Westerbeke WPDS-20 Technical Manual

TECHNICAL

MANUAL

WESTERBEKE 60

Marine Diesel Engine

WESTERBEKE

WPDS-20

Marine Diesel Generator

Publication #15204

Edition

September

Four

1979

j'-.v-

~

'WESTERBEKE

WESTERBEKECORPORATION MYLES 150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

TECHNICAL

MANUAL

WESTERBEKE 60

Marine Diesel Engine

WESTERBEKE

WPDS-20

Marine Diesel Generator

Publication #15204

Edition

September

Four

1979

j'-.v-

~

'WESTERBEKE

WESTERBEKECORPORATION MYLES 150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

SECTION INDEX

GENERAL

Introduction Operation Installation Maintenance

ENGINE OVERHAUL

3

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 TION.

FAILURE BUT

IT

READ KEEP KEEP

YOUR

IS A DETAILED

CONTAINS

IT IT

IN A SAFE

IT

HANDY

TO

DO

SAFETY

SO

INTRODUCTION

OF

IS

FOR WILL

AS

YOUR

WELL.

GUIDE

WESTERBEKE

VITAL

TO

PLACE REFERENCE

INVITE

TO

THE

MARINE

THE

ENGINE'S

AT

ALL

SERIOUS

INSTALLATION,

TIMES

RISK,

DIESEL DEPENDABLE,

NOT

ENGINE.

ONLY

TO

START-UP,

THE

LONG

YOUR

TERM

INVESTMENT,

5

OPERATION

INFORMA-

OPERA-

UNDERSTANDING

The

diesel gasoline is

essentially

are

arranged

its

crankshaft

as

that same connecting reverse

Therefore,

that a diesel preventative intelligent oline are

proper ricating of

fuel

the

time frequent water, is

also factor "high designed

The gasoline handling retor with ponent -the performs

Unremitting factory engine of

dependable urer treatment part

engine

above

of a gasoline

sort

of

valves,

rods,

and

reduction

maintenance

operator

engine.

maintenance

and

cooling

and

lubricating periods checking

sediment

essential.

is

the

detergent"

specifically

diesel

engine, and

firing

and

ignition

and

in

their

Fuel

the

function

have

capable

cannot

rests

resulted

control,

it

receives

with

THE

DIESEL

engine

inasmuch

the

same. its

is

of

lubricating

it.follows

engine

The

most

specified

for

etc.)

Another

use

of

diesel

engine

however,

its

systems place Injection

care

and

of

many

service.

you!

....

closely

closed

the

engine;

camshaft,

gear.

requires

would

of

systems.

filter

contamination in

the

lubricating

for

does

fuel.

of

attention

in a Westerbeke

thousands

What

however,

in

resembles

as

the

mechanism

Its

cylinders

crankcase;

same

general it

has

pistons,

system

to a great

the

as

that

which

give

to a gas-

important

the

fuel,

Replacement elements

is a must,

the

fuel

important

same

brand

diesel differ in

are

is a single

Pump -which

both.

service.

the

The done

the

is

engines. from

method

of manufact-

the

type

the

and

extent

same

factors

lub-

and

(i.e.

system

of oil

the

carbu-

away com-

at

the

hours

This

the

any

at

of

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

to

parts,

frequently

SETS

propulsion

except

of

the

is

provided Sets,

replacement

the

number

if

Be

sure and

insist

power.

all

sections.

upon

because not as

original

diesels

of

boats

details

in

regard

Installation,

Section

parts

complete

(see

not

part

to

include

serial

Westerbeke

"will

made

For

in

to

are

and generator of

to

Additional

the

T.

are

part

separate

of

this the

number.

fit"

the

same

equipment.

used

this

section

for

generating

Manual certain Operation

needed,

descrip-

Parts

pub-

Also

factory

parts

both

set

app-

por-

and infortitled

6

FOREWORD

Since details this

well gines. because

the the the

operator conditions

of section understood

However,

it

reasons installation installation

the

boats

engine

to

is

why,

should

for

INSTALLATION

in

which

installation advise and

the

valuable

the to

which

have a thorough

the

boatyards

well

the

engine

developed

following

in

precautions

operation

should

these

explaining

and

engines

are

and

outline

to

of

have a periodic

understanding

correct

are

equally

engine

procedures

of

general

the

functions

be

watched

the

engine.

procedure

used

so.

It

installers

for

and

check to

for

are

many and

is

not

on

installation

procedure

of

each

the

relationship

There

insure

and

its

are of good

servicing.

varied,

the

purpose

the

generally

of

is

included

component,

details

which

the

operating

7

of

en-

of of

INSPECTION

The mounted cessory

small

crate.

Before

transportation

be

opened

cealed cealed the

delivering damaged of

the

and

make

ancies.

loss

or

must

be

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 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

all

attached

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

been

of

slings

not

lifting

Strain

must

the

valve

in

moving

in

Eliminate

avoiding

from

the crated.

in a separate

with

the

from

crate

made

visible

should

"Received

check

packing

of

any

loss

not

lifting

be engine to

this

designed

the

engine,

are

not

be

so

eyes

on

not

be

A

spacer

two

lifting

cover

engines

used

and

is

place.

see

haste.

coupling,

factory

engine

the should

for

con-

or

con-

require

contents

list

discrepagainst or

damage

to

J.

rings.

at-

lifted

sling.

to

re-

short

in

sig-

the

in

excess

bar

studs.

amply

Move

that

possibil-

Do

as

is

or

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

in the

bond

weakened

this

with

coupling.

cases

engine

position.

be

lugs,

be and damage dirt

been

as

it

upwards,

of

weight

and

machinery.

recommended appropriate

flexible preferred is

weakened

the

to

pos~tion

in

lowered

which

is

to

reduce,

water

etc.

removed

special

to

entering

removed

soon

is front

very

damage

may work competent

the nut down be

between

by

it

extremely

necessary

the carefully

on

lifted.

at

crowbar,

may

be

necessary

other

such

any

as

mounts.

because

lag

or

its

than

It

may

endwise

cannot

to

some

as

generator,

tank,

This

end

bear.

all

accessory

by a competent

care

should exposed openings.

should

the

restriction

to

upwards

attachment

to

the

be

done

in

that

bronze

size

be

their

every

top

the

time

bolt

is

removed

The times, bolt

removal.

as

you

the

regular

be

that

through

be

made

restricted

extent,

filters,

be

parts

The

be

returned

hoist

or

of

to

avoid

parts

It

is

best

by

someone

the

handling

hanger used Lag

stays used

through screws hold

they

in to to

bolt

as a stud,

and

the

may to

the

a

larger.

it the

equip-

taken

and

parts

has

the

reverse

slings

the

on

if

on are pos-

tightpermit

itself

wood

8

FOUNDATION

A

good toward engine.

engine

the

The construction when

subjected position the keep andths

times.

push

the bearing engine

In

similar hulls to

the bolts reducing

The a

pair

be

resisted.

engine

hull.

the

effects

the

engine

of

an

It

of

the

propeller

in

bolts

fiberglas

wooden

be

formed

hull

to

be

noise

temptation

of

fiberglas

vibrations Flexible

foundation

are

to

do

bed

design

FOR

ENGINE

bed

satisfactory

engine and

neither

to

the

boat

may

of

rough

within

inch

has

of

to

withstand

propeller

shaft,

the

engine

and

engine

hulls,

stringers

and securely. installed

and

Such

mounts

against

their

"A"

job.

and

contributes

operation

bed

must

deflect engine have

seas.

one

this

position

which

to

the

and

finally

bed.

we

recommend

as

fitted,

This

firmly

transmitted

to

install

"angle

construction

to

pass

through

require

which

to

When

avoid

bed

GOOD

much

be

of

nor

weight

to

take

The

bed

or

two

the

forward

is

applied

thrust

in

wooden

then

glassed

allows

in

wood,

vibration.

the

engine

irons"

will

a

firm

react

possible,

design

of

the

rigid

twist

or

under

must

thous-

at

all

washer

to

the

that

hanger

thus

should

allow

to

the

if

they follow

"B".

the

to

on

PROPELLER

Each

Westerbeke

larly

fitted connecting engine.

The

coupling

power

must or bearing gear

is

of

also

astern

housing

very

which

carefully

fit.

For

all coupling, specific either of

the

The

has

clamping

forward

has a long

should

be coupling the

shaft

be

scraped

fit.

It properly coupling. the

keyway

touch

the

coupling.

If

it coupling be

expanded

ing

water. coupling the

centerline shaft.

COUPLING

with a suitable

the

propeller

must

the

engine transmit from

the

is

built

of

the

engine

bored

order,

to is

a keyway

type.

end

straight

removed

should

and

is fitted

very

top

seems

over

must

be a light

the

down

or

important

both

The

key

closely,

of

the

difficult

the

by

heating

The

face

be

exactly

or

Diesel

engine

is

coupling

not

to

turn

the

thrust

shaft

into

engine.

machined

shaft

only

to

the

the the

This

for

to

the

transmit

shaft,

either

thrust

reduction

coupling

accurate

models, a propeller

shaft supplied.

of

from

shaft

filed

should

shaft,

size

with

set

the

keyway.

the

should

in

that

to

the

but

keyway

to the

in a pail

of

the

for The

screws

propeller

Any shaft drive

not

order

the

key

shaft

fit

the

should

in

the

drive

coupling

propeller

the

coupling

burrs

end. fit

to

and

side

the

of

perpendicular

axis

of

the

propeller

regu-

ahead

or

shaft

on

have

get

be

not

hub

boil-

for

the but

half-

is

The

to

a

the

of

can

to

A

PROPELLER

The

type

with

the

to

fit

tests.

engine,

the

To

and ditions, ler

which

its

full

under

normal

ALIGNMENT

The

engine aligned matter

boat some its usually

what

it extent

shape

with

will

realized

operated

very

important

and

size

gear

ratio application utilize

to

achieve

it

is

desirable

will

permit

rated

speed

load.

OF

ENGINE

must

the

propeller

material

be

found

and

the

to a greater

when

in

the

water.

to

of

and

the

at

be

is

boat

check

propeller

must based full

power

ideal

to

use a propel-

the

engine

full

properly

shaft.

used

to

be

flexible

hull

extent

it

is

launched

It

is

the

engine

varies

be

selected

upon

boat of

loading

to

throttle

and

to

build

will

than

therefore

the

con-

reach

exactly

No

a

to change is

and

align-

9

ment any

at

errors

Misalignment

propeller

which

It rapid reduce the shaft

and

will

hull

it

are

shaft

the

will

is propeller straight.

One

particularly alignment oil

through make limits

or lings force all

the

sure

prescribed.

The

engine

bed

shims

can and

around. foundation

the

approximate rately

determined.

Never

the

boat the

water assume

to water usual main ging

its

do

the tank equipment

mast

has

Take alignment anything

The

alignment

can

be

slipped

the

counterbore feeler come two should

gauge

exactly

halves

be

I

\

frequent

when

shaft blamed

create

wear

life

fastenings.

have therefore shaft

may

be

the

that

should

and

supported

until

be

brought

so

that It

for

attempt on

land.

and

have

final

alignment

about

has

been

accomplished.

plenty

less

and

of

do

than

indicates together

of

the

parallel

intervals

they

may between is

the

often

excessive

and

will,

of

the

A

exactly

necessary

itself

annoying

leakage

rear

oil

alignment

be

on

the

two

together

the

flanges

is

best

the

foundation

alignment

a

final

The

had

water

with

half

on

full board stepped

time

not

be

perfect

is

correct

backwards

very

easily

at

propeller

within

~

\

and

appear.

the

engine cause on

other

bearing

in

hull

by

bent the

same

be

perfectly

of

transmission

seal. is

within

moved

the

halves

not

to

has

alignment

boat

should

an

opportunity

form.

the

and

in

making

satisfied

results.

when

and

that

the

all

coupling

0.002

to

correct

and

of

troubles causes.

wear,

many

cases,

loosening

propeller

effect

that

the

result

of

Check

the

around

on

screw-jacks

of

the

coupwithout meet

evenly

drill bolts been

the

until

accu-

with

be

It

is

best

fuel

and

all

the

after

final

the

rig-

this

with

the

shaft

forward

into when a flanges

points.

inches

/

the

mis-

to

using

in to

The

(A).

In

making

the

engine

one

position propeller coupling

half

coupling

in 900 between also

check

ling

is

Then,

position rotating position

The after to

three alignment found

whether

in

exact

keeping

the the each

engine

the

boat

weeks

remade.

that

the alignment. was

improperly

the

boat

has final stringers

moisture. align

and

hauled water, The very

coupling In bent to

water

dry

EXHAUST

erably particular

are mum

sea cannot should between the

makes

in followed straight sion fill exhaust

wet

salt

shape

have

It

at a further

The

coupling

the

bolts

out

or

and

during

flexibility

severe

or

some

cases

by

these

small

boats

when

not

for a considerable

SYSTEM

Exhaust

and

line each job.

to

provide

of

restrictions

water,

get

rain back

be a

the

discharge

it

difficult

very

far

by a

gradual

or

trough

with

water

gas.

Brass

or

exhaust

water

and

the

final

coupling

and

the

alignment

tested

each

of

four

each

position.

the

alignment

the

propeller

alignment

engine

half

900 from

alignment

has

been

and,

if

It

engine

This

in

not

done

taken

and

the

at

some

engine

probably

may

even

period.

should

removed

moved

from

storage

of

the strain both

the

on

when

shaft

strains.

that

are

in

use,

installations

must

an

The

outlet

be

general

and

water,

into

the considerable exhaust

end.

manifold This

for

by a wave;

long

slope

slope.

to

the

and

obstruct

Also

avoid copper systems,

is

as

diesel

check

for

should

with

positions,

This

propeller

on

its

coupling

should

be

coupling

the

next should in

service

necessary,

will

is

usually

no

longer

because

first,

time

but

to

bed absorbed

be

necessary

always

be

whenever

the

land

in a cradle.

boat

often

the

shaft

it

is

being

has

actually

This

does

hauled

unless

they

time.

vary

designed

requirements

line

with a mini-

arranged

or

condensation

engine.

fall

in

flange

slope

water

to

and a steep

is

better

Avqid

line

which

the

any

sharp

not

acceptable

the

combination

exhaust

gas

alignment,

be

held with the

the

propeller

rotated test half

shaft.

checked

to

one.

be

rechecked

for

the

be in

the

work

because

take

and

engine

some

to

opened

the

boat

to

puts

or

the

moved.

not

out

of are

consid-

for

so

that

There

the

and

in

the

be

driven drop than

any

depreswould flow

bends.

will

coup-

in

full

one

its

re-

the

a

been

apply

the

line

pipe

of

for

in

one

up is

a

of

10

cause iron

rapid

fittings recommended haust the

line

engine increased ly

long

run

be

increased

feet

beyond

EXHAUST

deterioration.

and

galvanized

for

the

must

be

exhaust

in

size

if

and/or

by

1/2"

the

first

SYSTEM

STANDPIPE

exhaust

at

least

manifold

there

many

in

elbows.

I.

10

WITH

WATER

Galvanized

iron

line.

as

flange

is

an

D.

for

feet.

pipe

is

The

ex-

large

as

and

be

especial-

It

should

every

10

JACKETED

support sagging,

for

bending,

pockets.

Always

into

the

rubber riser flange

back

entering against

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

possible

The

engine

during

be

asperated

Test

Mercury

PSI

Test

Mercury

PSI

and

that

section

cannot

cannot of

erosion

GAS

must

of

the to

the

as

shown

3"

Mercury

engines:

1-1/2"

hose

to

formation

water

discharge

is

below

the possibly

Also

make

spray

the

exhaust

will

BACK be

PRESSURE

measured

exhaust

the

engine

should

be

measurement

below. engines:

Test

Mercury

prevent

of

water

behind

exhaust

sure

directly

piping.

occur.

on

line

exhaust

run

Water

19-1/2"

a

flow

that

a and

at period.

Column 39"

Column

To

insure

hull,

use a flexible

stainless

threaded

close

at

to flexible no

bends

ial.

The supported

strain

on

installations

hose

lation

for

exhaust

line

and

WATER

"HYDRO-HUSH"

vibration

steel,

each

the

engine section and

covered exhaust by

brackets the

manifold

use

the

water

because

flexibility.

1.3/4"

0.0.

LIFT

doesn't

section

no

less

end

and

as

possible.

should

be

with

pipe

should

to

flange

flexible

cooled

of

the

0

'0'1"'0

0;

1"11J~"L

ER,

11-1/2"

PN

1)1;1,.

EXHAUST

MUFFLER

transmit

preferably

than

12"

installed

insulating

be

eliminate

studs.

rubber

section

ease

Provide

1-311.."

5-318"

01.0,

SYSTEM

overall,

as

This

properly

any

exhaust of

of

instal-

adequate

0,0.

WITH

to

of

with mater-

Many

the

Checking

1.

Exhaust

2.

Exhaust

3.

Transparent with

The Back

water.

exceed

engines

engines.

WATER

CONNECTIONS

Seacocks

full

flow

than

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,

Measurement

normally

for

turbo-charged

strainers

least

of

one

the

should

for

sea.

be

copper

rubber

partly

"A" may

asperated

should

size

sea

be

of

cleaning

tubing

hose.

filled not

be

of greater water

the

type

while

or

In

the

any

case,

that

will tween the

outlet takes to

be aligned. suction should

at

all

The

neoprene

water

FUEL

TANK

Fuel aluminum, made

Copper be

pump

minimum

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

FUEL

with line in

of interior from

contaminating

used.

tank

above provided

tank.

is

already

be

should

A

primary

fuel

of

lift

As

and

tank

To

of

fuel

the

engine

PIPING

We

suitable and

the

use a section not

collapse

the

hull

and

up

vibration

moved

be

connections

pump

or

The

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.

or

at

lines

may

plain

is

gel

galvanized It

is

the

will amount feet installed

be correctly eliminated

and fuel

should

and

type

fitted pump

fuel that overflow

should

as

satisfactory

must

diesel

and

the because

of

is

started

fittings,

the

return

of

under inlet the

coated

not

engine

being in

taken

and

lift required

be

near

care

time

or

pieces

and

engine exhaust and

permits

when

use

street

All

pipe

Use

to

prevent

in

the

never

be

steel

of

this

water

filter

the

is

on

the

element.

is connected

have a dependable

dirt

tank

the

copper

be

of

fiberglass,

or

terne

be

certain

to

the

fuel

necessary

level

raise

installed

be

available

the

pump

the

fuel.

when

line.

the

lift

maximum).

above

position.

to

ensure

and

precautions

entering

of

installed

fuel

The

engine

injection

has a capacity

by

piped

top

are

especially the

left

will

injector

for

tubing

both

obtainable

secondary

operation,

the

flexible

suction,

system.

the

it's

being

elbows

and

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

supreason, im-

tank

in

when

time.

the

supply

tubing

to

avoid

the

is

If

not the

lift

the

it

fuel

in

of

the

use

of nectors. between of

the

that

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

all

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.

the

tank

always

by

engine

hoses.

panel

for

pre-wired.

a

cables

the on

instrupanel

be

mounted

util-

PANEL

supplied

while

the

all

sup-

11

be

from to

be

the

12

plied, cicuit

close voltage bad

for amperage where

lights,

sounders,

complet"e,

charging

second

splitter".

which

(Diesel

sizes installation engine

especially breaker

Starter

to

drop practice other

there

alternator

Starter

permits

Carefully

shown

and

requirements.

batteries

the

engine through to

use

services

or

are

intermittent'.

are

substantial

refrigerators,

etc.)

separate

current

starting).

use

it

for

batteries

a

high

follow

in

the

so

the

those

unless

or

wiring

following

relating

should

as

possible

long

the

starter

radios,

is

essential

system

this "alternator

must

rate

the

recommended

battery

be

located

to

leads.

batteries

they

and by

diagrams.

loads

to

means

be

of a type

of

discharge

is

close

cable

require In

depth

to

fuse/

avoid

It

is

cases

(from

have

provide

of

a

output

wire

Plan

to

sizes:

as

low

a

111

-

for

111/0

#2/0

113/0

MECHANICAL

The recommended

stop-run

and

controlled

push-pull

throttle Morse a

sheathed

The connected ible, Morse gives full The with the

be transmission

After

installation that, at neutral the detent. and tion

throttle

two-lever

one

other. Any gradual.

the

transmission

the

pump

for

-

for for

-

lever

knob

lever

type

transmission

to sheathed type clutch

lever

bends

linkages

when

pilot

and

Check

stop-run

for

distances

distances distances distances

CONTROLS

practice loaded by a

at

the

should lever cable.

lever.

the

at

the

pilot

cable

and

throttle range type

and

in

the

End

sections

must

reverse,

be

are

for

full

transmission

station

is

the

lever full

The

provides throttle

completed,

throttle

travel.

up

to 8 feet up up up

to

the

sheathed

pilot be

connected

the

pilot

control

station

and

controlled

single-lever

in

neutral

control

securely

travel,

is

in

the

control

on

the

on

to

10

to

13

to

16

is

to

run

cable

station.

station

lever

by a

control

position. clutch control

cables

at

engine

mounted.

check

making

control

forward,

respective

control

the

fuel

feet feet feet

have

position

to

a The

to

a by

may

be flexby a type

with

control

with

should

and

the

sure

lever

injec-

the

on

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

surge top. run

for

is

released,

dropped.

one

cap.

battery above is

of

fuel No. 2

No. 2

lubricant

If

there

fuel

is

to

pour

grease with

FOR

FIRST

is

shipped

drained

Therefore, recommended starting

filler duty,

mark

under

entrapped

water

Weather

Check

fully

on

tank

is

tank, wire

a good

Maintenance

an

and

continue

Gear

highest

S.A.E.

the

same

Gear

is

mark

water

all

cooled

cooling

and/or

anti-freeze

to

be

tank

to this

a few

If

inch

of

water

the

battery

charged

the

extra

the

first

with

diesel

use preferred

is

no

the

fuel

screen.

cup

on

START

"dry"

from

cap

diesel

approved

on fluid.

cooling

experienced.

the

of content.

grade

the

procedures

the

engine

and

fill

lubricating

on

the

oil.

mark on

30

hydraulic,

pet-cocks

anti-freeze

precautions

within

minutes.

so,

top

fuel

filter

recommended

water

Do

grade

to

has a manual

lubricating oil

as

the

dipstick

Do

system

air

is

engines,

system

solution

one

level water

refill

and

level

plates

so

that

effort

start.

clean

No. 1 is

Diesel

oil

because

in

through a funnel

pump,

of

water

...

with crankcase be

sure

care-

for

the

oil

dipstick.

for

an

not

over-

from

use

it.

clutch,

the

dip-

oil.

in

the

fill

with

not

overonly

and

plugs

expelled.

fill

with

fresh

solution

in

Main-

if

inch

after

level replace

is

engine

If

trapped

may

tank

at

least and it

is

that

may

fuel

recom-

permissible

of

the

filler

proced-

if

pump

to

bat-

lubto

sump

oil

ap-

ento

the

cold

of

its

pres-

BLEEDING

The

sion

high

stroke

tiny duce ent

this correct

tion,

In air part repair

is a misfortune complete engine

The

system using and

Before that surrounding prevent the

DPA

ing

both

ed

DPA physical ernor cated

be

Fig.

THE

SYSTEM

fuel ignition fuel

movements .of

this

inside

air

from consequence

is

bled

of

or

can

following

in-line

2).

the

system. DISTRIBUTOR

and

mechanically

bleed

in

injection

engine

pressure

to

function pressure

the

acts

as a cushion

pressure,

being

from

the

system

serv~c~ng.

bleeding

be

restarted.

bleeding

DPA

priming

outside

area

dirt

and

venting

pumps. The

location

screw

the

appropriate

1

system

depends during correctly.

the

pumping

and

if

high

pressure

and

therefore

achieved.

it

is

the

system

has

been

Running

that

also

of

the

instructions

apply

of

is foreign

PUMPS

sequence

to

pumps (shown

and

bleeding, the thoroughly

The

and

hydraulically

only

on

the

"D"

and

of a compres-

upon

the

injection

Relatively

plungers

any

air

line,

and

prevents

essential

whenever opened

out

necessitates

system

for

typical

in

bleed

matter

difference

pump

screws

clean

following

is

applicable

of

this

illustration,

is

very

is

pres-

then

fuel

injec-

that

any

for

of

fuel

before

fuel

systems

Figs.1

insure

and

to

entering

prim-

govern-

is

the

gov-

indi-

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

screw

inlet

lever

from

both fed

carry

screw

Slacken

the

two

hydraulic

and

the

bleed

housing.

the

feed

bubbles

tighten NOTE:

ing

issues this

The

(vented filled, by

fuel plungers, vance normal filled

take a long

However, being jector or fuel, be

means

feed close as

to will

vented

or

serviced

then

filled

of

pump

the

fuel

free

If,

however,

the

system,

most

mechanically

2

fuel

system

pump,

"A"

slacken and

union

of

air

issues

the

fuel

out

the

and

fuel

the

vent

screw

Operate

pump,

until from

bleed

space

by

and

its

oil

back-leaked

the

device

way

in

with

oil time

if

the

is

because a pipe

filter

or

the

governor

with

fuel

the

hand

will

suffice.

governor

from

a new

then

likely

governed

is

the "B", the

and feed from

vent

connections.

system

same

inlet.

valve

head

"D"

the

hand fuel

the

screw.

within

screw

contents

pump

if

fitted.

which

and

at

reason

element

system

oil

priming

bleed

air

issues

pump

its

be

empty

governed

pumps.

..

:-y

-

I

I " I

fitted

both

the

injection

operate pump both

turn

on

procedure

fitted

locking

on

the priming

free

vent

the

"D")

"c"

governor

is

lubricated,

from

rotor

and

This this this feed

space can

pump

that

has

been

has

run housing and

bleeding

lever

In

this

screw

from

has

governor

of

fuel

and

Fig.

-l

with

a

filter

pump

the until the

fuel

vents.

In

the

fuel

with

to

one screws governor

lever

from

and

air

then

hous-

normally

the

pump

the

ad-

is

the

becomes

naturally

pressures.

the

pump

line

or

changed out

will

still by

of

the

event,

"D"

as

the

been

fitted

housing

oil

hand

a

the

of

"c"

of

is

in-

of

sOon

vent.

and

bleeding

Leave slackened. pipe Set ition from tighten

Start idling from this

line

the

and

air

the screw

proceeds the

throttle

turn

flows

the

loosened

the

speed

governor

and

Governing procedure, engine

therefore

should develop. RECOMMENDED doubt

as equipment depends location. populated up

the

quite

different prehensive

SPARES

to

the

spares

upon

General

areas

Amazon

spares

Generally

owner

service insurance servicing

is

within

centers

against

within

crew.

A

suitable

consist

a

set filter. filters easily ing injection a

fractured any these be agent already ally entry ed them

is

face

clean

right ticular correct able

when

use

of a replacement

of

sealing Spare

are

lost

or

the

system.

pipes

or

time

and

pipes.

obtained

or

service

bent

with

both

of

dirt.

as a set

this

vitally

of

and

way

important

the

until

A

spare

type

set

and engine seating

defective required

while

one

as

governor

slacken

to the from

engine until

bleed

stop

may

be

any

excessive

amount

to

the

use

is

delta,

and

kit.

speaking,

relatively and

breakdown

the

kit

for

and

bleed

also

required,

damaged

A

should

cracked

no

patching

The

correct

from

the center

to

shape

ends

They

it

until

pipe

is

fitted

of

fuel correctly together

washers

injectors

but

will

set

follows.

bleed

any

at

the

fully

engine

the

until

unions.

injector

and

run

air-free

screw

the

engine.

erratic

stand

Owners

of

by

are

fuel

carry.

of

the coastal one

for

would

use

thing,

example,

require

the

average easy

requires

scope

of

such a purpose

filter

"0"

rings

screws

for

in a boat

full

set

also pipe

is

set

engine

and

cleaned

plugged

will

is

be

important

required

that

kept

to

the

scrupulously

the

engine.

injectors

set

with a set

will

to

also

is

away

being

screw

it fuel

during

engine

"D"

two

injector

open

fuel

Then

pipe

at

fast

exudes

"D".

to

stop

often

end.

pos-

free

re-

unions.

Tighten

this

the

speed

in

injection

A

great

craft

but

and

in

well-

voyaging

deal

its

would

a com-

boat

spares

and

the

reach

for

of only general

owner

would

element

for

each

for

pumps

screws

of

high

be

carried, could possible

of

when

pressure

occur

pipes

and are bleed-

with

manufacturer's

will

be

supplied

intern-

against

supplied

for

to

use.

the

pack-

keep

internal

of

the

for

the

par-

of

the

not

only

en-

be

changed

permit

engine

serviced.

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

enough element

filter bolt.

ment,

is

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

will

wipe non-fluffy of

those

will

do

far spill wipe does

if track careful

any

it

off

not

left,

everywhere

where

to

regarding

injector

back

are

handy

leaking.

breaks

Breakdowns equipment sea!

forget

spanners

wrenches

injection

TIPS

for

It

absolute

times.

methods

hint

to

obtain

strong

put

this

before

the

center

and

base

the

bag

for

the

base

pieces

owners

for

use

soaking

or

removing

down

creams

and

make

the

grime the and

job

is

completed. majority be

supplied

the

pump

piece

grubby

old

more

fuel

on

right

evaporate

will

gather

you

check

with

whether

seating spare leak

banjo

pipes

things

Remember no

down when

and

is

working -and

the

tools. for

the

may

but

please,

equipment

is

essential

cleanliness

This

requirement

of

operating

and

to

precautions

when

changing

a

polythene

enough

around

unscrewing

bolt

all

to

into a bowl

the

contents

and

sealing

of

substance

who

live

in

cat

litter

up

diesel

before

of

the

life

from

hands.

job

is

tackled

cream

of

are

fueling

through a hose

nozzle

of

cloth swabs,

harm

than

tank,

deck

away.

as

does

dirt

and

keep

put

down

the

engine

the

engine

washers

bolts

and

low

to

have

it

is

station-

trouble

Always job

- hammers

be

all not

on

your

to

and

filter bag

to

hold the

element

the

and

allow

go

into

or to rings

in

apartments

boxes

fuel

pipe

lines.

working

oil-defying much

easier

Put and

removed

installations

with a clean

before

please

good.

or

fittings,

Diesel

fuel

gasoline,

and

grit,

on

smelling.

the

fuel

or

not.

and

preswhen a

equip-

occur

that

carry

right around

stress

of

the also

servic-

about

ele-

large

the

filter

center

ele-

the

bag.

container

be

separrecov-

familiar

is

spilled

Put

on

the

kind when

on

then

together

-

use.

-

they

If

you

oil and

will

tank

and

the

None

Be

cap

when

pick

up

a

lot

of

Avoid

lots

of bargain ion

equipment

damaged.

WHEN

ENGINE

1.

Check oil

pressure

operating

(Extremely

2.

Check at

exhaust

delay.

3.

Recheck gine quent

tion, crankcase

ant

as

to

compensate quired oil

passages

as

necessary. of

operation.

4.

Recheck applies or

a new stop eral

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

dirt

or

dirt

gets

dubious unknown they

appear

is

STARTS

Oil

Pressure

speeds,

hot

Sea

Water

outlet.

Crankcase

has

run

to

an

oil

stop

the

oil

it

may

to

fill

Transmission only

installation.)

the

engine

minutes

forward

as

necessary.

day

of

operation.

Expansion

is

fresh after or

filled

engine

after temperature to

within

The

system

and

It

against

slowly

of

the

cap

in

is

released.

the and

lifted

Instructions.

get

the

speed,

l30-lS0oF.

-

see

that

it

grit

origin

-

this

into

the

sources

are

to

be

expensive

of

and

is tank. fuel.

not

to

how

always fuel renew

immediately.

is

approximately

15

psi

when

engine.)

Flow.

Do

Oil.

Look

this

After

for

without

for 3 or 4 minutes,

change

engine level. be

necessary

for

the

and

oil

Check

subsequent

after

at

800

and

one

and

This

the

oil

engine's

filter. oil

Oil

running

rpm

into

or

new check

is to

that

internal

level

Level.

to

an

In

such a case,

with

reverse,

Check

Tank

Water

cooling

the

if

is

escaping

water

one

pressure

advisable

for it

has

of

l750F

inch

is

pressurized

the

filler

cooled. system the

first

reached

and

of

must

to

steam

top

cap

counter-clockwise

safety

this

spring

continue

stops

position

Press

to

turning

is

until

the

clear

off.

As

soon

boat

underway

until

water

It

temp. necessary,

doesn't

quite

Job

inject-

when

Normal

50

psi

idling.

water

the

subse-

installa-

the

import-

add

is

Add

each

(This

oil

for

one

shift

oil

level

Level,

(This

has

been

time.)

oper-

add

of

when

be

re-

is

protect

and until

felt.

cap

the

until

as

but

at

gauge

15

the

at

en-

oil

re-

oil

day

change

sev-

then

if

tank.

to

turn

the

all down-

pos-

re-

en-

16

gine

can

in

neutral

with

clutch tends partial detected

7.

Reverse gine

to

However, when

gaged, NOTE: when held no

The

backing

in

the

positive

be

warmed up

at

in

to

overheat

engagement

by

propeller

Operation.

idle

it

SAO

speed

will

tran-smission

down, reverse overcenter

with

the

clutch

1000 rpm. Warming up

neutral

the

carry

the

position,

takes

the

transmission,

occurs,

which

shaft

Always

when

reduce

shifting

transmission

full

engine

requires

shift

lever

since

locking

longer

can

rotation.

gears.

is

load.

that,

must

it

mechanism.

enen-

and if

be

has

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

STOPPING

1.

Position

2. Move

3.

Pull

off

(The

throttle fuel

stop

the

pump.)

NOTE:

Idle

dissipate OPERATING

1.

Never

when

excessive

extensive

2.

DO

NOT engine. block,

3.

Keep

intake

etc.

4.

Do

not

clutch

5.

Never damage circulation.

6.

7.

Keep Keep

the the

extreme

8.

fuel

Do

fuel

cause

not

intake enough system, quired

9.

Do

not show a stop full

after load.

release

metal

chamber.

engine

before

ENGINE

shift

lever

lever push-pull control

fuel

heat

from

engine

gradually

for

PRECAUTIONS

run

engine

overheating

internal

put

cold

water

It

can

or

manifold.

silencer

run

engine

engaged.

Race a

can

Cold

occur

engine fuel

clean.

care

because

more

allow

fuel

may

to

allow

resulting

for

priming.

be

alarmed

high

reading

engine

This

of

residual

masses

near

Prevention

at

idle

for a short

stopping

in to STOP

functions the

a few

for

extended

damage

crack

free

at

high

Engine

due

to

and

accessories

water

trouble

to

run

be

uncovered

air

to

in

lost

if

temperature

following

has

is

caused heat

the

for

it.

High

neutral.

idle

position.

control

by

fuel

injection

minutes

before

shutdown.

periods

occurs

can

be

in

an

overheated

cylinder

from RPM

without

as

internal

inadequate

Handle

it

and

service

low,

because

long

enter

the

-time

a

been

operating by

the

from

the

combustion

this

is

period

temperature

out.

cutting

to

as

caused.

head,

lint,

oil

clean. with

dirt

re-

gauges

sudden

heavy

to

in in-

at

run

TEN MUST RULES

17

IMPORTANT

...

for

your

ALWAYS

NEVER

8.

9.

10.

-

1.

Keep

2.

Use

3.

Check

or

4.

Close

5.

Investigate

-

6.

Race

7.

Run

Break Use galvanized

Subject

if

only

less.

the cotton

black

safety

this

filtered

cooling

all

the

engine

the

smoke comes from

and

Manual handy and

water

drain

any

unless

fuel

pump waste container.

engine

IMPORTANT

your

fuel

temperature

cocks oil

leaks

in

neutral.

seals.

or

fluffy

to

engine's

read

oil

and

refill immediately.

the

gauge shows

cloth

prolonged

the

dependability.

it

whenever

check

exhaust.

lube

frequently

with

overloading

for

water

proper

cleaning

in

oil

to

before

or

IMPORTANT

doubt.

level

make

oil

or

sure starting

pressure. store

continue

daily.

fuel

it

to

is

out.

in

run

190

a it

0

18

YOUR NOTES

MAINTENANCE

19

PERIODIC

After engine, following fifty

FIFTY Do

hours HOUR

the

1.

Retorque

2.

Retorque

adjust

3.

Check

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

of

CHECKOUT

following:

the the

valve

and

drum

on

manual

engine

for

Correct

cooling water for

etc.

to

loose

could

taken

right

its

operation:

cylinder rocker rocker

adjust,

assembly

lubricating

fuel

system

level.

loose

nuts,

engine

cause

delivery that

after

(INITIAL)

head bracket clearance.

if

necessary,

and

SAO

and

SA-l

and

lubricating

if

necessary.

for

fittings,

bolts,

Pay

particular

mount

mis-alignment.

you the

bolts.

the

oil

leaks

clamps,

vee

fittings.

of

your make first

nuts

reverse

trans-

and

oil

and

belt atten-

the

and

the

oil

in-

DAILY Do

SEASONAL Do

CHECKOUT

the

1.

Check

been

2.

Check

3.

Check Fill

4.

Turn

if

5.

Check

mission.

dipstick.

the

1.

Check belt

2.

Check

3.

Cqange sucked suction side aft

See

4.

Replace

See

5.

Fill quarts high fill.

following:

sea

water

installed.

water lubricating

to

highest

down

used,

CHECK-OUT

of

Note,

mark

grease

one

lubricating

Fill

generator

for

tension.

water

oil out

hose

the

with

of

diesel on

See

Note

strainer,

level

mark

cup

full

to

(MORE

or

level

in

sump.

of

sump

(3/8"

oil

sump

dipstick.

page.

approximately

lubricating

dipstick.

cooling

oil

level

on

dipstick.

on

water

turn.

oil

level

highest

OFTEN

alternator

in

battery. Oil

by

attaching

ID)

over

pipe,

Figure

oil

Do

page.

if

one

system.

in

sump.

pump,

in

trans-

mark

may

filt~r.

IF

POSSIBLE)

"V"

be

the

located

1.

4.5 oil

not

on

a out-

Fig.

over

has

US

to

2.

FIGURE

1

2

20

CAUTION:

lubricating been

plete

6.

ing

known

and

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

cause

may

in

starvation.

engine

Stop

gasket

level.

necessary

for

the

and

30, High

Service

NOTE:

150

IS

REACHED

Air

Filter. the conditions, dirty

time

will

wear,

thereby

engine.

engine sea

water

primary

bowl

filter

secondary

air

of

during

many

and

engine

for

This

the

oil

engine's

oil

Change

DG,

See

note

THAT

TO

WHEN

HOURS.

air

conditions,

should

periods

greatly

for

pump

filter

contains

bowl

need

filter.

different

oil extensive instances

run

for 3 or

and

leaks.

is

important

to

add

that

internal

filter.

oil

in

Detergent

DM,

or

below.

THE

CHECKS

TOTAL

IN

SOME

BEFORE

The

time

filter

therefore,

be

increased.

for

assist

extending

loose

bolts,

for

bowl and

and

secondary

to

be

cleaned

fuel

filter

brands

changes

oil

sludg-

cause

4 check Check

oil oil

as

oil

to

com-

is

required

oil

Add

oil

transmission.

Lubricating

DS.

Do

3,

OPERATING

INSTANCES,

END

OF

SEASON.

period

depends

the

replacing

in

reducing

the

nuts,

leaks.

screen.

water

or

more

element.

of

has com-

it

as

not

4,

5

for on under

season-

The

the life

sedi-

oil

3.

Fill antifreeze to

4.

Start

indicates

drain

place tergent

5.

Remove intake ive

6.

Seal cessible gine

7.

Remove cylinders.

8.

Replace

washer

slowly

9. Top air 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

Cold Weather

engine.

1750F, lubricating filter.

Lubricating

air

filter.

opening

tape

or

some

the

exhaust location

as

possible.

injectors

injectors under over

off

space

each

compression.

fuel

tank

remains,

formation

fuel

system

fuel

filters

back

in

engine

oil

in

with a coat

battery

condition.

the

battery

connectors

corrosion.

30

days.

alignment.

cooling

Precautions.)

When

shut

oil.

Fill

temperature

engine

Remove

sump

Oil.

Carefully

with

waterproofed other outlet

as

and

with

suitable

at

close

spray

new

injector. completely

thereby

by

condensation.

full

of

before

service.

of

transmission.

and

store

Before

terminals

should

be

Recharge

system

make.

down and

and

with

High

seal

the

most

to

the

oil

into

sealing

Turn

so

preventing

fuel.

putting

oil

or

in

storing

and

treated

battery

with

(Refer

gauge

reDe-

air

adhes-

medium.

ac-

en-

engine

that

no

the

fully

the to

END

OF

SEASON

1.

Drain moving opening

2.

Remove heat

exchanger) replacing. care

of

between

zinc

if

SERVICE

fresh

the

all

water

surge

water

zinc

The

any

electrolysis

dissimilar

necessary.

rod

cooling

tank

system

(usually

and

see

zinc

rod

metals.

system

pressure

petcocks.

located

if

it

will

that

cap

needs

take

may

Insert

by

and

in

occur

new

re-

21

Lubricating

standard

of

sustained

(API

not

These

listed

oils

Service

COMPANY

American

BP

Canada

Chevron

Cities

Oil

Service

Continental

oils

performance

high

speeds

meet

CC).

here

are,

Co.

Limited

Co.

Oil

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

engines

modern

S. Ordnance

to

OO/450F 450/80

Oil

10W/30

Oil

which

operating

Specification

these

specifications,

S.A.E.

lOW

lOW lOW lOW

offer

conditions

an

improved

such

MIL-L-2l04B

but

DESIGNATION

o

F

OVER

20W/20 20W/20

lOW/30

lOW/3D 20W/20 20W/20 20W/20

as

are

800F

30 30

30

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

ENGINE OVERHAUL

The

following information ing

characteristics

and

systems cluded sembly suitably service necessary only

are instructions

and

by

such

sections

relating

in

the

disassembly,

equipped

rebuilding

procedures

facilities.

of

for

and

contain

to

the

rework the

staffed

facilities.

should

detailed

proper

major

engine.

and

guidance

marine"

be

undertaken

components

Al

operat-

In-

reas-

of engine

The

Additional

included

manual.

Any

replacements genuine

operating

in

the

Operation

Westerbeke

characteristics

should

be

parts.

Section

made

of

only

are

this

with

A3

DESCRIPTION GENERAL EXTERNAL INTERNAL REMOVAL

Engine

Valve

Cylinder

Timing

Camshaft

Oil

Pump,

Flywheel

. Crankshaft

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

DATA

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

COMPONENTS COMPONENTS

AND

REFITTING

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

Rocker

Head

Chain,

and

Connecting

Housing,

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

ENGINE

OVERHAUL

CONTENTS

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

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

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

Shaft

and

Tappets

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

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

Chain

Front Plate

Wheels

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

Rods

Flywheel

and

Chain

Tensioner

Pistons

Backplate

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

..........

....

A4 A6

A8 A10 A12

A12 A12 A12 A13 A14 A15 A16

A18

OVERHAUL

Valve Cy Timing

Injection Oil Oi 1 Pump

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

Rocker

1 i nder

Chain

Pressure Relief

Shaft

Head

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

Tensioner

Pump

and

Chain

Tappets

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

Wheel

Valve

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

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

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

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

Flywhee 1 ..........................................

Camshaft

Connecting

Cyl

i nder

Crankshaft

DIESEL

Bearing Liners

Rod

Bores

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

FUEL

SYSTEM

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

and

Piston

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

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

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

A

19

A19

A20 A21

A22

A22 A23

A23

A24 A26

A27

A27 A28

A4

DESCRIPTION

This rated power

high

diesel

unit corporates research niques. weight and are

The

ratio

the

greatest

marked

Westerbeke constructed exacting withstanding inherent play routine

Westerbeke

an

important

attention minimum, preciably major

overhauls.

Outstanding include forged

monobloc

alloy-steel

'Tuftride'

and

the

Ricardo

cal

anti-chamber

efficiency,

engine

of

advanced

the

very

in

diesel

Favorable

with

outstanding

economy

features

60

engine

and

production

the

most

and

while

at

extending

features

treated

Comet

combustion

naturally

aspi-

is a well-proved

design

latest

engineering

high

and

results

techpower-toreliability

in

operation

of

the

engine.

is

robustly

manufactured

standards

arduous

qualities

role

in

duties

which

reducing

maintenance

the

same

intervals

of

the

time

between

design

construction,

crankshaft

bearing

Mk

journals,

VB

spheri-

system.

in-

of

to

for

-

to

ap-

a

with

a

three

shell diameter of

steel-lined

bearings.

10.424

giving a total

2

in

CONNECTING

'I'

section stampings. with shell diameter,

steel-backed

bearings,

and

steel-backed

1.

125

in.

(28.58

big-end

8.

720

bearing

in2 (56.

PISTONS

Anodized

skirt. faced faced scraper

trol

pins are

ring.

1.

located

aluminum

Each compression compression

ring,

The

125

in. laterally

reticular

2.478

(67. 24

cm

RODS

heat-treated

The

big-ends

lead-indium

2.248 the

small

lead-bronze

mm)

diameter.

projected

2

cm

).

26

alloy

piston

has

ring,

and

one

fully-floating

(28. 58

by

tin

aluminum

in.

(62.94

~rojected

mm)

area

).

alloy

are

steel

fitted

thin

in.

(57.07

ends

alloy

mm)

with

bushes,

Total

area

with

one

slotted

solid

chrome-

taper-

stepped

oil

con-

gudgeon

mm)

diameter

circlips.

CYLINDER Special

vided

with flanges, with

maximum water bore. ing

jackets

There

system

CYLINDER

cast

adequate

giving

BLOCK

iron

is a closed

fitted

HEAD

Manufactured and

secured (11.1 studs tion are guides

mm)

to

diameter

the

cylinder

chambers

incorporated

are

fitted.

CRANKSHAFT Special

'Tuftride' The balanced and

statically

shaft,

by

alloy

hardened

design

monobloc

a

rigidity.

are

from

by

twenty-five

of

Ricardo

and

steel

which

and

balanced,

AND

ribs

and

light

Large

cast

circuit

special

high

block.

Comet

renewable

forging

bearing

is

fully

also

is

CRANKCASE

casting

wide

pro-

joint

construction

capacity

around

each

breath-

cast

tensile

7/16

iron

in.

steel

Combus-

design

valve

with

journals.

counter-

dynamically

carried

in

VALVE

GEAR

Overhead operated type

by

tappets

camshaft,

engine

casing crankshaft. manufactured steel

nickel

Double

and

chromium

coil

valve.

CAMSHAFT Steel

gral

forging cams

steel-backed TIMING

The are Slipper to

ensure

GEAR

camshaft

chain

and

smooth

gear.

poppet-type

means

and

of push-rods

which

and

The

from

the

exhaust

springs

with

case-hardened

and

supported

white

and

driven

from

tensioner

working

valves

flat-faced

is

situated

adjacent

inlet

silicon

valves

manganese

are

fitted

metal

fuel

injection

the

units

of

are

piston-

from

valves

to

in

the the the

are

chromium

from

steel.

to

each

inte-

in

three

bearings.

pump

crankshaft.

are

fitted

the

timing

AS

LUBRICA

A

full

TION

pressure

employed.

pressure

engine gears

pump

crankcase

from has a delivery at

1000

provides

trolled

(3.

62 Oil in

the system external is

then shaft stricted rockers the

returning

push-rod

rev/min

by a relief

kgf/

is

drawn

sump

passes

filter

fed

and

oil

via

a

cm

to

small-end

ends,

SYSTEM

wet

sump

The

the

maximum

eccentric-rotor

is

located

and

driven

camshaft.

of 2 gall

of

engine

min

pressure,

valve,

2

)

to

all

through a gauze

and

before

through

of

the

full

the

main,

bearings.

supply

the

oil

is

hollow

lubricates

and

tappets.

fed

rocker

system within

by

The

(9. 1

speed

of

50

moving

entering

a

detachable

flow

big-end.

to

the

shaft

valve

type

the

helical

pump

litres)

and

con-

lbf/

in

parts.

strainer

the

type.

cam-

A

re-

valve

and

caps,

is

It

2

FUEL

A

INJECTION

distributor-type incorporating governor at

half-engine at 3500

lift

pump,

priming

ated

is

approximately

rev/min.

device,

from

provides

under tor and

(138.9

constant

is

fitted

injects

kgf/cm

EQUIPMENT

fuel

injection

an

all-speed

fitted.

speed

The

from

pump

500

which

the

fuel

The

is

engine

to

diaphragm-type

incorporates

mechanically

camshaft

the

injection

pressure.

with a Pintaux-type

at a pressure

2

(1984

)

psi).

mechanical

is stable rev / min

Each

of

135

pump

driven

idling

a

hand

oper-

and

pump

injec-

nozzle

atmos.

to

.:LJ

-----

,---

LJ

,,-

~-~-</

A6

MODEL TYPE

Number Bore Piston Compression Ratio

Torque Continuous Rating

Intermittent

Engine Weight (dry)

of

cylinders

and

Stroke

Displacement

Rating

GENERAL

Westerbeke

Indirect Four -

3.50

154.2

19.5:1

114.4 53 60 750 Ibs.

in.

Hp. Hp.

injection

Vertical

(89

in.

3 (2520

lb.

at at

approximately

DATA

60

mm) x 4.00

3

cm

ft.

(15.81 Kg.m) @

2,500

3,000

RPM

)

in.

with

(101.6

2,000

direct

mm)

RPM

dri ve

Oil

Pressure: Idling

Norma I

Oil

Capacity Injection Rotation (Engine) Cooling

Angle

Camshaft

Chain wheel

Valve Rocker

of

Method

t-Aethod

(including

Order

Capacity

Installation (max)

end

float

of

adjustment

alignment

of

adjustment

Clearance

Runn i ng

filter)

(cold):

15Ib./sq.

50

Ib./sq

7 quarts

1,

3,

Anti-Clockwise,

12 quarts 15

degrees .003 Renew

Crankshaft

Injection

Shims

Inlet

Exhaust

in.

4,

2

to

.006

locating

pump

behind

----

in.

(3.52

In.

and

crank

.012

(1.05

.015

Kg./cm

viewed

(.076

plate

camshaft chain wheel chain

shaft

in.

wheel

(.30

2

)

2

)

from flywheel

to

.152

mm.)

self

aligning.

chain

(.38

mm.)

mm

wheel.

)

end.

teeth

faces in

line.

Valve

TIming (with .021

Inlet

Valve

Exhaust

in.

Valve

(.53

mm.)

rocker

clearance:

open

SO

BTDC

600 BBDC

closes

0

40

SO

ATDC

ABDC

A7

Torque

Cylinder Manifold

Rocker

Big

Flywheel

Main

Wrench

head

bracket

End

bolts

bearing

Setting

Nuts

nuts

bolts

75

lb.

221b 25

lb.

50

lb.

50

lb.

100

lb.

ft.

(1

0 .

37

ft.

(3.04

ft.

(3.46 Kg. m.)

ft

(6.9 Kg.

ft.

(6.9 Kg.

ft.

(13.82

Kg.

m.)

Kg.

m.)

+++

...

++++

.....

1111111111111.1

••

-.-

..

111

••

'111.1.'

II

~"'I"'"

•••• , ••••

1.11.

1.111'1.111".,,11,

......

++

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

++++-+-++++-++

...

+1111'111111.1,1111

EXTERNAL COMPONENTS

J~

ife. ilfllii;:1: L

~

..

_"

3-t;~,~-,~

~~

"

66

_·_···,""",

..........

·

..

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_

..

·_

...

·l

57

j

I

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II

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

+-+++

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

111

•1'

111.1.11

......

+111111

•••••••

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"1'

I

••• I ••

I

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1++-+-++++.++-+

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

++

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

+-+_,

1

III I II

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•• _ .................................

+-++-++-+

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

...........

&';

............ --........... + .......

++

...

+

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

+++++.--

...

--++-+++-++.+

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

++-+

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

+++

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

+++

............................... _ ..

+

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

+++

.. ~ ....

++-

•••

++-

...

++-

......

+++-+

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

-++

........

+

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

++++.++

I •

· .

: i

1 i

: .

i j

i

KEY

TO

EXTERNAL COMPONENTS f

· .

i f

!

No.

Description

No.

Description

No.

Description I

i 1.

Water

outlet.

23.

Crankshaft

front

oil seal. 45. Oil

pump

locating

screw.

i

i 2.

Gasket.

24.

Degree

plate. 46.

Cylinder

side

cover.

I

I .

I 3.

Thermostat.

25. Oil

separator.

47.

Gasket.

I

i 4.

Heat

shield for injector. 26. Gasket. 48.

Combustion

chamber

insert.

! 5.

Washer.

27.

Sump

drain

plug. 49. Manifold gasket.

i 6.

Cylinder

head. 28.

Washer.

50. Exhaust manifold. f

f

I

1

~

j

I

i

!

I

i

1

I

i

I

i I

7.

Gasket.

8.

Cylinder

block.

9.

Oil dipstick.

10. Dipstick

tube.

11. Plug

for

oil

pressure

relief valve.

12.

Washer.

13. Spring.

14.

Oil

pressure

relief valve.

15.

Front

plate.

16.

Gasket.

17. Bolt for injection pump.

18. Lock

washer

for

front

plate bolts.

19. Timing

cover.

20.

Gasket.

21. Injection

pump

chain

wheel

cover.

22.

Gasket.

-1'111

II

II11I1

1 I I

11+1.11111111 I IIIIII1IIII

lit

III1I

1 1 I

I' I ••••

1111'

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

Sump.

51.

Manifold

stud.

Gasket.

52.

Inlet manifold.

Sealing

plug

for

front

and

rear

main bearing caps.

53. Yoke for manifold.

Main bearing

bolt.

54.

Washer.

Front

main

bearing

cap.

55.

Nut.

Centre

main bearing cap. 56.

Gasket

for flywheel housing.

Rear main bearing cap. 57.

Flywheel housing.

Sealing

strip

for

rear

main bearing cap.

58.

Crankshaft

rear

oil seal.

Main bearings. 59.

Ventilation

cover

for flywheel housing.

Crankshaft

thrust

washers.

60.

Top

gasket

for flywheel housing.

Water

drain

tap.

61.

Washer.

Camshaft bearing (front).

62.

Cylinder

head

nut.

Camshaft bearing

(centre).

63.

Cylinder

head

nut

and

rocker

cover

stud.

Camshaft

bearing

(rear).

64. Push

rod

locating plate.

Cap

nut.

65.

Gasket.

,

Washer.

66.

Rocker

cover.

(!6

+-+-+-+-+-+-+-+++

.............................. ++++-+

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

...........

+++++-+-+-+-+-

...........

+++

..........

++~

....

~

o

3--4~

1

9

°-'

~'

f,i~'8~~

17

2019

18

8=

---.

84

--

85

82

81

~

~~

83

86

~

92

62 / .

''-J

~

. I

~

'@>.

~

~\.

78~~"

76

~

I

•

.'

..

I

1,

.

60'

~.'

~~\

~~~..~~1,

I,

7

1

,

~J~

;'"

n'!

I . '

"~

~.

'r~

::.

f

J

'

~'

\

70 75

,~'

•

• "

80

102

/ . I

- ' =

•.

_.

__

._.

...

10

I ' I

_..............

" 79 '

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

.

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

_

100

I

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

I

...

_.......

I

_"

__

.,,

I

__

I

++++++++++-

+++++++++++++

..........

_.........

I

...........

I

................... I

++++++++++++++++....t

ss

r·······-····

..

·-··--······

..

····_-··

..

···-·····-·-

..

·······

....

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

--.---

.. -...

--.----

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

-.-.-

.. -.. --...

·-·-

...... · ..

--1

!

·

j

I

!

i

·

i

·

I

!

·

i

!

I

!

j

!

~

·

I I

i

j

!

No.

1.

2.

Description

Rocker

shaft.

Plain plug for shaft.

3.

Screwed

plug for shaft.

4.

Rocker

bracket

(plain).

5.

Rocker

bracket

(tapped).

6.

Locating

screw

for shaft.

7. Lock

washer.

8. Plain

washer.

9. Spring

washer.

10.

Nut.

11. Valve

rocker.

12.

Bush

for

rocker.

13. Adjusting

screw

for

rocker.

14. Locknut.

15.

Distance piece

(centre).

16. Distance piece (end).

17. Spacing spring.

18. Spring

washer.

19. Plain

washer.

20. Split pin.

21.

Valve

guide

(inlet).

22. Valve (inlet).

23. Valve

guide

(exhaust).

24.

Valve (exhaust).

25.

Circlip

for

valve

cotter.

26. Valve

cotter.

27.

28.

29.

Valve

spring

cup.

Oil seal

for

valve.

Valve

spring

(inner).

30. Valve

spring

(outer).

31. Valve

spring

collar.

32.

Push-rod.

33.

Tappet.

34. Camshaft.

KEY

TO

INTERNAL COMPONENTS

No.

Description

35.

Key for camshaft.

36. Locati ng

plate for camshaft.

37.

Spring

washer.

38. Bolt for locating plate.

39.

Camshaft

chainwheel.

40.

Lock

washer.

41.

Nut

for camshaft.

42. Timing chain.

43. Vibration

damper

for chain.

44.

Shim for

timing

cover

centre

boss.

45.

Screw

for

damper.

46.

Nut.

47. Lock

washer.

48.

Tensioner

for chain.

49.

Gasket

for

tensioner.

50.

Bolt

for

tensioner.

51. Lock

washer.

52.

Hub

for injection

pump

chain wheel.

53.

Gasket

for

hub.

54. Bearing for chain

wheel.

55. Injection

pump

chain wheel.

56. Internal circlip for driving flange.

57.

Injection

pump

driving flange.

58.

Washer

for flange.

59.

Bolt for flange.

60.

Oil

feed pipe for hub.

61. Banjo

bolt.

62.

Washer

for banjo.

63.

Injection timing

pointer.

64. Plain

washer.

65. Spring

washer.

66. Bolt for

pointer.

67.

Nut

for

crankshaft.

68. Lock

washer.

No.

Description

I

69.

Crankshaft

pulley.

70.

Oil

thrower.

71.

Crankshaft

chain

wheel.

n.

Adjusting shim

for

chain wheel.

73. Key for crankshaft.

74.

Cran

kshaft.

75.

Connecting

rod

and cap (Nos. 2 and 4).

76.

Connecting

rod

and cap (Nos. 1 and 3).

77.

Little

end

bush.

78.

Big-end bearing.

79. Big-end

bolt.

80. Lock

washer.

81. Circlip.

82.

Gudgeon

pin.

83.

Piston.

84.

Compression

ring.

85.

Stepped

scraper

ring.

86.

Slotted

oil

control

ring.

87.

Flywheel.

88.

Starter

ring.

89.

Dowel.

90.

Bearing for

primary

shaft.

91. Lock

washer.

n.

Bolt

for

flywheel.

93. Shaft for oil

pump.

94.

Key for shaft.

95.

Bolt for oil pump.

96.

Spring

washer.

97.

Oil

pump

body.

98.

Oil

pump

rotors.

99.

Oil

pump

cover.

100. Oil

strainer.

101.

Gasket

for

strainer.

102. Oil

delivery

pipe.

t

g::

~

Al2

ENGINE Removing

1.

Drain

2.

Pump

3.

Disconnect

4.

Disconnect

5.

Disconnect

6.

Disconnect

7.

Disconnect

8.

Disconnect

9.

Disconnect back

1

O.

Remove

fresh

water

lubrication

battery electrical fuel

pipe exhaust stop

control

throttle

propeller

approximately

engine.

system.

oil

from

cables

leads

clips

pipe control

shaft

four

refer

sump.

from

and

from

from coupling

inches.

to

"Cooling

engine.

terminals

fuel

pipe

exhaust

injection

from

System".

board.

from

lift

manifolds.

pump

lever.

pump

transmission

pump.

lever.

coupling

and

move

shaft

VALVE

ROCKER

Removing

1.

Remove

2.

Release

assembly

3.

Remove

4.

Remove

5.

Withdraw

6.

Lift

out Refitting Reverse

1.

Check

the

Head".

2.

Torque

3.

Adjust

CYLINDER Removing

1.

Drain Disconnect

2.

3.

Disconnect

4.

Disconnect

5.

Disconnect

6.

Disconnect

7.

Disconnect

8.

Remove

9.

Remove

1

O.

Remove

11.

Disconnect

12.

Remove

13.

Remove

14.

Remove

15.

Remove serve

16.

Lift

off

rocker

the

rocker

air

intake

the

cylinder

the

push-rods

the

tappets.

procedure

cylinder

rocker

the

valve

HEAD

cooling

exhaust

stop

throttle

electrical hose hose

fuel

pipes

high

fuel

pressure

return

electrical

rocker

combination

the

cylinder

as

rocker

the

cylinder

SHAFT

cover

brackets

manifold

in 1 through 6 noting:

head bracket

rocker

system

pipe

control

from from

from

cover.

shaft

cover

AND

side

cover

nut.

Torque

nuts

clearance

(refer

from

lead

thermostat expansion

fuel

pipes

lines

from

leads

assembly exhaust

head

nuts.

studs.

head

and

TAPPETS

from

with

75

(25

lb.

(refer

to

Section

manifold.

injection

from

injection

temperature

housing.

tank filter. from

each

from

the

and

manifold/

using

push-rod

the

cylinder

oil

separator

(refer

ft.).

to

D).

pump

to

heat

injection

injector.

heater

withdraw

expansion

tool

positioning

head

to

Section F ;.

Page

A30

lever.

pump

sender.

exchanger.

pump

plugs.

the

18 G 545

"Valve

lever.

and

push

tank.

to

plate.

and

lift

Par.

injectors.

rods.

and

remove

off

the

17b).

Rocker

air

intake

the

rocker

"Cylinder

Clearance").

manifold.

two

which

shaft

also

Al3

NOTE: must with

17.

a. b. c. d.

be

the Refitting. The

Tighten

Adjust

Bleed

The

combustion

refitted

inserts

cylinder

the

fuel

in

their

installed.

Reverse

head

cylinder

valve

system.

chamber

original

the

gasket

rocker

positions

procedure

is

head

nuts

clearance

inserts

marked

in

are a loose

because

in 1 to

to

ensure

the

order

(see

Data).

16,

fit

the

cylinder

noting:

correct

shown

in

the

head

fitting.

Fig.

cylinder

face

1.

Torque

2

head. is

machined

75

They

lb.

ft.

TIMING Removing

1.

Drain

2.

Disconnect

3.

Remove

4.

Remove

5.

Remove

6.

Slacken

7.

Remove

8.

Remove

9.

Withdraw

10.

Remove

11.

Remove

12.

Remove

13.

Remove

14.

Retract

15.

If

the

ponents

16.

Remove Position

17. sioner

18.

Draw

19.

Refitting.

CHAIN,

cooling

four drive water

alternator

alternator. the

the alternator the the the

the

chain

tensioner

are

the

if

it

the

three

Reverse

CHAIN

system

hoses

to

bolts

tang

pump

crankshaft

degree timing oil

thrower

chain

to

tensioner

be

removed

camshaft

chain

requires

chain

WHEELS

(refer

salt

water

securing

between

adapter

mounting

nut,

pulley,

mounting

plate

from

cover.

from

alone

nut

using

wheel

overhaul.

wheels

the

procedure

AND

to

Section

pump.

salt

water

plate.

and

using

bracket

the

slipper

requires

leave

tool

marks

and

CHAIN

D)

water

pump

and

remove

tool

18G

using

tools

and

timing

crankshaft.

as

shown

attention,

the

tensioner

13G

98A.

as

shown

chain

off

in 1 to

TENSIONER

.

housing

engine.

belt.

391. 18G

231

adjustment

cover.

in

Fig.

remove

in

position.

in

Fig.3

their

18

shafts.

noting:

to

adapter

and

18G

bracket.

2

it

now,

then

remove

plate.

231B.

but

the

if

other

chain

com-

ten-

a.

Check

b.

Assemble

shown

c.

Release

d.

Ensure

seal,

e.

Centralize

and, in

Fig.

the

that

using

if

necessary,

the

chain

4

chain

the

crankshaft

tools

the

timing

wheels

tensioner

18G

134

cover

adjust

and

as

front

and

18G

using

the

chain

shown

oil

seal

134CR.

tool

chain

to

in

is

18G

wheel their

shafts

Fig.2

serviceable.

3.

alignment

with

(see

the

If

necessary

Data).

timing

marks

renew

as

the

Al4

Fig.

3

Fig.

4

::,,-

--

..

l

:-

.

-

CAMSHAFT Removing

1.

2.

3.

4.

5.

6.

7.

8.

Refer Remove Retract Remove Position Draw Remove Remove

to

the

AND

II

Timing

the

oil

the

chain

the

camshaft

the

three

the

camshaft

the

alternator.

Fig.

FRONT

Chain.

thrower

chain

5

PLATE

Chain

tensioner

nut.

wheel

wheels

locating

from

using

marks

Wheels.

the

slipper

tool

as

and

plate.

and

crankshaft.

as

shown

18G

shown

chain

off

1·,.--

Chain

in 98A. in

Fig.

their

'

..

~-~..I

Tensioner".

Fig.

2.

3.

shafts.

r ,

J I i I I

,

__

~-I

Fig.

6

Step 1 through

12.

IF

THE

FRONT

PLATE

IS

NOT

TO

BE

REMOVED.

OMIT 9 AND

16.

Al5

NOTE:

9.

Remove

10.

Disconnect

the

11.

Disconnect

12.

Disconnect

13.

Remove wheel

14.

Remove

15.

Remove

16.

Drain

17.

Release

18.

Remove

19.

Remove

20.

Remove

21.

Withdraw

22.

Lift

23.

Withdraw

24.

Refitting.

a.

Before front

b.

Check

c.

Check

d.

Assemble

shown

e.

Release Ensure

f.

seal,

g.

Centralize

h.

Refer

i.

Adjust

J.

Bleed

The

front

the

injection

the

hub.

the the

and

the

the the

the

out

the

tightening

plate

the the

in

Fig.

the

that

using

to

Data

the

fuel

plate

timing

the

throttle

pump.

the

fuel

the

high

lubricating

front cylinder

remove

oil

delivery

dowel

screw rocker rocker

push-rods.

tappets.

camshaft.

Reverse

any

into

the

camshaft

chain

the

wheel

chain

4 •

chain

the

crankshaft

tools

the

18G

timing

for

valve

rocker

system.

must

chain

and

feed

and

pressure

oil

plate

complete

side

the

sump.

pipe

shown cover. shaft.

the

procedure

of

the

cylinder

end-float

alignment

and

tensioner

134 cover

torque

clearance

be

removed

tensioner.

stop return

pipes

feed

pipe

cover.

from

in

front

block

to

against

chain

wheels

slipper

front

and

oil

18G

with

wrench

to

renew

controls,

pipes from

from

with

the

from

the

injection

crankcase.

Fig. 5 and

in 1 to

plate

23

bolts,

ensure

the

figure

(see

Data).

to

as

shown

seal

is

134CR.

tool

18G

settings.

(see

Data).

the

and

the

injection

crankcase

pUT.:'lp.

withdraw

as

necessary

fit

all

correct

their

in

shafts

Fig.

positioning Data.

serviceable.

3.

chain

vibration

throttle

injection

pump.

and

the

oil

bolts

which

with

2.

If

return

pump.

injection

pump

noting:

pass

of

the

timing

necessary

damper.

spring,

pump

and

strainer.

through front

marks

renew

from

chain

the

plate.

as

the

OIL

PUMP,

Removing

1.

Remove

2.

Remove

3.

Remove

4.

Remove

5.

Withdraw

6.

Refitting.

a.

The

b.

Refer

c.

Fit

the

to

compress

d.

Tighten

e.

Adjust

f.

Bleed

CONNECTING

engine.

valve

cylinder

the

big-end

the

Reverse

cylinder

to

Data

connecting

the

cylinder

the

valve

the

fuel

rocker

head.

caps.

connecting

the

head

for

gasket

torque

rods

the

piston rocker

system.

RODS

shaft

rods

procedure

wrench

with

rings.

head

clearance

and

is

marked

their

nuts

AND

tappets.

and

settings.

offsets

in

the

PISTONS

pistons

in 1 to

to

ensure

as

order

(see

Data).

upward.

5,

noting:

correct

show~l

shown

fitting.

in

Fig.6 , using

in

Fig.

1 •

.

tool18G

55 A

Al6

FLYWHEEL Removing

1.

Take

2.

Remove

3.

Remove

4.

Close oil

5.

Disconnect

6.

Disconnect

7.

Disconnect

back

8.

Remove

weight

inlet

cooler

approximately

transmission

9.

Remove

10.

Remove

and

rear

backplate

11.

Remove

screws

12.

Remove washer

13.

from Remove tabs

crankshaft.

of

crankshaft.

14.

Remove

15.

16.

block Remove Remove

and

HOUSING,

off rear nut

securing

and

(hose

battery shaft

coupling

bolts

Starter

Flywheel

of

backplate)

two

Damper

securing

Flywheel.

and

remove

Gear

the

star

Remove

Backplate.

pull gasket oil

seal

FLYWHEEL

rear

mounting

outlet

sea

between

cable

four

and

lock

straight

Motor.

Housing.

locating

Plate.

damper

(Hydraulic

the

Drive

Plate

washer

star

Remove

backplate

from

(if

damaged,

of

engine

brackets

each

rear

water

oil

leads

or

rod

between

inches.

washers

back

securing

dowels.

(Hydraulic

plate

bolts

and

remove

washer.

from

cylinder

AND

with

from

mounting

cocks.

cooler

from

and

clips

transmission

securing

and

filt

Remove

housing

to

flywheel.

Transmission)

securing

Flywheel.

bolts Pull

bolts

the

and

cylinder block pressed

BACKPLATE

sling

attached

transmission

bracket

Disconnect

and

heat

starter

from

away

from

bolts

to

Transmission)

flywheel

(Manual

securing

drive

lock

washers

block

face.

fit).

to

rear

housing.

to

flexible

raw

exchanger).

motor.

transmission

and

propeller

transmission

engine.

and

lock

backplate.

Knock-up

to

the

cranksh

Transmission)

drive

gear

and

securing

two

locating

lifting

water

shift

shaft

to

washers

Pull

Remove

the

plate

flywheel

backplate

eye.

mount.

from

transmission

lever.

and

move

bellhousing.

(front

housing

the

socket

tabs

. .ift.

of

Pull

Knock-up

and

flywheel

from

crankshaft.

to

dowels.

of

housing

from

the flywheel

to

cylinder

shaft

Pull

the head star

the

To

View

Examine

gear

if

required. heating ment

17(a). the

the

available

Place

assembly

Arrange gear mended

Heat

uppermost.

that

the equipment, the

ring

(b)

Ensure

burrs.

(c)

Heat

Fit

the

ring

flywheel

18.

Clean

flywheel.

19.

Check

and

the

ring

the

ring

thus

gear.

the

gear

and

the

that

Overhaul

flywheel

The

evenly

proceed

the

flywheel

in

the

flywheel the

bottom

gear

expanding

Lift

that

the

new

ring

over

allow face

of

the

two

starter fitting

to

as

container

assembly

The

complete

face

evenly

out

the

face

gear

tlle

the

ring

the

cylinder

locating

ring

of a new

shrink

it

follows:

in a suitable

by

so

of

the

around

the

ring,

ring

gear

of

the

flywheel

to

the

approximate

flywheel

to

cool

block,

dowels

gear

teeth

ring

onto

the

container

positioning

that

it

is

ring

must

ring

be

its

circumference

whi.ch

and

will

completely

and

with

the

lead

at

room

crankshaft,

in

the

for

damage

requires

special

flywheel.

of

four

metal

partly

be

submerged

above

the

approximately

allow

the

dry

new

ring

temperature,

in

on

the

temperature.

backplate,

cylinder

block

or

With

clean

blocks

water 1/4

using

flywheel

it

gear

teeth

face

wear,

workshop

special

cold

water

under

in

water

line

in.

above

oxy-

acetylene

to

off. are

clean

refer

to

facing

flywheel

are

and

replace

equipment

workshop

and

the

ring

with

and

i-es

water

drop

away

and

"General

the

front

housing

free

from

equip-

support

the recom-

welding

free

burrs.

ring

for

gear.

ring

level.

from

Data".

of

the

and

20.

Check holes locating

free

21.

Position ment

To

Install

It

is

aligned

22.

Install

23.

Install

24.

With the plate

the

for

from

of

most

important

with

oil new

the

backplate

locating

backplate

the

dowels

burrs.

the

flywheel

locating

the

crankshaft.

seal

gasket

two

flywheel

to

holes.

cylinder

in

the

housing

holes

that

if

removed.

to

the

cylinder

for

flatness.

block

backplate

and

the

backplate,

cylinder

housing

Secure

dowels

over

dowels.

block

locating

block

with

Examine

for

the

backplate

flywheel

face.

gasket

bolts

are

the

alignment

Ream

dowels

with

and

the

free

and

installed

cylinder

lock

backplate

from

locating

fit

and

flywheel

washers.

burrs.

of

the

dowels,

oversize

in

the

block

two

dowels

Examine

flywheel

checking

dowels

housing

backplate.

dowels

locating

the

housing

if

required.

be

correctly

in

the

Al7

two

are

align-

Install

back-

Alignment

25.

Secure Set

the crankshaft axis.

right

All

adjustments

and

fered

26.

Fitting a.

Install star

b.

Bend

c.

Fitting

d.

Secure

27.

Fitting a.

Install with

b.

Secure

set shaft

flywheel

of the

plunger

This

angles

under

with.

Flywheel.

washer

Flywheel.

bolts.

gauge

Backplate

dial

test

of

and

check

facing

to

crankshaft

to

NO

CONDITIONS

flywheel

and

over

tabs Damper damper

the

flywheel

Bend

base

plunger

one

way,

face

indicator the

that

should

bring

(Hydraulic

on bolts.

of

star

Plate.

plate

(Manual

gear

over

of

the

against

to

take

should

gauge

the

be

against

face

within

axis.

the

backplate

must

Transmission)

crankshaft

washer.

(Hydraulic

to

flywheel

Transmission)

drive

tabs

dial

test

vertical

up

end

be

within

with

of

the

flange

with

plate

of

star

indicator

float,

o.

002

the

base

the

vertical

backplate

inches

within

rear

and

(total

the

face

secure

Transmission)

sockhead

and

star

washers.

to

the

machined

and

turn

in.

of

the

face

is

at

indicator

limit

of

the

flywheel

screws.

washer

backplate

face

of

flywheel.

gauge

of

the

right

angles

must

cylinder

to

crankshaft

adjust

flywheel.

to

the

backplate.

to

readmg)

be

on

the

block

to

crankshaft

gauge

Press

The

run

crankshaft.

Turn crankshaft of

being

backplate

be

inter-

with

and

secure

so

as

crank-

out

on

the

at

to

Install

28.

29.

30.

and

Locate housing and

lock Attach against ing

that is

O.

006

shaft

With

axis.

indicator interior indicator

Align

the

flywheel

to

backplate

washers.

indicator

the

flat

this

face

in.

(total

of

bored

gauge

Flywheel

machined

gauge

reading).

Housing

housing

(from

gauge

is

perpendicular

indicator

base

hole

in

on

front

base

face

to of

gauge

still

flywheel

the

backplate

of

housing

flywheel,

the

flywheel

to

crankshaft

reading)

attached

housing.

and

adjust

housing.

of

being

to

flywheel,

The

two

rear

axis.

limit

locating

of

backplate)

the

indicator

Turn

The

at

right

set

for

limit

angles

plunger

this

dowels

with

gauge

crankshaft

for

to

is

0.010

and

this the

of

secure

set

bolts

plunger

check-

facing

crank-

gauge

in.

(total

to

Al8

CRANKSHAFT Removing

1.

Remove

2.

Remove

3.

Remove

4.

5.

6.

7.

8.

9.

10.

Pump Remove Release Remove Remove Remove Lift

lubrication

out

Refitting

11.

Reverse a.

Refer

b.

Check

c.

Before the front

d.

Check

e.

Assemble

shown

f.

Release Ensure

g.

the

h.

Centralize

1.

Ensure

the

k.

Use

1.

Bleed

engine. flywheel

timing

sump.

the

oil

the

dowel

the

big-end

the

main

the

crankshaft

the

procedure

to

Data

crankshaft

tightening

front

plate.

the

in

Fig.

the

that

seal,

that

seal,

tool

18G

the

chain,

delivery

plate

chain

the

chain

the

using

the

using

554

fuel

housing,

chain

oil

from

screw

caps

bearing

in 1 to

for

torque end-float

any

into

wheel

and

tI

•

tensioner

crankshaft

tools

timing

crankshaft

tools

to

system.

flywheel

wheels,

sump.

pipe

from

shown

and

separate

caps,

and

coll~ct

wrench

of

the

cylinder

alignment chain

18 G 134

cover,

18G

134

align

the

in

using

35

noting:

against

front

wheels

slipper

front

and

using

rear

and

clutch

and

the

crankcase.

Fig.

the

tools

the

settings.

the

plate

block

(see

oil

18 G

tool

oil

18G

backplate.

chain

5,

and connecting

18G

main

bearing

figure

bolts,

to

Data).

to

their

as

shown

seal

is

134

CR.

18G

seal

is

134CQ.

plate.

ter;.sioner.

withdraw

rods

284

and

in

Data.

fit

all

bolts

ensure

shafts

in

correct

with

Fig.

serviceable.

3.

serviceable.

the

from

18G

thrust

2.

oil

pump.

the

284AJ.

washer

which

positioning

the

timing

If

necessary

If

necessary

crankshaft.

halves.

pass

through

of

marks

renew

the

as

Al9

Valve

rockers

1. Remove rocker

2.

Withdraw

3.

Slide

the

4.

Unscrew

to

clean

5.

Renew

18G

21

Q.

Drill

the

b.

Position Fig.

6. Burnish-ream Data.

7. Fit

8. Fit

the

it

with

the

positions

Tappets

9.

Worn finish machining

the

shaft locating

bracket.

the

split pins from

components

the

pi

ug

the

shaft internally.

worn

rocker

as

shown

the

rockers.

2.

rear

the

remaining

shown

tappet

in

bushes to coincide

the

bushes

the

rocker

locating screw.

in

bores

to

VALVE

screw

the

off

the

rocker

from

the

front

bushes. using Service

Fig. 1.

in

the

rockers

bushes

to

the

bracket

components

Fig.

suit

to

the

3.

may be cleaned up by fine-

oversize

ROCKER

from

shaft ends.

shaft.

end

of

with

the

oilways

as

dimension given

shaft and position

to

the

shaft

tappets

(see Data).

the

shaft

tool

shown

in

SHAFT

rear

in

the

AND

TAPPETS

Fig.

1

Data

Rocker

Bore Clearance

Tappets

Outside Oversizes Clearance

bushes

diameter

on shaft

diameter

in

(reamed

..

crankcase

in

position)

Fig.

2

Fig.

3

·8115

to

·8125 in. (20·61

·0005

to

·0025 in. (·013

to

·99875

·010 and ·020 in. (·254 and ·508 mm.)

·0005

·99925 in. (24·47

to

·00175 in. (·013

to

20·64 mm.)

to

·064 mm.)

to

·044 mm.)

24·48 mm.)

A20

1. Detach

2. Remove tool 18G 106.

3. Renew in If

4. through new valve gUides in

5. Ream

6.

If in listed

7.

Lap

8. Check

stand-down fitted, machine fit valve seat inserts.

if

9. Renew valve Fig.

the

the Data. the

valve gUides

the

to

the

position shown

the

gUides

necessary, regrind

Data and reface

in

'SERVICE TOOLS'.

the

valves

the

normal refacing will

the

components

1.

CYLINDER

spring clips from

valves and

valve spri ngs if

are

upper

face

through

to

the

onto

their

valve head stand-down (see Data).

is

excessive, even with a new valve

the

cylinder head (see Data) and

Inserts should also be fitted

valve

stem

to

the

valve

cotters.

their

components, using

they

are

not

as

specified

worn,

of

the

in

dimensions given

valves

valve seats with

seats, using

not

restore

oil seals, and reassemble

cylinder head as shown

drive

the

cylinder head. Fit

ports

and drive

Data.

to

the

angle given

tool18G

the

seats.

them

in

Data.

the

out

them

tools

29.

the

in

HEAD

...s--.

t

clio

./-\

If

f~

~---

Fig.

1

Data

Valve

springs

Free length Fitted length Pressure (valve closed)

Working Wire Core

Valve

gUides

Fitted position

A=·75:::::~6

..

coils

diameter

in.

(19·05::::~

mm.)

Inner

2·187 in. (55·55 mm.) 1·5 in. (38·1 mm.) 23

to

25 lb. (10·43

11·34 kg.)

71

in. (2·65 mm.)

·104

·75

to

·765 in. (19·05

19·43 mm.)

to

2·5 in. (63·5 mm.) 1·703 in. (43·26 mm.)

56·5

to

27·44 kg.)

5t

·156 in. (3·96 mm.)

to

1·125

to

28·96 mm.)

A

Outer

60·5 lb. (25·63

1·140 in. (28·58

to

Length: Inlet

Exhaust

Inside diameter: Inlet (reamed

Exhaust (reamed

Outside diameter: Inlet and exhaust

Oversize gUides

in

Valves

Seat angle: Inlet and exhaust Seat face width: Inlet

Exhaust

Head diameter: Inlet

Exhaust

Stem diameter: Inlet and exhaust

lift: Inlet and exhaust

Stand-down: Inlet and exhaust

Va

Ive

seat ;

nse

rts

Cylinder head machining dimensions:

Inlet

(A)

1·6615

C.

(42·20

1·540

D.

1·46 in. (37·08 mm.)

E.

·090

F.

(2·29

·278

G.

(7·06

H.

(·38 mm.) 45°.

J.

40°.

K.

to

1·6625 in.

to

42·23 mm.)

to

1·545 in.

(39·12

to

39·24 mm.) (33·02

to

·095 in.

to

2·41

mm.) (2·29

to

·281

in.

to

7·14 mm.)

Max. radius ·015 in.

L.

M.

N.

P.

Q.

R.

S.

T.

position)

in

position)

..

Exhaust

1·4215 (36·11

to

BOO

to

1·22 in. (30·99 mm.)

·090

to

·278

to

(7·06

to

Max.

radius ·015 in. (·38 mm.) 45°. 40°.

to

1·4225 in.

36·13 mm.)

1·305 in.

to

33·15 mm.)

·095 in. 2·41

mm.)

·281

in.

7·14 mm.)

(B)

2·14 in. (54·36 2·5 in. (63·5

·3438

to

·3433

to

·5645

to

·5735

to

45°

·195±·0025

·199±·0025 in. (5·055±·063 1·557

to

1·307

to

·34175

to

·39 in. (9·9

·020

to

·030 in.

mm.)

·3443 in. (8·733

·3438 in. (8·720

·5650 in. (14·34

·5740

in. (14·567

in. (4·953±·063

1·562 in. (39·55

1·312 in. (33·20

·34225 in. (8·68

mm.)

(-508

to

to to

to

·762 mm.) stand-down

8·745 mm.)

8·733 mm.)

14·35

mm.)

14·580 mm.)

mm.) mm.)

39·67 mm.) 33·32 mm.)

8·69 mm.)

A21

1.

If

ovality near

bore exceeds

complete chain tensioner.

Data

Permissible ovality

the

mouth of

the

figure given

of

tensioner body bore

TIMING

the

tensioner body

in

Data renew

CHAIN

the

TENSIONER

2.

If

the

slipper head

and cylinder assembly.

·003 in. (·076 mm.) maximum

is

worn, renew

the

slipper head

A22

1.

If

the

chain wheel bearing requires renewal (see

Data). remove

the

driving flange from

wheel.

2. Press

3. Finish

4. Fit

from

in

Data.

out

the

chamfered end

the

bore

the

driving flange

old bearing and press

ofthe

new

to master spline and timing mark positions shown

that

its securing bolts

in

Fig.

slots.

Data

Chain wheel bearing Clearance on chain wheel hub

bore

(finished

INJECTION

of

the

chain wheel

bearing

the

chain wheel with

1. Position

are

central

in

position)

the

in

a new bearing

bore.

to

the

size given

in

the

relative

the

flange so

in

the

adjusting

..

PUMP

chain

the

CHAIN

1·75025

·001

to

WHEEL

to

1·75075 in. (44·46

·002 in. (·03

to

Fig.

1

to

·05 mm.)

44·47 mm.)

1. Unscrew the

2. Remove

3.

If

the

4. Renew

the

relief valve spring.

the

valve cup

the

valve spring if it

Data.

5. Reassemble

the

Data

Free length Operating pressure

of

oil pressure relief valve spring

plug shown

valve cup. using

to

seat contact

onto

its seat with

components

..

OIL

in

Fig.

1 and

tool18G

is

unsatisfactory. lap

tool18G

is

not

as

to

the

crankcase.

PRESSURE RELIEF

withdraw

69.

specified

in

3 in. (76·2 mm.) 50

VALVE

to

55 Ib./sq. in. (3·52

Fig.

1

to

3·87 kg.Jcm.

2

)

1. Remove

2.

Check

the

pump cover.

the

rotor

end-float against

Data. Excessive end-float can be

3.

lapping Check

rotor Renew necessary

the

pump body face.

the

diametrical clearance

and

the

pump body against

the

rotors,

to

correct

or excessive clearance.

Data

Oil pump Outer Rotor

rotor

end-float

rotor

to

body diametrical clearance

lobe clearance:

pump

the corrected

between

the

figure

body,

figure in

the

or

both,

in

OIL

by

outer

Data.

as

PUMP

4.

Check against clearance

5. Reassemble chamfered the

the

pump

rotor

figure

is

excessive.

the

end

body.

·005 in. (·13 mm.) maximum

·010 in. (·25 mm.) maximum

·008 in. (·2 mm.) maximum

lobe clearance (in

in

Data. Renew

components,

of

the

outer

rotor

two

the

ensuring

is

innermost

A23

positions)

rotors

that

the

in

if

1.

If aged, splitting and chisel.

2.

Heat

the

C030r

00302

teeth

on

remove

the

new

the

starter

the

starter

ring across

starter

ring uniformly

FLYWHEEL

ring

are

worn

or

dam-

ring by drilling a hole and

the

hole with a

to

hammer

the

tem-

·006 in. (·15 mm.) maximum

perature indicating to

3. Fit away from

grey

the

given

paint

at

the

starter

the

in

Data;

on

the

correct

ring

with

flywheel register.

the

strip

of

temperature-

ring will change from pink

temperature.

the

tooth

chamfer facing

Data

Starter

ring fitting

temperature

200

0

to

2300 C.

(39r

to

4460 F.)

A24

1.

Withdraw ing liner, using shown

in

2.

Withdraw ing liner, using shown

in

the

Fig.

the

Fig.

front

1.

rear

2.

the

bear-

tools

beartools

CAMSHAFT

I

BEARING

,

LINERS

Fig.

18GI24B

1

3.

Withdraw bearing liner, using tools

shown

4. Fit a new liner, using shown

up

the

liner with

crankcase.

the

in

front

in

Fig.

oil holes

those

4, and lining

Fig. 3.

bearing

the

in in

centre

the

tools

the the

Fig.

2

laG 124H

3

,

I

T

Fig.

4

5.

Fit a new rear bearing liner. lining up holes and using

shown

in

Fig.

the

5.

oil

tools

A25

18GI24B

\-,."...----,"-I~§C~",';J..,

~~~~~~~~

Iii

,

Fig.

5

6. Fit a new liner. lining

holes

shown

7.

Ream bearing liners. using

tools shown

centre

and using

in

Fig.

6.

the

front and

in

up

the

Fig.

bearing

the

oil

tools

rear

the

7.

18GI24D

IBGI23

M

Fig.

18GI24H

6

7

8. Ream

Data

Camshaft journal diameters: Front

Clearance End-float

the

liner. . using

shown

in

Fig.

in

centre

the

8.

bearings

bearing

tools

..

Centre

Rear

..

18GI23AD

1·78875 1·74875 1·62275

·001

to

·003

to

Fig.

8

to

1·78925

to

1·74925

to

1·62325 in. (41·22

·002 in.

·006 in. (,076

(·03

in. in.

to

(45·43 (44·42

·05

to

·152

to to to

mm.)

45·45 mm.) 44·43 mm.) 41·23 mm.)

A26

1.

Separate

2.

Check

bush against excessive,

a.

b.

3.

Check piston ring gap against

the

4.

Assemble the

shown

the

gudgeon

renew

Position

side

Finish-ream

rings,

combustion

the

of

the

piston ring

or

the

in

Fig.

piston from

the

figure

the

new

connecting

the

piston and rings,

piston

cavity and oil

2.

the

pin clearance

in

Data.

little-end bush.

bush with its

rod

bush

to

groove

the

figures

to

the

CONNECTING

connecti

as

the

as

connecting

ng

in

the

If

the

clearance

jOi

nt

shown

size given

clearance and

in

Data.

necessary.

jet

hole in line

rod.

little-end

on

the

in

Fig.

in

Data.

Renew

rod

with

cap

1.

the

ROD

AND

PISTON

1--'----

is

as

Fig.

1

Data

Gudgeon

pins

Diameter Fit

in

piston

in

connecting

Fit

Little-end bushes

Inside

diameter

Pistons

and

rings

Ring/groove clearance:

Top

and 2nd (compression)

3rd

(stepped

4th

(slotted

Ring gap:

scraper)

Top

Remainder

rod

(reamed

in

position)

Fig.

1·1248

to

1·1250 in. (28·57

·0003 in. (-008 mm.) clearance interference

·0005

to

·0012 in. (·013

1-1255

to

1·1260 in. (28-588

·0026

to

·0046 in. (-066

·0026

to

·0046 in. (-066

·0025

to

·0045 in. (-064

·014

to

·019 in. (·36

·010

to

·015 in. (·25

to

·030 mm.) clearance

to

·117 mm.)

to

·117 mm.)

to

·114 mm.)

to

·48 mm.)

to

·38 mm.)

2

28·58 mm.)

to

·0001 in. (-003 mm.)

28·60 mm.)

A27

1.

If

the

cylinder

maximum oversize given

dimension given

bores

cannot

in

Data

for

fitting cylinder liners.

Data

Standard cylinder Oversizes: First

Bore size for fitting liners

bore

Second (maximum if Third

..

linered)

Data

Crankshaft journal Clearance Crankpin Clearance Undersizes Oournals and crankpins):

First

Second

Third

Fourth

End-float

in

diameter

in

..

diameter

main bearings

big-end bearings

..

be cleaned

bore

..

CYLINDER

up

at

the

them

to

the

CRANKSHAFT

BORES

2.

Press

in

the

standard

3·4995

to

3·501 in. (88·89

·010 in. (·254 mm.)

·020 in. (·508 mm.)

·030 in. (·762 mm.) 3·642

to

3·6425 in. (92·507

2·4785

to

2·4790 in. (62·95

·0015

to

·003 in. (·038

2·2480

·002

·010 in. (·254 mm.)

·020 in. (·508 mm.)

·030 in. (·762 mm.)

·040 in. (1·016 mm.)

·002

to

2·2485 in. (57·099

to

·0035 in.

to

·003 in.

(·051

cylinder liners and

bore

size.

to

88·93 mm.)

to

92·520 mm.)

to

62·96 mm.)

to

·076 mm.) to

57·112 mm.)

to

·089 mm.)

to

·076 mm.)

then

bore

them

to

A28

INJECTION

Removing

1. Disconnect cover

2. Remove

panel.

the

battery

and

remove

high-pressure pipes from

the

engine

and injectors.

3.

Disconnect

the

throttle

return

spring from

pump.

4. Disconnect

throttle

and

stop

controls

from

the

pump.

5. Disconnect

delivery and

return

pipes from

the

pump.

Data

Injection timing

of

in

line with

Fit

the

adjustment:

front

face

of

crankshaft pulley and

in

place

pressure

set

the

timing

the

tool

as

shown.

the

master

the

qUill

shaft and injection pump

the

master

mark

spline

on

the

of

the

pointer

in

the in

pump

degree

injection pump,

to

eliminate chain

in

line

with

pump

drive

the

driving flange.

to

the

engine.

flange

with

Method

1. Position No. 1 piston 25° B.T.D.C. com pression (mark on plate on timing cover).

2. Fit tool 18G 698 apply gentle clockwise slack and mark on

3. Position

lining up timing pointer.

pump

the

hub

the

PUMP

6. Remove injection pump and

Refitting

7. Reverse

Q.

Time

described b. Bleed c.

Adjust described

25° B.T.D.C.

the

three

the

procedure

the

injection pump

in

Data.

the

fuel system.

the

in

Data.

securing nuts and

qUill

shaft from

in 1 to

withdraw

the

6, noting:

to

the

engine.

engine

maximum and idling speeds

the

as

Governed speed:

Maximum (light running)

Idling

of

Method

1. Adjust

adjustment

the

maximum speed

an engine speed

2.

3.

4.

nut, fit seal

Stop

(2) Start

to Screw

increase

the

sleeve and seal

usi

ng

tool 18G 541.

the

engine and

until

it

is

out

the

engine and adjust

give an engine speed

in

the

anti-stall

is

noticed,

turn.

5. Readjust speed

6.

Test engine

Q.

the

idling

of

500 r.p.m. and

the

anti-stall

at

3,000 r.p.m. and releasing

If

the

engine stalls.

slightly and

b.

If

the

engine deceleration

the

anti-stall

(engine

at

normal running

stop

of

3,700 r.p.m. Tighten

it

with

unscrew

of

contact

with

the

of

450

screw

then

unscrew

stop

screw

tighten

screw

setting

screw

in

re-test.

is

screw

slightly and

screw

wire

the

anti-stall

the

governor

idling

stop

to

500 r.p.m.

until a

slight

it

one-third

to

give an engi ne

the

locknut.

by

running

the

anti-stall screw

sluggish,

re-test

temperature

(1)

to

give

the

lock-

and a lead

screw

arm.

screw

(3)

speed

of

the

throttle:

unscrew

a

3,700

r.p.m. (this gives a maximum speed

3,500 r.p.m.).

500 r.p.m.

and

air

cleaner

serViced):

under

II

I

load

of

A29

7. Tighten operation

Note.-After

screw

ensure

idling

stop

Removing

1. Disconnect

cover

2.

Disconnect

3.

Disconnect injectors.

4. Remove

tors,

Refitting

5.

Renew

washers as

6. Reverse

securing nuts

7. Bleed

the

anti-stall

of

the

every

that

screw

and

the

panel.

the

securing

using tools 18G 284 and 18G 284

the

atomizer

shown

the

procedure

to

the

high-pressure pipes.

screw

locknut and check

stop

control.

adjustment

the

idling speed

not

by

the

battery

spill rail from

high-pressure pipes from

nuts

seal washers, fitting

in

Fig. 1.

in 1

the

figure given

of

is

controlled

anti-stall

and remove

the

injectors.

and

withdraw

to

4,

tightening

in

Data.

the

anti-stall

screw.

the

P.

the

by

the

INJECTORS

engine

the

injec-

new

the

Data

Torque

Removing

wrench

1. Disconnect the

end

siphoning.

7..

Disconnect

3. Remove pump.

setting

of

the

for

both

pipes

the

pipe from

the

priming cable from

two

securing nuts and

injector

from

securing nuts

the

lift

pump

the

tank

to

the

pump.

withdraw

LIFT

and seal

prevent

the

12 lb. ft. (1·7 kg; m.)

PUMP

Refitting

4. Reverse system.

the

procedure

Fig.

1

in 1 to

3 and bleed

the

fuel

A •

.30

VALVE

The

correct

1.

Unscrew

2.

Check

Check Check Check Check Check Check Check

3.

Adjust until

4.

Hold

checking

ROCKER

clearance

the

clearance

No. 1 valve No. 3 valve No. 5 valve No. 2 valve No. 8 valve No. 6 valve No. 4 valve No. 7 valve

ifnecessary.

the

clearance

the

screw

that

CLEARANCE

between

rocker

cover

at

the

with with

with

with with with with

by

loosening

is

correct.

against

its

gasket

rotation

(Fig.

the

valve

nuts

(1)

position

No. 8 fully No. 6 fully No. 4 fully No. 7 fully No. 1 fully No. 3 fully No. 5 fully No. 2 fully

the

and

is

serviceable.

C.3)

rockers

and

lift

illustrated

open open open open open open open open

locknut tighten

and

off

(2)

the

stem

cover.

and

the

and

turning

locknut.

is

given

order

adjustment

Refit

in

"General

as

follows:

the

screw

rocker

Data".

(3)

cover,

OIL

The

at

the

FILL

oil

fill

CAP

cap

recommended

Fig.

(Fig.

(1)

incorporates

C.3.

C. 4)

interval.

an

Fig.

Valve

air

C.4.

Rocker

filter

Oil

Clearance

which

Fill

Cap

cannot

be

cleaned.

Fit a new

cap

AIR

INTAKE

The

manifold.

replaced.

SILENCER

air

intake

The

intake

Depending

silencer

is

covered

on

operating conditions

performing maintenance checks.

Clean

screen with fuel

oil

and

is

located behind the heat exchanger

by

a metal screen

If

clogged

lint

free

check

it

cloth.

which

does

to see the screen

will impair proper engine operation.

not

and

have

exhaust

to

be

is

clear

A31

when

LUBRICATING

The

the

dipstick

OIL

engine

assembly.

application they

LUBRICATING

Note

they

must

OIL the positioning be

replaced exactly

will not function

SERVICE

1.

HINTS

When

replacing the heat exchanger or intake these attached

2.

The

zinc

end

of

3.

The

rear

the

one

DIPSTICK oil

pan

contains a boss The

may

be

reversed

LINES

as

it

is· designed to pass

silencer

it

rather

is

located

the engine.

most

petcock

forward of

on

either

side of the engine to accept

opposite side contains a plug.

if

desired.

of

the

as

is

easier

on

that

lines originally

than

the

is

before

removing installed. and

filter

if

you

to each bottom

remove

part

the exhaust Inanifold assembly with

individually.

of the heat exchanger

the heat exchanger

the fresh water.

them

If

in only

should

is

the

Depending

for

any

on

service

reversed the

one

direction.

have

to

remove

at

the forward

raw

water drain

your

as

filter

the

and

air

OTHER OVERHAUL

Q.l

MARINE

Activation

COOLING

TRANSMI

Type

SAl

Paragon

Warner

Short

CONTENTS

ENGINE

ELECTRICAL

SYSTEM

SS

IONS

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

SAO

Manual

and

SAO

and

SAO

P-2l

Hydraulic

Profile

by

Fuel

Pressure

(EXTERNAL)

......•.............................

Clutch

Reduct:i_on

Series,

Sailing

Adjustrnents

........................•..........

SYSTEM

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

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

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

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

Units

Hydraulic

Gear

............•...........

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

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

SECTION

Q

R S

S . 9

S.2l

S

.23

S.29

S

.35

S.4l

PAGE

Q.2

SECTION Q

Q.2

MARINE ENGINE ELECTRICAL SYSTEM

ACTIVATION

(Push

Button

This

six

cylinder January very

engine of

sure

removes heating

a NOTE:

simple

separate

Starting the

starting

Once

developed

the

fuel

pressure to

the

alternator

instruments.

When

sure

drops

When

separate

installation breakers, Responsibility" supplied

BY

FUEL

Start)

system

1975. switch

alarm

start

motor

the

injection switch.

alarm

the

voltage

an device,

It

is as

with

PRESSURE

is

Westerbeke

Basically,

and

eliminates position

system,

is

accomplished

push

to

engine

in

system

for

engine

and

the

from

engine

the

push

button.

important

includes

described

on

your

supplied

engines

when

button crank.

is

running,

the

low

pump

Voltage

excitation

is

the

operates

(if

supplied)

is

stopped,

fuel

pressure

these

supplied

device

that

fuses

under wiring

engine.

on

all

the

system

the

to

activate

supplied.

by

which

pressure

is

then

and

devices.

with a pre-

is

energized

your or

"Ownership

diagram

four

beginning

is

need

operation causes

fuel

circuit

for

the

pres-

side

a

fuel applied and for

pres-

switch

engine

and

a

the

of

to all

by

SECTION Q

ACTIVATION BY FUEL PRESSURE

(PUSH

~====:=:::;t--.J@

~-.-.-r-r-r-r~@

BUTTON START)

WIRING

DIAGRAM

'-0@

II

't"0PTI

ONAL

ALARM

I :

I

I I

I '

(If>

i"lr~

I I

I

ClPTIONAL

I

SPUTTER

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8,

I I I

START

SW.

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Isr

....

R;i

sw

I......

I I

L

@,

040

....

5t:t:

NO'rE-e

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I

L.

PANE~

WESTERB£KE

ASSEMSL.Y.

P~E

... E ....

'T

~w.1

~

I

J@

r-------------

.,...

PRE-HEATER

RED

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WIRING

(N5EFtT

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hoIOTOR.

c;::.,

® I SEE NO'T'E-A

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F"OR

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.

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Q.3

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____

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1Io

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I I eA'TT'1

CHART

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HEATERS

NO:5

wE:STERBEKE

6!:W

wESTEReEKE: 120

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SEC

NorE-A

OA'T":' I

Q.4

Marine Engine Electrical System

ACTIVATION

(Keyswitch

This

cylinder

to

January

Putting

tion plied). position

Turning tion the

engine.

switch

When

voltage

excitation ever sure

When

heating

arate

When electric a

separate panel. NOTE: stallation breakers,

ponsibility" with

BY

LUBE

Start)

system

Westerbeke

1975.

the

energizes

Returning de-energizes

the

operates

is

released the is

supplied

and

the

engine

removes

an

engine

device,

push

your

an

It

button engine

stop

push

is

includes

as

engine.

OIL

PRESSURE

is

supplied

Operation

start

engine

voltage

described

switch

an

alarm

start

the

starting

Upon

on

starting,

to

all

stops,

is

it

at

is

solenoid,

button

important

the

diesels

in

system

the

start

the

switch

to

the

develops

to

the

instruments.

loss from furnished

is

energized

the

key

furnished

it

at

that

fuses

under

wiring

on

all

produced

is

very

the

(when

switch

alarm.

to

Crank

motor

the

Run

position.

oil

alternator

of

oil

these

with a pre-

switch

with

is

energized

the

key

your

or

circuit

"Owner's

diagram

4

and

prior

simple.

Run

posi-

sup-

to

posi-

and

starts

start

pressure,

for

When-

pres-

devices.

by a sep-

panel. an

switch

engine

Res-

supplied

6

Off

by

in-

ACTIVATION BY LUBE OIL PRESSURE

(KEYSWrrCH

STARn

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Drawing

No.

15245

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<;.6

YOUR NOTES

SECTIONR

COOLING SYSTEM (EXTERNAL)

1.

DESCRIPTION

The 4 and cooling system. Transfer of heat the sea (raw) water radiator.

water.

tubes of the heat exchanger while the fresh water around the tubes of the heat exchanger. so

the water cooling passages in the engine stay clean.

20

absorbed heat exchanger; here cylinder block,

means

the cylinder bores connect with corresponding openings in the cylinder head, the fresh water ci rcul

engine reaches

through the thermostat into the expansion tank

An

FRESH

WATER

Heat

by

of

a centrifugal fresh water

6 cylinder marine diesel engines are equipped with a fresh water

from

the fresh water (closed system)

is

It

differs

unrestricted

SYSTEM

rejected

the fresh water.

where

its

because

in combustion,

it

ates

operating temperature, the fresh water then passes out

accomplished

raw

fast-flowing stream of sea water flows through the

The

is

cooled

is

circulated

around the

by

a heat exchanger,

water, not

as

well fresh water flows and

discharged into the lower part of the

through the block

pump.

val

air,

The

raw

water

as

heat developed

Openings

ves

and

Juel

and

cools the engine's fresh flows

in the water

the

similar

rapidly under

and

fresh water never

from

the expansion tank to the and

injectors.

circuit

to

by

friction

cylinder

jacket

When

repeats.

an

circuit automobile

low

pressure

is

head

around the

to

mix

by

where

FROM

COCK

SURGE

TANK

FRESH

WATER

PUMP

RAW

WATER

PUMP

SEA

OIL

FILTER

EXHAUST

MANIFOLD

I -

...

0

-~-

HYDRAULIC

OIL

--¥

COOLER

--lBOARD

~~--~~

......

,

~

> >

~-

r-~

GEAR/1:J.'/CXSJ

If

lOVER

HEAT

EXCHANGER

-,

r )=<P

~

Cl

RAW

FRESH

-.

-

ENGINE

IUSED

t::l

RAU L IC

FROM

<J::!

COCK

WATER

ON

ONLY

SE

A

OIL

HYD-

GEAR

R2

3.

SEA

of

sea water

This

water

WATER

The raw

pump,

engine water

SYSTEM

is

indirectly

which

and

absorbs the heat

is

picked

passes through the

up

cooled

from

passing through the heat exchanger the

raw

water

The

surfaces

and

cooled

the engine

sailing oil and

4.

gear the sea water cooler, transmission

SEA

WATER

The

cover

and

positive

The

impeller

NOTE:

oil by

water displacement

housin9, producing the

is

then piped overboard.

cooler conducts heat

the

lubricating

by

the flow

is

equipped with a water cooled transmission for a hydraulic or

and

then piped overboard.

oil

cooler are heat exchangers.

oil,

of

sea water through the tubes of the

is

also

PUMP

pump

driven

has

may

from

the fuel rotary

flexible

be

vanes

belt

pump,

driven

pump

which pumping

As

the water account should carry

a spare impeller

pump

contains a neoprene

it

be

by

the

unrestricted

from

the freshwater via the heat exchanger.

the sea

oil

(and

away

which

circulated

gear.

by

a powerful neoprene impeller sea

cooler to the heat exchanger. After

transmission

from js

the bearings

circulated

through the tubes

In

this

or

mounted

sense both the engine

The

water

with a brass case

wipe

against

action.

run in a dry

and

gasket.

condition.

oil

by

the

on

t~e

pump

and

a curved impeller,

fast-flowing

cooler and

other

oil

if

pressure

oil

stream

installed), friction

pump

r.ooler.

When

RB

of

a transmission

oil

cooier

front

of the timing

is a selfpriming,

a neoprene impeller.

cam

on

plate

no

in the

Always

DRAIN

5. side

petcock

COOLING Remove of

the on

SYSTEM the pressure cylinder

block behind the

the bottom

of

counter-clockwise to open.

6.

FILLING

Ensure

on

the bottom

fill

cap the top is

reached. Stop engine,

7.

IMPELLER

a.

b.

c.

d.

e.

f.

8.

THERMOSTAT

COOLING that

on

top

of

the tank.

of

SYSTEM the petcock the heat exchanger are closed.

of

expansion tank

Start

REPLACEMENT Remove Remove

To with a Align impeller

impeller blades

the

Secure

In

front

end

impeller.

replace the neoprene impeller coat

good

grade water

key all

pump,

the event

end

i.e.,

cover

of

a. Drain cooling system (approximately

b. c.

Remove and Lift

the nuts

lift

up

housing.

out thermostat.

cap

from

expansion tank

starter

and

motor,

open

the petcock

and

the fresh water drain

the heat exchanger. (Forward petcock)

on

the side

engine

carefully

cover

blades

and

wear

and

way

with

lie

in the

trailing. gasket with four screws being present

retaining

and

pump

the thermostat housing to the

of

the

pour cooland

run

~ntil

remove

the cap

gasket.

grease only.

shaft

same

key.

direction

en

cylinder

Turn normal

the

Care

end

two

quarts).

block

clockwise to

into

system to

operating temperature

and

add

coolant

impeller

and

should relative

and

lockwashers.

cover, the cover

Turn

and

impeller

be

taken

to the

cylinder

on

the

petcocks

the petcock close.

one

inch

as

required.

chamber

that rotation

may

be

head

Remove from

the

of

reversed.

9.

10.

d.

Test the opening temperature Raise to the temperature

e.

If

to cool.

f.

Install to cylinder head.

g.

Replace to within

corrosion

h.

Start Stop engine, as required.

REMOVE

a.

b.

SEA

Remove Remove away

c.

Remove

d.

To

(Rector seal or to prevent

ENGINE

HOT

thermostat

If

fails

it

sticks

to open, thermostat with coolant,

one inhibitor

engine

inch

and

remove,

from

or

run

until

carefully

WATER

hoses

PUMP

from

(Timing

pump.

the four bolts securing

from

replace the

plate.

drive tang

air

WATER

HEATER

between

pump,

its

reverse the procedure above, using sealing

equivalent

leaks. Secure with

INSTALLATION

by

placing

stamped

fit

open,

new

top

or

renew

gasket

if

system

of

tank with clean ftesh water

antifreeze

normal

remove

cover

expansion tank

mounted)

pump

water

pump

on

th.e

ttterrnostat in the water.

on

bottom

new

thermostat.

new

and

of

thermostat.

Allow thermostat. secure thermostat housing

was

drained,

fill

solution. operating temperature

to adapter

coupling

inlet

hose

and clamps)

filler

plate,

and

discharge

cap

fuel

•.

the temperature

expansion tank

and a suitable

is

reached.

and add

and

pull

pump

coolant

pump

drive gear.

compound.

hose

connections

R3

10

~"'Ore:

__

WHEN_"!2_T

!N,;,TALLED A BO.E.....ENGI

:;URg._!A~~

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. ."'E •

-I\IHEN

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R:EM'?T~

!-~-.STA~~~E~?~

(A~_

PARr

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F'I'...~

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POINT

~UR('E.

~-~(

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EN~I!'IE

__

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TANK

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A~

'NI'TH

_~I

7

TRANSMISSIONS

SECTION S

8.2

Description

The

Westerbeke-Paragon

verse

gear

unitsconsistofa and a planetary are

self

contained

engine

Operation

On multiple

solid

locked

when

position.

same

The

reverse contains reverse moved ion

gears

to

With multiple

unc

the

It

is desi

mission in

boat

that

RPM lower

mission

lubrication

the

forward

disc

coupling.

or

the

direction

reverse

bandaroundthe

the

band

to

the

is

then

thus

the

engine

the

shift

disc

lamped

prope

Iler

rab

neutral,

in

either

the

shifting

and

preferably

to

prolong

and

clamped shift Thus

drive

planetary

is reverse obtai

turning

and

shaft

Ie

to

of

reverse

and

system.

drive,

clutch

The

lever

the

propeller

as the

is

clamped

position.

ned

the

rotation.

lever

in

clutch

the

remains

start

thus

direction.

be

done

the

boat.

manua

multipledisc

gear

are

the

reverse

are

locked

multiple

by

the

is

moved

engine.

obtained

reverse

when

by

driving

propeller

the

neutral

and

the

planet

stationary.

the

engi

avoiding

at

in

the

life

of

TYPE

Ily

operated

train.

independent

pressure

shaft

The

gears

ne wi

It is

speeds

800

the

These

gear

case

together

disc

clutch

produced

to

the

turns in

by

clamping

gearca~e

gear

train.

the

shift reverse

through

shaft

opposite

position

reverse

engine,

band

run

idle

th

the

moving

recommended

be low

RPM

range

SA1

re-

clutch

units

of

the

and

as a

is

forward

the

which

The

lever

is

mot-

the

are

and

trans-

the

1000

or

trans-

MANUAL

The

number

oi I

changes ditions. should season,

Mode I and

The mode I numbers the

name

The

parts areintendedonlyto to

disassembly

ed

to

be

order

parts,

as gi

ven

accompanying

The

shou

Id

out

prior bestaspossible the

exploded cussions stood

so indicated be

carried

DISASSEMBLY

As

in

any

must

and a II

Some

of

hours

varies

Under

be

changed

whichever

Seria I Numbers

plate

on

lists

accompanying

and

used

to

refer

in

the

above

TROUBLE-S

be

studied

to

any

what

views should that

any

from

the

out

properly.

OF

servicing

rules

these

rules

that

can

with

normal

every

is

and

the

cover

identify

assembly

identify

to

the

and

disassembly

the

and

be

carefully

or a II

trouble-shooting

TRANSMISSION

operation,

for

are

the

conditions,

100

shorter.

and

seria I numbers

of

the

and

parts

part

numbers

mentioned

HOOT!

'trouble-shooting'

the

suggestions

trouble

the

accompanying

of

the

good

workmanship

as

follows:

be run operati

hours

Part

Numbers

the

transmission.

exploded

parts

in

are

not

by

number.

and

parts

N G

to

determine

may

be.

read

and

service

c harts

clean

liness is a

between ng

con-

the

oil

or

each

are

on

views regards intend-

To

names

lists.

charts

carried

Also,

dis-

under-

work as

may

apply.

as

Lubrication

It is

recommended

lubrication.

the

ang

Ie

ion

model.

the

highmarkonthedipstick.

be

checked

ation.

The

of i nsta

The

periodically

that

quantity

lIati on

level

should

SAE

as

to

30

of

oi I

we

II

be

The

ensure

oi I be

depends

as

maintained

level

proper

the

used

upon

reduct-

should

oper-

for

at

1.

2.

3.

Use

only

washing

Use

only

pressing

Never

in

place.

clean

of

clean

parts

use a

parts.

oil

together

hammer

fluid

for

In

any

lubrication

to

drive

cleaning

ball

bearings

or

when

4.

5.

Never

is

carried

Use

only

moving

press a

through

properly

or

securing

ball

bearing

the

balls.

sized nuts

so

that

wrenches

and

capscrews.

the

force

in

re-

3.

Slide

entire backapproximately 3 inchesuntil is c

lear

verse

gine.

gear

of

reverse

engine

housing

gear

assembly c lear

housing

(92)

and

S.3

straight

housing

lift

re-

of

en-

6.

Replace

material.

7.

Work teeth scratches.

REMOVAL

FROM

NOTE: sion from the tain t hat a II verse tempted.

1.

2.

NOTE:

REMOVAL SEMBLY FROM

1.

2.

REVERSE

reduction

and

Remove

flange

Strike mallet reduction duction 3

inches

ion

of

reverse

for

uni

t.

Remove

lange

f

Remove

secure

end

gaskets

on a

and

OF

To

faci

the

of

reduction

capscrews

of

gear

to

unit

until

drive

Refer

disassembly

OF

capscrews

of

capscrews

reverse

plate

and

clean

oil

REDUCTION GEAR ASSEMBLY

GEAR

litate

engine,

gear

the

reduction

half

break

adapter

gear

to

REVERSE

ENGINE

cover

(58)

benc h and

seal

surfaces

HOUSING

remova I of

it

assembly

oi I is

unit

and

coupling

reduction

plate . Slide

straight

reduction

and

lift

housing

reduction

and

(4)

and

gear

or

timing

11

110

is

simpler

first.

removed

before

lockwashers

gear

housing.

flange

gear

back

approximately

unitclears

reduction

assembly.

gearservice

assembly

GEAR

housing

HOUSING

lockwashers

and

remove

lockwashers

gear

rings

with

protect

from

nicks

the

transmis-

to

Make

from

removal

with

unit

entire

unit

of

reduction

(6'1)

cover.

gear

remove

cer-

the

is

around

soft

from

reduct-

clear

manual

AS-

from

cover.

that

to

f~ont

nev'

and

re-

at-

re-

4.

Remove

engine gear.

5.

Remove

sion.

6.

Remove following mendati0n,

7.

If

necessary

(94) from

REMOVAL

REVERSE

1.

Remove

and

remove

er

(82) from

assembly.

2.

Loosen shafts careful

housing.

3.

Remove

assembly

housing.

4.

Remove

case

NOTE:

On

link,

pins

housing housing.

pilot

gear

front

engine

OF

GEAR

REDUCTION

screw

capscrews

(78) from sides

not

yoke

reverse

assembly

older

it

wi

that

before

roller

(92)

end

engine

only

to

replace,

front

end

GEAR

HOUSING

(81) from arm

ba

II

joint

eye

to

damage

(2) from

(40)

through

band

from

reverse

II

be

anchor

removing

bearing

if

it

remains on

plate

gear

manufacturer's

if

CASE

of

in

necessary

the

(93) from

(92) from

necessary

remove

plate

ASSEMBLY FROM

MODE

link

yoke

front

bands

L

(80)

and

on

and

of

housing

oi I

seals

operating

cover

assembly

of

housing.

using to

reverse

(95) from

engine

trans-

engine,

recom-

to

replace.

oi I seal

of

yoke

lockwash-

reverse

remove cross-

opening

from

remove band

band

being

(68) in

sleeve

gear

the

drag

the

to

the

from

(79)

in

S.4

5.

6.

7.

8.

10.

Remove tai

Ishaft

nut

(69).

Support that

2

Press shoft is

Lift

housing

Remove adapter and

bearing

(76) from

reverse

gear

inches.

on

free

reverse

plate

remove

cotter

clears

capscrews

pin from reverse

and

remove

gear

case

may drop

reverse

of

reduction

gear

tailshaft.

(79) to reverse

reduction

(72)

and

reverse

housing

free

gear

t.Jilshaft unti I

drive

housing

reduction

gear

that

adopter

straight

secure

housing.

gear

tai

Ishaft

face

down so

approximate

tai

gear

(76).

up

unti

reduction

gear

housing

plate,

drive

ba

gear

Iy

1-

II

16.

Press

gear

half

coupling

bearing

direct

17.

If

necessary

(47) from

I

(63)

drive

direct

and

plate

to

press ba

(61).

replace,

drive

(68) from

II

remove

plate

bearing

oil

(61).

boll

from

seal

r--,..----@

11.

Press boll

drive

plate

reduction

NOTE:

12.

13.

14.

When

use

Bend

locknut

tailshoft

(68)

Support so

that

imate

Press on reverse shaft reverse case shaft.

bearing

~ear

(79)

tong

with

Iy 2 inches.

is

assembly unti I housing

(76) from

and

drive

disassembling

the

following

of

lockwasher

(96)

and

by

holding

spanner

reverse

gear

case

free

of

gear

housing

(72)

reduction

press ba

gear.

remove trom

wrench.

gear

may drop free

gear gear

II

direct

procedure.

gear

housing

tailshaft

half

straight

and

(66)

coupling.

reduction

beari

drive

away

reverse

half

face

until

up from

clears

adapter

ng from

units,

from

gear

coupling

down

approx-

tail-

Lift

gear

tai

1-

15.

Remove

secure

gear plate

ha

If

ing

capscrews

direct

housing (60)

(61) boll

coupling

(60).

drive

(68) from reverse

and

plate

and

remove

bearing

lockwashers

(61) to

(63)

reverse

direct

and gear

that

drive

gear

hous-

S.5

Early

Late

1/4" 4

1/8

4

5/8"

models: thick

11

1/2"

th i

models

long

ck

DISASSEMBLY

GLE OPERATED

1.

2.

3.

4.

Remove washer ear

Remove

band

lever

Remove

Remove (44) bled

Remove

screw (57)

of

reverse

cotter

and

remove

(52) in

short

locknut

and

remove

levers from

adjusting

screw.

_---../-1

--

__

-

OF

THE

TYPE

(55), nut

that band

forked

lever.

(50) from

adjusting

reverse

--1

~

i

--,._.

REVE

RSE

secures

(51) .

(54) from

(53)

ear

nut

(50) from

-;--

BAN D-TOG-

(58)

ond

loc

brace

that

of

reverse

adjusting

earof

holds

(56)

reverse

short

band.

screw

screwandassem-

band.

adjusting

k-

to

DISASSEMBLY

1 . Remove.

reverse and

Woodruff

and

thrust

shaft

on

2.

Remove (41) from screw

co

Lift

operating

tai

Ishaft

3.

If

finger worn, removing

(38) •

OF

thrust

gear

washer

tai

Ishaft

key

washer

direct

drive

lockscrew

screw

liar

from

collar

gear

sleeveasse.r:nbly

when

removing

assembly

remove from

cotter

pins (39)

GEAR CASE

(73) from

on

reduction

(74)

sea I washer

(64) from

units.

(42)

and

(37)

case

by

screw

(36)

seems loose

screw

collar

and

end

units

end

of

tatl-

lockwasher

and

remove

unscrewing.

(40) from

<:ollar.

(37)

finger

pins

of

or

by

5.

Remove in (48),

CAUTION:

(61)

6.

If move reverse

cotter

assembled

adjusting

Do

or

disturb

necessary

rivets

band.

pins (47) from ends

levers

bolt

not

disassemble link (48)

setting

to

re-line

holding

and

disassemble

(44)

of

jam

reverse

and

nut.

band

of

pins

link

pins (46) .

or

band,

lining

re-

to

4.

Lift pressure

(34)

5.

Bend sidesoflocknut

(24)

while

and

(33) from

tang

of

and

remove

clamping

plate

(35)

end

lockwasher

(31)

locknut

reverse

and

of

(30)

clutch

gear

case.

away

plates

from

insidepropellergear

and

lockwasher

gear

tailshaft.

S.6

6.

Properlysupport

carrier

(28) from plate

carrier

rier

from

7.

Remove (26)

from

8.

Remove (13)

from

9.

Remove (15) from and

remove

race.

10.

Before

ions

is

teethforindication

each

pinion

ing

rotation.

placement

(27)

and

prope

(27).

gear

case.

case

ball

groove

capscrews

case

roller

case

removal

attempted,

to

check

If

is

necessary,

gear

press

"er

bearing

in

roller

bearing

roller

of

first

further

case

gear

Lift

gear

(14)

the

of

wear. for

on

tailshaft

(24)

clutch

retaining

case.

and

bearing

retaining

bearing

short

or

inspect

Also,

rough inspection proceed

clutch

lockwashers

and

plate

race

race (16)

long

the

spots

with

plate

(29)

clute

rings

from

pin-

gear

rotate

dur-

or

car-

ring

(12)

rethe

or

disassembly. unless

h

11.

Drive pinions case ion Push dummy pinion

Remove

inside

12.

Remove case.

The from

time.

13.

Remove long

shaft

14.

Remove

case

required.

pinion

approximately

shaft

of

prope

the

as in

(1).

However,

shaft

(11) from

on

through

shaft

(11)

and

short

pin i on

gear

case.

remaining

Iler

gear

case

ball

pinions

removing

thrust

pads

(6)

threaded

1/2

until

short

and

short

(24)

bearing

short

(2) from

donotdisassemble

of

one

of

the

end

of

inch.

with

centered

pinion

dummy s

pinions

can

(5) using dummy

Push

dummy

spacer

from

be

(25)

pinions.

inside

shaft.

in

haft

pressed

at

short

gear pin-

short

(7).

from

gear

this

gear

GEAR

CASE

ASSEMBLY

S.7

ASSEMBLY

92

OF

\

,~

REVERSE

BAND

AND

77

YOKE

TO

~

I

I 8 I

I

i

GEAR

CASE

ASSEMBLY

80

·78

TOGGLE

OPERATED

REVERSE

BAND

47

ASSEMBLY

STANDARD

S.8

YOUR NOTES

DESCRIPTION

S.9

TYPE SAO MANUAL

The

multiple

tained

OPERATION On

together pressure propeller

The

gear

clamped

reverse peller

With

band

stationary.

It

moving

It

ably

and

Westerbeke

disc

and

the

forward

as a solid

produced

shaft

reverse

case

when

motion

shaft

the

shift

are

unclamped

is

desirable

the

is

recommended

in

the

of

the

clutch

are

independent

drive

which

opposite

lever

boat

800

boat.

Paragon

drive,

when

turns

contains

the

is

to

start

in

either

RPM

manually

and a planetary

of

the

reverse

coupling.

the

in

the

is

obtained

shift

then

obtained

to

the

in

the

and

the

direction.

that

the

range

shift

same

the

lever

engine

neutral

planet

engine

shifting

or

The

lower

engine

gear

multiple lever direction

by

clamping

planetary

is

moved

by

driving

rotation.

position

gears

with

be

to

operated reverse

lubrication

case

disc

is

moved

as

reverse

and

through

the

run

the

transmission

done

at

prolong

reverse

gear

and

clutch

to

the

engine.

the

reverse

held

multiple idle

speeds

the

train.

system.

multiple

the

gear

in

the

and

below

life

gear

The

is

locked

forward

band train. the

reverse

gears

disc

clutch

the

propeller

in

neutral,

1000

of

the

units

disc

or

position.

around

The

thus

engine,

consist are

clutch

clamped

the

reverse

position.

turning

and

the

shaft

thus

RPM

and

transmission

self

are

Thus

reverse

band

the

reverse

remains

avoiding

prefer-

of con-

locked

by

the

is

The

pro-

a

TROUBLE The

trouble suggestions what sions as

DISASSEMBL

As

manship

the

should

indicated

in

1.

2.

3.

4.

5.

6.

7.

NOTE:

oil

to avoid fouling the

SHOOTING

trouble

any

servicing

apply. Use

Use Never Never Use

screws. Replace Work nicks

Remove

shooting

carried

be

carefully

from

Y

only

use a hammer

press

only

on a clean

and

out

may

the

operation,

Some

clean clean

properly

gaskets

scratches.

the reverse

charts

prior

be.

read

trouble

of

these

fluid oil

a

ball

and"

and

bilges.

below

to

any

Also,

for

bearing

sized

bench

the

and

understood

shooting

cleanliness

rules

in

any

lubrication

to

drive

wrenches

0"

rings

and

cleaning

reduction gear

and

on

the

disassembly

exploded

charts

is a must

are

as

follows:

or

when

ball

bearings

so

that

the

in

with

new

protect

views

so

that

may

as

be

washing

pressing

force

removing

material.

gear

teeth

a complete

page determine

in

should

and

the

any

or

carried

and

of

parts

place.

is

carried

or

and

all

parts.

unit

be

studied

as

well

accompanying

all

of

the

service

out

properly.

rules

securing

oil

for

together.

through

nuts

seal

surfaces

before

and

as

possible

discus-

good

the

and

work-

balls.

removing

the

work

cap-

from

the

S.10

Ch

art

TROUBLE

1

DRIVE

SHAFT

WITH

ROTATES

SHOOTING

GEAR

SHIFT

CHARTS

DRAGGING

EITHER

LEVER

FORWARD

IN

NEUTRAL

OR

I

Check

I

1.

DEFECTIVE

I

2.

REVERSE

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

I.

For~ard

Hemove

2.

Improper

reverse

~.

C.heck

.

a.

Bearings

case.

clutch

and

band

the

Replace

FORWARD

BAND

plate

replace

reverse

as

following

and

gears

necessary

CLUTCH

ENGAGING

v,'arped

clutch

hand

adjustment.

outlined

items:

worn

PLATES

GEAR

and

rlates.

under

adjustment

excessively

parts.

CASE

sticking.

Adjust

in ,gear

I

1

For

I

1

3.

BINDING

4.

OVER

FORWARD

b.

Engine causin/Z. place

.

of

4.

Over-adjustment or

hoth

and

readjust

/Z.ear misalignment

necessary

en~ine

will

,gear.

result

as

REVERSE

-1

IN

PLANET

I

ADJUSTMENT

AND

hearin~s

parts.

of

either

in

loss

outlined

MY

REVERSE

worn

of

en/Z.ine

Check

forward

of

under

ASSEMBLY

ON

excessively,

shaft.

misali~nment

and

neutral.

adjustment.

He-

reverse

Check

Chart

2

WITH

SHIFT

GEAR

SLOW

LEVER

SLIPPING

TO

ENGAGE

IN

FORWARD

OR

REVERSE

I

Check

Far

I

r

3.

I

1.

2.

FORWARD

WORN

CLUTCH PLATES I

I

CLUTCH

NOT

ENGAGING I

I

4.

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

\.

I.

Hemove

,,{'.If.

2.

Improper

outlined

forward

HepLlce

f()f\\ard

under

clutch

if

\\orn

excessively.

clutch

adjustment.

plates

and

adjustment

check

. .''\dJusc

for

as

Hem(lVe place

·l.

Improper outiin<·d

WORN

REVERSE BAND

reverse

linin~

if

reverse

under

REVERSE BAND I

I

NOT

ENGAGING I

band

and

check

for

wear.

\\orn

helow

rivets.

band

ad

jus

tment.

,Idjustment.

Ad

just

He-

'IS

S

.11

Chart 3

I

r

I

1.

I{Crllo\·t" <ldectin'

or

2.

Remo\'e

defective

or

serv

,.

Check

a.

I

1.

FAILURE

OF

PLANETARY

r

2.

FAILURE OF REDUCTION

I

3

..

FORWARD

damaged

reduction

dama,ged

ice

manual.

the

Improper f()f\"lrd

ge'ar

or

damaged

parts.

damaged

parts.

follo\\

fOf\\ard

clutch

CLUTCH

case

gear

in).!

items:

clutch

.IS

()utiincd

assc:mhly

parts.

assemhly parts. Refer

DRIVE

SHIFT

ASSEMBLY

GEAR

NOT

ENGAGING I

and

l{epL.l.ce

and

Replace

to

reduction

.Idjustment.

undt'r

'ldius!ment.

TROUBLE

GEAR

SHAFT

LEVER

IN

l

I

J

check

for

defective

check

for

defective

gear

:\dju.~!

SHOOTING CHART

INOPERATIVE

OOES

NOT

ROTATE

FORWARD

OR

I

Ch.,(.~

For

1

I

REMEDY

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

h.

forward

plate.

4.

Check a.

Improper reverse

h.

R('verse

c.

Cracked

parts.

5.

Clled: fCClin'

WITH

REVERSE

4.

REVERSE BAND ENGAGING G

5.

BROK

clutch

the

following

reverse

band

ears

i{el,lace

for

hroken

shaft.

I

NOT

EAR

I

EN

OUTPUT SHAFT

plates

as

lining

or

dcfectivc

items:

band

outlined

hent

output

"orn.

adjustmc:nts.

worn.

or

shaft.

CASE

Replace

under

I{Cf,lae<: linin.!!.

dama).!cd link<.lge

lIIatcrial.

clutch

·\djus!

<.ldj\l~!nlell('

l{cpldCC:

de-

NOTE:

those

REMOVAL

HOUSING

NOTE:

before draining

1.

Disassembly

difficulties

OF

IF

Remove

starter

need

which

REDUCTION

INSTALLED

the reverse gear

oil,

motor

2. Disconnect propeller

3.

4.

Remove

Strike

capscrews securing reverse gear to bellhousing. gear

half

bellhousing. Slide

ately

3 inches until reverse gear clears bellhousing

engine.

(Refer to "Reduction

reduction

unit.)

be

interfere

GEAR

carried

with

out

proper

ASSEMBLY

with reduction gear attached

to avoid

half

fouling the

coupling

coupling flange with

entire

Gear"

reverse

section of

only

as

marine

FROM

bilges.

and

slide

soft

mallet to break reverse gear

and

reduction gear

manual

far

as

is

necessary

gear

operation.

REVERSE

GEAR

as a complete

back

approximately 4 inches.

streight

and

lift

for disassembly

units

and

to

back

assembly

correct

unit

from approximclear

of

S.12

1

I

42

62

56

44

SAO

MANUAL

TRANSMISSION

72

71

65

S.13

94

67

SAO

MANUAL

TRANSMISSION

25

S.14

REMOVAL

1.

Remove to Slide

2. until housing

3.

Remove remains

4.

If

proceed

a. b.

c. d.

REMOVAL

REDUCTION

1.

Remove from

2.

Through washer band

3.

Remove,

cam reverse

4.

Remove

OF

REVERSE

capscrews

front

end entire housing

assembly

pilot

on

necessary

as

Remove engine Slide front of

engine.

Remove

seal

(22).

Replace

OF

GEAR

MODEL

four

reverse

cover

and

assembly

adjustment

(65)

cam cross

plate

reverse

is

roller

gear.

to

follows:

caps

flywheel

front

plate

retaining

new

CASE

capscrews,

gear

opening

screw,

(62).

from

slide

shaft

GEAR

and

(5).

gear

clear

bearing

replace

crews

housing.

end

plate

engine

oil

seal

ASSEMBLY

housing securing

Remove nut

eye

in

assembly

(13)

HOUSING

lockwashers

housing

of

front

of

front

(60)

front

and

gear ring

and

end

lockwashers

(5)

straight

(1) (36),

bearing

FROM

cover

(3).

in

reverse

adjustment

lock

(66)

yoke

from

(34)

(63).

from

reverse

ASSEMBLY

that

(3)

straight plate plate

engine

(5).

from plate

back

is

clear bearing

if

required.

REVERSE

seals

gear

housing

nut

spring.

reverse

and

gear

FROM

secure

back

gear

front

(5),

plate

oil

securing

approximately

of

flywheel

(37),

(33),

cover

(3), remC"ve

lockspring

cam

slide

out

housing

ENGINE

reverse

approximately

(1)

and

lift

engine

seal

(22),

front

housing,

retaining

GEAR

HOUSING

(10),

(68)

(65).

Remove

reverse

(3)

as

gear

housing

reverse

gear

or

bearing

end

plate

two

inches

and

ring

(35)

and

nut

to

ear

cam

follows:

3

inches

(1)

lift

and

gasket

(70),

of

reverse

(65)

(3)

gear

if

(37)

(5)

to

until

clear

oil

(4)

lock-

brake

from

it

5.

6.

7.

8.

9.

10.

a.

Loosen shaft

b.

With from with shaft in shaft.

c.

Slide

(34)

On

dipstick

ing

pin inspect Slide front

brake of

Remove

Support

may

drop Press drive Lift

(2-

reverse

2).

(13). small

left operating under

right

cross

from

(12)

"0"

housing.

cotter

reverse

free

on

reverse

gear

the

two

end

to

right

yoke

side

of

shaft

operating

side

of

that

ring

band

secures (23) (62)

and

gear

approximately

(87).

gear

capscrews

of

housing

being

sleeve

arm

housing.

out

sleeve

housing

and from

nut

housing

gear

tailshaft

housing

careful

bearing

(34)

isn

of

housing

remove

brake

replace

gear

(18-2)

(3)

two

(3)

securing

toward

(50),

It

forced

Remove

(50).

roll

band

if

damaged.

case

assembly

from

with

inches.

(2-2)

straight

mechanic,

cross

or

against

the

and

remove

to

housing.

reverse

front

until

up

the

shaft

Woodruff

two

Woodruff

(24)

securing

(41)

gear

end

down

tailshaft

until

yoke

slide

doesn

cross

brace

Remove

and

tailshaft

so

is

housing

(34)

to

cross

It

come

key

(26)

shaft

keys

(67)

brake

locking

remove

that

gear

free

clears

the

shaft in

in

oil

seal

from

and

band

(2-2).

case

of

reduction

cross

(13)

contact

cross

(20)

cross

lift

yoke

lock-

and

from

(41)

tailshaft

11.

Remove

(85)

to

a.

Remove tion

b.

Press

c.

Press

capscrews

reverse

drive

bearing

and

gear

housing

reduction

gear

(87). with from

lockwashers

(3).

adapter

drive

plate

gear

gear.

that

with

from

secure

attached

adapter

reduction

bearing

plate.

adapter

(88)

and

S.IS

plate

reduc-

DIRECT

12.

13.

14.

DRIVE

Bend from

tang

reverse spanner Support free

approximately

Press

wrench.

on coupling assembly

15.

Remove reverse

a.

gear

Remove half

b.

Press

c.

Press

d.

If

necessary

DISASSEMBL Y OF

1.

Remove

2.

gear and Remove screw

tailshaft

thrust

locks

collar

assembly

3.

Lift

pressure

case.

4.

Properly

5.

6.

7.

(2-1)

clutch Remove Remove

gear

Before

gear rough

or

plate

case.

removal

teeth

spots

necessary.

8.

9.

unless Drive of dummy

Push

required.

pinion

gear

shaft.

dummy

spacer

10.

Remove

11.

12.

Press Remove

propeller

UNIT

of

lockwasher

gear

reverse

(14).

(41)

Lift

until

capscrews

housing

direct

coupling

gear

half

bearing

GEAR

thrust

washer

on

washer

crew

from

(50)

from

plate

support

(2-2)

from

carrier

case

ball

capscrews

for

indication

during

proceed

shaft

case

approximately

shaft

(56).

Remove

remaining long

pinions

(perform

tailshaft

Remove

gear

2

inches.

gear

reverse

housing

and

(3).

drive

(14)

from

coupling

from

to

replace.

CASE

reduction

(16-1)

(55)

gear

tailshaft

(49)

gear

propeller

from

bearing

(14)

of

the

rotation.

with

(20)

until

short

gear

(43)

(44)

procedl..res 1 through 6 above)

(19)

away

(2-1).

from

by

locknut

holding

gear

lockwasher.

housing

tailshaft

lockwashers

plate

drive

(16-2)

from

and

case

gear

<;l.nd

short

of

pinion

pinions

using

(3)

face

(2-1)

gear

clears

housing

tailshaft

(15)

reverse

from

bearing.

plate.

remove

and

retainer

units.

end

and

of

lockwasher"

case

when

by

removing

clutch on

clutch

gear

case.

retaining

lockwashers

or

lon~

of

wear.

If

further

the

disassembly.

one

of

the

1/2

inch.

centerec

shaft

(46)

from

the

dummy

down

until

(3) (2-1).

that

secure

with

gear

oil

attached

housing

seal

ring

Woodruff

tailshaft

from

screw

unscrewing.

screw

plates

(48)

plate

(43)

and

ring

(59) (13)

pinions

Also.

is

rotate

inspection

short

pinions

Push

in

short

(42)

from

case

ball

shaft

from

gear

as

so

tailshaft

(21)

on

carrier

attempted.

However.

pinion

bearing

(18-1)

half

that

straight

direct

bearing

(3).

from

(6) key direct

collar

Lift

collar.

and

clutch

from

and

case

each

(22)

shaft

(46)

front

case.

in

removing

coupling

gear

is

free

up

drive

direct

from

(27).

drive

operating

(54)

from

and

plate

groove

bushing

pinion

or

do

from

on

and

end

(58).

and

remove

(14)

case

from

of

may

gear

plate

(25)

and

drive

end

of

reverse

seal

washer

units.

(53)

and

end

press

carrier.

in

gear

(23)

first

inspect

to

check

replacement

not

disassemble

threaded

through

short

of

gear

short

pinions.

nut

with

drop

half

case

(15)

to

gear

plate.

(6)

remove

sleeve

of

gear

tailshaft

Lift

case.

from

the for

end

with pinion

case.

is

a

NOTE:

Bushings

are

pressed

into

the

long

and

short

pinions.

S.16

INSPECTION

All

parts

wear

should

1.

Ball and

2.

Long

3.

Pinion

4.

Long

5.

Long

6.

All pattern

7.

All

8.

Clutch excessive

9.

Clutch splines.

10.

Examine

11.

Reverse

12.

Reverse

should

be

and

pitting

and

gear

shafts

be

thoroughly

replaced.

roller

on

and

short

shafts

and

short short teeth

or

excessive

should

plates

heating

plate

all band

band

balls

pinion

should

pinion pinion

should

carrier

oil

seals

links,

lining

cleaned

bearings

or

rollers

bushings

be

spacers

bore

wear.

be

examined

be

and

wear

should

for pins,

should

examined

diameters

be

examined

or

be

rough

etc.

be

before

be

and

races.

should

for

should

for

wear

for

peening

examined or

charred

should

examined

inspection.

examined

be

examined

wear

be

examined

should

or

be

Ilpitch

on

splines

flatness,

of

driving

for

lips.

be

examined

for

wear.

Parts

for

indication for

"brinellingll.

for

wear.

examined

line

pittingll,

and

shoulders.

roughness,

lugs.

wear

and

for

showing

wear.

for

peening

wear

excessive

of

corrosion

wear. unever

indicating

of

lugs

or

bending.

wear

of

and

NOTE:

13.

Lining Gear

or

long

threaded

14.

Screw

15.

Pressure

16.

All

old

17.

Operating

18.

Engine

bearing

uneven

NOTE:

When

eccentricity.

19.

Where

springs

ASSEMBL Y OF

1.

If

pinion

removed a.

should

case

should

pinions

end.

collar

plate

gaskets

sleeve

gear

race,

wear

uneven

Maximum

special

and

GEAR

gears

from

Insert

be

wearing

and

should should

should

pilot

or

excessive

gear

eccentricity

vibration

splines

CASE

(45)

gear

dummy

replaced

be

examined

finger

assembly be be

assembly

be

examined

bearing

teeth

for

wear.

and

case

shaft

before

for

into

inside

examined replaced.

should

race

wear.

wear

at

pilot

dampers

(46)

bushings

(41),

assembled

into

long

rivets

wear

should

for

be

for

and

has

pinion

from

faces

be

wear.

examined

wear

gear

been

bearing

are

used

(21),

(44).

come

reverse

or

wear

examined

on

oil teeth

noticed,

race

as

and

as

follows:

in

contact

for

wear.

seal

for

is . 005

flexible

pmlOn

band

in

clutch for

surfaces,

Ilpitch

check

with

gear

linking,

plate

wear.

case

line

engine

inches.

couplings,

shafts

(42)

case.

short

slots

on

roller

pittingll,

gear

for

check

were

NOTE:

NOTE: out.

Use b.

Smear

Install

c.

same Insert

shalt

dummy

bushing

Lay

gear

with

hole

dummy

four

in

gear;

spacer

case

in

shaft

bushings

shaft

outer

then

(56)

(41)

as

used

(21)

assemble

with

in

gear

on

row.

equally

cup

side

in

disassembly.

spaced

remaining

grease

and

insert

to

first

around

bushings.

prevent

row

long

dummy

bushings

of

bushings.

pinion

(44)

shaft

from

in

case

to

center

dropping

to

align

2.

3.

4.

5.

6.

7.

8.

9.

d.

Insert case out

e.

Remove Do are

f.

Assemble

g.

Using in

same

pinion,

h.

Insert

to

described

i.

Assemble

Assemble flats Insert

on

propeller pinions. Press supporting case. gear

Make

and groove Press Align peller

splines

gear already front Place

end

Woodruff Install first

with bronze Install plate

cavity.

pmlOn

and

the

dummy

not

drive

inserted.

dummy

use

short

line

up

case

pinion

case

ball

entire

certain

into

in

gear

clutch

until

on

tailshaft.

of

gear

clutch

bronze

clutch

pressure

shaft

push

through

shaft.

shaft,

pinion

remaining

shaft,

manner

pinion

with

in d above.

remaining

bushing

shafts.

gear bearing

assembly

that

gear

case

plate

on

case. next

carrier

reverse

propeller

case

key

(61)

plates

clutch

plate.

plate

(42)

pinion

shaft

long

insert

covered

spacer

(46)

hole

short

(23)

Replace

(24)

(58)

case

to

gear

Support

dudng

on

in

clutch

plate

(49)

plain

and

start

all

pinions

in

(56).

into

in

inner

pinions

to

gear

through

into

on

ball

Install

case

(27)

onto

tailshaft

gear

the pressing

end

oftailshaft plate

on

top

end

first,

as

far

as

pinion

the

way

in

gear

short

bushings

paragraphs

gear

case,

row

in

case

lockwashers

rear

gear

propeller

bearing

case

ball

bearing.

reverse

is

seated

entire

assembly

operation.

cavity

(54)

and

of

last

into

rear

shaft

into

case.

a

pinion

and

insert

gear

case.

with

of

gear

case

and

gear

is

seated

ball

bearing

gear

and

press

against

inside

in

rear

alternating

bronze

unthreaded

wall

of

gear

into

rear

gear

(47)

case

into

until

short

and b above.

toward

pinion

edges (13)

inside

case

onto

of

race

and

in

propeller front

capscrews

mesh

properly

retaining

tailshaft

the

clutch

on

propeller

of

gear

steel

clutch

plate

end

case,

wall

pinion

With

front

shaft

in

end

on

ring

(2-1)

through

plate

gear

gear.

case

plate

of

gear

forcing

of

case.

all

shafts

(46)

short

of

case,

(20)

line

with

(14).

with

long

gear

of

gear

propeller

(59)

or

(2-2).

pro-

carrier

inside

starting

(34)

and

in

clutch

5.17

as

by

in

NOTE: during

Make

assembly.

10.

Assemble and

11.

Thread of

12.

Place finger

13.

Continue will pressure

14.

Push

certain

securing

the

thread

operating assembly

snap

operating

finger

with

screw

length.

screwing

over

plate

free.

15.

Place one end

16.

On

making gear

lockwasher

hole

of

near

locks

reduction

certain

tailshaft.

crew

tailshafts,

that

collar

sleeve

over

center

(49).

sleeve

edge

lines

that

all

plates

assembly

cotter

pins.

(53)

assembly

sleeve

screw

and

assembly

over

of

end

screw

up

retaining

(52)

onto

assembly.

collar

lock

of

collar

with

install

ride

to

freely

screw

gear

(50)

onto

into

(50)

lockscrew

closest

retaining

ring

is

case

onto gear

position

forward

(53).

hole

seated

and

that

collar

assembly

tailshaft.

case

against

until

(55)

and

Rotate

in

pressure

ring

properly

(53)

(41)

screw

on

no

binding

using

(41)

approximately

Position

until

the finger thread

collar

plate.

reverse

in

groove

is

apparent

finger

pins

ball

finger

assembly

shoulder

assemblies

lockscrew

until

gear

in

(51)

half

ends

of

the

are

into

dog

on

tailshaft

reverse

of

S

.18

CAUTION: Proper

tions

as

The

adjustment

outlined

ASSEMBL Y OF

REDUC

1.

2.

3.

TION

Place gear

If

in

housing

removed

housing.

Support

gear

lowered

4.

Lower

5.

gear

Place

tailshaft

gear shoulder Press

6.

7. Plc:.ce drive

ball

bearing

8.

gear Press

tailshaft

necessary

9.

Install

10.

Tighten

cotter

11.

12.

13.

14.

gear

Install

Place Install gear With

tailshaft.

housing. reduction

cover

ating

mechanic.

15.

Align

cross

16.

Pull

cross insert tion

yoke

17.

Secure

18.

Slide hole

in

19.

Position

20.

Replace

(63) .

21.

Secure and

nut

forward

is

under

REVERSE

MODEL

new

gaskets for

gear

case

over

reverse

thrust

tailshaft

of

reduction

new

gear

reduction

bolts.

reduction

all

can

cotter

new

gasket

brake

opening sleeve

and

hold

shaft

through

shaft

Woodruff

to

yoke

reverse

arm

and

lock

(70).

clutch

made

section

GEAR

(3).

replacement.

case

so

that

gear

(2-

2)

washer

(2-

2).

retaining

drive

gasket

(87)

and

is

seated

nut

(18-2).

gear

capscrews.

be

installed

and

(72)

band

adapter in

housing

assembly

hole

out

key

cross

to

shaft.

cross

cam

of

yoke

in

brake

tighten

spring

is

not

after

installation

on

adjustments.

CASE

(8).

(7).

assembly

reverse

case

assembly.

housing

protruding

(16-2)

(Make

ring

(6)

gear

(8)

on

ball

bearing

against

adapter

crescent

Tighten

bedn

on

reduction

assembly

plate

placing

(50).

in

brace

yoke

from

in

and

right

cross

shaft

(65)

through

(34).

band

adjustment

(68)

over

properly

IN

REVERSE

and

(4)

install

(41) gear

(3.)

thll~:>ugh

with

new

on

propeller

housing

over

counter-bored certain on

tailshaft

(87)

into

reverse

gear

(88)

thrust

plate

(85)

(74).

reverse

through

ends

castellation

over

adapter

(62)

onto

(85)

facing

forked

Ensure

(67)

on

brace

side

to

of

shaft

by

tightening

reverse

(62)

in

hole

nut

adjustment

adjusted

in

boat

on

oil

gear

bore

that

ball

on

washer

over

nut.

gear

mechanic.

inside

left

housing

to

the

in

(66)

is

GEAR

front.

seals

(3)

case

in

thrust

(2-2.

bearing

housing

reverse

ball

gear

plate

case

arms

part

right

side

right

two

cam

brace

to

reverse

nut

(66)

at

the

end

complete.

HOUSING

rear.

gear

will

(20)

(43)

not

and

in

inside

rest

assembly

rear

of

side

washer

housing.

down

seats

)

(88).

(3)

and

gear

(16 - 2).

tailshaft

Thread

bearing

tailshaft

in

nut

and

(85).

assembly

insert

of

yoke

number

of

housing.

hole

over

of

in

approximately

of

each

cap

slide

yoke

screws

assembly

(67).

cam

with

screw.

of

this

Follow

top

cross

press

and

nut

hole

(41)

yoke

in

slide

assembly.

instruc-

of

reverse

shaft

front

on

face

with

over

reverse reverse

properly

reduction

(2-2)

on

reverse

secure

08-2)

in

reverse

in

reverse

(34)

through

pins

of

is

and

one

inch

hole

to

yoke.

(63)

assembly

lockwasher

holes

end

of

when

on

until

with

until

oper-

facing

push

and

posi-

and

in

DIRECT

22.

DRIVE

After tailshaft.

UNIT

paragraph

Place

4

seal

above

washer

place

(6)

thrust

over

washer

reverse

(16-1)

gear

tails

over

haft

reverse

against

gear

thrust

S.19

washer

23.

If

plate

24.

Place support

ing

be

25.

Align tail washer

26.

Place gear

27.

Install to

28.

Tighten lockwasher

29.

Continue

ASSEMBLE

1.

If

engine a.

b. c.

d.

and

install

removed

(15).

direct

(25)

taken

direct

shaft

(16-1).

and

until

not

and

for

Press

drive

press

gear

to

damage

drive

press

lockwasher

half

coupling

lockwashers

reverse

gear

all

capscrews.

(19)

with

paragraphs

TRANSMISSION

front

end

plate

flywheel

Replace Slide

Align

housing

After

oil

engine

mounting

and

installing

eccentricity

Woodruff

replacement,

ball

bearing

plate,

gear

half

coupling

oil

plate

and

together

(19)

over

and

thread

and

capscrews

housing. over

housing

seal

gear

locknut.

TO

ENGINE

(5)

proceed

(22)

(1)

was

holes

secure

is

on

.005

with

engine,

inches

key

(25)

oil

seal

coupling

seal

during

gear

until

reverse

Tighten

13

through

removed

or

bearing

into

flywheel

in

lockwashers

(27)

in

pre-ss

into

and

is

seated

half

ball

locknut

in

locknut

as

follows:

(37)

front

check

at

pilot

keyway

new

oil

direct

ball

(14)

into

against

assembly.

coupling

bearing

gear

tailshaft

(18

-1)

holes

(18-1)

20.

from

if

necessary.

housing

end

plate

and engine roller

in

tailshaft.

seal

drive

bearing

oil

seal

ball

up

with

is

on

reverse

in

direct

and

reverse

damper

(5)

capscrews.

gear

bearing.

(21)

into

plate.

assembly

(21)

bearing.

key

seated

with

tang

drive

bend

gear

spline.

with

f0r

holes

runout.

direct

on

and

in

reverse

against

in

gear

plate

up

one

housing

drive

suitable

ball

bear-

Care

must

gear

thrust

keyway

tailshaft.

and

tang

(3)

in

flywheel

Maximum

in

bolt

on

or

.

2.

Insert plate

3.

Check propeller

4.

Start

engine rotate pinions

5.

Install

6.

Remove

Tighten

ASSEMBLY

HOUSING

NOTE:

1.

Refer

Install

adapter

2.

Position

and tion

3.

Installlockwashers

and

two

studs

(5).

to

be

certain

gear

reverse

gear

in

(1)

case

gear

lockwashers

the

two

all

capscrews.

OF

REDUCTION

ASSEMBLY

to

reduction

two

studs

plate.

reduction

slide

ring

tighten

onto

gear

uniformly.

three

that

inside

gear

housing

right

slightly

case.

and

studs

GEAR

gear

3

1/2

gear reduction slightly

and

inches

pilot

cas

up

against

to

capscrews

and

install

ASSEMBLY

assembly

inches

assembly

drive

to

properly

capscrews

long

roller

e.

(3)

over

flywheel

properly

remaining

and

long

over

gear.

mesh

in

two

bearing

the

two

housing.

mesh in

holes

TO

disassembly

in

two

studs

It

may

gear

around

opposite

(60)

studs

teeth

on

around

lockwashers

REVERSE

opposite

with

be

necessary

teeth.

flange

of

bolt

holes

is

properly

and

slide

It

may

be

engine

gear

flange

and

GEAR

procedures.

holes

oil

drain

to

reduction

in

front

installed

housing

necessary

and

of

housing.

capscrews.

in·

reduction

plug

at

rotate

gear

end

in

over

to

short

bottom

reduc-

housing

S.20

YOUR NOTES

S.21

SA1

AND

With the transmission replace not adjustments factori

Before securing the the

that .002

section

14 and 15 The

as

specified

The fore the eng i ne has

all

water

connect

the shifting

have

Iy

tested~

gear

half

coupling,

the couplings

inches

wi

"AI

ignment to Engine

of

Technical

been

th

respect

lines,

do

transmission should

under

transmission

lubrication.

can

propeller

been

complete running test

ori

Iy

been

determine

properly

whether the adjustments

made.

SAO

secured

etc.

linkage

MANUAL CLUTCH ADJUSTMENTS

to the

However, do

until all the

made and

half

coupling to

check

not

to

to make

run

each

out

other.

II

Manual.

be

partially

filled

with new oil

adjusted

run. However, a

is

necessary to

engine,

are

satis-

certain

more than

Study

on Pages

satisfact-

have

be-

I.

Back

out

the

lockscrew (42) unti I the dog on the hole

2.

Rotate the screw

end

of

the lockscrew

in the pressure

plate

Collar

is

clear

(35).

(37) to the right until the lockscrew (42) is opposite the next

hole

in the pressure

3.

Tighten the lockscrew making

plate

(35).

certain the dog on the end properly enters the in the pressure

4.

Continue this until a

pi

ate.

decided

effort quired to shift into forward (approximately

26 foot pounds).

48

of

the

that

hole

is

re-

The

preliminary adjustments for the forward

arE'.

drive cover and

screw

made

plate,

coli is up and facing fully to avoid dropping

into

clutch

Typical Clutch

ment (SAl &

as

rotate

ar

housing

Forward

Adjust-

SAO)

follows: remove reverse

pressure finger assembly

(37) unti I lock screw (42)

you.

Then, working

either

screw

--

care-

or

tools

~r:F===4----

The

preliminary adjustments for the reverse

drive

2.

are made

as

follows:

1. Loosen the locknut ear

at

upright

the top

Tighten the adjusting

of

the

ear

until both nuts are again

against the

3.

Repeat until a

ear

of

decided

(50)

of

nut

the reverse

50

SAl

Reverse

Adjustment

(Top View)

on the inside

the reverse

(50) on the outside

band.

snap

is

shift into reverse.

4.

Do

'Jot tamper with adjustment of link (48).

of

the

band.

tight

required to

5.

For Four-99s and a cam tum screw

operated

head

early

Four-107s there was

reverse adjustment. Simply

(103) clockwise one a time unti I satisfactory reverse is

obtained

(see Figure

3).

flat

at

engagement

S.22

SAO

Reverse

Adjustment

(Top

View)

Replace the The transmission which may

Check ing the

With the

the

transmission into forward and reverse

ing how well the transmission responds.

If the transmission does not

both

of

dockside adjustments are necessary. Continue

the adjustments

transmission will reverse dri ves.

A complete running test mine

that

The transmission should not

away under full power conditions in drive and should hold mal reversing conditions.

cover

be

all

of

test,

engine

the forward or reverse positions further

the

on the reverse

is

ready for a preliminary test

done

at

dockside,

the mooring I ines before

running

CIS

engCGe in both forward and

transmission

at

outlined

is

necessary to

is

in

reverse under all

gearhousing.

i.dle

speed,

engage

above untit the

properly

sl

ip

or

the

continu-

in

one

deter-

adjusted.

IIbreak

forward

shift

not-

or

II

nor-

If

further adjustments are

the adjustments

factory operation

noted however carried reached since transmission.

justed forward and reverse and the parts ily stressed and ure. Therefore, ments ount forward a

half full a very small adjustment verse

On the forward is the lockscrew coli the pressure the lockscrew. A ing and screw the right unti I the plate screw. Make the clutch.

When the transmission replace the cover and secure all and fasteners. Before replacing the shifting linkage, ates free I y

the

secure properly.

out

it

will

have

of

adjustment will

or

a step on the forward,

step

is

drive.

as

outlined

ar

(37) to the right unti I the

the

lockscrew

pi

acing

coil

ar.

is

lined up under the dog

hole

properly

check to make

I

inkage

CIS

outlined

is

that

only unti I satisfactory

it

is

possible to

If

the transmission

be

more

subject

once

been

reverse. Usually, an adjustment

required for full adjustment.

ol'ld

on the transmission

made,

drive,

above or

(42)

plate

it

(35) can be lined up under

half

out

in the hole adjoining

Then

or

it

ooes

not

necessary,

above until

reached.

the adjustments should

over-adjust

difficult

to

early

the preliminary

only a very small

be

necessary for

or

is

required for the

a full step

is

made by loosening

and rotating

a step

of

rotate

that

will bind up

is

certain

bind or

is

the hole

the screw coil

hole in the pressure

the lockscrew enters

properly

that

drag.

sh

continue

It

should

operation

is

over-ad-

to

shift

wi

II

be

fatigue

adjust-

at

the most, a

of

adjustment the

made by

that

it

of

the

forward

adjusted,

external

it

Replace

ift

lever

satis-

heav-

fail-

either

Only

screw

tak-

is

in the

ar

lock-

bolts

oper-

be

the

into

am-

of

re-

in

in to

and

is

WHEN

pqOPER

BUT A SLIPPING

CLUTCH

SLIPPING

ADJUSTMENT

WILL

CLUTCH

REPAIRS.

IS

NOTICED,

MAINTAIN

MAY

DESTROY

STOP

YOUR

ITSELF,

AND

ADJUST

CLUTCH

CAUSING

FOR

AT

ONCE.

YEARS,

COSTLY

S.23

DESCRIPTION

The

Westerbeke/Paragon

drive

ADJUSTMENTS

There

running DISASSEMBLY NOTE:

those

Remove

gear

difficulties

that

are

no

condition.

Disassembly

reverse

offers a variety

adjustments

OF

and

avoid fouling the

1.

Remove

2.

3.

4.

5.

6.

7.

8.

9.

10.

drain from

Remove and reduction Bend using Remove entire to

Support

free reduction Remove reduction

If

Remove and

Press Remove ring

oil

reverse

slide

tang

suitable

force

approximately

necessary

spacer

gear

SA1

which

AND

REDUCTION

need

interfere

reduction gear

bilges.

oil

drain

from

gear

caps

crews

entire

unit

clears

of

lockwasher

wrench

gear

assembly

coupling reduction

gear

retaining

gear

Woodruff

ball

capscrews

(71)

half

housing. housing

to

(73).

bearing

from

reduction

necessary

be

plug

unit.

and

reduction

coupling

under

from

gear

ring

replace,

key

and

flanged

SAO

of

UNIT carried

REDUCTION UNITS

gears

reduction

with

proper

as

from

Make

lockwashers

unit

reduction

(78)

and

lift

flange

assembly.

housing

2

inches (76)

from

and

press

remove

(80)

from

(84)

from

lockwashers

shaft.

to

maintain

out

consist

ratios.

only marine

as

of

the

far

gear

an

internal

reduction

as

a complete unit before

bottom

certain

straight

drive

away

lockwasher

(75)

of

gear

so

and

oil

flanged

from

pinion.

from

with

that

press

groove

ball

seal

from

of

reduction

that

flange

back

locknut

from

gear

half

coupling

flanged

(79).

shaft

rim

all

lubricating

of

approximately

shaft.

type

shaft

flanged

to

from

and

using

of

flanged

necessary

operation.

removing

gear

reduction

(77).

puller

and

ball

housing.

remove

or

press assembly

shaft

bearing

two

shaft

ring

gears

housing

oil

is

gear

3

inches

Remove

by

agamst

assembly

seal holes

washer

and

gear

to

in

correct

and

proper

the oi} to

(86)

and

removed

housing

until

locknut

supporting

shaft

can

drop

from

(84) in..;ide

(74)

in

flange.

remove

a

INSPECTION All

parts

wear

1.

2.

3.

4.

5.

ASSEMBLY

1.

2.

should

Ball on

All pattern Examine Retaining All

Replace Press

ing

be

replaced.

bearings

balls

OF

and

gear

gaskets

ring

teeth

or

oil

REDUCTION

oil

ball

(76)

thoroughly

excessive

rings

should

drain

bearing

should

races.

should

seal

should

into

cleaned

wear.

for

rough

be

replaced.

UNIT

plug

(84)

groove

be

examined

be

examined

be

checked

into

or

charred

reduction

to

ball

inspection.

for

indications

for

lips.

for

burrs

gear

bearing.

"pitch

or

housing

Parts

of

line

deformities.

(86).

showing

corrosion

pitting",

(86)

and

uneven

install

excessive

pitting

wear

retain-

S.24

If

3.

housing. Place

4.

those Place

5.

shaft Press

6.

next Install

7.

Place

8.

ball with a soft Turn

9.

flanged tion Support

10.

press

coupling keyway

11.

Place

lockwasher

secure

12.

Bend

13.

Install adapter

14.

Position

of

rotate

15.

Install ing

removed

flanged

in

ring

lockwasher

and

ball

to

ball

Woodruff

reduction

bearing

unit

shaft

housing.

unit

gear

is

in

lockwasher

using

one

two

plate.

redu.ction

housing

reduction

lockwashers

and

tighten

for

replacement.

shaft

gear.

secure

flanged

bearing

key

gear

(84) mallet. over

with

until

on

inside

half

seated

coupling

in

slot

suitable

tang

of

lockwasher

studs 3 1/2

and

slide

gear

uniformly.

over

(84)

and

(80)

housing

on

flanged

small

spacer

of

coupling

against

and

key

(78)

on

flanged

wrench.

gear

onto

slightly

and

press

ring

gear

capscrew

shaft

onto place into

to flanged

seal

keyway

over

shaft

end

(73)

is

flanged

(75)

onto

ball

in

shaft

over

end

into

inches

assembly

reduction

to

capscrews

new

(71)

and

ring

washer

in

small

into

of

housing

seated

shaft

bearing.

before

of

flanged

shaft.

slot

long

into

over

drive

properly

around

insert

gear.

shaft.

flanged bore

against

with

Place

on

locknut.

studs

oil

seal

and

line

capscrew

Place

(74)

end

in

down

large

end

Care

pressing

shaft

locknut

two

opposite

with

ge8.r.

mesh

flange

(79)

up

spacer

over shaft. of

flanged

housing

and

ball

bearing

and

into

must

together.

with

oil

It

gear

of

into

holes

into

shaft

by

tapping

press

end

of

ball

be

taken

tang

(77)

holes

drain

may

be

teeth.

reduction

in

flange

hole

in

(73)

over

to

spacer.

and

housing

on

center

(84)

in

unit

down

bearing

to

on

inside

onto

in

plug

shaft

reduction at

necessary

gear

with

flanged

shaft

start

of

reduc-

and

until

line

up

of

and

bottom

to

hous-

\

\'-----.. ~ 'v

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

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

__

~/

---...---~

-

:?6

,

S.25

The

Volvo

RB,

has a bui

ion

ratio 1 .91:

tern"

takes which with

the

When

moved front output

with

the

mediate output neutral

plunger oetween

Penta

It-in

place

are

held

he

Ip

of

engaging

with

its

cone.

shaft

When

is

inner

gear.

shaft

wi

position

in

such a potition

the

cone

1.

cone

II

Reduction-reverse separate

oil

changer

TYPE

reduction-reverse

reduction

Engagement

by

means

in

the

"Ahead",

cone

moved

which

The

direction

therefore

the

cone

and

gear

of

engaged

prope

so

Iler

that

"Astern"

backwards

operates

is

that

the

gear

with

and

is

se

the

be

held

watercooled.

gear,

with

"Ahead"

If-adjusting

position

thrust.

output

it

meshes

is

engaged,

and

via

of

rotation

reversed.

by

the

there

is

whee

ratio 1 .9

RB

- FREEWHEELING

type

reduct-

or

"As-

cones

partly

shaft

with

the

meshes

an

inter-

of

the

In

the

locking clearance I.

: 1 has a

is

the

2.

3.

4.

5.

Remove

to

the carefu is re

Ily

leased

Remove ling

flange protector removed.

Remove control (2).

Pullout

eccentric

stud

which

Remove

gear

housing (32)

the

casi

light

blows

the

bolts

engine

aft,

and

without

from

the

bo I t

(10).

(18).

the

reverse

shaft

(1).

the

stud

(9)

has

the

bolts

ng from

with a mallet.

holding

pull

the

breaking,

the

engine.

(1

2)

and

pu

Also

The

key

lift

(15)

gear

Then

remove

control

(note

marked

which

to

the

shaft

the

sides.

secure

the

casing

housi ng by means

reverse

II

off

the

need

lever

(1)

position

the

(33).

so

that

the

rubber not

from

the

and

of

reverse

gear

it

coup-

be

the

cover

the

Part

of

Fig.

1.

2.

3.

4.

REPAIR

The

repair

1.9

:1.

1.

Disconnect (rqtio

and

1.

RB

type

reduction-reverse

gear,

ratio

1.9:1

Plug for

Oil

Plug for

Drain

oi

dipstick

draining

plug

I fi Iling

for

cooling

oil

water

INSTRUCTIONS -REMOVING

instructions

the

1.9

:1).

push

it

aft.

refer

to

Fig.

cooling

water

connections

Removethepropellershaft

2 for

ratio

6.

8.

9.

10.

11.

Remove

shaft

(17)

Remove

P

lace

ho

off

ing wheel, (26)

ed

Lift

Remove (34) from

Ie

of

the

(29) is

after

out.

out

the

one

the

gear

remove

the

the ion-reverse ing

is

made

the

bevelledside

See

Fig.

2. flange shaft. the

(44)

Press

cover

the

bolts

with

the

bolts

of

the

support

wheel

to

be

the

whic h the

cone

gear

housing

gear

with

easier

Remove

need

not

out

the

(43tandthe

(22) sleeve

(23)

and

bo I

ts

beari

(30).

removed

bolts

ba

(28).

wheel

(33).

ratio

by

tapping

of

the

be

shaft

(42)

ball

and

take

(20).

the

(23) in

ng (27)

If

the from

(25)

II

bearing

(31)

with

Forthe

1.9 carefu

gear

bolts

removed

together

bearing.

out

washer

the

and

ball

the

and

the

is

: 1 J

wheel

(38).

from

the

(24).

center

pu

II

bear-

gear

ring,

press-

bearing reduct-

remov-

Ily

on

(31),

The

the

with

Pres-

S.26

sure

is

applied bearing needle tect

the

that

it

will

when

12.

13.

See

done been to

INSPECTION

Before

being

Drive (37) taking

bearing

(44) .

out

and

Fig.

in a press removed.

the

care

reverse

Fig.

2.

ta

(35).

bearing

the

(3) from the

outer

Take

bearing

take

fitted.

the

shaft

bearing

of

the

2.

Removal

after Pressure must

ci

gear

(35)

up

rcumference

Cross-section

the

shaft

journal for the

care

to

ensure

is

not

damaged.

from

dirt

and

the

same

position

(40)

wi

th

the

(36).

bearings,

the

is

refitted,

of

flange

shaft

locking

With

see

(42) should be

not

of

all

of

reduction-reverse

that

the

Pro-

place

gear

again

whee

regard

point

(44)

flange

be

applied

the

flange

its

it

so

to

11.

and

has

com-

I

gear,

ponents shou time

inspect worn. ers. are

See wheel compensated the

in

"X"

measurement "X"

termines how much the thickness shall

measures 83mm

shim should be

the

then

ion linings in the

interchangeable.

Fit new gaskets,

Check

undamaged.

Fig.

2.

(31),

shim (21) as follows:

the

gear

shown in

be

increased.

measurement

the

worn parts must be

ratio

Id

be

the parts

carefully

Friction lining

which

for by

wheel (31)

Fig.4

(3.

fitted.

1.9

carefully

and

to see

is

most

increasing

The

is

less

For

29"),

If

"X"

is less than 81mm

gear

: 1

cleaned.

replace

O-ring

that

subjected

Place

and

measure

amount

than

85mm

example, then a 2mm

the

wearis

replaced.

wheel

and

all

wear

the

of

and

At

those

spring sealing

on

the

to

thickness

the

cone

the

by

which

(3.35")

the

shim (21)

if

the

(0.08")

so

great

(3.19"),

The fri

cone

the

same

that

are

wash-

ring~

gear

wear,

distance

are

is

of

(28)

the de-

thick

that

ctnot

1.

Fit

(37),

2. Fit into

3.

See bearing (44)

is

the

teeth in damage cover, A vent

sage

4.

See

housing gear both

the

bearing

also

the

gear

the

housing

Fig.

2.

(39),

into

one

fitted

so

bearing

on

the

cover

or

itshould

protecting

damage

of

the

Fig.

2.

(33).

wheel

gear

wheels

(36)

press

the

wheel

(33).

Fit

cover

unit.

that

(Fig.7)

shaft

(43) shows

if

it

has

be

sleeve

to

the

keyway

Fit

Take

on the

and

shaft

(31)

with

together

(43)

Th~

the

recess on

faces

(42).

been

If the

removed

replaced

shouldbe

sealingring

in

the

shaft

care

to

shaft

(37

and

the

gear

into

the

housing.

bearing

the

shaft

and

the

blJII

bearing

one

opposite

sealing

the

least

from

bya

new

used

to

by

the

shaft

(42).

unit

into

ensure

that

(42) meshes

31).

wheel

(34)

(42),

flange

(39)

side

the

ring

sign

the

one.

prepas-

the

with

of

12.

Fittheflange(9),

er

(8),

er

housing

fore

fitting.

its sides marked

a I

direction

gear

lever

positions equi-distant. ection direction,

the

flange center in

relation

portion that

movement the

"Ahead"

creased.

so

that movement the

"Astern"

sleeve

lever from

respectively,

is

appreciably

(9). This

of the

(guide).

the

projecting

If

the

(4),

(6).

Oil

The

flange

"0"

of

the

and

check

neutra

this

of

I to

If

the

is

rectangular

to the

center

the

position

theflange

projecting

the

position

shaft

(1),

spring

the

(5)

parts

(9)

follow

engine.

the movements

"Ahead"

which

movement

more

than

to be

adjusted

is

shaped

of

If

the

flange

side

faces

reverse

to

"Neutral"

is

turned

side

lever

from !lI'Jeutral" to

is

decreased.

locking

and

the

plungplung-

liberally

is

fitted

the

Fit

and"

so

lonoitudin-

the

reverse

Astern"

should be

in one

in the

by

turning

such

that

portion

the

is

cylindrical

is

fitted

forwards, the

gear

lever

is

half a turn

faces

aft,

S.27

be-

that

of

the

dir-

other

the

offset

so

from

de-

the

5.

6.

7.

8.

9.

10.

See

Fig.

Fit

the

cone

Fit

togetherthe

ing

support

and

the

and

tighten bearing of

on the

the

is

bearing

gear

port (27)

the

middle

Place

Fit the

Fit

the

cone

the

shaft

reverse

assembled

housing

(33).

2.

Fit

(28) in

bearing

(27),

gear

wheel

on

fitted

faces

whee I (30).

and

the

throu!=lh

unit

in

(17)

(28).

gear

parts

the

needle

the

bearing

(30)

the

cover

so

that

washer

hole

the

and

housing (32)

and

gear

support

into

the

away

The are

comes

cone

the

tighten

bearing

wheel

(27),

(29),

one

(24).

recess

from

bearing

fitted

(28).

sleeve

it

(35).

(31).

bear-

cover

(24)

unit

The

ball

one

side

the

teeth

sup-

so

that

upwards.

(20)

onto

over

onto

and

the the

13.

Then c in

Fit ingthe ting

the for fully

heck

both

the

"Ahead"

thereversegearto

reverse

is

faci

litated

driving

these in

coated

that

the

and

gear

withratio

if

the studs (45) the

engine

with

talc.

reverse

!lAstern"

the

engine.

rubber

as

we

II

flywheel,

1.

Spring

2.

Interlock

3.

Control

4.

Cover

5.

Flange

6.

Bearing

7.

Reverse housing

gear

engages

positions.

Regard-

1.9

:1,

bushings on

as

the holes

are

care-

housing

shaft

hO'.lsing

gear

fit-

11. Fit

the

rubber

Ii

ng

flange

the

bolt

(12)

key (15)

is

way in the

protector

(10).

is

well

properly

shaft

(17).

Before

bedded

(18)

and

the

fi

tti ng c hec k

tightenedandthat

down in its

coup-

that

the

key-

Fig.

3.

Rear

section

of

reverse

gear

S.28

1.

Set

the

reverse

gear

position.

2.

Remove the bolts whic h hold

housing (6, Pull the meters (this gaging the carefu only

3.

Turn position

If sition verse and shaft

sea ling surfaces

lIy so

one

the

keyway on after

gear

flange

there

Fig.

bearing

is

the

lever),

that

of

bearing

and

being

lever

are

is

3)

housing

faci

litated

it

remains in

the

sealing

tighten

the

moved round

cannot

turned

only

one

lever

to

in the

the

aft

by

several

carefully

neutral

the

bearing

housing (7).

milli-

en-

insert a knife between

and

loosen

the

contact

basket

with

surfaces.

housing to

the

desired

down the housing.

shaft

is

in such a

that

be

fitted,

as

fo

lIows:

keyway so

the

On

that

po-

re-

shaft

the

both

the lever

turned.

a.

Remove the spring housing (1, Fig. 3)

and

b.

Remove the

off

c.

Lift the shaft (3) with

housing turn). turn

4.

Refit the parts.

If

the

remote control for the

verse

gear

a

way

that a constant reverse "Ahead" tro I

the the

gear

and device prope lIer thrust

reverse

lift

the

and

is

fitted,

retainer

out

shaft.

and

Turn

fit

and

the locking

cover

(4)

turn the shaft 1800

also

the

shaft.

it

may not

pressure

control components.

"Astern

must be

gear

II

complete

can

in

the

positions

maintain the

engaged

the shaft must

plunger

without

cover

(2).

pulling

(4) from

(half

flange

(5)

RB

reduction-re-

be

done in such

operates

half

on

In

the

remote

Iy

un

loaded so

cones

position.

be

it

the

a· a

the

both

con-

that

in

Type

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

Ratio IIAhead Ratio IIAstern

li

••••••••••••••••••••••••••••

li

••••••••••••••••••••••••••••

Lubricating system

Oil

capacity, Oi I grade Oi I viscosity. Oil

change Prope Iler type Weight,

approx

.•..•...........................

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

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

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

approx

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

DATA

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

..............•........

Volvo

1.9

Penta

:1

1.73:1 Circulation

0.5

liter

Service

..

SAE

20

Every 100 hours

Left-hand

28

kg

(61

(1

OS

lb.)

RB

1.9

type

quart)

thread

:1

5-29

I.

SPECIFICATIONS

A.

Description

MODEL

P21L P22L P23L

P24L

P25L

B.

Model

and

Serial

PARAGON

Chart

REDUCTION

DIRECT

1.

2:1

2. 5: 1

3:1

J

Numbers

P-21

5:

1

SERIES HYDRAULIC

RATIO

DIRECTION

ALL AS

THE OF

LEFT

VIEWED

OUTPDT

THE

MISSION

OF

ROTATION

HAND

FROM

TRANS-

END

P 2 -

Each a

serial

the

of

the

Gear.

reverse

number.

name

Size

plate,

transmission.

gear

has a model

located

1 -

Direct

number

These

numbers

on

the

housing

MODEL

DIRECT DRIVE MODEL

Drive

REDUCTION

AND

L -

GEAR

l

and

are

on

SERIAL

AND

Left

Hand

Rototion

MODEL

AND

5J-5678

NUMBER

SERIAL

NUMBERS

Unit

SERIAL

CHART

5J

NUMBERS

.1234

-

Tronsmission

Serial

No.

P 2 -

Geor

Size

~

I

Reduction

Geor

~

\

Size

------=====

1. 5: 1 J 5 J -

2.0:1

2.5:1

3.0:

,

Reduction

Geor

\

Ratio

1

-----------

L

-LeftHandRotationUnit

5678

. T

mission

Serial No.

ran

s·

S.30

II.

INTRODUCTION

Tl

ansmissions

operation

and transmission pressure

separated

system from

Transqlission engage a forward

III.

INSTALLATION

A.

The

installation

use

when

removed installed, is

to

be

ment

to a marine

B.

It

is

important mission tion

of

rotation

this

manual

of

the

engine output wise

end

rotation rotation the

engine

A

letter transmission trated

in indicates use

with

engine.

C.

The

hydraulic

the

engine

1.

Insert transmission engine

2.

Place

so

that matching housing

have

been

designed dependability is

self-

and

engine

oil

under

or

reverse

instructions

the

original

for

servicing

or

when

adapted

in

contained,

oil

supply

lubricating

pressure

drive.

transmission

and

the

transmission

as

non-original

marine

having

below

must

engine.

that

the

engine

rotatio:1s

of

are

of

an

as

the

crankshaft

the

transmission.

of

the

engine

matched.

engine

direction

as

viewed

is a right

and a countercluckwisE:

is a left

"R"

Section

whether

a

in

two

adapter

the

hand

or

"1."

serial

right

num},i::r

I,

"SPECIFIC\TIO;\S",

the

transmissiun

or

transmission

the

following

3-1/2"

mounting

plate.

transmission

studs

gu

holes

in

rotation.

appearing

left

hane!

is

manner:

studs

holes

against through thE:

trans!nis:.'ion

flange.

for

srilooth

Lise.

The

an

completely

oil

systems.

is

used

The

for-

are

for

has

been

be

re-

unit

eqUip-

and

t

rans-

The

di

rec-

is

defined

of

T0tation

from

the

A

clock-

hand

rotation

on

the

plate

illus-

is

for

rotating

attached

in CJl!posite

ill

ttlt~

the

Cituds

two

"f

the

oil

to

in

of

to

ward a

rrangement,

a

reverse train. cooled core, water. with

either

Gear

model Section

4.

Install washers housing plate. and \vith mission

D.

The

pIing

propeller miSSion,

consequent

engine,

To

align shaft, the

propeller

miSSion tact. in

contact ference. the

point.. If ti,e

tion by

lo()sening adding either

IJ10ve runaut

faces bulls coupling together.

lJolts,

E.

Connect

mission.

drive

is

through a multiple

while

clamp

The

transmission

through a sep"

which

is

Paragon

in

transmissions

dirp.ct

reduction

iclentificati,)n

I,

l~ndeI'

"SPI::ClFICATIO~~".

and

tighten

thr(.ugh

flange

Remove

tighten

lockv.'ashers

hOUSing

transmission

must

be

carefully

shaft

in

urder

damage

and

boat

the

coupling,

with

attached

transmission

shaft

CUUplil)g

The

coupling

throughOUt

The

total

faces

sh(Juld

runuut

tht:

engin~

tht: engin.::

or

removing

end

~)i

the

engine

or

to

laterally.

and

recheck

before

Connect

Juckwashers,

the

oil

thE:

band

turn

reverse

oil

rate

cooled

and

planetary

is

circulated

external

drive

by

are

drive

or

reductiol}

ratios

the

aild

numbers

four

into

the

3-1/2"

two

correspondl'1g

are

bolts

the

transm:ssiO[1

the

enginE"'

studs.

remaini-ng

through

flange.

and

propeller

aligned

is

connected

to

bull

c\Jup!ing

so

that

coupling

avoid

move

to

vibratiun

the

transllli":si'J11,

during

the

flange,

the

f:H.:es

n;iI1gl;

ihnge

are

flang'e 1acE;s

thei

r

€'lti

rUlllhit

n·.)t

exceed

or

g:1p

.002"

exceeds.002",

and

att:1(;hed transmi!-:<siGTl

support

shims

the

cIll!-ine.

sideways

:11

ign

'[

ighten

bulting

the

and

cooler

to

the

a:ignrnent

the

c<lupl i ng

nuts.

lines

raise If

to

~oupling

engine

coupling

flanges

to

disc

clU1.d\

uti 1

izes

g>::iI'

:H.d

oi I

c<)ok

r

the

png:nc

fcHllishl,d

gt::.il";.

liSted

with

in

lock-

ad~pter

Inshll

bolls

the

lram;-

shalt

(.;')U-

before

the

oper:iJ

pn~pt;!i\.'r

1

nns-

the

,[nd

:UIl.

tc,v>ard

,)1'

,he

:-i!~ri

,ff;llS-

:n ('()n-

shoujli

n,

bo.llts

nel~E:SSdI'y.

adjust

be

,;:

rClIn;-

he!\,1~::'11

:1t

:tny

n~p()si

:,11<.1

ur

ld""t:I'

trw

flange

suppllrl

"f

t.he

fla"gt:s

w:

til

tlw

IJ"i,LS-

3.

Slide

the

transmission toward the

enters engine

shaft

vibration

the

at

the

engine

the

front

matching

dampener.

so

of

splined

along

that

the

transmission

the spline

hole

studs

in

the

on

F.

Connect cockpit control page valve

the

control

valve

5.

Place

lever

shIft

station

lever,

the

in

control

shown

transmission

the

neutral

to

cable

the

11'on.

the transmission in

Figure

control

position

and

()n

GENERATOR TROUBLESHOOTING

T.59

PREPARATION

A few simple checks and a procedure can locate the probable source and

cut

down troubleshooting time.

1.

Check all modifications, repairs, replacements performed since last satisfactory operation

that

to be sure

connection of correct. A loose wire connection, overlooked when installing a replacement part problems. An incorrect connection, circuit

breaker,

or

a loose board are all potential eliminated by a visual check.

2.

Unless absolutely sure accurate, use portable test meters troubleshooting.

3.

Visually inspect components on dirt, dust, solder

or

moisture and cracks in the

conductors. Burned resistors, arcing

tracks are all identifiable. Do

circuit

conductive

boards with a pencil. Graphite lines are

and can cause

. components.

The question and answer troubleshooting which follows, gives a step-by-step

-;hecking the generator components. Refer to Figure

22

for

an electrical schematic

voltage regulator connections.

proper

troubleshooting

generator

could

an

plug-in

malfunction

that

panel instruments are

printed

areas

VR21.

not

mark on printed

short

circuits

procedure

of

the

generator

of

trouble

of

leads are

cause

opened

circuit

to

for

Look

for

printed

between

guide

for

and

set

be

TROUBLESHOOTING PROCEDURES

This troubleshooting information tables,

A. B.

C.

A,

B,

C, No build up AC

output

AC

output

and D as follows:

of

AC

output voltage builds up, voltage builds up,

is

voltage.

but but

divided

is unstable. is

high

or

low.

into

D.

AC

output

voltage

trips.

To

correct either answer

Letters A refer

a problem, answer the question

YES

or

NO. Then refer

column

to

detailed procedures in the Adjustments and

and proceed to that step next.

through

P in

Tests section, pages

TABLE

A.

1.

Is

Field

on

control

2.

Connect

terminals CB21.

voltage If

voltage

REPLACE

3.

Push

Does build If

voltage

is

high,

causes

Breaker, B,

C,

4.

Disconnect

leads

TB21·2

voltage

or

more?

No

Output

Breaker

jumper

of

Does

build

builds

FIELD

to

reset

AC

output

up?

builds

low,

tripping

refer

or

D.

1 & 2

on

across

Build

Up

Voltage

CB21

panel

ON?

wire

Field

AC

output

up?

up

BREAKER

Field

voltage

up

unstable,

of

to

Tables

alternator

from

VR22.

1 & 2

builds

the

8-15.

of

AC

across

Breaker,

.

Breaker.

but

or

Field

stator TB21·1 Is

and

reference

20

VAC

up,

but

field breaker

of

the step

to

the step

number

in the

Test Procedure column

Yes

No

Test

Proc.

2 3

-

14

4

13

F2-

BRUSHLESS

EXCITER

(39.

FI+

WYEl

FIGURE 22.

W9

F2-

TI

THROUGH

T4

OR

GENERATOR-REGULATOR

TI2

ELECTRICAL

TB21

REFERENCE

VOLTAGE

SCHEMATIC

DC

OUTPUT

VOLTAGE

4

3

2

CB21

CRI2.

CRIS.

7

B

CMR21

0

VOLTAGE REGULATOR ASSEMBLY

ARE

VOLT.

P.C.

VR21

CRI3.

AND

ON VR21

REG.

BOARD

T21

0

CRI4

CRI6

T.60

TABLE

Is

exciter

5. F1 + and

terminal

more? If

not.

W9

terminals 3 and

6.

Is

brush

(field)

I

7.

Are

CR4, rectifier Check than defective.

8.

Are

windings

Is

generator

9. winding

10.

Are

windings

A.

(continued)

field F2block

check

from

end

less

winding

diodes

CR5,

assemblies

all

diodes -more

one

may

brush

less

OK?

generator

OK?

on

wiring

bell

exciter

CRl.

CR6

exciter

rotor

stator

voltage

end

bell

7.0

VDC

harness

to

VR22

4. stator

OK?

CR2,

in

rotating

OK?

be

field

across

or

CR3,

rotor

Yes

6

7

8

9

10

11

No

Test

Proc.

-

- K

-

F

L

M

N

TABLE

l.

Are

wires voltage VR22?

Is

2. harness bell

Does

3.

Control on

voltage?

4.

Replace

~

located

TABLE

B.

AC

Builds Unstable

there

or

connections

regulator

W9

(exciter

from

OK?

adjustment

R27

VR21

PC

and

corrected

C_

AC

Output

Voltage

Up,

any

loose

assembly

field)

VR22

of

potentiometer

result

in

stable

Board

VR2l.

Do

not

the

trouble

to

Output Builds High

or

Up,

low

Voltage

But

Is

or

broken

on

wiring

to

End

Damping

replace

not

avoid

damage

But

is

the

on

Yes

- 2

3

-

printed

the

PC

to new

Yes

No

-

4 A

-

circuit

board

PC

board.

No

Test

Proc.

P

board

has been

Test

Proc_

until

Is

commutating

1l.

CMR21 Is

reference

12. T21

Flash

13.

reference 1

and 2 now

more?

Reconnect

14. 1 & 2 TB21-2 reference

Is

regulator

15.

voltage VR21-8 7 VDC See

16.

Are

SCR's

CR16

17.

Are

diodes

and

OK?

exciter

to

TB21-1

on

across

Figure

OK?

CR15

reactor

transformer

field.

voltage

20

across

VAC

generator

and

VR22.

Does

voltage

DC

build

output VR21-7 or

more?

22.

CR13

and

CR12,

CR14,

OK?

Is

or

leads

up?

and

12

18

14

-

5

17

18

-

5 E

15

16

-

I

J

H

G

Is

set

(See

appropriate

running

1.

manual

2.

Does

adjustment Adjusting on

VR22

output

Does

3.

adjustment

potentiometer result voltage?

4.

Is

correct

V4

to VR21 Refer

5.

Are

generator properly to

Figure

Replace

6. PC

board

to

set

knob

result

voltage?

in

correct

voltage

VI,

V2,

or

being

used?

to

Figure

output

connected?

6.

voltage

VR21

at

correct engine

RPM)

of

Voltage

for

R22

in

correct

of

R26

on

output

reference

V3

on

6.

regulator,

RPM?

VR21

leads

Refer

-

2

-

3

A

- 4 A

5

-

6

-

P

18.

Replace

PC

board

voltage

(VR21)

regulator

~

-

P

~

located

and

corrected

Do

not

replace the printed

the

trouble

to

avoid

nol

on

damage

the PC

to

new

circuit

board

PC

board.

board

has been

Uf.

I

TABLE

I

1.

2.

3.

4.

5.

6.

7.

D.

AC

Output

Builds Breaker

Does

AC

output

build

up

to

of

rated

voltage

Field

Breaker

Are

there

any

broken

wires

nections

Is

Are connections

Are

leads Refer

Replace

Are

CR4, rectifier Check

than

defective.

diode

CR15

T21

windings

generator

properly

to

Figure

VR21.

diodes

CR5,

assemblies

all

one

on

CR6

diodes -more

may

UP.

Trips

voltage

140%

before

trips?

loose

or

con-

VR22?

on

VR21

and

OK?

stator

connected?

6.

CR1.

CR2, CR3,

in

be

Voltage

But

or

more

or

OK?

rotating

OK?

Field

Yes

2

-

4

5

6

-

8

No

7 -

3

-

Test

Proc.

G

J

-

P

F

ADJUSTMENTS pages 8-15.

A.

VOLTAGE

B.

VOLTAGE

C.

BATTERY

D.

VOLTAGE

E.

FLASHING

F.

TESTING

G.

TESTING

H.

TESTING

I.

TESTING

J.

TESTING

K.

TESTING

L.

TESTING

(ARMATURE)

M.

TESTING

N.

TESTING

O.

WIRING

P.

VR21

CALIBRATION STABILITY

CHARGE RATE

REGULATOR

ROTATING

OUTPUT

SCR'S

REACTOR

REFERENCE TRANSFORMER

EXCITER STATOR

BRUSHLESS EXCITER ROTOR

GENERATOR ROTOR

GENERATOR STATOR

HARNESS

REPLACEMENT

AND

TESTS - REFERENCE LIST,

THE FIELD

BRIDGE

CHECK

T_61

ADJUSTMENT

CHECKOUT

RECTIFIERS

DIODES

8.

9.

10.

11.

Is

brush

stator

winding

Is

generator

winding

Is

brushless

OK7

Are

generator

windings

less

OK?

exciter

OK?

rotor

exciter

stator

field

rotor

9

10

11

6

-

K

M

L

N

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

various

requires

contain

components

to

the

systems.

yourself

the

appropriate

service

supplementary

and

proper

with

functioning

the

or

overhaul.

Bulletin(s)

subjects

and

service

SECTION V

up-

pro-

of

and

Westerbeke WPDS-20 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual