

=-:-.""..:::.:=--.":.-

-----.

==

removal procedure, and adjust the valve rocker

clearance (Section Aa.11).

':-

..

"":

..

:---=-:..

..

:;:=

Fig.

Aa.16

Reaming a valve guide using tool

l8G

229A

Cutting

18G

213

tool

18G

inserted

Fig.

AaJ8

a·

thread in

A.

to enable the sleeve to be withdrawn

213.

an

injector sleeve. using tool

by

Shown inset is the 'Alkathene' plug

ill the sleeve to prevent swart entering the

cylinder

bore

Section Aa.16

VALVE SEAT INSERTS

If

a valve seating cannot cutting and refacing tools, or if valve head stand-down is

excessive with a new valve, a valve seat insert should

be fitted.

To

fit

an insert. machine the seating in the cylinder

head

to

the dimensions given

Valve seat machining dimensions

Inlet

(A)

C. Nominal diameter 1·450 in.

(36,8 rnm.). (32-75 rnm.).

D.

1·775

to

E.

Maximum radius ·015 in. N Maximum radius ·015 in.

(·38 rnm.). (·38 mm.).

F.

·325

8·33 mm.). 8'33 rnm.).

G. '135 to '140 in. (3,43 to

3-56 rnm.). 3'56 rnm.).

H.

·070 to ·080 in. (1·78

2·03 rnm.). 2·03 rnm.).

J.

45·

L Chamfer ·020

('508 to '762 rnm.).

1·776 in. (45'076 M. 1·625 to 1-626 in. (41'27 to

45·102

mm.).

to ·328 in. (8·25 to

to

·030 in T. Chamfer '020

at

be

restored with the normal

in

Fig. Aa.l7. and press

Fig. Aa.17

Exhaust

L.

Nominal diameter 1·290 in.

41·30 mm.).

P.

·325

to

Q.

·135 to ·140 in. (3,43 to

to

R. ·070 to ·080 in. (1·78 to

s.

45·.

45·. ('508 to ·762 rnm.)

(8)

·328 in. (8,25 to

to

'030 in.

at

4S·.

the insert. which has an interference

('051

to

'102 mm.), into the cylinder head. Finally, grind or machine the new seat in Fig.

Aa.l7, ensuring that the throat of the new

fit

of

·002

to

·004

to

the dimensions given

in.

seat

blends into the throat in the cylinder head.

Check the area of contact between the new seat and its valve with marking blue, and if necessary lap the valve onto its seat (Section Aa.14).

Section Aa.17

DECARBONIZING

Remove the valve rocker shaft assembly (Section

Aa.9).

Drain the cooling system.

th~

Remove valves (Section Aa.13).

Plug the waterways in the cylinder head and the

cylinder block with clean rag.

If

special equipment for decarbonizing is not available

it will be necessary

the piston crown and cylinder head by scraping. A length of copper tubing with the end flattened and up makes an ideal scraper which will not scratch.

The ridge of carbon should not be disturbed and a ring of carbon should also be left round the periphery of each piston crown. An old piston ring sprung into the bore and resting on the top of the piston will facilitate this operation.

Remove the carbon deposit from the valves, valve

ports, valve guides, and cylinder head. Thoroughly

clean the cylinder head and ensure that all traces of

cylinder head (Section Aa.12) and the

to

remove the carbon deposit from

filed

in

the top of each cylinder bore

60

DIESEL ENGINE

J-Ig.Aa.l9

• Withdralt'ing

carbon dust are removed from the head and cylinder bores.

Replace the components. reversing the removal

procedure. and adjust the valve rocker clearance (Section As. I I).

an

injector sleeve. using too/18G 213

D.

Section Aa.18

REMOVING AND REPLACING

THE

INJEcroR

If

it is found necessary to renew an injector sleeve

the operation can

cylinder head.

Remove the injector.

.Insert

18G 213 A, into the injector sleeve

entering the cylinder. Using tool 18G 213 A. cut a

thread on the inside but leave the plug in position. Screw tool 18G 213 0 into the injector sleeve Aa.19)

Remove the 'Alkathene' plug from the injector sleeve.

Crank the engine to position the piston. in the cylinder

being operated on.

Coat part the cylinder head

ISG 561.

an 'Alkathene' plug, supplied with tool

.•

the new injector sleeve with sealing compound

number

be

carried

of

at

B.D.C.

AKF

1702 on those surfaces which contact

and

drive it into position using tool

SLEEVF.S

out

without removing the

to

prevent swarf

the sleeve. Remove the tool

and

withdraw the sleeve (Fig.

..

--.-.~

_._-

--=:';''':":

~~:'

---==:';-~'-="

--

..

"::'.:

.-".

..

~~':~:~~

-.-=

Fig. Aa.20

Installing an injector sleeve. using tool 18G

Drain

the

cooling system.

Remove the cylinder

If

No. 1 connecting rod is to

oil strainer and suction pipe from the oil pump.

Remove the

bearing.

Clean the carbon deposit from the top of the cylinder

bore and withdraw the cunnecting rod and piston

upwards

cap

through the cylinder.

NOTE.-Each

with

the

Dumber

removed

engine oil. space the compression ring gaps equally round the circumference of the piston. and compress the rings, using too118G

through the cylinder bore. so positioned connecting rod cap will

(Fig.

ALll).

Lubricate the cylinder bore and piston with clean

Insert the connecting rod and piston downwards

head.

and

the

collDeCtiDa

of

the

cyliader from which

55

be

towards

be

bottom

rod

A.

removed detach the

half

of

aad

cap

the

left-hand side

561

the big-end

Is

stamped

it

w.

that

the

.

-

of

Section Aa.19

REMOVING AND REPLACING

A CONNECTING ROD AND PISTON

Drain

Remove the valve rocker shaft assembly (Section AL9).

and

remove the

sump.

~.

-

...

,,,

...

,,

.....

.

~

-:F

Fig. Aa.21

Installing a piston and connecting rod assembly

using

tool18G

55 A

61

DIESEL ENGINE

1.

Connecting rod.

2.

Cap.

3.

Bearing.

4.

Bolts.

S.

Tab washer.

6.

Hollow dowel.

7.

Little-end bush.

5--"""~~~

Fig. Aa.22

The arrows and grooves. The arrows number from which the connecting rod was

the engine. The cavity in the piston crown should now be offset towards the right-hand side

Ensure that the connecting rod and cap. the bearing. and the crankpin are absolutely clean. halves of the bearing

Each half bearing has a tag which locates in a groove

in

the connecting rod and cap (Fig. Aa.22). bearing is being used the two halves should be replaced in

their original positions. Lubricate the bearing and crank pin with clean engine oil. position the hollow

dowels between the connecting rod and cap, and cap into cap adjacent to each other. Fit new tab washers under the big-end bolts in

'GENERAL

Lock the bolts

Replace the remaining components, reversing the

removal procedure, and adjust the valve rocker

clearance (Section

(A)

positiQ.TI

DATA,' using torque wrench 18G 372.

in

indicate the bearing locating tags

(8)

indicate the cylinder

removed

to

the connecting rod and cap.

with the stamped numbers on rod and

and

tighten the bolts to the figure given

position with the tab washers.

Aa.ll).

......::I~~II

of

the engine.

Fit

If

the two

the old

fit

the

Fig. Aa.23 When checking the gap clearance ring

enmre

Section

DISMANn..ING

Remove the bearing halves from the connecting rod and cap. marked to ensure reassembly

Using tool 18G the piston and press the gudgeon pin out. Mark the piston and gudgeon pin to ensure correct reassembly.

Remove the rings from the piston and place them

the order

reassembling them in their original grooves.

Thoroughly clean all the dismantled components and inspect them for damage.

Check the cylinder bore for scoring and for wear 'GENERAL worn in any place

NOTE: and grooves. wrist the

VD

scraper

For

are

present ring ring starved

that the ring is inserted illto an unworn

part

of

the cylinder bore

Aa.20

AND REASSEMBLING

A CONNECTING

If

the bearing is to be re4lSed it should be

1004. withdraw the two circlips from

in

which they are removed. to assist in

DATA').

by

On

the

six

cylinder

one

pin.

for

series

rings

the

98

series

but

may

is

be

installed.

for

lubrication.

ROD

If

the diameter

·010 in. (·254 mm.) or more. a new

VD

series

engi!les above two

scraper

engines.

are

used.

engines

only

installed.

the

of

a new piston

AND PISTON

in

its original position.

of

the bore is

of

the

and

there

one

are

below

rings.

the

both

upper piston

both

If

of

grooves scraper

a

will

in

(see

four

two

the

For

these

lower

be

62

DIESEL

ENGINE

Fig. Aa.25

Removing

liner and piston should be fitted (Section Aa.21). In the event liner. the cylinder liner sealing ring should be renewed (Section Aa.21

Check the piston

and replacing a connecting rod little-end

of

a water leak

).

bush using

tool18G

at

the

to

cylinder bore clearance (see

616

bottom

of

the cylinder

'GENERAL DATA').

Insert each piston ring into the cylinder bore measure the piston ring figure in placed in an unworn used to position the ring square to the cylinder bore axis.

Check (Fig. Aa.24) against the figure in The clearance the ring should be fitted to the piston and inserted into into the liner until ring width has entered the liner. then check the ring

groove clearance.

If

cylinder. the glaze should be removed from the cylinder

bore.

Check the fit

'GENERAL DATA.'

the clearance

top

ring is taper-sided.

an

unworn cylinder liner. Push the piston

it is decided to fit new piston rings in a used

of

gap

(Fig. Aa.23) against the

The

ring should be

part

of

the bore

of

each ring in its own groove

and

'GENERAL DATA.'

and

to

check

about

three-quarters

the gudgeon pin in the piston (see

of

and

the piston

its groove

the piston

'GENERAL DATA').

Measure the gudgeon pin to small-end bush clearance

'GENERAL DATA').

(see

bush (Fig. Aa.2S). using tool 18G

in

a new bush. line

hole in the

Check the connecting rod alignment against the figure

in

'GENERAL

Fit piston. ensuring which are taper-faced. are installed with 'TOP'

top

the rings into their respective grooves in the

uppermost.

up

of

the

DATA.'

that

and.

if necessary. renew the

the oil hole in

connecting rod.

Nos. 2

and

616.

Before pressing

the

bush with the

3 compression rings.

the

side

marked

Reassemble the remaining components. reversing the

in

dismantling procedure. noting that the cavity piston crown should

the opposite side to the big-end cap.

be offset to the connecting rod on

the

Section Aa.21

REMOVING AND REPLACING

A CYLINDER

Drain

and

remove

Remove the valve rocker shaft assembly (Section

Aa.9).

Drain

the

cooling system Remove Withdraw the connecting rods

Aa.19).

Using tool

upwaros from the cylinder block (Fig. Aa.26).

Remove the cylinder

in

the bottom of the cylinder block.

the

NOTE.-1be

OCCllliODS

Inspect the cylinder liner seating in the top of the cylinder block for signs accumulation. Thoroughly clean the seating. being careful is liable to occur. the locating flange same care as for the liner seating.

Thoroughly clean the sealing ring groove in the

cylinder block.

Insert the cylinder liner into the cylinder block without fitting the sealing ring. and the fuIly-home

of

qUader

not

to remove any metal. otherwise a water leak

the

cylinder

ISG 227 C. withdraw the cylinder liner

liner sealing ring from its groove

aeaIiag

position,

riDg should

liDer removaL

If

the old liner is to be refitted. clean

at

the top

Fig.

Withdrawing a cylinder liner. using

LINER

sump

head

(Section Aa.12).

of

burrs. carbon.

of

the liner exercising the

Aa.26

and

pistons (Section

be

raaewed

clamp

tool18G

OD

aD

or

rust

the liner in

227 C

63

DIESEL ENGINE

Fig.

Aa.27

(A)

Insert shims at

to adiust the standing height the early cylinder liner. Shown inset are the faces of

the cylinder block and the liner from which the

standing

Check the standing height of the cylinder liner against the dimension in the liner is stepped

measured between the

top

face

of

the

ing height shims (see cylinder liner flange.

Remove the liner, install a new sealing ring in the

groove a coating of

reduced

the liner, using a semi-rotary motion sealing ring becoming twisted

liner fully home then area

·00175 in. ('04 mm.), withdraw the liner

of

early liners

'GENERAL DATA' for thickness)

in the

adjacent

bottom

Hylomar

diameter

to

heir:ht is measured

'GENERAL DATA.'

and

the standing height should be

lower face of the step

cylinder block.

of

SQ32 jointing

at

the lower

check its bore for ovality in the

the sealing ring.

If

can

be increased by fitting

the cylinder block, and apply

end

or

The

necessary, the stand-

compound

of the liner. Install

to

dislodged. Press the

If

the ovality exceeds

and

top

face

and

under

prevent the

check that

of

the

to the

the sealing ring

to

exchange the sealing ring to reduce the liner ovality

to an acceptable

Replace the remaining components, reversing the

removal procedure,

(Section

Aa.ll).

is

seating correctly. It may be necessary

limi,:.

and

adjust

the valve rocker clearance

Section Aa.22

REMOVING AND R£PLACING

THE

TIMING GEAR CASE COVER

T~ke

the w,;ight of the engwe at the

with a sling,

Release

mountings

Unlock

crankshaft, using

Withdraw the crankshaft pulley, using tool 18G 231

adaptor

and the end

be removed

Remove the engine front

timing gear case.

Unscrew the remaining bolts securing the timing

case cover

engine front lifting bracket and the

support

Remove the set bolts securing the front to the timing case bolts two complete turns.

Pull the timing case cover, complete with oil seal and distance piece, off the two locating dowels at

the lower end

not to damage the

Cover the open end

but

do

not

lift directly

~the

engine front

and unscrew the nut from the front of the

spanner

18G

231

A, and extract the pulley key from

of

the crankshaft.

and

replaced, using tool 18G 1111.

to

the timing

bracket.

cover

of

the timing

sump

of

support

18G 97.

The

support

gear

and

slacken the remaining

gasket.

the

sump

!iont,

prefelibly

under

the sump.

bracket from its

crankshaft oil seal

bracket from the

case.

and

detach the

alternator

of

the

crankshaft

gear

case, taking care

to

prevent the ingress

may

gear

sump sump

('.-.--.."

,.'

"/>

!i!)~_/

'/'"

,.

"<'.'j'

, '

I

...

j j

,

t,lxi

~'

"I/I(

~/

;','/

.I

~

.,

Fig. Aa.28

Removing the starting handle jaw

18G 97

64

nut, using tool

~~

..

:.:--.

~---

Fig. Aa.29

Withdrawing the crankshaft pulley, using tools

231

18G

and 18G 231 A

DIESEL ENGINE

Fig.

Aa.30

Withdrawing

18G

of foreign matter.

Clean the joint and examine them for burrs. Inspect the crankshaft oil seal and renew it. if necessary. Ensure that the crankshaft scratches where it contacts the crankshaft oil seal.

When replacing the components. which is a reversal of the foregoing gasket but between the sealing lips of the crankshaft oil seal should be filled with high melting point grease before assembly.

the camshaft

231.18G

distance piece

do

not use jointing compound.

231

faces of both timing case and cover.

procedure.

gear.

using tools

C.

and 18G 231 D

is

free from burrs and

fit

a new gear case cover

The

groove

Section Aa.23

REMOVING

THE

Before removing the timing gears check the gear

backlash against the figure in

Refit the crankshaft nut and rota'te the crankshaft. using spanner at

T.D.C. with stroke. This will correctly position the timing marks on the crankshaft and camshaft gears for reassembly.

kl:lI

(

using spanner

at

T.D.C. with stroke. This on the crankshaft and camshaft gears for reassembiy,

Press back the jocking washers and umcrew the from the camshaft and the injection pump dnve shaft. Remove the thrust washer and withdraw the from its shaft.

NOTE.-After

......

.....

pletely slackeaed oil

fully dOled.

may

foal

Remove the oil thrower from the end of the crankshaft.

Withdraw the oil pump driving gear and crankshaft gear. using tool

Using tool 18G the gears from the camshaft and the injection pump

Li1<:

.;rallkshai L

the

c:raaksbaft

all the

the

18G

No.4

18G

No.'l?

will

"alft

If

this conditioD is

pistODS

18G

AND

REPLACING

TIMING

GEARS

'GENERAL

DATA.'

Four-230

97. until Nos. 1 and 4 pistons are piston commencing its induction

Six-346

oj!.

L

.......

• C la

lC

'tile cr an""snall.

97. until Nos. 1 and 'piston commencing its induction

corr<:ctly position the timing marks

the idler gear bas

or

camshaft should

rocker

231

adjasdDg

to

allow all the "alvea to remain

Dot

&Dd

cause

serious

and adaptor

,6

pistons are

beea

be

serews are com-

obse"ed

d8JlUlle.

18G

231

18G

231

C. withdraw

n1.its

idl<:r

!l.ear

remon~d

rotated

the "alvet

B.

.

Fig.

Aa.3J

Timing

the

(A) drive

gears

'0'

gears

showing

marks on the

and

hubs.

and

(B) the timing nuuks on

the idler

and

drive

gears

o

®

o

0-"

o

, :

\ ',\ (

\\\_-~

\

~~-~

'

\\

\

___

'~I

;°1

10

I

J

. I

65

DIESEL ENGINE

:::,'::~-.

i,i:;::::

~

Fig

RelllOl'illg, replacing, and broaching to size the timing idler gear bush, using tool 18G 683

drive shaft. Thrust pads 18G

should be used for the camshaft gear and injection

pump drive gear respectively.

Thoroughly clean and inspect all the dismantled

components.

Check the idler gear bush to shaft clearance against the figures given bush. as described in

Refit the gears to the camshaft. crankshaft. and injection pump drive shaft and ensure that the timing marks on the teeth of these gears are in the position shown and

engage the teeth with those of the other gears so that the timing marks line up as shown in Fig Aa.31. noting that the double mark on the idler gear up with the timing mark on the crankshaft gear.

Tighten the nuts on the camshaft and injection pump

drive shaft and secure them with the locking washers.

Check the valve timing as described Fit the idler gear thrust washer to the shaft. with the

oil groove towards the gear.

Refit the crankshaft oil thrower with the chamfered

side towards the gear.

Replace the remaining components in the reverse

order to that in which they were removed.

Check the injection timing as

idler gear thrust washer thickness and the

in

'GENERAL

DATA.'

Section Aa.24.

in Fig. Aa.31. Slide the idler gear onto its shaft

2311

D and 18G

If

necessary. renew the

is

in Section Aa.26.

described in Section

23'1

lined

Da.

Section Aa.24

OISMANTLING

THE

Two of the timing

and

the injection pump drive

AND REASSEMBLING

TIMING

gears-those

GEARS

fitted to the camshaft

shaft-can

be dismantled

liiill!ll!

Aa.32

from their hubs without removing the hubs from their

E

shafts.

Position

Four-230 No. 6 piston duction

stroke

the

crankshaft

No. 4 piston

is

just

commencing

as

described

or

the

Aa.23.

Remove the thrust washer and idler gear from its

shaft. and the camshaft gear and injection pump drive

gear from their hubs.

If

the idler gear bush bush out. using tool 18G 683. with the larger bore of the tool support uppermost. Reverse the tool support so that its lipped end new bush. This will ensure that the bush is correctly positioned with its ends equidistant from the sides of the gear. With the tool support still in this latter position. broach the bush after first lubricating the broach liberally with clean paraffin.

Reassemble the camshaft gear and the injection pump drive gear to their hubs so that the timing mark on the inner face of each gear lines up with the timing mark on its hub as in Fig. Aa.31.

Refit the idler gear to its shaft so that the timing marks on all four timing gears are in the relationship

shown

in Fig. Aa.31. noting that the double mark on

the idler gear

crankshaft gear.

Tighten and rewire the securing screws on the

injection pump drive gear. but leave the securing screws

on the camshaft gear finger-tight.

Adjust the valve timing as described in

Refit the idler gear thrust washer with the oil groove

towards the gear.

is

lined up with the timing mark on the

is

to be removed. press the old

is

uppermost when pressing in a

so

that

the

Six-346

its

in-

in

Section

Section Aa.26.

66

DIESEL ENGINE

Section Aa.26

VALVE TIMING

G

Fig.

Aa.33

Valve riming diagram Four-230

E.

A. Inlet valve opens.

B. Exhaust valve

C. Exhaust valve opens.

D.

Inlet valve closes.

close.~.

Fuel injection timing B.T.D.C.

F.

Top dead centre.

G. Bottom dead centre.

28

Section Aa.25

REMOVING AND REPLACING

THE

TIMING

Remove the timing gear case cover (Section Aa.22). Withdraw the idler gear and the camshaft gear as

described

in

Section Aa.23.

Unscrew the idler gear shaft. which has a lefthand thread. and the timing gear oil fee4 jet complete with copper seal washer.

Remove the set screws securing the gear case to the crankcase and pull the gear case. complete with injection pump drive and the driving half of the injection pump coupling, on

the crankcase.

If

necessary, remove and dismantle the injection

pump drive as described in Sections Aa.27 and Aa.28.

Thoroughly clean and inspect al\ the dismantled

components.

When replacing the components, which

of

the foregoing procedure.

the crankcase and timing gear case, coating the

crankcase joint face with sealing compound.

Ensure that the injection pump drive coupling is

assembled correctly. The coupling dowel bolt must

engage the hole in the pump drive flange.

The idler gear shaft should only be tightened

sufficiently to retain it in position.

GEAR

off

fit

CASE

the three

I~cating

a new gasket between

is

a reversal

dowels

Four-

230

Engine

When timing pin AMK wheel,

No.4

degree plate must be set

With

the timing marks on the

piston is

9990

at

engages the

250 B.T.D.C. and the

at

250 before zero.)

g~ars

correctly

r~lated

as in Fig. Aa.3I. and the valve rocker clearance adjusted as in Section (see 'GENERAL

Aa.II.

final adjustment of the valve timing

DATA'

and Fig. Aa.33) is made by rotating the camshaft drive gear in relation to its hub. the securing bolt holes in the camshaft gear being

elongated for this purpose.

Rotate the crankshaft in the normal direction or

rotation until the

50

A.T.D.C. mark is

at

the top of the

flywheel in the vertical position with No. 1 piston

commencing its firing stroke and No. 4 piston commencing its induction stroke.

Slacken· the six set bolts securing the camshaft gear

to

its hub and rotate the camshaft

direction of rotation until the exhaust valve

No.4

cylinder is just closed.

in

the normal

(No.8)

A clock gauge. moun·ted on the engine with its indicator contacting the valve spring collar. will facilitate this operation. Tighten the camsllaft gear securing bolts. recheck the valve timing, and rewire the

gear securing bolts.

An alternative method of setting the crankshaft

50

A.T.D.C.

conjunction

(1) Rotate the crankshaft in the normal direction of

(2)

is

to use a degree plate and pointer

WIth

timing pin AMK

rotation until the inlet valve

cylinder

is

just closed. No. 1 piston will now

9990.

(No.2)

as follows:

of No. 1

be commencing its compression stroke and piston

will

be

on its exhaust stroke. Insert timing pin AMK hole

in

the lower half of the engine sandwich

9990

through the reamed

No.4

plate and. while maintaining pressure on the pin. rotate the crankshaft slowly until the pin engages

the timing hole

(3)

Mount the degree plate crankshaft, attach the pointer

position

at

to

280 (250 on engines with a Simms Minimec

in

the flywheel.

on

the front end

in

of

a suitable

the engine. and set the degree plate

injection pump) before zero.

(.1)

Remove the timing pin and rotate the crankshaft to bring the plate

in shaft will now be piston

50

after zero mark on the degree

line with the timing pointer. The crank-

at

50

on

its induction stroke.

A.T.O.C

.•

with No. 4

fly.

of

at

in

the

67

Six-346

THE ENGINE

To facilitate retiming, one tooth on each gear, with the exception

'0'

or

drill dimple

of

the idler gear,

(see

Fig. 28). The correspond-

is

marked with an

ing teeth on the idler gear which mesh with the

marked tooth on the camshaft drive gear and the

fuel

injection pump/exhauster drive gear are

identified with similar marks, while the

corresponding teeth which mesh with the marked tooth on the crankshaft gear are marked with drill dimples. Also, the faces pump drive hub, the camshaft

'OC'

or twin

of

the fuel injection

flan8C

or

drive hub, and their drive gears are stamped with

'0'

marks to ensure correct timing relationship between these components. Assemble the drive gear to the fuel injection pump

face

drive hub, lining up the

of

the hub with the

'0'

mark on the

mark on the face

of

the gear. In a similar manner, assemble the drive gear to the camshaft, lining up the of

the gear and the camshaft flange

'0'

marks on the faces

or

drive hub, but do not lock the securing bolts at this stage as final adjustment

of

the valve timing has still to be carried out. If

necessary, after first ensuring that the valve rocker adjusting screws are fully released, rotate the crankshaft to position No.

6 piston

at

T.D.C. on its induction stroke. The tooth with the timing mark on the crankshaft gear will now be between

11

and

12

o'clock (see Fig. 31).

Rotate the camshaft to position the gear tooth with the timing mark between eight and nine o'clock and then

tum

the fuel injection pump

drive gear so that its tooth with the tim-

is

ing mark Fig.

31:).

between three and four o'clock (see

Fit the idler gear to its shaft with the marked teeth on the drive gears engaging the corresponding teeth on the idler gear as shown in Fig.

31

Fit the idler gear thrust washer with the oil groove

in the washer next to the gear.

The valve timing may

be

checked, using a degree plate and pointer, a dial-gauge, and timing pin AMK follows:

(1) Set

(2) Insert timing pin AMK

No.6

cylinder inlet valve clearance to

(·53 mm.) then crank the engine until

is

on its firing stroke.

9990

through the reamed hole in the lower half Maintain pressure on the head

of

the engine sandwich plate.

of

No.6

the pin, and

crank the engine until the pin engages the timing

F

G

Vah'c

timing diagram-Engille fyl'('

A. Inlet valve opens.

n.

Exhaust valve closes.

c. Exhaust valve opens.

1>.

]nlet valve closes.

hole

in

the

flywheel.

E.

Fuel

retarded)

....

Top dead centre.

G.

Bottom dead centre

No. 6 piston

Six

inj~'Ction

timing (fully

14' B.T.D.C.

140 B.T.D.C. on its exhaust stroke.

(3)

Mount the degree plate on the front end crankshaft and attach the pointer position on the timing case. at

140 before zero then remove timing pin AMK

Set the degree plate

in

9990.

9990, as

·021

in.

piston

- 34 6

.•

is

now

of

the

a suitable

68

(4)

Mount the dial gauge on the cylinder head with its indicator resting on the collar

of

No.

~

DIESEL ENGINE

/~

"

Fig. Aa.34

Checking the camshaft end-float

Section Aa.27

REMOVING AND REPLACING

TIlE

INJECTION PUMP DRIVE

Remove the injection Remove the blanking plate from the timing gear case

and

cover. injection

Remove the six set bolts securing the injection

drive to the timing gear case

pump

separate the drive shaft from its drive gear.

When replacing the drive housing ensure that the

joint faces of the timing gear case and the drive housing

are clean.

timing

drive housing gasket.

Replace the remaining components by reversing the

removal procedure.

Bleed the fuel system as described in

unlock

pump

drive shaft.

drive. using tool 18G loo8B to

Smear the joint face on the rear of the

gear case with jointing compound, and

Section Aa.28

DISMANTLING AND REASSEMBLING

THE

INJECTION PUMP DRIVE

Slacken the clamp bolt nut on the coupling driving

flange and withdraw the flange from the drive shaft.

Extract the coupling key from the drive shaft and remove the end cover, complete with oil seal, from the drive housing.

Remove the cover plate from the front of the drive housing and press the shaft out of the housing in a forward direction from the housing as the drive shaft

Extract the drive gear key from the drive shaft.

Press the small ball bearing out of the rear of the housing and remove the oil seal from the end cover.

Clean

and

inspect all the dismantled components.

Commence reassembly by pressing the large ball

bearing into the front of the housing. Refit the front

pump

(Section Da).

and

unscrew the

and

withdraw the injection

The

large bearing will be ejected

nut

Section Da.

is

pressed out.

from the

pump

fit

a new

cover plate and when the countersunk screws are fully

tightened, lock them in position by peening.

Fit the drive gear key to the front of the shaft and insert the shaft into the housing from the rear end until the flange on the shaft is against the bearing.

Pass the small ball bearing over the shaft and press the bearing into the housing until it contacts the shoulder in the housing.

Fit the oil seal into the end cover so that its sealing lip

fJc(;:s

towards the bearings.

SmeJr the joint face of the end cover with sealing compound and relit the end cover being ca:eful not to damage the oil seal.

Refit the coupling key and driving flange.

Inject a liberal quantity of clean engine oil through the hole

lubrication

in

the top of the drive housing to provide initial

un

til

the oil

in

the engine

to

the drive housing,

is

circulating.

Section Aa.29

REMOVING AND REPLACING

THE

CAMSHAFT

Remove the timing gear case cover (Section Aa.22).

Withdraw the camshaft drive gear (Section Aa.23).

•

Remove the rocker cover and slacken fully the valve

rocker adjusting screws. Withdraw the pushrods.

Remove the fuel lift Disconnect the external oil pipe from the main oil

gallery and cylinder head.

Remove the tappet and pushrod cover and the oil

level indicator guide from the side

Lift

out

the tappets.

Remove the camshaft thrust plate and withdraw the camshaft. being careful to avoid damage to the bearing surfaces as the camshaft is withdrawn.

Thoroughly clean and inspect all the dismantled

parts.

Check the camshaft bearing clearance against the

dimensions in

Fit the thrust plate and the drive gear to the

camshaft. tighten the camshaft nut, camshaft end-Boat dimension given in

If

necessary. remove the locating bolt and withdraw

the camshaft front bearing from the cylinder block.

Press a new bearing into position, plain edge first. aligning the in

the bearing housing. When the bearing is in position

the holes can be tapped into final alignment. using a

'GENERAL DATA.'

rwo

holes in the bearing with the two holes

pump

of

the cylinder block.

and

check the

as

shown in Fig. Aa.34 against the

'GENERAL DATA.'

69

DIESEL ENGINE

soft drift against the aligning notch the locating bolt and line-ream the bearing to the

dimension given in 'GENERAL DATA.'

Replace the remaining components, lubricating all

the bearing surfaces with clean engine oil,

the

removal procedure.

Adjust the valve rocker clearance

Section Aa.11 and bleed the fuel system of air I

in

the bearing. Fit

by

reversing

as

described in

Section Aa.30

REMOVING AND REPLACING

THE

FLYWHEEL AND STARTER RING

Remove the

Unlock and remove all but two of the bolts securing the flywheel to the crankshaft flange. remaining bolts sufficiently to allow the flywheel to

drawn off the crankshaft flange.

Withdraw the flywheel by screwing two bolts into the withdrawal holes remove the

Examine the flywheel face and the starter ring teeth for wear against the figures given in 'GENERAL DATA.'

If

necessary, remove the starter ring by drilling a hole

in

the ring and splitting

and

chisel_

Ensure that the bore of the new starter ring and its

mating surface on the flywheel are perfectly clean and free from burrs. Heat the starter ring uniformly to the

temperature given in 'GENERAL DATA.' The strip

of

temperature-indicating paint on the starter ring will change from greyblue to buff colour when the temperature

Transmission

two

remaining flywheel

it

is

correct.

Unscrew the two

be

tin. UNF.

in

the flywheel, and

bolts_

across the hole with a hammer

Section Aa.31

REMOVING AND REPLACING

THE

ENGINE SANDWICH PLATE

Remove

the flywheel (Section

Remove the starter motor

Unscrew the set bolts securing the sandwich plate to the cylinder block, and pull the sandwich plate three dowels which locate it on the cylinder block. Remove

Replacement

using a new joint washer between the sandwich plate and the cylinder block.

the

Transmission

Aa.30).

the

sandwich plate joint washer.

is

a reversal of the foregoing procedure,

Section and

off

the

Section Aa.32

REMOVING AND REPLACING

THE

CRANKSHAFT AND MAIN BEARINGS

Remove the sump

(Section Aa.6), and the timing gear case cover (Section

Remove

Aa.22).

Remove the oil thrower from the front end of the

crankshaft and withdraw the oil pump driving gear and the crankshaft gear, using tool

18G

231

B.

Withdraw the two halves of the crankshaft

thrust washer from the front main bearing.

Remove the

sandwich plate

flywheel (Section AL30) and the engine

(Section AL31).

18G

the oil pump

231

and adaptors

-

..

_--'"

Place the heated starter ring, bore chamfer foremost, squarely the ring to hardwood across the ring and pressing or tapping until the starter ring the ring is cold the 'shrink' established and no further treatment

dowels are not a loose are

to ensure correct positioning of the flywheel.

Tighten the flywheel bolts

the torque figure given in 'GENERAL DATA.'

Check the flywheel alignment with a clock gauge,

against the figure given in

Lock the flywheel bolts and replace the rem

components by reversing the removal procedure.

on

the flywheel. The expansion should allow

be

readily fitted by placing a piece of

is

hard against its register. When

fit

will

be

permanently

is

necessary.

When replacing the flywheel check that the locating

fit

in their holes, and that they

free from burrs. The dowels are diagonally offset

in

diagonal sequence to

'GENERAL

DATA-'

a

;,,;",

70

it

Fig.

Checking the crankshaft

return

thread

Aa.35

rear

oil seal cover to oil

clearance

Aa

Fig. Aa.36

The arrow indicates the gauge paper used whell

checking the diametrical clearance

bearing

main

DIESEL ENGINE

of

a crankshaft

Fig. Aa.37

Checking the crankshaft end-finat

Remove the connecting rod bearing caps' and shells.

shel1s

keeping the replacement. and separate the connecting rods from the crankshaft.

Unscrew the two bolts holding the two halves of the crankshaft rear oil seal cover together. Remove the bolts securing the bottom half of the cover to the crankcase and remove the bottom half cover. taking

to

care not in

any way the top half of the cover should

and a new gasket fitted.

Remove the main bearing caps complete with the bottom halves of the main bearings. The crankcase and caps are marked for correct assembly. and the bearings and caps should always be replaced in their

original positions.

Lift the crankshaft out of the crankcase and remove the remaining halves of the bearings and the thrust

washers.

Thoroughly clean and inspect all the dismantled components and examine all bearing surfaces for wear or scoring.

Check the crankshaft endfioat and main bearing clearance against the figures given in

DATA.'

New bearings are prefinished to size and require any scraping or fitting.

When replacing the crankshaft lubricate all the bearings with clean engine oil and ensure hollow locating dowels are in position over the main bearing studs

Refit the crankshaft rear oil seal cover and check that the clearance between the cover and the oil return thread on the crankshaft is in accordance with the figure

'GENERAL DATA.' The ftat surface of the bottom

in half of the oil seal cover should be perfectly level with the crankcase surface

damage the gasket.

with their respective caps for correct

If

the gasket

before fitting the bearing caps.

to

which the sump

is

be

'GENERAL

is

mounted.

damaged

removed

do

not

that

the

Before attaching the connecting rods to the crank·

shaft. align the marks

in Section Aa.23.

Replace the remaining components

removal procedure. refill the sump with new engine oil.

bk:ed the fuel system of air as described in Section

and

Da.

on

the timing gears as described

by

reversing the

Section Aa.33

MODIFIED INLET VALVE LOCATING

A new type inlet valve locating key and thimble. and

a modified valve guide locating dowel have been

introduced on later engines. These parts. which facilitate the assembly of the valves to their guides. are interchangeable in sets with their equivalent parts referred to in

(.:.:::---;-.~

.....

,.':::..;/

f:·~

r1

:

.:

· .

:

::

:

:.:

· .

: :

· .

1

~

· .

:

~~~

/:

t:

..

,

. . .

.•.•

::..;.;.:;.."l

Section Aa.l3.

:

~

..

.....

Modified inlet valve locating details

I Thimble. 2 Key. 3 Dowel.

DETAILS

Fig. Aa.38

71

TRANSMISSION

HYDRAULIC

WESTERBEKE-PARAGON

INTRODUCTION INSTALLA

OPERATION. MAINTENANCE TROUBLE

REDUCTION

WARNER HYDRAULIC TRANSMISSIONS •

TION

SHOOTING

GEARS • • • •

. . . . .

• •

. . . .

. . .

CHART.

TRANSMISSIONS

. . . .

• •

. . .

. .

· . . . . . . . .

· . . . . . . .

· . . .

. . .

. .

Page

•

74

75

· 75

• 76

77

78

.85

91

.

73

I. SPECIFICATIONS

A.

Description

P200

Chart

MODEL

P300

P400

REDUCTION

RATIO

DIRECTION

OF

ROTA TION

P21R P31R P21L P22R P22L

P23R P23L P24R P24L P25R P25L

B. Model and

Each

serial

a the of

the

P31L P32R P32L P33R P33L P43L P34R P44R P34L P35R P35L

Serial

reverse

number.

name

plate,

transmission.

Numbers

gear

located

P41R P41L P42R

P42L

P43R

P44L P45R P45L

has

a model

These

MODEL

DIRECT

number numbers on

the

AND

DRIVE

DIRECT DIRECT

1. 5:1

1.

5:1

2.0:

2.0:1

2.5:1

3.0:1

and

are

on

housing

SERIAL

MODEL

1

NUMBER

AND

SERIAL

RIGHT

LEFT RIGHT LEFT RIGHT

LEFT RIGHT

LEFT

CHART

NUMBERS

74

P2·

P

2·

Gear.

G"or

Size

1 •

~

I R"du

Gear

: \

Si

Direct

Drive

REDUCTION

ction

Ztt

5J.

1234 .

Transmi

asion

R·

Right

Hand

Rotation

L • L

"ft

H

and

Rotation

GEAR

MODEL

L

5J-5678

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

1.5:

1 j

2.0:

1

,~:~~c'ion

2.5:

1 \

3.0:

1

AND

Ro'io

Unit

Uni t

SERIAL

R·

Right

L -

Left

NUMBERS

Hand

Rotation

Hand

Rota'ion

Unit

5J.5678·

Seriol

Trons-

S!:i~tn

No.

II.

INTRODUCTION

The Models P200, P300 and P400 hydraulic

transmissions

operation and dependability in

transmission pressure separated

Trans:qlission oil under

engage a forward

III.

INSTALLATION

A.

The installation use when the original removed installed, is

to be adapted

ment to a

B.

It

is mission tion of rotation of an engine this manual of the engine output end wise rotation and a counterclockwise rotation of the engine

A

letter transmission trated indicates whether the use

with a

engine.

C. The hydraulic

the engine in the following

1.

Insert

transmission

engine

2.

Place so that the matching holes in the

housing flange.

have been designed

is

se1£-

contained, having an oil system from engine lubricating oil

important that the engine and

rotations

rotation of the engine

- "R"

in Section It "SPECIFICATIONS",

and oil supply completely

pressure

or

reverse

instructions

transmi

for

servicing

or

when the

marine

is

two

adapter

the

engine.

are

as

the

crankshaft

of

the

a left hand rotation.

or

serial

right

transmission

3-1/2"

mounting holes in the

plate.

transmission

studs

transmission

as

non-original eqUip-

matched. The

direction'

as

transmission. A clock-

"L"

appearing on the

number

transmission

or

left hand rotating .

studs in opposite

go through two of the

for

marine

drive.

below

ssion

and

must

is

of

viewed from the

is a right

plate

is

attached to

manner:

against the

transmission

smooth

use.

The

systems.

is

used to

The

for-

are

for

has

been

be

re-

unit

transdirec-

defined in

rotation

hand

illusis

for

studs

TRANSMISSION

ward

drive

is

through a multiple disc clutch arrangement, a

reverse train. cooled through a

core,

water. with

Gear

model identification Section I, under

D.

E. Connect the oil

The

which

Paragon

either

reduction

4. Install and tighten four bolts with lockwashers housing flange into the engine plate. Remove the

and tighten the two remaining bolts with lockwashers through the mission

The

transmission

pling

propeller

mission, consequent damage to the engine, and boat hull during operation.

To align the coupling, move the

shaft, with attached coupling flange, toward

transmission

the propeller

miSSion shaft coupling flange

tact.

in contact throughout ference. The total runout

the faces should not exceed point. If the runout

tion the engine and attached

by loosening the engine support bolts and

adding

either

move the engine sideways to adjust the runout faces bolts and coupling before bolting the coupling flanges together. Connect the coupling flanges with bolts, lockwashers, and nuts.

mission.

while the

clamp

transmission

separate

is

in

transmissions

direct

"SPECIFICATIONS".

through the transmiSSion

housing flange.

must

be

shaft

in

order

shaft coupling flange and

The coupling flange faces should be

or

removing

end of the engine.

or

to align the coupling flange

laterally.

recheck

reverse

band and planetary

oil

turn

cooled

drive

ratios

numbers

3-1/2"

and

propeller

carefully

is

connected to the

to avoid vibration and

so

that the faces of the

their

exceeds .002",

shims

Tighten

the alignment of the

cooler

drive

is

circulated

external

by

are

or

reduction

and corresponding

are

studs. Install

aligned before the

transmission,

are

entire

or

gap between

.002" at any

transmission

to

raise

If

the engine support

lines to the

utilizes

oil

the engine

furnished

listed

shaft

propeller

circum-

or

necessary,

gear

and

cooler

gears.

in

adapter

trans-

cou-

trans-

in

con-

reposi-

lower

trans-

3.

Slide the

toward the engine so that the spline on

the shaft enters engine vibration dampener.

transmission

at

the front of the

the matching splined hole in the

along the

transmission

studs

F.

Connect the shift cockpit control page 5. valve

control

valve

Place

lever

control

station

lever,

the transmiSSion control

in the

cable

to the

shown in

neutral

from the

transmission

Figure

position and

on

75

adjust the shaft the cockpit in the control positions

neutral

hand

several

transmission

The

transmission

control

station hand

position. Move the cockpit

lever

to forward and

times

control

move fully into forward

lever

when the hand

is

cable

length until

lever

reverse

while observing the

valve

lever

valve

lever

or

reverse

moved into

motion.

should position forward

is

or

reverse exactly to the hand

lever

position, and should

neutral

is

in the

position when

neutral

position.

G. Remove the oil dipstick, shown in

on page 5, and fill the Type A

transmission

fluid to the

mark the dipstick. Replace the dipstick in the transmission

housing.

return

the

Figure

with

on

IV.

OPERATION

Principle

The are sure. the

transmission

external

returned,

distribution tube and

valve maintains the oil

closed

When

forward

livered which moves to planetary discs pling in the

reverse control oil under piston. The the case,

of Operation

transmission

operated

An

by

internal

oil

cooler.

still

until the oil

the

control

pOSition, oil

to the multiple

reverse

and

case

direction

drive

lever

to the

pressure

reverse

band around the

preventing the

forward

transmission

gear

type oil pump C1elivers

oil,

under

The

under

pressure,

relief

pressure

lever

under

clamp

the clutch

gear

then revolve

of engine rotation. The

is

engaged by shifting the

reverse

is

delivered

piston moves to

planetary from moving but allowing the to revolve to shaft in a

drive

direction

the 9utput

opposite to the rotation of the engine. With the neutral

poSition,

pressurized from entering the clutch piston band piston and the stationary

.

propeller

and

reved.

oil

undar

pressure,

transmission

to the

valve. The

by remaining

reaches

is

shifted to the

pressure

disc

clutch piston,

case

together. The

as

a solid

poSition,

to the

planetary

gear

planetary

or

control

lev~r

oil

is

or

shaft

drives

pres-

to the

oil

is

oil

relief

60

PSI.

is

de-

discs

and

cou-

so

that

reverse

clamp

gear case

gears

propeller

in the

prevented

reverse

remains

Starting

1. Always

Procedure

mission

start

the engine with the

in NEUTRAL to avoid moving the

boat suddenly forward

2. When the engine to idle

for a few and check the oil

if

necessary

to the

mark

is

moments. Stop the engine

transmission

to

on the

NOTE

ON

SUBSEQUENT

TRANSMISSION

ST

OIL LEVEL CHECKED BEFORE ENGINE,

WHEN

ENGINE

CHECKED.

3.

Start

the engine again, with the in NEUTRAL, and allow the up to operating

4. Shift the REVERSE stall

when the

FORWARD

mission

in NEUTRAL before

temperature.

transmission

as

desired.

transmission

or

REVERSE,

engine.

It

is

recommended that shifting speeds the

below 1000 RPM, and

800 RPM,

or

idle engine range, to long the life of the engine, and boat. higher

recommended

EMERG

engine

ENCY

speeds,

practice.

or

back.

first

started,

oil level. bring transmission

the oil level up

dipstick.

ART- UPS, THE

MAY

BE

RUNNING

THE

OIL

transmission

enginetowarm

into

FORWARD

If

the engine should

is

shifted

place

the

restarting

be

preferably

transmission,

shifts

but

this

may

is

trans-

allow

Add

IS

trans-

done

pro-

be

not a

it

or

to

the

at in

at

76

v.

MAINTENANCE

A.

Lubrication The

Models

missions

dent

of

The

units splash recommended Type

transmissions

The of model. the checked tory

When filling after running

that

from

A",

quantity

installation,

The

mark

operation.

an

the

oil

P200,

are

self-contained

the

engine

are

lubricated

its

is

commonly

in

automobiles.

of

oil

as

level

on

the

periodically

for

the

oil

change,

for

a few

cooler

P300 and P400

units,

lubricating

by

pressure

own

oil.

The type

"Transmission

used

for

depends

well

must

dipstick

first

check

minutes

and the

upon

as

the

be

maintained

and should be

to

ensure

time

the

to mnke

various

trans-

indepen-

systems.

and by

of

Fluid,

automatic

the

angle

reduction

satisfac-

or

refilling

level

after

certain

passages

oil

at

are

full.

on

the

of

the level oil

level

engine.

The

changed

under number oil

changes tions. bottom

reduction

B.

Adjustments

No

adjustment

WARD

reverse

sate

reverse

If

necessary,

dipstick

transmission.

should be

oil in the

every

normal

of

Drain

of

drive

for

is

hours

varies

the gear

band

lining band

checked

checked,

plugs

reverse

housing.

multiple

is

TRANSMISSION

refill

to

ensure

transmission

100

conditions.

that

with

is

necessary

self

wear,

adjustment

The

each

before

hours,

can

the

are

gear

disc

adjusting

so

proper

transmission

time

or

be

operating

located

housing and the

clutches,andthe

that

to

the

operation

the

engine

running the

should

each

season

However,

run

between

condi-

at

for

the

to

compen-

no

external

is

necessary.

mark

oil

be

the

FOR-

COUPLING

FLANGE

PARAGON

TRANSMISSION

OIL

TO

COOLER

77

C.

Trouble

Shooting

Chart

PROBLEM

GEAR INOPERATIVE

Drive with or

Shaft

selector

reverse.

does

valve

not

operate

in

forward

POSSIBLE CAUSES

1.

Low Oil

Pressure.

AND

METHODS

a.

Low lubrication.

b.

Faulty Oil obstruction and

c.

Plugged Clean

d.

Oil and

Clean control cloth

e.

Defective

seal

f.

Defective and

OF

CORRECTION

oil

supply. Add

oil gauge.

gauge slow

in

bleed

oil

gauge liLe.

oil

lines

or

pressure

relief

sticking.

valve

and

val ve housing

to

free

valve,

pistons

rings.

replace

Replace

oil

pump. Check

if

oil,

Replace

to

register,

oil

gauge

or

passages.

valve

Remove

valve

relief

bore

with

or

replace.

and oil

seal

necessary.

refer

to

S-auge.

air

or

line.

Clean

scored

valve.

in

crocus

distributor

rings.

for

wear

2.

3.

High Oil

Reverse engaging Gear

Cage.

Temperature

Band not

Planetary

a.

Low oil supply. Add lubrication.

b. Low

c.

d.

e.

f.

water

Add

,,'ater,

Plugged

Clean

screen.

Collapsed

inlet

hose.

Air

leak

line~

Raw

Replace

water

raw

or

in

damaged.

g.

Clogged

or

Remove and

a.

b.

Reverse

Replace

Defective

Replace

b"'o1d

lining.

reverse

"0"

level

in

cooling

and

check

water

inlet

disintegrated

Replace

cooling

water

suction

pump

impeller

Replace

dirty

impeller.

oil

clean

lining

piston

ring.

oil,

for

screen.

hose.

line.

cooler

worn

"0"

refer

system.

leaks.

water

suction

worn

element.

out.

ring.

to

or

78

4.

Failure

Assembly.

5.

Failure

Gear.

of

Planetary

of Reduction

Remove

for

defective

defective Remove

check

for

Replace

gear

case

or

damaged

or

damaged

reduction

defective

assembly,

parts.

gear

assembly

or

d::unaged

or

damaged

and

Replace

and

parts.

check

TRANSMISSION

PROBLEM

GEAR

DRAGGING

Drive forward Selector position.

GEAR

SLIPPING

ENGAGE

With

Selector

or

reverse

Shaft

or

Valve

rotates

reverse

in

neutral

OR

Valve

position.

either

with

SLOW

in

forward

TO

POSSIBLE CAUSES

1.

Defective

2.

Clutch Defective

Clutch

Plates.

Piston

Spring.

3.

Binding

in

Assembly.

1.

Low Oil

Pressure.

forward

Release

Planetary

AND

lfiETHODS

Forward

OF

clutch

CORRECTION

plates sticking. Remove clutch replace.

Forward

broken

a.

clutch piston

or

weak. Replace

Bearings in

gear

case.

and

parts.

b.

Input shaft

bearings

causing misalignment of input shaft.

necessary

Inoperative',' (1).

See

Replace

"Gear

warped and

release

gears

worn

Replace

parts.

plates

and

spring

spring.

excessively

necessary

worn excessively,

INTERNAL

LEAKS

AND

EXTERNAL

2.

Worn

forward

Plates.

3.

Reverse engaging

1.

Water

in

Oil.

2.

Excessive Engine

Flywheel Housing.

3.

Oil on

Exterior

Marine

4.

Loss

of

Transmission.

Clutch

Band not

Gear

Case.

Lubricating

Oil

in

Crankcase

of

Gear.

on

from

Remove

for plates.

See

a.

b. Oil

Defective

or

Replace

a.

b. Defective

a.

forward

wear

excessively,

"Gear

Hole

water

Inoperative", (3).

in

oil

cooler

to

seep

Replace oil

and

cooler

replace.

on

front

seal.

gaskets.

end plate

Oil seeping for

too high oil level.

rear

oil

seal.

Check

for

defective

seal.

clutch

into oil

cooler

from

end oil

plates

replace

element

compartment.

element.

Check

oil

seal.

breather.

seal.

gaskets

and check

clutch

permitting

gaskets

Check

Replace

and

79

VI.

PARTS

Each

part

has

a key the key number number

illustrated

number

in the

and

name.

to the

parts

in the exploded views

and

an

list

arrow

part.

to

pointing

Refer

determine

to

the key

the

from

part

ALWAYS NAME, AND TRANSMISSION ORDERING

GIVE

TRANSMISSION

THE

PARTS.

PART

MODEL

SERIAL

NUMBER,

NUl\1BER \VHEN

PART

NU~lBER,

80

Key

No.

2 3 4

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

42 43

44 45 46

47 48 49 50

51 52 53

54

55

56

57

58

59

60

61

62 63 64 65 66

PARTS

Description

Gear

Case

1

Gear Long Pinion Pinion

5 6 7 8 9

Roller Long Pinion Engine Engine Short Roller Short Short

Pinion Case Capscrew Engine Direct

Propeller

Propeller Steel

Bronze Screw Screw Screw

Forward

Forward Clip Lockscrew

Oil

Distributor Tailshaft Tailshaft Woodruff Key Spring

Retaining Ring Cover Distributor Tailshaft Tailshaft Retaining

Ball

Reduction

Reduction Adapter Capscrew Gasket

Crescent

Plain Lockwasher

Capscrew

Locknut Lockwasher

Capscrew

Lockwasher

Ball Direct Oil Seal Gear Rear Housing Dipstick

Front Reverse

Baffle

Flat

- Needle

Case

Thrust

Bearing

Pinion

Clip

Clutch

Bearing

Head Socket

Bearing

Shaft

Gear -Roller Gear

Pinion

Bearing Pinion Pinion

Half Coupling Gasket

Bearing Spacer

Shaft Locking

Gear

Thrust

Drive

Tailshaft

Gear

Plate

Clutch Collar Collar Collar

Piston Piston Piston

Screw

Thrust Seal

Retainer

Gasket

Tube Needle Needle

Ring

Pinion

Adapter

Plate

Steel

Washer

Drive

Tube

Gasket

Band Housing

Bearing

Pad

Washer

Thrust

Plate

Spring

- Needle "0"

"0"

Collar

Seal Rings

Washer

Thrust Thrust

Tailshaft

Plate

Seal

Plate

Capscrew

Spacer

Bearing

Spacer

Tab

Washer

Bearing

Ring Ring -

Race Bearing

Outer Inner

LIST

Key

No.

67 68 69 70

71

72

73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130

131

132

133

Description

Ho.d Down Spring Socket Head Pipe

Plug Control Capscrew Lockwasher Plain Control Control Control Control Control

Control

Cover Reverse Reverse

Piston

Reverse Retaining

Reverse

Piston

ReliM Valve

Relief

Front

Front Front Roller Pump Pump

Inner Outer

Pump Lockwasher Capscrew Dipstick Flat

Head Socket Breather Pump

Reverse

Pipe

Plug Brass Brake External

Detent Detent

Capscrew

Detent

Lockwasher Capscrew

Reduction Pipe

Plug

Oil

Seal Gear Lockwasher Loelmut

Internal

Bearing Retaining Ring

"0"

Ring Suction Tube Washer

Pipe

Lever

Washer

Lever Lever

Bushing

Lever

Pawl

Valve

"0"

Valve

Valve Retaining Ring

Piston Piston

Back

Piston Band Roll Band Roll

Back-Up

Valve Spring Valve Retaining Ring Valve Valve

Valve Housing Plate Plate Plate

Bearing Pert Housing

Pump

Pump Housing

Key

Washer

Band Support

Seal

Ball

Spring

Half Coupling

Gear Assembly

"0" and Shaft

Up

Plate Shaft

Ring

Band

Lever

Plate

Plug

"0"

Oil Seal

Thrust

Plate

Gear

Band

Socket Head Cap

Washer

Gear

Housing

TRANSMISSION

Plug

Ring

Assembly

"0"

Ring

Washer

Capscrew

Screw

BJ

GEAR

CA

E

ASSEMBLY

S

REVEJ

r----------._._

FRONT

END

."

__

.

PLATE

J®

AND PUM

-

--------

'24

31

/1

P

ASSEMBLY

-'.

"--

••

82

117

116

\ &

100

101

102

/ 103

\

"---

~

--

"

~

-------------

/ 104

'. " /

-

/~/

105

/106

~\

\

119

E

118

TRANSMISSION

SE

GEAR

"

HOUSING

\

~

,@

,.

. - '

'

•...

,..

1 .

-~_'--

---109

~Q.

(.,~.

,~~,

~

40'

'41

.

'.

\\

42

\

jl

...

.

.-

-',

R[OUCTION

DAlvE

.,

ASSEMBLY

44

\.

~5

'~6

~

"

I I I

; ! /

' /

i

/ '

••

\,

~

""

\ \

.~~

~-

\

.,

..

COVER

S!

~2

80

SI

81----tr

82

83

89

ASSEMBLY

-76

I

-75

71 72

73

74

70

77

78

79

RELIEF

VALVE

ASSEMBLY

B~

91

92 93

._~94

95

MPLETE

I

.••

·

~

'.

e

. , -

, !

.J

~

,I

ASSEM

0

BL

Y

,,~

4

113"

::""~~'~~yl~.

86/

87

88

REDUCTION

~

87

128

"

GEAR

ASSEMBLY

127

83

REDUCTION GEARS

Description The

gears

Westerbeke

consist and a drive of

reduction units manual

Model

The a transmis

The grams

parts

and

model

plate

parts

are

or

and

Part

affixed

sion.

are

in

regards

assembly.

To

order

Manual"

and

part

numbers

giving

number ~ with

of

Lubrication The

with gears.

reduction

the

same

Refer

Adjustments

There to proper

are

maintain

rUJ?Iling

of

an

gear

ratios.

used

integrally

hydraulic

Serial

Numbers

and

serial

to

list

accompanying

intended

parts

refer

complete

the

transmission.

gears

oil

as

to

"General

no

adjustments

the

condition.

Paragon

internal

that

offers a variety

The

with

reverse

numbers

the

cover

only

to

identify

to

disassembly

to

"Parts

description

Model

are

used

in

the

Data".

necessary

reduction

reduction ring

gear

reduction

either

gears.

are

on

of

the

dia-

the

and

List

and

Serial

lubricated

reverse

gears

in

Disassembly This

guide since details

manual

in

servicing

these

except

As

in any

liness workmanship apply. are

is a must

as

follows:

1.

Use only clean fluid ing

2. Use only clean oil for lubrication when

Neverpress

3. the force balls.

4. Never bearings

5. Use only

in

removing

capscrews.

6.

Replace gaskets with terial.

of

Reduction

is

intended

the

units

or

are

for

size.

servicing

and all

washing of

pressing

a ball bearing

is

carried

use a hammer

in

jllace.

properly

or

Unit

to

serve

reduction

similar

operation,

rules

Some of these

in

parts.

parts

together.

sized

securing

gears~

in

for

any clean-

so

through the

to

drive

wrenches

nuts and

DeW

as

most

clean-

good

rules

that

ball

ma-

a

ALWAYS GIVE MODEL NUMBER AND SERIAL NUMBER

WHEN ORDERING PARTS.

OF

TRANSMISSION

85

7. Work on a gear from

Before the

removing

reverse

bricating

reduction

the

oil

teeth nicks

gear,

from

unit.

clean

bench and and oil and

scratches.

the

reduction

drain

the

transmission

seal

all

unit

of the

DISASSEMBLY NEED BE CARRIED OUT TO CORRECT THOSE

WHICH

ONLY

AS

INTERFERE

FAR

AS

NECESSARY

DIFFICULTIES

WITH

PROPER

MARINE GEAR OPERATION.

DISASSEMBLY OF

1.

Remove oil

of

reduction

oil

from

unit. Make

lubricating

gear

unit.

2.

Remove

ers

(17)

capscrews

from housing and straight until

drive

3.

Bend tang of locknut suitable from

back

reduction

pinion.

(16).

wrench and lift

shaft.

drain

gear

oil

flange of

slide

10ckwasher(lS)away

REDUCTION UNIT

plug

(1)

from

housing

(2)

and

certain

is

removed

(18)

from

and lockwash-

reduction

entire

reduction

approximately 3 inches

unit

clears

reduction

Remove locknut using

lockwasher

protect

surfaces

from

lu-

and

bottom

drain

that

all

reverse

gear

unit

from

6.

Remove

next to gear from

7.

If

seal

8.

Remove Woodruffkey

shaft spacer

9.

Press

shaft

10.

Remove

(8)

move

(6).

retaining

ball

housing and

housing.

necessary

(5).

and

remove

(11).

ball

using two

caps

from

ring

rim

gear

INSPECTION

All

parts

should be thoroughly

before inspection.

1.

cessive

Ball

wear

bearings

indications of

2.

3.

balls

All

and

races.

gear "pitch tern

teeth should

line

or

excessive

Examine oil

pitting"

lips.

bearing

press

to

replace,

seal

bearing

holes

crews

of flanged

(7)

should be

should corrosion

wear.

seal

for

ring

(4)

(3)

inside

ball

(13)

washer

(10)

in

flange.

(9) and

shaft

from

Parts

replaced.

be

examined

and pitting on

be

I uneven

rough

from

groove

reduction

bearing

remove

from

flanged

(12). and

from

flanged

lockwashers

and

re-

flanged

shaft

cleaned

showing

ex-

for

examined

wear

or

for

pat-

charred

(3)

oil

4. Remove

gear

type

tire

assembly coupling and coupling

S.

Support flanged approximately flanged gear

housing.

86

gear

half coupling

puller

under

press

from

assembly.

reduction shaft

assembly

2

shaft

assembly

or

by flange of

against

gear

inches

(14)

supporting

gear

shaft

to

housing

can

from

so

drop

and

reduction

with

en-

half

force

that

free

press

4. Hetaining burrs

5. All

gaskets

rings

or

deformities.

should be

should

replaced.

be

·checked

ASSEMBLY OF REDUCTION UNIT

1.

Replace gear

2.

Press

oil

drain

housing (2).

ball

bearing

plug(l}

(3)

Into

into

for

reduction

3.

4.

5.

6.

7.

gear

housing

ring

(4)

If

removed

oil

seal

Place (7) and in

ring

Place (9)

and flanged to

ring

Press shaft. next

to

washer

Install

flanged

(2) and

into

groove

for

replacement,

(5)

into

reduction

flanged

line

up

shaft

holes

gear.

lockwasher

insert

shaft

and

gear.

ball

bearing

Place

ball

(12)

spacer

bearing

over

Woodruff

shaft.

install

(6)

in

flange with

(8)

capscrew

secure

(10)

(11)

and

shaft

(13)

ball

gear

over

into

flanged

onto

place

into

retaining

bearing.

press

housing.

ring

those

caps

crew

hole

shaft

flanged

over

shaft

to

spacer.

keyway

new

gear

in

seal

in

10. Support with

large

gear

half and into is

seated

must

be

taken

ling

and

key

gether.

11.

Place flanged washer

lockwasher

shaft

in locknut (16) onto suitable

12. Bend one on locknut.

13.

Install two plate

two

OPPOSite

.

TRANSMISSION

unit

on

inside

of flanged

end of unit down and

coupling (14) onto

ball

bearing

against

to

in

shaft

with

slot

on flanged

(3) until coupling

ball

bearing.

line

up

keyway

before

-(15)

tang

on

over

inside

shaft.

shaft

and

wrench.

tang

of

lockwasher

studs 3 1/2

holes

inches

in

reduction

press

shaft

in

pressing

end

of

secure

into

long into

adapter

shaft

end

Care

coup-

to-

of

lock-

Place

using

slot

8.

Place end

ing (10) on housing mallet.

9.

Turn down and

until bearing

reduction

offlanged

flanged

by

tapping

unit

over

press

spacer

(3)

in

gear

shaft

and

shaft

housing

with

small

on

center

(11)

is

reduction

housing

start

into

end

of flanged

seated

housing.

over

ball

bore

with a

of

housing

against

small

bear-

in

soft

shaft

ball

Position

14. studs

with

housing

gear.

It

reduction

gear

teeth.

15.

Installiockwashers (18)

around

housing

and

reduction

oil

drain

gear

plug

and Slide onto

may

be

necessary

gear

slightly

(17)

flange of

tighten

uniformly.

assembly

at

reduction

to

properly

and

capscrews

reduction

over

bottom of

drive

to

rotate

mesh

gear

87

REDUCTION

ASSEMBLY

8

DRAWING

4 3 5

I I

NOTE

S.ERVICE

OTHER

SEE

APPROPRIATE

MANUAL

REVERSE

FOR

GEAR

PARTS

88

10

II

12

13

14

16

TRANSMISSION

PARTS

7

LIST

6

AND

8

/ 9

/

\

,--.

EXPLODED

10

:""IIto.::-.....~

--.::::::-.....;:

VIEW

II

_.-------------

----

-.----_.___

-------\

----

12

i

! 4

/ 3

\

~13

------------

-----------

i

.J

:

KEY

NO.

1

2

3

4

5

6

7

8

I

/

I

'rfJ

14

I~

Fig.

2

KEY

DESCRIPTION

Drain Plug 10 Reduction Gear Housing

Ball Bearing Ball

Bearing Retaining Ring Oil Seal 14 Gear Half Coupling Flanged Shaft

Ring Gear

Lockwasher

NO.

11

12

13

15 Lockwasher

16 Locknut

17

/

16

DESCRIPTION

Ball

Bearing Spacer Seal Washer Woodruff Key

Lockwasher

9

Caps

crew

18

Capscrew

89

TRANSMISSION

DESCRIPTION The

Westerbeke Engines hydraulic gear

The of clutch, and control tained necessary provide operation. for the input direction. provide obtained

Oil cent which operates to

provide

are

direct

assemblies.

direct

a

drive

planetary

a

reverse

pressure

valve.

in a cast

forward,

all

forward

speed

of

shaft

quieter

with

pressure

type

is

keyed

at

screened

also

shafts

A

the speed, Helical

pump,

regulator. From

directed

to

ings~

lubricant parts

ing is reverse

the

bushings

requiring

whenever

and

positive

regulator

through

is

it

should

conditions.

WARNER

Six-346

furnished

drive

transmission gear

set,

clutch,

regulator

All

of

iron

housing

and

reverse

direct

drive

operation.

output

shaft

but

gearing

operation

spur

is

provided

gearing.

the

to

the

transmission

oil

valve

the

proper

and

anti-friction

lubrication.

present

the

in

forward,

front

be

at

noted

HYDRAULIC

and

Four-230

with

Warner

and

reduction

consists

a

forward

an

oil

and

these

are

along

connectors,

and

neutral

ratio

in

In

is

the

is

reverse,

equal

opposite

used

than

by

the

drive

gear

shaft

input

to

the

pressure

the

circuits

A

flow

the

required

pump

is

that

neutral

pump,

rotary

con-

with

to

used

to to

can

be

cres-

of

and

speed

oil

is

bear-

of

turn-

supply

and

TRANSMISSIONS

be

shifted

the

letter

is

located

poppet

if

the

ball

is control or

repositioned, remote lever both

does

directions.

to

the

"F"

in

its ball. shift

The

lever

permanently

lever

is

control

not

transmissions

Gear.

electrical

LUBRICATION The

properties transmission to

the

proper system. important automatic Type

"A"

PROCEDURE

are

Therefore,

that

transmission

be

used.

FOR

TRANSMISSION

When should

full tity the turned

short

including

PROCEDURE

filling

be

added

mark

of

oil

on

depends

installation.

over

time

in

the

at

cooler

the

order

FOR

LEVEL

point

on

the proper Warranty

poppet

removed,

changed

or

if

and

transmission

have

sufficient

This

equipped

shift

of

the

extremely

function

the

recommended

FILLING

WITH

the

transmission,

until

dipstick.

upon

The

engine

to

and

CHECKING

where

case

casting,

position

is

spring

in

any

linkage

does

not

with

control.

oil

used

of

the

it

is

fluid

OIL

it

reaches

the

unit idle fill

all

cooler

it

covers

by

cancelled

and/

or

if

manner,

between

shift

travel

apply

Warner

in

important

hydraulic

extremely

(ATF),

The

quan-

angle

should

speed

for

circuits,

piping.

OIL

and

the

or

the

in

to

the

oil,

oil

the

of

be

a

The

unit

has

of

oil.

Both

coaxial, for and flange

the

installation

the

for

with

output

shaft.

CONTROL The

position

transmission

seals

input

and

the

shaft

connecting

LEVER

of

the

when

to

prevent

output

input

shafts

shaft

of a drive

provided to

the

POSITION

control

in

forward

escape

are

splined

damper,

with

propeller

lever

should

a

on

The

oil

level

mediately sufficient transmission on

the

dipstick

assembly

case need until face

The

need

to

determine

only

the

cap

surrounding

transmission periodically and

oil

should

after

oil

added oil

assembly.

be

or

to

should

shutting

to

level

not

be

the

inserted

plug

the

should

assure

be

added

be

checked

off

again

to

the

The

threaded

oil

into

rests

oil

on filler

be

proper

if

im-

engine

bring

full

and

the

mark

dipstick

into

the

level.

the

case

the

sur-

hole.

checked

oil

level,

necessary.

91

It

CHANGING

It

is

recommended

sion

After

oil

be

draining

removable thoroughly the

mended

transmission

oil

OIL

changed

oil

cleaned

(ATF)

that

once

from

screen

before

with

Type

the

each

the

"A".

transmis-

season.

unit.

should

refilling

recom-

the

be

REDUCTION

The

reduction conjunction The

reduction

planetary

input

It

is tions suitable

prevent

when

pulsion.

operation

the

boat rotate. culated oil

pump

heating

may

result

peller

Except forward neutral

1000

engine.

gear

revolutions

recommended using

locking

rotation

the

boat

If

and

causes

lubricating

through

is

and

shaft

in

an

to

at

rpm

or

to

marine

GEAR

gear

with

the

gear

set

a

reduction

device

of

is

not

the

marine

the

the the

not

in

damage

unless is

prevented.

emergency.

reverse

engine prevent

gear.

BOX

box

operates

direct

box

consists

which

to

that

a

fixed

all

reduces

gear

or

the

propeller

under

gear

forward

propeller

oil

will

gear

because

operation.

to

the

marine

rotation

drive speeds damage

drive

installa-

have

brake

direct

is

motion

shaft

not

be

of

the

shift

through

in

unit.

of

the

ratio.

to

shaft

pro-

not

in of to

cir-

the

Over-

gear pro-

from

below

to

the

a

92

93

TABLE

OF CONTENTS

INTRODUCTION GENERATOR

General. Component Visual Question and Answer Troubleshooting

Flow Chart

Procedures

Inspection

A.

No Unstable

B. C. D. E.

Unbalanced Generator Terminal

No

Voltage Voltage Output Voltage Voltage Unstable Cycling Unbalanced Terminal

B. C.

No D. E.

Testing F. G.

Testing H.

J.

K. L. M.

Reconnection N. Voltage P.

Generator Q.

Voltage

..••••...•....................................................

SECTIO.,.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . .

Location

Output Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .

High or Low Output Voltage Field

Circuit

Troubleshooting

Builds

150~;

Output

Buildup

Flashing

AC

Testing

Testing Testing Testing Testing

....................•..................•.................

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

Output Voltage

Breaker

Guides.

Buildup

the

Power

Ll Diodes SCR's Transistors. Generator Generator Stator Brushless Brushless

Reference

Disassembly

Adjustment.

.......•.............................................

Up, But Circuit Breaker Too

High

or

More

Than Ratt'd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage.

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

Voltages.

Field

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

to

Exciter

Reactor

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

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

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

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

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

Rotor.

Exciter Exciter

Circuit

. . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . .

Guide.

...........

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

Trips

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

Voltages.

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

\lr

Too

Low

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

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

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

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

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

Rotor Stator.

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

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

. . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . . . • . . . . . . . . . . . . . . .

Trips

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

..

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

'. .

..

.. ..

..

" 8 .. ..

..

10

"

10 11 12

..

13

..

14 15

..

16

~i'

18 18 18 19

..

20

..

21

..

22

..

23

..

23 24

, 25

•.

25

1

4 4 6 7 7 8

9 9

94

LIST

OF

ILLUSTRATIONS

FIGURE

12-17.

1.

2.

3.

4.

7.

8.

9-11.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Static

Exciter RntClting Top Voltage Flashing

Testing

Testing Testing Testing Test Testing Testing Testing Connecting Reconnection VR21 Generator

Adjusting

(Brush

View

Regulator

the

Diodes

SCR's

Transistors

Rotor

ing

Rotor Stator Exciter Exciter

Printed

of

Disassembly Voltage

Design

less)

Exciter-Regulator

Field

...

for for

Windings

Lead

Diagram

Circuit

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

Exciter

Printed

..

. .

Grounds an

Open

Armature Field

..........

From

Terminal

...........

Board

on

VR21 .

..

.....

...

Design

Chassis

Circuit

......

.........

Board

.

63

LIST

Assembly.

Location

.

..

.

OF

. .

..

TABLES

:J

17

18

19

20 21

21

22

22 23 23

23

24

2S

Table Table

1.

Resistance

2.

Resistance

Values Values

for for

Rotors

Stators.

.

21

22

95

Tliere They field

The

rig

and was range

The

are

excitation.

Static

used

of

Brushless

assembly

The

brushless

25

KW

-175

NOTE:

section

two

generator

basically

Exciter

collector

on

25

KW

i~

place

KW.

Unless apply

the

(brush

rings

some

-90

KW.

design

of

design

otherwise

to

both

aeslgns

same

for

of

the

type)

field

earlier

us~u

except

design

excitation.

uses a rotating

the

brush

rig

is

standard

specified,

designs.

un

ln~

for

the

uses a brush

models

rectifier

for

field

on

all

the

GENERATOR

1 U

gi:im

UK

senes.

method of

This

design

within

exciter

excitation.

models

tests

In

the

from

this

below

1.

2.

3. On

4.

access

control

Exciter-regulator

on

the

rear controlled cessible

On

static-excited

the

brush

through

Figure

large

1.

brushless

mounts

directly

assembly

See

Figure Voltage-regulator Board) panel of

mounts

(left

control

to

box.

portion rectifiers).

for

testing.

rig

inside access

models,

with

all

2.

inside

side);

box

to

generator,

chassis

of

the

and

See

generators.

of

end

holes

rotating

behind

diodes

PC

Board VR21

the

turn

1/4

gain

access.

remove

assembly

generator;

diodes

Figures

gnue

VR22 mounts

SCR's

are

1-3.

brushes

bell

housing;

in

the

end

exciter

exciter-regulator

accessible

for

(Printed

control

turn

box

on

fasteners

See

Figure

section

(silicon

easily

attach

inspect

belL

assembly

chassis

servicing.

Circuit

the

rear

on front

4.

ac-

to

See

EXCITER

REVOLVING

VR-22

CHASSIS

GENERATOR

REGULATOR

ASSEMBLV

FIELD

END

VIEW

OVERSPEED

(GRILLE

ENDBELL

SWITCH

REMOVED)

__

~

,

--~

'--

STATOR

RESIDUAL

IN

ROTOR

PROCESS

EXCITATION

\oII::~---~=

MAGNETISM

STARTS

SCHEMATIC

AC

SOLID

STATE

EXCITER

...

ND

VOLTAGE

REGULATOR

.....

-4~

208-240

VOLTS

AC

C

("I

96

FIGURE

I.

STATIC

EXCITER

DESIGN

EXCITER-REGULATOR

CHASSIS

ASSEMBL

Y

\

OVERSPEED

SENERATOR

SWITCH

END

VIEW

WITH

(SRILLE

RECTIFIERS

REMOVED)

AL

TI:RNATOR STATOR

208-240

VOLTS

AC

VOL

REGULATOR

EXCITATION

TAGE

EXCITER

ARMATURE

SCHEMATIC

FIGURE

3.

TOP

2.

ROTATING

o

VI

EW

(BRUSHLESS)

CHECK

LCHECK

OF

EXCITER·REGULATOR

EXCITER

THESE

ACCORDING

THESE

ACCORDING

DESIGN

DOUBLE

TO

PROCEDURE

SINGLE

TO

PROCEDURE

CHASSIS

LEAD

RECTIFIERS

ASSEMBL

SCR'S

"F"

"E"

Y

VOLTAGE

PRINTED

VR21

REGULATOR

CIRCUIT

FIGURE

BOARD

4.

VOLTAGE

....:;;;;;;;;;..~;;.;..~~-...;;;.;;;;;;;

REGULATOR

PRINTED

.......

CIRCUIT

BOARD

LOCATION

97

Westerbeke FOUR-230 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual