Westerbeke FOUR-60 Technical Manual And Parts List

TECHNICAL

. . . . . . .

WESTERBEKE·

-

1-5.

hp. ,.,i.--i-Dies.el Engine

..'.

MANUAL

.

..

, : .

AND

PARTS

LIST

M'ODEL

!:

publication

Edition 2

-July

FOUR-60

Numlter

20~O

16521

WESTERBEKECORPORATION

AVON

INDUSTRIAL

PARK.

AVON.

MA

02322.

TEL:

(61

?j

58fJ..7100

INTRODUCTION

This
Westerbeke
for

The
nism
case,
it
system

Therefore,
preventive
give
the
filter

contamination
Another
lubricating

The
handling

and

forms

Unremitting

many

ever,

you.

manual

those
diesel

is

essentially

its

crankshaft

has

the

same

and

maintenance

to a gasoline

fuel,

diesel

in

lubricating

elements

important

oil

and

their

the

functions

thousands

is

the

concerned
engine

reverse

describes

Model

sort

it

follows

at

(i.

e.,

designed

engine

firing

place

care

of

treatment

the

Four-60

with

closely

the

is

of

and

engine.

the

water,

factor

does

its

is a single

of

and

hours

resembles
same.
one

valves~.

redqction

to. a

as

and

cooling

time

is

specifically

differ

fuel.

both.

attention

'of

the

operation.

Marine

the

of

great

that

The

periods

sediment,

the

from
Carburetor

service.

product

Diesel

operation

the

Its'

cylinders

the

same

camshaft,

gear.

extent
which
most

use

component -the

at

important

systems.

specified

of

the

for
the

the

factory

will

adjustment

Engine.

and

gasoline

are

general

pistons,

. . .

that a diesel

any

intelligent

Replacement

is a must

etc.)

diesel
gasoline

What

in

same

engines.

and

ignition

have

the

receive

and

and

is

maintenance

engine

arranged

type

connecting

factors

the

fuel

brand

engine,
Fuel

resulted

manufacturer

in

service.

inasmuch

as

that

engine

and

are

and
system

of a "High

however,

systems

Injection

maintenance

designed

of

above

careful

proper

of

in

its

of a gasoline

rods

requires

operator

fuel

and

frequent

is
Detergent"

in
are
Pump -which

an

engine

cannot

This

of

to

be

a ,guide

these

as

closed

and

maintenance

also

the

done

part

diesels.

the

mecha-

crank-

engine;

lubricating

the

same

would

lubricating

checking

essential.

diesel

method
away

capable

control

rests

how-

the

of

for

of

with

per-

of

with

(

Whenever
numbers

Please

The

serial

2

service

with

supply:
For
10

of

number

parts

engine

Four-60

11951

;s

are

model

Marine

LUBE

stamped

ordered.

and

Diesel

OIL

on

number.

Engine

FILTERS

the

name

always

As

give

an

example:

No. 3870

complete

description

and

plate affixed to the exhaust manifold.

part

WESTERBEKE

15 h.

p.

Mini

MODEL

Diesel

FOUR-

Engine

60

(

INTRODUCTION

PHOTOGRAPHS
INSTALLATION

GENERAL
INSTALLA
OPERATION

LUBRICATION

COOLING

FUEL

SAO

TRANSMISSION

TION

SYSTEM

SYS

TEM

DATA

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

TABLE

. . . . . . . . . . .

. .

,.

.

DRAWINGS

.....

SYSTEM

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

. . . . . . .

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

.'

.... " ...................

~

.....

.....

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

OF:'

CONTENTS

..

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

.'

. .

'.'

.

'.

. . . . . . . . . . . "

e' ' •••••

'

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

'

......

,,'

Page

~

.:

.

'

••

"

.

.

SECTION
SECTION

.

SECTION

No.

2

4
5

6

9

17

A

B
C

45

(

SSL

TRANSMISSION

.,It

62

3

COLD

START

SOLENOID

TACH

OIL

PRESSURE

OMETER

DRIVE

SWITCH

\

..!!L-~-------

LUBRICATION
FILLER

SECONDARY
FILTER

SCREW

FUEL
UNION

COLD
GLOW

FRESH

SEA

SEA

.

PUMP

OIL

CAP

FUEL

BLEED

INJECTOR

NUT

START
PLUG

WATER

PUMP

WATER

PUMP

WATER

DRAIN

SURGE

TANK

FILLER

CAP

ALTERNATOR
OPTIONAL

AIR

CLEANER

OIL

SUMP

DRAIN

PIPE

'RIMARY

FUEL

FILTER

~

(RemOve

after

installation)

LIFTING
BRACKET

HEAT
BLEED

EXCHANGER

SCREW

~--

STARTER

MOTOR

ADJUSTABLE
FLEX

~10UNTS

/

\

FUEL
PRIMING

4

PUMP

LEVER

STARBOARD

AND

PORT

VIEWS

-FOUR

60/SAO

PROPELLER
COUPLING

SHAFT

(

\

. (

r .

Photos

The gear

above show the SSL

is
Its small
creasing length

ST

ARBOARD

Transmission

available in two

size

and moderate offset greatly

to

30 inches and reducing depth belowpropeller shaft line

Ratios,

AND

PORT VIEWS-FOUR 60/SSL

which was designed

1.3:1 and 2:1.
increases

for

installability

the Four-60

of

Four-60

t04

3/4

Diesel.

by

de-

inches.

4A

/

\,

i

,

\

INSTALL}\.TION

DRAWINGS

Four-60/SAO

:32.L DIRECT

jo4-----37

Reverse

~-------2~'-----~·1

and

~

~.67:1

Reduction

AND

101--

DRiVe:

2:1

Gear

~

RATIO

I

I

~

. ---'

1-2;!z.o------

1--

______

Four-no/SSLReverse

-~3o!-!------'

16

.'.--

3-_ ..

34

-

..

~-.---'

_.----

~'.--~~-.:'::l

•

..I

Gear

5

GENERAL

DATA

DIESEL

Number
Compression ratio
Bore
Stroke
Capacity
Idling speed
Maximum governed light running speed
Maximum speed
Torque

Pistons and rings

ENGINE

of

cylinders

under

Piston ring groove

No.

1-compression
Nos. 2 and
Nos. 4 and

Piston ring fitted gap:

No.

1-compression
Nos. 2
Nos. 4 and

Piston

and

to

bore clearance

clearance:

3-compression
5-oil

scraper

3-compression
5-oil

scraper

load

(at

..

bottom

of

skirt)

4.

..

23·6:

1.

2'477

to

2·4785 in. (62'915
3·0 in. (76'2 mm.).
57·9 cu. in. (948 c.c.).

..

600 r.p.m.
2,750 r.p.m.

. .

_ . 2,500 r .p.m.

. . 38 lb. ft.

·0025

·0015

·0015

. .

·010

. .

·007

·007

·0031

(5'32

to·0045
to

·0035 in. ('038

to

·0035 in. (-038

to

·015 in.

to

·012 in. (-178

to

-012 in. (·178

to

·0037 in. ('787

kg.m.)

in. ('062

('2S4lo

to
to

to

62'94i nun.).

at

1,750 r.p.m •.

to

·113 mm.).

to

·097 mm.).

to

'097 mm.).

·381

mm..).

·305 mm.).

·305 mm.).

to

'940 mm.).

Gudgeon pins

Fit

in piston

Clearance in small-end bush

CODDecting

Length between centres

Side clearance

Crankshaft and bearings

Journal diameter
Crankpin diameter

Main bearing
Big-end bearing cleara;nce .
Crankshaft end-float

Camshaft and bearings

Bearing clearance
Camshaft end-float

rods

on

crankshaft

clearance·

..

..

..

·00025 in. (·0063 mm.) slack,
tight.

·0001

to

·0005 in.

5·75 in. (146'05 mm.).

·006

to

-010 in. ('152

2-0005

·001

·002

1·7505

·001

to

to

to

·001

to

·003

to

to

2·001 in.

to

1·7510 in. (44·462

·0027in. ('025

·0027 in. ('025

·003 in. ('051

·002 in. (·025 to
'007 in. ('076

(00025

to

(50·81-3

to
to

to

to

to

·254 mm.).

·068mm.).

·068mm.).

'076 mm.).

·051

·178

to

·00015 in. (-0038 mm.).

·0127 mm.).

to

50·825 mm.).

to.

44·475 mm.).

mm.).

mm..).

/

\

Timing chains and wheels

Camshaft drive
Injection pump drive
Injection pump

Inside diameter (finished
Clearance

on

..

chain

wheel bearing liner:

in

hub

..

position)

6

Duplex roller chain.
Simplex roller chain.

1·75025

·001

to

1·7507S·in.

to

·002 in. ('025 to

(44·456

·051

to

44·469 mm.).

mm.).

GENERAL

DATA-continued

Valve mechanism

Valve

opens]

with ·020 in. ('508 mm.) valve
Valve closes ance . .
Valve

seat

angle

seat

Valve

Valve

Valve

face width

stem

rocker

to

guide clearance

clearance-cold

Valve lift

stand-down

Valve

Valve springs:

Free

length

Fitted

length-valve

Fitted

length-valve

Load

to

compre!;s

Rocker
Rocker

Tappet

shaft

diameter

shaft

to

diameter

bush

..

closed

open

to

fitted

clearance

..

. . . . . . . .

..
length-valve

rocker

open

5°

clear-

B.T.D.C.
30° A.B.D.C.
45°

·075

·00

('038

·012 in. (,305

·276 in. (7'01

·018
(,457

1·672 in. (42·471
1·165 in. (29·6

·889 in. (22·576 mm.)
28·71b. (13 kg.)

. . ·5615 to ,5625

·0005

·81125

Inlet

in. (1·906 mm.)

15

to

·0025

in.

to

·062
mm.)
mm.)

to

·038 in.
to

·965

Inner

mm.)

in.

to

·002 in. ('013

to·81175

mm.)

mm.)

mm.)

(14'263

to

to

·051 mm.).

in. (20·606

Exhaust

45°

B.B.D.C.

5°

A.T.D.C.

45°

·075

in. (1·906 mm.)

·002

to

·003 in.

(·051

to

·076 mm.)

·012

in.

(·305 Inm.)

·276

in. (7·01 mm.)

·018

to

·038

.jn.

(·457

to

·965 mm.)

Outer

2·047 in. (52 mm.)
1·328 in. (33·746 mm.)
1·052 in. (26,746 mm.)
43 lb. (19'5 kg.)

14·288 mm.).

to

20·618 mm.).

Flywheel

Oil

Oil

and

starter
Number
Starter

of

ring

teeth

pump

Rotor

end-float

Rotor

lobe

clearance

pressure relief valve
Spring free length
Spring fitted length

Load

to

compress spring

Oil

pressure

Idling

speed

Normal

COOLING

Fan

Depth
Width
Angle
Lateral

belt

running

SYSTEM

..

(outside)

of

~V'

movement

fitting

..

ring

on

starter ring

temperature

to

speed

(measured

fitted length

at

the vertical

run)

94.
200

to

230°

C.

(392

to

446° F.).

·003 in. (·076

·004

in~

2·86 in. (72-64
2·156 in. (54,77

(·102

mm.)

maximum.

mm.)

maximum.

mm.).

mn1~).

13·5 lb. (6'127 kg.).

15

lb./sq. in. (1,05 kg.jcm.

50 Ib./sq. in. (3'52 kg./em.

H in. (10·72

tin.

(12,7

mm.)

mm.).

40°.

1 in. (25

mm.).

2

).

2

).

Thermostat

Opening

Fully

Water

Interference fit

Tnterference

temperature

open

puomp

temperature

spindle

in

hub

fit

in

vane

..

79

to
to

94

·0015

·001

84°

C.

(175

96°

C.

(201

to

·0028 in. ('038

to

·0023 in. (·025

to

183° F.).

to

205° F.).

to

·071

to

·058 mm.).

mm.).

7

VEL

SYSTEM

Diesel models

Lift pump ••
Main filter

Injection order
Static injection timing

Injection pump

Type'
Roller to roller dimension
Governor link length

Injectors

Nozzle
Nozzle holder

Opening pressure

Needle

lift

..

..

GENERAL

••

••

DATA-continued

A.C.-YE

C.A.

V.

bowl-less.

1.3,4,2.
16°

B.T.D.C.

DPA

3248530.

. . 1'962 in.
..

2·087±·039 in.

BDN.O.SPC.6389.

BKB.35S.S237.

..

135

·6

to

(49'84

atmospheres.

·75

mm.

type.

mm.).

(S3±1

mm.).

rorque

B::lectrical

Wrench

Cylinder

Inj

ector

Rocker

Flywheel
Main
Connecting
Injector

Nominal

Battery

Terminal
Recommended

Generator

Capacity
Voltage

Alternator

Capacity.

Voltage

Settings

head

clamp

bracket

bolts

bearing

rod

nozzle

~ystem

voltage

(NOT

....•......••..•.....•••...

(optional)

nuts

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

nuts

bolts

bolts
nuts

supplied

voltage

........•.....•••.....•...

...•••..••..•.••.•...•••..

. . . . . . • • . . • . .

•••••••••••••...••••.

nuts

..••••.•.•.••••.•......

••••••••••..•.••••••.••.

•.....•...•••.••...•..

•.•.••..••...••••••..

...•.....•..•.•..•••.

.••...

capacity

'

••

'.'

with

.••••.•••••...•..•..

engine)

•....•.....••.

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

..••.••.••.•..

•.

• . • . . • . . • . .

'

•..

60
15
25
40
70
35
50

12
12

130
negative
14

12V.D.C.

55

12

.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

volts

volts

amperes

amperes

V. D. C.

(ne

ampere

ground

gati

hours

ve

ground)

TRANSMISSIONS

Four-60

SAOD
SA002
SAOV

SSL-13
SSL-20

8

Gear

Options

· . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

· . . . . . . . . . . . . . . . . . . . . . . . . . . .

· . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

· . . . . . . . . . . . . . . . . . . . . . . . . . . .

· . . . . . . . . . .

..

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

Direct

2:1

1.

29:1

1.

67:1

2:1

1.

3:1

2:1

Drive
RG
RG
RG
RG
RG

.

RG

(

\

INSTALLATION

FOREWORD

INSPECTION

FOUNDATION

ENGINE

PROPELLOR

ALIGNMENT

EXHAUST

ENGINE

FUEL
FUEL
CONTROLS
ELECTRICAL

BOLTS

LINE

'COOLING
PIPING
SUPPLY

OF

SIllPMENT

FOR

COUPLING

SYSTEM

ENGINE

INSTALLATION

SYSTEM

Page

No.

10
10
10
11
11
11
11

12

12
12

13
14

PREWIRING
STARTING

AND

AID

OPTIONS

14

1.5...

c

9

FOREWORD

It

is

not

the

the

generally
engines.
it

is

However ~ the

valuable
precautions
of

the

engine.
check
good

and

operating

engine.

purpose

to

of

which

well

in

understood

explaining

be

watched

There·

the

conditions

of

this

following

and

are

details

operator

for

INSTALLATION

section

and

to

well

outline

the

functions

the

relationship

of

the

should

the

engine

advise

boatyards

developed

of

general

of

each

of

installation

have

and

a'

thorough

correct

and

procedures

procedure·

component,

the

inst.allation

which

understanding

procedure

engine

for

is

the

reasons

should

installers

installation

included

because

why ~ the

to

the

operation

have a periodic

to

ensure

in

servicing

on

of

the

INSPECTION

The
crated.
with
for

and

check

the

engine

Accessory

the

engine

possible

equipment.

with

agent

before

FOUNDATION

A

good

engine.

.

when

the

exact

this·

which
and

In

fiberglas

be

formed

to

be

The

engine

The

subjected

effects

position

position

is

applied

finally

to

installed

temptation

resisted.
hull.
to

do

Flexible

their

OF

SHIPMENT

is

shipped
crate.

accidental

Before

the

packing

accepting

FOR

bed

engine

to

the

of

rough

but

at

all

to

the

engine

hulls~

and

we

fitted~

firmly

to

Such

construction

mounts

job.

When

from

equipment

Immediately

damage

accepting

list

shipment,

ENGINE

contributes
bed

must

engine

seas.

must

keep

times.

the

propeller

bolts

recommend

then

in

wood~

install

the

require a firm

possible,

the

is

in

and

if

be

weight

The

the

It

has

and

glassed

thus

engine

will

factory

shipped

upon
transit

any

shipment

any

shortage

reporting

much

of

bed

engine

shaft~

engin~

that

towards

rigid

or

the

must

within

to

withstand

similar

to

the

reducing

on a pair

allow

foundation

follow

mounted

upon·

in a separate

arrival~

and

the

for

from

or

damage

same

the

construction
position
not

only

one

the
support
or

the

to

the

thrust

bed.

wooden

hull

securely.

noise

engine

and

of

fiberglas

vibrations

against

bed

design"

heavy

small

shipment

any

possible

the

transportation

is

to

the

shipper.

satisfactory

and

neither

boat

mCl,Y

the

two

thousandths

forward

washer

stringers

This

transmitted

"angle

to

which

A"

and

skids

box~

should

and

usually

be

shortage

noted~

file

operation

deflect

have

engine

to

firmly

of

push

bearing

of

as

in

.allows

the

in

wooden

hanger

vibration.

irons"

pass

avoid

to

through

react

bed

properly

packed

inspect~d

in

parts

comppny

claim

take

an

or

inch

with

of

the

twist
under
in

the

of

propeller

the

engine

hulls
bolts

should

if

they

design

to

are

11

B" •

be

the

~

(

\

"A'l

10

Fig.

1.

Bed

Design A and

(

\

B

ENGINE

It

is·

recQm.meJ}.cj~dJhat

-

·1.i~~d

tM.o:ugh

because

the

lag

.

the

engine
stays
is

.

in

not

weakened

BOLTS .

~he

their

bolt

hold

stays

down

position

3/S

enw.!l~·

on

in

position

or

are

at

all

by

its

~uJ).PC?r~~_g

the

wood

loosened

times·

removal.

mch

lag

is

and

the
to

as a stud

bolts

weakene~'every

nuts

permit

Cb.a.ng,~.:.r

mqunt$;'

bolts)~

·":L.~g~~crews

time

on

top·

of

the

lag

the

and

the

engine

bond.

to

between

preferably

are

they

are

bolts

be

moved.

the

of

bronze,.

less

move.d~

are

used

The

bolt

and

be

p!-eferred

whereas

to

tighten

bolt

itself

the

wood

PROPELLER

Each

WesterbekeDiesel

propeller

rate·
any

fit

fit.

burrs

on

the

get a fit.

COUPLING

shaft
The

forward

should

shaft

It

and

is

to

the

engine.

be

removed

the

shaft

important

engine

end

that

is

The

of

the
from

should

the

fitted

with a suitable

coupling

propeller

this

end.

not

have

key

be

is

very

shaft

The

to

be

scraped

properly

coupling

carefully

has

a

long~

coupling

fitted

should

down

both

for

connecting

machined

straight

be a light

or

filed

to

the

shaft

for

accu-

keyway

drive

in

order

and

the

and

to

the

coupling.

If

it

seems

by

heating

exactly

ALIGNMENT

When

,.

\.

take

The

the

making

plenty

,alignment

counter-bore
flanges
parallel
must
for

ment

not

alignmellt.

with
apart.
checked

90

degrees

'difficult

in a pail

·pe·rpendicular

the

alignment

of

time

is

correct

with

come

within

exceed

Keeping

by

together

O.

the

the

propeller

rotating

001

0.001
engine

the

apart.

to

fit

the

of

boiling

to

the

and

do

when

no

interference

at

mch

if"

inch

half

half

propeller

the

coupling

water.

center

between

not

b.e

the·

all

points.

possible.

per

coupling

coupling

coupling

engine

over

line

or

the

satisfied

shaft

and

The

However,

inch

of

should

checked

shaft

the

shaft~

The

face

axis

of

engine

can

with

be

and

anything

slipped

when a feeler

two

coupling

be

held

in

in

one

position"

half

coupling

the

of

the

the

propeller

propeller

halves
the

maximum

O.

D.
in

each

€oupling

propeller

shaft

less

than

backwards

gauge

of

the

In

making

one

position

of

four

positions

the·

alignment

in

each

can

be

coupling

shaft.

..

half

p.erfect

and

forward

indicates

coupling

allowable

the

and

of

four

expanded

must

be

couplings,

results.

into

that

tlie

should

be

tolerance

final
90

check

the

align-

degrees

should

be

positions

If

iriitial

still

on

shortly

Theen~ne

one

to
found
improperly

shape
NOTE:· A

wood

EXHAUST

{

\.

Exhaust
particular

1.

alignment

its

after

three

that
and

or

any

line

The

discharge

cradle~

the

launching.

alignment

weeks"

the

engine

done

the

at

engine

fiberglas

other

LINE

material

INSTALLATION.

installations

job.

Four

exhaust

cannot

is

~irst~

bed

accomplis~ed

coupling

should

and

if

is

no

but

has

boat

particular

line

possibly

should

be

necessary,

longer

because

probably

requires
used

vary

must

during

be

disconnected

re-checked

the

in

alignment.

the

boat

absorbed

the

same

in

boat

construction.

conSiderably

cautions

be

designed

run

apply:

back

boat

after

alignment

has

and

so

into

construction

and

the

boat
re-made.

This

some

taken

moisture.

is

some

not

"Alignment"

each

that

the

must

sea

water

engine.

or

all

alignment

has

been

because

time

procedures

be

o:t:'

while

the

rechecked

in

service

It

will

usually

the

to

take

designed

engine

boat

.

work

its

above

for

raw

is

for

be

was

fin.al

as

the

water

11

2.

The

the

manifold

3.

Use a flexible

(which

less

4.

The
from
opening,
increased

exhaust

should

than

12

exhaust

the

of

1/2

line

flange.

section

,be

inches

pipe

engine

the

inch

should

be

preferably

'W~a~ped

.overalI

'inust

due

Iengf1i~

be

of

properly

exhaust

for

m~ifold.

every

supported

to'

fhe" high"

suffici~nt

and

should

so

of

st~ess

threaaEi¢[

size

never

The

ten

feet

of

length

that

its

weight

steel

at

"temperature)

at

"eacn'"ena-.,

to

handle

be

made

I.

D. -of

the

beyond

does

the

and

th~

$maller

exhaust

the

first

not

manifold

no

'"

,"

exnaust

than

should

ten.

rest

on

f1~ge

--,

gases

the

be

ENGINE
The

"closed
through

e~changer

FUE~

We
for
to

avoid

line

tant
Keep

eliminate
The

'securely

m'eans
The

supplied

FUEL

To

ensure

of

clean

at

the

lines

started
interior

COOLING

Westerbeke

system",

the

is

PI~ING

recommend

the.

supply

.the

between
that

all

fuel

lines

II

fuel"

piping

anchored

of

copper

final

•.

SUPPLY

fuel

time

or

tank

for'

is _ gel-

SYSTEM

Four-50

wherein

engine

biock

cooled

1/4

line

and

u.se

of

the

fuel

joints

be

as

yapor

lock.

leading

to

straps.

connection

(see

satisfactory

oil.

when

will

the

For

the

certainly
first
coated

diesel

the

and

head,

by

the

sea

inch

O.

D.

return

unnecessary

tank

far

free

as

I'

and

of

pressure

possible

from

prevent

to

the

Fig. 2 for

operation,
this

reason,

fuel

tank

'time.

If a molded

to

prevent

is

fresh

fresh

·exhaust

water

copper

line.

fittings

engine

from

the

tank

chafing.

eng~e

Fuel

a

is

installed

cause

fouling

fibres

water

water

pump

tubing

Run

tne

and

should

cooled,

is

circulated

manif~ld,_

and

..

together

tubing

in

connectors.

be

of

the

fuel

leaks.

exhaust

to

the

Usually

should

inj~ction

Diesel

cleanliness

pipe

engine

the

be

through

P:t:imp

engine

and

compartment

must

c'are

because

of

~jector

tank

from

of

fiberglas

contaminating

utilizing

what

by a centrifugal

he~t

exchanger.

with

suitable

the

longest

oil

for

minimum

The

pieces

shut

type,

should

copper

lever

the

tubing

flexible

control

have a dependable

are

especially

dirt

left

anywhere

nozzles

is

used,

the

when

be

fuel

is

known

The

fittings,

obtainable

off

valve

and

it.

is

temperature

always

is

secured

rubber

positions)

import,ant

in

t:q..e

engine

ce.rtain

.that

system.

as

pump

heat

both

in

impor-

hoses

supply

the

fuel

a

the

to

be

by

is

the

(

In

the

Westerbeke

tion

pump

to

the

e~g~e

Two'

pump

fuel

(called

Secondary

is

to

trap

or

dirt

is

ment

type,
reaches
pump

which
filters,
or

whenever

by a fuel

is

'filters

Filter).

water

collecting

the

the

injection

has a hand

and

for

the

D~esel

returned

are

the

Primary

and

purpose

purging

system

fuel

lift

pump

to

provided

The

Primary

has

in

the

of

system.

primer

the"

has

the

Filter),

the

glass

which

system

been

12

system,

and

the

fuel

tank.

with

the

Unit

advantage

bowl.'

is

Connection

required

of

opened

:;tIl

excess

oversupply

engine;

the

one

other

has a bowl

that

the

The

Secondary

to

filter

for
for

air

when

for

any

0:( fue,l

which

is

an

mounted

and

owner

all

contaminants

the

fuel

filling

engine

reason.

oil

is

is

not

i,ntegral

on

screen,

can

tell

Filter

supply

the

fuel

is

started

supplied

required

part

the

engine

the

to
for

of

the

(called

purpose

t:q.e

at a glance

is a replacement

before

line

supply

for

is

on

lines

the

-the

the

first

injec-

injectic;>n

fuel

lift
the

of

which

if

water

ele-

fuel

oil

fuel

lift

and

the

time,

(

,

'-."

Throttle Control

Max

~-~

Idle

~

~

. 9

. /

JI!.'

/

Fuel

Stop

Stop

~-~

Control

Run

NOTE:

to

CONTROLS
If

or
require
is
is
the
is

Cable

member~'

without
balance

tend~

"Ahead"
SSL

ideally
sary
accessories.
dealers.)

there

controlled
button.

The'

the run position.

manual

conventional

connected
reduced

Morse

imperative

Transmission

cable

SAO

25

MJ

bends

so

lost

among

of

itself~

or

suited

In

is

also a stop-run

by

fue.l

pounds
again

motion.

"Astern".

ends

i njecti

transmission

rod

at

the

to

mechanism.)

that

must

that

effort

the

to

to

control

and

(The

addition

Bowdoin

Fig.

STOP

2

Fuel

/RUN

on

and

lever

of

effort6n

point

25

installation

be

several

pull

may

attaching

control

four

pounds

gradual.

put

With

the'

be

by

to

the

lever.

wires

rod

used;
the

and'

Injection
Lever

pump

is

Whether

into

members

throttle

Fuel

used~

assembly.

the

inches

at

the

be·

done

Anchor

the

and

clutch

it

Model

kits

we

cables

which

Control

Stop

clutch

clutch

from

operating

flexible

precisely

clutch

lever

so

lever

.

is

highly

ML

have

should

and

clutch

should

Pump

Throttle

Positions

Control 1 ever

control

Type

handle

the

cross

station

cable

points'

handle

installations.

that

the

from

efficient~

Morse

designed

be

function

be

SAO

or

and

must

reaches

weight

neutral

single

purchased

mounted

and

.

shoul d be

may

be

either

transmissi'ons'

75

pounds.if

shaft.

through

or

r.od

and

in a workmanlike

be

securely

it

is

of

position

simple.

lever

for

this

handled

These

adjacent

Morse

(75

pounds

the

leverage

levers

the

clutch
desirable
components

in

control.

unit

are

locally

by

spr;

ng

Morse

fixed

towards

design~

on

through
the
are

to

type

normally

type

@ 4

are

used,

manner.

to

cross

to

maintain
does

il'he

our

ML

control,

most

the

inches

ratio

either

and

neces-

list

Morse

easily

starter

loaded

MJ

cable

of

it

rigid

,shaft

not

is
of

SAO

Transmissions require

SSL

Transmissions require

Left-Hand

Right-Hand

Propellers

Propellers

13

ELECTRICAL

All

electrical
Engine
a

14-ampere
gram
optional

operate

for a generator

55-

ampere

SYSTEM

accessories

on a negative

generator

alternator

on a standard

grounded

mounted

and

skippe;r

arid

12

to

the

engine.,

panel,

Westerbeke

production

volt

system.

Shown

or

Fig.

All

Westerbeke

Included

in

4.

Electric

Fig.

a

wiring

panel.

Four-60

with

the

3,

is a wiring
diagram

Diesel

engine'

dia-

for.an

is

Carefully
the

installation

follows:

#1

#1/0

#2/0
#3/0

,PREWIRING AND

1.

alternator,
necting
panel

key

switch
standards.
two

#6

e~imination

10

foot

follow

--

fo'r

--

for

--

for

--

for

Prewiring
Prewiring

regulator,

terminal

including

panel

This

conductors

of

lengths·

so

distances

distances
distances

the

wiring
to

the

reconlmended

the

battery

up

to 8 feet

distances

up
up

OPTIONS

includes

starting

blocks,

pre-heat

is

neoprene

cable

for

accommodate

pressure

includes

the

mistakes

is

up

to

10

to

13

to

16

the

motor,

function.

jacketed,

ammeter.

all

wire

close

feet
feet
feet

installation

and

two

and

installations.

size

to

starter

temperature

The

waterproof;,

#10

Chief

minimum

shown

the

engine

and

solenoid,

cable

conductors

used

advantages

installation

in

the

'and

WIrIng

switches,

to

very

for

wiring

use

battery

of

the

following

instrument

separate

connect

flexible

the

pre-heat

are

pre-wiririg

time.

diagrams.

cable

senders,

key

the

engine

and

meets

function

The

cables

Plan

sizes

devices:

con-

switch

and

ABYC

and

will

are

as

its

be

{
\

2.

All

The.

built-in

anodized'
instruments

each

hour

instrument
ground and
electrical
55-amp

or
factory.
part

switches

by

switch,

3.

low

of

the

a1

oil

the

key

should

Electric

Westerbeke

meter. . Tachometer

aluminum,

are

is

may

be used

-systems-

Panel

an

ammeter,

back

and

eopxy

ternator.

Factory
This

pressure,

It

consists
key

are

switch

alarm

set

the

Installed

system,

is

of

switch

for

,compatibility

at

the

operator

all

electric

lighted.

with

may

Engine

designed

an

audible

panel.

'key

wish

cables

paint

protected,

water

This

negative

panel

temper.ature

ground,

utilizes

are

new

be mounted where

.

Alarm

to

indicate

The

switch

to

and

alarm
with

turn

installed

high

the

panel

System

the

to

water

engine.

and

off

an

electronic

no . longer . required.

for

gauge

all

electric
positive
visible.,

(Optional)

'existence

on

indicate

temperature

can

the

alarm.

long

be

lived

and

panel

ground,

It

of

your

either

The

Westerbeke

failure,

alarm

de-energized

tacho.meter

finish.

oil

pressure

or

must

high

water

and

system

with

The

panel

'The

..

mar,ine

gauge

is

isolated

isola'~ed

be

used

temperature
diesel

the

alarm

low

oil
is

by

the

gt"ound

with

at

pressure

energized

same

a

is

and

from

the

the

being

key

(

\

14

e

e

e

GROUND

e

"16

OIL
PRESS.
SENDER

@

·16

@

WESTERBEKE
SKI

tlf>

WATER

TEMP.
SENDER

@

'"16

ENGINE

PPER

OP

-

PANEL

SW.

@

@

~Y_S!!'.I!f!:!.

'10

"16

! 0

I

I

I

I

I

I

I

. I

I

L

____ --__

'":"

.f.~E~

______

01'1' I

RUN

START

®

. __

START

MOTOR

& SOLENOID

I

*

OPTIONAL

"*

@

.;rOIL.
PRESS.

sw

_...J

,

I

I

I

I

I

I

I

I

I
I

I

I

I

(

Fig.

. @)WESTERBEKE

.

LAMPS

Wiring

3

ALL

ELECTRIC PANEL. (WITH

~

Diagram

OIL

PRESS.

SENDER

ALTERNATOR

WATER
TEMP.

SENDER

@ ®

with

.

Generator

ONLY)

and

Skipper

@ KEY SWITCH

r

---;F;---

.10

~----~~--~~~

L

'6

BATTERY

CA8L.E

+

SATTERY -

IZVDC

~

0

®

START

'16

_____________

Panel

PANEL

-------1

RUN

PREHEAT I

...

SW I

® I

-10 I

@

'*

OIL

PRESS.

SW.

I

1

I

1

I

I

I

I

J

c.

4

Wiring

Fig.

ENGINE

Diagram

with

Alternator

and

Electric

"*

OPTIONAL

Panel

15

STARTING
The

starting

plug

preheater
chamber.
engine
during
the
is
directly

It

is

out
To

or
Both
If

after.
for
START

cranking~

cr~king.

glow

plugs

provided

across

most

of

the

start

the

longer

pushbutton

about

15

seconds

switch.

AID

(Fig'. 5)

aid

on

which

Due

to

four

A

when

in

the

the

important

glow

plugs

engine~

(depending

and

15

seconds

leaving

Westerbeke

operates

the

drop

9-volt
resistor
preheat

circuit

battery

that

the

and

provide

depress

upon

clj.matiG

START

the

Four-

by

in

battery
glow
is

used

is

used

to

bypass

while

cranking.

glow

battery

the

switches

cranking

PRE-HEAT

60

heating

plugs

in

without

plug

consists

voltage

are

the

glow

cranking

this

circuit

the

used

resistor

of a co'mbustion

air

from

plug

be

wired

charging,

glow

conditions)~

should

time

plug

the

PRE-HEAT

and

then

be

released

engine

pushbutton

coming

12

volts

to

provide

circuit

the

and

correctly

pushbutton.for

engage

has

not

depressed

into

to 9 volts·

full

to

prevent

engine.

connect

the

when

the

started~

chamber

the

combustion

preheat

A

start

the

to

prevent

START

engine

stop

and

then

during

power

burnout

solenoid

glow

burn-

30

seconds

switch.

cranks.

cranking

engage

glow

ail

of

plugs

B+

BATTE/?(

rE~MINAL.

TO

PRE-HEAT

SWIT~H.

TO

IGNITION

TO

HEArERS.

(

"

SW-

Fig.

16

5.

Starting

Aid

- Glow

Plug

Preheat

(

OPERATION

Page

No.

(

PREPARATION
BLEEDING
TO

START
WHEN
TO
OPERATING
COLD

POST

~NTENANCESCHEDULE

END

ENGINE

STOP

ENGINE

WEATHER

DELIVERY

OF

SEASON

FOR

THE

ENGINE

STARTS

PRECAUTIONS

STARTING

FUEL

PRECAUTIONS
CHECKOUT

SERVICE

SYSTEM

ENGINE

AFTER

INSTALLATION

19
19

20
20

21

21

22
22

23
23

17

LUBRICATING

OILS

Lubricating
improved
conditions

These

(API

oils

Service

but are not

oils

standard of

such
meet

listed

COMPANY

Ameri

BP
Chevron

can

Canada

Oil

0; 1 Co.

Limited

Co.
Cities Service
Continental
Gulf

Oil
Mobile
Shell

Oil

Oil

Corporation

Oil

Company

Company

are available for

performance

as

sustained

high

the requirements of the

CC).

Any

other

oils

here are, of course, also suitable.

f

i

American

,

I

BP

Vane11us

BP

Vane11us

RPM

DELO
CITGO
CONOeO

Oil

Co.

Co.

i

I

I

I

I

I
I

I

Gulf1ube

I

I

Delvac
Shell Rotella

Westerbeke

to

meet

the requirements of

speeds

and

U.

which

also

BRAND

Supermil

Multi-Service

Extra

TRACON

Motor

1200

Range

OIL

Oil

Series

TOil

Diesel engines

temperatures.

S.

Ordnance

conform

Motor

Oil

Oil

X.H.D.

which
modern

SpecificationMIL-L~2104B

offer

an

operating

to these specifications,

.

S:~A.E.

OO/45°F

DESIGNATION

45°/80gF

OVER

80°F

-

lOW

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10W/30

lOW
lOW
lOW
lOW

.

1210

20W/20
20W/20

10W/30
20W/20

20W/20

20W/20
20W/20

1220

30
30

10W/30

30
30
30
30

1230

/

(

(

\.

I

lOW I 20W/20

30

Sun

Oi 1 Company

Texaco,

18

Inc.

·f

.

Sunf1eet
Ursa

Oil

MIL-B

Extra

Duty

lOW

lOW

20W/20

20W/20

30
30

OPERATION

PREPARATION

The

engine

case

before

1.

and

starting

is

transmission.

Remove

of

diesel

Refer

Select

NOTE:

may

be

2.

3.

Due

to

required

Remove
fill

with S.A.E.

fi

11.

Fill

fresh

a.

Remove

b.

Remove
manifold)
Weather
from

c.

Fill

FOR

shipped

the

to

STARTING

11

dry",

The

engine

oil

filler

lubricatin~

page

an

approved

the

inclination

than

for

cap

18

for

grade

specified.

ENGINE

that

following

the

first

and

oil

to

an

approved

listed

of

reverse gear breather

30

lubricating

water

the

surge

cooling

the

square

surge

with

Precautions)

vent

point,

tank

tank
fresh,

to

system

head

filler

replace

within

is,

with

time.

fill

oil

the

engine

cap

vent

clean

and

AFTER

lubricating

procedure

.

sump

highest

lubricating

and

continue to

and

transmission

on

SAO

oil

to

high

as

follows:

screw

cap

and

water

when

and

tighten

one

inch

INSTALLATION

oil

drained

with

mark.

should

approximately

on

oil.

be

the

Do

use

dipstick.,

ft.

in

gear or dipstick

mark

top
fill
and/

coolant

of

top

on

of

heat

the

tank

or

anti-freeze

free

vent

of

dipstick.

exchanger.

(integral

of

screw.

tank.

from

checked

4.5

not over

the

boat,

on

SSL

air

bubbles

Replace

the

crank-

methodically

U.

S.

quarts

fill.

more

gear

and

Do

not

over

with

exhaust

(refer

to

issues

filler

Cold

cap.

oil

(

4.

Ensure
plates

that

5.

Fill
mended.
of

NOTE:

cedure

BLEEDING
One

may
necessary.

Before
the

tank

If

is

6.

Fill

7.

Open
System).

possible

have

bleeding

and

1.

Slacken

secondary

and

may

fuel
its
there

to

pour

grease

THE

cause

entered

that

when

storage

and

be

tank

The

higher

is
the

valves

FUEL

the

the

the

fuel

battery

battery

required

with

use

lubricant

no

filter

fuel

cup

in

fuel

SYSTEM

of

failure

the

system,

system,

fuel

supply

banjo

fuel

filterhead.

iss.uesfrom

is

fully

on

clean

of

No. 1 i.s

content.

in

through

on

water

line

to

first

bolt

water

charged

the

first

Diesel

the

filler

a ·funnel

pump

and

bleed

start,
in

which

ensure

is

turned

securing

Operate

the

level

permissible

or

banjo

is

at

so

that

start.

fuel

oil;

of

the

of

200

with a good

fuel

system

erratic
case

that

there

on.

the

injectors
the
bolt

least

it

No. 2 diesel

but

fuel

mesh

engine

"bleeding"

is

priming

free

3/8

is

capable

No. 2 is

tank,

wire

grade

.(refer

an

adequate

"fuel

of

inch

above

of

the

fuel

preferred

the

recommended

screen.

of

water

to

Bleeding

performances

of

the

system

supply

lever

air

return

bubbles,

on

pipe

the

the

extra

oil

is

pump

is

lift

tighten

battery

effort

recom-

because

pro-

grease.

the

Fuel

that

will

of

fuel

banjo"

pump,

bolt.

air

be

in

to

NOTE:

(

cam
dition

on

arises

It

the

will

not

camshaft

operate

be

possible

driving

the

cranking

the

to

fuel

operate

lift

motor

the

pump

until

lift

is

the

pump

on

maximum

hand

hand

primer

priming

lift.

If

lever

lever

such a con-

can

be

if
used.

the

19

TO

2.

Slacken

above
fuel
screw.

3.

Slacken

(pipes

4.

Position

5.

Ensure
run.

6.

Advance

7.

Turn
issues

START

1.

Position

2.

Push

3.

Advance

4.

Depress
depending

5.

Turn

6.

Immediately

the

the

flows

the

going

shift

fuel

)

throttle

key

from

ENGINE

shift

fuel

throttle

PRE-HEAT

key

air

pump

from

union
from

lever

STOP

switch

each

lever

stop

on

climatic

switch

upon

bleed

nameplate.

the

bleed

nuts

the

injection

in

neutral.

push-pull

to

maximum

to

START

injector

to

neutral.

control

to

into

maximum

pushbutton

conditions.

to

START

starting,

screw

at,

injector

pipe

full

position

on

the
Operate
screw

pump

, '

control

open

position,

union,

RUN

(to

obtain

for

position

fuel

injection

the

lift

pump

free

end

to

is

of
of

each

in

air

each

full

position.

and

when

tighten

position.

maximum

approximately

and

hold

..

throttle

bubbles,

of

of

the

run'

(For

fuel

union.

Release

to

idle

pump,

priming

the

high

four

injectors).

position.

maximum

oil

free

fuel

for

30

seconds

when

setting.

situated

lever,

tighten

pressure

of

easier

engine

directly

and

the

(Push

fuel

air

bubbles

starting).

or

longer,

starts.

when

bl~ed

pipes

in

to

flow. )

NOTE:

If

engine

pushbutton

Never

has

depressed
within a few
getting
If

battery

fuel.

is

a.
b.Ensure

c.
d.

WHEN

ENGINE

1.

Check
50

2.

Check
out

3.

Recheck
subsequent
the
oil
oil

day

4.

Recheck

change
running

into

operation.

operate

not

started,

revolutions

The

cranking

charged

Ensure
the

stop

Check

for

Determine

3

to

7"

nuts

at

STARTS

Oil

psi

at

operating

Sea

delay.

Crankcase

crankcase

to

compensate

passages

of

operation.

Transmission
or
for

reverse,

the

and

turn

of

motor . turning

and

engine

the

fuel

the

fuel

control

leaks

if

''Bleeding

injectors,

Pressure

Water

to

an

oil

oil

and

a

new

several

then

cranking

stop

cranking

switch

the

crankshaft

doesn't

valve
STOP

between

/RUN
lever
in

fuel

fuel

is

Fuel

bleed

immediately.

speeds,

Flow.

Oil.

change

level.

for

the

oil

filter.

Oil

installation.

minutes

add

oil

motor

to

start,

on

the

lines

reaching

System

complete

15

Look'

After

or

new

This

oil

is

that

Add

Level.

at

800

as

continuously

for

15

START

if.

battery

over

fast

check

tank

and

control

injection

and

at

injectors

u

If

•

system.

Normal

psi

when

for

water

the

engine

installation,

important

is

required

oil

as

(This

)

In

such

rpm

necessary.

seconds

position.

is

indicates

fuel

engine

lever

is

pump.

gaskets

fuel

oil

oil

idling.

at

exhaust
has
as

necessary.

applies

a

case,

with

one

Check

for

more

leaving

The

charged

the

system

is

open.

in

the

of

fuel

by

performing

doesn't

pressure

(Extremely

outlet.

run

stop

it

may

to

fill

only

stop

shift

oil

than

15

seconds.

the

PRE-HEAT

engine

battery

as

full

and

the

follows:

RUN

should

engine

is

charged.

position

start

filters.

procedures

issue

is

from

union

appro·r'; 1J:lately

hot

;ngine.)

Do

Llis

with-

for 3 or 4 minutes,

the

engine

be

nec,essary

the

engine

Check

subsequent

the

into

forward

.level

and

r s

oil

level

engine

each

check

to

add

internal

each

to

an

after

and

one

day

oil

is

at

of

\

f

\

20

5.

Recheck
has

been

reached

of

top

of

Expansion

drained
operating
tank.

Tank

or

Water

filled

temperature'

for

the

Level"

first

of

1750F

(This

time.)

and

applies

Stop
add

engine

water

after'cooling

after

to

engine

within

system

one

inch

has

WARNING:
released

hands

against
resistance
sure

stops,

is

and

6.

released.

Warm..:.up
reduced

mately
sary,
Warming

transmission,

propeller

7.

Prolonged
for. a prolonged
minutes
conditions

8.

Reverse
gears.
engine

NOTE:
must

locking

The

be

mechanism.

The

gradually

escaping

of

the

continue

engine

load.

SAO

firmly

system

if

the

safety

Press

turning

Instructions.

spe'ed

50

psi

of

and

can

up

with

shaft

idling.

every

half

favorable

Operation.

However,

transmission

held

in

is

pressurized

filler

steam

stops

the

is

cap

until

BOO-900

water

be

warmed

clutch

if

parti"aJ.

rotation.

When

time,

hour

to

when

the

reverse

cap

is

to

and

turn

felt.

Leave

downwards

it

can

be

As

soon

rpm,

temperature

in

neutral

engagement

required

increase

to

accelerate

sludge

and

Always

the

transmission

requires

position

when

be

removed.

the

lifted

as

until

up_

with

speed

carbon

reduce

that

overheated

cap

slowly

the

cap

against

off.

possible,

oil

pressure

gauge

the

takes

longer

occurs,

to

run

to

oil

circulation
formation.

~Ilgine

when

since

and

the

It

is

advisable

counter-clockwise

in

this

position

the.

spring

get

the

boat

gauge
indicates
clutch

in

and

130

neutral
tends

which

engine'

1000

at

rpm

idle

and

to

idle

is

engaged,

backing

it

has

down, ttte-

no

pressure

until

to

clear

underway

indicates

-1500F.
to

can

be

speed

for

at

thus

speed

it

will

positive

must

to

protect

until

all

the

approxi-

If

at

1000

overheat

detected

of

600

least

to

eliminate

when

shifting

carry

snift

overcenter

the
the

pres-

safety

but

neces-

rpm.

the

rpm

three

full

lever

be

at

by

(

TO

STOP

1.

2.

3.

NOTE:

OPERATING

1.

2.

3.

4.

5.

6.

7.

\

'.

B.

ENGINE

Position

Move

Pull

ting
Idle

throttle

fuel

off

the

engine

PRECAUTIONS

Never

as
Do
head,
Keep
Do

Never

run

extensive

Not

Put

block,

intake

not

run
Race

improper
Keep

Keep

in

Do

enough

fuel

not

the

the

cause

allow

to

shift

lever
lever

push-pull

fuel

fora

engine

internal

Cold

or

silencer

engine

a

Cold

oil

circulation.

engine

fuel

clean.

more

fuel

allow

in

neutral.

to

idle

STOP

from

few

for

the

minutes

extended

damage

Water

manifold.

free

at

high

Engine

and

accessories

Handle
trouble
to

run

air

to

enter

position

control

fuel

in

an

from

RPM

as

and

low,

the

..

out.

injection

to

dissipate

periods

can

be

overheated
lint,

without

internal

clean.

it

with

service

because
fuel

system,

(The

stop

pump.

heat

when

excessive

caused.

engine.

etc.

clutch

damage

extreme

interruptions

fuel

intake

control

)

"gradually

engaged.

can

care

because
may

resulting

functions

before

overheating

It

can

ocCUr

than

any

be

uncovered

in

engine

crack

due

water

other

by

cut-

shutdown.

occurs

cylinder

to

lack

of

and

dirt

factor.

long

stoppage.

21

9. Do
sudden

by

combustion
short
does

tional

is

not

be
stop

the

release

period

not

necessarily

difficulty,

operating.

alarmed

q.fter

of

chamber.

before

if

temperature

engine

residual

has

heat

Prevention

stopping

signal

alarm

temperatures

been

it.

wili

gauges

operating

from

for

High

against

quickly

show a high

at

the

heavy

this

is

to

temperature

restarting.

return

full

metal
run

to

reading

load~

This

masses

engine

reading

If

there

normal

following

is

caused

near

at

idle

~fter

when

is

a

no

func-

engine

the

for

stop

a

a

COLD

1.

. 2.

3.

NOTE:

with

the

4.

WEATHER

Precautions
be

left

exposed
make
are
freeze

and

equipped

with

Draining

tank

ing
Bleed

and

on

the

Cooling

amount

remove

coolant
vent
Start

screw.

engine

coolant

The

strength

solution

Fuel
(glass

filters

bowl,
densation
fuel

flow.

PRECAUTIONS

against

damage

to

inclement

incorporating

with

art·

Coolmg
open

fuel

high

Ethylene

System.

the

petcock

hand

pump

Systemo

of

anti-freeze

the

square

free

of

as

necessaryo

as

necessary.

must

water

Fill
and

of

air

the

bubbles
the
run

head

anti-freeze

be

trapp and

separated

by

freezing

weather

a

suitable

temp~rature

Glycol

Base

'Remove

(turn

sIde

When

and/

vent

counterclockwise)

of

filling

or

water

screw

issues

expansion

engine

for 3 or 4 minutes.

.

solution

checked

more

screen)

from

the

fuel,

by

corrosion

thermostats,

should

the

the

cylinder

the

for

on

top

from

tank

to

often,

to

otherwise

should
adding

be

pressure

cooling

the'

degree

of

this

vent

within

must

particularly

remove

be

taken

an

anti-freeze

inhibitor.

used

.
cap

near

if

the

As

a

permanent

from

the

engine

of

reputable

these

type

the

expansion

flywheel

1olock. .

the

heat

point,

one

be

maintained

all

this

system

of

inchfrom

the

may

with.

protection

exchanger,

replace

Stop

engine

by

the

primary

moisture

freeze

and

the

required,

and

and

top

and

topping

and

is

to

engines

anti-

hous-

correct

when

tighten

of

tank.

add

off

filter

con-

stop

the

/

\.

POST
After a customer

est,

in

DELIVERY

that a general

service.

1.

Retorque
Retorque

2.
(refer

3.

Check
on

manual
transmission.
Change

4.

5.

Check

6.

Check

7.

Check
sions,

which could

CHECKOUT
has

taken

check-over

the

cylinder

the

rocker

to

Section

and

adjust
SAO

)

engine

for

cooling

for

etc.

fuel

system

loose

(paying

cause

lubricating

and

delivery

Ao

if

type

~ubricating

fittings,

mis-alignment and subsequent problems.)

22

of

of

the

engine

head

bolts

bracket

7!J

Par.

15 a

necessary

transmissions.

oil

for

leaks

clamps,

particular

his

(refer

nuts

and

forward

and

oil

oil

leaks,

and

attention

engine,

be.

and

it

carried

to

Section

adjust

b).

drum

(No

adjustment

filter

..

and

inspect

connections,

to

is

advisable

'out

the

assembly

rectify

water

loose

after

A.

8,

valve

if

level.

nuts,

engine

in

his

the

first

Par.

34 b).

rocker
and

reverse

required

necessary.

bolts,

vee

mount

own

inter-

50

hours

clearance

band

on

the

SSL

belt

ten-

fittings

I'

~

\.

MAINTENANCE

DAILY

1.

Check

2.

Check

3.

Check

4.

5.

Turn
Check

down

SCHEDULE

sea

water
water
lubricating

lubricating.

level

grease

strainer,

in

cooling

oil

level

cup

on

oil

level

if

one

system.

in

sump,

water

in

has

been

fill

to

pump

transmission,

one

i~stalled.

highest

firm

fill

turn.

to

mark

high

on

dipstick.

mark

on

dipstick.

(

EVERY

1.

Check

2.

Check

EVERY

1.

Change
a suction
located

2.

Replace

3.

Fill
high
lubricating

CAUTION:
been
plete

known
oil

4.

5.

6.

starvation.

Start

gasket
necessary
engine's
Change
Service
Clean

50 HOURS

generator
water

100 HOURS

oil

level

in

hose

aft

of the

lubricating

sump

with approximately 4.5

mark

on

dipstick.

oil

The

use

of

to

cause

engine

for

leaks.

to

internal

oil

in

DG, DM,

Air

Filter.

or

alternator

in

battery.

sump.

of 3/8 inch

dipstick.

oil

filter.

and

continue to

different

extensive

and

run

add

oil

transmission.

oil

for 3 or 4 minutes.

Check

oil

to

passages

or

DS. Do

"V"

Oil

may

I.

Do

not over

use

brands

sludging

oil

sump

compensate

and

Use

not

belt

for

tension.

be

sucked

D.

over the outside

U.

S. quarts of diesel

fill.

out of the

Refer to

it.

of

lubricating

and

may

in

Stop

level.

for

oil

filter.

SAE

overfill.

30,

.

This

the

High

oil

Add

of

page

oils

during

many

instances

engine

is

important

that

is

oil

Detergent

sump
the oil

lubricating
18

for

oil

and

check

required

as

necessary.

Lubricating

by

attaching

sump

an

approved

changes

cause

oil

as

it

may

to

pipe,

oil to

has

com-

filter

be

fill

the

Oil,

(

NOTE:
tions,

should
assist

END
When a craft

measure
It

is

ately

The

therefore,

be

decreased.

in

reducing

EVERY

1.

Check

2.

Check

EVERY

1.

Wash

sediment,

frequently.

2.

Replace

3.

Replace

OF

SEASON

of

recommended,
after

the

time

150 HOURS

250 HOURS '

protection

period

under
bore

engine
sea

water

primary

filter

secondary
air

SERVICE

is

to

be

unit

is

The

for

filter.

taken

therefore,

withdrawn

for

extremely

correct

wear,

loose

pump

filter

bowl

fuel

out

be

afforded

replacing

dirty

time

thereby

bolts,

for

leaks.

bowl

and

and

secondary

filter

of

service

the

that

from

the

air

conditions,

periods

extending

nuts,

element.

the

s

erv~ce:

etc.

screen.

oil

for

engine.

following

for

the

fuel

the

filter

depends

the

replacing

life.·of

If

filter
filter

winter,

procedures

time

the

bowl

need

it

is

on

operating

limits

the

filter

engine.

contains

to

be

advisable

be

applied

of

250

will

water

cleaned

.

that

immedi-

condi-

hours

greatly

or

more

some

23

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Drain
cap
housing
Remove
mine

any

Insert

Fill
(Refer
Start
and
and

fresh

and

on

the

if

zinc

electrolysis

new

fresh

to

engine.

drain

fill

sump
Remove
adhesive
Seal
engine

the

as
Remove
divided

between
Replace
engine

Top

venting

Leave

slowly

off

fuel.

fuel

water

above.
Change
Wipe
Change

fuel

engine

oil
Disconriect
the

battery,

to

prevent

water

opening

the

fuel

hex

screw

rod

zinc

rod

water

Cold

Weather
When

lubricating

with

air

filter.

tape

or

exhaust

possible.

injectors

the

injectors

ov~r

tank

formation

system

filters

with a coat

in

transmission.

battery

the

corrosion.

cooling

the

petco~k

hand

pump

plug

in

plug'

that

in

may

plug

cooling

Precautions.

temperature

oil.

High

Detergent

Carefully

some'

outlet

and

other

at

spray

cylinders.

with

new

compression.

completely

by

full

of

before

of

and

store

battery

terminals

Recharge

system

(turn

side

on

port

needs

occur

if

necessary

system

Remove

seal

suitable

the

into

sealing

so

condens

fuel

putting

oil

or

in

by

removing

counter-clockwise)

of

cylinder

under

side

replacing.

between

and

with

antifreeze

)

gauge

and

indicates

replace

Lubricating

air

intake

medium.

most

accessible

cylinder

bores

washer

that

no

air

ation.

just

as

it

was

.the

engine

grease.

fully

battery

and

charged

cable

every

the

block.
of

heat

The

zinc

brass

replace

1750F,

filter.

Oil.

opening

location

1/8

under

space

on

back

in

condition.

connectors

30

days.

surge

near

tank

the

exchange
rod

will

take

.and

iron

components.

plug.

of a reputable

shut

engine

Replace

with

waterproofed

as

close

pint

of

lubricating

each

remains,

injector.

thereby

completion

service.

Before

should

pressure

flywheel

and

deter-

care

make.

drain

to

of

step

storing

be

treated

of

down

plug

the

oil

Turn

pre-

(4)

{

\

Fig.

24

B2.

One

The

of

the

Filler

Safety

Cap

Stops

Showing

Fig.

B3.

Turn

the

The

tap

Cylinder

in

the

arrow

Block

direction

to

open

Drain

of

the

Tap.

I

\

Camshaft

A

SECTION A

DIESEL ENGINE

Section

1\.9

Camshaft bearing liners

Connecting rods
Crankshaft
Cylinder head
Cylinder liners
Engine

Engine

Flywheel
Lubrication system

Oil

filter-external

Oil

I

\

\

pressure relief

Oil

pump

Oil

pump drive

Oil

strainer

..

back plate

front plate

.•

valve

.-.

A.16
A.12

A.ll

A.8

A.17

_A.IO

A.9

A.IO
A.2
A.3

A.S

A.4
A.6
A.II

(

Pistons
Sump

..
Tappets
Timing chains
Timing chain tensioners
Timing chain
Tractometer drive

Valves
Valve

rocker clearance-adjusting

Valve

rocker shaft

Valve

seat

Valve

timing check

wheels

..

reconditioning

..

. .

A.12
A.II
A.7
A.9
A.9
A.9

A.6

A.8
A.I3
A.7
A.IS
A.I4

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THE

DmSEL

ENGINE EXTERNAL COl\.fPONENTS

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No.

Description

1.

Clamp for injector.

2. Stud for clamp.

3.

Nut

for

stud.

4. Washer for nut.

5.

Heat shield· for injector nozzle.

6. Washer for heat shield.

7. Water outIetelbow.

S.

Joint washer for elbow.

9. Stud for elbow.

10.

Nut for stud.

11.

Washer for nut.

12. Thermostat.

13. Oil filler cap.

14. Cap nut for rocker cover.

15. Cup washer.

16.

Rubber bmh.

17. Valve rocker cover.
IS. Joint washer for rocker cover.

19. Exhaust manifold.

20. Inlet manifold.

KEY

TO

THE

ENGINE EXTERNAL

COMPONENTS

No.

Description

37.

Oil

seal for

crankshaft-rear.

3S.

Housing for oil seai.

39. Setscrew for housing.

40. Lock washer for setscrew.

41. Oil release valve.

42. Spring for valve.

43. Cap nut for valve.

44.

Washer for cap nut.

45.

Cylinder head.

46. Joint washer for cylinder head.

47

..

Combustion chamber insert.

48. Stud for cylinder head.

49.

Nut

for stud.

50. Washer for nut.

51. Cylinder block.

52. Cylinder

I~ner.

53. Side cover for cylinder block.

54.

Joint washer for side cover.

55. Bolt for side cover.

56.

Washer for bolt.

No.

Description

73.

Main bearing

cap-front.

74. Oil seal for front main bearing cap.

75. Dowel for main bearing cap.

76.

Bolt for main bearing cap.

77. Lock washer for bolt.

78. Front plate for engine.

79. Joint washer for front plate.

SO.

Joint washer for top fixing hole

of

front plate.

81.

Timing indicator for injection pump.

82. Timing cover.

83. Joint washer for timing cover.

84.

Vibration damper---camshaft chain.

85. Bolt for vibration damper.

86. Lock washer for bolt.

87. Vibration damper-injection pump chain.

88.

Stud for vibration damper.

89.

Nut for stud.

90. Lock washer for nut.

91. BoIt for timing cover.

92.

Nut

for bolt.

21. Joint washer for manifolds. 57. Oil reservoir. 93. Washer for nut.

22.

Stud for manifolds. 58. Joint washer for reservoir.

94.

Cover for injection pump chain wheel.

23. Washer for stud.

59.

Stud for reservoir. 95. Setscrew for cover.

24. Stud for manifolds.

60.

Nut

for stud. 96. Spring washer for setscrew.

25. Nut for

stud~

61. Spring washer for nut. 97. Oil filter.

26.

Washer for nut.

62.

Bolt for reservoir. 98. Joint washer for filter.

27.

Yoke for manifolds.

63.

Spring washer for bolt. 99. Bolt for filter.

28. Vent pipe for rocker cover. 64. Drain plug for reservoir.

100.

Spring washer for bolt.

29. Bracket for vent pipe.

65.

Copper washer for plug.

101.

Adaptor for filter.

30.

Hose for vent pipe.

66'.

Oil dipper rod.

102.

Joint washer for adaptor.

31.

Back plate for engine.

67.

Blanking

plate-oil

suction drilling.

103.

Bolt for adaptor.

32.

Dowel for back plate. 68. Joint washer for plate.

104.

Spring washer for bolt.

33.

Joint washer for back plate. 69. Bolt for plate.

105.

Oil

seal-timing

cover.

34.

'0'

ring for back plate. 70. Lock washer for bolt.

106.

Joint washer for chain wheel cover.

35.

Setscrew for back piate. 71. Main bearing

cap-rear.

107.

'0'

ring for oil suction drilling.

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..

0 " "

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No.

1.

2.

3.

4.

S.

6.

7.

8.

9.

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.
3S.

39.

40.

KEY

.TO THE ENGINE INTERNAL COMPONENTS

Description

No. Description

No. Descriptioll

Split pin

for

rocker shaft.

41. Bolt

for

housing. 81. Camshaft bearing

tiner-rear.

Plain washer for rocker shaft.

42. Spring washer for bolt.

82.

Locating plate for camshaft.

Spring washer for rocker shaft.

43.

Gasket·for housing.

83.

Bolt for locating plate.

Valve rocker.

44.

Tractometer and oil pump drive shaft.

84. Shakeproof washer for bolt.

Rocker shaft

bracket-tapped.

45.

Seal for shaft. 85.

Keyfor

camshaft.

Locating screw for rocker shaft.

46.

Oil pump body.

86~

Camshaft chain wheel.

Plate for rocker shaft bracket.

47.

Gasket for oil pump.

87.

Nut

for camshaft.

Spring for rocker shaft.

48.

Oil pump rotor and shaft assembly.

88~

Lock washer for nut.

Rocker shaft

bracket-plain.

49.

Oil

pump cover. 89.

Chain-camshaft

drive.

Screwed: plug for rocker shaft.

50.

'0'

ring

for cover.

90.

Hub

for injection pump chain wheel.

Valve

rocker shaft.

51.

Screw for cover.

91.

Bolt for hub.

Tapp~t

adjusting screw.

~2.

Bolt for oil pump.

92. Joint washer for hub.

Locknut for adjusting screw.

53

..

Spring washer for bolt.

93.

Injection pump chain wheel.

Valve:-exhaust.

54.' Crankshaft. 94.

Bearing liner for chain wheel.

Valve

guide-exhaust.

55.

Main bearing. 95.

Locating plate for chain wheel.

Valve-inlet.

56.

Thrust washer for crankshaft.

96.

Driving flange for chain wheel.

Vaive

guide-inlet.

57.

Dowel-flywheel

to

crankshaft.

97.

Bolt for driving flange.

Oil seal for valve.

58.

Ball race. 98.

Spring washer for bolt.

Valve spring

cup-bottom.

59.

Flywheel.

99.'

Chain-injection

pump drive.

Valve

spring-outer.

60.

Bolt-flywheel

to

crankshaft.

l00~

Chain tensioner

body-camshaft

drive.

Valve

spring-inner.

61.

Lock washer for bolt.

101.

Chain tensioner cylinder.

Valve spring

collar-top.

62.

Dowel-clutch

to

flywheel.

102.

Chain tensioner spring.

Valve cotter.

63.

Key for crankshaft. 103.

Chain tensionerslipper head.

Spring clip for valve cotter.

64.

Crankshaft chain

wheel-camshaft

drive.

104.

Chaintensioner back plate.

Tappet.

65.

Shim for chainwheel. 105.

Joint washer for chain tensioner.

Push-rod.

66.

Crankshaft chain wheel-injection pump drive.

106.

Bolt for chain tensioner.

Connecting

rod-Nos.

I and

3.

67.

Shim for chain

wheeL

107.

Lock washer for bolt.

Connecting

rod-Nos.

2 and 4.

68.

Oil thrower.

lOS.

Chain tensioner

body-injection

pump:drive.

Cap for connecting rod.

69. Timing disc.

109.

Chain tensioner cylinder.

Bolt for connecting rod cap.

70. Bolt for dies.

110.

Chain tensioner spring.

Lock washer for bolt.

71. Spring washer for bolt.

111.

Chain tensioner slipper head.

Big-end bearing.

72.

Crankshaft

pulley-dynamo

drive. 112.

Chain tensioner back plate.

Small-end bush.

73.

Crankshaft

pulley-hydraulic

pump drive.

113.

Joint washer for chain tensioner.

Piston.

74.

Bolt for hydraulic drive pulley.

114.

Packing block for chain tensioner.

Compression

ring-top

groove.

75.

Spring washer for bolt.

115.

Joint washer for packing block.

Compression

ring-2nd

and 3rd grooves.

76.

Starting nut.

116.

Bolt for chain tensioner.

Scraper

ring-slotted.

77.

Lock washer for starting nut.

117.

Lock washer for bolt.

Gudgeon pin.

78.

Camshaft.

118.

Oil

pipe.

Circlip.

79.

Camshaft bearing

liner-front.

119.

Banjo bolt.

Tractometer drive housing.

SO.

Camshaft bearing liner--centre.

120.

Washer for banjo bolt.

.

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DIESEL ENGINE

A

Section A.2

EXTERNAL

The external filter is

that all oil

filter before reaching the bearings.

Oil is passed· through the filter from
pressure controlled
the engine oil press.ure release valve.

Shou1d
ncglectt a balance valve is provided to ensure that oil

will

in

the lubrication circuit passes through the

the

filter· become completely choked due

still reach the bearings.

OIL

of

the full-flow type,

at

50

lb./sq. in.

FILTER

(3·5

thus

the

pump

kg./em.1)

ensuring

at

by

to

The filter element is removed by unscrewing

the

case from its base. A small

ag~

will occur when

this

waste container should be held

the

element is unscrewed.

amount

is done

of spill-

and

a small

underneath

as

a

LUBRICATION SYSTEM

The

/

i

\

~.

(

oil supply is carried in the sump

through a filler aperture in the valve rocker cover.

An

eccentric-rotor type oil pump, mounted exter-

nally

on

the left-hand side
driven by means
pressure
pressure relief valve fitted in the right-hand side
crankcase.

In
in
in

to

through a drilling. This same drilling connects with the

pressure relief

After

gallery on the right-hand side
to
big-end bearings are lubricated from· the main bearings
through the crankshaft, and a hole in each big-end feeds
oil

from the main bearings. A passage from the camshaft
centre bearing feeds oil to the camshaft skew gear and a
drilling from the camshaft front bearing supplies oil
the

rocker shaft via the· front rocker support bracket. The
oil
tunnels to the sump.

shaft chain tensioner
bearing.

injection pump chain tensioner.

(see

operation, the oil is drawn through a gauze strainer

the

sump and reaches the oil pump via drilled ·passages

the

sump and crankcase. The

the

full-flow filter

passing through the filter the oil enters the main

the

crankshaft main bearings by branch drillings. The

to

the thrust side

is fed to the camshaft bearings through passages

Oil

cylinder head where further drillings lead to the

from

At

the front

An oil pipe from the chain wheel hub feeds the

of

askew

'GENERAL DATA') is controlled by the

v_alve.

the rocker gear drains down the push-rod

of

the main gallery, oil is fed to the cam-

gear

on

the opposite side

of

the cylinder bores. '

and

the injection pump chain wheel

and

is

of

the· crankcase,

on

the· camshaft. The oil

oil

passes from the pump

of

the crankcase

of

the crankcase and

replenished

is

shaft-

of

the

is

fed

to

A..9

A

DIESEL ENGINE

Inspection

(4)

Check the relief valve spring against the specifi­cation given

(5) Check the valve seating by appJying engineer;s blue

to the conical valve face and testing for continuous
marking.
using tool 18G 69.

Refitting

(6) Reverse the procedure in (I) to (3), ensuring

the cap nut washer is in a serviceable condition.

Section A.6

in

'GENERAL DATA'.

If

necessary, lap the valve onto the seat,

that

Fig.

A.2

Removing

the

oi/pressure relie/vaive

with

tool 18G

Section A.4·

OIL PUMP

Removing

(1) Remove the four bolts securing the oil pump

left-hand side
pump from the engine.

Dismantling

(2) Remove the two cover-plate screws and lift

cover-plate and

Inspection

(3) Check the

given in 'GENERAL DATA'.

(4) Check the

in 'GENERAL DATA'.

Reassembling

(5) Reverse the dismantling procedure.

of

the crankcase and detach tbe oil

'0'

ring.

rotor

lobe clearance against the figure

rotor

end-float against the figure given

69

to

off

the

the

TRACTOMETER AND

OIL

PUMP

DRIVE

SHAFT

Removing

(l)

Unscrew the centre-bolt and remove the oil filter
bowl and element.

(2) Disconnect the tractometer cable from the angle

drive.

(3) Remove the tractometer drive housing and with-

draw the oil seal from the (later"type) housing.

(4) Withdraw the drive shaft, allowing

disengage from the camshaft. Slight rotation
crankshaft may be necessary
shaft gear to' clear the crankshaft web.

it

to rotate

to

allow the drive

Inspection

(5) Ensure that the drive shaft

that

the oil

drive are not worn

Refitting

(6)

Grease the drive shaft seal and reverse the pro­cedure in (1)
drive sufficiently
of

the drive shaft as it engages the camshaft.

pump

or

to

(4), starting with the oil

out

is

perfectly straight

drive and tractometer square

damaged.

of

line to allow for rotation

to

of

the

and

pump

(

\

Refitting

(6) Reverse the removing procedure, with the driving

slot

in

the pump shaft positioned

tongue

Section

A.S

on

the drive.

OIL PRESSURE RELIEF VALVE

Removing

(1) Unscrew the centre-bolt

bowl

and

element.

(2)

Unscrew the relief valve cap nut and withdraw the
relief val

(3) Remove the plunger, using tool

ve

spring.

and

remove the oil filter

180

A.IO

to

engage the

69.

When

thtJt

rebushing

the

buSh

Fig.

the

lorged-type

joint is

in

A.3

the

valve

rocker

position·

elfSUre

indicated

I

~

\

Section A.7

DIESEL ENGINE

A

VALVE ROCKER SHAFT AND

TAPPETS

RemoviDg

Valve

rocker shaft

(1) Disconnect

Unscrew the two rocker cover retaining nuts and

(2)

remove the two engine sling brackets.

(3) Remove the rocker cover, cup washers,

the

breather pipe from

the

rocker cover.

and

rubber

bushes .

. (4) Remove the eight nuts

four

plates from the rocker shaft brackets, and

lift

off

th~

rocker shaft assembly.

and

spring washerS,

and

Toppets

Carry

out

Withdraw

(5)

assembly

(6) Remo.ve

the

engine

The

tappets should

in

th.eir

the procedure

the

in

their original positions.

the

two covers from the left-hand side

and

original positions.

in

(1)

to

push-rods

lift the tappets

be

labelled

(4).

and

label them for

out

of

their hoUsings.

to

ensure reassembly

Dismantling

Valve

Tock~rsluJft

(7)

Remove the grub screw locating the rocker shaft in
the

front mounting bracket

(8)

Withdraw

and

spring washers from the ends

slid~

the rockers,

shaft.

(9) Remove

shaft

to

the

split

pins, remove

brackets,and

the

screwed plug fitted

clean

out

the oil-way.

•.
the

of

the shaft, and

springs from the

in

one

fiat washers

end

of

Inspection

(10) Check the ro·cker bush to rocker shaft clearance

against the figures given in
If

the rockers are

bushes are worn, the rockers should

If

the bushes are worn in forged rockers, they should

be

renewed using tools 18G 226

of

the pressed-steel type,

Fit new blishes with the·· butt

the

top

of

the rocker bore,

'GENERAL DATA'.

and

be

renewed.

and

180226

joint

positioned

and

drill oil holes

the

of

the

the

A.

at

in

Fig.

A.S

Fitting a valve

each bush
rocker.
the adjuster screw from the rocker
the end plug

(2·26

rom.) drill. Replace the drilled-out plug with

a rivet (part
The second hole
a No. 47, ·078 in. (1'98 mm.) drill,

shQuld then
'GENERAL DATA'.

(11) Ensure

that

the ends

(12) Check the diameter

figure in 'GENERAL
bottom face

rocker

bush

and18G

to

coincide with the oil-ways in

If

the holes are drilled after fitting, remove

and

No.

be

burnish-reamed

that

the

push-rods are peq"ectly straight

are

of

the tappets for wear.

226

bush, using a No. 43, ·089 in.

SC 2436) and.weld

in

the

bush should

not

damaged.

of

DATA'~

Reassembling

Valve

rocker shaft

(13) Reverse the procedure in (7)

Refitting

Tappets

(14)

Reverse the'procedu:re in (5)

U$ing

tools

18G

226

A

and

drill through

it

in position.

be

drilled with

and

the

to.

the

size given

the tappets against

·and examine

to

(9).

and

(6).

the

bush

in

and

the
the

(

\

Fig •

The

pressed-steel type

not

of

be

..4.4

valve·

rocker,

rebushed

which

should

Valve

rocker

(15)

Revers~

following points:

(a) Tighten

figure given

(b)

Adjust
in Section A.13.

Section A.8

Removing

(1) Remove the

to

(10».

(2) Remove

shaft

the

procedure

the

rocker bracket nuts

in

the

valve rocker clearance as described

in

'GENERAL DATA'.

CYLINDER

bonnet

the

radiator expansion tank.

and radiator (Section B.3, (1)

(1)

HEAD

to

(4), noting the

to

the torque

A.l1

A

Fig.

A.6

Compressing

(3)

Remove the bowl from the hydraulic filter
drain

(4)

Release and withdraw the suction pipe from the
top

of

(5)

Disconnect the hydraulic pressure pipe union
located just above

(6)

Release the hydraulic pressure pipe from the
bracket on the cylinder head by unscrewing the
two nuts and removing

(7)

Remove the three bolts securing the hydraulic

pump

(8)

Detach
pump

(9)

Remove the exhaust pipe and silencer from the

manifold.

(10)

Remove the air cleaner

(11)

Remove the fuel filter (Section C.5, (1) and (2) ).

(12) Disconnect and remove the fuel return pipe from

the injection pump.

(13) Remove the hydraulic tank (Section M.5, (1) to

(9)

).

(14)

Disconnect the high-pressure pipes from the
injectors.

(IS) Remove the feed and the three connecting links

from

(16)

Remove the rocker shaft and push-rods. (Section

A.7, (1) to

(17)

Withdraw the engine . breather pipe from the
bracket grommets. .

(18)

Slacken the water by-pass hose clips.

(19)

Remove the

and

A.12

the

valve

springs

the system.

the hydraulic reservoir.

the

mounting bracket to the cylinder head.

the drive belt and remove the hydraulic

from the engine.

with

engine oil filter.

the

CU'

clamp'.

to

manifold hose.

the heater plugs.

(5».

11

cylinder head nuts

lift the cylinder head off the cylinder block.

tool

18G

and

flat washers,

nmSEL

45

and

ENGINE

Dismaniling

(20) Unscrew the heater plugs from the cylinder head.

(21) Remove the two nuts and washers securing the

and

exhaust manifold,
securing both air
both manifolds away.

(22) Remove the spill pipe and clamps from the in-

jectors, and . withdraw the injectors from the

cylinder head, using tool

18G

284

P.

(23)

Unscrew the three nuts and remove the water
outlet elbow. Ease the outlet elbow gasket off
three studs

(24) Detach the spring clips from the valve cotters

using tool

remove the cotters,
the inner and outer valve springs, the valve oil seals,

and

the valve spring

(25)

Withdraw the valves from their guides, marking

them for reassembly

(26)

The combustion chamber inserts can be removed by

means

locatian in the

faces

machined after fitting
they are removed
ensure reassembly

(27)

The injector nozzle heat shields can
wards
combustion chamber inserts.

Inspection

(28) Check the cylinder head

(29)

Ensure

head are free

(30)

Check
'GENERAL DATA'.

and

withdraw the thermostat.

18G

45

of

a drift inserted thro'ugh the injector

top

of

the combustion chamber inserts are

out

of

the cylinder head after removal

that

the heater plug drillings in the cylinder

of

the

valve springs against the specification

the six nuts and washers

and

exhaust manifolds,

18G 284 and adaptor

to

compress the valve springs,

the

valve spring

bottom

of

the

in

carbon.

cups.

in

their original positi.ons.

the cylinder head. The lower

to

the cylinder head,

inserts should be labelled to

their original positions.

be

joint

face for flatness.

top

tapped up-

A

Fig.'

A.7

The

valve

guides

in position.

R

in.

(15 mm.)

Dimension

(A)

should

and

lift

the

aad,

collars,

and

of

the

be

in

if

(

\

..

(

DIESEL ENGINE

(31)

Check

the valve stem

figures given

guides
be

H in. (15 mm.) above the valve spring seat

surface

(32) Check the valve head stand-down against the

figure in

in

are fitted, the

of

the cylinder head.

'GENERAL

Reassembling

(33) Reverse the procedure

following points:

(a) Ensure

of

(b) Check

chamber inserts are

head face.

(c) Renew

,

of
of
washers.

(tl) ,Tighten the injector clamp' nuts

that

each

heat

that

the

the

heat

the injector

in

given

Refitting

(34) Reverse the procedure in (1) to (19), noting the

following points:

(a) Ensure

in
with
uppermost.

(b) Working

tighten

figUre

(c) Tighten

figure given

(d) Adjust

A.13).

(e)

Refill the hydraulic system (Section M.6).

(I)

Refill
(11)

(g) Bleed

that

a serviceable condition and' is fitted dry

the

the

given

the

the

the

or

Section B.6,

the

to

guide clearance against the

'GENERAL DATA'.

top

face

of

DATA'.

in

(20)

the

joint

washer under the flange

shield

is

in

serviceable condition.

the lower faces

not

pr()ud

corrugated washers

shields

'GENERAL

side marked

in

cooling system (Section B.I, (9) to

fuel system (Section C.8).

and

check the serviceability

to

heat shield flange

DATA'.

the cylinder head

'TOP'

the

order shown

cylinder head nuts

in

'GENERAL
rocker bracket nuts
in

'GENERAL

valve rocker clearance (Section

(6)

to

If

new valve

each guide should

to

(27), noting the

of

the combustion

of

the cylinder

in

the

bottom

joint

to

the figure

joint

washer

and

'FRONT'

in

Fig. A.9

to

the

torque

DATA'.

to

the torque

DATA'.

(9) ).

is

Fig.

A.9

Cylinder

head

nut

tightening

sequence

Section A.9

CAMSHAFT,

Removing

Timing

cover

(1)

Remove the radiator (Section B.3,

(2)

"Remove the hydraulic

(3)

Remove the dynamo

(2)

"

(4)

Remove the water

"'(5) Unscrew the starting

crankshaft.

(6)

Unscrew
drive pulley from

(7)

Withdraw the
shaft.'

(8)

Remove

'timing cover from the engine.

Injection

Carry
(9)

Remove the oil thrower from

(10)

Unscrew
pump

(11)

Unscrew the
flange from the injection pump chain wheel.

(12)

Detach
the

(13)

Remove

aild withdraw the injection pump driving chain

c01l1piete'

(14)

Remove
of

to

(5».

TIMING

the

GEAR, AND

PLATE

and

pump

four bolts

the

crankshaft pulley.

pump

drive belt (Section K.5,

(Section B.4, (3) to (5».

nut

and

cranksh~tpulley

th~

13

securing bolts and detach the

pump

driving

out

the

driving chain tensioner.,

the

face

of

the

camshaft driving chain wheel.

chain

and

procedure

the

two bolts

two halves

the injection

the

key from the frqnt

With

any

shims fitted

in

four

bolts

both

its chain wheels.

tensioner

(1)

and

and

of

the retaining' plate from

pump

on

ENGINE

(1)

drive belt.

from the front

detach, the hydraulic

from

to

(8).,_

th~

crankshaft.

remove

remove the driving

chainwheel.

of

the crankshaft

to

the

'

the

the

A

FRONT

(10) ).

of

the

crank-

injection

crankshaft

in

front

Fig.

The

top

faces

of

the

valves

cylinder

A = ·018

to

·038 in. ('46

A.8

should stand

.~ead

face

to

·97 mm.)

below

the

Camshaft

Carry

(15)

(16)

(17)

driving

out

Rotate'the
both
position shown

Unscrew
using

Unscrew

. driving chain tensioner.

chain

the

procedure in

crankshaft' until the timing marles

camshaft driving chain wheels are

the

tool

18G

the

and

tensioner

in

Fig. A.12.

,nut

from

98

A.

two bolts

(l)

to

(14)~

the

end

of

the camshaft,

and

remove the camshaft

in

on

the

A.I3

--=-==

nmSEL

II

9S

A

A

''';O'O:::==------=---A65

Fig.

A.lO

Slackening

(1S)

Withdraw the camshaft driving chain complete
with both

(19) Remove

the camshaft driving chain wheel.

the camshaft

its

chain wheels.

any

shims fitted on the crankshaft behind

nut

with

toollSG

Camshaft

Carry

out

the procedure

(20) Remove

(Section A.7, (1) to

(21)

Remove

(22)

Unscrew
locating plate.

(23) Withdraw

diseng~.ge

Engine

front plate

Carry

out

(20)

to

in
but is

not

(24) Disconnect

injection

(25) Remove

the

(26) Remove

nect the high-pressure pipes from the injectors.

(27) Disconnect and.remove the oil pipe from between

the chain tensioner packing block
pump
Unscrew

(28)

the crankcase and front main bearing cap, and
remove­pump

joint

the

the

fuel lift pump (Section C.4,

the

three bolts and remove the camshaft

the

from

the procedure in

(23)

(camshaft removal) may also be carried

necessary.

the

pump.

the

fuel feed and return pipes from between

injection

washer

pump

the

radiator expansion

chain wheel hub.

the

five bolts securing the front plate

the

front plate complete with injection

and

high-pressure pipes.

at

in

(1)

to

(19).

valve rocker shaft and tappets

(6».

camshaft, allowing

the oil pump drive.

(1)

to

throttle and stop controls from the

and

filter.

the

top

fixing hole.

.

(1)

to

(3)

it

to

rotate

(19). The procedure

tank

and discon-

and

the injection

Note

the separate

).

to

out

to

ENGINE

the chain tensioner packing block and the injection
pump

chain wheel hub.

(30) Remove the injection

(3) ).

(31)

Remove the chain wheel

Inspection

(32)

Examine the crankshaft front oil seal, and renew it
if

there is the slightest sign

(33)

Check both chain tensioners.
mouth

('OS

and

head
existing body, provided the body is
condition.

(34)

Check the clearance between
chain wheel hub
'GENERAL DATA'.

(35)

Fit
shaft,
float) between the locating plate
the camshaft journal.
the figure given in 'GENERAL DATA', renew the
locating plate.

Refitting

Injection

(36)

Reverse the procedure in (29) to (31), noting the

following points:

(a)

(b)

Engine

(37) Reverse·· the procedure

the fuel· system as described in

of

the body bore is in excess

mm.), the chain tensioner should be ·renewed;

if

the slipper head is badly worn, a new slipper

and

cylinder assembly should be fitted

the

locating plate

and

measurel· the clearance (camshaft end-

pump

chain

After refitting the injection pump driving
chain it
timing as described in Section C.6, (S4)
When all.fuel system unions have been recon­nected, bleed
Section

will

C.S.

front plate

pump

(Section

hub

from the front plate.

of

wear

If

the

and

bearing against the figures in

and

chain wheel to

If

the end-float is outside

wheel

hub

be necessary to reset the injection

the

system

in·

(24) to

Section C.S.

C.6,..

or

damage.

ovality

of

in

serviceable

injection

and

the face

as

described in

(2S)

and

(1)

near

·003 in.

to

pump

the

to

bleed

to

the

the

cam-

of

(

(S7).

Injection

in (15)
sary.

(29) Disconnect

Carry

pump

out

the procedure

to

(28)

may

chain

and

wheel

hub

in

(1)

to (14).

also

be

carried out

remove the oil pipe from between

A.l4

The

but

is not neces-

procedure

Checking

the

chain

edge

Fig.

wheel

and

A.II

alignment

feeler

gauge

with

a straight-

Camshaft

(38) Reverse the procedure in (20)

following points:

(a)

Fit

the camshaft retaining plate with its white-

metal· face towards the camshaft.

(b) Bleed the fuel system as described in Section

C.8, after the lift pump has been connected

into the system.

(c) Adjust the valve rocker clearance as described

in Section

A.13.

to

(23),

DIESEL ENGINE

noting the

A

(

Camshaft

(39)

driving

Rev~J:'se

following points: .

(a) Secure

(b)

(c) To refit the chain tensioner, remove the plug

chain

and

tensioner

the proct!dure in (16) to

both

chain wheels,
shafts.
engine and check the chain
by
faces.
shims behind the crankshaft chain wheel
position it ·005 in. (·127 mm.) rearwards
camshaft chain wheel.
When the driving chain and wheels are
assembled
the timing marks line

from the base
the cylinder and spring into the slipper
plunger,
key, rotate the cylinder in a clockwisedirec­tion until
the peg inside the plunger. Fit the slipper

Push both chain wheels towards the

nieans

assembly into the tensioner body, hold the
complete assembly in the closed position,
using the Allen
base,rotate
tion
the plunger peg. Still holding the assembly
closed, refit

of

a straight-edge across the teeth

Increase

until

or

to

their respective shafts ensure that

of

and

using a

it

is held

the cylinder

the helical groove

and

"decrease the thickness

up

the tensioner body. Assemble

in

key

.through the· hole

lock the plug in the· base

(19),

less

chain,

wheel' alignment

as shown in Fig. A.12.

tin.

(3·18

the closed position by

in

a clockwise direc-

is

felt to engage

noting the

to

their

of
to

of

the

mm.) Allen

and

in

the

of

Fig.

A.13

Using

too/18G 3

to

centralize

the

timing

cover

crankshaft

the tensioner . body
the closed position by wrapping with wire.
After fitting the chain tensioner

remove the wire.

Injection

(40)

. following points:

Timing

(41)

pump

driving

Reverse the procedure in

(a)

Check and adjust the chain wheel alignment
as described in (39)
teeth faces should be in line.

(b)

The timing marks

on

the injection pump driving flange should
be positioned as shown
are assembled to the engine.

(c) Refit the chain tensioner. as described in

,

(39)

chain

(c).

cover

Reverse the procedure in (1)

18G 3

to

centralize the timing cover

shaft,

and

fill

the

to (11)

or

Section B.6,

an,d·

secure the plunger

to

and

tensioner

(9)

to

(14), noting

(a),

but

in this case

on

both chain wheels

in

Fig. A.12 when they

to

(8), using tool

cooling system (Section B.l, (9)

(6)

to (9) ).

on

the engine,

on

the

crank-

the

in

the

the

and

Fig.

Showing

the

positions

timing

1.

Injection

2.

Injection

3.

Crankshaft chain

4.

Crankshaft chain wheel-camshaft drive.

S.

Camshaft chain wheel. .

pump
pump

oj

gear

is

correctly

..

driving flange.
chain wheel.

wheel~injection

A.12

the

timing

assempled

marks

when

pump drive.

the

Section A.tO

FLYWHEEL AND BACK PLATE

Removing

Flywheel

(1)

Remove the clutch (Section

(2) Remove the six flywheel to. crankshaft bolts

withdraw

the

flywheel from the

Backplate

Carry out the procedure in

(3)

Unscrew the six bolts and remove the oil seal
housing from the back plate. .

(4)

Remove the

from

the

in the groove

12

bolts and withdraw the back plate

two locating dowels, noting the

in

the back plate.

(1)

0.2,

(l).to

two

locating dowels.

and (2).

(23)).

'0'

and

ring

A.IS

A

DIESEL ENGINE

Inspection

(S)

Examine the crankshaft oil seal,
there is

(6) Examine the starter ring teeth for wear

If
a hole and splitting it with a hammer
Heat
perature given in 'GENERAL
of
change from pink
correc}:.
facing away from the flywheel register.

the

slightest sign

necessary, remove

the new starter ring uniformly

temperature-indicating paint

to

Fit

the starter ring with the

of

damage.

the

starter ring by drilling

grey when the temperature is

DATA';

Refitting

Backplate

(7) Reverse the procedure

in

(3) and (4).

Flywheel

(8) Refit the flywheel and tighten the bolts

figure given in 'GENERAL

(9) Reverse the

noting

(40)

(b),

(10) Adjust the cllitch pedal free movement (Section

D.1,

(11) Bleed

(12) Refill

Section

SUMP,

A.II

CRANKSHAFT, AND MAIN BEARINGS

procedu~

the

points mentioned

(c),

and

(e):

(1)

to

(3)

).

the

fuel system (Section C.8).

the

hydraulic system (Section M.6).

D:ATA'.

in

Section D.2, (1)

in

Removing

Sump

(1)

Drain

the sump.

(2)

Remove the radiator (Section B.3, (1)

(3) Raise the front

under the gearbox.

(4)

Remove the front axle (Section G.1, (2), (3), (5),

(6)

and

(7) ).

(S)

Take the weight

(6) Remove the clutch (Section D.2, (3)

(21)

to

(23) ).

(7) Remove the flywheel

(2)

to

(4».

(8) Remove the

sump

to

the engine, noting:

(a)

The

(b)

THe
bearing cap joint.

Oil strainer

Carry

out

the procedure in (1)

(9)

Unscrew the two bolts securing the oil suction pipe
flange

to
oil stra:;.ner bracket
oil strainer and suction pipe.

A.16

of

the tractor and place a support

of

the engine on a crane.

and

13

bolts

the crankcase

'0'

ring

at

the oil pick-up

oil sealing strip

the sump

and

to

back plate (Section A.IO,

and

two nuts securing the

and

remove. the

at

the sump

to

(8).

the

two bolts securing the

the

sump, then remove the

and

renew it

or

da~age.

and

to

the tem­the strip

on

the ring will

tooth

chamfer

to

the

Section D.2,

to

(10) ).

to

(16)

sump

joint.

to

front

chisel.

torque

to

(23),

and

from

main

if

Crankshaft

Carry

(10) Remove the engine front plate (Section

(11) Unscrew

(12) Remove the main

(13) Remove the crankshaft, the main bearing

and

main

bearings

out

the procedure in (1) to (8).

(S), (7)

caps with their bearing halves,
necting rods
rods and caps should be marked
in their original positions.

bearing bottom halves,

The
be
their correct positions.

to

(19),

and

the

connecting

up

washers positioned

main bearing caps,

marked

halves,
on

the faces

and

to

ensure

the

two

of

the centre bearing housing.

(2S)

to

(28».

rod

cap bolts, remove the

the cylinder bores. Connecting

"bearing cap bolts, caps, main

and

the two

on

the faces

and

the crankcase, should

that

the caps are replaced in

half

thrust washers positioned

A.9.,

and

push the con-

to

ensure refitting

half

of

the centre cap.

(2)

thrust

Inspection

(14) Check the crankshaft journals for

figures in 'GENERAL DATA'.

(IS) Check the crankshaft

against the figures in 'GENERAL

(16) Check

Refitting

Crankshaft

(17)

(18) Refit the front plate and timing gear by reversing

(19) Ensure

. the engine,

the

crankshaft end-float against the figures

in

'GENERAL DATA', and adjust the end-float

by

selective assembly

and

main

bearings

Fit

the main bearings
crankcase
the
to

the

the
(19),

(a) Check the chain wheel alignment as described

(b)

(e) Ensure

(d) Use tool 18G 3 to centralize

are
connecting rods
bolt -heads should be towards

figure given

and

caps, fit the crankshaft

crankcase; tighten the main bearing cap bolts

torque

procedure

and

in

Refit the timing chain tensioners as described

in

in Fig. A.12.

to

correctly located in the rods

figure given

in

(2)

to

Section A.9, (39) (a)

Section A.9, (39) (c).

that

the crankshaft.

that

the connecting

and

in

'GENERAL DATA'.

to

main

of

the thrust washers.

and

in

Section A.9, (25)

(5), noting the following points:

the timing marks line

to

the

crankshaft noting

tighten the bolts

wear

against

bearing clearance

DA~A'.

thrust washers

'GENERAL DATA'.

to

and

(40)

the

rod

big-end bearings

and

caps. Refit the

the

camshaft side

to

to

and

caps

(28), (7)

(a).

up

as shown

timing cover

that

the torque

Oil strainer

(20)

Fit

the oil strainer

and

tighten the suction pipe flange bolts before

tightening the oil strainer bracket bolts.

~nd

suction pipe into the sump,

Sump

(21) Refit the sump

securing bolts and nuts evenly.

to

the crankcase and tighten the

to

top

the

the

to

to

the

of

/

;

\.

DIESEL ENGINE

A

(9) Remove the rocker shaft

A.7,

(1) to (5) ).

(10) Remove the cylinder

(11)

and

(12), (14) and (15),

(11) Unscrew

caps
connectin'g rods
cylinder bores. The connecting rods ,and caps
should be marked
original positions.

the

connecting

with their bearing

and

and

push-rods (Section

head

(Section A.S, (6) to (9),

and

(17)

to

(19) ).

rod

cap

bolts, remove the

halves~

pistons

to

and

withdraw the

fro~

the

top

ensure refitting in their

of

the

Pistons . "

Carry

(jut the procedure

(12)

Mark

the pistons

'the,circlips,

Fig.

A.I4

Refitting a piston

lSG

55

(22)

Fit

the

back

and

(S».

(23)

Fit

the
SectionD.2,
following points:

(a)

Position the clutch driven plate

in

Section D.2, (40) (b)

(b)

(

\

(24)

(25) Bleed
(26) Refill
(27) Refill

(2S) Refill

Adjust

, described

(c)

When

injection pump, ensure

the

Refit

the

procedure

B.3~

(1)

to

the
the
the

Section B.6

the

and

connecting rod, using tool

A

to

~ompress

plate

clutch by ,reversing

(21)

to

the clutch pedal free movement as

in

Section D.1,

connecting

pump

has its full range

front axle

in Section
(10).

fuel system (Section C.S).

hydraulic system (Section M.6).

cooling system (Section

(6)

to

sump.

the piston

and

flywheel (Section A.10, (7)

(23)

and

and

the

stop control cable

that

and

radiator by reversing the

G.l,

(2)

(9) ).

ring~'

the

procedure in

(3)

to

(16),

(c). '

(1)

to

(3).

the stop lever

of

movement.

to

(7)

B.l,

as

and

(9)

noting

the

described

to

the

on

Section

to

(11)

or

.

release the pistons from the connecting rods.

Inspection

(13) Check the big-end bearing

against the figures
(14) Check the connecting
(15) Check the gudgeon

in 'GENERAL DATA'.

(16) Check the piston ring

figures

(17) Check the piston ring

bore,

Refitting

Pistons

(18) Refit the pistons

that

the combustion
on'the
big-end' cap.

Connecting rods

(19)

Fit

the connecting

cylinder bores, using

" the piston rings.

and

in

'GENERAL

against

opposite side

in

(1)

to

(11).

to

ensure correct refitting, remove

press

out

the

gudgeon pins

to

crankpin clearance

in

'GENERAL

rod

alignment. ,

pin

clearance

DATA'.

again~t

'

grooveclearan~e

DATA'.

gap,

in

an

unworn

the figures

in

'GENERAL

to

the

connecting,rods, ensuring

trough

in

the

'piston crown is

of

the connecting rod

rods

and

pistons into

tool

18G,55 A to compress

the figures

against

part

DATA'.

the

'

of

the

to

the

the

to

Section A.12

CONNECTING

Removing

Connecting rods

(1)

Drain

the

s'ump.
(2) Remove the radiator (Section B.3,
(3) Raise

(4) Remove the front axle (Section

(5)
(6)

(7)

(8) Remove the sump (Section A.11,

the

,'front

under

the

gearbox.

(6),

and

(7)

Take

the

weight
Remove the clutch (Section D .2,
(21)

to

(23) ).
Renlove the flywheel
(2)

to

(4)).

RODS

of

the

).

of

the

"

AND

PISTONS

(1)

to

trilctor

and

and

place a support

G.l,

(2), (3), (5),

engine

on

a crane.

(3)

to

backplate (Section A.I0,

(S».

(10».

(16)

and

The correct assembly

pistons to the crankshaft

Fig •

.4,.15

of

the connecting rods and

A.17

A

Fig.

A.16

Checking and adjusting the

(20) Ensure

that

the big-end bearings are correctly
located in the connecting rods
connecting rods and caps to the crankshaft with the
bolt heads towards

The combustion troughs in

should now be

on

to the camshaft. Tighten the connecting rod bolts

to the torque figure given

NOTE.-The

big-end bearings

connecting rods, and the rods should be fitted so that
the

bearingS

of

Nos. 1 and 3
rear of the engine, and the bearings
are offset towards the front (see Fig. A.l5).

(21) Refit the cylinder head by reversing the procedure

Section A.S, (17) to (19), (14)

in
(12), and

(a)

(6)

to (9), noting the following points:

Ensure that the cylinder head

a serviceable condition
side marked 'TOP' and

(b) Working in the order shown in Fig. A.9,

tighten the cylinder head
figure given

in

(22) Refit the rocker shaft

the prccedure in

Section A.7, (1)
the rocker bracket nuts to the torque figure given
in 'GENERAL DATA', and adjusting the valve
rocker clearance

(23) Refit the sump

securing bolts
Fit

(24)

(25)

the back plate

(7)

and

(S)

Fit

the clutch by reversing

Section-D.2, (21)

as

to

and

).

to

following points:

(a)

Position the clutch driven plate as described
in Section D.2,

(b) Adjust the clutch pedal free movement as

des~ribed

(c) When connecting the stop control cable to the

in Section D.1, (1)

injection pump ensure
the pump has its full range

A.I8

valve

rocker clearance

and

the camshaft side

the

the opposite side

in

'GENERAL DATA'.

are

and

is fitted dry with the

'FRONT'

nuts

'GENERAL DATA'.

and

push-rods by reversing

described

in

the crankcase and tighten the

nuts evenly.

and

flywheel (Section A.10,

(23) and (4)

(40)

(b)

and

that

DIESEL ENGINE

caps,

a~d

fit the

of

the engine.

piston crowns

of

the engine

are

offset on the

offset towards the

of

Nos. 2 and 4

and

(15), (11)

joint

washer is in

uppermost.

to the torque

to

(5), tightening

Section A.13.

the

procedure in

to

(16), noting the

(c).

to

(3).

the

stop lever

o.f

movement.

and

on

(26) Refit

procedure in
B.3, (1) to

(27) Bleed

front axle

(10).

the

fuel system (Section C.S).

Section

and

radiator by reversing the

0.1,

(2)

to (7)

and

Section

the

(28) Refill the hydraulic system (Section M.6).

B.1,

(9)

to

(11)

(29) Refill the cooling system (Section

Section B.6,

(30)

Refill the sump.

(6)

to (9)

).

or

Section A.13

VALVE ROCKER CLEARANCE

of

The clearance between the ends

the valve rockers is checked

Crank

check

the

the

engine until

clearance

of

by

No.8

No.1

fully closed.

To

adjust the clearance, hold the adjusting screw with
a screwdriver and slacken the locknut. Rotate
ing screw until the clearance between the valve stem and
rocker is as given in 'GENERAL DATA'. Hold the
adjustings("Tew against rotation and lock it in position
with

the

locknut. Then re-check the clearance.

the

Check

remaimng rocker clearances by reference to

the following table:

No. I valve (ex.) with
No.3

valve (in.) with

No.5

valve (ex.) with

No.2

valve (in.) with

No~

8 valve (ex.) with

No.6

valve (in.) with

No.4

valve.(ex.) with

No. 7 valve (in.) with

No.8
No.6
No.4
No.
No.1
No.3
No.5
No.2

Fig.

A.17

Valve timing diagram

A. Inlet valve opens.

B.

Exhaust valve

c.

Exhaust valve opens.

D.

Inlet valve

closes.

closes.

Eo

. B.T.D.C.

F.
G.

the valve stems and

means

of

a feeler gauge.

valve is fully open and

valve which will now be

the

adjust-

valve fully open.
valve fully open.
valve fully open.

7 valve fully open.

valve fully open.
valve fully open.
valve fully open.
valve fully open.

F

G

Static injection timing,
Top dead centre.

Bottom dead centre.

16

0

('

\.

(

Section A.14

DIESEL ENGINE

A

VALVE TIMING

Set the valve rocker clearance

to

valve

·020 in. (,51

Crank

the engine until the exact

inlet valve is

plunger contacting the

about

mm..).

to

open. A clock gauge,

valve spring collar, will facilitate

this operation.

The

timing disc

5° B.T.D.C. position

Reset

the

(see

figure

Section

A.1S

on

the crankshaft should now show
in

the set

valve rocker clearance

'GENERAL DATA').

VALVE SEAT

If

them

the valves

to

their original efficiency

and

seats are

paste.

In

the event
valve grinder
and

reface
cutters shown
prepare

of'

to

the

in

the seats

severe pitting,

the'angle given ~ 'GENERAL

valVe

seats by means

Section

and

then the cutters

Remove only as much metal as is necessary

seats and then ·restore them to
'GENERAL

If

the

machine

DATA') by the use

seats

cannot

out

the

be restored

seatings

Fig. A.18 and press special inserts

Fi'g.

Valve

seat

machining

Inlet (A)

c. 1'031 in. (26'187

D.

1'135

to

(28'83

E. 1·2565

(31'915

F.

·070

c.

(1-78

G.

·258
(6'55

H.

Maxiniu'D radius ·015 in.
('381 mm.).

J.

4So.

K.

30°.

1'140 in.

to

tol·2S75

to

to

·075 in.

to

[,9

to

':!61 in. .

to

,5'63

.....

mm.).

28·956 mm.).

in.

31·94 mm.).

mm.).

mm.).

CHECK

of

No.1

cylinder inlet

point

at

which

of

markings identified 1.4.

to

the correct running

RECONDITIONING

not

badly pitted, restore

by

lapping with grinding

ref

ace the valves

of

the

R.

Use

the

glaze' breaker

to

clean

to

their

correct width (see

of

narrowing cutters.

by

the

recutting process,

to

the

dimensions given

into

the cylinder head.

A.18

dimensions

Exhaust (B)

L.

1-0375

to

(~6'352

M.

·916
(23'266

N.

·812.5 in. (20'638 mm.).

P.

·070
(1'78

Q.

'258
(6'55

R.

Maximum
(·381 mm.).

s.

45°.

T. 20°.

1'0385 in.

to

to

'921 in.
to

to

·075 in.

to

1·9 min.).

to

·261

to

6·63 mm.).

26·377 mm.).
23'393 mm.).

in~

.

radius ·015

No.1

wi:th

its

the

on

DATA'

valve seat

to

them

up.

correct

the

in

in.

Recu~ting

a

Cut

new valve seats

given

in

Fig. A.IS

insert blends

After reconditioning
valve stand-down against
DATA'.

Section A.16

Removing

Centre

bearing

(1) Insert pilot

bearing liner
adaptor
from the rear.

(2) With the body

centre screw, pass
adaptors already fitted into the bearing liners.

(3)

Place the slotted washer on
centre screw
behind the slotted washer.

(4) Tighten

bearing liner.

Front

~drear

(5) . Insert adaptor

liner from inside

(6) With the body

centre screw, pass
in

the

(7) Place' the slotted washer

the. centre screw, fit the ·tommy-bar in position

behind the slotted washer, and tighten up
nut

(8) Withdraw the

(5)

to

Fig.

A.l9..

a

valve

.into

seat with tools t8G

and

,18G

167

in

the

inserts

and

the

ensure

throat

the

in

valves

the

dimensions

that

the

27,

D

to

the

the

throat

cylinder head.

~nd

seats, check the

in

'GENERAL

CAMSHAFT BEARING LINERS

liner

adaptor

180

124 B into

and

up

the wing

bearing

180

from

inside the crankcase, and

oftoo1180

the

fit the tommy-bar in position

nut

liners

18G

124

the

crankcase.

of

too1180

the

screw through the adaptor

. . '

124 K

the

124 A positioned

screw

the

to

Kinto

124 A positioned

into

centre bearing liner

through

fiat

at

the

withdraw the centre

the front bearing

frontbea.ring.

on

to

withdraw

(7),' but using

the fiat

the

front bearing liner.

rear

bearing liner as described
adaptor

18G

·124

at

M.

18G

167,

dimensions

of

each

the front

on

the

the

two

rear

of

the

on

the

the

rear

the

wing

A.19

of

in

A

DIESEL ENGINE

Fig.

A.20

Removing a camshaft
tool

18G 124 A and

18G

124

K.

The

inset

liner

being

replaced

1. Slotted washer.

2. Slotted washer.

3.

'D'

washer.

4. Adaptor 18G

124

liner

using

adaptor

shows

K.

the

Fitting new bearing liners

The bearing liners should

holes line up

Front

(9)

with the oil boles

and

rear

Place the
diameter

bearing

new

of

adaptor 18G

be

so

positioned

in

the bearing housings.

liners

front bearing liner on the small

124

K and insert the

adaptor, large diameter first, into the front bearing
housing from inside the crankcase.

(10)

With the
the centre

b.ody

screw,

of

tool

pass the

180

124

A positioned on

screw

adaptor in the front bearing housing.

(11)

Position the larger

centre

screw

washer turned

of

the two

'D'

washers on the

with the cut-away portion

away

from the butt joint in the

bearing liner.

(12)

Place the slotted washer on the
the centre

screw

and fit the tommy-bar in position

flat

at

behind the slotted washer.

(13)

Tighten the

wing

nut

to

pull the bearing liner into

position.

(14)

Fit the rear bearing liner
(12),

and

(13),

but using adaptor

as

described· in (9),

180124

that

their oil

through the

of

the

the rear

of

(10),

M.

Centre

bearing

(15)

Insert pilot adaptor 18G

liner

214

K into the front

bearing liner from inside the crankcase.

(16)

Place the new centre bearing· liner on the small

of

diameter

adaptor

180

124

B and insert the

adaptor, large diameter first, into the centre
bearing housing from the rear.

(17) With the body

oftoQl180

214 A positioned
centre screw, pass the screw through the two
adaptors already

(18)

Fit the larger
centre

screw with the cut-away portion

positioned in the crankcase.

of

the two

'D'

washers onto the

washer turned away from the butt .joint in the
centre bearing liner.

(19)

Place the slotted washer on the fiat
the centre screw,

fit

the tommy-bar in position

behind the slotted washer and tighten the

to pull the centre bearing liner into position.

Reaming the bearing liners

Lightly lubricate

and

pilots

to

it.

the

arbor

before assembling the cutters

at

the rear

o~

of

wing

the

the

of

nut

The

camshaft

A.20

liner

reamer set

up

to

line

..

ream

(A)

Fig.

the

A.21

front

and

rear

liners

and

(B)

the

centre

Mini Tractor.

liner

Issue

3.

(

7927

DIESEL ENGINE

A

Feed the reamer very slowly. Keep the cutters dry and

cutter

flutes

free

of

the

swarf, preferably with air-blast

equipment.

When half-way through each bearing, withdraw the

cutter and remove all swarf from both cutter and

bearing

liner.

When reaming is completed, thoroughly clean all the

oil-ways.

Front and rear bearing liners

(20)

Insert

pilots 18G

and

centre

180

123

the

through

cutter

arbor

the

pilot

AN,

the

lSG

into the

(21) Place

(22) Pass

(23) Secure cutter

cutter

18G

(24)

Ream

the

pilot

lSG

bearing liner.

(25) Release

draw

the

the arbor.

Centre bearing liner

(26)

Insert

pilots

the

front

(

\,

(27) Pass

front
and

and

the

arbor

bearing,fit

slide the

bearing liner.

(2S) Secure cutter

arbor

and

(29) Release

the

Section A.17

The

cylinder liners
oversize
up

cylinder block, using either specialized proprietary

equipment,
as shown

moving

when fitting new liners

of

·020 in. (·51 mm.).

at

this figure, remove

or

a power press

in

Fig. A.22.

old

liners is 5

123

AT

and

18G 123

rear bearing liners respectively.

18G 123 AQ, followed

on

the

arbor

18G 123

arbor

pilot in

123

AP

ISG

123

AP

through

pilot

123

in

the

the

centre bearing liner.

onto

the

in

the rear bearing housing.

AN

in position

position

front bearing liner, clear

123

AQ

enters,

cutters

from

their positions

ISG

123

Be

and

rear

bearing liners respectively.

lSG

123 A through

cutter

18G

arbor

into the

ISG

123 B in position

A.

front

bearing

arbor

and

No.

No.7,

on

it

of

swarfbefore

then

ream

18G

123 BB into

the

123 B onto

pilot

No.7

ream the centre bearing liner.

cutter

and

CYLINDER

may

be

them

The

to 8 tons

it

is 3 tons (3048 kg.).

withdraw

LINERS
bored

If

through

and

necessary pressure when re-

the

arbor.

out

to

the liners will

the

top

a set

of

adaptors

(5080

to

8128 kg.)

BA

into the

by

cutter

and

Fit

then

slide

10,

and

the

arbor.

the

rear

and

with-

pilot in the

the

arbor

in

the

rear

on

the

a maximum

not

clean

face

of

the

made

and

Fig.

A.22

Cylinder liner pilots should be made to the

above
dimensions from case-hardening steel and case­hardened.

The pilot extension should be made from
55-ton hardening and tempering iteel, hardened in
oil,

and

then tempered at a temperature

of

5500 C.

(1,0200 F.)

Pressing-out pilot

A. 2·5937

B. 2·452

c. Ii- in. (44'45 mm.).

D.

E. i in. B.S.W. thread.

F. 31 in. (82'55 mm.).

G.

H.

J.

K.

L '003

M.

N.

p.
Q.
R.

s. ! in. B.S.W. thread.

T.

Press new liners

block, leaving

·002

to

·005 in. (·05

block face.

Do

After fitting, machine

dimension given in

~:ggg

in. (65·88

::g8~

in. (62'28

1-

in; (19'05 mm.).

Pressing-in

to

be

machined

(66'68 mm.) apart.

21 in. (69'85 mm.).
2·451

~:gg<f

11

in. (31·75 mm.).

tin.

(15·87 mm.).

::88i

10!-

in. (26'7 em.).

tin.

(22·22

on

this diameter,

in. (66'26

in. ('076

Pilot extension

mm.).

i in. (15'87 mm.).

i in. (15·87 mm.).

1 in. (25'4 mm.) flats.

1*

in. (31·75 mm.).

in

from the

the

top

face

of

to

·13 mm.)

not

machine the

and

'GENERAL

::M6

mm.).

+:m

mm.).

pilot

Two

parallel flats

21

in.

::m

mm.).

::g~~

mm.).

top

face

of

the

cylinder

the liner parallel with,

proud

of

the

cylinder

top

face

of

the

liners.

hone

the

liner bores

DATA'.

to

and

the

A.21

B

FUNCTIONAL'DESCRIPTION

The
fresh

The

fold

returned

type

The
driven
from
board

In
a
circuit

SEJ.'-\.
This

Before

indirect

water

coolant

and
water

open

the

discharge.

order
thermostat

WATER

is a self-priming
single
curved

system

circuit
circulation

surge

to

the

pump.

circuit

sea

water

fresh

that

the

fitted

when

neoprene

cam

each

the

PUMP

plate

initial

and

tank,

surge

water

engine

coolant

impellor.

uses

pump

to

(Fig.

at

the

start"

through

of

heat

an

in

the

tank.

sea

passes

closed

will

the

temperature

B1)

positive

top

turn

COOLING

exchange

open

sea

closed

the

Flow

water

reach

cylinder

of

drawn

it

circuit, . and

displacement

The

impellor

the

down

water

circuit

heat

exchanger

is

continuous

through a sea-cock

through

its

operating

head

has

impellor

grease

SYSTEM

cooling

circuit.

is

from

the

heat

finally

will

open

reached

has

housing"

cup

is

used

the

combination

and

engine

and

is

exchanger

into

the

temperature

to

allow

1750F.

rotary
flexible

one

pump,

vanes

producing

full

turn.

and

consists

water

assisted

and

strainer,

where

engine

as

quickly

circulation

.

with

which

the

of a closed

exhaust

jacket,

by a centrifugal

it

collects

exhaust

as

in

brass

wipe

pumping

mani-

and

an

engine

for

possible,

the

closed

case

against

action.

then

heai

over-

and

a

·a

1

2·

1.

2.

3.

4.

5.

6.

3

Screw

Cover
Gasket

Snap-ring

Impeller

Shaft

4

5

7.

8.

9.

10.

11.

12.

Cam

Screw-cam

Body

Seal

Plug
Grease

Cup

,

1 1

12

Fig.

Bl.

Sea

Water

Pump

Bl

B

THERMOSTAT

Removing:

1.

Drain
surfaces

2.

Loosen

3.

Remove

cylinder

4.

Lift

housing

5.

Remove

Inspection:

6.

Place
ture

this

temperature

Refitting:
7 .

Ensure

8.

Reverse

9.

Fill

and

1

o.

Start
ture,
tion
inch

the

cooling

of

the

clamp

the

head.

gasket

thermostat

at

which

all

gasket

the

bleed

engine

check

for

leaks.

from

top

system

thermostat

securing

three

from

procedure

and

thermostat

of

retaining

cylinder

and

thermostat.

in a bowl

the

valve

figure

material

cooling

after

Check

tank

so
housing.

water

head;

commences

in

"General

in 2 to

system.

engine

housing

level

if

required.

that

hose

nuts

of

water

is

removed

has

of

the

coolant

to

thermostat

securing

disconnect

and

heat

opening

Data".

from

5"

coating·

reached
mounting
water

in

level

the
water

it

slowly.

and

the

the

its

normal

surface

surge

is

below

housing.

thermostat

hose.

Note

is

fully

mounting

new

gasket

operating

and

water

tank

and

the

housing

the

open,

surfaces.

fill

with

hose

to

within

and

mounting

to

the

tempera-

check

sealer.

tempera-

connec-

one

.

FRESH

CAUTION:
gradually

Open

by
COLD

Water
siderable
avoided

Only
rosion

WATER

DRAINING

1.

Turn
is

2.

Leave

3.

the

turning

WEATHER

expands

by

anti-freeze

inhibiter

1.

2.

3.

4.

5.

6.

PUMP

THE

As

the

when

Press
continue

cylinder

Drain
Pour
required
Add
Run
Add
Attach a label

the

felt.

it

in

risk

adding

in

water

the

sufficient

the

the

and

COOLING

system

filler

cap

cap

the

cap

turning

block

an

anti-clockwise

PRECAUTIONS

when

of

bursting

anti-freeze

of

the

is

suitable.

flush

the

(see

until

engine

is

pressurized

cap

is

slowly

in

this

Qbwnwards

until

drain

it

freezes,

the

ethylene

the

cooling

correct

table).

the

level
until
water

to

it

the

SYSTEM

when

removed.

anti-cloGkwise

position

it

can

tap

located
direction.

tank

to

the

glycol

quantity

is

to

bring

filler

until

against

be

lifted

on

and

if

precautions
or

water.

type

system.

of

is 1 inch
hot.

the

neck

indicating

hot,

until

all

the

the

cylinder

anti-freeze

from
surface

the

the

pressure

spring

off.

left-hand

incorporating

top

the

pressure

resistance

to

clear

are
block.

for

of

tank.

up

to

that

anti -freeze

side

not

the

the

is

the

of

taken,

Such

the

degree

correct

must

of

the

released.

safety

the

cylinder

there

damage

correct

working

has

be

released

safety

stops,

is
may

type

of

of

protection

been

stops

and

block

con-

be

cor-

level.

added.

NOTE:
with

B2

The

solution

strength

as

necessary.

of

the

anti-freeze

solution

must

be

maintained

by

topping

up

B

REMOVING

1.

Drain

2.

Slacken
drive

3.

Unscrew

4.

Sl~cken

5.

Unscrew
from

FRESH

the

the

belt

the

the

the

water

DISMANTLING

6.

7.

8.

Using
Extract
tap

Withdraw

water

out

an

extractor,

the

the

seal.

WATER

cooling

dynamo

from

four

by-pass

the

four

pump

bearing

spindle

the

vane

system.

the

water

bolts

water

and

PUMP

mounting

pump

and

hose

clips

pump

adaptor.

withdraw

locating

bearing

from

the

~

6

(Fig.

and

pulley.

remove

body

the

wire

assembly.

spindle,

5

B5)

adjusting

the

water

bolts

pulley

through

and

hub

the

using

.9~.

IO~

link
pump

withdraw

from

hole

an

extractor,

bolts

pulley.

the

spind.le.

in

.

14--t.

and

the

the

disengage

water

pump

and

remove

pump

body

the

and

the

1. By-pass

2. Washer

3.

Water

4.

Joint

5.

Set
Joint

6.

7. Vane.

pump

washer

screw

washer

adaptor.

for

for

by-pass adaptor.

adaptor.

for

pump

adaptor.

pump

adaptor.

body.

pump

for

F(r:

B.5

Water pump :omponents

8. Seal.

9. Set screw

10.

Fibre

11. Water pump body.

12. Set screw for body.

13. Shakeproof washer.

14. .Locating wire for bearing.

for

lubricating point.

washer. for set screw.

19

~~

~~

21

15. Bearing assembly.
Hub

for

16.

11.

Water

18. Set screw for pulley.

19.

Spring washer.

20. Set screw for body and adaptor.
Spring washer.

21.

pulley.

pump

pUlley.

A

"")0

J.

6559

18

~

B3

B

INSPECTION

9.

Check
spindle
components.

10.

Ensure

REASSEMBLING

11.

Fit
bearing
locating

12.

Press
body

13.

Press

REFITTING

14.

Reverse

the

the

(see

interference

(see

that

the

bearing

coincides

wire

the

vane

Fig.B.

the

pulley

the

procedure

GENERAL

bearing

as s embly

with

and

the

water

onto

4).
hub

the

onto

fit

of

DATA).

grease

into

the

lubricating

seal.

spindle

the

in 2 to

both

the

If

retainers

the

pump

until

spindle

5,

and

A

pulley

the

hole

its

to

fill

hub

fit

has

are

body.

in

face

the

dlmenslon

the

cooling

been

in

good

Ensure

the

is

...

and

the

destroyed,

·condition.

body,

flush

system.

vane

that

and

with

shown m Flg.

the
fit

the

on

renew

hole

the

face

the

bearing

.

pump

the

in

the

of

the

B.4.

Fig.

B4.

Water

A = 3;961 to 3·981 in. (100·609 to 101·117 mm.).

Pump

.Assembly

(

\

Dimension

134

(

SECTION C

FUEL SYSTEM (DIESEL MODELS)

c

Altitude settings

Filter-main

Injection

Injectors

Lift

pump

Maximum

Tap

.•

pump

••

and

..

idling speed adjustment ••

..

C.IO

CoS'

C.6

C.7

CA

C.9

C.3

(

\

C.l

n

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11$

THE INJECTION PUMP COMPONENTS

86

8~

71"-..

72

73

66

____

77

'"

r

~70

'~

/ f

~:':~-.78

/'/

'-----

~

12~

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88

,,:"-

.

=-

'67.

~79

II~

er--

18

89

90

84-AJ~.'

..

"·~

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

~

..

::"

..

_.'

..

yBI

80

I~--l

~i!

:~~

~

7

__

1fJ

fIiil

_

~

~"-"75

9-~

:

69

--{)

1ill!J~.....-

13

P---;;=-L~

ft

i-

6-.-~

~

)9

20 22

68

__

, n . -.-··74

5--~~JI

~~

64-

=-it

57

58

59

60

61

/",?"

-;

:~,

65-

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4 / . ,".

56

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&:::

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63

52

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.".......

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53

62

30

55

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~

31

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23

35

34 38

40 42

44~

45

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25

33

36

37

cO,.-39

41

43

.

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27

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.

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1

119

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120

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125

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124

~

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128

9"

:'=.-~~\;

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100 104

103

102 105

6.6855

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11'1'

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KEY

TO

THE

INJECTION

PUMP

COMPONENTS

No.

Description

No.

Descriptio"

No.

Description

1.

End plate.

44.

Governor weight.

87. Control cover.

2. Locating pin.

45. Weight retainer.

88.

Control cover vent screw.

3.

Screw for end plate.

46.

'0'

ring for drive shaft.

89.

Body for vent screw.

4. Stud for end plate. 47. Control bracket.

90.

Washer for vent screw body.

5.

Nut for stud.

48. Screw for bracket.

91.

Gasket for control cover.

6.

Piston retaining spring.

49. Tab was4er for screw. 92.

Pump body.

7.

Regulating piston.

50.

Governor arm.

93.

Joint washer for pump mounting flange.

8. Regulating sleeve.

51. Spring for governor arm.

94.

Drain connection.

9.

Washer for sleeve.

52.

Governor spring.

95.

Washer for connection.

10.

Regulating spring.

53.

Spring guide.

96.

Hydraulic head locking screw.

11.

Spring peg.

54.

Shut-off bar. 97. Washer for screw.

12.

Transfer pressure adjuster. 55. Metering valve. 9S. Vented locking screw for hydraulic head.

13.

Sleeve retaining spring.

56.

Linkage hook.

99.

Vent screw.

14.

Filter.

57.

Spring retainer.

100.

Drive hub.

15. Inlet connection.

58. Linkage spring. 101.

Drive hub seal.

16.

Washer for inlet connection. 59. Linkage washer.

102. Drive shaft screw.

17. Fuel

feed

pipe connection.

60. Pivot ball washer. 103. Spring washer for screw.

IS.

Olive for fuel feed pipe.

61. Backing washer.

104.

Support washer.

19.

Transfer pump seal.

62. Linkage nut. 105. Quill shaft.

20.

Transfer pump rotor.

63. Keep plate.

106. Cover plate.

21. Transfer pump vanes.

64.

Control cover stud. 107. Gasket for cover plate.

22. Transfer pump liner.

65.

Tab washer for stud.

lOS.

Screw for cover plate.

23.

Hydraulic head and rotor assembly.

66.

Nut

for stud.

109. Washer for screw.

24. Rotor plug.

67.

Washer for nut.

110.

Advance unit housing.

25. Washer for plug.

6S.

Throttle shaft.

111.

Gasket for housing.

26. Hydraulic head seal.

69.

'0'

ring for shaft.

112. Stud for housing.

27.

Banjo pipe.

70. Dust cap for shaft.

113. Cap nut for stud.

2S.

Bolt for banjo pipe.

71.

Nut

for shaft.

114.

Washer for cap nut.

29. Washer for bolt.

72.

Washer for nut.

115.

End plug for housing.

30.

Radial connection.

73.

Throttle arm. 116.

'0'

ring for plug.

31.

Washer for connection.

74. Shut-off shaft.

117.

Spring cap for.housing.

32. Adjusting

plate-bottom.

75.

'0'

ring for shaft.

11S.

'0'

ring for spring cap.

33.

Adjusting

plate-top.

76. Dust cap for shaft.

119.

Screw for spring cap.

34.

Roller.

77.

Nut

for shaft.

120. Washer for screw.

35.

Roller shoe.

78. Washer for nut.

121. Advance piston.

36.

Drive plate.

79.

Shut-off lever.

122.

Outer spring for piston.

37. Drive plate screw.

80. Idling stop screw.

123. Inner spring for piston.

38. Cam ring.

81.

Locknut for screw.

124.

Hydraulic head locating bolt.

39. Cam advance screw.

82.

Washer for

nut~

125.

Outer

'0'

ring for bolt.

40. Circlip.

83.

Maximum speed stop screw.

126.

Inner

'0'

ring for bolt.

41. Drive shaft.

84.

Locknut for screw.

127. Washer for bolt.

42. Thrust sleeve.

85. Washer for mit.

128.

Non-return valve ball.

43. Thrust washer.

86.

Sealing cap.

e

III

.... , ...

11"",""".11

••

"""""" " "",.""""

••••••

11

••

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••••

++++

...... , ••••••

11

................ +++++++++++++++

..

+++++'

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..

11",

•••••

,+++++++++++++++,

""",

•• , ••

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•••••

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........

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•••••••••• ,

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..

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~

OWNERS

NOTES

(

\

\

FUEL SYSTEM (Diesel Models)

Section C.3

FUEL TAP

Removing

(1) . Turn the fuel tap off.

Disc9nnect the fuel supply pipe

(2)

return pipe

from

their connections

and

injector spill

on

the fuel tap.
(3) Drain the fuel tank.
(4) Unscrew the fuel tap from the fuel tank.

Inspection

(5) Thoroughly clean the pencil-type filter gauze,

to

attached

the fuel tap, with fuel

(6) Inspect the pipe connections

and

a stiff brush.

in

the fuel tap for

damage to the threads and seats.

Refitting

(7) Reverse the removal procedure

bleed the fuel system (Section

in

C.S).

(1)

to

(4),

Section C.4

FUEL ·LIFT

Removing

(1) Turn the fuel tap off.

(2) Disconnect the two fuel pipes from the lift pump.
(3) Unscrew the two nuts and withdraw the lift pump

from the engine.

PUMP

and

Fig. C.4

Section through the

1. Diaphragm spring. 9. Clamp.screw.

2.

Diaphragm.

3. Pump cover.

4.

Outlet valve.

5.

Inlet valve. 13. Operating link.

6.

Filter gauze.
Sealing ring. 15.

7.

8.

Filter bowl.

fuel

lift pump

10.

Steel

11.

12.'

14.

16.

w~her.

Sealing washer.
Pull rod.

Rocker arm return spring.

Pump

body.

Rocker arm.

Dismantling

(4)

Scribe a mark across the pump body and cover
joint flanges for location purposes during re­assembly.

(5)

Slacken the clamp screw

and

remove the pump

filter bowl.

(6)

Withdraw the bowl sealing ring and the filter gauze
from the pump cover.

(7)

Remove the

five

screws

and

separate the cover

. from the pump body.

(S)

Press the centre

wards and rotate it through
pull-rod

from· the operating link. Withdraw the

of

the diaphragm lightly down-

90° to disengage the

diaphragm assembly and remove
washer, steel·washer, and
the pull-rod.

(9)

If

the rocker arm assembly is to be removed,

.

diaphragro spring from

secure. the rocker arm in a vice and tap the face
the pump mounting flange with a soft mallet until
the rocker arm pin retainers

are dislodged.

the

sealing

of

Inspection

(10)

Examine the

pump

body and cover for cracks
damaged threads, and ensure that the faces
mounting and diaphragm flanges

(11)

Examine the diaphragm for splits or cracks.

(12)

Check the rocker arm pin and linkage for wear

are true.

damage.

(13)

. Check' the operation

in the pump cover.
the valve assemblies

of

the inlet and outlet valves

If

they are not serviceable prise

out

of

the cover with a screw-

driver, renew the valve gaskets, and fit new valve

assemblies into position. Press the new valve
assemblies fully home and stake the cover casting
in six places round each valve with a punch.

of

or

the

or

C.s

c

FUEL SYSTEM (Diesel Models)

Section C.S

Main fuel filter components

1.

Centre bolt.

2. Washer.

3. Filter head.

4. Sealing plug.

5. Copper washer.

6. Non-return valve.

'Ao---IO

1188!&!ii~:-JJ

1-----11

Fig.

C.S

7.

8.

9.

10.

11.

A

6590

Sealing ring.
'0'

ring.
Element.
Sealing ring.
Filter

base.

MAIN

FUEL

FILTER

Removing,

(1)

Disconnect the fuel pipes from the filter head.

(2)

Remove the two bolts from the filter head mount­ing flange and withdraw the filter from the engine.

Dismantling

(3)

Unscrew the centre-bolt
detach the base from the filter.

(4)

Separate the filter element from the filter head.

(5)

Remove the sealing ring from the filter base, and
the sealing ring and

(6)

·Remove the non-return. valve from
connection and the sealing plug from No. 4
(outlet) connection·

in'

the filter head and

'0'

ring from the filter head.

in the filter head.

Inspection

(7)

Examine the filter head and base castings for

damaged threads, damaged seal seats, and cracks.

(8)

Check the operation

of

the non-return valve.

Reassembling

(9)

Reverse the procedure

in

(3)

to

(6).

Refitting

(10)

Reverse the procedure in (1) and
fuel system as described in Section

(2),

C.S.

Section C.6

No.3

(in1et)

and bleed the

(

Reassembling

(14) Reassemble the rocker arm, operating link,

packing washers, onto the rocker arm pin. Place
this assembly, and the rocker
into position in the pump body and tap two new
rocker

arm pin retainers into the grooves in the

body casting. When the retainers are

secure them

grooves.

(15) Fit the diaphragm spring, steel washer, and sealing

washer onto the
the pump body with the notched fiat on the lower

of

end
operating link.
and rotate it through

with the operating link.

(16)

Push the rocker arm towards the pump until the
diaphragm is level with the body joint flange. Hold
the rocker
body with the scribe marks in line,
five

screws evenly.

(17) Refit

Refitting

(18) Reverse the procedure in

fuel

system as described in Section

C.6

in

position by staking· the ends

pull·rod. Insert this assembly into

the pull·rod in line with the slot in the

Press the diaphragm downwards

90°

arm

in this position, fit the cover to the

the filter gauze, sealing ring, and

arm

to engage the pull-rod

(1)

to (3), and bleed the

and

return spring,

fully

home

of

and

tighten the

:filter

bowl.

C.S.

the

FUEL INJECTION PUMP

Removing

(1)

Disconnect the throttle and stop controls, and the
fuel feed and
pump.

(2)

Disconnect the high-pressure pipes from the

injectors.

(3)

Remove the three securing nuts and plain washers
and withdraw the injection pump from the engine.

Dismantling

(4)

Disconnect the high-pressure pipes, remove the
cover-plate from the side
and drain the

(5)

Withdraw the quill shaft from the drive hub and
check the drive hub end-float by inserting a feeler
gauge between the drive hub and pump body.
The end-float should not exceed
Excessive end-float can be corrected by renewing
the pump body and the governor weight retainer.

(6)

Mount the pump on assembly base 18G
secured in a
pressure connections from the hydraulic head.

(7)

Unscrew the nuts and remove the shut-off lever

and throttle arm from their shafts. Withdraw the

dUst

cover from each shaft and remove the two

nuts and washers securing the control cover.

return pipes, from the injection

of

the pump housing,

fuel

oil from the pump.

·010

in.

vice

and remove the four high-

(·254

mm.).

633

A

FUEL SYSTEM (Diesel Models)

(S)

Press the throttle shaft downwards and withdraw
the control cover complete with shut-off shaft.
Discard theco'ntrol cover gasket.

(9) Detach the governor spring from the governor arm

and the shut-off

Remove the two control cover
set screw securing the control bracket. Detach the
keep plate and lift the control bracket assembly
from the pump.

(10)

Disconnect the metering valve from the linkage
hook and

place the valve in a container of, Shell
Calibration Fluid
ground surface.

(11)

Disconnect the linkage hook from the governor
arm. Detach the governor arm spring
the governor arm from the

(12)

Slacken both the spring cap and end plug in the
advance unit. Remove the hydraulic head locating
bolt complete
not
side

(13)

Remove

to

of

with its outer

lose the non:-return valve ball located in the

the head locating bolt.

the

cap-nut

advance unit from the pump. Detach the inner

ring

and

washer from the head locating

and discard the advance unit

(14)

Unscrew the spring cap and

advance unit

and

the piston. Note the 1 mm. shim inside the spring

cap.

(15)

Remove the end plug and

,

advance unit.

(16)

Unscrew the cam advance screw from the cam ring,
with spanner

(17)

Slacken the fuel inlet connection

ISG 646.

screws and studs securing the end plate to the
hydraulic head. Lift
and withdraw the transfer pump liner.

(1S)

Unscrew the fuel inlet connection

the regulating valve components in the following

order: sleeve retaining spring, nylon filter, transfer
pressure -adjuster, regulating spring
regulating sleeve with piston and joint washer, and
lastly the piston retaining spring.

(19)

Hold the drive hub with tool lSG 659 and, using
spanner

lSG 634, slacken the transfer
by turning it in the direction of pump rotation as
shown

on the pump nameplate.

(20)

Remove the two hydraulic head locking screws,
one

of

which incorporates an air vent valve, and
withdraw the hydraulic head and
from the pump. Remove the

I

I

\

'--

groove in the periphery

(21)

Unscrew the transfer pump rotor,

,the pumping

out

fall

(22)

Stand the hydraulic head with the drive plate

and

of

the hydraulic head.

uppermost. Hold the drive plate· with spanner

180641

and unscrew the two drive plate screws

bar

from the control bracket.

studs and

'C'

to protect its precision-

and

the

small

separate

control bracket.

'0'

ring, and take care

and

washer, and' withdraw the

bolt

hole,

sasket.

'0'

ring

from

withdraw the two springs and

'0'

ring from the

and

remove the

out

the transfer

of

the hydraulic head.

pump

and

pump

rotor

'0'

ring from the

but

do

vanes

withdraw

and

peg,

rotor

assembly

not allow

distributing rotor assembly to

'0'

the

(see Fig. C.7). Remove the drive plate and
adjusting plate,

and

withdraw

the

rollers and shoes

from the pumping and distributing rotor.

(23) Withdraw the rotor from

the

hydraulic
remove the 'bottom adjusting plate, and refit
rotor to the hydraulic

head~

Immerse the head
rotor assembly in Shell Calibration- Fluid
protect the working 'surfaces.

(24) Withdraw the cam ring from the

noting the arrow etched

on

pump housing,

the visible

face
cam ring. This arrow indicates the,direction
rotation as shown on the

(25) Remove the cam ring locating

the pump, using circlip pliers

(26) Hold the drive hub with tool 18G

torque adaptor 18G

pump

nameplate.

circ1ip

ISO

644,

unscrew the drive

from inside

1004.
659

and~

screw from inside the' drive hub. Withdraw

drive shaft

and

governor weights assembly

inside the pump housing.

(27) Remove the

ring, the weight

reta~ner,

'0'

thrust washer, and sleeve from the drive shaft.

from

the

(28) Withdraw the drive hub

pump and remove
the spring washer and support washer from inside
the drive hub.

oil

(29) Remove the drive hub

housing, using tool lSG

seal from the

65S.

Inspection

(30) Wash all components in Shell Calibration

'C';

hold the pumping plungers in their bores

blowout the passages in the

rotor

with compressed

air.

(31) Remove the pumping plungers one at a time

examine them and their bores in the rotor for wear

Fig.

C.6'

Removing

the

drive

hub

18G

oil

658

seal,

using

extractor

top

head,

the

and

'C'

to

of

the

of

with

shaft

the

from

weights,

pump

Fluid

and

and

C.7

c

FUEL SYSTEM (Diesel Models)

Fig.

C.7

Holding the drive plate with spanner

unscrewing the drive plate screws

and abrasion.
polished where
plungers should be replaced in their original
positions.

(32)

Examine the hydraulic head bore·
surface
of
worn, renew the

(33)

Check the cam ring lobes for wear, the plunger

rollers for flats, and the roller shoes for freedom

their guides in the rotor.

(34)

Fit the drive plate
that
splines.

on

these components

there is no excessive radial movement

Th~

end

of

it

contacts the roller shoe, and the

the rotor for wear or scoring.

or

the pumping plungers are

rotor

and head as a unit.

to

the drive shaft

18G

641

each plunger

and

when

will

its mating

If

either

and

ensure

on

be

in

the

(35) Check

(36) Inspect the bore

(37) Check all springs for fractures

that

the transfer

fit

in

their slots when lubricated with fuel oil.

and

wear

freely through it.

the governor weight retainer, thrust washer, and
sleeve for signs

ensure that the valve piston can move

of

pump

vanes are a sliding

of

the regulating valve sleeve for

and

weakness, and

wear.

Reassembling

Rinse the components in clean Shell Calibration Fluid

'C'

and assemble them wet.

(38)

Fit

a new drive

using

tool18G

into the oil seal

tinuous black line should
plug.

(39)

Fit

the two washers into the drive hub and insert
the hub into the hub oil seal.
Using tools 18G

(40)

governor weights, thrust washer, and sleeve, to the
weight retainer (see Fig. C.8). The stepped flange
of

the sleeve must go away

(41) Slide the governor weight assembly onto the drive

shaft,

fit

shaft splines and a new
the drive shaft.

(42) Insert the drive shaft and weight assembly into the

pump housing and engage
with the splines in the drive hub. Fit the drive
shaft screw and, using tool
drive hub, tighten the screw with adaptor 18G 664
to

the torque figure given

Check the drive hub end-float as described in (5).

(43)

Using circlip pliers 18G 1004,

locating circlip against the shoulder in the pump

hub

oil seal

663.

Insert inspection plug 18G 660

and

examine the oil seal; a con-

661

and

protection cap

to

the pump housing,

be

visible through the

18G

662, assemble the

from

the thrust washer.

180

657 over the drive

'0'

ring

in the groove on

the

drive shaft splines

18G

659

to hold the

in

'GENERAL DATA'.

fit

the cam ring

(

\

Fig.

C.S

Assembling the governor weights, thrust washer, and
thrust sleeve into the weight retainer, using tools

18G

661

and

18G

662

C.8

Fig.

C.9

Holding the drive hub with drive

18G

tool
with torque adaptor

659 while tightening

18G

664

18G

537

shaft

screw assembly

the

drive shaft screw

and

torque wrench

(

Assemble the top adjusting plate and the drive plate
with the slots in their

mark

on

scribed

the pumping

housing. Place the cam ring in position against the
circlip

and

ensure that the direction

on the visible face

the

directiolJ.

of

the arrow
Fit the cam advance
the cam ring

for· freedom
hydraulic head and rotor are being renewed, ensure
that the direction
of

the

rotor

conforms with the direction

arrow

on

the pump nameplate.

(44) Withdraw the rotor from the hydraulic head and

fit the top adjusting plate· so that the slot in its

is

periphery
(see Fig.

in line with the mark on the rotor

C.l

0).

(45) Fit the drive plate to the rotor with its relieved face

top

next to the

periph~ry

on

the

rotor

screws lightly

adjusting plate and the slot in the

of

the drive plate

(see Fig.

and
assemblies into their guides
sure

that

the contour
forms.with the contour
top adjusting plate.

(46) Fit the bottom adjusting plate, engaging its slots

with the lugs on the top
ensuring

that

the. c()ntour

matches the contour 'of the roller

(47) Insert the rotor assembly into the hydraulic head,

fit.

then

. Stand the head and rotor assembly

(48)

and lightly tighten the transfer pump rotor.

drive plate uppermost.

180

adaptor

653
to high-pressure outlet
and connect this assembly

109

18G

(49) Operate the

and

A (see Fig. C.l2).

. pumping lever

tum

the

rotor
rotation until the pumping plungers are forced
outwards as far as the eccentric ,slots

will

ing plates
position.

allow; this is the maximum fuel

Using

tool18G

FUEL SYSTEM (Diesel Models)

Fig.

C.10

periph~ries

of

the cam ring conforms with

screw·

of

the arrow

C.1
insert the roller

of

of

A, preset

'V'

in the normal direction

aligned with the

end

of

th~

rotor

of

0;1.1

the pump nameplate.

finger-tight and check,

of

rotation.

on

the pumping end

in

line with. the mark

0). Tighten die drive plate

in

the rotor. Make

the roller shoe ears con-

the eccentric slots in the

adjustin~plate,

of

the

e~entric

shoe ears.

on

Fit

the relief valve timing

at

J 5 atmospheres

on

the'

hydraulic head

to

testing machine

of

the

testing

in the adjust-

656,

rotate the adjusting

the arrow

If

the

of

the

and

shoe

and

slots

the bench

machine

of

Fig.

C.ll

Tightening the transfer pump rotor, using

wrench 180536 and tools 180659' and

18G

torque

634

plates as necessary to set the roller-to-roller
dimension

at

the figure given in 'GENERAL

DATA' (see Fig. C.12). Hold the drive plate with

180641

tool
to

the torque figure given in 'GENERAL DATA'.

and tighten the drive plate screws

Disconnect the adaptor from the hydraulic head.

(50)

Rotate the drive shaft in the pump housing to

at

12

position the master spline

~O'

ring to the groove in the, periphery

hydraulic head

and

align the master spline in the

o'cloc~.Fit

drive plate with the metering valve bore

hydraulic head. Lubricate the periphery

of

hydraulic head and the bore
liberally with clean Shell Calibrated

the pump housing

FI uid 'C' and

assemble the hydraulic head to ,the pump body.

Fig.

C.12

Setting the roller-ta-roller dimension, using a micro-

meter

and tools 18G

109

A and

18G

653 A

a

of

in

of

new

the

the
the

C.9

FUEL

Fit the two hydraulic head locking screws finger­tight, positioning the screw with the vent valve
above the pump nameplate.

(51)

Hold the drive hub with tool
spanner 18G 634, tighten the transfer pump rotor
to the torque figure given
(see Fig.

C.ll).

Fit the transfer pump liner and

insert the transfer pump vanes into their slots.

(52)

Ensure that the locating peg
pump end plate and seat the piston retaining spring

of

in the bottom

(53)

Fit

a new seal washer to the small-diameter end

the regulating valve bore.

the regulating valve sleeve and fit the piston into
the

sleeve.

Insert the regulating spring and peg
into the large-diameter end of the sleeve and place
the transfer pressure adjuster

Fit

sleeve.

the sleeve retaining spring onto the
pressure adjuster and pass the filter, small end
leading, over the spring and onto the shoulder
the valve sleeve. Insert this assembly, valve
first, into the bore

of

the end plate and

inlet connection and washer.

(54)

Place a new sealing ring in its recess in the hydraulic
head face

and,fit the end plate to the head,engaging
the locating peg with the slot in the transfer pump
liner. Tighten the end plate screws and studs to the
torque figure given in 'GENERAL DATA', then
tighten the fuel inlet connection to the torque

in

figure given

(55)

Using spanner 18G

'GENERAL DATA'.

646,

screw to the torque figure given in 'GENERAL

and

DATA'

check the cam ring for freedom

rotation.

(56)

Fit

new

'0'

rings to the advance unit end plug and
spring cap, using protection cap 18G
the rings over the threads. Screw the end plug
finger-tight into the end
the fuel duct enters the bore. Fit the piston into the
advance unit, with its counterbored end at the open
end

of

the housing, and place the two springs in

position in the piston.

washer inside the spring cap and screw the cap

finger-tight into the housing.

end plug are renewed, ensure that the
the same identification letter as the component it
replaces.

Unmarked components should be used

to replace unmarked components.

(57)

Fit a new

'0'

ring under the head
head locating bolt, using protection cap
Position the non-return valve ball in the side
head locating bolt and fit the bolt to the advance
unit.

Using assembly cap

·0'

ring to the shank

of

the plain washer on top

(58)

Place a new advance unit joint washer on the pump
housing with the straight side
hole

at

the drive end

of
this joint washer should be fitted dry. Position the
advance unit

on

the pump,

and rubber washer to the stud, and

C.10

180

in

'GENERAL DATA'

is

in position

on

tighten the cam advance

of

the advance unit where

Place the 1·0 mm. shim

If

the spring cap

180647,

the locating bolt, and place

of

the

'0'

of

the pump; to ensure sealing,

fit

a new aluminium

SYSTEM (Diesel Models)

659

and, using

'C'

in

the

of

the top of the

sleeve

fit

the fuel

640

to pass

new

part has

of

the hydraulic

·18G

639.

of

the

fit

anew

inner

ring.

the 'D'-shaped

fit

the cap nut.

of

of

or

Setting the governor link length (the dimension
between the metering
cover

(59) Tighten the two hydraulic head locking screws, the

(60) Insert the metering valve into its bore in the

(61)

(62)

(63)

(64)

(65)

(66) Locate the. spring guide in hole No. 2 in the

Fig.

C.13

valve

lever pin and the control

stud) with the vernier held parallel to the axis

.

of

the pump

hydraulic
cap-nut, to the torque

head locating bolt, and the advance unit

figures given in 'GENERAL

DATA'. Tighten the advance unit end plug and

to

spring . cap

the torque figures given in

'GENERAL DATA'.

hydraulic head.

Assemble the governor arm,

governor arm spring, then

contr<>l

fit

bracket, and

the assembly to the
pump housing, ensuring that the lower end of the
governor arm engages the stepped face

of

thrust sleeve flange. Fit the keep plate with its open

fit

end towards the shut-off bar, and

new
washers with their pointed tabs towards the
governor arm.

Screw

in·

the two control cover

studs to the torque figure given in 'GENERAL

. DATA' and secure them with the pointed tabs.

Fit the small screw and tab washer to the metering

of

valve end

the control bracket. Tighten the screw

to the torque figure given in 'GENERAL DATA'

it

and lock

with the tab washer.
Assemble the spring retainer, spring, and linkage
washer onto the linkage hook.
end

of

the hook through the governor arm,

Pass the threaded

fit
pivot ball washer and backing washer, and screw
on the linkage nut about three turns.

Press back

the

spring retainer and attach the link­age hook to the metering valve so that the hook
end is turned towards the metering valve.
Press

the

governor arm lightly in the direction
the metering valve and, using a
parallel to the pump axis,.

(see

length

Fig. C.13) to the dimension

'GENERAL DATA'. This adjustment

or

slackening

tightening the linkage hook nut.

v~rnier

gauge held

set the governor link

given

is

made by

governor arm (see Fig. C.l4) and connect the

governor spring to the guide.

the

tab

the

of

in

Governor

1.

Hole No. 1 in the throttle shaft link.

2.

Hole

No.2

(67)

(

\

Insert the plain end
in the control bracket
under the tab

(68)

Using protection cap
rings

to

the shut-off and throttle shafts.

upper

'0'

ring to each shaft, using protection cap

180665,

and pack'

of

rings on each shaft with Shell Alvania

(69)

Press the shut-off
cover, positioning theeccentric.peg close to the
edge

of

the control cover and projecting slightly

from the

(70)

Place a new control cover joint washer in position

joint

face.

on the pump housing, engaging the tabs with the
slots under the keep plate. To ensure sealing, this
joint washer should be soaked in

'C' before assembly.

Fluid

(71)

Connect the free end
No.1

hole in the throttle shaft link

and press the throttle shaft into its bore in the

coVer.

control

Place the control cover in position
on its studs; ensuring that the shut-off peg engages
the

shut~offbar.Pull

as the control cover is lowered onto the pump

housing~

(72)

Fit

.

new sealing washers
and screw on the stud nuts to the torque figure in
'GENERAL DATA'.

(

\

(73)

Place the dust caps on the throttle and shut-off
shafts, fit the throttle arm and shut-off lever

th~ir

shafts and secure them

nuts and washers.

(74) Refit the inspection cover to the side

housing and refit

FUEL SYSTEM (Diesel Models)

Fig.

C.l4

spring

location

in the governor arm.

of

the shut-off bar into the s]ot

and position the shut-off bar

the control cover locking washer.

180654,.

tlu~

shaft

into its bore in the control

of

the shut-off shaft fully home

to

the

quill shaft.

fit

new lower

Fit

a new

groove, between the

No.2

grease.

Shell Calibration

the governor spring

(see

Fig. C.14)

the control cover studs,

in

position with their

of

the pump

'0'

'0'

to

to

Testing and adjusting

(75) The following precautions must

be

observed when

testing the pump:

(a) Ensure that the power-driven test bench is set

to

run

in the direction

of

pump rotation as

indicated on the pump nameplate.

(b) Ensure that the fuel flow

not less than 1,000 c.c./min.

at

the-pump inlet

If

this

flow

cannot
be obtained. a maximum feed pressure
2 lb./sq. in. ('15 kg./cm.

(c) Do

not

run the pump for long periods

2

is

permissible.

)

at

high

speed with low fuel output.

(el)

Do

not

run the pump

for

long periods with the

shut-off control in the closed position.

(e)

Ensure that the throttle and shut-off controls
are in the fully open position except where
stated otherwise.

(76) Mount the pump on the test bench and connect up

the drive.

.

(77) Fit radial connections to the four high-pressure

outlets in the hydraulic head and connect them, by
means

of

high~pressure

test injectors set to open
pipes should be 6 mm.

pipes to . a matched set of

at

175

atmospheres. The

X 2 mm. X

865

mm. (34 in.)
long, and the injectors should have Type BDN.12.
SD.12 nozzles mounted in Type BKB.50.SD.19b
nozzle holders.

'psing

(78)

flexible pipes, preferably

of

the transparent
type, connect the injection pump to the test equip­ment as 'follows.

(0) Fit transfer pressure'adaptor

of

the hydraulic head locking screw (not the

with the vent· valve),

one

180636

and

connect the

in place

adaptor to the pressure' gauge.

(b)

Fit

the end plate' adjuster '180

690

to

the fuel
inlet on the pump and connect the adjuster,
means

of

a

'T'

coupling,

to

both the fuel

supply and the vacuum gauge.

(c)

Corinect the pump drain

(back~leakage)

con­nection to the measuring glass inlet, and the
measuring glass drain cock to the test bench

. return connection.

.

(79)

Fit automa:tic advance gauge

advance unit spring cap in
screw.

Set the degree scale to give a zero read-

ing.

180

.place

638 B to

of

the small set

(80) Unscrew the idling and maximum speed stop

to

screws
range

Unscrew the transfer pressure adjuster in the pump

(81)

end plate to the
11

(82)

Fill and prime the injection pump as follows:

(a) Connect the

ensure that the throttle arm has its fun

of

movement.

maximuDl extent, then screw

turns. . .

fuel

feed pipe to the drain con-

it

nection on the pump.

(b)

Open both the vent screws

on

the injection
pump, turn on the gravity feed, and when
oil free

of

air bubbles

flows

from the vent
screw on the hydraulic head, close this vent
screw. When test oil free

of-air bubbles

flows

C.Il

is

of

by

the

in

test

FUEL SYSTEM (Diesel Models)

Fig.

C.15

Checking the automatic advance, using advance gauge

lSG

63S

B

from

the

control cover vent screw, close this

vent screw

(c)

Rotate

repeat the procedure in

(d)

Fit
connections.

(e) Slacken the high-pressure pipe unions

injectors
until oil, free
injector connections. Tighten the high-pressure
pipe unions while the

(83)

Check the oil-tightness

and

seals,
running
following sequence

Test

I-Transfer

Run
oil feed cock
sion registered on the vacuum gauge should

reach
maximum. Do not

exceeding

turned off. After the vacuum test
test oil supply
100 r.p.m. air-vent the pump
vent screw

Test

2-Transfer

Run
pressure gauge reading. This should be

11

Ib.fsq. in.

Test

3-Transfer

Increase the
pressure gauge reading should now

,,66

lb./sq. in. (3·5

Test

4-Advance

With
end plate adjuster
reading

C.12

-also.

the

pump

drive through IS0° and

(b).

the

feed

and

and

return pipes

run

the test bench

of

air

to

bubbles, issues from the

test machine is running.

of

all joint washers, oil

pipe connections, while the

and

when stationary. Then carry out the

of

tests:

pump vacuum

the

pump

at

100 r.p.m.

to

the

'off'

position. The depres-

16

in~

(406 mm.) Hg within 60 seconds

run

tbepump

60 seconds with the test oil supply

and

with the

on

the hydraulic head.

pump pressure

the

pump

at

100

r.p.m.

kg.fcm.

2

minimum.

)

(·S

pump pressure

pump

speed

to

to

4·7 kg.fcm.

setting

the

pump

of

running

21°.

to

at

900 r.p.m. set the

give

an

their respective

at

at

100 r.p.m.

pump

and

turn

the test

for periods

turn

on

pump

running

by

means

of

and

note the

Soo

r.p.m.

be

I

).

advance gauge

the

is

the

at

the

The

50 to

Test

5-Advance

Increase the
advance gauge reading should now
to

41°.

position

pump

speed

to

1,400 r.p.m. The

be

Test6-Back-kakage

Run

the

pump

at
back-leakage
be 5 to

Test

7-Maximumfuel

Run the
delivery for
injectors should

1,000 r.p.m.

in

the measuring glass:

50

C.c.

per

100 shot time cycle.

delivery

pump

at

1,000 r.p.m. The average

200 shots from all

be

2·9±·1

c.c.

and

In

measure the

it

should

four

arriving at

this figure compare the delivery from all

to

ensure

that

injectors

betwe~n

any two does

the difference

not
Before taking a reading allow
settle

in

measuring-glasses for
allow the glasses to drain
a fresh test is made.

turn

incorrect,
remove
pump.
tum

the

Slacken the two drive plate screws

the
periphery
Using tool

off the test oil supply and

cover-plate from the sido

pump

drive until the slot

of

the

top

ISO

656 engaged
the adjusting plate
to

correct the fuel delivery. Movement
adjusting plate
pump

rotation will increase· the output, and

movement

in

in

the opposite direction

for

30 seconds before

If

the fuel delivery is

adjusting plate is visible.

in

the direction necessary

the direction'

decrease output. This adjustment
carried

out

very carefully as the

in

output

exceed ·7 c.c.

the

test oil

15

seconds

of

in

in

the slot,

of

or

normal

must

amount

movement required will be very small. Tighten

the drive plate screws

in

given

adaptor

'GENERAL DATA', using torque

ISG

655

to

the torque figure

A. When tightening the
screws, the torque wrench and spanner must
be

in line (see Fig. C.l7). After making the

Fig.

C.16

Adjusting the maximum fuel setting, using maximum

fuel adjusting probe

lSG

656

3!

test

to

and

the

and

the

tap

the

will

-be
of

(

't

\

FUEL SYSTEM (Diesel Models)

adjustment replace the cover-plate and prime

(S2).

the pump as described in
fuel delivery and,
pump output.

Test

8-Maximum

Decrease
average delivery for
not

less

1·6

c.c.

the

than

fuel

pump

that

if

necessary, re-adjust the

delivery

speed to 150 r.p.m. The
200 shots should

obtained in 'Test 7' minus

Re-check the

check,

now

be

9-Cut-off

Test

Run the
lever in the fully closed position.
delivery for

Test 100Throttleoperation

Run
arm in
off lever
delivery

Test 11:"-Puel delivery check

Run
throttle
open

200 shots.

for

Test 12-Governor setting

Increase
set the throttle
speed stop screw
delivery
exceed

Test

13..;...-Puel

Reduce the
average delivery for
not

less

·4

C.c.

operation

pump

at

200 r.p.m. with

200 shots should

the

pump

at

200 r.p.m. with

the

fully closed position

in

the

open position.

for

200 shots should

the

pump

at

1,250

and

shut-off "controls in their fully

pbsitions~

the

of·8

1·0 c.c. T.ighten

than

Record the average delivery

pump

speed to 1,360 r.p.m.

ann

by

to

give a maximum average

C.c.

per

200

delivery check

pump

speed

200' shots should now be

that

obtained in 'Test 11' minus

the

The

not

exceed

the

and

The

not

exceed ·5 c.c.

r:p'.m. with

means

of

the

maximum

shots;

no

line should

the

stop screw locknut.

to

1',250

r.p.m. The

shut-off

average

·5

C.c.

throttle

the shut-

average

both

the

and

Fig.

Scribing the timing mark

flange, using

14-Timing

Test

After the foregoing tests have been completed,
remove the
mount flange marking gauge

84°,

to
machi,ne

outlet
the drive hub, by means
in
When resistance
marking' gauge steady on
flange

. scribing tool along the guide

If

the pump
Finally, seal the cpver-plate screws
of

sealing pliers

pressur~

on

ISO

653

'V'

the'

direction

and

necessary, delete the old timing

the pllmp, using wire, a lead seal,

toollSG

setting

pump

the

pump

180

A, apply 100 atrnospheres pressure to

in the hydraulic

mark

'flange before

lSG

connections

C.t8

on

the

fuel

infection pump

648 A

from

the

test bench

lSG648

quill, shaft. Using testing

109 A alia

of

normal -pump, rotation.

is

encountered, hold

the

541,

to

timing

head

of

the

marking gauge,

the

pump

pump

making

and

fit

the

the

hydraulic head.

while rotating

by drawing a

on

the new

correct high-

and

A, preset

adaptor

the

mO'unting

the gauge.

mark

from

mark.

on

the side

and

Tightening the drive plate screws, using torque wrench

ISG 537 and torque adaptor

and spanner must be in line as shown

Fig.

C.l7

lSG

655

A. Torque wrench

Refitting

(84)

Crank
B.T.D.C. on its compression stroke.

(85) Insert timing gauge'

pump
splines

(86) Apply a gentle clockwise (as seen

the engine) pressure to the
backlash
engine front plate with the
gauge (see Fig. C.19).

(87)

Fit
pressure pipes, to the engine. Align
mark
securing nuts.

(88)

Connect

·thafboththe
pump

the engine until No. 1 piston is

180

1052

chain wheel hub from

on

the tool with those in

and

line up the timing pointer

the injection pump, complete with high-

with

the

timing pointer ,and tighten the three

the throttle and stop contrdls, ensuring

throttle

have their full range

the

mark

arm

and shut-off lever on

of

at

into

the injection

rear, engaging the

the

driving flange.

from

the

rear

gauge

movement.

to eliminate

cut

inthe'timing

the

pump scribe

9.tl

16°

of

the

the

C.l3

FUEL SYSTEM (Diesel Models)

Fig.

C.19

Checking

(89)

(90) Bleed

(91) Adjust the maximum and idling speeds as described

the

position

pointer,

Connect the mgh-pressure pipes to the injectors,
and

the fuel feed

..

pump

the fuel system as described

in Section C.9.

using

of

the

timing

and

return pipes

injection

gauge

18G

pump

1052

to

in

timing

the injection

Section C.8.

Section C.7

FUEL

INJECTORS

Removing

(1) Disconnect the spill and high pressure pipes from

the injectors.

(2)

Unscrew the securing nuts and remove the injector
clamps.

(3) Withdraw the injectors, using tool

adaptor·18G 284 P, and plug the injector holes in

the cylinder head.

180

284 and

Fig. C.20

Clearing

pintle

Fig.

Cleaning

annular

(a) Clean all carbon from the nozzle valve

(b)

(c) Clear the auxiliary ·spray hole in the nozzle

(12) Ensure

(13)

the

orifice

C.21

the

chamber

outside
Remove all foreign matter from inside the
nozzle body by means
as shown in the illustrations.

with the probing tool. The wire should be
fitted into the tool so

about

end

of

Fit

the nozzle into adaptor
nozzle tip towards the small diameter connection.
Attach the adaptor
and operate the pumping lever several times, thus
clearing the nozzle passages by reverse-flushing.

of

the body with the brass

"*

in. (1·6 mm.).

that

the lapped pressure face

the nozzle

is

perfectly smooth and fiat.

to

testing machine

..

wire brush.

of

the shaped scrapers

that

it

protrudes only

on

180

109

and

the

~e

upper

E with the

180

109

A

/

\

Dismantling

(4)

Mount

(5) Remove the injector cap-nut and

washer.

(6) Slacken the locknut, unscrew the spring cap-nut,

(7) Unscrew the nozzle nut, using spanner 18G 210,

Inspection

(8)

(9)

(10)

(11)

the injector

and

remove the copper joint washer, spring, and

spindle.

and remove the nozzle body and valve assembly.

Wash all the components thoroughly

Calibration Fluid

Examine the spring for signs

or

fraeture, and ensure· that the ends·
square. Check the spindle for straightness.
Ensure that the face
contacts the nozzle is perfectly smooth
Using cleaning kit
nozzle body and valve:

in

dismantling fixture

'C'.

of

weakness, rusting,

of

the nozzle holder which

180487,

thoroughly· clean the

C.l4

the

copper joint

in

clean Shell

are

and fiat.

180388.

perfectly

Withdrawing

an

adaptor

Fig.

injector,

C.22

using

18G

tool

284 P

18G

.

:

..

.;;.

284

-=:=

I

A6S9S

and

FUEL SYSTEM (Diesel Models)

Fig. C.23

Cleaning the

nozzle

seat

Fig. C.24

Clearing the auxi-

[iary spray hole

(14)

In

~ses.

where the ca.rbon deposit is particularly

it

hard,
in a caustic solution:

(a)

(b) Boil the nozzle bodies

(c) Wash the nozzles' in

(15) Examine the valve seat in the nozzle body through

a nozzle microscope. The seat should

can besoftened by boiling the nozzle bodies

Dissolve 2 oz.

1 pint (·57 litre)

(14'2 gm.)

minimum
hours.
evaporate, because a concentration
soda above
of

Do

the nozzle bore

(56·7

gm.)

qf

caustic soda in

of

water

and

add

oran

ordinary washing detergent.

in

the

liquid

of

1 hour and··

not

aIlow

not

too

much . water

mote

of

15

per cent. may cause roughness

and

seat which would

t oz.

for

than

caustic

Ii

to

make the nozzle unserviceable.

running

immerse them iri·;a de-watering oil such

water

and

as

Shell Ensis 254. Remove the surplus oil by

or

draining

the

carbon as described

with compressed air, then remove

in

(11) and (13).

not

be

II

~C!-=----2

--

3

·4

____

1'11111

--5

~----6

9

a

Fig. C.26

Section through a

1.

Injectpr cap-nut.

2.

Joint

3.

4.

S.

6.

washer.

Locknut.

Joint

washer.
Nozzle holder.
Nozzle nut.

stepped, and should
pitting.

(16)

Examine the conical surface which forms the seat
of

the

nozzle valve through a nozzle microscope.

The most critical

it

where
This angle should

no

with

anywhere
ance as

(17)

If

all

the

forms an angle with the. parallel stem.

rounding

on

shown in Fig. C.25.

components appear serviceable, assemble

part

be

or

its diameter. Check the pintle clear-

the injector as described

adjust

and

test the injector as described in (34)
(43). Provided the wear is not excessive,
serviceable nozzle body
ditioned
as described in

on

a nozzle grinding

(18)

to

~-----7

fuel

injector

..

Nozzle body.

7

8:

Nozzle

9.

10.

11. Washer.

2.

t

be

free from scores

of

the··

conical surface is

sharp·

and

vaJve.

Spindle.

Spring.
Spring cap-nut.

and

. clearly defined,

wear breaking the knife-edge

in

(32) and (33). Then

to

an

un-

and

valve can

and

(31).

be

recon-

lapping machine

/

\..

. Fig.

Testing the pintle
not

tilt

at

and

orifice

a greater angle than 200 from

centre-line

C.

25

for

wear. The valve must

the body

Reconditioning

(18)

Select a nozzle lap from those· supplied with the
machine. The bore diameter varies slightly from
one nozzle
fit

.

the

valve

to

another,

and

the.

lap chosen should

nozzle in the same manner as

to

ensure concentricity

of

the. valve seat

nozzle bore after lapping.

the

nozzle

and

C.l5

FUEL SYSTEM (Diesel Models)

Fig.

C.27

Reversellushing
machine
tioned

(19)

(20)

(21) Apply a small quantity

(22)

(23) After

(24) Reface

(25) When

18G

adaptor

Mount
the

lap is pointed remove the tip to avoid damaging
the pintle hole. Grind the conical
nozzle
backwards
feeding
surface is entirely cleaned up. Inspect the
the nozzle microscope
rough,

Fit

the

and

apply a coating

of

the

lap

of

the

extend
Start

the machine
over the rotating lap. Oscillate the nozzle
lap in very
per

minute, engaging the nozzle seat with

at

each stroke. Apply only light pressure
nozzle
in

contact with the lap

a time.

30 seconds lapping time

the

clean
There will
in

contact
stages
have a
indicate

t minutes

1

seconds' lapping with a freshly ground lap, use fine
lapping
surface. Lapping should be kept
because excessive lapping will allow the nozzle valve

C.16

an

injector

109 A

and

with

a nozzle

the

lap

in the lathe

body

seat angle

and

forwards across the grinding-wheel,

in

the

lap very gradually until its conical

dress

the

grinding wheel and regrind

lap

into the lapping chuck

for

lubrication.

lap,

taking care

to

the

parallel stem

and

short

strokes

and

do

not

allow

lap,

and

be a mat

with the nozzle seat,

of

lapping this surface may

bright

circumferential ring. These markings

the

extent

of

the

lap

as described

of

lapping time.

the

seat appears satisfactory after a few

paste

to finish the seat off

lzozz1e

adaptor

of

examine the conical

surface where the

the wear

18G

in

position

of

the machine

end

of

59°. Pass the

and,

if

the

ground

tallow

to

the guide surface

of

lapping paste

that

the

of

the lap.

carefully slide the nozzle

at a rate

the

for

of

nozzle seat

more

than

withdraw

on

in

with

testing

109

E.

A sec-

is

shown

inset

and

to

the correct

lap

slowly

lap

under

surface is

the

lap.

of

the machine

to

the tip

paste .does

20

to

5 seconds

lap

and

in

be

the nozzle seat.

(19) after every

to a smooth

to

a minimum

not

on

the

30 strokes

the

lap

to

the

to

remain

the nozzle,

lap

tip.

has

been

the

early

narrow

or

mat

if

at

Fig.

C.28

Correct

to

seat

hole and the nozzle will· be useless.

(26) Reverse-flush the nozzle

with compressed air,
under

(27)

Make

correctly and adjust the

machine
Mount

(28)

reface the conical seat. Be particularly careful not

to damage the pintle

it

to

touch the grinding-wheel,
absolute minimum
just

enough to change
otherwise the nozzle valve
increased. As a guide, there should
hiss from the grinding-wheel when refacing the

valve. Watch the refacing procedure through a
magnifying-glass, focusing

seat face away from

nozzle and

in a lower position

the nozzle microscope;

sure

that

to

60°

to

the valve

valve

than

as

described

and

make

the

gI:inding-wheel is dressed

ref

suit the nozZle valve.

in

the

lathe

end

of

of

material from

the

lift

on

the

grinding-wheel.

seat

angles

the auxiliary spray

in

a final inspection

acing angle

of

the

machine and

the valve by. allowing

and

remove only the

the

colour

of

(needle lift)

be

no

the

surface

,;,

.

',-

":-;-:-'~-::'~_/'

~i

Fig.

C.29

Lapping a nozzle
circumferential
in

the

early

lap

ring

stages

upon

seat.

The·arrow

which

of

lapping.

completion

indicates

may be present

A.

view

of

is

shown

inset

the

on

the

(13), dry it

of

the

valve seat;

the seat,

will

be

sparks

or

of

the

i:

Ii

/I!

1;

····

..

-=---:..=..=..~17·7~

bright

the

lap

seat

and

(

FUEL SYSTEM (Diesel Models)

c

(29) After refacjng, inspect

microscope.

(30) If, due

fitting valve should
its own weight when

(31)

DATA'.
joint

joint

Reassembling

(32)

nozzle body while

(33)

Fit
and
the

injector as described

to

slight distortion.or deposits
surface, the valve is found
nozzle body,
guide surface
lapping chuck
valve, using fine lapping paste
collets supplied with

After

attention
seats, assemble
needle lift against

face

plate. Be careful

face must remain

the

nozzle axis.

Wash

all
Fluid

the

in

the

reverse the procedure in (5) to (7), tightening
nozzle

'GENERAL

it

can

of

the valve.

and

to
the

To correct excessive needle lift, lap the

of

the nozzle

th~

components in clean Shell Calibration

'C',

and

assemble the nozzle valve to the

oil.

nozzle holder

nut

DATA'. Then adjust

Adjusting and testing

Back-leakage test

(34)

Connect the injector
with

the

nozzle facing away from the

open

the check valve

(35) Operate

pressure at which injection occurs.

(36)

With
spring cap-nut

the

pumping

the injector cap-nut removed adjust the

to

170 atmospheres.

Testing

an

18G

injector

109

for

A and adaptor

the

valve under

to

be

be

corrected

Mount

lap

the guide surface

the

machine. A correctly

just

slideiIitothe

lubricat~d

either the noZzle

valve

the

body

not

to

tilt the nozzle because the

true

both

components

to

dismantling fixture

to

the

in

(34)

to

testing machine 18G

to

the

give

Fig. C.30

Jpray, using testing machine

with fuel oil.

and

body

figure

on

and

torque figure given in

to

(43).

pressure gauge.

lever and observe the

an

injection pressure

18G

the

on

its guide

a tight fit in

by

lapping

the

valve in

and

one

body

body
and

check the

in

'GENERAL

a surface lapping

at

right angles to

are

immersed

and

operator

10~

B

nozzle

the
the
the

of

the

of

the

under

or

valve

180

388

test the

109

and

of

Reassembling a

spanner

(37) Operate

registers
time the pressure drop from
spheres.
should be between 6 and 40 seconds.

Seat

tightness test

(38) Adjust

pressure
and depress the pumping lever until a pressure

90

A

atmospheres is obtained. Maintain this pressure
for
dryness.

pressure for 60

blotting
of

the wet

tin.

Adjustment and spray test

(39) Adjust

pressure
and re-check the injection pressure.
cap-nut

(40) Connect

in place

opening pressure to

(41) Connect

check valve

(42) Operate

minute
be well formed
A slight central core may be disregarded.

(43) Increase

a minute
be well atomized
distortion. A slight central core may be disregarded.

Fig.

C.31

fuel

injector, using fixture

18G

210, and torque wrench

the

pumping lever until the pressure gauge

160 atmospheres. Release the lever

150

For

a nozzle in good condition this

the

spring cap-nut

of

100

atmospheres.

10

seconds and examine the nozzle

If

in

doubt;

maintain the

second"s

paper

below the nozzle tip; the diameter

spot

on

the

(13

mm.).

the

spring cap-nut

of

135 atmospheres, tighten the locknut,

and

joint

washer.

adaptor

of

18G

the injector

220

the

injector

to

the

pumping lever

and

observe

the

operating speed

and

to

the pressure gauge.

the

and

free from splits

observe the main spray. This

and

to

give

Dry

while holding a piece

paper

should

to

give

109

B to the testing machine

and

adjust the

atmospheres.

the

adaptor

at

about

auxiliary spray. This

to

about

free from large splits

18G

18G

372

to

100

an

injection

the nozzle

tip

90

atmospheres

not

an

injection

Fit

the injector

adaptor

and

close

60 strokes a

should

or

distortions.

140

strokes

should

388,

and

atmo-

time

tip

of

for

of

exceed

the

or

C.17

FUEL

Refitting

(44) Reverse the procedure in

following:

(a)

Renew both sealing washers on each injector.
One washer passes over the nozzle and seals

between the nozzle nut and the heat shield

flange. The second washer (atomizer seal

washer) seals between the nozzle face and the
bottom
be fitted with its two edges downwards.

(b) Tighten the injector clamp nuts

figure given in 'GENERAL DATA'.

(c) Bleed the fuel system as described in Section

of

the heat shield; this washer should

C.S.

(1) to (3), noting the

SYSTEM (Diesel Models)

(1)

Ensure
run position and remove the sealing cap from the
maximum speed stop screw.

(2) Run the engine until

running temperature.

(3)

Slacken the locknut and adjust the maximum speed
stop screw
speed
maximum governed speed under load
r.p.m. Tighten the locknut.

to

the

torque

(4)

Fit

seal, using sealing pliers 18G 541.

(5)

Adjust

of

that

the stop control is fully home in the

it

bas attained its normal

to

set the engine maximum light running

at

2,750 r.p.m! This will give the engine a

the sealing cap and seal

the

idling stop screw

600 r.p.m.

and

tighten the locknut.

it

with wire and a lead

to

give

an

of

2,500

idling speed

Section C.9

MAXIMUM

Before making either

the engine

-AND

air

cleaner is correctly serviced

IDLING SPEED ADJUSTMENT

of

these adjustments -ensure that

and

fitted.

NOTE.-Adjustment

alter the pump timing in relation
mounting flange; therefore, after adjustment of the maxi-

mum

fuel setting, the mounting flange

marked as described in Section C.6 (83), Test 14.

of the maximum

to

the mark

fuel

on

.should

setting

the pump

be

will

re-

I

\

"

C.18

SAO

TRANSMISSION

DESCRIPTION
OPERATION
TROUBLE

SHOOTING
DISASSEMBLY
REMOVAL

GEAR

REMOVAL

OF

HOUSING

OF

ENGINE.

REMOVAL

OF

HOUSING
DISASSEMBLY
INSPECTION

ASSEMBL

YOF

OF

SAO

REDUCTION

IF

" . "

REVERS.E

GEAR

OF

GEAR

TRANSMISSION

GEAR

INSTALLED

GEAR·HOUSING

CASE

GEAR

ASSEMBLY

CASE

CASE

ASSEMBLY

FROM

FROM

ASSEMBLY

REV'ERSE

REVERSE

FROM

GEAR

Page

46

46

No.

46

46

48

51 .

51

52

53

53

ASSEMBLY

OF

HOUSING
ASSEMBLE
ASSEMBLY

'GEAR

TRANSl\llSSION
OF

HOUSING

ADJUSTMENTS'

REDUCTION

UNIT

REVERSE

GEAR

REDUCTION

ASSEMBLY

TO

ENGINE

GEAR

CASE

IN

ASSEMBLY

REVERSE

TO

GEAR

55
56

REVERSE

56
57

59

(

45

DESCRIPTION

SAO TRANSMISSION

The
multiple

tained
OPERATION

On

together
pressure
propeller

The
gear
clamped
reverse
peller

With
band
stationary.

It
moving

It

ably

and

Westerbeke

disc

and

are

the

forward

as a solid

produced

shaft

reverse

case

when

motion

shaft

the

shift

are

un.clamped

is

desirable

the

is

recommended

in

the

of

the

boat.

which

clutch

independent

drive..

turns

drive

contains

the

is

opposite

lever

to

boat

800

in

RPM

Paragon

and a planetary

coupling.

when

in

is

obtained

shift

then

to

in

and

start
either

that

range

manually

of

the

reverse

the

shift

the

same

the

lever

obtained

the

engine

the

neutral

the

the

engine

direction.

the

shifting

or

the

planet

engine

gear

The

multiple

lever

direction

by

clamping

planetary

is

moved

by

driving

rotation.

position

gears

with

be

lower

to

operated
reverse

lubrication

case

disc

is

moved

as

the

reverse

and

through

the

run

the

transmission

done

at

prolong

reverse

gear

system.

and

clutch

to

the

the

engine.

reverse

gear

held

multiple
idle

and

speeds

the

life

gear

train.

multiple

is

locked

forward

band

train.

in'

the

the

gears

disc

the

in

below

of

the

units

The

units

disc

clutch

or

position.

around

The

reverse

thus

clutch

propeller

neutral

·1000

RPM

engine

consist
are

self

are

clan;tped

Thus

the

reverse

position.

turning

and

the

shaft

..

thus

and

..

transmission

of

(:on-

loc.ked

by

the

the

reverse

band

the

reverse

remains

avoiding

prefer-

is

The

pro-

a

TROUBLE

The

trouble
suggestions
what
sions
as

DISASSEMBLY

As

manship

the

should

indicated

in

1.

2.

3.

4.

5.

6.

7.

NOTE:

oil

to avoid fouling the

SHOOTING

trouble

any

servicing

apply.

Use
Use
Never

Never
Use

screws.
Replace
Work
nicks

Remove

shooting

carried

be

from

only
only

only

charts

out

may

carefully

OF

Some.

use a hammer

press

gaskets

on a clean

and

be.

the

trouble

SAO TRANSMISSION

operation,

of

clean
clean

properly

scratches.

fluid
oil

a

ball

the reverse

prior

Also

read

these

for

and

bench

and

below

shooting

in

to

bearing

sized

"0"

bilges.

and

on

the

next

to

any

disassembly

..

the

exploded

and

understood

charts

cleanliness

rules

any

lubrication

are

cleaning

drive

and

ball

so

wrenches

rings

protect

as

when

that

with

views

so

that

may

is a must

follows:

or

washing

pressing

bearings

the

force

in

removing

new

material.

gear

page

to

determine

be

in

teeth

shoUld

and

the

any

or

carried

and

all

of

parts.

parts

place.

is

carried

or

and

be

studied

as

well

as

accompanying

all

of

the

service

out

properly.

rules

together.

securing

oil

for

through

nuts'

seal

surfaces

good

and

pOGsible

discus-

work

work-

the

balls.

and

cap-

from

the

reduction gear as a complete unit before removing the (

"

..

.

46

TROUBLE

SHOOTING CH,ARTS

Ch

art 1

DRIVE

SHAFT

WITH

GEAR

ROTATES

SHIFT

.-.

D~AGGING

EITHER

LEVER

FORWARD

IN

NEUTRAL

OR

REVERSE

r

Check For

I

I

t

1.

DEFECTIVE

I

2.

REVERSE

------------------------------REMEDy-------------------------------

1.

Forward

Remove

2.

In'proper
reverse

3.

Check

a.

and

band

the

Bearings
case.

Replace

FORWARD

BAND

clutch

replace

reverse

as

following

and

gears

ENGAGING

plate

warped

clutch

band

outlined

items:

worn

necessary

CLUTCH

GEAR

and

pI

ates.

adjustment.

under

excessively

parts.

PLATES

CASE

stickin.g.

Adjust

adjustment.

in

gear

I

I

1

3

..

BINDING

b.

Engine

causin~

place
of

engine

Over-adjustment

4.
or

both

will

and

readjust

IN

4.

OVER

FORWARD

gear

bearings

misalignment

necessary

gear.

of

result

as

outlined

I

PLANET

AAY

ASSEMBLY

1

ADJUSTMENT

AND

parts.

eit'her forward and

in

loss

under

ON

REVERSE

worn

of

engine

Check

of

neutral.

adjustment.

misalignment

exce55ively,

shaft.

Re-

.

reverse

Check

Chart 2

I

I

------~----~--~~~~~------,REMEDY-·--------------~~~-

{

\

1.

Remove
wear.

2.

Imp~orer

oudined

1.

2.

FORWARD

forward

Replace

under

WORN

CLUTCH PLATES I

CLUTCH

clutch

if worn

forward

clutch

adjustm~rit~'

WITH

NOT

ENGAGING

rlaies

,and

excessively.

adjustment.

SHIFT

check'

Adjust

GEAR

SLOW

LEVER

I

Check

1

for

as

SLIPPING

TO

ENGAGE

IN

FORWARD

T

For

T

I

I

,

3.

Remove
place

4.

Improper
outlined

OR

OR

1·

4.

REVERSE

lining

REVERSE

3.

WORN

reverse

if

worn below

reverse

under

adjustment.

REVERSE

BAND

band

and

band

BAND

NOT

ENGAGING

check

for wear.

rivets

•.

adjustment.

Adjust

I

I

Re-

as

47

C

I

I

I

hart

a

1.

FAILURE

2.

FAILURE OF

3

..

FORWARD

r

OF

PLANETARY

I

REDUCTION

I

CLUTCH

DRIVE

SHIFT

ASSEMBLY

NOT

ENGAGING

TROUBLE

GEAR

SHAFT

LEVER

GEAR

INOPERA

OOES

IN

Cht:ck For

I

I

I
I

SHOOTING

riVE

NOT

ROT

FORWARD

I

1

CHART

ATE

OR

REVERSE

WITH

4.

REVERSE
ENGAGING

5.

SROK

EN

OUTPUT

I

SAND

GEAR

I

NOr

CASE

SHAFT

1.

Remove

de-fective
or

d

2.

Remove
defective
or
service

.~.

Check
... Improper forward

NOTE:
those

difficulties

REMOVAL

HOUSING

NOTE:

~eoar

or

ama~ed

dama~ed

forward

parts.

reduction

or

manual.

the

followin~

dutch

Disassembly

OF

IF

Remove

before draining

case

assemhly

d

ama~cd

dama~ed

parts.

parts.

J!,e~u

assembly
parts.
Refer

items:
clutch

as

outlincd

adjustment.

need

which

interfere

REDUCTION

I~STALLED

and

Replace

and ch

Replace

to

reduction

under

be

GEAR

check

adjustment.

for

defective

eck

for

defective

~ear

:\djust

carried

with

ASSEMBLY

REMEDY

out

proper

----------~-----------------

b.

plate.

4.

Check
a. Improper

h.

c.

5.

Check
fective

only

marine

FROM

Forward

reverse

Reverse
Cracked

parts.

as

clutch

the

fol1owin~

reverse

band

hand

ears

Replace

for broken

shaft.

far

as

gear

REVERSE

the reverse gear with reduction gear attached

oil,

to

avoid

fouling the bilges.

plates

as

lining
or

defective

is

worn.

items:

hand·

adjustments.

outlined

worn. Hepla,oc

bent or dama,gcd

output

shaft.

necessary

operation.

GEAR

as a complete

Heplace

under

adjustfllC'tlt.

llIuu:rial .

Replace: d{··

clutch

Adjust

lining.

linkage

to

correc.t

(

unit

1.

Remove

starter

motor

2. Disconnect propeller half coupling

3.

Remove

4.

Strike gear half coupling flange

capscrews

securing reverse gear

bellhousing. Slide entire reverse
ately 3 inches until reverse gear clearsbe1lhousing

en§ine.

(Refer to

"Reduction

reduction unit.)

48

Gear"

and

with

and

section of

slide

to

soft

back

bellhousing.

mallet to

reduction gear

manual

for disassembly

approximately 4 inches.

break

streight

and

reverse

lift

gear

back

approxim-

units clear of

and

assenbly of

from

/

....

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n

d

en
en

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65

67

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DI~«r

L)II21;-£

".~

w",rr,l2.'s

"Y" /:WIll'''

REMOVAL

1.

Remove
to

2.

Slide
until
housing

3.

Remove

remains

4.

If
proceed

a.

b.

c.
d.

OF

REVERSE

capscrews

front

end
entire
housing

assembly

pilot

on

necessary

as

Remove
engine

Slide"

front

,of

front

plate

engine.

Remove

seal

(22).

Replace

GEAR

and

plate

(5).

revers e gear

is

clear

clear

roller

bearing

gear.,

to

replac.e

follows:

capscrews

flywheel

end

housing.

plate

engine

retaining

new

oil

seal

HOUSING

lockwashers

'housing

of

front

of

front

and

gear

front

(5)

plate
plate

(60)'

end

lockwashers

straight

(1)

is

'

ring

and

(36)"

bearing

ASSEMBLY

that

secure

( 3)

straight

engine

(5).

from
plate

front

(5),

securing

back

clear

bearing

if

approximately

of

flywheel

(37)"

required.

FROM

back

gear

plate

oil

seal

retaining

ENGINE

reverse

gear

approximately

(1

)

and

lift

,

engine

(22),

front

or

end

two

housing,

ring

housing

3

reverse

gear

bearing

plate

inches

and

lift

(35)

inches

gear

(1)

if

(5)

until

clear

and

(3)

it

(37)

to

oil

(

REMOVAL

REDUCTION

1.

2.

3.

4.

5.

6.

7.

8.

"

9.

10.

OF

GEAR

Remove
from

reverse

Through

washer

band

as,sembly

,Remove'

cam

(65)

reverse
Remove

a.

Loosen
shaft

b.

With
from
with
shaft
in

shaft.

c.

Slide

(34)

On

dipstick

ing

pin
inspect
Slide

front

brake

of
Remove
Support
may

drop
Presson
drive
Lift

(2-

reverse

2).

CASE

MODEL

four

cover

and

screw"

adjustment

from

cam

slide

cross

the

(13). "

small

left
operating
under

right

cross

from

side

(12)

that'

"0"

ring

band

housing.

cotter

reverse

free

reverse

gear

(87).

ASSEMBLY

capscrews,

gear

housing

opening

in

securing

(62).

Remove
nut

eye

in

assembly

shaft

to

two

end

right

(13)

capscrews

of

being

sleeve

yoke

side

arm

of

housing.

' ,

shaft.

out

operating

of

housing

secureS'

(23).

and

(62)

from

pin

and,

nut

gear

housing

approximately

gear

gear

housing

FROM

cover

(3).

reverse

adjustment

lock

(66),

yoke

from

fro:m

(34)

(63"). ,

reverse

REVERSE

seals

gear

spring.

reverse

and

gear

(33)"

housing

nut

slide

securing

housing

(34)

toward

,careful

,bearing

isn

It

Remove

m,echanic"

cross

(50)"

forced

the

against

,','

of

housing

sleeve

remove

b~ake

replace

gear

(18-2)

(3)

two

tails

haft

(3)

(50).

band

case

from

with

straight

and

roll

to

if

damaged.

assembly

reverse

front

inches.

(2 -2)

pin

housing.

until

up

GEAR

cover

(3)"

remove

lQckspring

cam

housing

the

out

(65).

reverse

(3)

yotte

slide

shaft.,

or

doesn

Woodruff

cross

two

Woodruff

remove

(24)

brace

securing

Remove

(41)

and

gear

end

down

tails

haft

until

housing

HOUSING

(10)"

(68)

and

to

,','

Remove

cam

as

follows:

\;'41

cross

It

come

key

shaft

keys

(67)

brake

locking

remove

tailshaft

so

that

IS

free

clears

nut

ear

to

(26)

,

gear

gasket

(70)"

of

reverse

(65)

the

shaft
in

in

oil

seal

from

and

lift

band

band

(2-2).

case

of

reduction

tailshaft

(4)

lock-

brake

from

cross

(13)

contact

cross

(20)

cross

yoke

lock-

pin

and

from

(41)

51

11.

Remoye

(85)

to

a.

Remove
tion

b.

Press

c.

Press

caps

reverse

drive

bearing
bearing

crews

gear

and

housing

reduction

gear

(87).
with
from

lockwashers

(3).

adapter

drive

drive

plate

gear

gear.

that

with

from

secure

attached

adapter

reduction

bearing

plate.

ada

(88)

:>ter

and

plate

reduc-

DIRECT

12.

DRIVE UNIT

Bend
from
spanner

13.

Support
free

14.

approximately 2 inches.
Press
coupling
assembly

15.

Remove
reverse

a.

Remove

half

b.

Press

c.

Press

d.

If

DISASSEMBLY

1.

Remove
gear
and

thrust

2.

Remove

screw

assembly

3.

Lift
case

.•

4.

Properly
(2-1)
clutch

5.

Remove

6.

Remove
gear

7.

Before
gear
rough

necessary~

unless

8.

Drive

of

gear

dummy

9.

Push

spacer

10.

Remove

11.

Press

12.

Remove

tang

of

reverse

wrench.

reverse

on

reverse

(14).

(41)

capscrews

gear

coupling

gear
bearing

necessary
OF

GEAR

thrust

tailshaft

washer

lockscrew

collar

(50)

pressure

support

or

(2-2)

plate

case
capscrews

case.

removal

teeth

for

spots
required.

pinion

case

shaft.

dummy

(56).

remaining

propeller

long

(perform

lockwasher

gear

tailshaft

Remove

gear

housing

gear

Lift

reverse

until

housing

and

housing

direct

half

(3).

drive

(14)

from

coupling

from

to

replace~

CASE

washer

on

reduction

(16-1)

(55)

and

from

from

plate

gear

tailshaft

(49)

gear

from

carrier

ball

propeller

from

bearing

(14)

of

the

short

indication

during

proceed

shaft

rotation.

with

(20)

approximately

shaft

until

Remove

short

gear

pinions

(43)

(44)

procedures 1 through

(19)

away

(2-1)~

from

by

holding

lockwasher.

(3)

tails

haft

(2-1)

gear

clears

lockwashers

plate

(15)

reverse

from

drive

plate.

remove

(16-2)

from

and

units~

end

lockwasher

case

by

when

and

clutch

case

on

clutch

gear

gear

case.

retaining

and

lockwashers

or

long

of

wear.

If

the

disassembly.

of

one

of

1/2

inch.

centerec

pinion

pinions

from

using

shaft

(46)

the

dummy

face

housing

tailshaft

bearing.

of

removing

the

do~

until

that

with

gear

oil

seal

retainer
and

Woodruff

tailshaft

from

unscrewing.

plates

(43)

ring

pinions

A1so~

further

short

Push

in

short

(42)

from

case

shaft

locknut

gear

so

tailshaft

(3)

straight

(2-1).

secure

attached

housing

(21)

ring

on

screw

screw

(48)

plate

and

carrier

clutch

(59) :from
(13)

is

attempted~

rotate

inspection

However~

pinions

pinion

pinion

from

gear

ban

bearing

as

6 above)

(18-1)

half

that

gear

is

direct

bearing

(3).

from

(6)

from

key

(27)~

direct

collar

Lift

collar.

and'

(54)

groove

and

case

each

(22)

snaft

(46)

front

case.

(58).

in

removing

~d

coupling

case

free

up

from

drive

direct

end

seal

drive

(53)

operating

from

and

press

plate

bushing

first
pinion
or

replacement

do

not

from

on

and

end

remove

(14)

may

of

gear

gear

plate

(15)

(25) ·and

drive

of

reverse

washer

units.

and

remove

sleeve

erd

of

tailshaft

carrier.

in

g-ear

(23)

in.spect

to

check

disassemble

threaded

through

short

of

gear

short

pinions

nut

with

drop

half

case

to

gear

plate.

(6)

gear

Lift

case.

from

the
for

is

end

with

pinion

case.

a

!

t

\

.

NOTE:

.

52

Bushings

are

pressed

into

the·

long

and

short

pinions.

INSPECTION

All

parts

wear

1.

should

should

Ball

and

2.

Long

3.

Pinion

4.

Long

5.

Long

6.

All

pattern

7.

All

8.

Clutch
excessive

9.

CI~tch

splines.

10.

Examine

11.

Reverse

12.

Reverse

be

be

replaced.

and

pitting

and

shafts
and
and

gear

or

shafts

plates
plate

thoroughly

roller

on

short

bearings

balls

pinion

should

short

pinion

short!pinion

teeth

should

excessive

should

be

should

heating

and

carrier

all

oil

seals

band

band

links,

lining

cleaned

should

or

ro.!.lers

bushings

be

examined

spacers

bore

be

examined

wear.

examined

be

examined

wear

should
for

rough

pins,

should

before

be

and

races.

should

for

.snould

diameters

for

wear

or

peening

be

examined
or

charred

etc.

be

should

examined

inspection.

examined

be

examined

wear

be

o;r

examined

should

for

"pitch

on

splines

for

flatness,

of

driving

for

be

for

Parts

for

"brinelling".

for

be

examined

line

and

roughness,

lugs.

wear

lips.

examined

wear.

showing

indication
for

wear.

wear.

for

pitting",

shoulders.

and

peening

for

wear

excessive

of.

corrosion

wear.
unever

wear

indicating

of

lugs

or

bending.

of

and

NOTE:

13.

L:i.ning

Gear
or
threaded

14.

Screw.collar

15.

Pressure

16.

All

17.

Operating

18.

Engine

bearing

uneven

NOTE:

When

eccentricity.

19.

ASSEMBLY

1.

should

case.should

long

old

gaskets
gear
wear

uneven

Maximum

Where

springs

OF

If

pinion

removed
a.

Insert

pinions

end.

and

plate

sleeve

should

race,

or

special

and

splines

GEAR

gears

from

dummy

oe

replaced

be

examined

wearing

finger
should
should

assembly

be

pilot

bearing

excessive

gear

teeth

eccentricity

vibration

for

CASE

(45)

and

gear

case

shaft

before

into

inside

assembly

be

examined

be

replaced.

should

examined

race

wear.

wear

at

dampers

wear.

(46)

bushings

(41),assembled

into

long

rivets

for

should

be

for

and

has

pilot

pinion

wear

from

faces

be

for

wear.

examined

wear

gear

been

bearing

are

used

(21),

come

or

wear

examined

on

oil

teeth

noticed,

race

as

as

follows:

(44).

in

contact

reverse

in

for

wear.

seal

for

check

is

flexible

and

plnlon

with

band

clutch
for

wear.

surfaces,

"pitch

engine

. 005

inches.

couplings,

shafts

gear

linking,

plate

slots

case

line

pittingfl,

gear

(42)

case.
short

on

roller

for

check

were

NOTE:

NOTE:
out.

Use
b.

Smear

Install

c.

same
Insert

shaft

dUmmY

bushing

Lay

gear

with

hole

dummy

four

in

bushirlgs

gear;

shaft

spacer

case

in

outer

shaft

then

with

(56)

(41)

as

used

(21)

equally

assemble

cup

in

gear

on

side

row.

in

disassembly.

spaced

remaining

grease

~eJ.rt

and

to

to

first

insert

around

bushings.

prevent

row

long

pinion

dummy

bushings

of

bushings.

(44)

shaft

..

from

in

case

to

center

dropp.ing

to

align

53

d.

e.

f.
g.

h.

i.

2.

3.

4.

5.

6.

7.

8.

9.

Insert
case

out

the
Remove
Do

not
are

inserted.

Assemble

Using
in

same
pinion"
Insert
to

line

described

Assemble

Assemble
flats
Insert

on

propeller

pinions.

Press

case
supporting
case.
gear
groove
Press

Align

peller

already

front

Place
Install
first
bronze
Install
plate

Make

and

in

clutch

splines

gea.r

on

end

Woodruff

clutch

with

clutch

pressure

cavity.

plnlon

and

push

dummy

dummy

drive

dummy

manner

use

short

up

case

pinion

ball

entire

certain

into

gear

until

tailshaft.

of

gear

bronze

shaft

through

shaft.

shaft,

pinion

remaining

shaft,

covered

pinion

spacer

pinion

with

hole

in d above.

remaining

bushing

shafts.

gear

(24)

bearing

assembly

that

gear

case

plate

on

case.
next

carrier

reverse

propeller

Support

case

key

plates

during

(61)

in

clutch

plate.

plate

(42)

plain

pinion

and

~haft

long

pinions

insert

(56).

(46)

into

in

short

(23)

to

Replace

through

(58)

on

case

Install

to

case

(27)

gear

gear

the
pressing

on

end

clutch

plate

(49)

on

end

as

far

start

all

the

short

in

paragraphs

gear

inner

pinions

gear

lockwashers

L."'1.to

gear

propeller

ball

bearing

case

ball

onto

tailshaft

is

seated

entire

of

tailshaft

plate

(54)

top

first,

as

pinion

way

in

gear

bushings

.

case,

row

in

gear

case

rear

of

case

ball
bearing.
reverse

and

assembly

operation.

cavity

and

of

last

into

unthreaded

rear

wall

shaft

into

gear

case.

(47)

a·

arid b

pinion

and

insert

case.

with

gear

edges

(13)

case

"

and

gear

is

inside

seated

bearing

gear
press

against

the

on

inside

in

propeller

rear

alternating

bronze

of

gear

into

rear

case

into

short

above.

toward

pinion

of

and

in

onto

propeller
front

properly

retaining

tailshaft

tailshaft

clutch

propeller

of

gear

steel

clutch

end

case,

wall

of

until

all

pinion

With

front

shaft

race

in

line

capscrews

mesh

with

end

on

propeller

ring

(2;..1)

or

through

plate

gear

gear.

case

plate

plate

in

of

gear

forcing

case.

shafts

(46)

short

of

case,

(20)

with

(14).

long

gear
of

gear

(59)

(2-2).

pro-

carrier

inside

starting

(34)

and

clutch

as

by

in

{

\

NOTE:

during

Make

assembly

10.

Assemble

and

11.

Thread
of

12.

Place
finger

13.

Continue
will

pressure

14.

Push

c"ertain

..

securing

the

thread

operating
assembly

snap

operating

finger

with

screw

length.

screwing

over

plate

that

collar

sleeve
over

center

(49).

sleeve

free.

15.

Place
one
end

16.

On

making
gear

54

lockwasher

hole

of

near

lockscrew

reduction

certain

tailshaft.

edge

tailshafts..

that

all

plates

assembly

cotter

(53)

assembly

sleeve

screw

and

assembly

over

of

screw

lines

up

retaining

ride

(52)

pins.

onto

assembly.

collarbnto

lock

end

of

collar

with

install

ring

freely

to

screw

gear

(50)

into

(50)

case

position

lockscrew

(53).

closest

retaining

is

seated

and

collar

assembly

onto

tailshaft.

gear

case

forward

(55)

Rotate

hole

in

ring

that

(53)

(41)

(41)

against

until

and

screw

pressure

on

properly

no

binding

using

finger

approximately

Position

until

finger

the

finger

assemblies

thread

collar

plate.

reverse

in

groove

is

apparent

pins

ball

assembly

shoulder

lockscrew

until

gear

tailshaft

in

reverse

half

ends

of

into

dog

(51)

of

the

are

on

CAUTION:

Proper

tions

adjustment

as

outlined

The

forward

is

made

under

clutch

after

section

is

not

properly

installation

on

adjustments.

adjusted

in

boat

at

the

is

complete.

end

of

this

Follow

assembly.

instruc-

ASSEMBL Y OF

REDUCTION

1.

Place

2.

3.

gear
If
in
Support

housing

removed

housing.

gear
lowered

4.

Lower

5.

gear
Place

tailshaft

gear
shoulder
Press

6.
Place

7.
drive
ball

bearing

8.

gear
Press

tailshaft

necessary

9.

Install

10.

Tighten
cotter

11.

12.

13.

14.

gear
Install
Place
Install

gear

With

tails

housing.

cover
ating
mechanic.

15.

Align

cross

16.

Pull

cross
insert
tion

yoke

17.

Secure

18.

Slide
hole

in

19.

Position

20.

Replace

(63).

21·.

Secure
and

nut

REVERSE

MODEL

new

gaskets
for

gear

case

so

over

reverse

thrust

tailshaft

of

retaining

reduction

new

gear

gasket

(87)

reduction

'bolts.

reduction

all

pin

can

haft.

cotter

new

gasket

brake

reduction

opening.
sleeve

and

hold

shaft.

through

shaft

Woodruff

to

cross

yoke

to

reverse

arm

of

pin

in

and

lock

(70).

GEAR

(8), (7),

(3).

replacement,

case

.gear

(2-

washer

assembly

that

case

gear

2)

protruding

reverse

housing

(16-2)

(2-2). (Make

ring

is

nut

drive

and

seated

gear

gear

gear

(8)

ball

(18 - 2).

adapter

crescent

on
against

capscrews.

be

installed

pin

and

bedn

(72)

on

band

assembly

adapter

in

housing

plate

assembly

hole

in

yoke

out

from

key

in

shaft.

cross

shaft

caIIl. (65)

yoke

brake

tighten

spring

(34).

band

adjustment

(68)

CASE IN

.and
install

(41)

gear

assembly.

(3)

through

with

certain

(6)

on

(87)

into

reverse

bearing

thrust

plate

(74).

Tighten

through

ends

over

reduction

(62)

(85)

placing

(50).

brace

and

cross

br~ce

right

by

tightening

(67)

side

shaft

through

(62)

in

over

adjustment

REVERSE

(4)

on

front,

new

oil

on

propeller

housing

over

gear

bore

counter-bored

that

thrust

tailshaft

gear

(88)

ball

on

(2-

bearing

hou·sing
reverse

washer

(85)

over

reverse

castellation

nut.

adapter

onto

gear

facing

forked

Erisur~

on
to

of

to

left

inside
housing

the

mechanic,

arms

part

side

the

reverse

hole

nut

(66)

in

cam

brace

to

nut

GEAR

rear,

seals

(20)

gear

(3)

will

case

in

assemhlywith

rear

side

washe:t-

2. )
(88).

(3)
gear

(1.6-2).

ball

bearing

gear

tailshaft

in

plate

case

(85).

assembly

of

yoke

number

right

of

housing.

approximately

right

two

of

cap

slide

(67).

reverse

(66)

with

HOUSING

and

top

in

cross

(43)

inside

not

rest

of

housing.

down

on

over

seats

and

press

tailshaft

Thread

and

nut

nut

and

hole

(41)

insert

hole

each

screws

yoke

over

of

in

yoke

pins

yoke

yoke

hole

in

assembly

cam

slide

screw,lockwasher

of

reverse

shaft

front

face

reverse
reverse

properly

reduction

(2-2)

on

reverse

secure

(18-2)

in

reverse

ip

reverse

(34)

through

of

is

and

one

inch

to

yoke.

(63)

assembly

holes

end

of

when

on

until

with

until

oper-

facing

push

and

posi-

and

in

DIRECT

22.

DRIVE

After

paragraph

tailshaft.

Place

UNIT

4

seal

above

washer

place

(6)

thrust

over

washer

reverse

(16

gear

-1)

over

tailshaft

reverse

against

gear

thru·st

55

washer

23.

If
plate

24.

Place
support
ing
be

25.

Align
tail
washer

2S.

Place
gear

27.

Install
to

28.

Tighten

lockwasher

29.

Continue

and

removed

(15).

direct

and

(25)

until

taken

not

direct

shaft

(IS-I).

lockwasher

half

lockwashers

reverse

all

install

for

Press

drive

press

gear

to

damage

drive

and

press

coupling
gear

capscrews.

(19)

with

paragraphs

Woodruff

replacement~

ball

bearing

plate.

gear

half

coupling

oil

plate

together

(19)

and

and

key

oil

half

coupling

seal

and

gear

over

reverse

thread

capscrews

(27)

press

(25)

seal

is

during

·until

locknut

housing.

Tighten

over

locknut.

13

through

in

new

into

and

seated

half

coupling

ball

gear

in

locknut

20.

keyway

oil

direct

ball

bearing

(14)

into

against

assembly.

bearing

tails

(18

-1)

holes

in

(18-1)

in

tailshaft.

seal

drive

oil

ball

up

with
is.

haft

on

direct

and

(21)

plate.

assembly

seal

(21)

bearing.

key

seated

with

reverse

drive

bend

into

and

in

against

tang

gear

up

direct

on

ball

Care

reverse

in

keyway

tailshaft.

plate

one

drive

suitable

bear-

must

gear

thrust

in

and

bolt

tang

on

ASSEMBLE

1.

If

engine
a.

b.
c.

d.

2.

Insert
plate

3.

Check
propeller

4.

Start

engine
rotate

pinions

5.

Install

S.

Remove
Tighten

ASSEMBLY

HOUSING

TRANSMISSION

front

end

flywheel

Replace
Slide

engine

Align

housing

After

plate

housing

oil

seal

mounting

and

secure

installing

eccentricity

two

studs

(5).

to

be

certain

gear

reverse

gear

gear

in

('1)

case

gear

inside

gear

right

case.

lockwaShers

the

two

all

caps

crews.

OF

REDUCTION

ASSEMBLY

TO

(5)

(22)

gear

holes

on

is

. 005

three

that

housing

slightly

and

studs

GEAR

ENGINE

was

proceed

or

bearing

(I)

into

in

with

lockwashers

engine~

inches

inches

pilut

gear

cas

(3)

up

against

to

properly

capscrews

and

install

ASSEMBLY

removed

as

follows:

flywheel

front

check

at

pilot

long

roller

e.

over

flywheel

remaining

from

(37)

housing

end

engine
roller

in

two

bearing

the

mesh

in

TO

reverse

if

necessary.

damper

plate

and

capscrews.

gear

bearing.

opposite

(SO)

two

studs

housing.

teeth

holes

lockwashers

REVERSE

(5)

with

for

bolt

is

and

It

on

around

gear

spline.

holes

runout.

holes

properly

slide

may

engine

flange

GEAR

hOUSing (3)

in

flywheel

Ma.~imum

in

front

installed

housing

benecess

gear

and

and

of

housing.

capscrews.

end

over

ary

short

or

in

to

NOTE:

56

1.

Refer
Install

to

adapter

2.

Position
and

slide

tion

ring

3.

Instalilockwashers
and

tighten

reduction

two

studs 3 1/2

plate.

reduction

onto

gear

uniformly.

reduction

slightly

gear

gear

and

assembly

inches

assembly

drive

to

properly

capscrews

long

gear.

and

disassembly

in

over

It

may

mesh

around

two

studs

gear

flange

opposite

with

be

necessary

teeth.

of

procedures.

holes

oil

drain

plug

to

reduction

in

reduction
at

rotate

gear

bottom
reduc-

housing

I

\.

ADJUSTMENTS

1.

With

Howev~r,

have

2.

After

the

3.

The

the

been

alignment.

transmission

replace

4.

The

transmission

Howeyer,,, a

.

mine

The

preliminary

1.

Back
clear

2.

Rotate

site

the

3.

Tighten
enters

4.

Continue

The

preliminary

1.

Loosen
reverse

2.

Tighten
again

3.

Repeat

4.

Replace
capscrews

test

which

5.

Check

6.

With

and

reverse

7.

If

the

reverse

the

adjustments

both

forward

transmission

"db

not

made

securing

any

oil

and

the

that

c9mplete"

whether

the

adjustments

out

the

lockscrew

of

the

hole

the

screw

next

the

hole

the

lockscrew

hole

this

in

until

adj,:;tstments

the

locknut

band.

the

adjusting

tight

against

until a decided

all

the

gasket

and

may

of

engine

the

(4),

cover
be

mooring

running

noting

transmission

positions

and

secu~ed

connect

are

the

satisfactorily

propellerhaIf

should

was

can

be

removed

be

parti~ly

running

adjus,tments

for

the'

(55)

in

the

pressure

collar

in

the

(53)

pressure

making

the

pressure

a

decided

for

the

(70)

on

nut

(66)

the

ear

of

snap

cover

seals.

done

at

dockside.

lines

at

how

well

does

further

as

outlined

reverse

drives.

to

the

shifting

coupling

filled

with

from

adjusted

test

have

forward

until

plate

to

the

plate

certain

plate.

effort

reverse

the

inside

on

the

the

reverse

is

required

(10)

and

The

transmission

before

idle

speed,

the

transmission

not

engage

dockside

above

engrne,

:linkage

replace

until

all

all'

tested.'

to

the

gear

half

'.

new

oil

as

specified.

the

engine.

before

is

necess~y

been.prop~rly

drive

the

right

drive

dog

(49).

(49).

that

is

of

are

on

until

the'

required

are

the

outside

the
to

made,.

'mad.e'as

the

end

the

lockscrew

dog

to
made
upright

of

the

ear

engine

,:satisfacto~ily

on

as

ear

band.

to

shift

secure

continuing

shift

into

to

reverse
is

ready

the

the

transmisslon

reverse.

test.

responds.

in

one

or

both

adjustments

until

the

are

necessary.

transmission

water

of

the

lin~s"

adjustrhents·

.'

coupling,

B'e

,has

c:heck

c,~rte.in

been

deter-

follows:

of

the

lockscrew

(55)

is

OP~)o

the

end

properly

shift

into

forward.

follows:

at

the

top

of

until

gear

both

nuts

housing

for a prelimlnary

into

forward

of

the

forward

Continue

will

engage

etc.

to

run.

is

the

are

witt.

or

in

A

complete
properly
power

conditions

reversing

If

further

until

satisfactory
adjustments
since

it
adjusted,
will

be

heavily
preliminary
will

be

necessary

a

(

'-.

step

Only a very

on

running

adjusted.

conditions.

adjustments

should

is

possible

it

will

stressed

adjustments

the

forward,

small

in

operation

be

for

adjustment

test

The

the

is

transmission

forward

are

be

carried

to

over-adjust

more

difficult

and

have

either

or

neces

sary

drive

necessary,

is

reached.

out

the

to

subject

been

forward

at

the

most, a full

is

required

to

.should

and

should

continue

It

only

until

transmission.

shift

to

made,

or

into

early

only a very

reverse.

for

determine

not

slip

hold

the

adjustments

should

satisfactory
forward

fatigue

Usually,

step

is

the

reverse

that

or

in

reverse

be

noted·

If

the

and

failure.

small

required

drive.

the

transmission

break

away

under

as

outlined

however,

operation

transmission

reverse

and

Therefore,

amount

an

adjustment

for

of

full

is

under

all

full

normal

above

that

the

is

reached

is

over-

the

parts

once

the

adjustment

of a half

adjustment.

57

On

the

forward
loosening
next
step
the

until

Make

hole
is

hole

the

certain

forward

the

locks

in

the

made

by

adjoining

next

hole
that

clutch.

drive,

crew

pressure

taking

it

in

in

the

the

a

full

(55)

plate

the

the

screw

pressure

locks

step

and

locks

crew

of

adjustment

rotating

(49)

can

crew

collar.

plate

enters

the

be

out

is

the

screw

lined

of

Then

lined

hole

is

the

rotate

up

as

outlined

collar

up

under

hole

under

properly

that

the

(53)

the

lockscrew.

it

.is

screw

the

dog

or

above
to

the

in

.and

collar

of

it

will

or

is

right

placing

to

the

lockscrew.

bind

z.nade
until

A

half

the

up

by

~he

it

in

right

the

a

~

When
external
certain

the

the

transmission

bolts

that

trans~ission

and

it

operates

fasteners.

shift

lever

is

properly

freely

and

Before

and

secure

adjusted,

replacing

does

not

properly.

replace

the·

bind

shifting

or

drag.

the

linkage,

Replace

cover

and

check

the

secure

to

make

linkage

all

on

(

"

58

DESCRIPTION

The

Westerbeke / Paragon

drive

gear

that

ADJUSTMENTS

reduction

offers a variety

REDUCTION'

gears

of

reduction

GEARS

consist

ratios.

of

an

internal

ring

gear

and

a

There
rurming

DISASSEMBLy
NOTE:

those

Remov.e

are

no

adjustments

condition.

OF

Disass~mbly

difficulties

reverse

avoid fouling the

1.

Remove

drain

2.

3.

4.

5.

6.

7.

8.

9.

10.

from
Remove

and
reduction
Bend
using
Remove
entire

to

Support
free
reduction
Remove
reduction
If

Remove
and

Press
Remove
ring

reverse

slide

tang

suitable

force

approximately

necessary

spacer

gear

REDUCTioN

need

which

and

interfere

reduction gear

bilges.

oil

drain

oil

.from

,gear

capscrewsand

entire

ll:llit

clears

of

lockwasher

wrench

gear

assembly

coupling
reduction

gear

retaining

gear

Woodruff

ball

capscrews

to

(73).

bearing

(71)

half

housing.
housing

replace

from

necessary

UNIT

be

carried

plug

unit.

unit.

lockwashers

reduction

reduction

and

coupling

under

from

flange

assembly.

gear

2

ring

and

..

key

(80)

(84)

and

lockwa.shers

flanged

with

proper

as

from

Make

unit

(78)

lift

(75)

housing

inches

.

(76)

from

press

remove

from

from

shaft.

to

maintain

out

only
marine

a complete

bottom

certain

straight

dr'ive

away

lockwasher

of

gear

so

and

oil

flanged

flanged

from

pinion.

from

with

half

that

press

groove

ball

seal

from

of

that

bearing

the

as

gear

un;

reduction

all

flange

back

locknut

from

gear

coupling

flanged

flanged

next

(79).

shaft

shC3,ft

rim

reduction

far

as

necessary

operation.

t before

remov;'ng

gear

lubricating

of

reduction

approximately

(77).

shaft.

type

puller

and

pressag~ilnst

shaft

shaft

to

ball

from

and

of'

remove

using

flanged

housing'.

two

gears

in

to

proper

correct

the

housing

oil

3 iI].ches

Remove

or

by

'

assembly

assembly

bea.~¥1g

seal

.'

holes

shaft

(86)

is

removed

gear

housing

locknut

supporting

can

(84)

washer

in

arid

remove

.

0;

1 to

and

until

shaft

drop

from

inaide

(74)

flange.

INSPECTION
All

parts

wear

1.

2.

3.

4.

5.

ASS.EMBLY

1.

2.

should

should

Bal~

on
All
pattern
Examine
Retaining

All

Replace
Press
ing

be

be

replaced.

bearings

balls

gear

and

teeth

or

oil

rings

gaskets

OF

REDUCTION

oil

ball

ring

(76)

thoroughly

should

races.

should

excessive

seal

for

should

should

drain

bearing

into

be

plug

(84)

groove

cleaned

be

examined

be
wear.
rough

be

checked

replaced.

UNIT

into

into

next

before

examined

or

charred

reduction

reduction

to

ball

inspection.

for

indications

for

"pitch

lips.

for

burrs

gear

gear

bearing.

Parts

line

.

or

deformities.

. .

housing

housing

of

corrosion

pitting"..

(86).

(86)

showing

uneven

and

install

excessive

and

pitting

wear

retain-

59

3.

If
housing.

4.

Place

those

5.

Place
shaft

6.

Press

next

7.

Install

8.

Place
ball
with a soft

9.

Turn

flanged

tion

10.

Support
press

coupling
keyway

11.

Place

lockwasher

secure

12.

Bend

13.

Install

adapter

14.

Position
of
rotate

15.

Install
ing

removed

flanged

in

ring

lockwasher

and

ball

to

ball

Woodruff

reduction

bearing

unit

shaft

housing.

unit

gear

is

in

lockwasher

using

one

two

plate.

housing

reduction

lockwashers

and

tighten

for

replacementJ

shaft

gear.

secure

flanged

bearing

bearing

key

gear

(84)

mallet.
over

with

until

on

inside

half

seated

coupling

in

slot

suitable

tang

of

lockwasher

studs 3 1/2

reduction

and

slide

gear

uniformly.

over

over

caps

(84)

and

(80)

housing

on

flanged

small

spacer

of

coupling

against

and

key

(78)

on

flanged

wrench.

gear

onto

slightly

and

press

ring

gear

crew

shaft

onto
place
into

to

flanged

seal

keyway

over

shaft

end

(73)

is

flanged

(75)

onto

ball

in

shaf'~

over

end

into

inches

long

assembly

reduction

to

capscrews

new

(71)

and

insert

ring

gear.

shaft.

washer

in

small

into

of

housing

seated

shaft

shaft

bearing.

before

of

flanged

shaft.

slot

on

into

over

drive

properly

around

oil

seal

and

line'

capscrew

Place

(74)

flanged

end

bore

in

down

against

with

end

Care

pressing

shaft

Place

locknut.

two

studs

gear.

meSh

flange

(79)

up

spacer

over

shaft.

of

flanged

housing

and

ball

bearing

large

and

into

must

together.

with

locknut

opposite

with

oil

It

gear

of

into

reduction

holes

into

hole

shaft

next

shaft

by

tapping

press

end

of

ball

be

taken

tang

(77)

holes

drain

may

be

teeth.

reduction

in

flange

in

(73)

over

to

and

on

center

(84)

in

.

unit

down

bearing

to

on

inside

onto

in

plug

shaft

reduction
at

necessary

gear

gear

with

flanged

shaft

spacer.

start

housing

of

reduc-

and

until

line

up

and

bottom

hous-

of

to

/

"

\

60

--

OWNERS NOTES

(

\

MODEL SS.TRANSMISSION

Model

fitted
engine

SS

Transmissions

to

model Four-60 Diesel Model

and turns a right hand

are

made for both'i"ightand

propeller.

ModelSSL -

SSL

13

is

It is

used.

left

handed engines.

It

is

suited

available

in

(1.3 : I Ratio)

to a

left

two ratios.:

As

hand

It is

differentiated
having
fitted
the

the

clutch

to Model

transmission.

Model

from the Model

lever

on the

Four-60

the

SSL

left

water

- 20

SSR

- 20 (For right

hand

side.

pump

is

omitted

(2:

It

I Ratio)

is

also

from

handed

notable

the

high speed

engines)

that

by

when

shaft

of

61

SSL

TRANSMISSION

The SSL Transmission
operates the gear to give ahead, neutral
slant position, the transmission
when " shift
SSL

is
dire cti on to that of the engine.
No

adjustments are required. The only maintenance

lubricating oil

lever

is

available in 2 ratios 1.3:1

at

time periods specified.

1.

Disconnect

2.

Remove

coupling

3.

Slide

4.

Remove

flywheel

5.

Slide

shaft

is

designed and built for marine use. The three position hand lever {optional)

moved

forward.

REMOVAL

shift

the

capscrews

to

the

propeller

the

capscrews

housing

reverse

clears

adapter

is

in

FORWARD

or

2.1. The propeller turns a

OF

SSL

cable

propeller

shaft

back

adapter

gear

housing

plate

or

REVERSE

from

and

half

and

plate

engine.

6.

Drain

DISASSEMBLY

1.

Remove

2.

Remove

3.

Remove

4.

Remove
bearing

5.

Lift

Bearing

6.

Remove
washer'

7.

Drive

8.

Rotate
Remove

9.

Remove

10.

Support

oil

from

reverse

PROCEDURES

waterpump
Woodruff
four

(23).

out

front

shaft

(20)

race

capscrews

plate

Protect

(15)

and

(30),

(25).

forward

arm

shoe

nut

pin

(43)

(52).

(41),

housing

(54). -

key

race

bearing

(48)

to

rear,

washer

on

front

gear

from

securing

(1)

containing

seal·by

which

(19)

into

(34). -

11.

12.

13.

14.

15.

Remove

gear
Knock
Remove
Drive
Remove
pin
Remove

as

necessary.

(27)

pin

(10)

snap

containing

out

pin

detent

(51)

shaft

..

and

bearing.s..

ring

(44).

plate

into

(9)

with

O-ring

Press

(33)

bearing

Remove

(49),

shaft

(11).

seals,

from

(9)

associated

seals

hammer.

16.

Reassemble

sure

or

17.

Align

to

something

propeller

in

protect

.similar.

reverse

input

shaft

order,

shaft

half

astern action.

gear when the shift lever is moved aft or in RgVERSE

is

GEAR

With

the·

shift

lever mounted in the normal

righ~

hand gear which

to check the lubricating oil level and change the

ASSEMBLY

FROM

ENGINE

is

the opposite

transmission.

lockwashers,

securing

the

drive

shaft

coupling.

away

and

from

drive

lockwashers

straight

lift

"back

reverse

shaft.

securing

reverse

approximately

gear

housing

gear

three

inches

assembly

housing

housing.

Not

applicable

reverse

tape

has

·pu~p

are

now

(32),

box,

using

allowing

(40),

O-ring

face.

shaft.

(28),

handle

spririgs

with

flat

snap

rings

and

replacing

seal

coupling

front

Press

and

bearings

by

on

Iv\odel

gear

bearing

over

engine

end

key

plate

(16),

shaft

removable.

gear

dog

(26)

flat

(24)

end

(39),

shaft

Remove
washer

(43),

(47)

..

and

end

punch.

gear

(12),

from

with

seals,

covering

to

reverse

Four-60

shaft.

(1)
snap

slot

in

shaft.

(22)

screwed

containing

punch.

to

move

coupling.

(23)

forward

washers

(25).
slide
spring

shaft

washers

washers
respective

suitable

gaskets

input

gear

to

housing"

ring

(17),

into

bearing

forward

(38),

(31),

(42)

(13)

..

housings

toolso Do

..

and

shaft

keyway

assembly

seal

rear

(28),

and

off

and

out

of

bearing

into

(46).

bearings

and

O-rings.

half

half

until

clear

(18).,

end.

and

shaft.

key

(37).

bearing

(32),

housing.

(14),

gears

not

use

with

tape

coupling

to

of

'\\

Be

('.

62

(

t-

t.{)

U}

~

(.5

z

~

«

0::

0

z

0

en

!!!

~

en

Z

~

I-

-I

en

en

••

c

.9

()

-

CI)

en

en
en

e

u

(

\

63

(

PARTS LIST

(

1.

NOTES

Unit

ON

USING

of issue for

THIS
all

is inches (not feet or yards).

PARTS

linear

LIST
commodities

Start

2.
cannot find

eous

3. Please
us

via

(Attention:

looking in the contents

any

item,

check

page.

--

Report

speed

errors
letter.
John

H.

and

Westerbeke,

... -if

you

miscellan-

omissions

Jr.)

to

(

MODEL

FOUR-60

CONTENTS

Block
Block

(Internal)
(External)

Crankshaft

Injection
Cylinder
Rocker
Lube
Lube
Fresh
Cooling
Fuel
El

ectri;ta 1

Head

Shaft -

Oil

Pump

Oil

Sump

Water

System

System

...

Camshaft-

Pump

Drive

Valve

- Strainer -

Pump

Sys

tern

Rod

System

Cover

Filter

200

202
204
206
208

.

210

212
214
216
218
220
222

Mounts
Back
Type

Type

End

Arrangements

SAO

Transmission

Freewheeling

SS

Transmission

Raw

Water·

Pump

Sailing Transmission

Miscellaneous

(

\

226
228
230
234
238
242
244

13

FOUR

60:

BLOCK

(INTERNAL)

8

10

\:

~G

6

..

3

kr-

(

\

200

FOUR

6~1

~l

OCK

.( I NTt::RNAL.)

REf

1-1

1-2

3

4

5

6

7

8·

9

10

11

12

13

14

15
16
17
18-1
18-2
19-1
19-2

2~

21

PN

12991

15452
15J92
15489
15J36

15451

~'4~5J

14~~;'

15481

15434

14433
15J47

1549~

15491

15492

15439

15J46

15449
154C;ro

1545J

15454
15J96

15469

NAME

ENGINE

BLOCK

8UL T

LOCKWASHER

DOWEL.

LIN[R
CORE-PLUG

PLUG

PLUG

PLUG

PLUG

PLUG

STUD

STUD

STUD

DOWEL

LINER

PISTON

PISTON

Rl·NG

RING
PIN

RING

ASSY

.ASSY

SET

SET

Rt.MARKS

LlSS

A

tvtAIN

MAIN
CAMSHAF'T

FLYWHEEl/BACKPLATE/SUMP/MANIFOLUS

SSE.t-1Bl

Y

BEARING

BEARING

BEARING

CHANKCASE
OIL.

RElEASEVAL,VE

CHAIN

Oll

MAFN.OIL

CYLINDER

CYLINDER
FUEl,;

TENSIONER

PUkp

GEAR

FElO -

HEAD ~ LONG

HEAD ~ SHOHT

PUMP

BACKPLATE

SE..T

OF

FOUR

51:.T

Of

FOUR

F'OR

ONE

PISTON

FOR

ONE

PISTON

PISTON

PISTON

PIN

CAP

CAP

OIL

GAL~tRY

PASSAGE

AND

FEED

-

STANDARD

,01~

-

~rTAINING

~

RE~R

, • .

~

STANDARD

,010"

-

OIL

REAR

FACE

0/S

OIS

PUMP

FACE

GEAR

FEEU

/

\.

201

FOUR

60:

BLOC/(

(

EXTERNAL)

~

51

if

30

(

/

\

FOUR

601

BL.OCK

(EXTE..RNAL>

REF

1
2

3

4

5

7

9

10

12
24

25

27

28

29

J(iJ

31

37

J9
40

42

4-5

46
47

51

58

~9

PN

15J9(O

14~43

15.s49

15196

15.s50
15J51

15410

154"'l

15.s91

13~26

14~62

14~64

14~6J

15.s97

15.s4ts

15-585

15.s9~

1546~

1548S

13687

i5439
15J94

15474

15.sC;,

15420

1540J

-

NAME.
COVER

S~AL.

OAHPER

STUD

LOC~WASHER

INDICATOR

DAMPER

LOCKWASHER

GASKET

CoOVER

GASKET

BUSfoU

NG

WASHER
PL.ATE

DOl~EL

GASKET

INDICATOR

PETCOCI<

WASHER

BACKPLATE
DOWEL
GASKET
a-RING

LOCKWASHER

SI:.AL

GASKFT

Rt.MARKS
T !

j.q

NG

[) I L,

INJECTION

PUMP

DAMPER

TiMING

CAMSHAFT

TIMING

CYLINDER

DRIVE

COVEH

SIDE

FHONT

TAPPED

tt-lONTPI,.ATE

INJECTION

CYLlNOER

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