Westerbeke L25 Technical Manual

TECHNICAL

MANUAL

WESTERBEKE

Marine

Diesel

PUBLICATION

EDITION

MAY

19419
3

1978

L25

Engine

~r-.v-

J WESTERBEKECORPORATION

•

'WESTERBEKE

MYLES

150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

TECHNICAL

MANUAL

WESTERBEKE

Marine

Diesel

PUBLICATION

EDITION

MAY

19419
3

1978

L25

Engine

~r-.v-

J WESTERBEKECORPORATION

•

'WESTERBEKE

MYLES

150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

3

SECTION

INDEX

GENERAL.

Introduction Operation
Installation Maintenance

ENGINE OVERHAUL

OTHER OVERHAUL

Marine Engine Electrical System

Cooling System (External)
Transmissions

GENERATOR SETS

HYDRAULIC CRANKING SYSTEM

SERVICE BULLETINS

4

YOUR

NOTES

IMPORTANT

THIS

MANUAL

AND

MAINTENANCE

TION

IT

TION.

READ
KEEP

KEEP
FAILURE
BUT

YOUR

IS A DETAILED
CONTAINS
IT

IT

IN A SAFE

IT

HANDY

TO

DO

SAFETY

SO

INTRODUCTION

OF

IS

FOR
WILL

AS

YOUR

VITAL

WELL.

GUIDE

WESTERBEKE

TO

PLACE
REFERENCE

INVITE

TO

THE

MARINE

THE

ENGINE'S

AT

ALL

SERIOUS

INSTALLATION,

TIMES

RISK,

START-UP,
DIESEL
DEPENDABLE,

NOT

ENGINE.

ONLY

TO

THE

LONG

YOUR

OPERATION

INFORMA-

TERM

OPERA-

INVESTMENT,

5

UNDERSTANDING

The

diesel
gasoline
is

essentially

are

arranged

its

crankshaft

as

that

of a gasoline
same
connecting
reverse

that a diesel
preventative
intelligent
oline
are
ricating
of
the
frequent

water,

is

factor
"high
designed

gasoline
handling
retor
with
ponent -the
performs

factory
engine
of
urer
treatment
part

sort

and

Therefore,

engine.

proper

and

fuel

and

time

periods
checking

sediment

also

The

Unremitting

dependable

essential.

is

detergent"

specifically

diesel

engine,

and

and

and

in

the

have

capable
cannot
rests

THE
engine

engine

above

of

valves,

rods,

reduction

it.follows
engine

maintenance

operator

maintenance

cooling

lubricating

the

use

engine

firing

ignition

their

Fuel
function

resulted

service.

control,

it

receives

with

DIESEL

closely

inasmuch

the

same.
its

is

of

the

camshaft,

lubricating

requires

would

The most

systems.

specified

for

etc.)

Another

of

the

diesel

does

however,

its

systems

place

Injection

care

and

of

many

however,

you!

••••
resembles

as

the

mechanism

Its

cylinders

closed

same

engine;

gear.

to a great

as

important

of

filter

contamination
in

the
same

lubricating

for

fuel.
is a single

of

both.

attention

in a Westerbeke

thousands

What

in

service.

crankcase;
general
it

has

pistons,

system

the

same

that

which

give

to a gas-

factors

the

fuel,

Replacement
elements

is a must,

fuel

important

diesel
differ
in

the

are

Pump -which

the

system

brand

engines.
from

method

The

carbu-

done away

at

of
manufact-

is

the

This

the

type

the

and

extent

any

lub-

at

and

(i.e.

of
oil

the

of

com-

the

hours

ORDERING

Whenever

always

tion

List

lication).
engine's

be

sure
packaged
are
specifications

GENERATOR

Westerbeke
the
electrical
lications,
apply,

tions

Maintenance

mation

Generator

PARTS

include

and

part

furnished,

model and

to

parts,

frequently

SETS

propulsion

except

of

the

is

provided
Sets,

replacement

the

complete

number

if

not

Be

sure

insist

not
as

diesels

of

power. For

all

details

in

Installation,

sections.

to

serial

upon

because

made

original

boats

regard

in

Section

parts

part

(see

separate

part

of

include

number.

Westerbeke

"will

to

the
equipment.

are

used

and

for
generator
of

this

to

certain
Operation

Additional

the

section

T.

are

needed,

descrip-

Parts

this

pub-

the

Also

factory

fit"

parts

same

for

both

generating

set

Manual

por-

infor-

titled

app-

and

FOREWORD

Since
details
this
well
gines.
because
the
the
the
operator
conditions

the

of
section
understood

However,

it

reasons
installation
installation

should

boats

engine

to

is

why,

for

in

installation
advise
and

the

valuable

the
to

which

have a thorough

the

engine

INSTALLATION

which

boatyards

well

following

in

precautions

the

should

these

are

developed

outline

explaining

operation

have a periodic

and

correct

engines

equally

and

procedures

to

be

of

understanding

are

engine

of

general

the

functions

watched

the

engine.

procedure

so.

installers

used

It

for

installation

procedure

and

There
check
to

insure

for

are

many and

is

not

on

of

each

the

relationship
and
its

the

purpose

the

generally

of

is

included

component,

are

details

of

which

good

operating

servicing.

7

varied,

of

en-

of
of

the

INSPECTION

The
mounted
cessory

small

crate.

Before

transportation

be

opened

cealed

cealed

the

delivering
damaged
of

the

and

make

ancies.

loss

or
be

must
Westerbeke

RIGGING

The

Rope

tached

by

means

The

lifting
carry
therefore
quired

CAUTION:
to
nificant

engine

of
must

eyes,

to
strong
engine a little
is
ity
not

the

place

100

be

if

The

see

firmly

of
lift

OF

engine

securely
equipment

box,

usually
accepting
and

damage.
damage

condition".

shipment

sure

This
damage.
made

Corporation.

AND

engine

or

chain

to

the

of

full
auxiliary

or

desired.

Slings

the

sheer
lifting
from

placed

supported
general

that

all

and

firmly

supported.

accidents

from

EQUIPMENT
is

shipped

and

is

company,

an

inspection

If

is

noted,

agent

against
note
is

your
Claims

to

the

LIFTING

is

fitted

slings

rings
tackle
rings

engine

the

have

weight

must

stress.
eyes

vertical.

between

by

rule

equipment

fixed

at a time

by

the

propeller

properly
shipped

packed

shipment

the

either

you

to

sign

Also

the

is

made

protection

for

carrier,

with
should

and

the

attached

been

of

the

slings

not

lifting

Strain

must

avoiding

not

the

valve

in

moving

in

Eliminate

from

the

crated.

in a separate

with

visible

check

be

used
and

the

from
crate
made

should

"Received

contents

packing

of

any

loss

not

lifting

be
engine
to

this

designed

engine,

are

not

so

.short

eyes

on

be

in

A

spacer

two

lifting

cover

engines

is

place.

see

possibil-

haste.

coupling,

factory

engine

the

should

for

con-

or

con-

require

list

discrep­against
or

damage

to

J.

rings.

at-

lifted

sling.

to

re-

as

in

sig-

the

excess

bar
studs.

amply

Move

that

Do

or

is

Ac-

in

H.

the

it

pry

against

distort

In

lift

horizontal

engine
small
If

the

is

possible
outside
cooling

mounting
ment
mechanic

to

avoid

to

avoid

which

to

position

been

In
engine

gear
must
possibility
which
special
experienced
of

heavy

ENGINE

It
bolts
the
are

the
moved,
ition
en

the

the
stays
and
is

not

the

some

the

must

hatchway

opening

clearances
piping,

should

have

passed.

case

either

.end

be

done

the

rigging

BOLTS
is
of

engine
less

wood

whereas
and

engine

engine

in

the

bond

weakened

engine

lugs,

and

damage
dirt

upwards,

machinery.

recommended
appropriate

preferred
is

position

this
coupling.

cases
position.

be

which

to

reduce,

be

removed by a

special

entering

been

as

it

is

front

very

of

damage

weight

and

flexible

weakened

the

the

nut
down

to

be

between

with

crowbar,

it

may

in

other

It

lowered

cannot

is

extremely

such

water

etc.

to
removed

soon

necessary

may
work
competent

lifted.

by

tank,

This
care

any

as

end

the

attachment

carefully

to
bear.
be

that
size

mounts.

because

every

lag

on

top

or

is

at

all

the

its

as

you

be

necessary

than

the

regular

may

be

that

endwise

to

as

accessory

exposed
openings.

should

the

upwards

the

done by someone

bronze
be

bolt

is

removed

The
times,
bolt

removal.

through

be

made

restricted

some

should

in

extent,

generator,

filters,
competent

parts
be

restriction
to

hoist

or

to

avoid

parts

It

is

the

used

Lag
their
time

they

stays

used

bolt

as a stud,

and

be

The
returned

reverse

of

on

best

handling

hanger

through
screws
hold

in
to
to

itself

the

may
to
the

a

larger.

it
the

equip-

taken

and

parts

has
the
slings

the

if

on
are
pos-

tight­permit

wood

8

FOUNDATION

A good
toward
engine.

engine

the

The

construction

when
position

keep
andths

push
bearing

engine
similar

hulls
to
bolts
reducing

a
be

hull.

the

effects

times.
the

propeller

In

the

The

pair

resisted.

engine

subjected

the

the

engine

of

an

It

of

the
in

bolts

fiberglas

wooden

be

formed and

hull

to

be
noise

temptation

of

fiberglas

vibrations

Flexible
foundation
are

to

do

their

bed

design

FOR

ENGINE

bed

satisfactory

engine

and

to

boat

of

rough

bed must be

neither

the

may

within

inch

has

of

to

withstand

propeller

shaft,

the

engine

and

engine

hulls,

stringers

fitted,
securely.
installed

and

transmitted

to

"angle

Such

construction

to

mounts

against

which

job.

"A" and

avoid

contributes

operation

deflect
engine
have

seas.

one

this

weight

to

The

or

position

the

which

to

and

the

finally

is

thrust

bed.

we

recommend

as

in
then

This

allows

firmly

install

in
the

irons"

pass

through

require

to

react

When

possible,

bed

design

much

of

of

rigid

nor

or

take

under

bed

must

two

thous-

at

forward

applied

washer

to

that

wooden

glassed

hanger

wood,

vibration.

engine

should

will

to

a

firm

if

"B".

the
twist

the

all

to

the

thus

on

allow
the

they
follow

PROPELLER

Each
larly
connecting

COUPLING

Westerbeke

fitted

with a suitable

the

engine.

The

coupling

power

must
or
bearing
gear

is

of

also

astern

housing

very

the

engine
transmit
from

which

of

carefully

fit.

For

all

engine
coupling,
specific

either

ot

the

The
has a long
should
coupling

the

shaft

be

scraped
fit.
properly
coupling.
the

keyway

touch

the

coupling.

If
coupling

bored

order,

has

a keyway

clamping

forward

straight

be

removed from

should

and

down

It

is

important

fitted

The
very

the

top

it

seems

over
be expanded by
ing

water.
coupling
the

centerline

The

must

shaft.

Diesel

propeller

must

the

the

shaft

is

built

the

not

to

engine.

engine
shaft
only

turn
thrust

to

into

machined

models, a propeller

to

shaft

is

supplied.

with

size
set

type.

end

of

the

propeller

keyway.

the

be a light

the

shaft

or

filed

drive

should

in

that

both

key

closely,

of

difficult

the

heating

face

be

or

to

should

the

keyway

shaft,

of

exactly

axis

the

fit

but

to

the

in a pail

the

perpendicular

of

the

coupling

to

transmit

the

shaft,

either

the

thrust

the

reduction

This

for

accurate

for
The

screws

Any

burrs

shaft

end.
fit

not

order

the

key

shaft

the

should

in

the

drive

coupling

of

propeller

propeller

is

regu-

for

the

ahead

coupling

half­the
coupling

or

is

shaft

The

on

have

to

get

be

and

the
side

of

not

hub

of

the

can

boil-

to

the
but

to

a

PROPELLER

The

type

with

to
tests.
engine,

ditions,

ler
its
under

the

fit

which
full

normal

gear

the

To
and

it

rated

ALIGNMENT

The

engine
aligned
matter
boat
some

its
usually
operated
very

with

what

it

will

extent

shape

realized

in

important

and

size

ratio
application
utilize

to
is

will

the
achieve
desirable
permit
speed

load.

OF

ENGINE

must

be

the

propeller

material

be

found

and

the

to a greater

when

the

water.

to

check

of

propeller

and must

based
full
ideal

to

the

engine

at

full

properly

shaft.

is

used

to

be

boat

hull

extent

it

is

It

is

the

varies

be

selected

upon

power

loading

boat
of

the
con-

use a propel-

to

reach

throttle

and

exactly
No

to

build

flexible

will
than

launched

a

to
change
is

and

therefore

engine

align-

ment

at

any

errors

Misalignment

propeller

which

It
rapid
reduce
the

shaft
and
propeller
straight.

alignment
oil
make
limits

the
or
lings
force
all
foundation
the
rately

the
the

assume

to

water
usual
main
ging

alignment
anything

can
the
feeler
come
two
should

are

will

shaft

the

hull

will

it

is

One

particularly

through

sure

prescribed.

The

engine

bed

and

shims

can
and

around.
approximate

determined.

Never

boat
water

its

do

the
tank

equipment
mast
has

Take

.plenty

The

alignment

be

slipped

counterbore

gauge

exactly

halves

be

i

\

frequent

when

shaft

blamed

create

wear

life

fastenings.

have
therefore
shaft

may

the

that

supported

until

be
so

for

attempt a final
on

land.

and

final

alignment

about

has

been

and

less

of

parallel

intervals
they
between
is

the

often

excessive

and

of

the

exactly

necessary

itself

annoying

be

leakage

rear

alignment

should

the

two
brought
that

the

It

is

best

the

foundation

alignment

The

have

had

water

with

half

on

board

been
accomplished.

do

indicates
together

the

stepped

of

time

not

than

perfect

is

correct

backwards

very

propeller

within

may

appear.

the
cause
on

other

bearing

will,

hull

A

bent
the

be

perfectly

of

oil

seal.

is

be

moved

on

the

halves

together

flanges

not

has

alignment
boat
an

opportunity

form.

the

full

and

in

making

be

satisfied

and

easily

that

at

all

0.002

and

to

correct

engine

of

in

by

propeller

same

result

transmission

within

screw-jacks

to

should

fuel

and

after

and

results.

when

forward

and

the

points.

coupling

..

and
troubles
causes.

wear,

many

cases,

loosening.

effect

that

the

Check

the

around
of

the
without
meet

evenly

drill
bolts
been

accu­with

be

It

is

and

all

the
the

final

this

with

the

when a
flanges

inches

~.

the

of

mis-

to

on
coup-

using

the

until

in
to

best

rig-

shaft
into

The

(A).

In

making

the

engine

one

position
propeller
coupling
900 between
also

check

ling

is

Then,

position
rotating
position

The

after

to

three
alignment
found
alignment.

was

improperly

the

boat
final
stringers

moisture.

align

The

the

and
hauled

water,
The

flexibility

very

water

mum

makes

wet

severe
coupling
In

some

bent

by
to

small

when

dry

for a considerable

EXHAUST

Exhaust
erably
particular
are

to
of

sea

water,
cannot
should
between
the

discharge
in

very
followed
straight
sion

or

fill

with

exhaust

Brass

exhaust

salt

water

half

coupling

in

whether

in

exact

keeping

the
the
each

engine

the

boat

weeks

remade.

that

the

has

shape

have

It

at a further

coupling

bolts

out

or

and

during

or

cases

these

boats

not

SYSTEM

line

and

each

job.
provide
restrictions

rain
get

back
be a considerable

the

it

difficult

far

by a
gradual

trough

water

gas.

or

and

the

final

coupling

and

the

alignment

tested

each

of

four

each

position.

the

alignment

the

propeller

alignment

engine

900
alignment

has
and,

engine

This

done

taken

and

probably

may

removed
moved from

strain
both

the
strains.

an

exhaust

end.

by a wave;

long

Also
copper
systems,

diesel

half

from

been

if

It

in

not

at

some

the

engine

even

period.

should

storage

of

the
on

when

shaft

that

are

in

use,

installations

must

The

outlet

and

water,

into

manifold
This

for
slope

slope.

to

the

and

obstruct
avoid
is

check

should

with

positions,

This

propeller

on

coupling

should

coupling

the

next
should
in

service

necessary,
will
is

whenever

be
general

the

not

as

exhaust

usually

no

longer

because

first,

time

bed

absorbed

be

necessary

always

the

in a cradle.

boat

often

the

shaft

it

is

being

has

actually

This

hauled

unless

time.

designed

line

arranged

or

condensation
engine.
fall

slope

water
and a steep

is

better

Avoid

line

which

any

acceptable

the

combination

for

alignment,

be

held
with
the

its

be

be

but

to

and

be

land

does

they

vary

requirements

with a mini-

in

flange

to

the

sharp

gas

propeller

test
half

shaft

checked

to

one.

rechecked

for

the

be

in

the

because

take

engine

some

opened

the

boat

to
puts

or

the

moved.
not

out

of

are

consid-

for

so

There

the

in

the

be

driven
drop
than

any

depres-

would

flow

bends.

will

the
rotated

will

coup­in
full

work

its

to

the

been

apply

the

the

that

line

and

pipe

of

for

9

in

..

one

one

re-

up

is

a

a

of

10

cause
iron

rapid

fittings
recommended
haust
the
increased
ly
be
feet

line

engine

in

long

run

increased

beyond

EXHAUST

deterioration.

and

galvanized

for

the

must

SYSTEM

be

exhaust

size

and/or

by

1/2"

the

first

at

manifold

if

many

WITH

STANDPIPE

exhaust

least

there

elbows.

in

LD.

10

feet.

WATER

Galvanized

iron

pipe

line.

as

flange

is

an

The

large

and

especial-

It

for

every

JACKETED

is

ex-

as

be

should

10

support

sagging,

for

bending,

pockets.

Always
into
riser

flange
back
entering
against

the

rubber

or

sufficiently

so

into

sea

the

Otherwise

MEASURING

Back

pressure

straight

as

near

section

as
manifold.
maximum

Set-up

1.

For

load

should

normally
Pressure
1-1/2"

2.

For

Max

turbo-charged
Pressure

0.75

Max

the

rubber

arrange

hose

that

water

the

engine.

water

inside

excessive

EXHAUST

must

of
possible
The

engine

during

be

as

asperated

Test

Mercury

PSI 3"

Test

PSI

Mercury
1-1/2"

and

formation

that

section

below

cannot

cannot
of

erosion

GAS

be
the
to

should
the
shown

Mercury

engines:

hose

water

to

discharge

is

the

possibly

Also

make

spray

the

exhaust

will

BACK

PRESSURE

measured

exhaust

the

engine

be

measurement

below.
engines:

Test

Test

Mercury

prevent

of

water

behind
exhaust

sure

directly

piping.

occur.

on a

line

exhaust

run

at
period.

Water

= 39"

Water

=

19-1/2"

a

flow

that

and

Column

Column

To

insure

hull,

use a flexible
stainless
threaded
close
flexible
no

bends

ial.

to

The

at
the
section
and

supported
strain

on
installations
hose

for

the
exhaust
lation

line

and

1-)/10"

WATER

"HYDRO-HUSH"

vibration

steel,

each

engine
covered

exhaust

by

brackets

the

manifold

use
water
because

flexibility.

0.0,

MUF'FLEA.,

LIFT

EXHAUST

doesn't

section

no

less

end and

as

possible.

should

with

pipe

should

to

flange

flexible

cooled

of

,-''''.

o.o~

PH

1)1710

transmit

preferably

than

12"

installed

be

installed

insulating

be

properly

eliminate

studs.

rubber

section

the

ease

of

Provide

___

!--...

11·1/2"

OIA.

adequate

SYSTEM

MUFFLER

overall,

as

This

with
mater-

any

Many
exhaust
of

the

instal-

WITH

to

of

Checking

1.

Exhaust

2.

Exhaust

3.

Transparent
with

The Back

water.
exceed
engines
engines.

WATER

CONNECTIONS

Seacocks

full
than

flow
the

inlet
pump. The
which
the

may

vessel

Water

lines

wire-wound,

pipe
line

plastic

39"

for

and

19.5"

and

type

at

thread

strainer

be

withdrawn

is

at

can

reinforced

Pressure

flange

hose,

partly

Measurement "A" may

normally

for

strainers

least

should

asperated

turbo-charged

should

one

size

of

the

sea

be

for

cleaning

of

be
greater
water
the

sea.

be

copper

rubber

tubing

hose.

filled
not

of

the

type

while
or

In

any

case,

that

will
tween
the

outlet
takes
to

be
aligned.
suction

should

at

all
The

neoprene

water
FUEL

aluminum,

made

Copper
be
tank
pump

minimum
is

can
care
system
locks
against

lecting

the

recommended
list

filter
fuel

has a replaceable

excess
pump,
tank
the

diesel
ply
cleanliness

portant
installed,
the
cause
the

FUEL

with

line
in

TANK

Fuel

of
interior
from

contaminating

used.

above

provided
tank.

already

be

should

A

primary

fuel

of

lift

As

and

tank

To

of

fuel

engine

PIPING

We

suitable

and

the

use a section
not

collapse

the

hull

and

up

vibration

moved

be
connections

pump

or

The amount

utilized

is

are

is

the

of

the

insure

engine

clean

fouling

recommended

longest

slightly

Do

not

piping.

of

bronze.

impeller

should

AND

FILTERS

tanks

fiberglass,

(6

dirt

type

tank

accessories.

should
or

at

lines

may

plain

is

gel

galvanized
It

is

the

will

feet

installed

be
correctly
eliminated

and
fuel

should

and

type

fitted
pump

fuel
that
overflow

as

satisfactory

must

diesel

and

the

because

of

is

started

fittings,

the

return

of

under
inlet
the

engine

being

in

taken

and

lift
required

be

near

care

time

or

pieces

and

engine

exhaust

and

permits

when

use

street

All

pipe.and

Use

to

prevent

in

the

never

be

steel

coated

not

of

water

filter

the

is

on

element.

tank

the

copper

be

of

fiberglass,

or

terne

be

certain

to

the

fuel

fuel

necessary

level

raise

this

be

available

the

pump

is
connected

the

have a dependable

fuel.

when

dirt

the

lift

maximum).

above

position.

to

ensure

installed

and

precautions

entering

of

installed

fuel

The

secondary

the

engine

injection

has a capacity

by

piped

top

operation,

are

especially
the

left

will

injector

for

the

tubing

both

line.

obtainable

flexible

suction,

system.

the

it's

being

elbows

fittings

sealing

air

sea

run

dry.

plate.

that

prevent

system.

tanks

to

as

the

fuel

should

engine

that

so

the

lift

from

between

the

injection

to

the

to

as

possible.

For

this

fuel
anywhere

certainly

nozzles
first

for

Run

the

hose

be-

and

between

This

engine

re-

in

compound
leaks.

(raw)

monel,

the

fibers

should

mount

fuel

from

be

kept

If a tank

level

Great

the

that

air-

taken

the

fuel.

water

pump. A

the

together

col-

between

the

fuel

pump

and

fuel

top

a
sup-

reason,.

im-

tank

in

when

time.

the

supply

tubing

to

avoid

If

not
the

lift

the

it

fuel

the

in

of

is

the

use

of
nectors.
between

of

the

that

all

Keep
exhaust
eliminate

The
to

the

securely
Usually
means

The

should

ELECTRIC

The
izes
built-in
are

no
Skipper
panel
gauge
ment

is

isolated

where

The

the

fuel

joints
fuel
pipe

"vapor
fuel
engine

anchored

the

of

copper

final

be

PANEL

Westerbeke

an

electronic

hour

longer

mechanical
are
and

is

lighted.

visible.

WESTERBEKE

SKIPPER

ELECTRICAL

Most

Westerbeke
pre-wired
Never

engine
instructions

make

is

and

running.

unnecessary

shut

off

fuel

tank

oil

type,

be

free
lines
for

piping

copper

connection

through

an

ammeter,

oil

from

as

minimum
locks".

leading

compartment

to

prevent

tubing

straps.

flexible

all-electric

tachometer
meter.
required,

panel.

pressure

The

ground

It

is

ALL-ELECTRIC

MECHANICAL

EQUIPMENT

engines

with

plug-in

or

break

on

connections
Carefully

the

wiring

fittings

valve
and
and

far

Tachometer

water

gage.

all-electric

normally

in

engine

it

is

of

pressure

as

possible

temperature,

from

should

chafing.

is

secured

to

the
rubber

with

except

Mounted

temperature

Each

and

may

TACH

are
connectors.

follow

diagram

and

con-

the

line

should

important

leaks.

from
to

the

tank

always

by

engine

hoses.

panel

for

pre-wired.

a

cables

the

on

instru­panel

be

mounted

util-

the

PANEL

PANEL

supplied

while

the

all

sup-

11

be

be

12

plied,
cicuit

especially
breaker

Starter

close

voltage

bad
for

to

drop
practice
other

amperage

where

lights,

there

refrigerators,

sounders,

complete,
charging

second

alternator

splitter"

Starter

which

permits a high

(Diesel

Carefully

sizes

shown

installation

engine

and

requirements.

batteries

the

engine

through
to

services

or

are
are

etc.)
separate

current

.

batteries

starting).

follow

in

the

so

use

the

those

relating

should

as

possible

long

use

the

starter

unless
intermittent'.
substantial

radios,

it

is

essential

system

for

this

or

"alternator
must be

rate

the

recommended

wiring

the

battery

following

to

be

located

to

leads.

batteries

they

require

In

loads

depth

to

and

to

provide

by means

output

of a type

of

discharge

diagrams.

is

close

cable

fuse/

avoid

It

is

cases

(from

have
of

wire

Plan

to

sizes:

as

low

a

a

f

#1

111/0
112/0
1;3/0

for

-

for

-

for

-

for

-

MECHANICAL

The recommended
stop-run
and
push-pull
throttle
Morse
a

sheathed

The
connected
ible,

Morse
gives
full
The
with
the

Any

be

gradual.

lever

controlled

knob

lever

type

transmission

to
sheathed
type

clutch

throttle

two-lever

one

lever

other.

bends

transmission
After

linkages

installation

that,
at
neutral

the
detent.
and
tion

when

the

pilot

and

transmission

Check

the

stop-run

pump

for

distances

distances
distances
distances

CONTROLS

practice
loaded
by a
at

the

should

lever

at

cable.

the

pilot

cable

lever.

and

The

throttle
range
type

provides

and

throttle

in

the

End

sections

must

the

be

are

completed,

for

full

transmission

station

reverse,

is

the

throttle

lever
full

travel.

up

to 8 feet
up
up
up

to

the

sheathed

pilot
be

connected

the

pilot

control

station

and

controlled

single-lever

control

in

neutral

control

at

securely

travel,

is

in

the

control

on

the
on

the

to

10

feet
to
to

is

run

13

16

to

feet

feet

have

position

cable

station.

station

lever

m,ay

by a

with

position.
clutch
control

cables

engine

mounted.

check

making

control

forward,

lever

respective

control

fuel

the

to

a
The

to

a

by

be
flex­by a
type

control

with

should

and

the

sure

lever

on

lever

injec-

OPERATION

13

PREPARATION

The

engine
ricating
and
follow
fully
first

1.

Remove
with
to
See
proved
fill.

the

2.

If
fill
stick
You
gine.
If

the
type A Hydraulic
fill.

3.

Fill
after
until
On
fresh
clean

(see

tenance

Use a
weather

Fill

the
has
air
have
within
filler

4.

Ensure

3/8"

tery

capable

required

5.

Fill

oil;
mended. The

but

higher

NOTE:

of

the

ure

of

200 mesh

6.

Fill

ent,

grease.

oil

transmission.

these
before
time.

oil

heavy

the

highest

table

lubricating
Select

listing
the

Reverse

to

the

with

may

use

Reverse

highest

fresh

opening

all

fresh

water

water

Cold

Section).

50-50

is··to

surge

top

..

run

for

is

released,

dropped.

one
cap.
battery

above

is

fully
of

fuel
No. 2

No. 2 is

lubricant

If

there

fuel

is

to

pour

grease
with

FOR

FIRST

is

shipped

drained

Therefore,
recommended
starting

filler
duty,

under

and

S.A.E.

Gear

mark

water

entrapped

water

cooling
and/or

Weather

anti-freeze

tank

Check

inch

the

the

on

tank

diesel

tank,
wire

a good

diesel

mark on

Maintenance

an

approved

continue

Gear

highest
the

same

is

on

fluid.
cooling

all

cooled

be

experienced.

to

this

a few

the

If

of

water

battery

charged

extra

the

first

with

use

of

preferred

content.

is

no

the

the

fuel

screen.

cup on

grade

START

"dry"

from

procedures

the

cap

and

oil.

has a manual
mark

30

lubricating
oil

hydraulic,

the

pet-cocks

air

engines,

system

anti-freeze

precautions

within

level

minutes.

water

so,

refill

top

level

effort

clean

fuel

No. 1 is

filter

recommended

through a funnel

water

•.•

the

crankcase
be

engine

fill

lubricating

the

dipstick.

for

Do

not

grade

to

use

on

the

as

in

dipstick

Do

not

system

and

is

expelled.

with

solution

one

after

If

level

and

replace
is

plates

so

that

that

start.

Diesel

oil

is

because

in

pump,

of

water

tank

permissible

the

with

sure

care-

for

the

oil

an
over­from

it.

clutch,

dip-

oil.

the

fill

with

over­only

plugs

fill

fresh

solution

in

Main­if

inch

engine

trapped

may

to

at

least

and

bat-

it

is

may

fuel

recom-

of

its

filler

proced-

if

pres-

pump

lub­to

sump

oil

ap-

en­to

the

cold

of

be

BLEEDING

The

sion

high

stroke
tiny
duce

ent

this

correct

tion,

In

air

is

part

repair
is a misfortune
complete
engine

The

system
using
and

Before

that
surrounding
prevent
the

DPA

DISTRIBUTOR

ing

and

both

ed

DPA
physical
ernor
cated

Fig.

THE

fuel

injection

ignition

fuel

pressure

to

function
movements .of
this

pressure

inside

air

of

2).

the

system.

mechanically

the

acts

pressure,

from

being

consequence

bled
or

can
bleeding

in-line

pumps. The

bleed
in

1

from

the

system

serv1c1ng.

bleeding

be

following

priming

outside

area

dirt

venting

location

screw

the

SYSTEM

system

engine

high

as a cushion

restarted.

DPA

and

appropriate

depends
during
correctly.

the

pumping

and

if

pressure

and

therefore

achieved.

it

is

the

system

has

been

Running

that

also

of

the

instructions

apply

of

PUMPS

sequence

to

pumps (shown

and

bleeding,

the

is

thoroughly

foreign

The

and

hydraulically

only

on

the

"D"

and

of a compres­upon

the

injection

Relatively

plungers

any

air

line,

and

prevents

essential

whenever

opened

out

necessitates

system

for

typical

in

bleed

matter

is

difference

pump
illustration,

screws

clean

following

applicable

of

this

is

very

is

pres-

then

fuel

before

entering

that

for

of

fuel

systems

Figs.l

insure

govern-

is

the

indi-

injec-

any
fuel

and
to

prim-

gov-

pro-

the

all

the

to

the

14

Fig. 1 for

2

for

hydraulically

Fig.

If

the

fuel

feed
bleed
fuel
priming
free
Tighten
gravity
and
bleed

the
and
housing.

the

bubbles

tighten

NOTE:

being
jecto.r
or
fuel,
be

means
feed
close
as

to

will

screw

inlet

lever

from

both

fed

carry

screw

Slacken

two

hydraulic

the

bleed

feed

issues
this

The
ing
filled,

by

fuel

plungers,

vance

normal
filled
take a long

However,

vented

or

serviced

then

filled

of

pump

the
fuel
If,
the

free
however, a new
system,

most

mechanically

2

fuel
pump,

air

out

Operate

pump.,

(vented

device

filter

with

the

will
governor

likely

system

"A" and

union

of

issues

the

fuel

the

and

the

vent

screw

until
from

bleed

space

by
and
oil

back-leaked

the

way

in

with

oil

time
if

the

is

because a pipe

or

the

the

governor
fuel

hand

suff~ce.

from

then

governed

slacken

the
"B",
the

feed
from

vent

system

same

fuel

inlet.

valve

head

"0"

the

fuel

the

screw.

within

screw

its

contents

pump

if

fitted.

which

and

at

reason

element

system

oil

priming

bleed

air

its

be

empty

governed

pumps.

is

fitted
both
injection

and

connections.

turn

procedure

locking

on

hand

vent
the

rotor

this
this
feed

housing
and

issues

pump

governor

the

operate
pump
both

on

fitted

the
priming

free

"c" and

governor

"0")

lubricated,

from

and
This
space
can
pump

that

has

been

has

bleeding

lever

In

this

screw

from

has

of

fuel

until
the

screws
governor

from

is

the
line

run

"0"

been

and

Fig.

with

a

filter

pump

the

fuel

vents.

In

the

fuel

with

to

one

lever

air

then
hous-

normally
the

pump

the

ad-

is

the

becomes

naturally

pressures.

pump

or
changed
out

will

still
by

of

the

event,

as

the

fitted

housing

oil

hand

a

the

of

"c"

of

is

in-

of

soon

vent.

and

bleeding

Leave
slackened.
pipe
Set

the
ition
from
tighten

Start
idling
from
this

Governing

procedure,
engine
develop.
RECOMMENDED

doubt

equipment

depends upon
location.
populated
up

the

quite

prehensive

Generally

owner

service
insurance
servicing
crew.

A
consist

a

set
filter.
filters
easily

ing
injection

a

fractured
any

these

be

obtained
agent
already
ally
entry
ed

as a set

them
is

vitally

face

clean

A

right
ticular
correct
able

when

use

proceeds
the

governor

Next

line

air

the

the

time

with

while

connections

throttle

and

turn

flows

the

loosened

the

speed

governor

screw

as

suitable

this
of

spare

defective

required

and

may

therefore

should

SPARES

to

the

spares

General

areas

Amazon

different

spares

is

within

centers

against
within

of a replacement

of

sealing
Spare

are

also

lost

or

system.

pipes

or

and no

pipes.

from

or

service

bent

both

of

dirt.

and

way

important

the

pipe

until

type

fitted

set

and
engine
seating

one

as
slacken
to

the

the

engine

from

the

engine
until

stop

any

the

delta,

speaking,

kit

bleed
damaged

The

to

until

but

set

and

air-free

bleed

the

be

erratic

excessive

Owners

amount

to

carry.

use

coastal

is

one

and

would

kit.

relatively
and

requires

breakdown

the

for

and

required,

A

full

should

cracked

patching

correct
the
center

shape

ends

plugged

They

it

is

required

is

kept

to

of

fuel

correctly

together

washers

injectors

will

is

follows.

bleed
at

injector

stand

of

of

for

scope

such a purpose

"0"

screws

also

engine

and

will

important

that

the

away

screw

any

two

the

injector

fully

unions.

run

screw

engine.

the

thing,

the

in a boat

set

pipe

and

injectors

witb a set

will

also

open

until

pipe

it

at

fuel

"0".

during

by

to

engine

are

often

fuel

example,

filter
rings

is

serupulously

set

to

injection

A

great

craft

use

in

but

require

average

easy

spares

and

of

the

for

for

for

screws

of

high

be

carried,

could

possible

set

of
manufacturer's
will

cleaned

against

be

supplied
for

the

internal

engine.

for

not
be
permit

being

fuel

reach
for

element
pumps

to

changed

serviced.

"0"

injector

end.

pos-

free

Then

re-

unions.

fast

exudes

Tighten

this

stop

when

the

speed

in

deal

and

its
well­voyaging
would

a com-

boat

of

only
general

owner

would

each

and

are

bleed-

pressure

occur

with

pipes
be

supplied

intern-

the

pack-

keep

use.

of

the

the

par-

of

the

only

en-

engine

be

as

or

and

for
at

can

It
sur-

Do

be

careful

parts

list

requires

Additionally,

washers

sure
joint

ment

ary
when
means

Do
the
and
in
your

for

pipes

starts

ever

in

port.

the

at

not
correct
adjustable

some

locations,

fuel
craft.
HINTS
the
fuel
extends

ing

AND

need

at

the

all

to
equipment

refueling.

A

useful
ments

is
enough and
element
filter
bolt.

ment,

and

head

Undo

oil
Then empty
large
ated
ered

enough

and

if

required.

Granulated

to

all

cat

and

sold

ideal

when

the

for

venting

material

system.

Barrier

are

useful
removing
cream
dirt,
when

fuel
always

In

before

grease

the

the

will

wipe
non-fluffy
of

those

will

do
spill
wipe
does

not
if

left,
track
careful

far

any

it

off

everywhere

where

to

check

regarding

injector

whether

seating

spare

back

are

leak

handy

pipes

things

leaking.

breaks

down

when

Breakdowns and

equipment

is

working

sea!

forget

the

spanners

tools.
for

wrenches

but

injection
TIPS

for

absolute

times.

methods

hint

to

obtain a polythene

strong

put
before

the

and

base

the

for

the

base

pieces

owners

for

use

soaking

or
down

creams

and

the

grime

the

equipment

It

is

This

of

and

when

enough

this

around

unscrewing

center

all

bag

into

the

contents

and

of

who

in

cat

up

removing

before
of

make

life

from

job

essential
cleanliness

operating

to

changing

sealing

diesel

the

is

and cream

job

is

completed.

majority

be

supplied

the

piece

grubby

of

pump

of

old

nozzle
cloth
swabs,

more harm

fuel

evaporate

will

on

right

gather
you

tank,

away.

as

and

put

dirt
keep

with

the

engine

the

engine

washers

banjo

bolts

and

to

low

have

Remember no

it

is

or

and

equip-

station-

trouble

- and

Always

the

job

- hammers

may

be

all

right

please,

not

on

your

to

around

stress

of

requirement

and

precautions

filter
bag

large

to

hold

the

the

element

the

center

bolt

and

allow

to

go

into

a bowl

to

or

be

the
container

rings

substance

live

in

litter

pipe
working

fuel

familiar

apartments

boxes

spilled

lines.

on

oil-defying

much
hands.
tackled

are

fueling

easier

Put
and

removed

installations

together

through a hose

with a clean

before

use.

please -they

than

deck

Diesel

does

down

good.

or

gasoline,
and
on

smelling.

the

If
fittings,
fuel

grit,

fuel

not.

pres­when a

occur

that
carry

the

also

servic-

about

ele-

filter

and

ele-

bag.

separ­recov-

is

Put

the

kind
when

on

the

then

­None

you
oil

and

will

Be

tank

cap

when
pick
a

lot

up

dirt

of

Avoid

lots

of

unknown

bargain

ion

equipment

damaged.
WHEN

1.

ENGINE
Check
oil

pressure

operating

(Extremely

2.

Check
at

exhaust

delay.

3.

Recheck
gine
quent

tion,
crankcase
ant

as

to

compensate
quiredto
oil

passages

as

necessary.
of

operation.

4.

Recheck
applies
or

a new
stop
eral

minutes

into

add

oil

each

5.

Recheck
engine
applies
drained
Stop
ating
water

WARNING:
overheated
leased
be
the

the

gradually

removed.

hands

cap
resistance
Leave

the
pressure
wards
safety

it

6.

against

stops,

can

be

Warm-up

sible,
duced
indicates

refueling

or
dirt
dubious

grit

gets

­into

sources

origin

they

appear

is

expensive

STARTS

Oil

Pressure

is

approximately

speeds,

hot

engine.)

Sea

Water Flow. Look

outlet.

Crankcase

has

run

for 3 or4

to

an

oil

change

stop

it

the
oil
may

engine
level.
be
for

fill

the

and

Check

Transmission
only

subsequent

installation.)

the

engine

forward

as

day

of

necessary.

after

at

800 rpm

and

operation.

Expansion

is

fresh
after
or

engine

water

cooling

filled

after
temperature
to

within

The

and

one

system

the

if

It

is

against

slowly

of

cap

is

released.

lifted

escaping

counter-clockwise

the

safety

in

this

the

spring

and

continue

off.

Instructions.

get

the

boat

speed,

until

l30-l500F.

see

that

-

this

the

of

are

to

be

and

immediately.

15

psi

Do

this

Oil.

or

and

This

necessary

the

oil

engine's

oil

filter.
oil

Oil

running

one

into

Check

Tank

Water
cooled.
system

for

the

it

has

of

l7S

inch

is

pressurized

pressure

the

filler

advisable

stops

position

Press

to

As

underway

water

It

it

doesn't

is

how
tank.
fuel.

not

always

fuel

to

renew

50

when

idling.

for

without

After

the

minutes,

new

installa-

check

is

import-

to

add

that

internal

Add

level

Level.

to

an

oil

In

such a case,

for

with

one

reverse,

oil
Level,

has

first

reached

0

F

and

of

top

must

be

cap

to

protect

steam

and

until
is
until

the

cap

clear

turning

soon

but
temp.
necessary,

quite

Job

inject-

when

Normal

psi

water

en-

subse-

the

oil

is

re­oil

each

(This

change
sev-

shift
level

(This

been

time.)

oper-

add

of

when
re-

is

turn

felt.

all
down-

the

until

as

pos-

at

gauge

15

the

at

day

then

if

tank.

to

the

re­en-

16

gine
in
with

can

neutral

clutch
tends
partial
detected

7.

Reverse
gine

to
However, when
gaged,

NOTE:
when

held
no

The

backing

in

the
positive

STOPPING

1.

Position

2.

3.

Move
Pull

off

(The

throttle

fuel

stop

the

pump.)

NOTE:

Idle

dissipate

be

warmed up

at

in

to

overheat

engagement

by

propeller

Operation.

idle

it

will

SAO

transmission

down,

reverse

overcenter

ENGINE

shift

push-pull

control

fuel

engine

heat

gradually

with

the

clutch

1000 rpm. Warming up

neutral

the

speed

the

transmission

carry

takes

transmission,

occurs,

shaft

Always

when

full

shifting

engine

longer

which

rotation.

reduce

is

requires

the

lever

lever

from

for

shift

position,

locking

to

STOP
functions
the

a few

in

neutral.

idle

fuel

before

lever

since

mechanism.

position.

control

by

cutting

injection

minutes

shutdown.

must

and

if

can

be

en-

gears.

en-

load.

that,

be

it

has

out.

to

reading
sarily
If

there

after

signal

is
temperatures
normal when

a

stop

alarm

no

functional

will

engine

does

against

quickly

is

operating.

not

neces-

restarting.
difficulty,
return

to

OPERATING

1.

Never
when

PRECAUTIONS

run

excessive

extensive

2.

DO

NOT

put

3.

engine.
block,
Keep

It

or

intake

manifold.

etc.

4.

Do

not

run

clutch

5.

Never Race a Cold

damage

engaged.
can

circulation.

6.

Keep

7. Keep

8.

Do

9.

Do

show a
stop
full

release
metal
chamber.
engine
before

the

the
extreme
fuel

cause

not

fuel

intake
enough
system,
quired

not

after

load.

masses

engine
fuel

care
allow
to

allow

resulting

for

be

alarmed

high

of

Prevention

at

idle

stopping

engine

overheating

internal

cold

can
silencer

engine

occur

clean.

because

more

fuel

may

priming.

reading

engine

This

residual

near

for a short

for

extended

occurs

damage

water

crack

at
Engine

due

and

accessories

trouble

to

be

uncovered

air

to

in

if

can

in

an

overheated

cylinder

free

from

high

RPM

as

internal

to

inadequate

Handle

water
run

and

low,

it

and

service

long

enter

lost

the

time

temperature

following a sudden

has

is

the

caused
heat

been

combustion

for

operating

by

from
this

period

it.

High

temperature

periods

as

be

caused.
head,
lint,

without

oil

clean.

with

dirt

because

re-

gauges

the
the

heavy

is

to

in
in-

at

run

TEN MUST RULES

17

IMPORTANT

•••

for

your

ALWAYS

1.

3.

4.

NEVER

6.

8.

9.

10.

-

Keep

2. Use
Check
or
Close

5.

Investigate

-

Race

7.

Run

Break

Use
galvanized
Subject

if

only

less.

the

cotton

black

safety

this

filtered

cooling
all

the

engine

engine

the

the

smoke comes from

and

Manual handy and

water

drain

fuel

cocks

any

oil

in
unless
pump

waste
container.

engine

IMPORTANT

your

fuel

or

oil

temperature

a~d

leaks

neutral.

the
seals.
fluffy

to

prolonged

engine's

read

and

refill
immediately.

gauge shows

cloth

the

exhaust.

dependability.

it

whenever

check

frequently

overloading

with

for

lube

water

proper

cleaning

in

oil

to

before

or

IMPORTANT

doubt.

level

make

oil

or

sure

starting

pressure.
store

continue

daily.

fuel

to

it

is

out.

in

run

190

a
it

0

18

YOUR

NOTES

MAINTENANCE

19

PERIODIC

After
engine,
following
fifty

FIFTY
Do

hours

HOUR

the

following:

1.

Retorque

2.

Retorque
adjust

3.

Check and
forward

band

missions.

4.

Change
filter.

5.

Check

leaks.

6.

Check

spect

7. Check
connections,

tensions
tion

These

ATTENTION:

you have

it

is

important

checks

CHECKOUT

valve

on

for
cooling

water

for

to

could

of

its

the
the

adjust,
drum
manual

engine

fuel
Correct

loose

etc.

loose

right

level.

cause

taken

cylinder
rocker
rocker

assembly

nuts,

delivery
that

after

operation:

(INITIAL)

bracket

clearance.

if

SAO

and SA-l

lubricating

and

lubricating

if

necessary.

system

fittings,

bolts,

Pay

particular

engine

mis-alignment.

of
you make
the

first

head

bolts.

nuts

necessary,

and

the

trans-

oil

for

leaks

clamps,
vee

mount

fittings.

your

the

and

the

reverse

and

oil
oil
and

in-

belt
atten-

DAILY
Do

SEASONAL

Do

CHECKOUT

the

following:

1.

Check
been

2.

Check

3.

Check
Fill

4.

Turn

if

used,

5. Check
mission.
dipstick.

the

following:

1.

Check
belt

2. Check

3.

Change
sucked
suction
side
aft

See

4.

Replace
See

5.

Fill
quarts
high

fill.

sea

water

installed.

water
lubricating

to

down

lubricating

CHECK-OUT

generator

for

water

oil
out

of

of

the

Note,

Note,

sump

of

mark on

See Note

level

highest

grease

one

full

Fill

tension.

level

in

of
hose
the

oil

dipstick.

next

lubricating

next
with
diesel

dipstick.

strainer,

in

cooling

oil

level

mark on

cup on

turn.

oil

level

to

highest

(MORE

sump.
sump

(3/8"

page.
approximately

nex~

OFTEN

or

alternator

in

battery.
Oil

by

ID)

sump

pipe,

Figure

page.

oil

lubricating

page-.--------

attaching

over

if

one

system.

in

sump.
dipstick.
water

may

filt~r.

Do

pump,

in

trans-

mark on

IF

POSSIBLE)

"V"

be

a

the

out-

located

1.
Fig.

4.5
oil

not

over

has

US

to

2.

FIGURE

FIGURE

1

2

20

CAUTION:

lubricating
been

known

ing

and

plete

6.

oil

Start
minutes.
filter

sump
may

be
pensate
to

fill
passages
necessary.

Use

SAE

Oil,

overfill.

IMPORTANT

IT

IS

MANDATORY
AND 6 BE
TIME
THIS

7.

ATTENDED

REACHES

TOTAL

Clean
replacing
operating
extremely
al

frequency
correct
filter
bore
of

the

8.

Check
etc.

9. Check

10.

Wash
If

filter
ment,
fuel
frequently.

11.

Replace

12.

Replace

The

use

oils

to

may

in

starvation.

engine

Stop

gasket

level.

necessary

for
the

and

30,

Service

NOTE:

150

I~

REACHED

Air

Filter.
the
conditions,
dirty

time

will

wear,

engine.

engine

sea

water

primary

bowl

filter

filter

secondary
air

of

different

during

cause

many

and

engine

for

This

the

oil

engine's

oil
Change
High

DG,

See

note

THAT

TO

WHEN

HOURS.

air

conditions,
should
periods

greatly

thereby

for

pump
filter

contains

bowl and

need

filter.

oil
extensive
instances

run

for 3 or

and

leaks.

is

important

to

add

oil

that

internal

filter.

oil

in
Detergent
DM,

or

DS.

below.

THE

CHECKS

TOTAL

IN

SOME
BEFORE

The

END

time

filter

therefore,

be

increased.

for

assist

extending

loose

bolts,

for

bowl and

water

secondary

to

be

cleaned

fuel

filter

brands

changes

oil

cause

of

has

sludg-

com-

4
check
Check

is

oil
oil

as

it

to

com-

required

oil
Add

oil

as

transmission.

Lubricating

Do

not

3,

4,

OPERATING

INSTANCES,

OF

SEASON.

period

depends

on

under

the

season-

replacing

in

reducing

the

life

nuts,

leaks.

screen.

or

sedi-

oil

more

element.

5

for

The

the

3.

Fill
antifreeze
to

Cold Weather

4.

Start
indicates

drain

place

tergent

5·.

Remove

intake
ive

tape

6.

Seal
cessible
gine

7.

Remove
cylinders.

8.

Replace
washer
slowly

9.

Top

off

air

space

water

10. Leave

11.

Change
engine

12.

Wipe

grease.

13. Change

14.

Disconnect
charged
battery,
cable
prevent
every

15.

Check

fresh

water
of a reputable

engine.

l750F,
lubricating
filter.

Lubricating

air

filter.

opening

or

some

the

exhaust

location

as

possible.

injectors

injectors
under
over

compression.

fuel

remains,
formation
fuel

engine

fuel

back

oil

system

filters
in
with a coat

in

battery

condition.

the

connectors

corrosion.

30

days.

alignment.

cooling

Precautions.)

When

temperature

shut

engine

oil.

Fill

sump

Oil.

Carefully

with

waterproofed
other
outlet

as

close

and

spray

with

each

injector.

tank

completely

thereby

by

condensation.

full

before

servic.e.

transmission.

and

Before

battery

terminals

should

Recharge

system

make.

Remove

with

suitable

at

the
to

oil

new

sealing

preventing

of

fuel.

putting

of

oil

store

storing

be

treated

with

(Refer

gauge

down

and

High
seal

adhes-

medium.

most

the

into

Turn

so

that

or

in

fully

and

battery

and

re-

De-

air

ac-

en-

engine

no

the

the

to

END

OF

SEASON

1.

Drain

fresh
moving
opening

2.

Remove
heat

exchanger)

replacing.

care

of

between

zinc

if

SERVICE

water

the

surge

all

water

zinc

rod
The

any

electrolysis

dissimilar

necessary.

cooling

tank

system

(usually

and

see

zinc

rod

metals.

system

pressure

petcocks.
located

if

it

will

that

Insert

by

cap

in
needs
take

may

re-

and

occur

new

21

Lubricating
standard
sustained

These
(API

Service

not

listed

COMPANY

American

BP

Canada

Chevron

Cities

Oil

Oil

Service

Continental

oils

of

performance

high

oils

speeds

meet

CC).

here

Co.

Limited

Co.

Oil

Oil

are,

Co.

are

available
to

and

the

requirements

Any

other

of

course,

Co.

LUBRICATING
for

meet

the

requirements

temperatures.·

of

oils

which

also

American
BP

Vanellus

BP

Vanellus

RPM

DELO
CITGO
CONOCO

Supermil

Multi-Service

Extra

TRACON

Westerbeke

the

U.

also

conform

suitable.

BRAND

Motor

Range

OIL

OILS

Diesel
of

S.

Ordnance

Oil

Oil

engines

modern

which

operating

Specification

to

these

specifications,

S.A.E.

OO/450F 450/80

lOW

lOW

10W/30

lOW
lOW

lOW

offer

an

improved

conditions

MIL-L-2l04B

but

DESIGNATION

o

OVER

F

20W/20
20W/20

lOW/30

10W/30
20W/20
20W/20
20W/20

such

are

30
30

30

30
30

as

800F

Gulf

Oil
Mobile
Shell
Sun

Oil

Texaco,

Corporation

Oil

Company

Oil

Company
Company
Inc.

Gulflube

Delvac

Shell

Rotella
Subfleet
Ursa

Oil

Motor

1200

MIL-B

Extra

Oil

Series

TOil

Duty

X.H.D.

lOW

1210

lOW
lOW

lOW

20W/20

1220
20W/20
20W/20
20W/20

30

1230

30
30
30

22

YOUR NOTES

Al

ENGINE

Two

series of engines
They
MK

can

be

identified

3 prefix

Firing order .
Camshaft
Connecting rod end-float on crankpin .
Crankshaft
Valve

Valve seat width - inlet and

Flywheel run out .
Oil pressure .
Projection above

Clearance
Compression ring to groove

Oil control
Ring gap
Valve face angle
Valve clearance

Inlet valve face (fitted) below cylinder head

Exhaust

seat angle .

TOC

at

face .

head face .

is

SP

end-float

end-float

block face by piston crown

between block and piston .

ring to groove clearance .

- inlet and exhaust (cold) .

valve face (fitted) below cylinder

and

have

by

the 2

the

MK 4 is

exhaust.

clearance

been

TECHNICAL DATA

OVERHAUL

used
letter

referred to in the text

prefix in the serial

FK.

1,2,4,3

•

0·0025
0·004
0·003
44°

TI, in.

0·005
35

Mk
Mk
1·09
0·0016
0·0018
0·009
45°
0·015

Mk
Mk

Mk
Mk

30'

(1'59

to

40

4:

1-Mk

mm.)

to

1-Mk
4:

1-Mk
4:

to

0·0075

to

0'010

to

0·011

to

45°

in.

(0·13

Ib./sq.

0'010

3:

to

0'0036

to

0·0038

to

0'014

45°

15'

in.

(0·38

3:

0·050

3:

0·050

in.

in.

(0'10

in.

(0'08

inlet and exhaust

mm.)

mm.) maximum
in.

to

0·026

0·025

in.

in.

in.

mm.,

0'050

0'025

in.

in.

in above

in.

(0'064

in.

to

0·043

(0'041

(0'046

(0'23

number.

to

to

0·25

to

0·28

(0·25

in.

to

to

0·36

as

MK 3 and

0·191

mm.)
mm.)

to

0·67

(0'64

0·091

to

0·097

mm.)

The

mm.)

mm.)

to

mm.)

mm.)

MK

4.

Tightening Torques

Cylinder head:

Main bearing cap:
Connecting road big end:
Flywheel: i in.

Rocker shaft:

Manifolds

Bolts:
Nuts:

Front cover:
Sump:
Rear oil
Crankshaft
Oil pump:
Camshaft thrust
Camshaft sprocket:
Rocker cover:
Chain tensioner to

Injectors to cylinder

-(6

-fr

-1-

seal retainer:

UNF)

1'6

in.

1'6

(24

UNF) .

i in.

in. (18 UNC) .

in. 124 UNC)

-1-

in.

(20

in.

(20

UNC) .

pulley:

-fr

1'6

in. (18 UNC)

plate:

-(6

-1-

in.

cylinder block:

(14

UNC) .

in.

(14

i in.

(16

UNC)

UNC)

-fr

in. (18 UNC)

in.

(20

-fr

in.

in.

(18

(20

UNC) .

head.

UNC) .

(24

UNF) .

(20

UNC)

UNC) .

-1-

UNC) .

in.

(20

65 to

70

65 to

70

30

to

35

50

to 55

17 to 22

15 to 18
15 to 18

5 to 7

6 to 8
12 to 15
24

to

28
12 to 15
2·5

to

3'5
12 to 15
2·5

to

3'5

5

to 7 Ib./ft.

10

to

14

Ib./ft.
Ib./ft.

Ib./ft.
Ib./ft.
Ib./ft.

Ib./ft.
Ib./ft.
Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

Ib./ft.

(8'98
(8'98

(4'15
(6·92
(2'35

(2'07
(2'07

(0'69
(0'83
(1'66
(3'32
(1'66

(0·35

(1'

66 to 2

(0'35

(0'69
(1·38

to
to

to
to
to

to
to
to
to
to

to

to

to

to

9'67
9'67
4'84
7·61
3·04

2·49
2·49
0·97
1'11
2·07
3·87
2·07

to

to

0·97

1·93

0·48

'07
0·48

kg./m.)
kg./m.)

kg./m.)

kg./m.)

kg./m.)

kg./m.)
kg./m.)
kg./m.)
kg./m.)
kg./m.)

kg./m.)
kg./m.)

kg./m.)

kg./m.)

kg./m.)

kg./m.)
kg./m.)

•

A2

Camshaft
Valve timing
Bearings
Oversize bearings available

Journal diameter

End-float

Connecting Rods and Big End Bearings
Length between centres
Big end bore .

Small end bore

Bearing
Undersize bearings

liner wall thickness

available

End-float on crankpin

Crankshaft and Main Bearings

Main bearing journal diameter:
Blue
Red
Green
Yellow
Regrind diameters:
0·010
O'

020

undersize

undersize
Main journal fillet radius:
Front intermediate and rear
Centre
Crankpin
Crankpin
Crankshaft

Double radius

journal diameter

fillet radius

end-float

of

.

Thrust washer thickness

0

0

0

17

_

_

51

51

0

17

_

Steel backed white metal bush
0'020

0'0025

4·927
2·0825
0·8121
0'0719
0'002,0'010,0'020
0·004

2'1253
2·1257t02·1261
2
2·1157t02·1161

2
2·1055

0'080
0'07
1
0·070
0'003
0·091

in.

1'5597to

to

to

to
to
to

to

to

·1153

·1152

to 2

to 2
to

to

to

0'08

·9368

to 1

to

to

to

(0'513

1'5605

0'0075

4·929

2'0830
0'8125

0'07225

0'010

2·1257

'1157

'1157

2·1060

0'094

in.

·9376
0·084
0'011
0·093

mm.)

o/s

on

in.

(39·617t039·637mm.)

in.

(0'064

in.

In.

in.

in.

in.

in.

in.
in.
in.
in.

in.
in.

in.

in.
in.
in.
in.

00

to

0·191

std.

10

mm.)

Cylinder

block
Standard cylinder bore diameter
Cylinder liners available
Bore

for

cylinder liners

Flywheel
No

and Ring Gear

of

teeth on gear .
Ring gear fitting temperature
Maximum run out .

Pistons
Protrusion above

block face

Piston pin diameter .
Clearance in small end bush
Piston ring gap

Ring to groove clearance.

3·1881 to
Std. and

3·3115

3·1884

0'020

to

3·3125

o/s

in.

on

std.

110
600 degrees F

0'003

Mk
Mk4:
0·8119-0·8123
0·0001-0'0003
Measured in
top ring gap
2nd ring gap
3rd ring
Gap
every
0'0015-0'0035

in.

3:

0·010-0·022
0'010-0'026

in.

in.
in.
in.

3·188

in diameter ring

0'013-0·018

0'009-0·014

gap

0·009-0'014

increases by approximately

0'001

in. increase in bore above

in.

outside diameter

in.

in.

in.

0'003

3·

in.

188

for

in.

Cylinder Head
Valve guide protrusion above spring seats
Inlet valve depth below head face

Exhaust valve depth below head

Valve spring free length

Fuel Injection Equipment
Please

Maximum gross 8HP
Rated

Cylinder bore X stroke

Fuel consumption

Lubricating oil pressure
Lubricating oil capacity pints 6
Fresh water capacity pints

Exhaust connection . 1 * in.

Nett weight
Maximum torque 68
Standard rotation anti-clockwise looking at

Minimum battery capacity in ampere hours
Battery polarity
Water circulation thermostat
Fuel injection timing (static)

Fuel injection
Fuel injector pressure setting
Fuel injector type
Fuel injector pump type
Maximum

Minimum idling speed

Firing order
Alternator type
Compression ratio
Swept volume

see

BHP

flywheel

separate information booklets on overhaul

=

34

at 1.200 r.p.m.

1,400 r.p.m.
1,600

1.800
2,000 r.p.m.
2,200 r.p.m.
2,400 r.p.m.
2,600 r.p.m.

of

bare engine 372 lb.

timing

idling

r.p.m.
r.p.m.

on

full

(dynamic) .

speed

load

Ib./sq.

face.

at 2,800 r.p.m. (BS649)

Ib./b.h.p/hour

in.

O' 260 (inlet and exhaust)

Mk

3:

Mk

4:

Mk

3:

Mk

4:

1·48

10·6
13·8
16·8
19·4
21

·8
23'5
25·6
26'7

81 X 77·6
0·45
35-40

10

Ib./ft.

100

Negative earth
82 degrees centigrade
14°
cyl.
30°

165

CAV
CAV 3247F161
3,000
r.p.m.)
750
1-2-4-3
Lucas
Mk

1-3:

1,599

0·050
0·050
0·025
0·050

in.

of

BSP

at 12

BTOC No. 1 cyl.

Mk3

BTOC

ats

r.p.m. (normally set

r.p.m.

17

C.c.

in.
in.
in. above
in.

CAV fuel injection pump and injectors.

mm.

or 1

tin.

10 hose

at 2,000 r.p.m.

volt

No.1

ACR
18:1,

Mk4;

cyl. .

with

machine sensed regulator

Mk419:1

by

12°

BTOC No. 1

works

at

A3

2,500

A4

GENERAL DESCRIPTION

The engine is a four cylinder,
with

direct
are machined
of

the crankcase and are provided

The cast iron crankshaft runs in five large diameter main bearings fitted
tin,

steel-backed bearing shells. End-float and thrust are controlled by half-thrust washers

located in the cylinder block on either side
Seals pressed in the

and rear
on the crankshaft flange itself.

The connecting rods are
bolts and located by

aluminium/tin.
Solid

above the piston pin bore are used. The combustion chamber is machined in the piston
crown. The piston pins are
grooves

The camshaft is driven at half engine speed by a single
crankshaft. This
pivoted tensioner arm. A skew gear and
drive the
face and located between the front bearing journal and the sprocket flange retains the cam­shaft.

flow

cylinder head and bowl-in-piston combustion chambers. The cylinder bores

directly

of

the crankshaft. The

The small ends have steel-backed bronze bushes.

skirt

aluminium alloy pistons

at

each end

oil

pump and the fuel

in the cast iron cylinder block which is cast integral

front

hollow

of

timing

'in

line', overhead valve

with

full

length water jacketing.

of

the centre main bearing.

cover and the rear oil seal carrier prevent

front

seal runs on the pulley hub

'H'

section forgings having separate big end caps retained by

dowel pins. Big end bearing shells are, again, steel-backed

with

two

compression and one

fully

floating and are retained in position by circlips installed

the piston bore.

chain is automatically tensioned by a snail cam bearing against a

an

eccentric, machined integral

lift

pump. A thrust plate bolted to the cylinder

unit

operating on the four stroke cycle

with

the upper

with

aluminium/

oil

leaks from the

whilst

row

chain and sprockets

the rear seal runs

oil

control ring situated

with

the camshaft,

block

from

half

front

two

in

the

front

half

A duplex chain and sprockets driven at
jection pump and

Overhead valves are mounted
are operated by rockers, push rods and tappets from the camshaft. The rockers are mounted
on a shaft supported by
are adjusted by screws in the rocker arms.

A cast iron flywheel is mounted on the crankshaft flange and ensures a smooth
gine. A
gearbox. The drive

wheel periphery.
The sump is a steel pressing and has a

tion
is mounted externally on the engine,

vane type. Both types
An

case ventilation. Crankcase ventilation is by semi-closed positive systems.
Four-point mounting

ber flexible mountings are available.

CYLINDER BLOCK

The cylinder block is cast iron and is cast integral
Internally the crankcase incorporateS'" five main bearings

bolts fitted

positions must not be interchanged. When dismantling these caps ensure that their positions

drive

system is the force feed type incorporating a

oil

filler cap is located in the rocker cover and also incorporates a filter gauze

sea

water circulating pump.

'normal'

four mou"nting posts bolted to the cylinder head. Valve clearances

plate is fitted to the crankshaft flange or flywheel

for

the starter motor is provided by a steel ring gear shrunk onto the fly-

of

pump incorporate a non-adjustable plunger type relief valve.

for

the engine and gearbox assembly is provided. Sandwich type rub-

without

lockwashers. The intermediate and rear caps are identical,

engine speed drives the

to the cast iron cylinder head in valve guides and

well

for

the lubricating oil. The engine lubrica-

full

flow

oil

lTIay

be

of

the eccentric bi-rotor type or the

with

the upper

with

distributor

to

couple the engine

filter. The

half

of

removable caps retained

type fuel in-

running en-

to

oil

pump, which

sliding

for

crank-

the crankcase.

but

the

by

their

AS

are marked, this is normally done, in production, by a number 2 stamped on the
mediate cap and 4 on the rear intermediate cap. The rear cap is not marked.
be

fitted

with

the cast arrows pointing forwards.

The crankshaft bearing liner parent bore in the cylinder block may be either standard

0'015

crankcase are marked
be
may also be

with

The cylinder bores are machined directly into the cylinder block.
inder liners, however. may

and one
To remove and replace the cylinder liners. a cylinder liner remover and replacer ring should

be made to the dimensions shown. Locate the remover in the bottom
with
or fitting a

Data section). Place the remover adaptor in the replacer ring and locate in the cylinder liner.

which should

Press the liner into the bore from the top on a suitable press.
ance slots in the base
the piston being fitted.

in.

(0'38

0'020

WHITE paint adjacent to the tappet bores.

0·020

the cylinder block inverted, and press the liner out on a suitable press. When replacing

mm.) oversize. Where the bore is oversize the bearing caps and inside the

with

WHITE paint spots. The camshaft bearing parent bore may

in.

(0'51

0·004

liner, ensure that the cylinder bore is machined to the correct size (see Service

be

mm.) oversize but in this case the block is unmarked. Tappet bores

in.

(0'10

in.

(0·508

lubricated on the outside

of

mm.) oversize and the cylinder block in this case is marked

Cast iron

be

fitted and two sizes

mm.) oversize

the liner and machine the bore

on

the outside diameter.

with

of

tallow

liner are available. a standard size

of

the cylinder liner.

(no other lubricant should be used).

Cut the connecting rod clear-

to

give the correct clearance

front

All

caps must

dry

type cyl-

inter-

or

for

(3'18

2~in.-

(63-50

mm.)

iin.-~~

mm.)

'1

-

~jin.

;

(12'70

mm.)

----A------

--r--

3·14 in.

(79'76

._L_

I

i

I

mm.)

I

___

1.

__

3'30 in.

(83'82

mm.)

---1---

13

.

'

l

----

Cylinder

CYLINDER

The cylinder head is made
in.

The valves operate in guides fitted directly in the cylinder head. When fitting valve guides,
press each new guide into the cylinder head until the upper end protrudes above the spring
seat face the correct distance (see

Liner Remover

(96·3

mm.) long. The cylinder head gasket is

HEAD

.

16

In.

(20'64 mm.) ,

--------

I '

2irl.~

(12-70 mm.)

- I

; I

, 1 I

---I.in.~

,

(44-45 mm.) .

-

of

cast iron. Ten bolts are used

Service Data section).

3'145 in.

(79'89

mm.)

(101'60

I

_____

Replacer Ring

to

retain the cylinder head,

of

an

asbestos composition steel faced.

I

4 in.

,

I

I

.1

__

mm.)

_

3'79

After

fitting new valve guides or reaming the valve stem bore the valve seats

to

ensure that the seat is concentric

with

the valve stem bore.

must

be recut

A6

The valve seats may be re-faced
diameter

of

the cutter should

be

with

a cutter tool

0·310

in.

(7·87

with

an included angle

mm.).

INLET MANIFOLD

The

inlet

manifold
ped hole is incorporated in the air cleaner mounting flange
vacuum connection. The
aid is fitted below the air filter.

EXHAUST

A cast aluminium exhaust
The heat exchanger tube stack is retained by
Raw water is fed into the forward end cover and discharged
direct
plug is located at the lowest point. An air bleed valve is fitted at the
ling

with

manifold

The
the correct way up

FRONT

The

front
block. A composition gasket ensures
shaft

MANIFOLD/HEAT

to

the engine exhaust system. A 4 lb. pressure cap is fitted to the header tank. A

fresh water.

COVER

cover is an aluminium gravity

pulley boss, an

is

of

gaskets are

as

the centre flange is not symmetrical.

oil

cast

aluminium

manifold

gasket is

and has separate ports

of

a composition type material. A

EXCHANGER

manifold

of

compressed asbestos fibre. Ensure

seal is pressed in the

combined

die

casting bolted

an

oil

tig:lt

with

heat exchanger and header tank is fitted.

two

neoprene end covers and

joint. To prevent oil leaks around the crank-

front

cover.

for

the engine ventilation system

from

that

to

the

of

90°

and the

for

each cylinder. A tap-

cold

worm

drive

the rear cover

forward

the centre gasket is fitted

front

face

end

of

to

the

pilot

starting

clips.

normally

drain

assist fil-

cylinder

timing

A
12°

mark is incorporated on a pad on the

BTDC

No.1

cylinder

..

front

cover

FUEL INJECTION SYSTEM

Injectors. Fuel injectors have long stem four hole nozzles set

between injector face and cylinder head ensures a gas

tight

FUEL INJECTION PUMP

The rotary
by 3 studs and nuts and
by rotating the pump

are provided on a machined pad on the rear face

jection

Injector pipes should always
any connection. Pipe nuts should not be over-tightened in an
fit

a new pipe

FUEL

Fuel
tric

on the camshaft. A non-return valve on the
sibility
via a disposable cartridge type filter. The
located on the
point

distributor

pump flange.

if

FEED

oil

on the main fuel tank.

SYSTEM

is fed

to

of

fuel syphoning back

filter

type fuel injection pump is retained

bodily

a sound

the engine by a diaphragm type mechanical

head. This vent. combined

~

paper

joint

to

joint

ensures an

within

the

limits

be

fitted carefully. ensuring that there is no undue strain on

cannot be obtained.

to

the tank. The

oil

tight

seal. Injection

of

the slots in the mounting flange.

of

the

front

inlet

connection

lift

pump feeds fuel

filter

is constantly vented

with

injector

to

facilitate

to

170

joint.

the rear face

cover and on the adjacent in-

attempt

lift

pump operated

to

the pump prevents the pos-

leak off,

injection

ats. A copper washer

of

the

timing

to

cure a leak.

to

the

of

air

by

is

connected

timing

timing

is

adjustable

Timing

Always

by

an eccen-

injection

a bleed valve

to a high

at

cover

marks

pump

The fuel injection pump
filter

via a non-return valve. A final

injection pump.

is

lubricated entirely by fuel

filter

is

fitted

beneath the

oil

and the excess

inlet

is

fed back

connection

of

the fuel

to

the

·

A7

REAR

The crankshaft rear oil seal is pressed into
block rear
of
placed. When fitting the carrier the seal must be aligned concentrically
if

OIL SEAL

face, and fitted

the flywheel mounting figure.

oil leaks are to

CARRIER

be

avoided.

with

an

aluminium carrier which is bolted to the cylinder

a composition type gasket. The oil seal runs on the periphery

After

removing the carrier, the oil seal can be easily re-

with

the crankshaft

SUMP

The pressed steel sump has a well and is bolted
dip

stick tube is located

When fitting the sump ensure that the
ening up. Hylomar non setting jointing compound should be used.

ROCKER

The rocker cover is a steel pressing retained by screws and plain washers around the flanged
edges. A cork and rubber gasket is set into the rocker cover flange to prevent oil leaks.

This gasket should give satisfactory service for up
place the gasket when

COVER

on

the starboard side. The gaskets are made

front

it

no

longer provides

to

the base

face is flush

to

ten removals

an

effective seal.

of

the cylinder block. A drain

of

cork and aluminium.

with

the block face before tight-

of

the rocker cover. Re-

VALVES AND SPRINGS

The valves, which have
positions are: inlets
head diameter but are not interchangeable. The inlet valves are
longer than the exhausts. Valve stems are phosphate coated to improve durability and pre­vent scuffing during 'running in'. A neoprene oil seal is fitted to each valve stem immedi­ately below the valve spring retainer. The valve springs are

be fitted either way round. Valve spring retention is by a steel retainer and tapered

which have three ribs locating in corresponding grooves in the valve stem. The collets do
not grip the valve

wear anrl promoting longer life.

stem, but allow the valve

45°

seats, are mounted vertically in the cylinder head. The valve

2,

3,

6 and 7 and exl:lausts 1,

4,

5 and 8. The valves all have the same

0,125

of

a symmetrical design and can

to

rotate during engine operation, thus reducing

in.

(3,17

collets,

mm.)

ROCKER

The rocker shaft assembly is retained by four bolts fitted

The rocker arms which are banded are arranged in pairs
rocker shaft support. A compression spring between each pair holds them against the sup­ports, the end rockers being retained by the washers and split pins at the ends.

The chilled cast iron tappets can only be removed from the crankcase after removing the
camshaft. Rockers are fitted at

SHAFT AND TAPPETS

No.2

and

No.7

with

a radius ground

with

plain washers.

with

rockers

on

either side

to

clear the rocker cover.

of

a

CAMSHAFT AND TIMING CHAIN

The camshaft used
and by a band

The camshaft runs in three steel-backed white metal bushes, which may have a standard size
or a

0·020
sized and require no machining after fitting. When one bush requires replacement
visable
changed.

Remove the bushes using camshaft bearing remover Tool No.
P.6031-3.
spigot in the bearing.
Remove the bush by screwing down the

in.

to

replace all three bushes

Locate the remover and guide detail

can

be

of

paint (BLUE).

(0·51

mm.) oversize outside diameter. The bushes available in service are pre-

If

the centre liner is being removed also use the centraliser detail

identified by the number 109E cast

as

camshaft alignment .nay

'-3a'

adjacent

wing

nut.

on

the shaft at the rear end

be

affected

to

if

only one bush

P.6031
the collar and

with

adaptor set

it

is ad-

with

is

the

'-3d'.

A8

The camshaft front and rear bushes are both
one having
mately
adaptors

Ensure that the
and that the

an

additional oil hole for the rocker shaft oil feed, and the centre bush approxi-

tin.

(15·9

mm.) wide. Fit the bushes using a replacer detail

previously used.

oil holes in the bushes and cylinder block are correctly aligned before fitting

splits in the bushes are upwards and outwards at

scribed on the remover and guide detail

approximately!

'-3a'

can

be

used

as

alignment.

The camshaft is retained by a sintered iron thrust plate bolted
and located in a groove behind the camshaft flange.

A single
consists
runs across a synthetic rubber pad
grooves in the pad
of

the pad

row

timing

of

spring-loaded snail cam bearing against a pivoted tensioner arm. The

to

remove the grooves.

chain,

so

with

that the chain runs

an

automatic mechanical tensioner, is used. This tensioner

on

the tensioner arm and in use the links wear

directly

on

the rollers.

in.

(19·1

mm.) wide, the

'-3b'

45°

to

the vertical. A line

a guide

to

the cylinder block

DO

to

NOT dress the surface

front

in addition to the

facilitate

oil

front

timing

hole

face

chain

two

B.D.C.

Nominal

The sprockets incorporate

timing

Valve

Timing

Diagram

marks to facilitate correct valve timing. Note the identifica-

tion pin on the crankshaft sprocket. The crankshaft sprocket can

mover Tool No. P.6116 and replaced

with

replacer Tool No. P.6032A

CRANKSHAFT AND BEARINGS

The cast iron dynamically balanced crankshaft runs in five

aluminium/tin

shaft is heat treated to improve fatigue strength.
In new engines the crankshaft may be either standard or

the main bearing

journals and crankpins. The crankshaft main bearing journals .are graded,
the standard crankshaft webs being marked, adjacent
for the
undersize the grades are

The crankshaft main bearing
mm.),
shafts undersize

remove the benefits

smallest grade and

RED

for

GREEN

journals may

undersize and the crankpins

it

is important to maintain the correct

of

heat treatment and thus reduce the

the largest. Where the crankshaft is

and YELLOW respectively.

be

ground

to

0,030

in.

(0·76

0·010

to

the journal,

0·010

in.

mm.)

fillet

radii at all times.

life

(0·25

undersize. When grinding crank-

of

be

removed

or

B.

main bearings. The

in.

(0,25

mm.) undersize on

with

a paint spot, BLUE

0·010

mm.),

0·020

Re

the crankshaft.

with

in.

(0,25

grinding

in.

re-

mm.)

(0'51

will

The

centre main bearing journal has a double radius

(2'03

mm.) and the rear main bearing has a double fillet radius. the inner radius
must.be maintained at
ing main

fillet
0·080

journal fillet radii are

radii are

to

0'094

0'080

in.

0·100

to

(2·03
viewed from the front. Ensure that the
marks. The main bearing
to

0'020

in.

(0'51

mm.) providing

to

0·094

to

2·39

0'110

0·080

in.

to

(2'03

mm.).

in.

0·094

to

Grind the crankshaft revolving anti-clockwise when

fillet radii are smooth and free from visual chatter

journal length between the thrust faces can be increased by up

an

equal amount is machined from each face and the

(2'54

2·39

in.

of

to

2·79

(2'03

mm.).

0'070

to
The crankpin journal

corresponding oversize thrust washers fitted. The crankpin
in.

(0·25

mm.) oversize.

A9

in.

(1'78

mm.) when regrinding. The remain-

2·39

mm.).

length must not exceed

mm.) and

0·080

of

which

in.

The crankpin journal

fillet

radii are

0'010

Main bearing
and taper
rear

journals should not exceed

to the main journals

either side
be

smooth and square
ing. crankpins and
revolving clockwise to produce a good surface finish. Grinding

treatment and reduce the

Crankshaft thrust is taken by steel-backed

journal and crankpin ovality should not exceed

0·0005

of

in.

(0'013

mm.,.

0·002

within

0·001

in.

the centre line through

to

the bearing journal

journals should

overall

be

life

The centre main bearing run - out relative

in.

(0'05

mm.) TIR. The crankpins should be parallel

(0'02

mm.)

No.1

crankpin and main journal. The thrust faces should

polished.

of

the crankshaft.

white

and

within

0'0005

with

a fine lapping paper and the crankshaft

metal half thrust washers located in the

be

0·0004

within

in.

(0'013

will

0·005

remove the surface heat

cylinder block at the centre main bearing. Standard size washers and

mm.).

size washers are

0·005

in.

(0'127

available.

mm.).

0·0075

in.

(0·191

mm.) and

0·010

in.

CONNECTING RODS

Connecting rods are H section steel forgings

located by

are
bolts fitted
on the web. An
to the non-thrust side

The steel-backed big end bearing

two

hollow

without

dowel pins pressed into the connecting rod and retained by

lockwashers .. The connecting rod can

oil squirt hole machined in the connecting rod feeds

of

the cylinder bore.

liners have
which locates in the connecting rod incorporates
Undersize liners are available in

(0'51

mm.).

0·030

in.

(0'76

0·002

mm.) and

in.

0'040

with

detachable big end caps. The caps

aluminium/tin

an

oil hole. the lower liner being plain.

(0'05

in.

mm.).

(1'02

be

identified by the number forged

oil

bearing surfaces. The upper liner

0·010

in.

(0·25

mm.) sizes.

in.

(0'010

to

in.

(0'13

mm.) TIR.

0·0025

(0'254

from

mm.).

mm.,

TIR

the

front

and

mm.)

After

in.

mm.)

on

grind-

(0'064

over-

two

the crankpin

0·020

in.

Crankshaft

Fillet

Radii

AlO

The

connecting

in service,

rod

the

connecting

small

end

rod

bearing

being

is a steel-backed bronze bush,

serviced

with

the

bush

already

which

fitted.

is

not

available

When

straightness. A heavy

correspondingly
rod

and

inch
When

The

dismantling

which
big

marking

should

ends

(cm.)

length.

assembling a connecting

an engine

heavy

either

should

'FRONT'

marking

marking

be

be parallel and square

is embossed on the

examine

on the

straightened

below

rod

piston

to

CONNECTING ROD NUMBERING

Connecting
correct

The

number
numbers
connecting

It

is

ting

rods
1 Red, 2

rods

reassembly

is

together

rod.

advisable

have been

Yellow,

are

numbered

should

stamped

must

when

3 Blue, 4 None.

on

be in

removing

colour

tr.ey be

the

when

camshaft

its

cod6d

dismantled.

original

connecting

correctly.

PISTONS, PISTON PINS AND RINGS

The

in
ber

pistons

the

bowl

oil

are

control

is

machined

made

ring

of

an

aluminium

groove and

in the

piston

the

crown.

the

piston

skirt

above the

the

pin

on

or a replacement

to

the

longitudinal

the

piston

web

installed

side
position.

alloy

upper

ensure

to

facilitate

in

the

of

the

rods

The

connecting

and are

part

markings

the

engine

big

Never reassemble a

from

of

the

to

pin

other

side

fitted.

that

it

this.

end so

an engine

of

the

solid

piston

check

on one

indicates a bent

The

centre line

is

fitted

during

that

to

rods

are

skirt

skirt.

the

connecting

side

together

connecting

within

the

manufacture,

a cap replaced

bearing

check

colour

type

The

0·005

correct

cap

that

coded

with

combustion

rods

with

connecting

rod

small

in. per

way

round.

to

facilitate

with

to

another

the connec-

as

follows

thermal

slots

cham-

for

a

the

The

piston

the engine,
The

piston

The

tubular

in

grooves

fit

in

the

in

service

be

interchanged.

Three
sion
and tapered on
round.

piston

piston

ring

The

should

when
pin

steel

at

each end

complete

rings· are

is stepped

oil

be

facing

is

offset
piston

pin

bore and

the

control

fitted

the

flywheel.

in

tl-.e

pins

of

the

with

the

fitted,

externally

periphery.

rings

with

piston

are

fully

piston

small

piston

two

have

on the

Both

the

combustion

0·04

in.

floating

pin

bore. The

end bush

pin,

compression

narrow

to

bottom

rings

ring

in
ensure

are

chamber

(1

·0

mm.)

and are retained in

piston

t:r:e

connecting

the

and one

face

marked

lands

and

bowl

towards

pins

are selected

rod. Pistons are

correct

oil

control

and the upper

'TOP'

may

be

offset

the

position

fit.

The

and

fitted

thrust

piston

ring.

ring

must

to

side

by

to

The

is

be

either

the

left

of

the

circlips

give

the

only

pins

lower

chrome

fitted

way

side

engine.

installed

correct

supplied

should

compres-

plated

this

round.

of

not

way

All

Oversize pistons and rings are

Pistons graded

to

cylinder

not

available and replacement

cylinder

liners should be fitted.

bore size are fitted to new engines. One grade

only

is supplied

for

spares.

FL VWHEEL
The cast iron
bolts fitted

gear shrunk onto the

bolted to the flywheel to increase inertia and provides a smooth running engine

flywheel ring gear locates in a retention groove and can be removed by

The
two

adjacent teeth

should pressure be applied in

AND

RING GEAR

flywheel is located

with

washers and Loctite. A

flywheel.

with

a hack saw and

concentrically

An

additional

an

attempt to

drive

splitting

dismantle

on the crankshaft flange and retained by

for

the engine starter

steel

or

cast

iron

motor

weight

is

provided

is

dowelled
at

cutting

the gear

with

a chisel. In no circumstances

the ring gear

for

repositioning on the

by a ring

low

speeds.

between

six

and

flywheel.
When replacing the ring

(316°C)
by a naked
cular

or

the ring gear wear resistant properties

flame place the ring gear on a bed

motion

onto the

g~ar

bricks

it

must

be heated evenly

about n-in.

(38·1

of

to

a temperature

will

be destroyed.

fire

bricks

mm.)

from

not

exceeding

If

the ring gear is heated

600°F

and then play the flame in a

the inside

of

the gear

until

cir-

reaches the required temperature. The correct temperature can be detected by using a special
type

of

temperature sensitive crayon.

until

it

turns

and heating
of

the gear teeth relative

air, DO
The

NOT

QUENCH.

flywheel and ring gear assembly are

dark

to

the

located on the flywheel by three

blue.
direction

or

Fit

dowels

alternatively
the

ring

of

rotation.

dynamically

by

polishing

gear

with

Allow

balanced to close

and is retained by

a section

of

the ring gear

the chamfers on the leading faces

the ring gear

six

bolts

to

cool naturally

limits.

with

spring washers.

The

weight

in

is

it

THE

OIL

PUMP

The

oil

pump and
can be removed
the engine camshaft. has the
tegra I

with

the oi I pump body.

Oil is sucked
spring-loaded

filter

assembly is bolted

with

the engine in place. The

full

flow

from

thlil sump through a tube pressed

filter

gauze located on the end

to

element type

of
can be removed by bending back the retaining
sure
the

inlet

relief valve

tube.

oil

return pipe is also pressed

the right-hand

oil

pump.

which

filter

into

the

this

tube provides

lug and

into

sliding

the

cylinder

side

of

the

is

driven

bolted to a

cylinder

primary

the gauze

block

cylinder

block

by a skew gear on

mounting

block

filtration.

out

sideways. A pres-

flange in-

sump face. A

The gauze

sump face parallel

and

to

Eccentric

BI-rotor

Type

011

Pump

A12

THE OIL FILTER
The

full

flow

type

oil

filter

is screwed

and is

VENTILATION SYSTEM
A semi-closed
and oil separator and a connecting tube

of

the disposable cartridge type.

positive

ventilation system is

to

a mounting flange integral

to

fitted

the

as standard and consists

inlet

manifold.

with

the oil pump

of

a breather

body

ADJUSTING

Valves Open

1 Exhaust and 6 Inlet

3 Inlet and 8 Exhaust

2 Inlet and 4 Exhaust
5 Exhaust and 7 Inlet

VALVE

..
..
..
..

CLEARANCE

Adjust

.
.
.
.

3 Inlet and 8 Exhaust

1 Exhaust and 6 Inlet

5 Exhaust and 7 Inlet

2 Inlet and 4 Exhaust

2

1-

ADJUSTING
2-VALVE
3-

FEELER

the

Venting

1. Open the

2. Operate hand

3.

Slacken high pressure pipe unions on injectors.

4. Unscrew the vent screw one turn located on the side

hand
hand

No.2.

5. Operate the starter and observe the high pressure connections on the injectors when fuel
issues

Start engine in normal way, using cold

6.

Fuel System

throttle

primer

primer

for a few

is operated tighten the vent screw. Refer

from

all

to

primer

four,

maximum,

with

seconds. When fuel issues free

tighten connections on injectors.

ensure the stop control

filter

vent open.

start

device

ROCKER

BLADE

is

in the run position.

of

the fuel injection pump and operate

of

air

bubbles when the fuel

to

illustration

if

fitted.

SCREW

ARM

lift

Fuel Injection Pump

pump

A13

MAINTENANCE

Section A
TOP

ENGINE OVERHAUL - DECARBONISE CYLINDER HEAD

AND

REPAIR

AND

Op. No.

A 1 Disconnect battery.

A2 Shut

A3

A4 Disconnect sea

A5
A6 Remove

A7 Loosen hose

A8 Remove

A9 Remove
A10

A 11 Disconnect alternator tensoner bracket

A12

A13

A14
A15

A16 Remove

off

fuel supply.

Turn

off

seacock. Drain cooling system. Drain taps are located on

block

and underside

Disconnect exhaust pipe

all

four

posed unions on injectors and pump

clips

two ~ in. AF

stat.

six ~ in.

Remove

and remove
Remove five 1 in.

in
Remove

four
Remove
Slacken ten

der head. Place head on a suitable
protruding

washers

all

position.

four 1-in. UNC

T96"

in.
eight

eight

from

injector

drive

AF

pushrods and retain in assembly order.

it

injector

of

heat exchanger.

water

outlet

hose on top

from

exhaust

injector

AF

belt.
AF

bolts evenly and remove rocker assembly.

in.

lin.
cylinder

high pressure supply pipes

on

two

hoses connecting exhaust

bolts

from

thermostat housing and detach complete

bolts securing

leak

off

pipes

bolts securing

'posidrive

AF

cylinder

nozzles.

AF

nuts and washers and

head.

inlet

head

of

sea

water pump.

manifold.

with

plastic

manifold

(l6"

in. AF) and fuel filter vent to

tin.

AF and slacken alternator

manifold

screws and detach

bolts

evenly

working

also

throttle

(i

in. AF unions) and

caps.

manifold

to

cylinder

to

until

surface taking care

withdraw

head and remove

cylinder

cylinder

loose. remove

injectors

cable.

to engine.

head and leave

A17 Using a valve spring compressor witQdraw all valves and retain

Thoroughly clean
inlet

and exhaust ports and
rotary
throat where the
the
posits and re-cut seats
grind

wire

inlet

ports

all valves before assembly.

cylinder

brush

to

airflow

will

ensure highest engine performance. Clean all valves

A18 Re-assemble valves in

should be reseated
such

as

colloidal

retainers and

split

with
graphite on valve stems.
cones.

head

of

all

dirt

and carbon. paying

injector

give a

polished

fin is

at

if

necessary to

cylinder

lapping compound then smear an anti-scuffing compound

its

widest

head.

holes.
finish

If

possible clean the

particularly

point. A smooth unobstructed surface

limits

if

outlined

new valve guides have been

fit new

stem

in the area around the valve

in reference data.

oil

particular

seals and assemble springs.

REGRIND VALVES

port

side

of

cylinder

protect

with

manifold:

No.4

mounting

head cover. Remove

bolts

and

not

to

damage the

and

copper seating

in

assembly order.

attention

inlet

ports

of

carbon de-

Lightly

fitted

the valves

ex-

thermo-

injector.

bracket

manifold

cylin-

to

with

in

re-

a

A14

A19

A20

A21 Fit new gasket and carefully position head on engine. replace the ten bolts and tighten

A22

TO

Check valve rocker

rocker pillar base.

Clean tops

top

of

and pressure setting. Take care no gasket material enters push rod holes.

evenly in the order below to
Reassemble engine in reverse order

washers where applicable.

SERVICE

of

pistons

cylinder block. Thoroughly clean out exhaust manifold. Check injector sprays

FUEL INJECTION PUMP

oil

feed hole is clear

of

carbon and remove all traces

65-70

Ib./ft.

of

A1-A16

obstruction. hole is located at No. 1

of

old cylinder head gasket

using new joints and copper seating

from

Op. No.

B1
B2
B3
B4 Disconnect fuel feed and return pipes from top
B5 Disconnect stop cable and return spring. also throttle cable from pump.
B6 Remove three

Disconnect battery.
Shut off fuel supply.
Remove fuel injector high pressure pipes.

tin.

AF nuts securing pump to chaincase and

the rear, note position

of

master tooth on drive shaft

of

injection pump.

for

ease

withdraw

of

re-assembly.

pump to

Note: It is necessary to remove the port bearer before removing the fuei injection pump.

B7

B8 Reassemble pump in reverse order and vent system before attempting to start engine.

Service pump in accordance

Ensure timing marks

on

pump flange and chaincase are aligned

with

Lucas-CAV schedule. (Lucas-CAV agent).

as

in illustration

No.2.

TO

SERVICE

FUEL

INJECTION PUMp DRIVE CHAIN AND SPROCKETS

Op.No.

C1
C2 Drain fresh water from cylinder block.
C3 Remove alternator drive belt, fresh water pump pulley

C4 Remove

C5 Remove twelve

C6 Fit the crankshaft pulley bolt and a suitable spacer to prevent damaging the thread in

C7 Remove the
C8 Apply heat to the chaincase in the area around

C9 Using crankshaft sprocket remover tool No.

C10 Locate new sprocket

Carry out operations

shaft pulley

out

of

fully

lever

position.

the crankshaft and turn the crankshaft until the removable

in the position shown in illustration No. 3 below.

the chain.

i in. AF bolts).

sea

water pump

the way

off

cover from either side taking care to leave the

81-86.

(t

in. AF bolts) and drive coupling to pump and swing pump

still

attached to hoses.

if in. AF bolts and one

tin.

AF

(4Xt

bolt

from chaincase cover and care-

Withdraw

if in. AF bolt and ball race retainer.

the

driven sprocket. When approxi-

mately

sprocket. . .

sprocket on

100°C carefully lever out sprocket and ball race assembly.

S2340 locate on sprocket and

on

with

a suitable brass

crankshaft, align keyway

or

aluminium

with

drift.

Fit sprocket dowel.

in. AF bolts) and crank-

two

locating dowels in

link

in the duplex chain is

the

link

and remove

draw

off

crankshaft key and drive

A15

'

THROTTLE

FUEL

INJECTION

LEVER

VENT

SCREW

PUMP

VENTING

AND

TIMING

DETAIL

Tighten the bolts
shown in Fig. 1. This
should preferably
done
hot, using a Torque
wrench and repeating
the sequence in stages
until
figure

achieved.

operation
necessary
valve clearances.

with

the engine

the correct torque

of

65/70

(8·9-9·7

kg./m.)

After

it

to

reset the

will

as

be

Ib./ft.

is

this

be

F,C

I

CYLINDER

HEAD

BOLTS

A16

C11

C12 To replace needle roller inner race use tool No.

C13 To replace needle bearing outer race in chaincase cover press out race

C14
C15 Heat chaincase again and press in sprocket assembly ensuring that

C16 Turn crankshaft until timing mark on camshaft sprocket is opposite dowel on

C17

To replace ball race
placement ensuring that ball race is properly seated against shoulder.

replacement flush

S2360 and
If

necessary overhaul fresh water pump

against shoulder. Check this by placing a straight edge on sprocket face and

ing gap between straight edge and chaincase
semble ball race retainer and bolt.

shaft sprocket. fit duplex chain and position pump sprocket so that

opposite right hand dowel on chaincase and chain ends are in position to accept
joining link.

Fit

joining link and retaining
Remove
See illustration

TIMING

PUMP

DETAIL

AND

with

See

bolt

from crankshaft and reassemble in reverse order

FOR FUEL

CAMSHAFT.

on

driven sprocket. drive off old race

with

end

the tool

illustration

No.5.

illustration

of

sprocket hub.

fit

replacement

No.3

below.

clip

with

No.3

INJECTION

with a drift

S2350 and draw

as

shown in illustration No. 4 below.

as

outlined in Section D below.

joint

face at three different points. As-

open end facing opposite direction

and

No.4

and

No.5.

and press on re-

off

race and press on

with

it

is

its

timing

C1-C5

fully

of

and

tool No.

seated

measur-

crank-

mark is

rotation.

81-86.

o

The

#1

cylinder

is

-a-

-.~.-

at

the flywheel end.

I

i

/

NEEDLE

OUTER RACE

FLUSH
BOSS

ROLLER

WITH

FACE

Al7

CHAINCASE

COVER

FITTING

SECTION

JOINING

LINK

OF

CHAIN

TO FUEL

CASE COVER

PUMP

DRIVE

.~/

/"

CHAIN

.~:!!!:;.

AlB

TO SERVICE

Op. Nos

TO

SERVICE

Op. No.

01

02

Carry out operations
Withdraw

pin when fitted.

03

Remove bearing retaining

front

04

05

Draw
Heat the chaincase cover and press in replacement bearing and shaft assembly using

Loctite or
chaincase then fit

06

Press
pulley flange to correct dimension and replace drive pin when fitted. Check dimensions
again before reassembling cover
to

flat

07

Reassemble in reverse order
the

impellor turns freely in the timing case.

FUEL

INJECTOR PUMP DRIVE CHAIN ONLY

C1-C6

FRESH

and

C16-C17.

WATER

PUMP

Replace chain

if

wear greater than -002 in. per link.

C2-C5.

fresh water pump pulley flange from pump shaft, after removing drive

clip

if

fitted and press out pump and bearing assembly from

to rear.

off

impellor and remove venturi ring and thrust spring.

equivalent compound.

Fit

the pump seal over the shaft and locate in the

seal thrust washer.

on

pump impellor

on

shaft.

See

with

illustration

C1-C5.

spring and venturi ring in position shown. Press on

to

engine. Ensure correct alignment

of

locking screw

No.6.

When tightening 3 bolts around the pump ensure

SPRING

VENTURI,ING

ASSEMBLY

CIRCULATING PUMP

DETAIL

\

OF

WATER

...

,

, ,

. ,

! !

! :

r--:r·L_~t

.

~---"-1

: '437"

--~~

11·10mm

I

I '

, '

i !

, I

!a

•

..!

SECTION
PUMP ASSEMBLY

OF

CIRCULATING

A21

G8 Carefully align the pivot pin hole

fit

ing solenoid assembly and

Note: A new pin

Fit

G9

TO SERVICE INJECTORS
H1

H2
H3
H4

TO CHANGE FUEL FILTER
J1 Turn off fuel supply.

J2

J3
J4
J5

J6
J7
J8

the two bolts retaining the solenoid ensuring that the rubber sealing diaphragm

properly seated in the recess and

Carry out operations A6. A10. A16.
Insert plugs in cylinder head injector holes to avoid ingress
Service injectors in accordance

Replace copper seating washers and reassemble in reverse order.

Unscrew the securing

Discard the elements and upper and lower sealing rings.
Wash out bowl
Unpack the new element and rings and

bowl.

Reassemble bowl.
Bleed system.

Run

and check for leAks.

MUST

with

be

bolt

clean fuel oil.

pin (with head uppermost when installed

used after dismantling a starter.

and remove the filter bowl and element.

of

yoke

with

pivot

pin hole in end bracket by mov-

fully

tighten bolts.

of

dirt.

with

Lucas - C.A.V. schedule (Lucas-C.A.V. agent).

Do

not use a cloth.

fit

new sealing rings to filter head and filtet

on

engine).

is

A22

DIESEL ENGINE FAULT FINDING CHART

ENGINE
OVERHEATS

ENGINE

KNOCK~

EXHAUST EMITS Broken valve springes);
EXCESSIVE SMOKE

________________

__________________

________

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

_r----~~------------------~

..-

ENGINE Poor compression.
MISFIRES

________________

~--_

ENGINE STARTS

AND STOPS

ENGINE DOES

NOT

MECHANICAL

Insufficient water;
Insufficient lubricating
Fan

belt
Thermostat sticking:
Injection
Water pump needs attention;
Engine needs top

Bearings worn;

~iston

Sticking

___

In_je_c_t_io_n_t_im_in..;g_i_n_co_r_re_c_t_.

Maximum

........

Sticking

Sticking

Engine needs top overhaul;
Broken

Valve!s)
Governor

slack or broken;

timing

incorrect;

overhaul.

slap;

valve

rocker(s);

stop

screw

__

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

valve(s);

piston rings;

injector

pipe.

sticking;

idling

setting incorrect.

GIVE FULL POWER

ENGINE IDLES

IMPERFECTLY

Sticking
Worn
Incorrect valve clearance;
Sticking
Injection
Engine overheating;
Engine

Governor
Injection

Air
Sticking

Broken valve springes).

valve(s);

piston rings and bores;

piston

rings;

timing

incorrect;

misaligned.

idling

setting

timing

leak

incorrect;

in

governor system;

valve(s);

oil:

_____

out

of

incorrect;

adjustment;

FUEL

Faulty

injector(s)

Faulty

injector!s);

Air

in

system.

.,

Incorrect Pump

Faulty

injector!s);

Faulty pump.
Faulty

Injector!s);

Air

in

system;

Faulty pump.

Air

in

system;

Faulty

11ft

Fuel

filter

Insufficient

Air

in

system;

Faulty

lift

Fuel

filter

injector!s);

Faulty
Insufficient
Dirty

air

Stop

control

Air

in

system;

Fuel

filter

Faulty

injector!s);

Faulty

lift
Insufficient
Faulty

pump.

Timing;

pump;
restricted;

fuel

in

pump;
restricted;

fuel

cleaner;

pulled

restricted;

pumr;

fue

in

in

tank.

tank;

out

tank;

slightly.

isolation

timing

cylinder

air

''''

lift

pump;

down;

switch;

switch;

motor.

incorrect;

compression; +

cleaner.

pipeline;

'0

filter;

Battery run
Lead disconnected;

Faulty starter
Faulty
Faulty starter

Injection
Poor

Blocked

Blocked fuel

'0'""""0'

Faulty
Restricted fuel
Air

leaks in pipeline.

ENGINE WILL

I

Starter does

crank engine

I

not

Starter cranks

engine

~g==l--------.J

MECHANICAL

__

_

____

_

Fuel

Not

I

'OiOC"'f

"OQd

NOT

I

Reaching

P.mp

START

Starter cranks
engine

I

slowly

I

________

+_Connections

~

FUEL SYSTEM

I

Air

in

Fuel System.

Stop

control

on

or

partially

Battery

partly

Terminal!s)

Wrong

grade engine

Faulty

starter

Fuel Reaching

Injection

on._

...

run

down;

loose;

dirty;

oli;

motor.

I

Pump

__

....

Faulty Injecto.

TO SERVICE SEA WATER PUMP

Op. No.

E1

Shut off seacock. Remove hoses. from pump.

E2

Remove

E3 Remove pump cover plate.

Pull out shaft

E4

replacement
seals and

E5

E6

Check cover for wear marks. either replace cover or machine flat and square
Check gasket and refit cover.

Replace pump and drive coupling.

two

tin.

AF bolts and

with

impellor and remove cam

impellor and cam.

'0'

ring are fitted in correct relationship to each other.

withdraw

See

pump and drive coupling.

if

worn. Replace seals and refit shaft and

section through

sea

water pump

with

to

A19

ensure

bush.

.

TO SERVICE CRANKSHAFT, BEARINGS, PISTONS AND CAMSHAFT

Op. No.

F1
F2 Carry out operation
F3 Drain lubricating oil and remove dipstick and extension tube.
F4 Disconnect fuel feed from

F5 Remove
F6 Disconnect fuel supply from

F7 Remove three

Fa

Carry out operation A

I

fold.

Remove inlet manifold complete

wiring

Remove starter motor

face

of

flywheel housing and remove cover plate.

SECTION

1-A

15 inclusive.

81-86

harness and alternator.

tin.

inclusive and

lift

pump

lift

AF bolts and

(2X

16"

in. AF bolts). Remove

pump and remove pump

withdraw

OF

WATER PUMP

C2-C5

to

with

inclusive.

filter and crankcase breather

fuel filter.

(two

oil pump and filter.

two

I, in. AF bolts

tin.

to

inlet

AF bolts).

from

forward

mani-

A20

F9 Remove gearbox
F10

Remove flywheel and stubshaft

AF bolts) and drive plate
F11
F12

Invert engine and remove sixteen
Remove

plete

two

with

F13 Bend over lock tabs and remove

if

fitted and flywheel housing

(1'

in. AF nuts) or flywheel inertia

if

hydraulic gearbox is fitted.

16

in. AF bolts securing sump.

remaining T

7

in. AF bolts

,

duplex sprocket and chain

two

(6X1'

from

chaincase and remove chaincase com-

in. AF bolts).

..

tin.

AF bolts and camshaft sprocket and chain

also chain tensioner pad.

tin.

F14 Remove four
F15 Remove eight

AF bolts and crankshaft rear oil seal housing.

9

1

6 in. AF connecting rod bolts and remove the bearing caps and retain in

assembly order.

F16 Remove ten

order.
F17 Push out piston/connecting rod assemblies through top

H-

Withdraw

in. AF bolts and remove main bearing caps and place in assembly

crankshaft and thrust bearings.

of

cylinder block.
F18 Remove circlips from pistons and push out gudgeon pins. retain pins
F19
F20

Remove
Withdraw

two

bolts securing camshaft thrust retainer and camshaft thrust bearing.

camshaft.

F21 Remove tappets (Cam followers).

Refer to dimensional data in this manual and check

to

Refer

earlier pages for information on the replacement

all wearing surfaces

of

cylinder liners. connecting rod

for

small end bushes and camshaft bushes.

with

the

Re-assemble engine in reverse order F1-F21

following

addition:

weight

with

pistons.

deviation.

(6Xt

in.

1. Ensure that the connecting rods are placed the correct way on the piston - one side

con. rod is marked

'front'.

liberally oil the assemblies and

2. When replacing chaincase ensure that the sump face is flush

face and position fuel pump drive sprocket centres using tool No.
sure correct chain tension and centering

Space the piston ring gaps at

fit

to

the cylinder bores using a piston ring clamp.

of

the crankshaft pulley oil seal.

120

degrees between each,

with

the cylinder block sump

52370.

This

will

3. When fitting gearbox stub shaft to flywheel check runout on ground diameter. This
not

exceed

limit.

0'003

in. Lightly tighten nuts and tap

Tighten nuts to

50

Ib./ft.

with

hammer and

A special spanner is available

drift

until

within

for

the purpose Part No.

52380.

TO

SERVICE STARTER MOTOR

as

for

Service

G1

Remove starter from engine and .clamp in a vice.
G2 Unscrew and
G3 Remove

G4

Withdraw
G5 Drive the

off

G6

Fit

Lucas 25689F starter

withdraw

two

bolts and remove solenoid assembly.

long clamping bolts. Remove yoke

end bracket.

circlip

locking ring

the shaft. Remove the locking ring and then the pinion assembly.
a replacement pinion assembly on shaft and ensure that the yoke is facing the cor-

rect way - the radiused portion
G7 Fit the solenoid assembly over the yoke arm and then

bracket to the starter body and tighten the

with

the exception

off

the

of

of

circlip

pinion drive assembly

pivot

pin.

towards the pinion and lever the

as

the arm must face towards the solenoid.

fit

the

two

clamp bolts.

circlip

and ring and end .

follows:

of

the

en-

must

above

circlip

Q.l

MARINE

COOLING

TRA.NSMI

ENGINE
Activation
Activation

SS

Type

Type

SAl
SAl

OTHER

CONTENTS

ELECTRICAL

by
by Lube

SYSTEM

IONS

SAl

SAO

and
and

(EXTERNAL)

•.••••••••.••.••••••••••••••••••••••

t1a.nual......................................

Ma.nual............

SAO

SAO

SYSTEM

Fuel

Clutch
Reduction

Pressure
Oil

••••••••••••••••••••••••

Adjustments

OVERHAUL

SECTION

••••••••••••••••••

••••••••••••••••••••••••••

Pressure

Units

••••••••••••••••••••••

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

•••••••••••••••••••••••

••••••••••••••••••••••••••

Q

R

s

..

PAGE

Q.2
Q.4

s. 2

S.

9

5.21
S.23

Type

RB

- Freewheeling

Paragon

Warner

P-2l

Hydraulic.....................................

Series,

•••

'.

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

Hydraulic

•••••••••••••••••••••••

25

S.29

S.

35

SECTION

Q.2

Q

MARINE

ENGINE

ELECTRICAL

SYSTEM

ACTIVATION

(Push

Button

This

six

cylinder
January
very

removes

hea~ing

a
NOTE:

breakers,
Responsibility"

.s4Pplied

simple
separate
engine

Starting

of

the

starting

Once

sure

developed
the

fuel
pressure
to

the

the

alternator

ins

trumen t

When

sure

drops

When

separate

installation

BY

FUEL

Start)

system

1975.
switch

alarm

start

motor

the

injection
switch.

alarm

s.

the

and
voltage
an

engine

device,

push

It

is
as

with

PRESSURE

is

supplied

Westerbeke

Basically,

and

eliminates
position

system,

is

accomplished

push

engine

engine

described

button

to

crank.

is

in

the

pump

Voltag~

system

for

excitation

is

the

fuel

from

is

the

device

button.
important
includes

on

the

your

engine.

engines

to

when

which

running,

low

operates

(if

supplied)

stopped,

pressure
these
supplied

that

fuses

under

wiring

on

all

beginning

the

system

the

need

activate

supplied.

by

operation
causes

fuel

pressure

a

is

then

and

fuel

switch

devices.

with a pre-

is

energized

your

engine

or

circuit

"Ownership

diagram

four

and

is

for

the

the

pres­side
fuel

applied
and

to

for

all

pres-

a

of

by

SECTION Q

DRWG

DEC

-'

..

INSTRUMENT P

...

NEL ",S$E

r------------~

:

~WTG

1

I

I

I

I

I

1

L~

__

_

19201

75

::=======:::::}-.J@

Lr-r-""T"'""TI;-r-r~@

ACTIVATION

..

eLY I

••

~~~

@

(PUSH

__

_

~

BY

FUEL

BUTTON

®

rQ

I QPTION"'L
I I

"'L

...

I I

1 I

I I

I :

I I

I~·

I I

RM

i'"

PRESSURE

START)

WIRING I

N:)[RT

L-~_~R!"~!!.o.!OIl.

q-

IrL I NOT u ..

w -lsI:ENon-A

I

I
I

!

)T"'RTtR

L_~

rOil

I v

_____

i

@

I

L.

lOA

.. [ NOT['<

__

Q.3

J

_+

I

..1

•

.-

=

"

r-",

I ) I

L I '

~.~

...

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4N?IV

".r~~1

rwllI9I!r.

"/IIN

NOT

AT

'C!!pC

MUfT

",,I

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POI-I

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OT"HIIlt

REO

L--+

__

~r_~Y~[L~·~'.~

(

I

L

_____

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_________

NorG,j

!IN

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c:'.t"t!NIrW«.

EXc:'IEP

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~'_l'IJl!!NAJJ.Y..1I~.

N'~"

DA_CI

NOTES

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S""Tell

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SENP,IP ; .8#AT,Ir

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---

IN

IN

AN

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OR

BIVEAlClllt

INS7"ALLFP

CONNE'CrION:

a

..

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.,.

,

______

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~

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----------

•

r'IIIS

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IN

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.,.

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Tr.!.~Rr

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P~~SV~.~/1rNIS..

IN~LUpING

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NEAtrllY-

FUll.

000

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~'DH

NOV","II

SWITCH

"(#NT

'9'"'''''''''

/NS7;t"LED

,sWITCHES

til.

IWUCHEA,R

_

A'E

~FQ'J:)

FUlle

NIfL~

AND

AT

7_

Prl{EfU~€.rwtTc/I

PLlISrtC.

.,;,.;",

----

AL~

IfUl:ICHI.

CONNECTED.

.•

Q.4

Marine

ACTIVATION

(Keyswitch

This
cylinder
to

January

Putting

tion

energizes
plied).
position

Turning

tion

operates
the

engine.

switch

When

voltage

excitation
ever

the
sure

removes

When
heating
arate

When

electric
a

separate
panel.
NOTE:
stallation
breakers,

ponsibility"
with

your

Engine

BY

LUBE

Start)

system

Westerbeke

1975.

the

start

Returning
de-energizes

the

is

released

the

engine

is

supplied
and

engine

an

engine

device,

push

an

stop

It

button
engine

push

is

includes

as

engine.

Electrical

OIL

PRESSURE

is

supplied

diesels
Operation
switch

an

alarm

the

start

the

starting

Upon

voltage

described
on

starting,

to
develops

to

to

all

stops,

is

it

is

at

is

solenoid,

button

important

fuses

the

wiring

on

produced

is

in

the

system

start

the

switch

the

the

instruments.

loss
from
furnished

energized
the
furnished

it

at

that

under

switch

alarm.

to

motor

the

Run

oil

alternator

of

these

key

switch

is

the

your

or

circuit
"Owner's

diagram

System

all

4 and 6

prior

very

Crank

position.

oil
with

with
energized
key

simple.

Run

posi-

(when

by a sep-

sup-

to

posi-

and

starts

start
pressure,

When-

pres-

devices.

a pre·-

panel.
an

switch

engine

supplied

Off

for

by

in-

Res-

SECTION

R

1.

DESCRIPTION
The Four Marine

equipped

Transfer

(closed

water

similar
differs
the
fast-flowing
through

while

low
exchanger.
never
the

engine

2.

FRESH
Heat

heat

with a fresh

of

system)

is

accomplished

to

an

because

engine's

the

the

fresh

pressure

mix so

stay

WATER

rejected

developed

heat

automobile

fresh
stream

tubes

around

The raw.

the

COOLING

from

circuit

raw

water,

water.

of

of

the

w~ter

the

water

water

clean.

SYSTEM

in

combustion,

by

friction

Diesel

water

the

by a heat

flows

cooling

fresh

to

the

radiator.

not
An

sea

water

heat

rapidly

tubes

and

cooling

is

SYSTEM

Engines

water

sea

exchanger,

air,

unrestricted

exchanger

of

fresh

passages

as

absorbed

system.

(raw)

It
cools

flows

under

the

~eat

water

well

are

by

in

as

(EXTERNAL)

the

fresh
from
changer;

into
where
and

cylinder

ugal
water

connect

cylinder

culates

ors.

ting

passes

expansion

3.

SEA

The
unrestricted
water

water.

the

expansion
here

the

lower

it

is

fresh

jacket

with

head,

around

When

temperature,

out

WATER
engine

which

it

circulated

head by means

water

around

corresponding

the

through

tank

SYSTEM

fast-flowing

absorbs

The

fresh

tank

to

is

cooled

part

where

is

of

the

through

pump. Openings

the

cylinder

the

fresh

the

valves

engine

the

the

and

the

indirectly

the

and
reaches
fresh

thermostat
circuit

heat

water

the

and

cylinder

of a centrif-

openings

water

cooled

stream

flows
heat
discharged

the

block

in
bores

water

fuel

from

inject-

its

opera-

th~n

into

repeats.

of

the

by

ex-

block,

the

in

the

cir-

the

the

sea

fresh

SURGE

FROM

COCK

TANK

FRESH

WATER

PUMP

RAW

WATER

PUMP

SEA

OIL

FILTER

EXHAUST

MANIFOLD

I -

...

~.--+

0

-.-

HYDRAULICGEAA>./'ltf4' C

Q.U.

~~--~"

.....

,

• •

> >

.... --.

COOLER)f

.f?VER

~TOARD

EXCHANGER

_..

f )=<P C

I'

-

CI

RAW

FRESH

-

ENGINE

IUSED

RAULIC

FROM

<J:l

SEA

COCK

WATER

WATER

ON

GEAR

ONLY

OIL

HYD-

R.l

R.2

water
water

ful
passes
exchanger.
exchanger
installed),

via

the

is

picked

neoprene

through

(and

heat

up from

impeller

the

After

passing

transmission

the

raw

exchanger.

the

sea

water

oil

cooler

through

water

is

sea

oil

overboard.

The

oil

cooler

the

bearings

by

the

lubricating

by

the

oil
flow
oil

of

cooler.
with a water
draulic
also

circulated

transmission
overboard.
oil

cooler

heat

4.
of

SEA

The

the

fuel

exchangers.

WATER
water
timing

pump

priming,

and

pressure

sea

water

When
cooled

or

RB

oil

In

and

PUMP
pump

gear.

positive
with a brass
The

impeller
against
housing,

NOTE:

As
prene
it

be

a

curved

producing

the
impeller,
run

carry a spare

5.

DRAIN
Remove

tank

cylinder

the

fresh

left
cocks

6.

FILLING
Ensure

cylinder

heat

to

close.)

Open
changer.
sion

until
from
on

top
fill
of

tank.

COOLING

the

and

open
block

water

side

of

counter-clockwise

COOLING

the

block

exchanger

air

vent

Remove

tank

and

coolant

vent
system

petcock.

of

heat

to

conducts

other

oil,

pump
through
the

transmission

sailing

through

cooler,

this

sense

transmission

is

mounted on

cover

The

and

water

displacement

case

and a

has

'flexible

cam

plate

the

water

pump

on no

in a dry

impeller

SYSTEM
pressure
petcock

below

drain

heat

exchanger.

SYSTEM

petcock

and

petcock

is

closed.

pet

cock

fill

pour

free

coolant

of

Close
exchanger
within

heat

friction

which

and

the

engine
gear

the

the

tubes

and

both

oil

is

driven
pump

neoprene

vanes

in

pumping

contains a neo-

account

condition.

and

cap

from

on

left

the

air

petcock

to

open.)

on

left

on

(Turn

on

cap

on

into

air

bubbles
air

and

one

inch

This

by a
pump,

to

the

the

cooler

then

piped

away from
surfaces

is

circulated

cooled

tubes

is

equipped

for a hy-

sea

water

of

then

piped

the

engine

cooler

the

from

is a self-

rotary

impeller.

which wipe

the

impeller

action.

should

Always

gasket.

expansio~

hand

side

filter,

on

bottom

(Turn

hand

side

bottom

clockwise

top

of

heat

top

of

system

issues

vent

pet

completely

from

raw

power-

and

heat

heat

if

by

the

of

the

a

are

front

the

pump,

of

and

pet-

of

of

ex-

expan-

cock

top

is

7.

IMPELLER

a.

Remove

b.

Remove

c.

To
coat

chamber

No. 2 grease

d.

Align

key. Care
impeller

direction

the

e.

Secure

four

f.

In
end

8.

THERMOSTAT
a.

Drain

two

b.

Remove

ostat

and

c.

Lift

d.

Test
placing
Raise
bottom

e.

If
thermostat.
to
new

f.

Install

and

inder

g.

Replace
was
within

clean

rosion

solution.

h.

Start

erating

engine,

tank

required.

9.

REMOVE
a.

Remove

b.

Remove

to

from

c.

Remove
coupling

d.

To
procedure
pound.
ent
nections

Secure

REPLACEMENT

front
impeller.

replace

the

the

impeller

with

impeller

should

blades

relative

pump,

screws

the

cover,

i.

end
event

cover

and

the

cooling

quarts).

the

nuts

housing

lift-up

out
the

to

of

housing.
thermostat.
opening

the

thermostat

the

thermostat.

thermostat
cool.

If

thermostat.

thermostat

secure

thermostat

head.

coolant,

drained,

one

inch

fresh

water

inhibitor

engine

temperature

carefully

filler

SEA

WATER
hoses
the

four

adapter

plate,

plate.

drive

and

replace

the

above,

(Rector

on

inlet

to

with

end

cover

neoprene

and

TEXACO

Regal

only.

key

way

be

all

lie

to

e.,

blades
and

lockwashers.

of

wear

cover

system

retaining

to

the

temperature

temperature

fails

Allow

it

to

the

sticks

with

remove,

fill

expansion

from

and a

or

antifreeze

and

run

is

remove

cap

and add

PUMP

from pump.

bolts

and

tang

between

fuel

pump

pump,

using

seal

and

discharge
prevent
hose

air

clamps.)

and

gasket.

impeller

impeller

Starfak

with

taken

the

shaft

that

in

t~e

rotation

the

same

trailing.

gasket
being

may

with

present

be

reversed.

(approximately

the

therm-

cylinder

head

by

in

water.

stamped

open,

fit
temperature
open,

housing

new

or

renew

gasket

to

if

system

tank

top

of

tank

suitable

until

normal'op-

reached.

expansion

coolant

securing
pull

water

drive

reverse

sealing

or

its

pump

pump

gear.

the

co~

equival-

hose

as

away

pump

con-

leaks.

of

on

on
new

cyl-

to
with
cor-

Stop

L25 TRANSMISSION

SECTION S

MANUAL MARINE REVERSE GEAR

SPECIFICATIONS

a/A

Length

a/A

Length (Reduction

Maximum
Weight
Weight
H.P. Rating

Torque Capacity
Maximum

Astern
Lubrication -Splash

Oil Capacity:
Direct

Drive

2:1 Reduction

(Direct

Width

(Direct

Drive)

(Reduction

R.P.M.

Revolutions

Drive)

2:1)

2:1)

10

in.

12i

9i

28t

41t

1·5

100

50

4,000

79%

S.A.E.

1

pint

1 t

pint

in.
in.
lb.
lb.

h.p. per

r.p.m.

Ib./ft.

r.p.m.

of

Ahead

30

Oil

ADJUSTMENT

First remove Inspection Cover

Rotate the
This tab locks the
engages in castellations
the

drum

off

slack

not

to

slacken

Lift

tab

the
overdo this, otherwise you may burst the
mendous pressure can be exerted by the leverage obtained
through the toggles. These toggles
dead centre and are thus self-locking in Ahead. There
be NO continual strain on the Operating Collar such as
be caused by constant pressure on the gear lever. The lever
is held lightly in position in neutral by means
which
on page:S2

Tighten the hexagon lock nut

locked when lever is pulled
or the reverse band
cause overheating and los:: of power. When the correct adjust­ment is found, replace top cover. If the lock nut is slack

remove and give a sharp

re-assemble.

Bearings. THERE

ment

Gear Box and reduction gear have a common lubricating
system.

whichever is the more frequent. To
pump to tube on side of gearbox having first removed the
hexagon plug

out

aft

portion clockwise one or

engages the indent in the cam plate. See

If the gear slips in reverse, remove Inspection Cover.

drive

The

with

CHANGE the oil once per season or every

OF GEAR

of

Gear Box.

(Ref:

Plate

AHEAD CLUTCH
drum

M4

until

aft

by

pulling

the set screw

of

is by

the Propellor Shaft is VERY IMPORTANT. The

the Gear Control Lever into reverse and

too

far

the slot. Tighten the Ahead Clutch by turning

will

REDUCTION GEAR

triple

ARE

the locking tab

part

of

drum

cut

in the forward portion. Lock

M22

securing locking tab. Take care

and drop the screw into the gearbox.

REVERSE

drag in Neutral and Ahead. This

roller chain and all bearings are Ball

NO

BAND

M43

right

blow

to the top locking portion and

ADJUSTMENTS. Careful align-

"M")

M20

to

the

two

divisions. Do NOT

M23

slightly

back. Do NOT overtighten

is observed.

forward

drum

must

so

that

part and

since tre-

throw

would

of

a roller

illustration

drum

500

DRAIN OIL. attach sump

M49.

over

must

will

hours,

is

DESCRIPTION

The Forward Drive is engaged by moving the gear lever
forward
tion takes place through a ball-bearing control operating a
system
clamping together a series
which
engine shaft and propeller shaft.
end a
locks the
ment
noticeable

between
are then released and

back. This releases
brake band
portion
propeller shaft through
is

IMPORTANT:
gear

which

engages the double

of

toggles which force home a set

are interleaved, alternative plates being attached

split

cone clamps the engine shaft and

epicyclic

eliminates entirely the

The Neutral Position is obtained

The Reverse Drive is obtained

approximately 79%

in

forward

of

the gear and causing a reverse

and

reduction

gearing

the normal type

and reverse, the

permit

the

by

means

See

forward

of
epicyclic

of

the engine speed.

that

oil

drive.

to

a cam, thus clamping the outer

level
if

friction

of

hardened steel

Additionally,

it.

The double

slight

of

epicyclic

the gearing

fitted.

rattle

gear.

with

forward

by

drawing

drive

and contracts a lined

gearing. The reverse

is

maintained

clutch. The opera-

the lever

and reverse drives

to

of

plungers, thus

friction

at

the engine
frictionally

clutch

at

run idle.

arrange-

low

midway

the lever

motion

in

the

reverse

discs

to

the

speeds

right

of

the

drive

SERVICE INSTRUCTIONS

Normal adjustments

S2

and particular attention is directed

gear controls given below.

to

traced
are
indent
levers and
the Neutral position, otherwise
and cause the reverse band
impose a constant load on the operating

heat and then wear

Ahead.
IF

examination and find

(a) The controls have bends

(b)

(e)
(d)

(e)

distant

too

flimsy,

in

the camplate in Neutral. Do

try

to

GEAR

TROUBLES SHOULD DEVELOP,

Have elbows or joints
bulkheads
and
See

lubricated.

See that control handle does not strike the dash

loose
fail
See
maintain a constant pressure against the trunnions
operating
friction

or

throw

at the gear.

that

joints are

from

to

reach the gear.

that

the controls

collar

when running in Ahead.

for

the reverse gear are given on page

90%

controls

or

cause the cam roller

arrange

from

if:

adjacent parts, thus preventing

not

the bracket

and so cause heat and wear

of

which

that

the remote lever is upright in

it

to

bind in Neutral. It

undue

which

which

stiff

so

that

do

not cramp, rub

to

all gear troubles can be

are either badly designed,

may drag on the gear

strike against the floor

to

NOT

use long or heavy

friction

will

flex and weaken,

or rusty and keep them

full

travel and pressure

notes on remote

ride

out

of

the

shift

will

which

make an

pressure

or

so as

of

undue

also

will

or
or

pull

to

the

collar

when running in

first

full

or

stick

from

82

(f)

Check

the

to

see

that

these are correct.

(g)

Check

for

worn

or

Links. These may have been replaced

adjustments

not

were
the
they should

correctly

clutch

plates through the plungers. Examine the

all

come

as shown in Sketch Fig.

up and
shows

equally

correct
be filed
toggles.
it

two

correct

and the

is best

remain open as

should be

at

this

point
third

slightly

As

until

this

is

to

order three complete sets

blies comprisirrg Parts Numbers M24, M25, M28, M23,

M26

and

27.

When adjustment is

throw

in

should

with

disengage the toggles.

of

both AHEAD and REVERSE

unevenly adjusted Toggles and

at

adjusted

into

correct

1.
filed

when closed.

to

produce even pressure on

Should one

in

Fig.

slightly

some

closed position

of

the

2,

then the

at

'A'

If

two

open, then both closed ones

this

space

is

most

important

when

fairly

closed

fitting

of

toggle assem-

tight,

a snap and require a sharp pull

time

links

until

links

by

new

Toggle

and

links;

at

'A'

close

link

that

all bear

show

must

all three

toggles

the lever

to

~

FIG

~MTE~

NEUTRAl.

5

FIG6

FIG

FIG2

ADJUSTMENT

IMPORTANT

Ahead clutch
so

tight

up

with
shows correct position
pin just past dead center and

I

A

therefore
constant pressure on the control
lever end

must

at .

not

A'

will

Fig. 2. Fig. 1

that toggles

links

locked in ahead

operating collar.

be

adjusted

not close

with

without

central

AHEAD

THIS

WITHIN

!Ol

TtD

SHAn

'002"

TO rLYWH£tL

DRIVE

MUST
Af'T[R

RUN

IT

OF

IS

Turn drum
is at top position.

3. Pull control lever
as to

screw
of

slot. Tighten ahead clutch
by turning clockwise
portion that carries toggles.
Correct adjustment is im­portant.
will
See

Fig.

If

too slack the clutch

slip under load. A notch

two

or
all the difference. Note the
tab is offset and can
reversed for closer adjust­ment.

FIG?

so

lock

drum. Slack off

'B'.

lift

that tab

tab

See

'C'

aft

'C'

Fig.

so

out

aft

I f too

not remain in ahead.

2.

either way

tight

will

gear

will

make

be

FIG3

ADJUSTMENT

REVERSE

BAND

Pull control lever

OF

rollers rests on cam at .

see

Fig, 4.

sufficiently to lock drum.
Do

not
so
pinch the drum as the
rides out

between

Figures
relative positions
roller

reverse, ahead and

overtighten the nut

as

to cause the band to

of

'E'

4,

and cam plate in

Now

tighten nut

neutral notch

and

'F'.

5, and 6 show

of

REVERSE

FIG"

aft

until

D',

roller

the cam

neutral.

VIEW[D

2!!Y!4

FIG.S

FROM

FORWARD

END

8.3

Plate Description

L1
L2
l3

l4
l5
l6

L7

L8
19
l10

L11

l12

l13
l14
l15
l16

L17
l18
l19
l20
l21 Nut for stud
l22
l23
l24
l25

l26
l27
l28
l29
l30
l31
l32
L33

L34

Gearbox
Joint. support flange

Cross shaft seal
Dip-stick. gearbox

Drainplug.
Set screw. and anti-rattle
lock

nut
Inspection cover
Joint. Inspection cover

Stud

Nut

all

filler plug. inspection cover
Fibre washer.
Engine Identification label

Brass pin. securing label
Joint gearbox/reduction also
Ball

bearing. main
Support bracket rear engIne.
Stud securing
Spring washer for stud

all

seal.
a rIng coupling
Washer coupling
Half coupling. gearbox
Half
Key.
Nut. securing coupling
Register. coupling
Shaft half coupling
Bolt. couplinr
Nut. self loc Ing for bolt
Shaft lock
Gear lever socket
Gear Lever assembly
Clamp bolt gear lever 1

aft

co~"ng.

sha

to

gearbox

011

tearbox

011

aft

end cover or bearer

gearbox for flex coupling

to

coupling

screw

level

to

filler plug

shaft

bearer

to

(state

gearbox

maIn

bore)

GEARBOX

used on
vertical (Wolf)

DO

DO

shaft

AND

REDUCTION

Oly.

Plate Description

,

L35

1

L36

2

L37

1

L38

1

L39

1

L40

1

L41

1

L42

1

l43

4

L44

4

L45

1

l46

1

L47

1

L48

2

l49

1

l50

1

L51

1

l52
l53

6

L54

6

l54

8

1

l55
L55

1

1

l56
l57

1

1

l58
l59

1
1

l60

1
1

3
3
2 Straight connector

1

,

S.L. nut for
Transax pin secur ng lever
Reduction gear
Cover. reduction gear ouslng
Joint. reduction gear cover
Socket
Spring washer for socket
Bolt securing reduction
Stud securing reduction
Spring washer 6
Nut
Elbow
Pipe (drain) 1
Clip
Set
Washer
Drive sprocket
Spacer for drive sprocket
Ball bearing.

Triple chain.

Trl~le

Dr
Driven sprocket
lower
KeYi
Ba
Clrclip
all
Aft end cover. reverse gearbox

Support bracket rear

Support bracket. rear eng ne. starboard
Elbow

Drain plug
Fibre washer for drain plug J

GEAR

clam~

housln~

screw

screw

aft

top

50

aft

links/or

46

links

38T

31T

bearer

chain.

ven sprocket

shaft. reductIon gear

for driven sprocket

I bearIng. lower

seal

• Not Illustrated

bolt

to

screw

case

case

{

"'

/ or

r

shaft

en~Ine.

1

housing

to

to

vertIcal (Tiger)

for water cooled
GB

GB

GB

as

required

Ory.

1
1
1
1

8

8

3
3

3
1

1
1
1
1
1

1

1

1
1

2

1
1
1

1
1

84

PLATE 'M'

Plate

Description

M1

Gear,
M2
M3
M4
M5
M6
M7
M8
M9
M10
M11
M12
M13
M14
M15
M16
M17
M18
M19
M20
M21
M22
M23
M24
M25
M26

forward

Pilot

bush

Cone key

Drum
Drum bush
Split

cone
Forward push
Stud, long
Stud,

short

Long

pinion

Bush

only,

Short

pinion
Needle
Thrust

disc
Head
Clutch

disc
Clutch

disc

Clutch

disc
Drum

arm
Adjusting
Spring washer }
Set

screw

Toggle

assembly

Toggle

only

Toggle

Pin only

for

pinion

roller

plate

clip

for

links

toggle

stub

for

gear

gear

plate

pinion

with

long

with

with
with
with

clip

only

bush

pinion

needle

lugs
teeth
lugs,

with

(set

and

shaft

thick

plunger

of

plunger

roller

3)

CLUTCH

Qty.

1
1

1
1

1

1

1

2
2
2

2

2
2
1

1
4
4
1
1
1

1

3
3
3
6

M27

Plunger only

M28

Pin

M29

Split

M30

Operating

M31

Control shoe

M32

Fork lever

M33

Transax pin,

M34

Cross

M35

Camplate

M36

Split

M37

Cam shoe

M38

Camshaft

M39

Cam

M40

Pin

M41

Brake bands

M42

Spring

M43

Adjusting

M44

Link pin, starboard

M45

Split

M46

Link

M47

Transax

M48

Link
M49
M50

M51
M52
M53
M54
M55

Cross

D.O.

Reduction main
Key,
Gear,

Ball bearing,

Circlip
Bush

pin

collar

shaft

pin

with

roller

only

only

for

for

brake band

nut, brake band

pin

for

pin

only,

pin

plate

shaft / Li

Main

shaft/or

main

shaft

main

shaft

for

main

assembly

pair

roller

cam

roller

with

link

link

pins

port

for

link

nk spacer

shaft

to

drum

shaft

and

pin

pins

(short)

pins,

}

gear and

arm

plate

S/L

pair

coupling

3

3

6

1

2
1

2

1
1
1
1
1

1

1

1

1

1
1
1

1

2

2

1

S5

(h)

Check

for

badly

worn

Split

Cone

M6
have been
neglect to

This

adjustment
had been fitted.
recess in the
that
plates may also become worn or the surface torn,
would
which
Clutch so that the toggles snap over dead center by
moderate pressure
force, then the

M1

so

play can

removed and indicates that the cone is
still
ling the gear
engages the keyway in the cone and

cone.

TO

Disconnect tail

The gearbox is secured by

nuts inside. Remove gearbox

off.

allowed
adjust

would

might

the

drum

necessitate renewal. In order to test

might

that

there is no end play

be

grip the sleeve.

See Figs. 7 and 8.

REMOVE

CAUTION: Observe the

stub shaft and also the bronze
either is
placing,
within

be checked by means

the reverse gear assembly.

REMEMBER

OVER THE
KEYWAY
CONE

completely dismantle the reverse gear,
the nut
ing
lock

worn

the stub shaft

it

is very

'002

in. after

ALSO WHEN PUSHING THE ASSEMBLED DRUM
GEAR

AND

M6.

See

L27

to

the shaft

TO

which

remove the gearbox as

M50

DISMANTLE

(Reference:

to

slip continuously in Ahead, due

the clutch when

cause wear on the

fail

to

It

drum

requires replacing or re-bushing. Clutch

require replacement:

split

observed when the Inspection Cover is

it

is

correct

is possible that the corresponding

may also have become

of

the gear lever and

cone should

It

must be replaced. When reassemb-

important

to

split
until

grip

of

see

THE REVERSE GEAR

FROM

(Reference:

shaft

important

it

of a dial

M1,

NOT

Figure 8. Another

secures the

to

prevent

ENGINE

Plate

"M")

coupling and slide

two

nuts outside and

lid,

undo nuts and slide gearbox

condition

is

bolted to the flywheel. This should

TO ENTER THE CONE KEY IN THE

THE SPLIT IN THE BRONZE SPLIT

of

the gear on the

pilot

bush inside the gear.

must

be

that the shaft

indicator

point:

coupling

it

is then so much easier

it

from

turning.

THE REVERSE GEAR

Plates

"L"

and

The gear may

it

became necessary.

cone

which

a new

badly

for a split

Adjust

the sleeve

the Drum. Such end

NOT

well

removed. When re-

before

if

it

is better to slack

BEFORE commenc-

"M")

without

worn

that

the Key

the

aft.

must

it

is intended

the Ahea.d

too much

split

two

finally

split

worn

which

undue

of

in the

similar

forward

run true

fitting

to

later

cone

so

cone

Gear

to

M2

to

off

to

If

CAUTION:

Drive
great care
does not
second,

is held against the
thrust
place.

fully

is

engine.

see·

that

shaft.

will

There should be n in. to

Disc
assembled.

6. To remove
as

Item 1. then. after

M18

and
inwards when the gears
If

the Cone is

corresponding surface in the Drum should also

for

similar
M7
ance between the Plate and the Drum to
to be
When reassembling, the
forward
These should enter the holes adjacent to the
on the
Cone in
then drop the
these short pinion studs home flush.
pinion
press these studs home. Assemble the Thrust Disc
and drop the Head in position over the ends
studs.

When reassembling
is: Head M15, Plate
alternately thereafter, finishing
Plate

with

drum

into

M52

into

Arm

Plate

the key

first

checked there are no cuts in the ring. Next
washer then
then move the washer into the recess in the face
coupling. A
that the washer
coupling home.

If

Sprocket

when the coupling or sprocket is

This

If

be

Either the Coupling

L51

must

trip

that

operation

assembled

After

the ball bearing is
there is a gap here

pinched because the Gear

has been removed

be

taken in replacing;

or

fall

into

something heavy like a

replacing the coupling

the reduction

forward

must

not be attempted when the gear

or

when the reverse gear is fitted to

tight

n-

M14

between the

Cone

Head

M15

wear. When the Cone and Forward Push Plate

are in position there should be n-in. to i- in. clear-

forced

studs, small end first. hold the pinions in place and

the splined plates,

M19

to

forward

end

of

forward

position,

two

Lugs M18.
gearbox by

When replacing the coupling

the shaft

fit

the key. Slide the coupling on past the key

little

two

Gears

M6

or

Planet Gears

lifting

the

pinion

worn

the Drum. Begin

boss. Turn the Drum over and place the

slide

grease placed in the recess helps to ensure

will

will

or

scored

and close

pinion

followed

short pinions over the studs. Next press

Clutch Plates in the Drum the seauence

with

It

by the Forward Push Plate M7.

Lugs M16, Plate

will

be

tilting

the box and entering the gear

finally

the

'0'

not

be

L25

or the Reduction

from

the Shaft M50,

first

that the Key

drive

end

it

out

come free and the Cone also.

with

found easier to assemble the

displaced when pushing the

block

of

Shaft

or

against the

means

that

M52

in.

of

end float on the

M52

and

M10

the Clutch Plates

studs should be pressed

it

must

tightly

studs are er.tered

with

Pressure Plate, i.e.

screwing

ring up to the bearing. having

housing, and

of

lead

M50

to take the

driven

sprocket. check to

is too far

M1

be

the

Now

with

L25

back

circlip

Thrust Disc

when

and

M12

replaced and the

be

examined

permit

on the Gear

two

short studs.

enter the long

of

the

TeethM17and

home the Drum

before

slide

M51

or

brass

into

on the

M14

forward.

Thrust

correctly

proceed

M17,

M16,

the Cone

M1

from

the

two

flats

M14

pinion

Thick

fitting
on the
of

the

Clamp
portion
follows:

1. The Drum Assembly may be removed, after the

2. The Brake Band Assembly can

3. To remove

4. The

the gearbox

at the bottom behind the

clip

M20
anti-clockwise
clutch plates can then be removed and examined.
5

slacking the
Plate M35.
from
lose the

removal
Coupling
L26. Move the Fork Lever so as
Operating Collar
out
release

punch
first

required
removed

disturb

has been

for

removal

It

the assembly,

Cam Shoe

Operating Collar Assembly. This necessitates

of

Main

L25

by means

M30

Ball Bearing should be

from

be removed; six set screws secure this.

inside the box but the

to

replace the Oil Seal

after

the keys

firmly

in a bench vice, gripping that

lifted

clear

away

from

of

gears,

thrust

Nut

M43

is

not

necessary to
but

M37

Shaft M50. Undo

with

a coupling

M30

of

a rubber hammer. Press

Take care

pulling

the coupling.

if

the shaft is

of

the Drum

plates, etc.

sufficiently

if

this

.

The shaft may

not

to lose the shoes

driven

to

is done be careful

drain

plug;

proceed

the notch, by unscrewing

Arm

Plate

now

be removed after

to

slidt!

withdraw

Nut
drawer
to

free the shoes

out

Aft

L23.

It

be

out

the cam plate

L27.

and remove Key

now

be

off

gear

with

is

driven out.

M31

a suitable brass

End Cover

If

this

cover can be

only

necessary

as

adjusting

M19

The

See

Item

the Cam

not

to

draw

off

off

the

driven

M52

and

.

must

it

is

only

to

TO

DISMANTLE

WHEN

1. Drain the oil by removing the bottom
to

the housing.

ing

cover

2. Remove the
Draw

off

3. Warm the cover around the
allow
necessary
hammer
cover is required

After

4.
chain
sprockets evenly and

withdrawn

is

to

2 in.
bolts

and

screwed evenly home.
To

remove the lower sprocket complete

5.
forward
same

FITTED TO REVERSE GEAR

or

bolts

or

drain

nut

the

them

by

removal

which

3 in. The sprocket is already threaded

will

ball-race. then ease the

time

securing the

coupling

to

be

drawn

to

tap the

making a glancing

to

of

the cover. in

is

endless.

by means

be

forced

as the top sprocket is being

REDUCTION DRIVE

the drain plug, then remove the remain-

with

a sump pump.

with

go.

at

coupling

coupling

ball-race housings

away

bolt

from

bosses

it

is necessary
the same
of

two

off

the

blow

order

bolts t diam

shaft

shaft

bolt

holding

to the

drawer.

the housing.

lightly

time.

as both these

with

in

the

to

remove the

to

The top sprocket

with

from

the case

withdrawn.

the cover

lower

shaft.

which

should

It

may

be

a rubbel

direction

remove both

and length

shaft.

for

bolts

the

triple

these

are

warm

at

the

56

6.

If

it

is desired to remove the housing from the gearbox,
undo the six bolts
clear from the ball bearing which forms a spigot between

the

two

castings.

TO FIT REDUCTION DRIVE CASE

or

nuts which

TO REVERSE

will

GEAR

allow

it

to

come

1. Offer the top sprocket
the key is fitting the keyway. Do
yet.

2.

Bolt

the reduction housing to the gearbox.

3.

See

that both the sprockets are perfectly clean and free

from any burrs.

Fit

the chain over both the sprockets and tap the top

4.
sprocket on
of

the way when the ball-race on the lower sprocket

enter

its

housing, then tap both the sprockets home evenly.

home, sprockets should be t in. outside the

When
face

of

the housing.

to

the end

the oil seal to the cover and

5.

L53
Fit

Fit

to

the gearbox shaft approximately two-thirds

of

NOTE: Immersing the cover in

to

casting
over the ball-races.

6. Screw up cover evenly and test to see that reduction drive
turns freely.
between the faces
perfect freeness. When replacing the coupling
fitting the key
having first checked there are no cuts in the ring. Next
slide on the washer then
on past the keyway then move the washer into the recess
in the face
recess helps
when pushing the coupling home.

expand and

It

is sometimes necessary

to

of

the coupling. A

to

ensure that the washer

NOTE: These Fitting Instructions are

already have had a Reduction Drive fitted.
Drive is to be fitted
shaft must be changed
the operation described above, and oil transfer holes must
be
with

drilled

in the

those in the

aft

front

to

the gearbox shaft and

NOT

the ball-races

See

the

'Caution', page 12.

M50

allow

of

the housing and the cover

the shaft slide

to a direct

for a M50

end

of

face

the gearbox case to correspond

of

the reduction case.

to

the lower shaft.

shaft.

fit

the cover

hot

the cover

'0'

fit

the key. Slide the coupling

little

for

drive gearbox, the gearbox

shaft before commencing

see

fit

the sprocket just

Fit

the bearing

to

water

grease placed in the

will

the housing.

will

to

be tapped easily

to

fit

an extra

L25

up

to

the bearing

not

be displaced

Gearboxes which

If

a Reduction

that

will

cause the

joint

to

give

before

The
dated
cedures
your

make

whenever

information

engine

You

sure

SERVICE BULLETINS

following

which

and

should

that

your

Bulletins

about

are

important

its

support

familiarize
you

consult

engine

requires

contain

various

to
systems.

yourself

the

supplementary

components

the

proper

with

appropriate

service

or

~nd

functioning

the

subjects

Bulletin(s)

overhaul.

and

service

SECTION

up-

pro-

of

and

V

WESTERBEKE

SERVICE

Subject: Exhaust
Models:

When

engine sea water

stream

All

strikes

Proper design of
exhaust
inlet

strike

system

be

positioned

a surface

water stream should

inlet
In

fittings

addition to the

system

failures

marine generators

is

fed into

a surface, erosion

either

to prevent

directly.

as

big in diameter

above

a water jacketed or a water injected ("wet")

this

so

that

the entering stream of sea water

Also, the velocity of the entering sea

be

as

low

design considerations,

tageous to divide the sea water
exhaust
The

system

remainder

proportion of the sea water
can

only

be

so

that

is

normally

determined

only a portion of

piped

flow

by

trial

MARINE

problem

as

ENGINE

BULLETIN

and

marine engines

an

exhaust

may

cause premature

possible

as

possible.

flow

at

directly

to pass through the exhaust

and

error.

excessive exhaust temperatures with the

PRODUCTS

#69

system

so

that

the

failures.

requires

that

the sea water

does

which

is

achieved

it

is

by

usually advan-

the point of entry to the

it

enters the exhaust system.

over the side.

The

proper
system

The

least

goal

amount

is

to prevent

of sea water.

full

not

having

PN

19149

J

H.

WESTERBEKE

CORP.·

AVON

INDUSTRIAL

PARK·

AVON.

MASS.

02322

U.S.A.·

TELEPHONE:

6i7

May

588·7700·

6.

TELEX:

1974

92-4444·

CABLE:

WESTCORP.

WESTERBEKE

REISSUED:

SUBJECT:
MODEL:
DISTR:

The

diagram

Hush

stainless steel muffler.

Make

sure

anqle of
Muffler

engine
Muffler

heel

remains

is

shut

must

October

Hydro-Hush
All

All

on

the reverse side

installation

or pitch.

aporoximately twenty-five percent full of water

down

with

be

installed

SERVICE

3,

1975

Muffler Installation

is

such

maximum

as

close to fore-aft centerline of boat

BULLETIN

shows

a proper

that water

thirty-three

#81

cannot

inch

installation

enter engine

lift

used.

of the

at

after

any

possible. .

There
sea water

vaccuum

·uoon
water

copper

running.
oipe
it
by

must

engine

throuqh

be

circuit

which

shutdown.

an

unblocked

(where

would

its

exhaust.

encourage

Such

tubing to discourage water

If

it

over the side or into the transon exhaust

will drain

water

upon

flows
engine

venting the sea water

vent to

it

nasses

siphoning
siphoning
Pipe

through

shutdown

circuit

atmosphere
above

the waterline) to

through

the

flow

the

and

would

air
air

fill

vent with aporoximately 3/16

through

vent

function properly

to atmosphere.

at

the

high

point of the

break

the sea water

the engine with sea

it

when

when

the engine

the engine

outlet.

as

But

a siphon

the

circuit

is

running,

be

Hydro-

as

is

sure

break

Use

as

few

right angle

to

back

Exhaust

soecifics
The

be

resoonsible in

pressure,
line diameters indicated are

regardin~

installation

understanding of

J H

WESTERBEKE

PN

CORP.·

19468

AVON

INDUSTRIAL PARK·

10/3/75

check

run

tips

any

good

fittings

your

lengths

given

way

for muffler

marine

AVON.

as

engine

and

are to

practice

MASS

02322

possible.

If

there

is

any

question

manual.

minimums.

Refer to enqine

sizes greater than indicated.

be

used
installation.

on

U.S A .

as

a guide only.

We

the part of the

TELEPHONE:

617588·7700·

We

presume

installer.

TELEX

manual

cannot

basic

92·4444·

Page

CABLE.

1/2

as

for

WESTCORP.

HYDRO

-HUSH

AIR

VENT

HYDRO-HU~H

BELOW ENGI NE .

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PH,llI7"1

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/

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WATER

puwp

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HYDRO-HUSH

..

AIR

VENT

POINT

AND

IN

~EA

WATER

AFTER

ENc;l

JioIPHONINca 0 ..

MU~T

8E

INSTALLED

A80VE

NE

WATER

CIRCUIT

SHUT

SEA

WATER

.

I

\,~r~~·

....

L:Jlc··

LINE

TO

8R~AK

DOWN,

PREVENTINCO

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Drwg

15294

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HYDRO-HUSH

ABOVE ENGI

NE

.

Page

2/2

WESTER.EKE

ISSUED:
SUBJECT:

MODEL:

DISTR:

May

Battery

All

Owners , Distributors,

MODEL
Vire,

DS, 5 Horsepower,

7 Horsepower,

7,

1975

Recommendations

gasoline

diesel

MARINE

SERVICE

ENGINE

BULLETIN

Dealers, l,1anufacturers

BATTERY

BATTERY

RECOMMENDATIONS

AMPERE

HOURS

40-60

60-90

PROOUCTS

#82

VOLTAGE

12

V.D.C.

12

V.D.C.

Pi1ot-10,
Four-6O,
Pi1ot-20,
Four-91,

125,

25

Four-107,

WPDS-15,
Four-154,

WPDS-20,

Four-230,

10 Horsepower,

15

Horsepower,

20

25

Horsepower,

Horsepower,

37

15

Kilowatt,

53

20

Kilowatt,

75

Performer-Six,

The

ampere hour range

Horsepower,

diesel·

Horsepower,

diesel

Horsepower,

diesel

Horsepower,

115

Horsepower,

shown

diesel

diesel

diesel

diesel

diesel

diesel

diesel

is

diesel

minimum.

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

125-150

125-150
150-170
150-170
170-200
200

minimum

There

is

no

real

maximum.

12

V.D.C.

12

V.D.C.

12

V.D.C.

12

V.D.C.
12 V.D.C.
12

V.D.C.

12

V.D.C.

12 V.D.C.

12 V.D.C.
12 V.D.C.
12 V.D.C.

J H

WESTERBEKE

PN

20442

CORp·

5/7/75

AVON

INDUSTRIAL PARK·

AVON.

MASS

02322

USA

.

TELEP~ONE

617588·7700·

TELEX

92·4444·

CABLE

Page

WESTCORP

1/1

WESTERBEKE

SUBJECT:
MODEL:
DISTR:

DESCRIPTION
The

short

via

a
aluminum
hardened
gear

shifting

finger

profile

mechanical

resistant
and

tip

LUBRICATING

Short

WESTERBEKE

All

transmission

sailing

friction

their

requires

control.

OIL

TYPE

Profile

to

sea

shafts

little

MARINE

ENGINE

SERVICE BULLETIN

L25,

Sailing

30,

40,

Gear

50

Shipments,

gear

clutch.

water.

run

is

on

a

helical

The

Helical

heavy

movement

PRODUCTS

#83

Distributors

gear

housing

gears

duty

and

roller

minimum

transmission

is

made

are

shaved

bearings.

effort,

of

high

and
a

truly

shifted

strength
case

Mechanical

Type
20
grade

A

transmission

or

30,

engine

may

LUBRICATING
The

circular
able
lowable
ing
into

oil

the

the

level.

oil

threaded

housing
MAINTENANCE
Check

same
after
every
open
blowing

LONG
If

the
pletely
drain

the

best

the

type

the
season.

at

all
the

TERM

gearbox

with

to

gearbox
oil
first

STORAGE

procedure

normal

be

oil

OIL

LEVEL

marking

level.

when

hundred

Air
times
rear

is

oil

level

used

is

The

plug

at

oil

adding
Vent

for

seal.

put

to

of

fluid

if

NOT

ring

bottom

The

on

all.

level

proper

out
protect

the

before

is

strongly

engine

acceptable.

on

the

of

the

level

top

is

of

at

monthly

oil.
hours
Hole

of

in

operation

of

operation

it

same

ty?e
next

speed

dipstick

dipstick

measured

the

housing

The

gearbox

operation.

dipstick

from

normally
start.

preferred

never

indicates
on a dry

intervals.

oil

cover

of

the

for

a

corrosion

used.

but

exceeds

indicates

dipstick

-

it

must

Always

should

Then

it

must

transmission,

prolonged

is

to

Don't

HD

engine

2800

the

the
not

be

should

be

kept

period

fill

oil,

RPM.

HIGHEST

LOWEST

by

be

threaded

use

the

changed

be

clean
to

of

it

com-

forget

SAE

Multi-

allow-

al-

rest-

changed

and

prevent

time,

to

-

J

H.

WESTERBEKE CORP . AVON INDUSTRIAL

PN

20629

rev'd

7/16/75

11/22/77

PARK·

AVON. MASS

02322

U.

SA·

TELEPHONE 617

588·7700·

TELEX

92·4444·

CABLE WESTCORP

Page

1/2

SERVICE BULLETIN

#83

con't

INSTALLATION

The

installation
ROTATION
This

transmission

models.
OPERATING
This

transmission

TEMPERATURE

compartment
mission
erally
escape

SHIFT
By

loosening

into

must

in

neutral
either
furthest
the

produces
FORWARD.

effect

FORWARD

oil
not
of

heated

CONTROLS

any

position

be

at

side

from

photograph

REVERSE,

If

occurs.

while

ANGLE

is

required.

should

be

exceeded

its

right
position.

of

neutral

the

below,

the

Shifting

shifting

angle

turns

is

air

not

air.

retaining

required

angles

The

shaft.

shifting

while

shifting

must

not

a RIGHT

cooled

The

exceed

if

the

Higher

screw,
for

to

the

control

position,

When

shifting

lever

the

aft

produces

exceed

HAND

and

propeller

proper

operating

230

degrees

engine

compartment

Temperatures

the

the

control

shift

lever

must

measured

the

shift

the

lever

towards

is

in

lever

toward

REVERSE.

180 to

ventilation

temperature

F.

risk

shifting

cable.

when

allow

at
lever
toward
the

the

down
the

the

horizontal.

on

the

This

is

oil

lever

the

1

3/8"

the

shift

is

vertical

the

propeller

position

flywheel

above

of

of

the

figure

vented

seal

can

The

control

shift

r.UNIMUM

lever

flywheel

end

the

end

engine

the

engine

trans-

will

for

damage.

be

rotated

lever

travel

hole

as

end

produces

opposite

produces

gen-

cable

is

in

PN

20629

Page

2/2

WESTERBEKE

SERVICE

ISSUED:
SUBJECT:
MODEL:
DISTR:
GENERAL

two

batteries to

from

a single alternator

lates

each

other.

of discharge).
ability,

It

also assures that ships' services

September
Alternator
All

Marine

Distributors,

DESCRIPTION:

battery

Changing

This

18,

1975

Output

Splitter

Engines

Shipments

The

splitter

be

recharged

as

large

so

that discharging

rates are in proportion to the

method

precludes the necessity,

of a rotary switch for selecting

battery.

MARINE"

ENGINE

BULLETIN

is a solid

and

brought to·the
as

120

cannot

PRODUCTS

amp

one

which

#87

state

same

and,

will

have
batteries'

battery

drain the

device

which

ultimate voltage

at

the

same

no

effect

voltage (state

and

even

is

to

engine

allows

time, iso-

on

the

the desir-

be

charged.

starting

INSTALLATION:

1.

Mount
in
system.

2.

Be
ated alternator.
from

solitter

an

air

stream

on a metal

if

Install with cooling fins aligned vertically.

sure to

use

a wire size appropriate to the output of the associ-

In

the alternator to the

batteries.

3.

Connect

4.

Connect

5.

Connect

TEST

INFORMATION:
minals
splitter

With

shOUld

the alternator output terminal to the center

one

splitter

the other

solitter

When

read

the

volta~e

terminal should read zero voltage.

the engine runnina

terminals shou1d.read the

regulator or

volts hiaher

. . .

This

somewhat

than

unit

is

less.

the readinas of the side terminals.

sealed for

surface other

available.

full

power

Do

systems

splitter

side terminal to

side terminal to the other battery(s).

the engine

is

not running, the side

of the respective battery.

and

alternator charging, the side

same

voltage

The

center

maximum

life

than

not

install

number 4 wire

and

from

one

which

splitter

and

the engine, preferably

near engine exhaust

is

recommended

the

splitter

to the

splitter

battery(s).

splitter

The

center

splitter

should

be

the voltage of the

terminal should read

is

not repairable.

Continued-Reverse Side

terminal.

ter-

.82

J H

WESTERBEKE

PN

CORp·

20701

AVON

INDUSTRIAL PARK·

9/75

AVON,

MASS.

02322

U.S.A.'

TELEPHONE:

617588·7700,

TELEX

Page

92·4444·

1/1

CABLE:

WESTCORP.

BY-PASSING
directly
#2

to terminal

done

simultaneously for

at,

the

SPLITTER:

from

same

alternator

A,

bypassing the

voltaQe

(state

In

the event of
by

connecting

both

batteries unless they are,

of charge).

failure,

splitter

either

itself.

batteries

splitter

This

may

be

terminal

should not

and

will

charged
#1

or

be

remain

ALTERNATOR

DRWG

-20701

,5PLITTER

I .

A

PNZ0654

Z

~+

STARTING

BATTERY(S)

-

FUSE

8+

SERVICE
BATTERV(S)

-

I

-

-

,STARTER

-

-

SHIP'S

SERVICE

LOADS

-

-

PpWER
DISCONNECT

SWITCH

9/75

WESTERBEKE

ISSUED:
SUBJECT:
MODEL:

DISTR:

Overleaf

September
Fuel

9, 1976

Pressure

All

Distributors,

1s

a parts

Switch

Shipments

list

and

of the fuel pressure switch

MARINE

SERVICE

ENGINE

BULLETIN

Installation

an

illustration

used

on

most

PRODUCTS

94

showing

of

our

the proper installation

'engine

products.

PIN

21564 .

J

H.

WESTERBEKE

CORP

..

AVON

INDUSTRIAL

PARK·

AVON,

MASS.

02322

U.S.A.·

TELEPHONE:

617

588·7700·

TELEX:

92-4444·

9/9/76

CABLE:

WESTCORP.

NeE

:-.:::=-~

~·A::::_

••••

FUEL

INJECTION

PUMP.

(ON

EN~INE)

.... 1 ... 1

••

VI.,._

••

COWD

rUY"I-1

c

•.

9

19187

flEK

NO.

SCREW

I

d

19

442

~t.,#Jr

WASHER

,

7 1 if!)

320

"0"

RINt::.

J1,"

OeD.

I

~

11388

FUEL

PReSSI.IRE

.sw/rCII

T I

5

/I

fDI5

PlU~

I ,

4

/9321

·0"

RII'llt;

-A,

O.D

•

.3

I

19185"

I

ADAPTER

2 I

1926/

I

COPP£~

iAlIISHE,

I I

192.04

I

SC~eW

Ass'", (8/.£'£D.

'TENlpAlC'r NO·1

DESCI</pTION

~.:=.IJ·

H.

WESTERBEKE

CO

AVON.

MA.

02122

.. c ......

t

~

".ACTIO

..

AL

1 /'\......-

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21743

,,".ULA"

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.•.•

,

PARTSLIST

CONTENTS

WESTERBEKE
WESTERBEKE
WESTERBEKE
WESTERBEKE
WESTERBEKE
WESTERBEKE

J

TYPE

J

TYPE

SUPERCEnF.D

L25:
L25:
L25:
L25:
L25:

L25:
MANUAL
MANUAL

PARTS

BL0CK
HEAD -MANIFOLDS
PUMPS -COVERS -ALTERNATOR
FUEL

SYSTEM

BACK

ELECTRICAL

TRANS~ISSION:

TRANSMISSION:

USED

END -STARTER

SYSTEM

EXTERNAL -REDUCTION

INTERNAL -CLUTCH

PRIOR

TO

SN

5375

101
105

109
113
117

119

121

125

128

WEST£RBEK£

L25:

100

WESTERBEKE

L251

BI.OCK

1

2

:3

4

5

6

7

8

9

HJ

1t

12

13

14
15
16

17

18
19
20

~1.

22-1

22-2

23-1
23-2
24-1
24-2
25-1
25-2

2~

27

28

29

32

33
34

3?

36

37

58

39

5~

51

52

53

54

55

;~

57

58

59-1
59-2
59-3

PN

21224
21225
21226
21227
21228
21229
212321
21231
21232
21233
21234
21235
21236
21237
21238
21239
212421
21241
21242
21243
21244
21245
21391

21.246
21392
21247
21393

21.248
21394
21249
2125121
21251
21252
21255
21256
21257
21258
21259
212621
21261
21262

21275

21276
21277
21278
21279
2128121

2j281
21282

21283
21284

212B5

21286

NAME
BI.OCK

PI.UG
PI.UG
PI.UG
PIPE
SUPPORT
BOLT
GASKET
SEAl.
PUMP

GASKET

F"ILTER
SWITCH
CRANKSHAF"T
STUD
NUT
SHAF'T
KEV
BEARING
BEARING
ROD
BEARING

ISOI.ATOR
PISTON
BOLT
RING
LOCKWASHER
CAMSIoIAF'T
WASHER
BEARING
BEARING
BEARING
SPROCKET
BEARING
RETAINER

CHAIN

TENSIONER
PAD
BOLT
BOLT

F'OLI.OWER
PI.UG
O-RING

DOWEL
SPROCKET

MOUNT
MOUNT
BOLT
WASHER
PETCOCK
SUMP
SUMP

PI.A

n:

REMARKS
CYI.!NDER-BARE

CORE
DIPSTICK

BORE
CORE
OIL

PICK-UP

OIL

SEAl.

OIL

OIL

SEAl.
SEAl.

SUPPORT

SUPPORT
OIL

OIL

OIL

PUMP

OIL
OIL

PRESSURE

STUB
STUB

SHAF'T

SHAF'T

STUB

CRANKSHAF'T
CRANKSHAF'T-HALF'

ONLY

THRUSTwCRANKSHAF'T
CONNECTING
CONNECTING

ROD-HALF'

ASSEMBLV

ISOLATOR

PISTON.COMPLETE

ISOI.ATOR

BOL.T

SET

F"I.AT-ISOLATOR-BOLT
CAMSHAF"T
CAMSHAF'T
CAMSHAF'T

F'RONT

CENTER

REAR
CAMSHAF'T
THRUST
CAMSHA'T

..

CAMSHAF'T

THRUST

BEARING
CAMSHAF'T
CAMSHAF'T
CAMSHA,T

CHAIN
CHAIN

TENSIONER

CAM

BLOCK

REAR

F'ACE

CRANKSHAF'T
F'RONT
F'RONT

LErT
RIGHT

MOUNT
CYLINDER

BLOCK

DRAIN

F"RONT

ONLY

F'OR

ONE

PISTON

1

3

1

1
1

1

4

1
1

1

1

1
1

1

6

6

1

1

1IIJ

2

4

8

4

4
4

1

4

1

4

1

1
1
1
1

1
1

1

1
1

1

8

1

1

2

1
1

1

8

8

1

1

1

1

101

BL.OCK

WESTERBEKE

L251

BLOCK

~rF'

;q.4

()0

()1

S2

()3

S4

S5

S6

S7

sa

S9

70

71

72

73

74

75

7~

71

7R

79

90

PN

21287
21288
21289
212921
21291
21292
21293
21294
21295
21296
21297

21298
21299
213v.10
21301
21302
213eJ3
21304
21305
21306
21307
213eJ8

NAME
NUT

SEAL
SCREw
GASKET
ADAPTER
ELBOW
OIPSTICK
TUBE
BRACKET
TUBE
PLUG
wASHER
WASHER
TURE
BOLT
LOCK

WASHER
WASHER
WASHER
WASHFR
ROLT
WASHER
WASHER

REMARKS

SUMP

REAR
SUMP
SUMP-ONE
SUMP
SUMP

PLUG

PLUG
DIPSTICK

DIPSTICK
DIPSTICK
OIL

GALLERY

ASSY-OIL

PICK-UP

TO

SUMP

SUMP

PLUG

BLOCK

PAIR

TUBE
EXTENSION

PUMP

RETURN

BLOCK

QUAN

1

1
18

1

1
1

1

1

1

1

1

4

2
1
1

1
16

1
1

3

:5
:5

103

WESTERBEKE

L25.

HEAD -HANlrOLDS

~A

/

104

WESTERREKE

L251

HEAD -MANIFOLDS

1

2

3-1

3-2

4

C;

6

7

8

9

1"1

11

l'

1.~

14

t'3

16

17

1A
19
20
21

?2

23

24

2C;

26

27

2A

29

30

31

32

33

34

3'3

36

37

38

..

1

38

.. 2

39

4

til

41

4~

43

44

45

4~

47

48
49

5V1-1

;ti!-2

PN

212188
21089

2j2J9~

21396
212191
212192
21093

21094

212195
212196
212197
21098
212199
21100
21101

21102

211013

211014

21105
2111216
21107
211Q18
211(19
211Hl
21111

21112
21113

21114
21115

21116

21117

21118
21119
21120

2j121
21122
21123

21124
21125
21126
21127

21.128
21129

21130
21131
21132

21133

21134
21135
21136

21137
21138

21207

HEAD
ROLT
GASKET
rLANGE
VALVE
VALVE
SPRING
RETAINER
SPLITCONE
SEAL
CQREPLUG
PLUG
SHAFT
PLUG

PIN

WASHER
WASHER
ROCKER
ROCKER
SPACER
SPRING
SUPPORT
BOLT
LOCKWASHER
PUSHROD
COVER
GASKET
SCREW
CLAMP
WASHF.:R
THERMOSTAT
HOUSING
GASKET
BOLT
HOSE
CLAMP
CAP
HOSE
NAMEPLATE
RIVET
MANIFOLD
SCREW
GASKET
ELBOW

PLUG

rILTER
STUD
SCREW

MA~IrOLD

SCREW
LOCKWASHER

GASKET

CLAMP

REMARKS
CYLINDER

CYLINDER
CYLINDER

HEAD
HEAD

EXHAUST

INLET

EXHAUST

VALVE
VALVE
VALVE

OIL-VALVE
CYLINDER

TEMPERATURE

SPRING
SPRING

STEM

HEAD

AFT

SENDING

ROCKER

ROCKER
COTTER·ROCKER

ROCKER

ROCKER

ARM-RIGHT

ARM·LEFT

SHAFT
SHAFT

SHAFT

HANO

HAND

END

SHAFT
END
END

ROCKER

ROCKER
ROCKER
ROCKER
ROCKER

SHAFT
SHAFT
SHAFT

SUPPORT
SUPPORT

VALVE
VALVE
VALVE
HOSE-BREATHER
VALVE

COVER
COVER

COVER

HOSE

SCREw

THERMOSTAT
THERMOSTAT
THERMOSTAT
THERHOSTAT
HOSE,THERMOSTAT

HOUSING
HOUSING
HOUSING

HOUSING
BREATHER
BREATHER
"WATERMOTA"-VALVE
VALVE

COVER

NAMEPLATE

COVER

INTAKE
INTAKE
INTAKE

BREATHER

MANIFOLD
MANIFOL.D

HOSE

TO

FILTER

AIR

INTAKE

AIR

AIR

FILTER

FILTER

BRACKET
EXHAUST
EXHAUST
EXHAUST
EXHAUST

MANIFOLD
MANIFOLD

MANIFOLD.CE~TE~

HOSE-MANIrOLD

MOUNTING
HaUNTING

OUT~ET

TAPPING

BOLT

AT

VALVE

PORT

COVER

QUAN

1
10

1

1

4

4

8

8

16

8

1

1

1

2

2
4
2

4

4

4

3

4
4

4

8

1

1

4

1

4

1
1

1

2

1

2

1
1
1

4

1

5

1

1

1

1
1

1

1

6

6

1

1

105

WESTERBEKE

L25:

HE.O -MANIfOLDS

106

WESTERBEKE

L251

HEAD • MANIfOLDS

~F'r

51
52-1

52

..

2

53
54
55

56

57

;8

59

Sfill

S~

S'­S3

S4
55
SA
S7
SR

PN

21139
19438
21141
21142
21143
21144
21145
21146
21147
21148
21149
21150
21151
21152
21153
21154

21155

21156

21157.

NAME

GASKET
ELROW

INLET
GASKET
SCREW
EYE
GUIDE
lOCKWASHER
lOCKWASHER
LOCKWASHER
LOCKWASHER
NUT
PLUG
ELBOW
CLAMP
CLAMP

EXCHANGER

CAP
ADAPTER

REMARKS

EX~AUST

EX~AUST.WATER

EX~AUST

EX~AUST

EX~AUST

MANlfOlD-rRONT

INJECTED
ELBOW
f"LANGE

fLANGE
LIF'TING
VALVE
THERMOSTAT
EXHAUST

INTAKE

AIR

FILTER

AIR

CLEANER
THERMOSTAT
MANIF'OLO
HANIF'OLD
HOSE-MANIfOLD
BUNDLE

HOUSING

flANGE

MANIFOLD

CAPSCREW

SCREW

BRACKET

STUD

TAPPING

INlET.MOLDED

ELBOW

INLET

ONLY

fILLER
BREATHER

HOSE

TO

BOLT

SCREW

F'It.TER

AND

REAR

Et.BOW

PORTS

QUAN

2

1

1

1

4

1

8

2

4
5
1

1

1

1

1

1
1

1

1

107

WESTER8EK[

L25,

PUMPS -COVERS -ALTERNATOR

50

33

53

49

51

1118

WESTERBEKE

L25:

PUMPS -COVERS • ALTERNATOR

1

3

4

5

6

7

8~1

~-?

Q

tvl

11-1

11-2

1:?-1

1'-2

t~-1

13-2
14-1

14-:>-

15

1';

17

1R

19

~0

21

2'

2~

24

25

26

27

2~

2Q

3Vl-:1.

3ri!-2

31.-1

31-2

3'

3~

34

35
36

37

3A

4/1

41

4'
43

44

45

4~

47

4A

21158
211621
21161
21162
21163
21164
21165
21386
21166
21167
21168
21387
21169
21388
211713

21.389

21111

213913
21172
21173
21174
21175

21176
21177
21178

21179

21182)
21181

211A2

21183

21.1R4

21185
21186
21187
21253

211A9
21254
21190

21191

21192

21193

21194

21195

21196

21197

21198

21199

212C'J0

21201

212v'2

21203

21234

21205

NAME
CASE

BOLT
SCREW
SPROCKET
RACE
RETAINER
BEARING
ALTERNATOR
RACE
ROl.T
CHAIN
BOLT
BRACKET
NUT
BOLT
STRAP
PLUG
ROLT
COVER
GASKET
PUMP
CLIP
RING
SPRING
PULLEY

F"LANGE
ROLT

ROLT
LOCKWASHER
BOLT
BOLT
WASH(R
AOLT
WASHER
aOLT
WASHER
RETAINER
nowEL
PULLEY
BOLT
WASHER

SEAL

SPROCKET
PIN
HOSE

CLAMP

TUBE
PUMP
nRI-VF
KEY
GASKET
BOLT
WASHER

REMARKS
CHAIN

BRACKET
PUMP

TO

DRIVE
RALL
BALL
NEEDLE

RACE

ROLLER

INNER

BALL

RACE
DUPLEX
ALTERNATOR
ALTERNATOR
ALTERNATOR

ADJUSTING
CHAIN

COVER
ADJUSTING
CHAIN
CHAIN
ASSEMBLY

CASE

CASE

..
LOCATING
VENTURI

WATER
WATER

WATER
CHAIN

CHAIN
CHAIN
CHAIN
CHAIN
CHAIN

PUMP
PUMP

PUMP
CASE

CASE
CASE

CASE
CASE
CASE

CAMSHAF'T

..

WATER

PUMP

CAMSHAFT
CHAIN

CASE

CRANKSHAF'T
CRANKSHAFT
CRANKSHAFT
OIL-FRONT
CRANKSHAFT
DRIVE
MOLDED
HOSE
HOSE
SEA
SEA

CONNECTING
WATER
WATER

nRIVE
SEA

WATER

SEA

WATER

SEA

WATER

CHAIN

CASE

RETAINER

HOLT

STRAP

COVER

WATER-CENTRIF"IJGAL

PULLEY

PULLEY

FLANGE

COVER
COVER

COVER
COVER

GEAR

PULLEY

GEAR

BOLT

COVER
PULLEY

PULLEY

BOLT

PUMP
PUMP

TO

COVER
PUMP
PUMP

QUAN

1

1

2

1

1
1

1
1

1

1

1

1

1

2

2
1
1

1.

1

1
1
1
1
1

1

1

4

5

3

7

1

12

1
1

2

4

1

2

1
1

1

1
1
1

2

4

1

1

1

1

1

2

2

109

W£ST£RBEKE

L25;

PUMPS -COVERS w ALTERNATOR

110

WESTERBEKE

L25:

PUMPS

-

COVERS -ALTERNATOR

F'

pr-,!

21236

212~7

21206
21209
21210
21211
21212
21213

21214
21215
21216

21.217
21218
21219
21220

21222
21223

~r:-

49

HI

;1

;2

;~

;4
;5
;6
;7

;R

;9

!I

91

S1

S2

5~

54 21221

55
59

NAME
HOSE

CLAMP
CLAMP
BELT
9USHING
LOCKWASHER
LOCKWASHER
BEARING

I~PELLER

SEAT
SEAL
SLINGER

IMPELLER

SHAFT
SEAL
O-RING
GASKET
WASHER

REMARKS
SEA

WATER
HOSE-SEA
HOSE-SEA

HOSE

REINFORCING

PUMP
WATER
WATER

ASSEMBLY·FRESH
F"RESH
F"RESH
FRESH
F"RESH
SEA
SEA
ASSEMBLY-SEA
SEA
SEA
CHAIN

WATER
WATER
WATER

WATER
WATER
WATER

WATER
WATER

CASE

PUMP
PUMP
PUMP

PUMP
PUMP
PUMP

WATER
PUMP
PUMP

COVER

OUTLET

LINE
FROM

PU"1P

WATER

PUMP

FRONT

BOLT

PUMP

COVER

QUAN

1
1
1
1
1

1

3

1
1

1
1

1
1
1

2

1

1

7

111

WESTERBEKE

L25:

FUEL

SYSTEM

112

WESTfRBEKE

1..25.

FUEL

SYSTEM

~F"F"

1-1

t-2

2

3

4
5
6

7

R

9

1"

11

t~

1~

14

15

17

18

19

2?J

21

2~

23

24

25
26
21

2A

29

3

til

31-1

31.-2

31-3

32-1

'3'-2

~'-3

33-1

33-2

34

31\

38

39

401
41
42
43
44

45

46
47

48

49

;~

PN

21.313
21314

21315
21316
21317
21318

21319

213221
21321
21322
21323
21324
21325
21326
21327
21328
21329

21330
21331
21332
21333
21334
21335
21336
21337
21338
21339
213421
21341
21342
21343
21344
21345

21346
21347
21348
21349
21350
21351
213';2
21353

21.354
21355
21356
21357

21358

21359

21360

21361
21362

21363
21364
21365

NAME
PUMP

PRIMER
GASKET
SCREW
LINE
FILTER
BRACKET
ELEMENT
SCREW

LINE
LINE
VALVE
VALVE:
ROLT
PLUG
KIT
PUMP
STUD
WASHER
NUT
GASK£T
LINE
LINE
LINE
LINE

CLAMP

INJECTOR

STUD

NUT
WASHER
LINE
LINE
BANJO
LINE
LINE
BANJO
LINE
LPJE
BOLT
WASHfR
WASHER
WASHER

TERMINAL
CARLE
CLAMP

ARM
BRACKET
SPRING

NUT.
F'ERRULE

WASHER
NUT
LOCKWASHER

REMARKS
FUEL

FUEL
FUEL
FUEL
Ln"T

LIfT
LIFT
LIFT
LIFT
PUMP

PUMP
PUMP
PUMP
TO

FILTER

MOUNTING

FUEL
LIFT
FUEL
FUEL
FILTER

INJECTION

PUMP
F'ILTER
FILTER

TO

INJECTION

PUMP

MOUNTING

PUMP

DRAIN

TO

FILTER

NON-RETURN
CONSTANT
BANJO.rILTER

BLEED

VENT
FILTER
DIAPHRAGM-LIFT

PUMP

INJECTION

INJECTION
INJECTION
INJECTION
INJECTION

PUMP
PUMP
PUMP
PUMP

MOUNTING
MOUNTING
MOUNTING

#1

#2
#3 1
#4 1

FUEL

LINE

(PAIR)
INJECTOR
INJECTOR

ASSEMBLY-INJECTOR
RETURN-INDIVIDUAL

ASSEMBLY-RETURN
RETURN-EXCL

RETURN

ASSEMBLY-CONSTANT
CONSTANT

SEAT

RETURN
EXCL

FROM

BANJO'S

LINE-INJECTOR

BLEED

BLEED-EXCL

BANJO'S

INJECTOR

TO

FILTER

BA~JO'S

TO

FILTER

QUAN

1

1

1

2
1

1

1
1

2
1
1

1

1

1
1
1
1

3

3

3

1

1

1

2

4

8

8

4
3

3

1
1

1
1

BANJO
BANJO-INJECTOR

12

BANJO-FILTER
BANJO-FILTER

ATTACHMENT

F'UEL

PUMP

HEAD

TO

STOP

FUEL

P·UMP

CABLE
THROTTLE

THROTTLE

STOP

FUEL
rUEL

CABLE

LINE
LINE

RETURN

7
1

4

1

3
2
1

1

1
1

1

6
6

2

2

2

113

WESTERBEKE

L25.

FUEL

SYSTEM

114

WESTERBEKE

L251

FUEL

SYSTEM

~~r

51

52
53

54
56

57
58
59

50!
51

S2

53
54

55

PN

21366
21367
21368
21369
2137"
21371
21372
21373
21314

21375
21376

21.377
21378
21319

NAME

WASHER
BOLT
LOCKWASHER
WASHER
SCREW
LOCK

WASHER
PIN
PIN
SCREW
BOLT
NUT
LOCKWASHER

NO~i!LE

COVER

REMARKS

SHAKEPROOF'

SPLIT
ANCHOR
CLIP
EXTENSION
EXTENSION

BOLT

INJECTOR
INJECTION

PUMP

QUAN

2
2
2

8
2

2
2

1

1

2
2
2

1

1

115

WESTERBEI<E

L25t

BACK

E

ND

•

STARTER

349

501i

347

---

____

_

381

504

504

116

WESTERBEKE

L25'

BACK

END -STARTER

~F'

F"

1.

2

3
4

5

15

11>
17

26

4

ill

4t

4'-

43
44-1
44-2
44-3
44-4
46
41

48

49

77

90!

91

92
93

94

PN

213821
21382

21383

21384
21385
21238
21239
212421
21395
21263
21264
21265
21266
21267
21268
21269
21213
21271
21272
21213
21274
21305
21308
21309
213UI
21311
21312

NA~E

MOTOR
BOLT

NUT
LOCKWASHER
PINION
STUD
NUT
SHAF'T
BOLT

n.

YWHEEL
WEIGHT
BOLT
DOWEL
HOUSING
HOUSING
HOUSING
HOUSING
BOLT
PLATE
SCREW
SCREW
LOCKWASHER
LOCK

WASHER

SEAL
STUD
LOCKWASHER
NUT

REMARKS
STARTER

STARTER
STARTER

MOUNTING
MOUNTING

ASSEMBLY
STUB
STUB

SHAFT
SHAFT

STUD

STUB
STARTER

MOUNTING

FLYWHEEL

F'LYWHEEL

F'LYWHEEL~BW

F'LYWHEEL-TMP
FLYWHEEL

.. J TYPE

TYPE

TYPE

... i TYPE
HOUSING
HOUSING

HOUSING

COVER

COVER
HOUSING

FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL

HOUSING
HOUSING
HOUSING
HOUSING

BOLT

PLATE

STUD
STUD

QUAN

1

1

1

2

1

6
6

1

1

1

1

6
3

1
1

1

1

4

1

2
2
6

2

1

4
4
4

117

DRWG

DEC

WESTERBEKE

I N:'TRUMENT PANEL AS!>EMIILY I

r------------""--:.---

:

~W.T.G.

1

I

I

I

I

1

1

L!

__

_

19201

7~

L251

....

....

'

ELECTRICAL

...,

®

r~

II

oPTIONAL

I

ALARM

1 I

I I

I I

I :

I

I

I'"

~.,.

I

1

I

I

1

I

I

I

1

OPTIONAL L
SPLITTER

91~~~~~

XE

@,

·°"_1

NOT'E-I •

SYSTEM

WIRING

IN3f!T

L-~~!.~~!Oll.

qf

rn

j"""'

',",-'""

: I

I

I

L

--

I"","UsrJ

I _

~

.....

• +

~

!

@IOAr-,

'EE

NOT[-C

f'0f!

- J

SEE

MOT.'"

...

-'~

L;

t:;

Iii

II
i

•

r

I

•

!

~

I ) I

L I I

~.~

118

I

L

_____

~!!

_____________________

L-

__________

-=~~D~~~.

________________

~~.!.:!..

______

~

_'

i

I

5WI-I

-+

WESTER8EKE

L25'

ELECTRICAL

SYSTEM

~rF'

1

2

3

4

(,

A

1t
12
13

2CJ1

25

26

27

29
301

31

32

3~

39

4t

42
44

45

46

PN

19165
11917
19166
19168

11.957
21386
11383
19167
19169
213AiZJ

192CJ19

192~8

192~6

12885

192~3

11675
11532
11432

16~23

192~5

19216

20654
20946

2~947

NAME
AMMETER

TACHOMETER
GAUGe:

GAUGe:
SWITCH
ALTERNATOR
SWITCH
SENDER
SENDER
MOTOR

CABLE
HARNESS

CARLE
PANEL
PANEL
CABLE
KIT
LAMP
RING
HARNESS
HOLDER

SPLITTER
BREAKER
BREAKER

REMARKS

HOUR
OIL
WATER

METER

PRESSURE

TEMPERATURE

PUSHBUTTON
F'UEL

OIL
WATER

N.O.

PRESSURE

TEMPERATURE

STARTER

INSTRUMENT

PANEL
ENGINE-INSTRUMENT
STARTING
LESS

PANEL

INSTRUCTIONS
START-PREHEAT
ALTERNATOR

TO

REGULATOR

SUPPRESSION-ALTERNATOR
ADAPTER

ENGINE-STARTING
LAMP
OPTIONAL
CIRCUIT
CIRCUIT

...

1WJ

..

4QJ

AMP

AMP

QUAN

1

1

1

1

2

1

1

1

1

1
1

1

1

1
1

1

1
4

3
1

4

1

1
1

119

J

TYPE

MANUAL

TRANSMISSION.

EXTERNAL ~ REDUCTION

120

J

TYPE

MANUAL

TRANSMISSION:

EXTERNAL -REDUCTION

1.

2

3

4

C;

6

1

A

9

11'1

11

t'

13

14

t5

16

17
1R-1

tR-2

1R-3

19

2~

21
22
23

24

25

21>

27

~8

29

3ri.1

31

32
33

34

35

31>

37

3R

39

4V1

41.

4'-

43

44

45

46
47
4R
49

;V!

;1

PN

21212~

212J19
21421

21iU8

2"'991

21~~7

20985

212J11
212J12

214~1

20987

21302

2121213

21~13

2121UJ

212J09

2~994

21441
21439

21438

214OJ1

20989

20987

201996

21~0eJ

212101

20999

2UJ60

2~998

291997

2099121

210992

2"'986

21416

2141214

20992

20986

21443

212122
212123

2111J24

2112125

20989

2a993

21401

2~98.9

20987

2141212

21416

21419

2141218

21.420

2t2l26

HOUSING

GASKET
SEAL
DIPSTICK
PLUG
SCREw

NUT
COVER
GASKET

STUD

NUT

PLUG

WASHFR

NAMEPLATE
PIN
GASKET
BEARING

MOUNT

MOUNT

ADAPTER
STUD
LOCKWASHER
NUT
SEAL
COUPLING
COUPLING
COUPLING

KEY

NUT
RING
COUPLING
BOLT

NUT
SCREW
BUSHING
BOLT
NUT
P.IN
HOUSING
COVER
GASKET
SCREW
LOCKWASHER
BOLT
STUD

LOCK

WASHER
NUT
ELBOW
PIPE
CLIP
SCREW
WASHER

SPROCKET

REMARKS
rOR

TRANSMISSION
SUPPORT
CROSS

TRANSM
DRAIN-TRANSM
SET-BAND

rLANGE

SHAF'T

HSING

OIL

HSING

ANTI-RATTLE

TO

LEVEL

LOCK

INSPECTION

INSPECTION

OIL

rILLER-INSPECTION
FIBER-OIL
ENGINE
BRASS,SECURrNG

TRANSM

RALL-MAIN

COVER

FILLER

TO

PLUG

IDENTIfICATION

NAMEPLATE

HSING/REDUCT

SHAFT
REAR -LOW
REAR -HIGH
USED
SECURES
FOR
FOR
OILwAF'T

WITH

STUD
STUD

END

21439

AFT

MOUNT

BEARER

COVER
a-RING
WASHER
HALr"TRANSM
SHArT

TO

SECURES

HSING

COUPLING

COUPLING

TO
COUPLING-PILOTING
SHAFT

HALF
COUPLING
SELF-LOCKING-FOR
SHAFT
SHIFT
CLAMP-SHIF'T

LOCK

LEVER

LEVER
SELF-LOCKINGwfOR
TRANSAX.SECURES
REDUCT
REDUCTION
REDUCT

TRANSMISSION

TRANSM

TRANSM

BOLT

CLAMP

LEVER

HSING

COVER
RUSHING
FOR

BUSHING
SECURES
SECURES

SCREW

REDUCT

CASE

REDUCTION

DRAIN
SET
DRIVE

TRANSM

TRANSM

COVER

ALSO

OR

BEARER

MAIN

BOLT

TO

HSING

TO

GB

CASE

TO

HSING

HSING

USED

DO

SHAFT

GB

ON

00

QUAN

1

1

2

1

1

1

1
1
1

4

4

1

1

1

2

1
1

1

1

1

6

6
6

1
1

1

1

1

1
1

1

3
3

2

·1

1

1

1

1
1
1

8

8

.3

3

6

3

1

1

1

1

1
1

121

.

J

TYPE

MANUAL

TRANSMISSIONI

EXTERNAL.

REDUCTION

122

J

TYPE

MANUAL

TRANSMISSIONI

EXTERNAL.

REDUCTION

~rl="

5t'

,3

54-1
54

...

2

;5-1
55-2

;6

57

SA

;9

SOl
St

S~

S~

S4

se;

Sf,

S1

SA

S9

PN
212'28

21~27

21Z1r;,S

210eJ6

21030

212'31
21a29
212160

21a04

21~:53

212134
21398
21417

21~08

21412
21397
21415

21.413
21399

2140.10

NAME
SPACER

BEARING
CHAIN
CHAIN
SPROCKET
SPROCKET
SHAFT
KEY
BEARING
CIRCLIP
SEAL
COUPLING
LEVER
COVER
BRACKET
BRACKET
ELBOW
CONNECTOR
PLUG
WASHE:R

REMARKS

fOR

DRIVE

BALL

..

AFT
TRIPLE-50
TRIPLE

SPROCKET

TOP

LINKS

..

46

LINKS

DRIVEN-3aT

DRIVEN-31T

LOWER·REDUCT
fOR

DRIVEN

BALL-LOWER

SPROCKET

SHAFT

OIL
HALf-TRANSM

SHIfT

AFT

ASSEMBLY

END-REVERSE

SUPPORT.

HSING

REAR

ENGINE-VERTICAL
SUPPORT-REAR
fOR

WATER

COOLED
STRAIGHT-fOR
DRAIN-AfT
fIBER-fOR

BEARER-fOR

DRAIN

GEAR

fOR

fLEX

TRANSM

COUPLING

HSING

ENGINE-STARBOARD

TRANSM

WATER

COOLED

WATER

PLUG-FOR

TRANSM

COOLED

WATER

TRANSM

COOLED

QUAN

TRANS

1
1

1

1
1

1

1
1

2

1

1

1
1
1

1

1

1
1
1

1

123

J

TYPE

MANUAL

TRANSMISSION'

INTERNAL.

CLUTCH

1

2

3

4

r;

,

"

A

9

1"

11

12

t~

14
115

16

17

1A

19

291

21.

22

23

24

25

26

27
2A

29

3"

32

33

34

3'5

36

37
38

39

401

4:1.

42
43

44

4'5

46

*

PN

2UJ61
21062

21063
2UJ43
21044
21054
212149

21.2148
2Ul47

212167
2UJ64
212165

212166
21079
2t:fJ5f2J
212152
212151
2HJ53
212145
212186
20988
2UJ87

2UJ74

212169

2121721

212172
2121821
2UJ71
2UJ73
212178
2141t15
21442

21414
21068
212157

212184

2UI77

212183

21085
212158

21076
212175

212155

2UJ57
212156

NAME

GEAR

BUSHING
KEY
DRUM
BUSHING

CONE

PLATE
STUD
STUD
PINION
BUSHING
PINION
ROLLER
DISC

HEAD

DISC
DISC
DISC

PLATE
CLIP
LOCKWASHER

SCREW
TOGGLE
TOGGLE
TOGGLE

PIN
PLUNGER
PIN
PIN
COLLAR
LEVER
PIN
SHAFT
CAMPLATE
PIN
SHOE
CAMSHAFT

ROLLE:R
PIN
BANDS
LOCK
NUT

PIN

PIN
PIN

REMARKS
FORWARD

PILOTING-FOR

CONE~FOR

STUB

SHAFT

GEAR

TRANSMISSION

DRUM
SPLIT

FORW~RO

LONG
SHORT
LONG-WITH
LONG
SHORT-WITH

PUSH

PINION

PINION

BUSHING

PINION

NEEDLE

ROLLER
NEEDLE
THRUST

CLUTCH-WITH
CLUTCH-WITH
CLUTCH-WITH
DRUM

ARM

LUGS
TEETH
THICK

LUGS
ADJUSTING
SET-FOR

ASSEMBLY~WITH

LINKS
FOR

CLIP

ONLY

TOGGLE

PLUNGER

(SET

AND

PLUNGER

3)

SPLIT

ASSEMBLY~OPERATJNG

FORK
TRANSAX-PAIR
CROSS

SPLIT
CAM

WITH

ROLLER

AND

PIN
CAM
FOR

CAM

ROLLER
BRAKE-WITH
FOR

BRAKE
ADJUSTING-BRAKE
LINK

..

STARBOARD
SPLIT-FOR
LINK-PORT

LINK

PINS

BAND

BAND

LINK

PINS

(SHORT)

SIL

QUAN

1

1

3

1
1
1
1

2

2

2

2

2

2

1
1

4

4

1
1

1
1

1

3

3

3

6

3

3
6

1

1

2

1

1
1

1

1
1
1
1

1
1

1

1

1

*31

21406

SHOE

125

,

,

,

,

,

,

,

,

,

,

TVPE

J

MANUAL

TRANSMISSIONI

INTERNAL • CLUTCH

~F'~

47

4A

49

;"'-1

5&'1

.. 2

H.

;'-

;3

54

55

PN

21444
212'81

21382
212116

21317

212160
212159
212146
212115
212114

NAME
P I

~~

PLATE
SHAFT
SHAFT
SHAFT
KEY
GEAR
BEARING
CIRCLIP
BUSHING

REMARKS

TRANSAX·rOR

LINK

LINK
CROSS/LINK

SPACER
MAIN-DO
MAIN-REDUCTION
MAIN
MAIN
BALL

MAIN

SHAFT
SHArT

..

ORUM
SHAFT

TO

TRANSM & COUPLING

ARM

PLATE

PINS

(PAIR)

tlUAN

2
2

1

1

1

1
1

1

1

1

127

SUPERCEDED

PARTS

USED

PRIOR

TO

SN

~375

1

,

3

4

5

6

7

R

Q

1~

1t

1~

1~

14

15

t~

17
1R
19

2~

21

~,

2~

24

2'5

2~

27

2R

~9

371

31

3'

33

34

3'5

36
37

21441
21432

21.427
2141i19

212140

214"3
214U'

21429
21423
201984

212138

212138
21428

21422

21435

2~995

212,39

212141

214~3

21188

212135

2t4~5

214~7

21436
21431
212142

212J37
21437
21426
21036
21434
21430
21Z21
212132
21424
21445
21446

NAME

EXCHANGER

BRACKET

OUTU::T
MANIF'OLD

EL.BOW

REND
ALTERNATOR
BRACKET
RELAY
STARTER
SOLENOID
SWITCH
DRIVE
AL.TERNATOR

8RACKET

REGULATOR
SOLENOID

PULLEY

ROLT
BOLT
STRAP
HOUSING

FLANGE

COUPLING

HOUSING

ALTERNATOR
STARTER
HOUSING
COVER
GASKE"
STUC
NUT
SEPARATOR
HOSt
CAP

SLrEVE

PU~1P

REMARKS
FORWARD

FORWARD
FORWARD
EXHAUST

EXHAUST
EXHAUST

12/24

ALTERNATOR
STARTER-12/24

12/24

STARTER-12/24
SERIES-12/24

ASSEMBLY-TAC~OMETER

24

VOLT
ALTERNATOR-24
24

VOLT
STARTER-24

ALTERNATOR~24

CHAINCASE
CHAINCASE

ALTERNATOR
TACHOMETER
TACHOMETER
TACHOMETER

FLYWHEEL.
12

VOLT

12

VOLT

(LYWHEEL
ROCKER
ROCKER

ROCKER
ROCKER

OIL

AREATHER
OIL

rILTER

OIL

FILTER

FUEL

(SN
HEAT
HEAT

(SN

~ANlrOLD

MANIFOLD-45

VOLT

VOLT

VOLT

SYSTEM
SYSTEM

DOWEL

(SN

(SN

SYSTEM

SYS-BTM

(SN

(SN

COVER
COVER
COVER

(SN

172-4075)

(S~

INJECTION

172.3372)
EXCHANGER

EXCHANGER

172~3372)

(SN

172~3372)

DEGREE
SYSTEM
(SN

SYSTEM

VOLT

(SN

172·6073)

VOLT

SYSTEM

(SN

SYSTEM

SYSTEM

172-6~73)

172-6073)

(SN

(SN

(SN

(SN

6173-16974)

VOLT

VOLT

VOLT

172~17374)

ADJUSTING
QRIVE
DRIVE
DRIVE

172~16974)

MTD

17074~21475)

SYSTEM

(SN

6173-16974)

SYSTEM

SYSTEM

(SN

172~17374)

(SN
(SN
(SN

(SN

17074-4175)

SOL

(SN

(SN

6~73-1~974)

6A73-16974)
6073-16974)

172-23074)

(SN

172w23074) 1

(SN

172-23074)

(SN

172N23~74)

172"4075)

(SN

172-4~75)

CAP

(SN

172-4~75)

(SN

172-4075)

(SN
(SN

(SN

172.3372)

172-3372)

(SN

172-3372)

(SN

172-6073)

172-6073)

172-6073)

172-6073Y

(SN

6173-16974)

6173-16974)

(SN

6173-16)74)

6073-16974)

17974-21475)

QUAN

1
1
1
1

1

1
1

1

1

1
1

1

1
1

1

1
1
1
1
1
1
1

1

1

1

1
1

1

1

1

1

1

1

1

1

1

128