Westerbeke Diesel W 120 Parts Manual

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TECHNICAL MANUAL WESTERBEKE Marine Diesel Engines MODEL FOUR230 70hp MODEL SIX346 115hp Marine Diesel Generators MODEL WPDS30 30kw MODEL WPDS45 45kw Publication Number 13315 Issue Date June 11975 Edition 2jrv WESTERBEKE J MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 TECHNICAL MANUAL WESTERBEKE Marine Diesel Engines MODEL FOUR230 70hp MODEL SIX346 115hp Marine Diesel Generators MODEL WPDS30 30kw MODEL WPDS45 45kw Pu bl i cat ion Number 13315 Issue Date June 1 1975 Edition 2rv WESTERBEKE J MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 INTRODUCTION This manual describes the operation adjustment and maintenance of theWesterbeke Model SIX346 and FOUR230 Marine Diesel Engines and is designedto be a guide for those concerned with the operation and maintenance of thesediesel enginesThe diesel engine closely resembles the gasoline engine inasmuch as the mechanism is essentially the same Its cylinders are arranged above its closed crankcase its crankshaft is one of the same general type as that of a gasoline engineit has the same sort of valves camshaft pistons connecting rods and diesel engine does differ from the gasoline engine however in the method ofhandling and firing its fuel Carburetor and ignition systems are done away withand in their place is a single component the Fuel Injection Pump which performs the functions of bothTherefore it follows to a great extent that a diesel engine requires the samepreventive maintenance as that which any intelligent and careful operator wouldgive to a gasoline engine The most important factors are proper maintenance ofthe fuel lubricating and cooling systems Replacement of fuel and elements at the time periods specified is a must and frequent checking i e water sediment etc in the fuel system is also important factor is the use of High Detergent diesel lubricating oildesigned specifically for diesel engines and continued use of the same brand o f lubricating oil is care and attention at the factory have resulted in an engine capable ofmany thousands of hours of service What the manufacturer cannot control however is the treatment the product will receive in service This part rests service parts are ordered always give complete description and partnumbers with engine model and number The engine model and number is stampedon the nameplate affixed to the exhaust manifold Example SIX346 Marine Diesel Engine No 57PS 1641 20801 or FOUR230 Marine Diesel Engine No 38PS 164139101 2 TABLE OF CONTENTSENGINE IDENTIFICATION 45INSTALLA TION DRAWINGS 6ENGINE DESCRIPTION 78GENERAL DATA 912INSTALLA TION 1318OPERATION 2427COOLING SYSTEM 2932FUEL SYSTEM 334OBENGINE 4171HYDRAULIC TRANSMISSIONS 7392GENERATOR 94117VOLTAGE REGULATOR POWER CONNECTIONS DIAGRAM 118MANUAL STARTER DISCONNECT ROTARY SWITCH 119125 3ENGINE I N E IDE NT I FICA T ION 5 INSTALLATION DRAWINGSRATIO DIM A DIM 8 IOFFSET1501 16118 i 450 85 aNLU2041 cuB 1450S21 6150 525 I 130 190 wJm 3CO1 6150 525 210 125 CONN 1156 1 11 EtIJNE 1 0fc5f r iI rLEX RAPIUS 9I2RL i 1 MfG CENTERS B9LTS OB lli 1 i FO L A512IRE LAGRE T RIV I DIPSTICK CAN BE QJ EITHER SIDE SIX346 RATIO DIM A DIMS OFFSET 1501 5156 450 85 2041 5156 450 130 2521 5187 525 190 3001 5187 525 210 WATER QVLLT iJP FA FLEX MOUNTING CENTERS EQR BOLTS OR LAG SCREwS 3062j 8 1 4550RCTlReyV I AI T FOUR230 6 ENGINE DESCRIPTION fitted to the front of the crankshaft The Westerbeke Six346 and Six346 engine only to absorb crankFour230 Marine Diesel engines are shaft vibrations A lip type oil sealdirect injection six cylinder four mounted In a onepiece housing sealsstroke units and four cylinder four the rear main bearingstroke units respectively Right hand side or left hand TIMING GEARS AND TIMING CASEside means the side of the engine as A train of gears is utilized toseen from the flywheel end drive the camshaft and the fuel injec tion pump The camshaft drive gearCYLINDER BLOCK AND CRANKCASE is mounted on the steel camshaft by The cylinder block and crankcase means of a separate hub and nut Anis a one piece casting employing idler gear transmits the drive fromdetachable wet liners sealed at their the gear on the crankshaft to both thelower end by synthetic rubber 0 rings camshaft and the fuel injection pump drive gearsCYLINDER HEAD AND VALVES PISTONS AND PISTON PINS The cylinder head carries thevalves valve rocker gear and injec The pistons are attached to thetors it is completely water jacketed connecting rods by fully floating pistonaround the ports and injector sleeves pins and are equipped with threeThe air induction manifold and the compression and one scraper ringexhaust manifold are mounted on The top compression ring on eachopposite sides of the cylinder head piston is chromium inserted to give greater wear resistance rapid seatingThe valves are set vertically in the and extended lifecylinder head and are operated throughthe medium of the rocker gear pushrods and tappets from the camshaft LUBRICATING OIL SUMPThe inlet valves are larger in diame The oil sump is fitted with ater than the exhaust valves and are suction tube extension combined withshrouded to assist air swirl on the dipstick tube from which the oilinduction may be removed by a suction pumpCAMSHAFT LUBRICATING SYSTEM The camshaft is mounted in the The rotortype oil pump gearcrankcase running directly in the driven from the front of the crankcrankcase bores with the exception of shaft is mounted on the front mainthe front which runs in a whitemetal bearing cap and incorporates an oilbearing Camshaft endfloat is con pressure relief valve in the pumptrolled by a thrust plate between the bodycamshaft shoulder and the camshaft Oil is drawn from the sumptiming gear through a strainer to the oil pump From the pump the oil is through an external oil filter via a The crankshaft for the Six346 housing attache to the is mounted on seven replace From the outlet side of the filter oilable main bearings and the Four230 is fed under pressure through theengine is mounted on five replaceable oil cooler to the main oil gallerymain bearings in the crankcase End Drillings from the main gallery feedthrust of the crankshaft is taken by oil to the crankshaft main bearingsthrust washers on the front main bear and camshaft bearings and a drillinging A torsional vibration damper is across the front of the crankcase 7ENGINE oil to the idler gear shaft to The atomisers fuel injectors arelubricate the idler gear bearings An located on the right hand side of theoil jet screwed into this drilling lubri cylinder head in an accessible positioncates the train of timing gears They are retained in the head by From the crankshaft main bear flanges secured with nutsings oil is fed through the crankshaftto the bigend bearings Oil splash INDUCTION MANIFOLDfrom the crankshaft lubricates the The induction manifold is made ofgudgeon pins and cylinder walls diecast aluminum on the right hand An external pipe feeds oil from side of the cylinder head and an airthe main gallery through drilling in filter is fitted in this manifoldthe cylinder head and brackets to the hollow centers EXHAUST MANIFOLDof the rocker shafts Oil pressure in A water cooled exhaust manifoldthe rocker shafts is controlled by a is fitted to the left hand side of thepressure relief valve fitted on the cylinder head The water is not infront intermediate rocker bracket direct contact with the exhaust gasesThe rocker bearing surfaces are but circulates in an outer jacket formlubricated by oil from the rocker ing the coolant expansion tankshafts and oil mist in the rockerchamber provides the necessary valve COOLING SYSTEMguide lubrication Two methods of indirect fresh Discharged oil from the valve water cooling are available and relief valve drains down to customers requirements Freshthe pushrod tunnels and lubricates water is circulated round the enginethe tappets and cams before returning by a centrifugal type water pump andto the sump this water is in turn cooled by either a heat exchanger or keel cooling pipesFUEL INJECTION SYSTEM A distributor type fuel injection ELECTRIC SYSTEMpump is flange mounted on the right Twelve volt electrical equipmenthand side of the cylinder block and is fitted to the enginedriven by a splined shaft The 12 volt 55 ampere alternator An automatic device is incorpo is mounted on the left hand side of therated in the fuel injection pump to engine and is belt driven from theadvance or retard the point of fuel front end of the crankshaft Belt teninjection according to changes of sion is adjusted by means of an adjustengine speed able link and pivot pin The engine speed is controlled The flange mounted starter motorby a mechanical type governor incor is fitted on the right hand side of theporated in the fuel injection pump the engine in accessible positionspeed control lever being located ontop of the fuel pump together with anengine fuel stop lever A fuel lift pump of the diaphragmtype and equipped for hand priming isfitted on the cylinder block on the lefthand side of the engine The pump isoperated by an eccentric from thecamshaft 8 GENERAL DATA GENERAL DATATypes Six346 115 HP 2600 rpm Four230 70 HP 2500 rpm Bore 3 937 in 100 mm Stroke 4 724 in 120 mm Capacity Six346 345 3 cu in Four230 231 cu in Compression ratio Six346 168 1 Four230 168 1 Torque Six346 255 lb ft 35 26 kgm 1750 rpm Four230 174 lb ft 2406 kgm 1400 rpm Cylinder liner bore diameter 37401 to 37409 in 9500 to 9502 mm Thickness of liner shims 003 and 005 in 076 and 127 mm Piston to bore clearance on thrust face at bottom of skirt 0055 to 007 in 139 to 18 mm Piston ring groove clearance 0095 to 011 in 24 to 28 mm Remainder 002 to 004 in 051 to 102 mm Piston ring fitted gap 014 to 020 in 36 to 51 mm Remainder 011 to 016 in 279 to 406 mm Gudgeon pins Fit in piston 0005 in 013 mm interference to 00025 in 006 mm clearance Pin to smallend bush clearance 0005 in to 0013 in 013 to 033 mm Connecting rods Length between centres 8185 to 8187 in 20790 to 20795 mm Permissible out of parallel of big and smallends 0001 in per inch 0001 cm per cm effective mandrel length Bigend bearing to crankpin clearance 0015 to 0030 in 04 to 08 mm Connecting rod to crankshaft sideclearance 008 to 012 in 2 to 3 mm Littleend bush bimetal wrapped type inner diameter 137525 to 137575 in 34931 to 34944 mm Crankshaft and main bearings Journal diameter 32495 to 3250 in 8254 to 8255 mm Crankpin diameter 26245 to 26250 in 6666 to 6667 mm Undersizes 015 in 030 in 045 in 381 mm 762 mm 1143 mm Bearing to crankshaft journal clearance 002 to 004 in 05 to 10 mm Rear oil seal cover to oil return thread clearance 0070 to 0085 in 0178 to 216 mm all round End float controlled by thrust ashers Four230 006 to 010 in 15 to 25 mm Six346 006 to 013 in 015 to 33 mm 9GENERAL DATACamshaft and bearings Bearing to camshaft clearance No 1 bush 0015 to 0040 in 038 to 102 mm Remainder 00275 to 00475 in 0698 to 1206 mm No 1 bush inner diameter finished in position 19995 to 20010 in 50787 to 50825 mm Endfloat controlled by thrust plate 002 to 012 in 051 to 305 mm Cam lift 261 in 663 mm Timing gears Backlash 004 to 006 in 102 to 152 mm Number of teeth Crankshaft gear 25 Camshaft gear 50 Fuel injection pump gear 50 Idler gear 58 Idler gear bush inner diameter finished in position 1125 to 11255 in 28575 to 28 588 mm Idler gear bush to shaft clearance 001 to 002 in 025 to 051 mm Thickness of idler gear thrust washer 068 to 070 in 173 to 178 mm Oil feed jet diameter 062 in 159 mmCylinder head and valve mechanism Valve timing Six346 with 021 in 53 mm rocker clearance Four230 with 019 in 48 mm rocker clearance Inlet valve Opens 212 0 B T D C Closes 4212 0 A B D C Exhaust valve Opens 37120 B B D C Closes 7120 A T D CValve seat angle cylinder head and valve 45 0Valve seat face width 055 to 070 in 140 to 178 mm Valve stem to guide clearance 001 to 0025 in 025 to 064 mm Valve stem to rocker clearance hot or cold 013 in 33 mmValve lift 430 in 1092 mmValve springs Inner Outer Free length 18 in 45 72 mm 2 25 in 57015 mm Fitted length 1594 in 40487 mm 1 875 in 47625 mm Load to compress to fitted length valve open 40 lb 18 14 kg 90 lb 4082 kgRocker to rocker shaft clearance 001 to 002 in 025 to 051 mmRocker spacer sizes Six346 243 to 250 340 to 343 and 8055 to 8125 in 6017 to 635 864 to 871 and 2046 to 2064 mm Four230 between each rocker and bracket 290 to 297 in737 to 753 mm between each pair of rockers 8055 to 8125 in 2046 to 2064 mm Tappet to gUide clearance 0005 to 0023 in 013 to 058 mm Flywheel and starter ring To fit starter ring to flywheel heat to Six346 275 0 C527 0 F Four230 350 0 C 662 0 F 10 GENERAL DATAIniection pressure 175 atmospheres 2570 ps 0 Add 5 atmospheres to the opening pressure when setting new injectors or fitting new springs to allow for settling of the components Injector securing bolts 144 lb in 1 7 kg mOil pump Driving shaft to pump body clearance 0025 in 063 mm maximum Endfloat of pump rotors 0020 to 0045 in 051 to 114 mm Backlash between driving and driven gears 004 in 102 mm Pump body to bearing cap shim thicknesses 002 and 003 in 051 and 076 mm Number of teeth on driving and dri ven gears 46Main oil relief valve Spring free length 21764 in 57 6 mm Spring fitted length 2 in 508 mm Load to compress spring to fitted length 11 lb 12 oz 533 kg Rocker gear oil relief valve Spring free length 34 in 19 mm Spring fitted length 58 in 159 mm Load to compress to fitted length 3 oz 85 gm Diameter of ball 236 in 6 mm Oil pressure engine hot Idling speed 10 to 15lbsqin 7 to 105 kgcm 2 Normal running speed 35 to 60 lbsq in 246 to 422 kgcm 2 Oil capacity Six346 11 5 qts Four230 8 qtsCOOLING SYSTEMWater pump Fan hub pump spindle fit 0015 to 0028 in 04 to 07 mm interference Impeller to pump spindle fit 0010 to 0023 in 03 to 06 mm interference Impeller vane to impeller housing clearance 010 to 021 in 25 to 53 mmThermostat Opening temperature Bellows type 77 to 800 C 170 to 176 0 F Fully open temperature Bellows type 94 0 C 201 0 FTORQUE WRENCH head nuts I 200 lb in 13 8 kg m Cold I 080 lb in HotCrankshaft pulley nut Four230 3 000 lb in 34 56 kg mMain bearing bolts Four230 1200 lb in 13 8 kg mBig end bolts Four230 720 lb in 8 3 kg mMain bearing studs 600 lb in 70 kg m 11GENERAL DATAMain bearing nuts Slotted type 1000 lb in 11 5 kg m Nyloc type 1200 lb in 138 kg mConnecting rod bolts 700 lb in 8 1 kg mExhaust manifold nuts Six346 350 lb in 4 kg m Four230 600 lb in 6 91 kg mValve rocker bracket bolts 516 in diameter 180 lb in 2 1 kg m 38 in diameter 350 lb in 4 kg mFlywheel bolts I 200 lb in 13 8 kg mC A V starter motor pinion stop nut 40 to 50 lb ft 5 6 to 7 0 kg mC A V distributor injection pump Cam advance screw 400 lb in 4 6 kg m Transfer pump rotor 65 lb in 75 kg m RECOMMENDED LUBRICANTS ENGINE atit tOIIdititHII Above 32 C 90 F CaIftI Castrol Essoftect MoIIII Delvac SIleO Shell BP VaneDus Filtrate Panther rw F1eetol CIlI30 HDX30 1130 1l0teDa S SAE30 Diesel 30 HDX30 Oil 30 30 32 C 90 F down Castrol Essofteet Delvac Shell Vanellus Filtrate Panther Fleetol to12 C 10 F CIlI 20 HDX20 1120 Ilotella S SAE20 Diesel 20 HDX20 Oil2O20W 20 12 C 10 F Castrol Essoftect Delvac Shell VaneDus Filtrate Panther Fleetol down toISO C CIlIIO HDX lOW 1110 1l0teUa S SAE lOW Diesel 10 HDXIO Oil lOW lOW BelowISC 0 F Castrol Esso Extra Mobiloil Shell Winter Filtrate Sternol CIl 5W20 Motor Oil 5W20 Special 5W20 WW 5W20 Motor Oil Multiarade Q53O or SheD 5WlD Super Motor Oil 5W30 In addition to the lubricants listed we approve the UIe of the appropriate multiJrade oil supplied by the above compuiel for the particular condition prevailinl down to ISO C 0 F Below ISO C 0 F usc a 5W20 oil or the curreat practice of the COUDtry concemed TRANSMISSIONS AND VEE DRIVE Hydraulic Transmissions Automatic Transmission Fluid Type Vee Drive Heavy Duty Motor Oil SAE30 12 INSTALLATION position but must keep the engineIt is not the purpos e of this section to within one or two thousandths of anadvise boatyards and engine installers inch of this position at all times Iton the generally well understood and has to withstand the forward push ofwell developed procedures for instal the propeller which is applied to thelation of engines However the follow propeller shaft to the thrust bearinging outline of general procedure is in the engine and finally to the engineincluded because it is valuable in bolts and engine bedexplaining the functions of each com In fiberglas hulls we recommend thatponent the reasons why the pre similar wooden stringers as in woodencautions to be watched and the rela hulls be formed and fitted thentionship of the installation to the glassed to the hull securely Thisoperation of the engine There are allows hanger bolts to be of the installation which should firmly in wood thus reducing noiseha ve a periodic check and of which the and transmitted should have a to ensure good operating The temptation to install the engine onconditions for the engine and correct a pair of fiberglas angle ironsprocedure in servicing the engine should be resisted Such construction will allow engine vibrations to passINSPECTION OF SHIPMENT through to the hull Flexible mounts require a firm foundation againstThe engine is shipped from the factory which to react if they are to do theirmounted upon heavy skids and properly Jobcrated Accessory equipment isshipped in a separate small box RIGGING AND LIFTINGusually packed with the engine upon arrival the ship The engine is fitted with two liftingment should be inspected for possible rings designed so that the engine mayaccidental damage in transit and for be lifted without damage Rope orany possible shortage in parts and chain slings should be attached to the rings and the engine lifted by meansequipment Before accepting anyshipment from the transportation of a tackle attached to this short sling The lifting rings have been the crate should be opened to carry the full weight of the engineand an inspection for concealed therefore auxiliary slings are notdamage made If either visible or required or damage is noted requirethe delivering agent to sign Received The general rule in moving engines isin damaged condition This is your to see that all equipment used isprotection against loss Claims for amply strong and firmly fixed insuch damage must be made to the place Move the engine a little at acarrier not to J H Westerbeke Corp time and see that it is firmly sup ported Eliminate possibility of acciFOUNDA TION FOR ENGINE dents by avoiding haste Do not liftA good engine bed contributes much from the propeller coupling or prytowards the satisfactory operation of against this with crowbar as you maythe engine The engine bed must be distort the couplingof rigid construction and neither In some cases it may be necessary todeflect nor twist when subjected to lift the engine in other than the regularengine weight or the position the boat horizontal position It may be that themay have to take under the effects of engine must be lowered endwiserough seas The bed must not only through a small hatchway which cannotsupport the engine firmly in exact be made larger If the opening is restricted it is possible to the key be properly fitted both to thereduce to some extent the outside shaft and the coupling The key such as cooling piping fit the side of the keyway very closewater tank filters mounting lugs ly but should not touch the top of theetc This accessory equipment should keyway ir the hub of the couplingbe removed by a competent mechanic If it seems difficult to fit the couplingand special care should be taken to over the shaft the coupling can beavoid damage to any exposed parts or expanded by heating it in a pail ofthe entrance of dirt where openings boiling water The face of the prohave been made The parts which peller coupling must be exactly perhave been removed should be returnedto position as soon as the restricted pendicular to the center line or axis of the propeller shaftopening has been passedIn case it is necessary to hoist the either front end upwards or The type and size of propeller variesreverse gear end upwards the at with gear ratio and must be of slings must be done verycarefully to avoid the possibility of to fit the application based upon boat tests To utilize the full power of thedamage to the parts on which the engine and to achieve ideal loadingweight may come It is best ifspecial rigging work be done by conditions it is desirable to use asomeone experienced and competent propeller which will permit the engine to reach its full rated speed on fullin the handling of heavy machinery throttle This can be determined only by actual trials of the pilot modelENGINE BOLTSIt is recommended that bronze hanger ALIGNMENT OF ENGINEbolts of appropriate size be used The engine must be properly andthrough the engine flexible mounts exactly aligned with the propellerLag screws are less preferred because shaft No matter what material istheir hold on the wood is weakened used to build a boat it will be found toevery time they are moved whereas be flexible to some extent and the boatthe lag bolt stays in position and the hull will change its shape to a greaternuts on top of the lag bolts are used to extent than is usually realized when ittighten the engine down or are loosened is launched and operated in the waterto permit the engine to be moved The It is therefore very important to checkbolt itself stays in position at all tlmes the engine alignment at frequent interas a stud and the bond between the bolt vals and to correct any errors whenand the wood is not weakened by its they may appearremoval Misalignment between the engine andPROPELLER COUPLING the propeller shaft is the cause of troubles which are blamed often onEach Westerbeke Diesel engine is other causes It will create with a suitable coupling for con bearing wear rapid shaft wear Bndnecting the propeller shaft to the will in many cases reduce the hfeengine The coupling is very carefully of the hull by loosening the hullmachined for accurate fit The for fastenings A bent propeller shaftward end of the propeller shaft has a will have exactly the same effect andlong straight keyway and any burrs it is therefore necessary that theshould be removed from this end propeller shaft itself be perfectlyThe coupling should be a light drive straightfit on the shaft and the shaft should nothave to be scraped down or filed in One particularly annoying result oforder to get a fit It is important that misalignment may be leakage of 14 oil through the rear oil service for one to three weeks and if seal While it is possible for this type necessary the alignment remade Itof leakage to be caused by defective will usually be found that the engine isparts one should always first check no longer in alignment This is notthat alignment is within the limits because the work was improperly doneprescribed at first but because the boat has taken some time to take its final shape andThe engine should be moved around on the engine bed and engine stringersthe bed and supported on the screw have probably absorbed some moisturejacks or shims until the two halves of It may even be necessary to realignthe couplings can be brought together at a further periodwithout using force and so that theflanges meet evenly all around It is The coupling should always be openedbest not to drill the foundation for the up and the bolts removed whenever thefoundation bolts until the approximate boat is hauled out or moved from thealignment has been accurately land to the water The flexibility ofdetermined the boat often puts a very severe strain on the shaft or the coupling orN ever attempt a final alignment with both when it is being moved In somethe boat on land The boat should be cases the shaft has actually been bentin the water and have had an oppor by these strainstunity to assume its final water formIt is best to do the alignment with the WATER and water tank about half full andall the usual equipment on board Seacocks and strainers should be ofTake plenty of time in making this the full flow type and of a size at leastalignment and do not be satisfied with equal to the inlet pipe of the sea wateranything less than perfect results pump see installation drawing TheThe alignment is correct when the strainer should be of the type whichshaft can be slipped backwards and may be withdrawn for cleaning whileforward into the counterbore very the vessel is at seaeasily and when a feeler gauge indi Water lines can be either copper tubingcates that the flanges come exactly or reinforced rubber hose In any casetogether at all points The two halves use a section of flexible hose hose thatof the propeller coupling should be will not collapse under suction within 0001 in if possible the hull inlet and engine and outletHowever the maximum allowable before it enters the exhaust line so astolerance must not exceed 0001 in to take up vibrations and permit theper inch of coupling O D engine to be moved Slightly when it isIn making the final check for align being realigned All pipe and fittingsment the engine half coupling should should be of bronze or brass Usebe held in one position and the align sealing compound at all connections toment with the propeller coupling prevent air leaks The neoprenetested with the propeller coupling in impeller in the sea raw water pumpeach of four positions rotated 90 should never be run drydegrees between each position Thistest will also check whether the pro EXHAUST SYSTEMpeller half coupling is in exact align Exhaust line installations vary conment on its shaft Then keeping the siderably and each must be coupling in one position the for the particulCLr job The should be checked rotating requirements are to provide an outletthe engine half coupling to full position line with a minimum of 90 degrees from the next one and arranged so that sea water rainThe engine alignment should be re water or condensation cannot get backchecked after the boat has been in into the engine There should be a fall in the line between mount the tank above the engine levelthe exhaust manifold flange and the as the fuel lift pump provided willdischarge end This slope in the pipe raise the fuel from the tank Themakes it difficult for water to be amount of lift should be kept minimumdriven in very far by a wave and a 6 feet being maximum If a tank issteep drop followed by a long slope is already installed above engine level itbetter than a straight gradual slope can be utilized in this position GreatAvoid any depression or trough to the care should be taken to ensure that theline which would fill with water and fuel system is correctly installed soobstruct the flow of exhaust gas Also that airlocks are eliminated and preavoid any sharp bends cautions taken against dirt and water entering the fuelBrass or copper is not acceptable forwet exhaust systems as the combina A primary fuel filter of the water coltion of salt water and diesel exhaust lecting type should be installed betweengas will cause rapid deterioration the fuel tank and the fuel lift pump ACast iron or wrought iron pipe is recommended type is available for the exhaust line the list of optional extras The mainThe exhaust line must be at least as fuel filter is fitted on the enginelarge as the engine exhaust manifold between the fuel lift pump and theflange refer to Installation Drawing injection pump and has a replaceable elementTo insure vibration doesnt transmitto hull use a flexible section prefer As the fuel lift pump has a capacity inably of stainless steel no less than excess of that required by the injection12 in overall threaded at each end pump the overflow is piped to the fueland installed as close to the engine as tank and should be connected to the toppossible This flexible section should of the tank or as near the top asbe installed with no bends and be covered The exhaust pipeshould be properly supported by ELECTRICAL to eliminate any strain on Starter batteries should be situated asthe manifold flange studs Many close to the engine as possible use flexible rubber avoid voltage drop through long leadsexhaust hose for the water cooled sec It is a bad practice to use the startertion of the exhaust line because of the batteries for other services in theease of installation and flexibility boat unless these are light or veryProvide adequate support for the intermittent In cases where thererubber hose to prevent sagging are substantial loads from lightsbending and formation for water refrigerators radio depth etc it is essential to have a completeAlways arrange that water discharge separate system and to provideinto the rubber hose section is behind charging current to this from ana rlser or sufficiently below the auxiliary generator driven from theexhaust flange so that water cannot power take off at the front of thepossibly flow back into the engine engine Starter batteries must be of a type which permit a high rate ofFUEL TANK AND FILTERS discharge Diesel startingFuel tanks should preferably be of Carefully follow the steel or terne plate reinforced wire size shown in tlle wiring diagramsglass fiber is also suitable Be cer Fig 1 Plan the installation so thetain that the interior is gelcoated to battery is close to the engine and useprevent fibers from contaminating the battery cable sizes as indicatedfuel system It is not necessary to16 DErAIL ro START SWITCH T82 A ETR 55 T811 12VDC I S5 SOLRELAV ALAR SPARE 1 8ATTERY 111 RETURN I MODEL 6346 I TERINA 5TARTER INTEGRAL ENGAGE ENT 50LENOID 1 T8Z 8 l9 10 j I TO12VDC T822 CASE RETURN CONNECTION F5 r CRllop IQP IWT II NI I I iII i TO SENDERS DC NEATlVE RHJRN OPGT823 T825 q 1 SNQT 2 1 I ll 1 I lJ I WTG T824 DETAIL oB AR VIEW PcAL IA C ENGINE MODL 4107 WITH TWOTERMINAL STARTER SEE DETAIL A ENGINE NOTES fOR OTHER ENCOINES NOTE BATTERY fADS L THIS DRAWIN IS FOR USE ON CONTROL PANELS USIN FARIA OIL IS WATER COAUGES 1 FOR OISTANa UP TO 8 H USE 12889 FOR PANELS WITH VDO GAUGES DWG NO 17309 NEGATIVE GROUND 110 FOR OISTANa UP TO 10 H 2SENDRS 501 S02 ARE I WIRE 1I00Y RETURN TVPE 10 FOR DISTANCE UP TO 13 FT JO FOR DlSTANa UPTO 16 FT 3 SEE MOTOROLA INSTALLATIoN INSTRUCTIONS Fig 1 WIRING AND OPTIONS position and controlled by a Bowdoin wire or flexible sheathed cable to a1 PreWiring pushpull knob at pilot station includes the installation and to starter button or key switch and thewiring of the following devices throttle lever connected to a Morse type lever at pilot station by a regulator starting motor ble sheathed cable Refer below tostarter solenoid instrument senders transmission terminal blocks pressureand temperature switches separate key Transmission Control The controlswitch panel electric panel wiring lever on the transmission housing hasharness and engine harness The two three positions with detents cables between engine Forward F Neutral N andkey switch panel and all electric panel Reverse R This control lever maymeet or exceed ABYC Standards be connected to the pilot station by aChief advantages of prewiring are flexible sheathed cable and of wiring mistakes and by Morse Type levers The singleminimum installation time Morse control lever gives clutch and throttle control with full throttleALL ELECTRIC PANEL range in the neutral position The two lever Morse control provides clutchMarine instruments used include control with one lever and water temperature gauge control with the otherand oil pressure gauge The instruments are back lighted vented and Any bends in the control cables shouldnegative grounded The instrument be gradual and end sections at enginepanel should be mounted so that it is and transmission must be from direct contact with mounted After the linkages are comsalt spray pleted check the installation for full travel making sure that when the2 Factory Installed Engine Alarm transmission control lever at pilot System Optional station is in forward neutral and reverse the control lever on theThis alarm system to indicate the transmission is on its of high water temperature or detent F against stop pin N detentlow oil pressure is designed and and detent R against stop pin Checkinstalled on your Westerbeke diesel throttle control lever and stoprunat the factory It consists of an audi lever on fuel injection pump for fullble alarm to indicate either failure travelthe alarm being part of the key switchpanel The high water temperatureand low oil pressure switches are setfor compatibility with the engine The Throttle Control MaxIdlealarm system is energized by the keyswitch at the key switch panel and can be deenergized by the same keyswitch should the operator wish toturn off the control and stoprun controlThe fuelengine supply speed to the engine is controlled by twoand LJI Ir CIOJjIl the smalllevers on top of the fuel injection pumpwhich is mounted on the righthand side of the engine refer to Fig 2 The recommended practice is to havethe stoprun lever loaded to the run Fig 2 FUEL INJECTION PUMP18 OPERATION FOR STARTING ENGINE AFTER INSTALLATION 20BLEEDING THE FUEL SYSTEM 20TO START ENGINE 21WHEN ENGINE STARTS 21TO STOP ENGINE 22OPERATING PRECAUTIONS 22COLD WEATHER PRECAUTIONS 22 19OPERATION for starting engine The engine is shipped BLEEDING THE FUEL SYSTEMdry that is with lubricating oil One possible cause of the engine faildrained from the crankcase and ing to start or erratic engine The following pro eration is that air may have enteredcedure should be checked methodically the system in which case bleedingbefore starting the engine for the first of the system will be necessarytime Before bleeding the system first1 Remove engine lubricating oil insure that there is an adequate supplyfiller cap and fill oil sump with diesel of fuel in the tank and that the oil to the highest mark on supply is turned onthe dipstick Select an approved grade 1 Slacken the bleeder screw securlisted in General Data and continue ing the fuel injectors return pipe toto use it Do not overfill Replace secondary fuel filterhead Operatefiller cap the priming lever refer to note below2 Remove transmission breather cap on the fuel lift pump when fuel oil34 in hex fitting Paragon transmis issues from the bleeder screw free ofsion or filler plug Warner transmis air bubbles tighten bleeder screwsion and fill housing with fluid Type A to high NOTE If the engine camshaft cammark on dipstick Do not overfill driving the fuel lift pump is on maxi mum lift it will not be possible to3 Remove expansion tank filler cap obtain a full pumping stroke with theand fill tank with fresh clean water priming lever and the engine shouldand or antifreeze refer to Cold be turned with starter motor oneWeather Precaution to within one complete revolutioninch of top of tank Replace fillercap Ensure cylinder block drain tap 2 Slacken the air bleed screw on theand heat exchanger petcocks are side of the fuel injection pump situclosed ated directly above the pump name4 Ensure storage battery water plate Operate the lift pump priminglevel is at least 38 in above battery lever and when fuel flows free of airplates and battery is fully charged so bubbles tighten the bleed screwthat it is capable of the extra effort 3 Slacken the air bleed screw onthat may be required on the first back of the fuel injection pump coverstart behind the throttle lever Operate the5 Fill fuel tank with No 2 clean lift pump priming lever and when fuelDiesel Fuel Oil No 1 is permissi flows free of air bubbles tighten theble but No 2 is preferred because of bleed screwits higher lubricant content 4 Slacken the union nuts at injector end of each of the high pressure pipesNOTE If there is no filter in thefiller of the fuel tank the recom 5 IMPORTANT Position transmismended procedure is to pour the fuel sion shift lever in neutral as enginethrough a funnel with a fine mesh may start when corrpleting Step 8wire strainer 6 Ensure fuel STOPRUN pushpull control is in full run position6 Open valves in fuel line and bleedfuel system refer to Bleeding Fuel 7 Advance throttle to maximum openSystem position for maximum fuel flow 20 OPERATIONB Turn key switch to START posi WHEN ENGINE STARTStion and in sequence when fuel oil 1 Check the Sea Water Flow Lookfree of air bubbles issues from each for water at exhaust outlet Do thisinjector pipe union tighten each without delay Heat Exchange Coolunion If engine should start during ing System this procedure immediately movethrottle to idle speed 2 Check Oil Pressure immediately Normal oil pressure is START ENGINE 10 to 15 psi when idling 35 to 60 psi1 Position shift lever to neutral at operating speeds2 Position fuel stoprun control to 3 Recheck Crankcase Oil After thefull run position engine has run for 3 or 4 minutes subsequent to an oil change or new3 Advance throttle to maximum installation stop the engine and checkto obtain maximum fuel for easier the crankcase oil level This isstarting important as it may be necessary to4 Turn key switch to START posi add oil to compensate for the oil that is required to fill the engine I s internaltion and hold Release when engine oil passages and oil filter Add oil asstarts See note below necessary Check oil level each day5 Immediately upon starting posi of operationtion throttle to idle setting 4 Recheck Transmission Oil Level This applies only subsequent to an oilNOTE Never operate the cranking change or a new installation In suchmotor continuously for more than a case stop the engine after running15 seconds If engine has not started for several minutes at BOO rpm withstop cranking for 15 seconds The one shift into forward and one intoengine should start within a few revo reverse then add oil as of the crankshaft if battery ischarged and the engine is receiving 5 Check temperature gauge Norfuel mal operating temperature is belowThe cranking motor turning over fast 190 o Findicates the battery is charged If a 6 Recheck expansion tank waterbattery is charged and engine doesnt level This applies after coolingstart check fuel system as follows system has been drained and refilled Stop engine after engine has reached a Ensure the fuel valve between operating temperature of 170 to IBO o Ftank and engine is open add water and or antifreeze as re b Ensure the stoprun and quired to within one inch of top ofthrottle control levers on the injection tankpump are in their full run positions c Check for leaks in fuel lines WARNING The system is pressurized when overheated and the pressure mustand at gaskets of fuel filters be released gradually if the filler cap d Determine if fuel is reaching is to be removed It is advisable toinjectors refer to Bleeding Fuel protect the hands against escapingSystem Steps 4 to B If fuel oil stearn and turn the cap slowly counterdoesnt issue from union nuts at clockwise until ihe resistance of theinjectors bleed complete system safety stops is felt Leave the cap in position until all pressure is re 4 Do not run engine at high rpmleased Press the cap downwards without clutch engagedagainst the spring to clear the safetystops and continue turning until it can 5 Never Race a Cold Engine asbe lifted off internal damage can occur due to lack of proper oil circulation7 WarmUp Instructions As soon 6 Keep the engine and accessoriesas possible engage the forward clutch cleanand run the engine at reduced speed of 7 Keep the Fuel Clean Handle itBOO to 900 rpms until oil pressure with extreme care because water andgauge indicates approximately 35 to dirt in fuel cause more trouble and50 psi and water temperature gauge service interruptions than any otherindicates 170 to IBOoF Warming up factorwith clutch in neutral takes an unnecessarily long time B Do not allow fuel to run lowB Avoid prolonged idling because fuel intake may be uncovered long enough to allow air to enter the9 Reverse Operation Always fuel system resulting in enginereduce engine to idle speed when shift stoppageing gears However when the trans 9 Do not be alarmed if temperaturemis sion is engaged it will carry full gauges show a high reading following aengine load sudden stop after engine has been operating under load This is causedTO STOP ENGINE by the release of residual heat from1 Move throttle lever to idle position the heavy metal masses near the com bustion chamber Prevention for this2 Position shift lever to neutral is to run engine at idle for a short period before stopping it High temNarE Idle engine for a few minutes to perature reading after a stop does notdissipate heat gradually before shut necessarily signal alarm against redown starting If there is no functional3 Position fuel pushpull stoprun difficulty temperature will quicklycontrol to stop Control in stop posi return to normal when engine istion functions by stopping fuel flow to operatingthe injectors COLD WEATHER Key switch panel with STOPpushbutton switch depress push button 1 Precautions against damage by freezing should be taken if the engineand hold until engine stops is to be left exposed to inclement weather by adding an antifreeze of4 Turn key switch to OFF position reputable make and incorporating a suitable corrosion inhibitor As theseOPERATING PRECAUTIONS engines are equipped with high tem1 Never run engine for extended perature thermostats a when excessive overheating type antifreeze with an Ethyleneoccurs as extensive internal damage Glycol Base should be used Do notcan be caused use alcohol solutions2 DoNot Put Cold Water in an over 2 Draining Cooling System Removeheated engine It can crack cylinder pressure cap from expansion tank andhead block or manifold open the drain tap turn counter clockwise on righthand side of3 Keep intake silencer free from cylinder block next to flywheellint etc housing 22 OPERATION MAINTENANCE3 Filling Cooling System Determine capacity of cooling system NOTE The strength of the keel pipes if installed and solution must be maintained by toppingfill cooling system with the correct off with antifreeze if necessary useamount of antifreeze and water for the tester when in doubtdegree of protection required towithin one inch from the top of the 4 Fuel filters must be checked moretank Ensure drain tap is closed often particularly the primary filterStart engine to circulate antifreeze to remove all the moisture and condenand when temperature gauge indicates sation separated from the fuel othernormal operating temperature stop wise this may freeze and stop the fuelengine and add coolant as necessary flow MAINTENANCE CHECKOVER 24PERIODICAL ATTENTIONS 24FILTER MAINTENANCE 24PRESERVATION OF LAID UP ENGINE 26PREPARING THE ENGINE FOR RETURN TO SERVICE 27 23MAINTENANCE CHECKOVER Every 100 HoursAfter a customer has taken delivery of ReneN sump lubricating oil andhis engine it is advisable in his own lubricating oil filter Refer to that a general checkover of Maintenance Lubricating Oil Filter the engine be carried out after the Clean air intake filterfirst 25 to 50 hours in service Check alternator belt tensionThis checkover should comprise the Clean fuel filter water trap Clean battery terminals and applyfollowing points protective coating to terminal and con1 Renew sump lubricating oil and oil filter Refer to Filter Check level of electrolyte Oil Filter battery2 If necessary adjust slow running Every 300 Hours or Once a Seasonspeed Renew final fuel filter3 Check external nuts for tightness Renew transmission lubricating4 Check cylinder head nuts are to fluid Remove breather cap 34 inthe correct torque and check valve hex fitting Ins ert pump hose inclearances breather fitting opening and pump fluid5 Check for fuel and lubricating oil out of housing into a waste containerleaks and rectify if necessary Fill housing with Automatic Transmis sion fluid Type A to high mark on6 Check cooling system water level dipstick Do not overfilland inspect system for leaks7 Check alternator belt tension NOTE Warner Transmission has filler plug8 Carry out test to check of engine FILTER MAINTENANCE9 Check engine mounting bolts for Air The time period for cleaning the air10 Check all electrical connections filter depends on operating conditionsand wiring for tightness and chafing therefore under dirty conditions the time period of 100 hours recommended11 Check engine alignment to propeller shaft coupling for cleaning should be decreased The correct maintenance of the air maintenance periods should will greatly assist in reducing borebe in accordance with those given wear thereby extending the life of theunder 11 Periodical Attentions 11 engine To clean the air filter proceed asPERIODICAL ATTENTIONS followsKEEP ENGINE CLEAN 1 Unscrew the thumb screw securingDaily the air filter to its manifold and re move filter Check sea water strainer Check cooling system water level 2 The element may be cleaned by Check oil level in sump blowing compressed air from the in Check oil level in transmission side to the outside Do not attempt to Check fuel level in fuel tank clean the element by any other means 24 MAINTENANCEA strong light directed into the insideof the element and viewed from theoutside will reveal any damage to thepaper corrugations If the element isdamaged or shows a large deposit ofdirtl replace elementFuel Oil FiltersIt is essential to use clean diesel fueloil free from water or contamination 9r7Provided clean fuel oil is usedl notrouble should be experienced with thefuel system 91 The first filter should be a gauzetrap in the filler of the fuel tank thismust not be removed when fuel isbeing poured into the tank It should 10be taken out every 500 hours l cleaned lwashed in fuel o ill and If there is no filter in the 111filler of the fuel tank the fuel shouldbe poured through a fine gauzestrainer or a piece of chamois Fig 32 A primary fuel filter of the or separating type should be Main fuel filter between the fuel tank and the I Centre bolt 7 Sealing ringfuel lift pump The filter should be 2 Washer 8 0 ring 3 Filter head 9 Elementchecked and cleaned every 100 hours 4 Sealing plug 10 Sealing ringA recommended type is available from 5 Copper washer 11 Filter baseWesterbeke 6 Nonreturn valve3 The secondary fuel filter Fig 3is mounted to a bracket on the front Lubricating Oil Filterright side of the engine It is an element type filter and must be replaced The importance of clean lubricating oilevery 300 hours lJnless the condition cannot be stressed too highly If theof the fuel warrants more regular time period specified 100 hours forattention To remove filter element l replacement of the spinontype filterproceed as follows element and the use of the same brand of oil is used during oil changes l a a Unscrew the center bolt on top very long life can be obtained from theof the filter head and detach the base engine The spinontype filter isand filter element Discard element secured to its filter head on the left b Remove the sealing ring from hand side of the cylinder block Tofilter base and the sealing ring and replace filter l proceed as follows0 ring from filter head 1 Run engine until oil is hot c Wash base of filter in clean 2 Remove dipstickl and with the aidkerosene of the hoses and flllmp suppUed l fit the d Install new filter element l 38 in I D hose over the rings and a ring in reve rs e tube and pump the oil from sump intoorder above I a waste container 25MAINTENANCE3 Place a drip pan under filter or a Fill Sump Fill sump with bag completely over filter detergent diesel lubricating oil to thecanister and turn spin on filter high mark on dipstick Do not to remove Discard fill Refer to Recommended Lubrifilter cants and always use the same brand of oil4 To replace filter coat the gasketon the filter with oil Place the filter Sump Capacity Six346 11 5 Qtsin position and hand tighten filter until Four230 80 Qtsthe gasket contacts the filter head Fill Transmission Fill housing withthen advance onehalf turn Automatic Transmission Fluid Type5 Fill sump with the pproved A to high mark on dipstick Do notLubricating Oil being used to high overfillmark on dipstick Do not overfill Drain Cooling System Remove presOil Capacity Six346 11 5 Qts sure cap from expansion tank and Four230 80 Qts open drain tap turn on right hand side of cylinder block6 Start engine run until normal next to flywheel temperature is that filter joint is tight Shut Filling Cooling System down and add oil as required the capacity of cooling system includ ing keel pipes if inltalled and fill PRESERVATION OF LAID UP ENGINE system with the correct amount of antifreeze and water for the degree When a craft which is powered by a of protection required to within onediesel engine is to be laid up for inch from top of tank Ensure drain several months it is advisable that tap is closedsome measure of protection beafforded the engine to ensure that it Remove the hex screw plug from sidesuffers no ill effects during storage of heat exchanger and determine if zinc rod in the plug needs replacingJust before hauling laying up top off The zinc rod takes care of anyelecthe fuel tank completely so that no trolysis in the salt water system andair space remains thereby preventing should be checked every three monthswater formation or condensation Replace plug with new rod if necessaryStart engine and run until normal operating temperature is reached shut NOTE All threaded screw fittingsengine down must have sealing compound on threads when replaced to prevent leakageRemove dipstick and with the aid ofthe hoses and pump supplied fit the Start Engine Run engine until normal38 in 1 D hose over the dipstick operating temperature is reached totube and pump the oil from the sump ensure proper mixing of and circulainto a waste container tion of antifreeze During this proRemove breather cap 34 in fitting cedure exercise transmission inInsert pump hose through breather forward and reverse several cycles below 800 rpm to ensure that the newfitting opening to bottom of housing transmission fluid is properly circuand pump the oil out of the transmis lated Also check new lube oil filtersion Warner gear has a filler plug mating surface for leakageRemove and Replace Lubricating Oil After shutdown check oil level in sumpFilter Place a drippan under filter add lube oil if required to high mark onand turn filter to dipstick Check lubricating fluid inremove Hand tighten filter until the transmission add fluid if required togasket contacts the adapter face then high mark on dipstick Check level ofadvance filter onehalf turn 26 solution in expansion tank 4 Connect batteries fully chargedadd antifreeze solution if required to into circuitwithin one inch from top of expansiontank 5 Open valves in fuel lineTo ensure that any sea water left in the 6 Bleed fuel system refer tosea water cooling will not freeze an Operation Bleeding Fuel solution should be runthrough the system and expelled at theexhaust pipe outlet as follows Closeinput throughhull fitting hose from the seacock atits next connection Attach and securea separate length of hose to this connection the same I D as hose removedwith its other end in a container of50 percent antifreeze and two gallons Startengine Immediately check for flow ofantifreeze solution at exhaust outletBefore end of hose in container ofantifreeze is uncovered stop engineRemove hose from connection and reconnect and secure original hoseDrain exhaust pipe by removing drainplug if installed at the water cooledsection Replace drain plugRemove air filter Clean air intakefilter refer to Filter Maintenance Carefully seal air intake opening witha waterproof adhesive tape or someother suitable mediumSeal the exhaust outlet at transomChange and clean all fuel filtersClose all batteries and store fullycharged in a cool location Beforestoring the battery the battery terminals and cable connectors should betreated to prevent corrosion every 30 days when in storageIf winterization is performed by ownernotify yacht yard that engine is winterized and should not be runPREPARING THE ENGINE FORRETURN TO SERVICE1 Clean external parts of the engine2 Remove adhesive tape from airintake and install air filter3 Remove adhesive tape from exhaust outlet 27COOLING SYSTEM COOLING SYSTEM PageGENERAL 29HEAT EXCHANGER 29KEEL PIPES 29DRAIN COOLING SYSTEM 29FRESH WATER PUMP 29 To Remove Pump 29 To Dismantle 30 To View and Overhaul 30 To Reassemble 30 To Install 30THERMOSTAT 30 To Remove 30 To View and Overhaul 30 To Install 30ALTERNATOR V BELT ADJUSTMENT 31SEA WATER PUMP 31 To Remove Pump 31 To Dismantle 32ELECTROLSIS CONTROL 32COOLING SYSTEM TEST 3228 COOLING SYSTEM COOLING SYSTEM1 General 3 Keel PipesThe Westerbeke Six346 and Four230 When keel pipes are used which is aMarine diesel engines are equipped simplified version of the heat exwith a fresh water closed circuit changer system described above thecooling system With this system a fresh water closed system circuit isheat exchanger or keel pipes are uti drawn from the keel pipes through thelized to cool the fresh water after it dual oil cooler movement being assishas circulated round the water jackets ted by a centrifugal type water pump where it is circulated around the2 Heat Exchanger cylinder liners and cylinder head water jacket to the combination expansion Transfer of heat from the fresh water closed system circuit to the sea tank and exhaust manifold and finally returns to the keel pipes that are water is accomplished by a heat ex changer similar to an automobile cooled by the sea water outside theradiator it differs because salt raw hullwater not air cools the enginesfresh water Heat rejected in combus 4 Drain Cooling Systemtion as well as heat developed by fric To drain fresh water cooling systemtion is absorbed by the fresh water remove expansion tank filler cap andwhich flows from the expansion tank open drain tap turn the heat exchanger where it is on right hand side of cylinder blockcooled and discharged into the engine next to flywheel housing and freshblock and cylinder head by means of a water drain tap on heat fresh water pump Open Two drain taps are installed on bottomings in the water jacket around the of the exchanger the forward tap forcylinder bores connect with corre raw water and the center tap for freshsponding openings in the cylinder head waterwhere the fresh water then passes outthrough the thermostat into the expan 5 Fresh Water Pumpsion tank and the circuit repeats The water is circulated by a centrifu The engine is indirectly cooled by the gal pump which is mounted on the fastflowing stream of of the cylinder block and driven by araw water which absorbs the heat from V belt from the crankshaftthe fresh water via the heat exchangerThis raw water is picked up from the To Re move Pumpsea by a powerful neoprene impellersea water pump and after passing Loosen the set bolt securing the alterthrough the dual oil cooler engine and nator to its mounting bracket sion and through the heat the alternator adjustment strap boltsexchanger is discharged overboard and swing alternator toward the cylinThe dual oil cooler above conducts der block to release tension of the beltheat away from the bearings and other Remove the belt Remove the fourfrictional surfaces by the flow of nuts securing the water pump body tolubricating oil which is circulated by the impeller housin and withdraw theoil pressure pumps and cooled by the water pump noting the pump body toflow of raw water through the tubes of impeller housing gasketthe cooler 29COOLING the inlet and bypass hosesfrom the impeller housings Unscrewthe six bolts and remove the and its joint washer from thecylinder blockTo Dismantlea Withdraw the pulley hub from thewater pump spindle using an extractorb Extract the bearing retaining clipthrough the hole in the top of the pumpbody and drive the spindle and bearing assembly rearwards out of thebodyc Withdraw the impeller from thespindle using an extractor and re Fig 4move the water seal Water pump assembly dimensionsTo view and overhaul 731 to 738 in 1857 to 1874 mm B 3670 to 3700 in 9322 to 9400 mma Check the spindle and bearing as c 010 to 021 in 25 to 53 mmsembly for wear and ensure that thebearing seals are in good conditionb Check that the interference of the 6 hub and the impeller on the A thermostat is installed in thespindle has not been thermostat housing mounted on thedestroyed tront of the cylinder head above thec Inspect the water seal for damage fresh water pump The thermostatand wear impedes the circulation of the fresh water into the expansion tank until itTo Reassemble has reached a predetermined tempera ture in the cylinder block and so proReassembly is a reversal of the pro vides a more rapid warming up of thecedure To Dismantle noting the Normal operating temperature isa Ensure that the hole in the bearing 170 to 190 0 F 77 to 870 Ccoincides with the lubricating hole inthe pump body To Removeb Assemble the pulley hub and the a Drain the cooling systemimpeller to the dimensions given inFigure 4 b Disconnect the outlet hose from the outlet pipeTo Install c Release the two set bolts andReverse the procedure To Remove remove the outlet pipe from thetensioning the drive belt so that it can thermostat housingbe pressed in one in 254 mm at d Lift out the thermostat from itsthe center of its vertical run housing 30 COOLING SYSTEMTo View and Overhaula Test the thermostat by immersingit in water and heat up checking thetemperature The thermostat val veshould start to open between 1 70 and176 0 F 77 and BOOC and be fully openat 201 0 F 94 0 C If the valve does notopen between the given temperaturesor it sticks in the fully open positionthe thermostat should be renewedNo attempt should be made to repairthe thermostatb Clean the joint face of the wateroutlet pipe and thermostat housingTo InstallThe installation of the thermostat is areversal of the procedure ToRemove Fit a new joint gasketbetween the thermostat housing andthe water outlet pipe Fig 5 7 Alternator V Belt Adjustment Fan belt adjustmentThe purpose of the following adjustment is to maintain the performance B Sea Water Pumpof the alternator and fresh water pumpat their maximum and consists of The sea water pump contains a neomoving the alternator in relation to prene impeller and is mounted on thethe cylinder block to adjust the ten timing gear case cover and is drivension of the belt Proceed as detailed by the timing gear train The pump isbelow Other specific performance should be diagnosed by referringto FAULT DIAGNOSIS To Remove Pumpa Referring to Fig 5 slacken the Remove set screw on underside ofalternator securing bolt A Support pump and drainthe alternator with one hand and Uncouple inlet and outlet hose conrelease the set bolt B and nut C nectionsb Using a hard hand pressure press Unscrew the four capscrews and lifton the alternator sufficiently to swing pump away from timing gear caseit away from the side of the cylinder coverblock thereby taking up any slacknessin the belt Remove gasket between pump and gear case coverc The belt should be adjusted so thatwhen securing bolts are finally locked Replace pump by reversing the aboveup the long run of the belt can be procedure Use new gasket betweenpressed in 1 inch 25 mm at the pump and gear case cover Use sealcenter by normal thumb pressure ing compound when replacing drain set screwNOTE It is important that the fan beltis always run taut as any slackness NOTE The sea water system must bewill cause slip and rapid wear of the completely free of air leaks Refer tobelt Cooling System Check 31COOLING SYSTEMTo Dismantle 10 Cooling System TestRemove cover and cover gasket The fresh and raw salt water systems must be completely free of air leaksRemove impeller from pump shaft by Air in the system will reduce pumpmeans of suitable pliers Drive key lubrication and shorten the sea waterneed not be removed pump neoprene impeller lifeRemove the large retainer ring from To check the raw water system fordri ve end of pump leaks disconnect the outlet water hoseA suitable press may be used to drive from the pump and insert it in a bucketthe shaft seal and seat out the im of water Run the engine and watch forpeller end of pump air bubbles in the discharge Any bubbles indicate an air leak in the rawRemove the retainer ring and bearing water cooling system which can damagefrom inside pump body the pump impeller rubber exhaust lineClean inspect and replace any parts or a neoprene rubber muffler ifthat show damage or wear the procedure above coating NOTE Do not run engine for moreimpeller with a thin coat of glycerine than one minuteor a good grade of water pump greaseReplace cover with new gasketSecure pump to timing gear cover byreversing the procedure To Remove 9 Electrolysis ControlLocated on the left rearside of the heatexchanger is a zinc electrode whichdetects stray electrical currents oftenresulting from faulty ground connections and corroded terminals in otherparts of the electrical circuits Thiselectrode should be checked at leastonce a month and if it all terminals and ground connections should be cleaned by scrapingor sandpapering and life of the electrode in saltwater should be at least 3 months 32 FUEL SYSTEM FUEL INJECTION SYSTEMThe principal components of the equipment for Fuel Pumpdelivering the fuel oil to the engine cylinders The fuel pump is an instrument of precIsionare as follows Its working parts are made to extremely fine Fuel Filters limits and mishandling in any shape or form Fuel lift Pump or the entry of the smallest particle of dirt inta Fuel Pump its working parts may damage it and diminish Injection nozzles its accuracy of operation Hence the importanceThe fuel lift pump lifts the fuel from the tank to of making sure that the fuel is thoroughly filteredthe fuel pump which conveys it in measured before the pump is and at appropriate intervals to the When requesting information regarding the fuelinjection nozzles pump the type and number should be quoted This can be obtained from a plate fitted to theIn the fuel system the norma I course of the fuel pump gallery above the inspection platefrom the tank to the engine is firstta the Primaryfuel oil filter then the Secondary fuel oil filterand finally the fuel injection pump and Where service is required the matter should be referred to the fuel pump manufacturers agentsTwo conditions are essential for because the fuel oil ignites by heat of Ini ection it must be clean free from sus Injection nozzles and holders are attached to thepended dirt sand and other foreign matter cylinder head with a twobolt flange and two hex head nutsSecond that the fuel reaches the fuel pump in aperfectly clean state The connection between the nozzle holder and cylinder head is made with a special copperFuel should be filtered before entering the tank washer between the lower face of the nozzle cap nut and the recess in the cylinder headGiven these conditions ninety per cent at leastof potential engine troubles would be eliminated When putting the nozzle holders in place in theAttention therefore should be earnestly direc cylinder head care should be taken that only thisted towards the section of this handbook which type of copper washer is used The recess inrefers to the care and upkeep of the filtering the cylinder head the faces of the copper and the corresponding face of the nozzle cap should be perfectly clean if a leakproof jOint is to resu ItThe Fuel Lift PumpThe lift pump is of the diaphragm type It is It is always advisable to fit a new copper washerfitted to the tappet inspection cover on the off when the nozzle holder is replaced after havingside of the engine and is driven by a cam on the been removed for any reasonengine camshaftA hand primer is fitted for use if the supply of Make sure the old washer has been removedfuel from the tank has at any time failed from the cylinder head or nozzle holderTo use this primer pump by hand until pipeslift pump filters and fuel pump are full of fuel The j oint washer should be an easy but notoil loose fit for the injection nozzle and it is because this is such an Important feature that only wash 33ers especially made for the puspose should be Trouble in Serviceused and none other Under no conditions shouldan ordinary spark plug type washer be used The first symptoms of injector nozzle trouble usually fall in one or more of the follOWingThe nozzle holders can now be fitted in place headingsBefore tighten ing down it should be the nozzle holder is correctly placed and I Misfiringthat the fuel pipes can be fitted without bending 2 Knocking in one or more cylindersthem 3 Engine overheating 4 loss of powerFuel Pipes 5 Smoky exhaust blackNo two of the pressure pipes from the fuel 6 Increased fuel to the injection nozzles are alike Keep Often the particular nozzle or nozzles causingthis in mind when replacing trouble may be determined by releasing thePlace in position the pipe to the fuel pump and pipe union nut on each nozzle in turn with theinjection nozzle unions to check that the pipe fits engine running at approximately 1000 revminsquare at both ends Do notfitone end and then This will prevent fuel being pumped through thebend the pipe to square it with the other union nozzle to the engine cylinder thereby altering the engine revolutions If after slackening aWhen fitfing the pipe tighten the unions alter pipe union nut the engine revolutions remainnatively a little at a time first one end and constant this denotes a faulty nozzlethen the other The complete unit should then be withdrawnIf the pipe is square to the unions at each end from the cylinder head and turned round nozzleas described above no force will be needed to outwards on its pipe and the unions a good joint No force should be used After slackening the unions of the other injectionWhen changing an injection nozzle always re pipes to avoid the possibility of the enginemove the pipe entirely Never take off only one starting the engine should be turned until theend leaving the other tight Never bend thepipe nozzle sprays into the air when it will be seen at once if the spray is in order If the spray is unduly wet or streaky or obviously to one side or the injection nozzle dribbles then theMaintenance complete unit should be replaced See Fig I 10Injection nozles should be taken out for exami The faulty unit then being securely wrapped innation at regular intervals How long this inter clean greaseproof paper or rag with the protecval should be is difficult to advise because of tion cap on the nozzle for attention on the mainthe different conditions under which the engine tenance bench operates Great care should be taken to prevent the handWhen combustion conditions in the engine are from getting into contact with the spray as thegood and the fuel tank and filtering system are working pressure will cause the oil to in first class order it is often suffi the skin with easecient if the nozzles are tested twice yearly orevery 1000 hoursNozzles should not be removed for checkingunless a nozzle tester is available or sparenozzles are on hand for the cooling system maintained in goodcondition and absolutely clean fuel are usedthe less attention the nozzles will need andso their effiCient life In this connection sincethere is no other item of the equipment uponwhich the performance of the engine dependsso much it pays the user to see that the enginenever runs with any of the nozzles out of order Fig 110Nozzle Spray Paltern 34 FUEL SYSTEM 4 sucking noise should be heard In a similar manner seal the delivery side of the pump marked OUT and press the rocker arm inwards to charge the pum ling chamber with air If the pump is in good condition the air in the pumping chamber should be held under compression for two or three seconds Finally repeat this test but immediately the pumping chamber is charged with air immerse the pump in a bath of clean paraffin and inspect the diaphragm clamping flanges for signs of air leakage Lubricate the rocker arm and the rocker arm pin with clean engine oil and after replacing the pump bleed the fuel system Section Da3 Fig Dal DISMANTLING AND REASSEMBLING Fuel lift pump components THE FUEL LIFT PUMP I Delivery valve 9 Pivot pin Scribe a mark across the pump body joint flanges for 2 Filter gauze 10 Link guidance when reassembling 3 Sediment chamber U Punrod 4 Inlet valve 12 Hand priming lever Remove the set bolt detach the dome cover and its S Inlet port 13 Diaphragm spring sealing ring and lift off the filter gauze 6 Rocker arm spring 14 Diaphragm 7 Rocker arm IS Outlet port Unscrew the set screws and separate the two halves of 8 Camshaft eccentric the pump body Remove the two screws and withdraw the retaining plate inlet and outlet valves and valve gasket from theSection DaI upper half of the pump body Press the diaphragm downwards and turn it clockwise DESCRIPTION OF THE FUEL LIFT PUMP through an angle of 90 to release the diaphragm pullrod The fuel lift pump is mounted on the crankcase and from the connecting link Withdraw the diaphragm andis operated by an eccentric on the engine camshaft A its return spring from the lower half of the pump bodyhand priming lever permits pumping a supply of fuel for Remove the rocker arm pin retaining clips and withtesting purposes When the lift pump output is greater than the fuel injection pump requirements the fuel in the pumping chamber holds the diaphragm against the pressure of thediaphragm spring and the connecting link allows anidling movement of the rocker arm A spring maintainsthe contact between the rocker arm and the eccentric noiseSection Da2 REMOVING AND REPLACING THE FUEL LIFT PUMP Disconnect the two fuel pipes from the body of thepump unscrew the two set bolts securing the pump to thecrankcase and withdraw the pump and its joint washer Before replacing the pump which is a reversal of theforegoing procedure the pump should be tested In theabsence of special test equipment the pump may be testedas follows Immerse the pump in a bath of clean paraffin and flush Fig Da2it through by operating the rocker arm six to eight times Diaphragm assembly diagramRemove and empty the pump seal the suction side of the I Pump mounting flangepump placing a finger firmly over the inlet union marked Initial position of diaphragm locatingIN and operate the rocker arm several times Upon tab 3 Final position of diaphragm of the finger from the inlet union a distinct tab 35 FUEL SYSTEM Section Da4 DESCRIPTION OF THE MAIN FUEL FILTER The main fuel filter is of the crossflow type employing a resin impregnated paper as the filtration medium The main parts of the unit are a diecast head and a lower plate assembly clamped between which is a metal canister containing the filter element An 0 ring located in an annular groove in the centre boss of the filter head seals the dirty side of the filter from its clean side The air bleed point which is on the clean side of the filter is connected to the fuel injector leakoff pipe and provides continuous airbleeding of the filter during oper ation Section Da5 11 REMOVING AND REPLACING THE MAIN FUEL FILTER Disconnect the fuel pipe and leakoff connections from Main fuelilter C01lfHJMllIS the filter head 1 Centre bolt 7 Sealing ring Remove the two bolts and nuts securing the filter to its 2 Washer S 0 rinI bracket and withdraw it from the engine 3 Filter head 9 E1el1lCDt The installation of the fuel filter is a reversal of the 4 Sealing plug 10 SeaIiDa ring S Copper washer II Filter base removal procedure 6 Nonreturn valve Bleed the fuel systemdraw the pin to rlease the rocker arm distance washersspring and connecting link Section Da6 Detach the spring from the priming levr Reassembly is a reversal of the foregoing procedure DISMANTLING AND REASSEMBLING THEnoting the following MAIN FUEL FILTER I Ensure that the diaphragm and pump mounting Unscrew the bolt from the centre of the head casting flanges are true They may be lapped to restore and detach the bottom plate from the filter their flatness Remove the filter element using a twisting movement to release the element from the head casting Withdraw 2 Check that the wear on the rocker arm working the three sealing rings from their locations in the head and surface does not exceed 010 in 25 mm bottom plate 3 The rocker arm pin should be a tap fit in the pump Thoroughly clean all components excepting the ele body this may be restored by peening the holes in ment in petrol and allow them to dry the body Reassembly is a reversal of the foregoing procedure 4 Locate the diaphragm return spring in the dia using a new element and sealing rings The element is phragm lower protector washer and insert the dia fitted with its strengthened rim uppermost phragm into the pump body with its locating tab in Section Da 7 the 11 oclock position see Fig Da 2 Press the diaphragm downwards and turn it anticlockwise DESCRIPTION OF THE FUEL INJECTORS through an angle of 90 to engage the diaphragm The fuel injectors each comprise two main parts the pullrod with the connecting link nozzle and the nozzle holder which are clamped together 5 When assembling the two halves of the pump body axially by a nozzle nut The mating faces of both the ensure that the marks scribed on the joint flanges nozzle and the nozzle holder are lapped to ensure a high before dismantling coincide Hold the diaphragm pressure seal by means of the rocker arm level with the joint The nozzle is of the longstem type having four equally flange apd secure the two halves of the pump body spaced holes at an angle of 20 from the nozzle centre line leaving the screws fingertight Push the rocker and positioned to give a spray cone angle of 140 The arm towards the pump body to position the dia nozzle valve is accurately lapped into the nozzle body to phragm at the bottom of its stroke and tighten the give the closest possible fit within which it will operate securing screws diagonally freely The nozzle holder contains a spindle and spring which 6 Test the pump as described in Section Da 2 retains the nozzle valve on its seat The upper end of the spring is located in an adjustable cap nut by which 36 the opening pressure of the nozzle is let FUEL SYSTEM Mount the injector in dismantling fixture 18G 388 un screw the injector cap nut and remove the copper joint washer Cncrcw the spring cap nut and remove the spring plate spring and spindle Using spanner 18G 210 remove the nozzle nut and nozzle taking care not to let the valve drop out of the nozzle body OTEEach nonle body and valve are a mated as sembly and shOUld always be kept together Thoroughly clean the injector components using clean ing kit 18G 487 when dealing with the nozzles Using the brass wire brush remOe all carbon from the nozzle body and nozzle valve Examine the valve for scoring and scratches and for blueing due to overheating Clean out the internal feed passages the annular gal lery and the valve seat using the brass scrapers and clear the spray holes with an appropriate size cleaning wire fitted to the probing tool Assemble the nozzle body into adaptor 18G 109 E with the nozzle tip towards the inlet connection Connect the adaptor to testing machine 18GI09 A and reverseflush the nozzle See Fig Da25 to clear all loose carbon from Fig Da18 the internal passages Where the carbon buildup is particularly hard it may FUll Injector be softened in the following manner I Cap Dat 7 Nozzle holder Prepare a 10 per cent solution of caustic soda with an 2 SpriD cap DUt S SpiDdle 3 SpriD plate 9 Nozzle DUt added detergent by dissolving 2 oz 56 gm of caustic 4 SpriDJ 10 Needle valve soda in I pint 57 litre of water and add i oz 14 gm 5 Joint washer II Nozzle body 6 Feedpipe UDioD of an ordinary washing detergent Place the nozzle bod ies in the liquid bring it to the boil and allow it to boil for a minimum of I hour and not more than I hours Lubrication is by back leakage of fuel past the nozzle Take care not to allow the water to evaporate too muchvalve and a leakoff connection on the nozzle holder because jf the percentage of caustic soda rises above ISreturns this fuel to the fuel tank per cent the surface of the nozzle bore and sealing face may be roughened making it impossible for the De8 to be serviced correctly Remove the nozzle bodies from the solution wash REMOVING AND REPLACING AN INJECTOR them in running water and then immerse them in a de Disconnect the injector feed pipe union nut and all the watering oil such as Shell Ensis 254 Remove the leakoff unions oil by draining or compressed air Remove the two set bolts securing the injector to thecylinder head and withdraw the injector using tool18G491 A If the injector is to be stored for any length of time sealits inlet union using sealing cap 18G 216 Thoroughly clean the copper sleeve in the cylinderhead ensuring that all carbon is removed from its bottomface Place the injector in position in the cylinder head andtighten the securing bolts using torque wrench 18G 537set to the figure given in GENERAL DATA Connect the fuel feed pipe and leakoff unionsSection Da9 DISMANTLING AND REASSEMBLING THE INJECTORS As in the case of injection pump dismantling is essential when work is being carried out on Fig Da19the injectors Withdrawing an injector using tool l8G 491 A 37 FUEL SYSTEM and torque wrench 18G 372 set to the figure given in GENERAL DATA Do not overtighten the nozzle nut Fig Da20 Reassemble the spindle spring and spring plate and fit the spring cap nUL and the injector cap nut with its Clearing the feed copper joint washer channel bores Test and set the injector as described in Section Da 10 Section Da 10 TESTING AND ADJUSTING THE INJECTORS Fig Da21 To Lest or adjust the injectors it is necessary to use testing machine 18G 109 A and an oil such as Shell Cleaning the car bon from the fuel Calibration Fluid C which will not affect the skin of galiery the operator should be used in the machine WARNINGWben an injector is being tested the spray boles ill the nozzle should always be turned away from the operator Before removing an injector from the testing machine close the check valve to the pressure gauge in order to prevent damage which may result from a sudden drop in pressure Fig Da22 Checking and adjusting the nozzle opening pressure Connect the injector to the testing machine open the Decarbonizing the dome cavity check valve and operate the pump lever Note the read ing on the pflssure gauge at the instant the nozzle sprays If the pressure is incorrect see GENERAL DATA adjust the spring cap nut until the correct injection pres sure is obtained Check the tightness of the injector cap nut and make sure that the copper joint washer is in position Cbecking the nozzle spray Fig Da23 Close the check valve to cut out the pressure gauge and C I e ani n g the operate the pump lever at the rate of 60 strokes per min valve seat ute There should be four equal sprays from the nozzle evenly distributed and each spray should persist for about 6 in 15 cm without any visible core or jets of Fig Da24 C 1ear i n g the spray holes The carbon may now be removed using cleaning kit18G 487 as already described To reassemble the injector thoroughly wash all theinjector components in clean calibration fluid Immerse the nozzle body and valve in a bowl of clean calibration rtfluid and assemble them under the liquid The valveshould fit easily and without any tightness Mount the nozzle holder in fixture 18G 388 make surethe mating faces of the nozzle holder and nozzle body are Reverse lushing an injector nouJe using clean and undamaged and place the nozzle mochine 18G 109 A and adaptor 18G 109 Eassembly in position on the nozzle holder Fit the Shown inset is II sectioned adaptor with 1M nonozzle nut and tighten carefully using spanner 18G 210 In poation 38 FUEL SYSTEM After 30 seconds lapping time withdraw the nozzle ing valve Oscillate the collet over the valve guide surfaceclean the lap and examine the conical lap tip There will and after every IO to 15 seconds of lapping time cleanbe a mat surface where the lap has been in contact with the valve and test it for correct fit in the nozzle body Athe nozzle seat and in the early stages of lapping this correctly fitting nllve should just slide into the nozzlemat surface will probably be narrow or have a bright body under its own weight when lubricated with fuel ring in the middle These markings indi After attention to the nozzle body valve seat or to thecate the extent of the wear on the nozzle seat valve seat face on the nozzle valve check the nozzle valve The lap should be refaced as already described after lift needle lift against the figure given in GENERALevery Ifr minutes of lapping time but in the case of a DATA If the needle lift is excessive it may be restoredbadly worn nozzle seat it may be necessary to reduce this by lapping the joint face of the nozzle body on a surfacetime lapping plate Wip the lap stem clean and recoat it with tallow Wben lapping tbe nozzle face extreme care should beRecharge the tip of the lap with lapping paste and conti takeD to aloid tilting tbe nozzle as this face makes a highnue lapping until the seat is free from scorcs and grooves pressure joint witb the nozzle holder and must thereforeWhen the scat appears satisfactory after a few seconds be true and at rigbt angles to the nozzle axislapping with a freshly ground lap charge the lap with Reassemble the injector as described in Section Dafine lapping paste and continue lapping until a smooth 9 and test and adjust it as described in Section Da 10mat surface is produced over the entire seat Throughoutthe lapping operation the lap should be cleaned andexamincd after every 30 seconds of lapping time Thoroughly clean the nozzle by asdescribed in Section Da 9 and dry out with compressed air Make a final inspection of the nozzle seat underthe microscope Examine the conical valve face of the nozzle valveunder the microscope for scoring and pitting The mostcritical part of the valve face is the angle formed by theconical face and the parallel stem on which the conicalface is formed This angle shoul be sharp and clearlydefined with no rounding or wear breaking the knifeedge anywhere on its diameter The reason for this is toensure a high pressure fuel proof linecontact betweenthe nozzle valve and seat If wear is evident the conicalvalve face should be refaced on the nozzle grinding andlapping machine Ensure that the grindingwheel is dressed correctly andthat the refacing angle is set for the nozzle valve seeGENERAL DATA Mount the valve in the lathe of the machine and refacethe conical tip in the same way as already dcscribed forthe nozzle body lap Remove only the absolute minimum of material sufficient to change the colour of the valve face is the needle lift will be affected As a guidethere should be no sparks or audible hiss from when carrying out this operation The operation is best observed through a the point of focus being the surface of the conicalface away from the grindingwheel In the event of the noale valve being a tight fit in thenozzle body due to slight distortion or deposits on theguide surface of the valve it is possible to restore the fit Mount the nozzle valve in the lapping chuck of themachine using a suitable adaptor chuck and apply avery small quantity of fine lapping paste to the guidesurface of the valve Start the machine and thread thelapping collet supplied with the machine over the rotat 39 FUEL SYSTEM Select a suitable lap from those supplied with the grind ing and lapping machine The bore diameter varies slightly from one nozzle to another and it is necessary to choose a lap which fits the nozzle body in the same man ner as the nOlLle valve This will ensure concentricity of the valve seat in the body with the body bore after lap ping Mount the lap in the lathe of th nozzle grinding and lapping machine and grind the conical tip to the correct nozzle body SCJt angle as given in GENERAL DATA The lap should be passed slowly backwards and forwards across the surface lf the grindingwheel feedingin the lap very gradually until its conical surface is entirely cleaned up Inspect the lap under the nozzle microscope to ensure that its ground surface is smooth If the surface appears rough the grindingwheel should be dressed Fit the lap into the lapping chuck of the machine and apply a coating of tallow to the guide surface of the lap for lubrication purposes Apply a very small quantity of lapping paste to the tip of the lap taking care that the Fig Da26 paste does not extend to the top of the cone Reassembling an injector using fixture 18G 388 NOTEIf any lapping paste is allowed to get between and spanner 18G 210 with torque wrench 18G 372 the guide surfaces of the lap and the nozzle body the clearance between the nozzle body and valve will be unatomized fuel If the spray is not correct or if any increased and the nozzle will probably be made UD leaks or dribble occur wipe the nozzle dry and repeat the seniceable test to locate the cause Start the machine and carefully slide the nozzle over the rotating lap Oscillate the nozzle on the lap in very Checking the pressure tightness of seatings short strokes at a rate of 20 to 30 strokes per minute Open the check valve wipe the nozzle dry and depress engaging the nozzle seat with the lap at the end of each the pump lever slowly until a pressure of 160 atmos stroke The lap should not remain in contact with the pheres is obtained Hold this pressure for 10 seconds and nozzle seat for more than five seconds at a time and the then check the nozzle tip for drynessslight dampness pressure applied to the nozzle should be light Excessive is permissible If in doubt maintain the 160 atmospheres pressure will cause grooving of the nozzle seat pressure for 60 seconds while holding a piece of blotting paper below the nozzle tip The diameter of the wet spot on the paper should not exceed tin 13 mm Checking the backleakage Depress the pump lever slowly until a pressure of 160 atmospheres is obtained then check the time taken for the pressure to drop from 150 to 100 atmospheres For a new nozzle the time taken should be 12 to 30 seconds A nozzle which has been in service will show a faster pressure drop but as this does not seriously affect engine performance a nozzle may be considered serviceable until a time factor of less than 5 seconds is recorded Section Da 11 RECLAIMING INJECTOR NOZZLES If after dismantling cleaning and testing as described in Sections Da 9 and Da 10 an injector is found to be unsatisfactory it is usually possible to recondition the nozzle providing it has been found satisfactory when Checking the backleakage To recondition a nozzle the use of a nozzle grinding and lapping machine is required A nozzle microscope is also Fig Da27 necessary for inspection of the nozzle body and valve An injector assembled to machine J8G 109 A ready during the reclaiming process for spray testing40 FUEL SYSTEM D P A TEST DATAPump Type 3248880A 3248889AEngine FOUR230BASIC PUMP governor with Antistall deviceLight load advance deviceRotation looking on drive end link length 525 mm 1 mm control spring No 2 hole control arm and No 2 hole throttle lever linkRoller to roller dimension 50 37 mmPlunger diameter 6 5 mmTEST PROCEDUREFit autoadvance measuring device and set scale to zero before commencing testWhere marked thus use 30 seconds glass draining time and allow fuel to settle for15 seconds before taking of Light Load Advance DeviceA 05 mm shim is fitted to the piston cap on assembly This must NOT beremoved No further shimming is necessary Throttle idle and maximum speedscrew fully retractedTest No Description R P M Requirements 1 Priming 100 max Fuel delivery from all injectors 2 Transfer pump vacuum 100 Note time to reach 16 in 406 mm Hg Max time allowed 60 secs 3 Transfer pressure 100 11 lbin 2 08 kg cm 2 min 4 Transfer pressure 1250 48 to 60 lbin 2 34 to 4 2 kgcm 2NOTE on tests 5 and 6 To obtain the required degree of advance use the metering valve adjuster on the end of the governor housing 5 Delivery setting 1250 Fit shutoff lever adjustment tool to pump Obtain average delivery 60 to 68 cc by shut off lever adjustment Note Advance indicator must show zero 6 Advance setting 1250 With shutoff lever as at 5 set to obtain 1340 to 2140 advance 7 Delivery check 1250 With shutoff lever and external adjustment as at 5 and 6 average delivery to be 60 to 68 cc 8 Advance check 1250 With shutoff lever fully closed advance to be 3120 to 4120 40AFUEL SYSTEM Test No Description RPM Requirements 9 Back leakage 700 5 to 50 cc for 100 stroke time Throttle lever fully cycle closed lOMax fuel delivery 700 Set to 8 2 O 1 cc Spread between lines not to exceed 08 cc Note Advance indi cator must show zero 11 Max fuel delivery 100 Average delivery to be not less check than average at 10 minus 1 0 cc 12 Cutoff operation 200 Average delivery not to exceed Shutoff lever closed 1 5 cc 13 Throttle operation 200 Screw back antistall device Throttle lever closed and lock to give delivery not exceeding 08 cc 14 Fuel delivery check 1700 Record average delivery 15 Governor setting 1950 Set throttle by maximum speed adjustment screw to give maxi mum average delivery of 1 5 cc No line to exceed 25 cc Lock stop screw 16 Fuel delivery check 1700 With throttle set as at 15 average delivery to be not less than average at 14 minus 04 cc 17 Timing Using outlet V 30 ats pressure set indexing tool to 86 0 and scribe line on housing flange408 DIESEL ENGINE ENGINE PageCamshaft removing and replacing 69Connecting rod and piston 61 Dismantling and reassembling 62 Removing and replacing 61Crankshaft and main bearings removing and replacing 70Cylinder head removing and replacing 56Cylinder liner removing and replacing 60Diesel Engine FOUR 230 43 External components 44 Internal components 46Diesel Engine SIX346 49 External components 50 Internal components 52Engine sandwich plate removing and replacing 70Flywheel and starter ring removing and replacing 70Injection pump drive 69 Dismantling and reassembling 69 Removing and replacing 69Injector sleeves removing and replacing 61Oil pressure relief valve 55Oil pump and strainer 54 Dismantling and reassembling 54 Removing and replacing 54Rocker shaft assembly 55 Dismantling and reassembling 55 Removing and replacing 55Timing gear case removing and replacing 67Timing gear case cover removing and replacing 64Timing gears 64 Dismantling and reassembling 66 Removing and replacin 65 41Valve grinding 59Valve guides removing and replacing 58Valve rocker clearance 55Valve seat inserts 60Valves 58Valve timing 6742F 0 U R 23 0 LITRE DIESEL ENGINE Longitudinal Section 43 FOUR230 DIESEL ENGINE EXTERNAL COMPONENTS 178 179 P 9189 109 V r rO IS 34 192 u 190 III 113 r1I444 FOUR230 DIESEL ENGINE EXTERNAL COMPONENTS No Description No Description No Description No Description I Cyllnder block 5 I Ioint for timing gear case 93 Boltdelivery pipe to block 143 Spring washer for nut 2 Main bearing cap front 52 Bolttiming case to cylinder long 146 Thermostat 3 Main bearing cap intermediate block 94 Tab washer for bolt 147 Thermostat body 4 Main bearing cap centre and 53 Spring washer for bolt 95 Bolt delivery pipe to pump 148 Ioint for thermostat body rear 54 Dowel for timing gear case cover 96 Tab washer for bolt 141 Boltbody to cylinder head 5 Dowel for main bearing cap 55 Timing gear case cover 97 Oil strainer 150 Spring washer for bolt 6 Stud for main bearing cap short 56 Joint for timing gear case cover 98 Ioint for oil strainer 151 Plug for thermostat body 7 Stud for main bearing cap long 57 Crankshaft oil seal 99 Oil sump 152 Fibre washer for plug 8 Nut for stud 58 Bolttiming case and cover to 100 Gasket for sump 153 Water outlet pipe 9 Washer for nut block 101 Drain plug 154 loint for water outlet pipe 10 Main bearings 59 Boltdynamo bracket case and 1O Washer for drain plug 155 Boltoutlet pipe to thermostat II Crankshaft thrust washers cover to block 103 Blanking plug body 12 Dowel for flywheel housing 60 Spring washer for bolt 104 Washer for blanking plug 156 Spring washer for bolt 13 Dowel for cylinder head 61 Bolttiming gear cover to case 105 Boltsump to block 157 Rocker shaft bracket front and 14 Dowel for injection pump bracket 62 Nut for bolt 106 Spring washer for bolt rcar 15 Dowel for rear half of timing case 63 Spring washer for nut 107 Plain washer for bolt 16 Front camshaft bearing 158 Rocker shaft bracket centre 64 Front lifting plate 108 Oil level indicator 151 Rocker shaft bracket inter 17 Locating screw for bearing 65 Timing cover blanking plate 109 Guide tube for indicator 18 Seloc washer for screw mediate 66 loint for blanking plate 110 Breather pipe 160 Plug for intermediate bracket 19 Oil gallery plug front and rear 67 Screwblanking plate to cover 20 Washer for plug II I Clip for breather pipe 161 Waher for plug 68 Spring washer for screw 112 Bolt for clip 162 Rolt for bracket 21 Oil gallery plug brass 69 Oil feed jet for timing gears 22 Washer for plug 113 Nut for bolt 163 Spring washer for bolt 70 Boltlifting plate to cover and 114 Spring washer for nut 164 Plain washer for bolt 23 Oil gallery plug tapped case 24 Washer for plug 115 Cylinder head 165 Bolt for intermediate bracket 71 Spring washer for bolt 116 Gasket for cylinder head 166 Spring waher for bolt 25 Water gallery plug brass 72 Engine front support bracket 26 Washer for plug 117 Engine rear lifting plate 167 Plain waher for bolt 73 Boltsupport bracket cover and 118 Joint for lifting plate 168 Relief valve body 27 Water gallery plug steel cae to block 28 Water gallery core plug 119 Stud for lifting plate 169 Relief valve ball 29 Cylinder liner 74 Boltsupport bracket to cover I O Nut for stud 170 Relief valve spring 30 Cylinder liner sealing ring and case I I Spring washer for nut 171 Scat for relief valve spring 31 Cylinder block water drain tap 75 Steady for breather pipe 1 Injector sleeve I n Plug for relief valve body 32 Shim for drain tap 76 Spring washer for bolt I 3 Cylinder head stlld 173 Plain waher for plug 33 Washer for drain tap 77 Outrigger bearing for idler grar 124 Nut for stud 174 Tab wahcr for pillg 34 Adaptor for drain tap shaft 125 Core plug steel 175 Overnow pipe for relief val 35 Washer for adaptor 78 Ioint for bearing 126 Plug brass 176 Waher for overnow pipe hillaI 36 Rear cover plate and oil seal 79 Screwbearing to IImmg covcr 127 Air inlet manifold 177 Wahcr fo overnow pipe large 37 Bolt for plate 80 Spring washer for screw 1211 loint washer for manifold 1711 Valve roder cover 38 Spring washer for bolt 81 Dynamo adjusting link 129 BoltmanifolJ to head short 17 aiket for rocker covcr 39 Ioint for cover plate 82 Dynamo bracketfront 130 Boltmanifold to head long 180 Stlld for rorker eOr 40 Screwcover plate to block 83 Bolt for steady IJ I Spring washer for bolt III I Hand nut for stud 41 Spring washer for screw 84 Nut for bolt 132 Plain washer for bolt 182 ribre washer for nut 42 Sandwich plate 85 Spring washer for nut 133 Throttle unit Venturi 183 Oil liller COl p 43 Ioint for sandwich plate 86 Dynamo bracketrear 134 loint washer for throttle unit 187 Oil feed pipe to rockers lower 44 Boltplate to block 87 Boltbracket to cylinder block 135 Stud for throttle unit 188 Oil fed pipe to rockers upper 45 Spring washer for bolt 88 Spring washer for bolt 136 Nut for stud 18lJ Pin for feed pipe banjo 46 Valve tappet cover 89 Oil delivery pipe 137 Spring washer for nut IlJO Washer for pin small 47 Joint for tappet cover 90 Jointdelivery pipe to block 139 Exhaust manifold 111 Washer for pin large 48 Bolttappet cover to block 91 Iointdelivery pipe to pump 140 Joint washer for manifold 19 Tab waher for pin 49 Washer for bolt 92 Boltdelivery pipe to block 141 Stud for manifold IH Jnion for oil gauge pipe SO Timing gear case short 14 Nut for stUd tl4 Wahcr for IInionti FOUR230 DIESEL ENGINE INTERNAL COMPONENTS 21 3Se I II 2343e I 2 7 4 i W j f i 33 g 3 5 14fI1 3 Sij I 35 t 15 24 30 11 j 22 124 39 121 FOUR230 DIESEL ENGINE INTERNAL COMPONENTS No Description No Description No Description No Description I Compression ring taper sided 32 Spring washer for screw 64 Injection pump driving gear hUb 94 Spring washer for nut chrome face 33 Plain washer for screw 65 Injection pump driving gear 95 Coupling dog flange 2 Compression ring taper face 34 Valve rocker spacing washer 66 Locking nuthub to injection 96 Coupling insert 3 Scraper ring slotted thick pump drive shaft 97 Coupling pump flange 4 Piston 35 Valve rocker spacing washer 67 Tab washer for nut 9S Oil pump driven gear thin 68 Boltdriving gear to hub 5 Gudgeon pin clip 99 Nutoil pump gear to oil pump 36 Valve rocker 69 Injection pump drive housing shaft 6 Gudgeon pin 37 Valve rocker adjusting screw 70 Injection pump drive shaft 100 Split pin for nut 7 Small end bush 38 Lock nut for screw 71 Keydriving flange to drive shaft 101 Oil pump rotor and shaft assembly 8 Connecting rod 39 Push rod n Keyhub to drive shaft I 02 Keyil pump gear to shaft 9 Hollow dowel 40 Tappet 73 Drive shaft bearing large 103 Oil pump body 10 Connecting rod bolt 41 Camshaft 74 Cover plate for bearing 104 Adjusting shimil pump to II Tab washer for bolt bearing cap 42 Keyhub to camshaft 75 Cover plate retaining screw 12 Bigend bearing 105 Oil pump cover 43 Camshaft locating plate 76 Drive shaft bearing small 13 Crankshaft 107 lointrelief valve to pump 44 Boltlocating plate to block 77 Drive shaft oil seal 14 Inlet valve thimble 10S Boltrelief valve body to oil 45 Spring washer for bolt 7S Drive housing end cover pump 15 Inlet valve oil seal 46 Camshaft gear hub 79 Screwnd cover to drive 109 Washer for bolt 16 Inlet valve guide 47 Camshaft gear housing 110 Oil relief valve body 17 Thimble locating dowel 48 Boltcamshaft gear to hub SO Spring washer for screw III Oil relief valve seat 18 Inlet valve key 49 Washer for bolt S loinldrive housing to timing cae 112 Oil relief valve 19 Valve spring collar 50 Locking nuthub to camshaft 113 Oil relief valve spring 8 Screwdrive housing to timing 20 Retainer for collar 51 Tab washer for nut case 114 Oil relief valve plug 21 Spring clip for retainer 52 Idler gear shaft 83 Spring washer for screw 115 Tab washer for plug 22 Inlet valve 53 Idler gear 84 Driving flange 116 Screwcover to oil pump bod y 23 Exhaust valve oil seal 54 Idler gear thrust washer 85 Screwdriving flange to dog short 24 Retainer for exhaust valve oil 55 Keygear to crankshaft flange 117 Screwcover to oil pump body seal 56 Keypulley to crankshaft S6 Spring waher for screw long 25 Exhaust valve guide 57 Oil pump driving gear 87 Plain washer for screw 118 Boltcover to oil pump body 26 Exhaust valve 88 Dowel screwdriving flange to 119 Spring washer for bolt and screw 58 Crankshaft timing gear dog flange 27 Inner valve spring 59 Oil thrower 120 Flywheel 89 Spring washer for screw 28 Outer valve spring 60 Distance piece 121 Dowelflywheel 10 crankshaft 90 Plain washer for screw 29 Valve rocker shaft 61 Crankshaft pulley 91 Driving flange clamping bolt 122 Bush for crankshaft 30 Plug for shaft 62 lawstarting handle 92 Tab washer for bolt 123 Shims for starling jaw nut 31 Shaft locating screw 63 Tab washer for jaw 93 Nut for bolt 124 Boltflywheel to crankshaftI48 SIX346 DIESEL ENGINE 11111111 1111 I II I I I II I f i I I i i i f I i ls f N s 5 I co I M I i Cll i I I i 1111 III 111 1111111 49 11 411 4 lIlI lIZ r 4 III 2 I I f I I Fig 4 SIX 346 Engineexternal components 1 111 KEY TO FIG E4 ENGINEEXTERNAL COMPONENTS J Cylinder block assembly 9 Support bracket driUed intermediate 156 Set boltfilter to cylinder block 2J4 Boll for dynamo brakel to timing chain 2 Dowelinjection pump support braekel for rocker shaft 157 Plain washer or set bolt 215 Spring washer for holt icover 3 Dowelsandwich plate 80 Set bollsupport brackets to cylinder head 158 Spring washer for set bolt 2J6 Fuel pipeinjection pump to No I 4 Doweltiminl caserear half 5 Dowelylinder head 6 Camshafl bearinl bush 7 Localinl screw for bush 8 Sprinll washer for screw 9 Core disc for water IIery A in 80a St bollsupPOrt brackets 10 cylinder head 81 in lin 81a Sprinl washer for set bolt II in 82 Valve tappel 83 Pushrod 159 160 161 162 163 Oil pipeon cylinder head for rocker luhricallon Oil pipeoil gallery to pipe on ylinder Iin for hano of pipes Joint washer for pin Joint washer for rin head 237 218 2J9 cylinder Fuel pipeinjeclion pump to No 2 cylinder Fuel pipeinjeclion pump to No 3 cylinder Fuel pipeinjection pump 10 No 4 I 10 Plugbrassfor water lallery 84 Cover for pushrods 164 Tb wasber for pin ylinder i i II Waher for plug 12 Plugfor oir IIery I in gas circular head Il Core plugsteelfor waler gallery 14 Plugfor oil gallery l in gas IS Joint for Pluf No 12 85 Joinlover 10 cylinder block 86 Sel boltcover 10 cylinder block short 87 Spring washer for scI bolt 88 Valve lIear emer 89 Oil filler cap 165 166 167 168 169 Oil pipein liminll use for hain lubrice Pin for banjo of pipe Waher for pin 1 alo washer for pin CIi for pipe lion 240 241 242 243 Fuel pipeinicetion pump 10 No cylinder Fuel pipeinjeclion pump to N O 6 aamp for fuel pipes Bolt for clamp cylinder I 16 Union for oi uge pipe 90 Gasket for vahe gear cover 170 Oil sump 244 Nut for bolt 17 Washer for plug No 14 and union 91 Nut for alve ear ecr 171 Blanking plug 245 Sprinll washer for bolt 18 Cylinder liner 19 Sealing rinl rubber for liner No 16 92 Washer llibre for valve gear cove nu 93 Air manifold 172 171 Washer for plug Ora in plUI for sump 246 247 Starler Distance pieceslarter 10 sandwich pIa Ie I 20 Drain lap for cylinder block 94 Stud for air manifold 174 JoiDl washer for plug 249 Sludstarter 10 clUIb housinll I 21 Shin for drain tap 95 Joinlair manifold 10 cylinder head 175 Joinlum to crankcase 250 Nul for stud 22 Washer for drain lap 96 Sel ohohortair manifold 10 clinder 176 Sel hohshortsump 10 rankcase 2S1 Spring washer for stud 23 Sandwich pia Ie head 176a SCi boltlongsump to rankcase 252 A nchor pin for starter strap 24 Joint for ndwieh plate 97 Sel bollmediuRIair manifold 10 P7 Plain washer for sel bolt 251 Pinslrap 10 anchor pin 25 Sel boll for sandwich plale cylinder head 178 Spring washer for SCI bolt 254 Pintappedfor trap i i 26 Spring wuher fur sandwich plate 27 Cylinder head and valve guides assemhly 28 Valve guideexhausl 29 Vahe lIui einlet 30 Injlor sleee 98 Sel bolllon8air manifold 10 cylinder 99 Plain washer for bolt 100 Spring washer for bohs 101 Venluri control unil CAV 102 Jointvenluri hI air manifold had 179 180 181 IH2 ISl Oil rod for oil levol fuel injection pump I1rackel fr rel injeclion pump Set holt for fuel injetion pump hrackel Spring washer for sel bolt 2S 26 257 258 259 Screwpin No 254 to pin No 2901 Strap for starter lIanjo pin for hanjo of pipe to pump Fihre washer for banjo pin Clip for pipe I i 31 Core plugsquare hea 10J ocknulvenluri II air manifold 184 Set screwinJectinn pump to hrakel 261 Clip for pipeoillallery to cylinder head j 32 Joinlcopperfor core plUI 33 Inlel valve 34 Exhaust vahe 104 Plain washervenluri 10 air manif 105 Spring washerventuri to air manifolJ 106 Hollow dowel for main bedfing cps 1 I S6 187 Overflow pipe for injection pump in for banjn of pipe Waher for pin 262 263 264 Distance piece for clip Main leakofT pipe Banjo pin for pipeshort I I 15 Valve springinner 107 StuIhrt for main bearing cas 188 eady fnr overflow pipe 265 Washer for pin I I 36 Valve springouler 37 Cullar for oaloe 38 Relainers for collr 39 Spring clip for relait 108 Slu lonllfor maIO bearing caps 109 NUl for Iu 110 Split pin for nuls III Vacuum pipehort 189 190 191 192 hrrulc flr ovrrow lipe Driing coupling injeclion pump Ehauster Rolt f exhausler 266 267 268 2611 Fuel injector Se h1t for injeclor Sprinl washer for sct bolt Banju pinleakofT 10 fuel filler t t 40 Oil sc1 fnr valve 112 Vacuum pipelong 19J Srring h Ii holl 270 Uanjo pinlongfor banjo of leakofT ppes i 41 Relainer fr oil eill Ill Exhaust manifuld 194 1 iming chain gear I 42 Thimle for inltl voloe 114 Slud for exhausl manifold 195 Hul fIn chain wheeL 272 Adaplor for pipeauxiliary leakoff 10 43 Localirgpeg for Ihimble 115 Joinl for haut manifold pipe 191 Se I It huh to chain wh l 271 Copper washer for adaptor fuel filler 44 Seal f inner valve springinlel 116 Nut for ehausl manifld 191 01 fcd plpemp to exhauster 274 SCI holtfucl filler support brakel to 1 45 Decomr screw 117 half 19R Rilnill pinpilf to rlthauhr 275 Spring washer for It yrinder bck 46 Siud rear coverplalt 118 Jintasinglo cylinder block 19 lInjo pinpipe 10 sump 276 Ilain washer for boll 47 Sludexhausl manifM 119 Sel holtasing to cylinder hlock 200 wahr for pins 277 Adaptor fur fuel oil filter 48 Sludalve rocker cover 120 Dowelliming case to cnver Ol nil fr nil f pie 278 Copper waoher for adaplor 49 Gaskel for cylinder hed 50 Sludshortfor cylinder head 51 Studlongfor cylindr head 121 Spring washer fur sct Nit 122 Guide hracket and ad for liminl chain 121 Pad for guide bracket 202 201 204 SCI holt fr cli Speing aher for holt 1uJehaulfr to timing chain casing 279 280 281 Rodyrelief valve Ballrelief valve Spring for ball I 52 NUl for cylinder head studs 124 Rivel for pad 20S NUl fllr stud 282 Seal fr sprinll t 51 Lifting and rear coverplate 125 Set holtGuide hrackel to cylinder hlock 206 Sring aher for tud 283 Plug for ody t 126 Set screwguide braCtlll qlinder block i I 54 Jninl for pia Ie 55 Nut for plate 56 Spring wher for plate 127 Spring waher for bolt an screws 128 Tensioner for timing chain 207 208 209 Front uport hradet Set hol Iong for hraet Sel holt hfl fnr hradel 2R4 28S 286 Packing waoher for dy Tah washer for body Overflow pipe fm relief valve I I 57 Thermolat 129 Chain whtel for ensioner 210 Spring asher for IlUll 287 Washersmall hoie for banjo I 58 Rody for Ihermolat 130 Stu for chain tensioner in cylindtr hlock 211 Fuel filler 288 Washerlarge holtfor banjo 59 Joint for Ihenooslat boy Ill Sel bolt for hain lensioner 212 Iemenl for filter 289 Jointexhauster to timing chain c3ing 60 ScI holt fnr Ihermustal body 1l2 NUl for stud 21 J JIlin r cover 290 Pinplainfor starter slrap 61 Plu for thermoslat dy IlJ Tab washer for stud and holt 214 Sel bollfiller 10 bracket 291 Spacing washer for valve rocker thin I 62 Spring waher for sel bolt 134 Timing chain 21 Plain wash fur set holt 292 Orain lap lube 63 CIA washer for plug U5 Uftinl plalefronl 211i Sring w3her for set hh 293 Steady for drain lap tube I 64 Waler oulet pipe l6 Cover for liminll casefronl half 217 Fuel pipcIift pump 10 filter 294 Grommet for drain tap tuhe 65 Joinl for waler oUllel pipe 1l7 Jointover to casing 218 Fuel piefiher 10 injection pump 295 Cylinder block blanking pia Ie t t 66 Set bolt for water oullel pipe 118 Sel bollover to caing 2111 lekon pipeauiliary 9rackel fur fuel filter 296 297 Joinl for blanking platc Bolt for hlankinll pia Ie i 67 Spring washer for sel holt 139 SCI boltcover and casing to cylinder 220 68 Valve rocker 140 Spring washer for set bohs hlnck 221 Sleady plale for fuel filter 298 Valve cover venl pipe i 69 Spacing waher for valve rocker thick 141 Oil seal 222 Oynamn 300 Nut for cover vent pirt 70 Adjuslinll screw for valve rocker 145 Hlanking plale for fronl cover 22J ulle for dynamo 101 Wafer drain plug 71 Locknul for adjusting screw 146 Joinlblanking plate 10 fronl cover 224 IIracket fr dynamorear 302 Washer for plug 72 Shaft for valve rockers 147 Set screwblanking plale 10 fronl cover 225 Set holtrear dynamo brackel I cylinder 301 Set screw for oil pipe on cylin I ad t 73 Plug for valve rocker shaft 148 Spring washer for sct screw 226 Spring washer for sel boh block 304 Guide IUN assemhly for diprod i I 74 Locating screw for rocker shaft 7 Spring washer for localing screw 76 Supporl bracketfronl and rear for 149 Distance piece for front cover ISO ScI boll for diance piece IS Sprinl washer for set It 227 228 229 Bollbrackets to dynamo Nul for boh Sring washer for boh 105 306 107 Spacing washers for luide Plughra Plug for intermediate rocker brad et J I rocker ha 77 Support braketenlrcfor rocleer shaft 152 Oil filler 153 Oil filter elemenl 210 21 Set screwdynamo nange to adjustinl Plain washer for set screw Iinlc 108 309 Washer for plug W It iIn juuuu rocker 78 sUfcport brackel 154 Oil filter askel 232 Adjustin link for dynamo 310 J Bracket for dynamofronl 311 cn 121 119 U 2 2 a Fig E5 L I componenu DIESEL ENGINE Fig Aa4 Checking the oil pump drive Aa6 B Fig Aa6 REMOVING AND REPLACING mE OIL PUMP AND STRAINER Check the oil pump rotor lobe clearance with the rotors ill positions A alld B The dimensions given are for the maximum clewance Remove the sump still in situ hy ullscrcwlIlg tht two set holts whidl secure Unscrew the two set bolts securing the oil delivery the oil uction pipe flange to the oil pumppipe to the cylinder block Remove the nuts securing the oil pump to the frontmain bearing cap and withdraw the pump completewith delivery pipe oil strainer and pressure relief valvenoting the shims between the bearing cap and oil pump Section Aa7 To replace the oil pump reverse the above procedure DISMANTLING AND fit a new gasket to the delivery pipe flange Tighten TBE OIL PUMPthe oil pump securing nuts to the figure given inGENERAL DATA using torque wrench 18G 372 Check that the backlash on the oil pump drive gearsis as given in GENERAL DATA and if necessary Disconnect the delivery pipe oil strainer and pressureadjust the backlash by means of the shims between the relief valve from the oil pumpoil pump and main bearing cap Remove the gear and key from the end of the pump The oil strainer can be removed with the oil pump shaft Unscrew the set bolts separate the oil pump cover from the body and remove the pump shaft complete with inner and outer rotors Thoroughly clean and inspect aU the dismantled com ponents Check the rotor endfloat and driving shaft clear ance against the figures given in GENERAL DATA Excessive rotor endfloat can be remedied by lapping the pump body face Measure the rotor lobe clearance as illustrated in Fig Aa6 Reassemble the oil pump by reversing the dismantling procedure noting that the chamfered end of the outer rotor should be fitted towards the bottom of the rotor Fig Aa5 pocket During reassembly smear all working parts Checking the oil pump rotor endfloat with new engine oil DIESEL ENGINE bracket set bolts then reset the torque wrench see GENERAL DATA and tighten the i in diameter bolts Adjust the valve rocker clearance Section AaH and replace valve rocker cover Start the engine and inspect the rocker cover joint for oil leaks Section AalO 0 p A4588A DISMANTLING AND REASSEMBLING THE ROCKER SHAFT ASSEMBLY Fig Aa7 Unscrew the set bolts from the centre rocker Adjustillg the valve 10 rocker clearance bracket and separate the rocker shafts from the centre bracket Remove the rockers and distance collars and the remaining brackets from the rocker shafts and unscrew the blanking plug from the end of each shaft Section As8 Release the tab washer from the oil relief valve drain OIL PRESSURE RELIEF VALVE pipe on the front intermediate bracket and unscrew the relief valve from the bracket The pressure relief valve is mounted Remove the plug from the relief valve body and with on the outlet flange of the oil pump facing draw the spring spring seat and relief valve balltowards the front of the engine Clean all the dismantled components paying particu Release the locking washer and re tar attention to the oilwaysmove the oil pressure relief pI ug lockingwasher and valve seat from cover Inspect the components and check them against their Examine the valve seat and the specifications in GENERAL DATAplunger for wear or score marks and When reassembling which is a reversal of the discheck the spring against the specifica mantling procedure smear all moving parts with newtion in GENERAL DATA engine oil renew the tab washer and copper gaskets When reassembling which is a re on the oil pressure relief valve and fit the drain pipeversal of the dismantling procedure so that it is directed down the pushrod tunnel Alsorenewthe body plug locking washer and ensure that the rocker shaft distance collars are corthe mounting flange gasket rectly pOSitioned see GENERAL DATA Unscrew the set bolts from thecenter rocker bracket and separate therocker shafts from the center bracket Section Asll VALVE ROCKER CLEARANCE The clearance between tile ends of the valve stems and the valve rockers is checked by means of a feelerSection As9 gauge FOUR230 REMOVING AND REPLACING Crank the engin until No g valve is fully open and THE ROCKER SHAFT ASSEMBLY check the clearance of No 1 valve which will now be fully closed Remove the valve rocker cover Slacken the rocker adjusting screws until all pressure To adjust the clearance hold the adjusting screw withis relieved from the valve springs a screwdriver and slacken the locknut Fig Aa7 Remove the set bolts securing the rocker brackets to Rotate the adjusting screw until the clearance betweenthe cylinder head and lift off the rocker shaft assembly the valve stem and rocker is as given in GENERAL Refit the rocker shaft assembly to the cylinder head DATA Hold the adjusting screw against rotation lockwith all rocker adjusting screws fully slackened Using it in position with the locknut and then recheck thetorque wrench 18G 537 set to the figure given in DATA tighten the r in diameter rocker Check the remaining rocker clearances by reference 55 DIESEL ENGINE to the following table Remove water hose between fresh No1 valve ex with No8 valve fully open water pump and heat exchanger at pump 3 in 6 Remove water hose between heat 5 ex 4 exchanger and the dual oil cooler at 2 in 7 cooler 8 ex I Disconnect the water discharge hose from side of heat exchanger 6 in 3 4 Remove the two bolts securing the ex 5 dual oil cooler to the engine lifting 7 in 2 bracket and move cooler away from The valve rocker clearance should be checked at the intervals recommended Disconnect exhaust pipe from ex pansion tank exhaust manifold SIX346 Remove the expansion tank exhaust manifold from the cylinder head and Crank the engine until No 12 valve is fully opeD and lift away with heat exchanger attachedcheck the clearance of No 1 valve which wiD now be Release the T connection in thefully closed rocker feed pipe Seal ends to prevent To adjust the clearance hold the adjusting screw with entrance of dirta screwdriver and slacken the locknut Fig Aa7 Remove the two bolts securing theRotate the adjustina screw until the clearance betweeD wiring bracket to the cylinder headtho valve stem and rocker is u Jiven in GENERAL Disconnect the fuel pipe unions andDATA Hold the adjusting screw against rotation lock leak off unions at fuel injectors Sealit in position with the locknut and then recheck the off all pipes and injectors to the entry of dirt Check the remaining rocker clearances by referenm Remove the six bolts securing theto the following table intake manifold to cylinders head Remove intake manifold Check and adjust No I valve ex with No 12 valve fully open Remove the injectors from the 7 in 6 cylinder head 9 ex 4 2 in 11 NOTE The injectors should not be left 5 10 ex in 8 3 in position in the cylinder head as the nozzle tips protrude below the bottom face of the head and are liable to sus 12 ex I 6 in 7 tain damage 4 ex 9 II 8 in ex 2 5 Working in the order shown in Fig Aa8 A for the four230 or 3 in 10 Aa8B for the six346 slacken each The valve rocker clearance should cylinder head nut a quarter of a turnbe checked periodically at the intervals only then unscrew each nut a amount in the same order until loose Remove the cylinder head nuts and lift off the cylinder head Section h12 On no account should a screwdriver or similar tool be used as a wedge between the cylinder head and block REMOVING AND REPLACING A suitable method of removing the cylinder head is THE CYLINDER BEAD to place a sling round the exhaust manifold studs on Drain cooling system one side and round two hightensile iin UNF set Remove hoses connected to thermo bolts screwed into the air inlet manifold bolt holes on the other side When lifting the head a direct pullstat housing Remove the four bolts securing should be given to lift it evenly up the housing and engine lifting Unscrew the two locating dowels and remove thebracket from cylinder heads cylinder head gaskeL 56 Check the cylinder head joint face for flatness uSlnga straightedge If there is any doubt as to the condition of thecylinder head gasket it should be discarded and a newone fitted plain side downwards Replace the remaining components by reversing theremoval procedure The cylinder head DUts should betightened in the order shown in Fig AaS Adjust the valve rocker clearance as described inSection Aall Bleed the fuel system of air Start the engine and allow it to run at a fast idlingspeed until it is thoroughly warm Stop the engine remove the valve rocker cover andretighten the cylinder head nuts in the order shown inFig AaSRecheck the valve rocker clearance asdescribed in Section Aa 11 Fig Aa9 Using spanner 18G 396 and torque wrench 18G 372 to tighten the cylinder head nuts Fig Aa8A FOUR230 Cylinder head nut slackening and tightening sequence Fig Aa 8B SIX346 Cylinder head nut slackening and tightening sequence 57 DIESEL ENGINE I I A Ill I Fig Aa11 Fig AaJO Engine valve components showing the locating fiat Compressing the valve springs using tool18G 106 A on the inlet valve and the chamfered bore B of the exhaust valve oil seal Recheck the valve rocker clearance as described inSection Aall original positions in the cylinder head Position the inlet valves 80 that the small flat Fig Aall on the top of the valve stem is in line with the valve guideSection Aa13 locating peg Insert the valve key into position in the inlet guide slot and replace the thimble complete with REMOVING AND REPLACING THE VALVES oil seal Fit the inner and outer valve springs the Remove the valve rocker shaft assembly Section exhaust valve oil seal chamfer downwards andAa9 retainer and the valve spring collar Compress the Drain the cooling system valve springs with tool 18G 106 and refit the spring Remove the cylinder head Section Aal2 collar retainers Release the compressing tool and Detach the spring clips from the valve spring collar replace the spring clips on the collar Compress each set of valve springs using Check that the valve head standdown below thetool18G 106 and remove both halves of the spring collar cylinder head face is in accordance with the figures inretainer Release the compressing tool and remove GENERAL DATA If the valve head standdownthe valve spring collar oil seal and retainer exhaust is excessive fit new valves and in the event of thevalve only valve springs and the exhaust valve With standdown being excessive with new valves fit newdraw the thimble from the inlet valve stem detach the valves seat inserts as described in Section Aal6valve key from its slot in the inlet guide and removethe inlet valve Remove the inlet valve oil seal frominside the thimble Clean the valves and guides The carbon can beremoved from the guides by dipping the valve stemin petrol or paraffin and moving it up and down inthe guide until it is free If excessive wear is disclosedthe valve guides should be renewed Section Aa15 Inspect the valve faces and seats and as necessary Section Aal4 Check the valve springs against the specification inGENERAL DA TAt and ensure that the ends of thesprings are square with thp spring axis A new oil seal should be fitted to each valve to avoid the loss of oil tightness which willresult from refitting the old seals It will be foundthat the seals are more easily fitted if they are soaked Fig Aa12in engine oil before use Fit the valves with their top faces standing down lubricate the valve stems and guides with new engine below the cylinder head joint face to the dimensionoil and replace the valves which are numbered in their shown inset 58 DIESEL ENGINE angle see GENERAL DATA on a valve grinding machine and the valve seats recut using tools 18G 27 18G 28 18G 28 A 18G 28 B 18G 28 C 18G 174 18G 174 A 18G 174 B 8G 174 C and 180230 Use the glazebreaker to prepare the seat surface and recut the seats removing only as little metal as is necessary to ensure a true seat Restore the seats to their correct width see GENERAL DATA by using the narrowing cutters Finally lap the valves onto their seats as already described Section AsIS REMOVING AND REPLACING THE VALVE GUIDES Fig Aa13 Remove the valve rocker shaft assembly Section Grindingin a valve using tool18G 29 Aa9 Drain the cooling system Remove the cylinder head Section Aa12 and the valvesSection As14 Section Aa13 Drive the valve guides out of the cylinder head V ALVEGRINDING using tool 18G 228 inserted into the guide from the If only slightlY pitted the valve faces and seas aD port endbe reconditioned by grindingin with tine grmdmg New valve guides should be driven into position withcompound Smear the valve face lighly with griding tool 18G 228 until the shoulder on the guide is flushcompound and lap the valve on to Its sat usm a against the cylinder head When titting the inlet motion with tool 18G 29 ThIs operatlon guides ensure that the locating peg slot in the valveis not complete until a dull even mat surface free from guide shoulder is in line with the locating peg in theblemish is produced on both the valve face and seat cylinder head before driving the guide into position After cleaning away all traces of grinding compoundthe valve seating can be checked by applying a spot of Finish ream new valve guides using tool 18G 229Amarking blue to the valve face and rotating the valve then ensure that the valve seatings are concentric withabout one tum on its seat the marking should be the valve guide bores recutting the seatings if necessary Section Aa14completely reproduced on the valve seat A tinallapping using oil only is recommended Replace the remaining components by reversing the When the valve faces and seats cannot be correctedby lapping the valves should be refaced to the correct Fig Aa14Badly pitted valve seats should be reaced using Fig Aa1Stools 18G 27 18G 28 18G 28 A l8G 28 B 18G 28 C Driving a valve guide into position using tooll8G 174 l8G 174 A 18G 174 B l8G 174 C and 18G 230 18G 228 59 DIESEL ENGINE Fig Aa16 Fig AaJ8 Reaming a valve guide using tool l8G 229A Cutting a thread in an injector sleeve using tool 18G 213 A to enable the sleeve to be withdrawn byremoval procedure and adjust the valve rocker tool 18G 213 Shown inset is the Alkathene plugclearance Section Aa11 inserted ill the sleeve to prevent swart entering the cylinder boreSection Aa16 the insert which has an interference fit of 002 to 004 in VALVE SEAT INSERTS 051 to 102 mm into the cylinder head Finally If a valve seating cannot be restored with the normal grind or machine the new seat to the dimensions givencutting and refacing tools or if valve head standdown in Fig Aal7 ensuring that the throat of the new seatis excessive with a new valve a valve seat insert should blends into the throat in the cylinder headbe fitted Check the area of contact between the new seat and To fit an insert machine the seating in the cylinder its valve with marking blue and if necessary lap thehead to the dimensions given in Fig Aal7 and press valve onto its seat Section Aa14 Section Aa17 DECARBONIZING Remove the valve rocker shaft assembly Section Aa9 Drain the cooling system Remove th cylinder head Section Aa12 and the valves Section Aa13 Plug the waterways in the cylinder head and the Fig Aa17 cylinder block with clean rag Valve seat machining dimensions If special equipment for decarbonizing is not available Inlet A Exhaust 8 it will be necessary to remove the carbon deposit fromC Nominal diameter 1450 in L Nominal diameter 1290 in the piston crown and cylinder head by scraping A 368 rnm 3275 rnm length of copper tubing with the end flattened and filedD 1775 to 1776 in 45076 M 1625 to 1626 in 4127 to to 45102 mm 4130 mm up makes an ideal scraper which will not scratchE Maximum radius 015 in N Maximum radius 015 in The ridge of carbon in the top of each cylinder bore 38 rnm 38 mmF 325 to 328 in 825 to P 325 to 328 in 825 to should not be disturbed and a ring of carbon should 833 mm 833 rnm also be left round the periphery of each piston crownG 135 to 140 in 343 to Q 135 to 140 in 343 to An old piston ring sprung into the bore and resting on 356 rnm 356 rnmH 070 to 080 in 178 to R 070 to 080 in 178 to the top of the piston will facilitate this operation 203 rnm 203 rnm Remove the carbon deposit from the valves valveJ 45 s 45 ports valve guides and cylinder head ThoroughlyL Chamfer 020 to 030 in T Chamfer 020 to 030 in 508 to 762 rnm at 45 508 to 762 rnm at 4S clean the cylinder head and ensure that all traces of 60 DIESEL ENGINE JIgAal9 Withdralting an injector sleeve using too18G 213 D Fig Aa20 Installing an injector sleeve using tool 18G 561carbon dust are removed from the head and cylinderbores Drain the cooling system Replace the components reversing the removal Remove the cylinder headprocedure and adjust the valve rocker clearance If No 1 connecting rod is to be removed detach theSection As I I oil strainer and suction pipe from the oil pump Remove the cap and the bottom half of the bigend bearingSection Aa18 Clean the carbon deposit from the top of the cylinder bore and withdraw the cunnecting rod and piston REMOVING AND REPLACING upwards through the cylinder THE INJEcroR SLEEVFS NOTEEach collDeCtiDa rod aad cap Is stamped If it is found necessary to renew an injector sleeve with the Dumber of the cyliader from which it wthe operation can be carried out without removing the removed Fig ALll Lubricate the cylinder bore and piston with cleancylinder head engine oil space the compression ring gaps equally Remove the injector round the circumference of the piston and compressInsert an Alkathene plug supplied with tool the rings using too118G 55 A18G 213 A into the injector sleeve to prevent swarf Insert the connecting rod and piston the cylinder Using tool 18G 213 A cut a through the cylinder bore so positioned that thethread on the inside of the sleeve Remove the tool connecting rod cap will be towards the lefthand side ofbut leave the plug in position Screw tool 18G 213 0into the injector sleeve and withdraw the sleeve FigAa19 Remove the Alkathene plug from the injector sleeve Crank the engine to position the piston in the cylinderbeing operated on at BDC Coat the new injector sleeve with sealing compoundpart number AKF 1702 on those surfaces which contactthe cylinder head and drive it into position using toolISG 561Section Aa19 REMOVING AND REPLACING A CONNECTING ROD AND PISTON F Drain and remove the sump Fig Aa21 Remove the valve rocker shaft assembly Section Installing a piston and connecting rod assemblyAL9 using tool18G 55 A 61 DIESEL ENGINE 1 Connecting rod 2 Cap 3 Bearing 4 Bolts S Tab washer 6 Hollow dowel 7 Littleend bush Fig Aa23 When checking the gap clearance of a new piston ring enmre that the ring is inserted illto an unworn part of the cylinder bore 5 III Section Aa20 DISMANnING AND REASSEMBLING A CONNECTING ROD AND PISTON Remove the bearing halves from the connecting rod and cap If the bearing is to be re4lSed it should be marked to ensure reassembly in its original position Using tool 18G 1004 withdraw the two circlips from Fig Aa22 the piston and press the gudgeon pin out Mark the The arrows A indicate the bearing locating tags piston and gudgeon pin to ensure correct reassembly and grooves The arrows 8 indicate the cylinder Remove the rings from the piston and place them in number from which the connecting rod was the order in which they are removed to assist in removed reassembling them in their original grooves Thoroughly clean all the dismantled components and inspect them for damage Check the cylinder bore for scoring and for wear see GENERAL DATA If the diameter of the bore is the engine The cavity in the piston crown should now worn in any place by 010 in 254 mm or more a new be offset towards the righthand side of the engine Ensure that the connecting rod and cap the bearingand the crankpin are absolutely clean Fit the twohalves of the bearing to the connecting rod and cap NOTE On the VD series of the four and six cylinder engiles there are two Each half bearing has a tag which locates in a groove grooves one above and one below thein the connecting rod and cap Fig Aa22 If the old wrist pin for two scraper rings Forbearing is being used the two halves should be replaced the VD series engines both of thesein their original positions Lubricate the bearing and scraper rings are usedcrank pin with clean engine oil position the hollowdowels between the connecting rod and cap and fit the For the 98 series engines both groovescap into positiQTI with the stamped numbers on rod and are present but only the upper scrapercap adjacent to each other Fit new tab washers under ring may be installed If a lowerthe bigend bolts and tighten the bolts to the figure given ring is installed the piston will bein GENERAL DATA using torque wrench 18G 372 starved for the bolts in position with the tab washers Replace the remaining components reversing theremoval procedure and adjust the valve Section Aall 62 DIESEL ENGINE Reassemble the remaining components reversing the dismantling procedure noting that the cavity in the piston crown should be offset to the connecting rod on the opposite side to the bigend cap Section Aa21 REMOVING AND REPLACING A CYLINDER LINER Drain and remove the sump Remove the valve rocker shaft assembly Section Aa9 Drain the cooling system Remove the cylinder head Section Aa12 Fig Aa25 Withdraw the connecting rods and pistons Section Removing and replacing a connecting rod littleend Aa19 bush using tool18G 616 Using tool ISG 227 C withdraw the cylinder liner upwaros from the cylinder block Fig Aa26 Remove the cylinder liner sealing ring from its groove in the bottom of the cylinder block NOTE1be aeaIiag riDg should be raaewed OD aD liner and piston should be fitted Section Aa21 In the OCCllliODS of qUader liDer removaL event of a water leak at the bottom of the cylinder Inspect the cylinder liner seating in the top of the liner the cylinder liner sealing ring should be renewed cylinder block for signs of burrs carbon or rust Section Aa21 accumulation Thoroughly clean the seating being Check the piston to cylinder bore clearance see careful not to remove any metal otherwise a water leakGENERAL DATA is liable to occur If the old liner is to be refitted clean Insert each piston ring into the cylinder bore and the locating flange at the top of the liner exercising the measure the piston ring gap Fig Aa23 against the same care as for the liner seatingfigure in GENERAL DATA The ring should be Thoroughly clean the sealing ring groove in theplaced in an unworn part of the bore and the piston cylinder blockused to position the ring square to the cylinder bore axis Insert the cylinder liner into the cylinder block Check the clearance of each ring in its own groove without fitting the sealing ring and clamp the liner inFig Aa24 against the figure in GENERAL DATA the fuIlyhome positionThe top ring is tapersided and to check its the ring should be fitted to the piston andinserted into an unworn cylinder liner Push the pistoninto the liner until about threequarters of the pistonring width has entered the liner then check the ringgroove clearance If it is decided to fit new piston rings in a usedcylinder the glaze should be removed from the cylinderbore Check the fit of the gudgeon pin in the piston seeGENERAL DATA Measure the gudgeon pin to smallend bush clearancesee GENERAL DATA and if necessary renew thebush Fig Aa2S using tool 18G 616 Before pressingin a new bush line up the oil hole in the bush with thehole in the top of the connecting rod Check the connecting rod alignment against the figurein GENERAL DATA Fit the rings into their respective grooves in thepiston ensuring that Nos 2 and 3 compression ringswhich are taperfaced are installed with the side marked Fig Aa26TOP uppermost Withdrawing a cylinder liner using tool18G 227 C 63 DIESEL ENGINE the sealing ring is seating correctly It may be necessary to exchange the sealing ring to reduce the liner ovality to an acceptable limi Replace the remaining components reversing the removal procedure and adjust the valve rocker clearance Section Aall Section Aa22 REMOVING AND RPLACING THE TIMING GEAR CASE COVER Tke the wight of the engwe at the iont prefelibly with a sling but do not lift directly under the sump Fig Aa27 Release the engine front support bracket from its Insert shims at A to adiust the standing height of mountings the early cylinder liner Shown inset are the faces Unlock and unscrew the nut from the front of the of the cylinder block and the liner from which the crankshaft using spanner 18G 97 standing heirht is measured Withdraw the crankshaft pulley using tool 18G 231 and adaptor 18G 231 A and extract the pulley key from Check the standing height of the cylinder liner against the end of the crankshaft The crankshaft oil seal maythe dimension in GENERAL DATA The top face of be removed and replaced using tool 18G 1111the liner is stepped and the standing height should be Remove the engine front support bracket from themeasured between the lower face of the step and the timing gear casetop face of the cylinder block If necessary the stand Unscrew the remaining bolts securing the timing gearing height of early liners can be increased by fitting case cover to the timing gear case and detach theshims see GENERAL DATA for thickness under the engine front lifting bracket and the liner flange support bracket Remove the liner install a new sealing ring in the Remove the set bolts securing the front of the sumpgroove in the bottom of the cylinder block and apply to the timing case cover and slacken the remaining sumpa coating of Hylomar SQ32 jointing compound to the bolts two complete turnsreduced diameter at the lower end of the liner Install Pull the timing case cover complete with crankshaftthe liner using a semirotary motion to prevent the oil seal and distance piece off the two locating dowelssealing ring becoming twisted or dislodged Press the at the lower end of the timing gear case taking careliner fully home then check its bore for ovality in the not to damage the sump gasketarea adjacent to the sealing ring If the ovality exceeds Cover the open end of the sump to prevent the ingress00175 in 04 mm withdraw the liner and check that i j I j jtlxiII I Fig Aa28 Fig Aa29 Removing the starting handle jaw nut using tool Withdrawing the crankshaft pulley using tools 18G 97 18G 231 and 18G 231 A 64 DIESEL ENGINE Section Aa23 REMOVING AND REPLACING THE TIMING GEARS Before removing the timing gears check the gear backlash against the figure in GENERAL DATA Four230 Refit the crankshaft nut and rotate the crankshaft using spanner 18G 97 until Nos 1 and 4 pistons are at TDC with No4 piston commencing its induction stroke This will correctly position the timing marks on the crankshaft and camshaft gears for reassembly Six346 kllI Li1 rallkshai L oj L Cla lC tile cr ansnall using spanner 18G 97 until Nos 1 and 6 pistons are at TDC with Nol piston commencing its induction stroke This will corrctly position the timing marks on the crankshaft and camshaft gears for reassembiy Fig Aa30 Press back the jocking washers and umcrew the n1its Withdrawing the camshaft gear using tools from the camshaft and the injection pump dnve shaft 18G 23118G 231 C and 18G 231 D Remove the thrust washer and withdraw the idlr lear from its shaft NOTEAfter the idler gear bas beea remond of foreign matter the craaksbaft or camshaft should be rotated Clean the joint faces of both timing case and cover all the alft rocker adjasdDg serews are comand examine them for burrs Inspect the crankshaft pletely slackeaed oil to allow all the alvea to remainoil seal and renew it if necessary Ensure that the fully dOled If this conditioD is Dot obseed the distance piece is free from burrs and may foal the pistODS Dd cause serious where it contacts the crankshaft oil seal Remove the oil thrower from the end of the When replacing the components which is a reversal crankshaftof the foregoing procedure fit a new gear case cover Withdraw the oil pump driving gear and but do not use jointing compound The groove gear using tool 18G 231 and adaptor 18G 231 Bbetween the sealing lips of the crankshaft oil seal should Using tool 18G 231 and adaptor 18G 231 C withdrawbe filled with high melting point grease before assembly the gears from the camshaft and the injection pump o o o 1 Fig Aa3JTiming gears showing A the 0 marks on the o 10drive gears and hubs and I JB the timing nuuks on I Ithe idler and drive gears 0 65 DIESEL ENGINE ii liiillll Fig Aa32 RelllOlillg replacing and broaching to size the timing idler gear bush using tool 18G 683drive shaft Thrust pads 18G 2311 D and 18G 231 E from their hubs without removing the hubs from theirshould be used for the camshaft gear and injection shaftspump drive gear respectively Position the crankshaft so that the Thoroughly clean and inspect all the dismantled Four230 No 4 piston or the No 6 piston is just commencing its in Check the idler gear thrust washer thickness and the duction stroke as described in Sectionidler gear bush to shaft clearance against the figures Aa23given in GENERAL DATA If necessary renew thebush as described in Section Aa24 Remove the thrust washer and idler gear from its Refit the gears to the camshaft crankshaft and shaft and the camshaft gear and injection pump driveinjection pump drive shaft and ensure that the timing gear from their hubsmarks on the teeth of these gears are in the position If the idler gear bush is to be removed press the oldshown in Fig Aa31 Slide the idler gear onto its shaft bush out using tool 18G 683 with the larger bore ofand engage the teeth with those of the other gears so the tool support uppermost Reverse the tool supportthat the timing marks line up as shown in Fig Aa31 so that its lipped end is uppermost when pressing in anoting that the double mark on the idler gear is lined new bush This will ensure that the bush is correctlyup with the timing mark on the crankshaft gear positioned with its ends equidistant from the sides of Tighten the nuts on the camshaft and injection pump the gear With the tool support still in this latterdrive shaft and secure them with the locking washers position broach the bush after first lubricating the Check the valve timing as described in Section Aa26 broach liberally with clean paraffin Fit the idler gear thrust washer to the shaft with the Reassemble the camshaft gear and the injection pumpoil groove towards the gear drive gear to their hubs so that the timing mark on the Refit the crankshaft oil thrower with the chamfered inner face of each gear lines up with the timing markside towards the gear on its hub as in Fig Aa31 Replace the remaining components in the reverseorder to that in which they were removed Refit the idler gear to its shaft so that the timing Check the injection timing as described in Section marks on all four timing gears are in the relationshipDa shown in Fig Aa31 noting that the double mark on the idler gear is lined up with the timing mark on the crankshaft gearSection Aa24 Tighten and rewire the securing screws on the OISMANTLING AND REASSEMBLING injection pump drive gear but leave the securing screws THE TIMING GEARS on the camshaft gear fingertight Adjust the valve timing as described in Section Aa26 Two of the timing gearsthose fitted to the camshaft Refit the idler gear thrust washer with the oil grooveand the injection pump drive shaftcan be dismantled towards the gear 66 DIESEL ENGINE Section Aa26 VALVE TIMING Four 230 Engine When timing pin AMK 9990 engages the fly wheel No4 piston is at 25 0 BTDC and the degree plate must be set at 25 0 before zero With the timing marks on the gars correctly rlated as in Fig Aa3I and the valve rocker clearance adjusted as in Section AaII final adjustment of the valve timing see GENERAL DATA and Fig Aa33 is made by rotating the camshaft drive gear in relation to its hub the securing bolt holes in the camshaft gear being elongated for this purpose Rotate the crankshaft in the normal direction or rotation until the 50 ATDC mark is at the top of the flywheel in the vertical position with No 1 piston G commencing its firing stroke and No 4 piston Fig Aa33 commencing its induction stroke Valve riming diagram Four230 Slacken the six set bolts securing the camshaft gear Fuel injection timing 28 to its hub and rotate the camshaft in the normalA Inlet valve opens EB Exhaust valve close BTDC direction of rotation until the exhaust valve No8 ofC Exhaust valve opens F Top dead centre No4 cylinder is just closedD Inlet valve closes G Bottom dead centre A clock gauge mounted on the engine with its indicator contacting the valve spring collar will facilitate this operation Tighten the camsllaft gear securing bolts recheck the valve timing and rewire the gear securing bolts An alternative method of setting the crankshaft atSection Aa25 50 ATDC is to use a degree plate and pointer in REMOVING AND REPLACING conjunction WIth timing pin AMK 9990 as follows THE TIMING GEAR CASE 1 Rotate the crankshaft in the normal direction of rotation until the inlet valve No2 of No 1 Remove the timing gear case cover Section Aa22 cylinder is just closed No 1 piston will now Withdraw the idler gear and the camshaft gear as be commencing its compression stroke and No4 described in Section Aa23 piston will be on its exhaust stroke Unscrew the idler gear shaft which has a lefthand 2 Insert timing pin AMK 9990 through the reamed thread and the timing gear oil fee4 jet complete with hole in the lower half of the engine sandwichcopper seal washer plate and while maintaining pressure on the pin Remove the set screws securing the gear case to the rotate the crankshaft slowly until the pin engages crankcase and pull the gear case complete with the timing hole in the flywheel injection pump drive and the driving half of the 3 Mount the degree plate on the front end of theinjection pump coupling off the three Icating dowels crankshaft attach the pointer in a suitableon the crankcase position to the engine and set the degree plate If necessary remove and dismantle the injection at 28 0 25 0 on engines with a Simms Minimec pump drive as described in Sections Aa27 and Aa28 injection pump before zero 1 Remove the timing pin and rotate the crankshaft Thoroughly clean and inspect al the to bring the 50 after zero mark on the degree When replacing the components which is a reversal plate in line with the timing pointer The crankof the foregoing procedure fit a new gasket between shaft will now be at 50 ATOC with No 4 piston on its induction strokethe crankcase and timing gear case coating thecrankcase joint face with sealing compound Ensure that the injection pump drive coupling isassembled correctly The coupling dowel bolt mustengage the hole in the pump drive flange The idler gear shaft should only be to retain it in position 67 THE ENGINESix346 To facilitate retiming one tooth on each gear with The valve timing may be checked using a degree plate the exception of the idler gear is marked with an and pointer a dialgauge and timing pin AMK 9990 as 0 or drill dimple see Fig 28 The correspond follows ing teeth on the idler gear which mesh with the 1 Set No6 cylinder inlet valve clearance to 021 in marked tooth on the camshaft drive gear and the 53 mm then crank the engine until No6 piston fuel injection pumpexhauster drive gear are is on its firing stroke identified with similar marks while the correspond 2 Insert timing pin AMK 9990 through the reamed ing teeth which mesh with the marked tooth on the hole in the lower half of the engine sandwich plate crankshaft gear are marked with OC or twin Maintain pressure on the head of the pin and drill dimples Also the faces of the fuel injection crank the engine until the pin engages the timing pump drive hub the camshaft flan8C or drive hub and their drive gears are stamped with F 0 marks to ensure correct timing relationship between these components Assemble the drive gear to the fuel injection pump drive hub lining up the 0 mark on the face of the hub with the 0 mark on the face of the gear In a similar manner assemble the drive gear to the camshaft lining up the 0 marks on the faces of the gear and the camshaft flange or drive hub but do not lock the securing bolts at this stage as final adjustment of the valve timing has still to be carried out If necessary after first ensuring that the valve rocker adjusting screws are fully released rotatethe crankshaft to position No 6 piston at TDCon its induction stroke The tooth with the timingmark on the crankshaft gear will now be between 11 and 12 oclock see Fig 31 G Rotate the camshaft to position the gear toothwith the timing mark between eight and nineoclock and then tum the fuel injection pump Vahc timing diagramEngille fyl Six 34 6 drive gear so that its tooth with the tim A Inlet valve opens E Fuel injCtion timing fullying mark is between three and four oclock see n Exhaust valve closes retarded 14 BTDCFig 31 c Exhaust valve opens Top dead centre 1 nlet valve closes G Bottom dead centre Fit the idler gear to its shaft with the marked teethon the drive gears engaging the corresponding hole in the flywheel No 6 piston is nowteeth on the idler gear as shown in Fig 31 14 0 BTDC on its exhaust strokeFit the idler gear thrust washer with the oil groovein the washer next to the gear 3 Mount the degree plate on the front end of the crankshaft and attach the pointer in a suitable position on the timing case Set the degree plate at 140 before zero then remove timing pin AMK 9990 4 Mount the dial gauge on the cylinder head with its indicator resting on the collar of No 68 DIESEL ENGINE cover plate and when the countersunk screws are fully tightened lock them in position by peening Fit the drive gear key to the front of the shaft and insert the shaft into the housing from the rear end until the flange on the shaft is against the bearing Pass the small ball bearing over the shaft and press the bearing into the housing until it contacts the shoulder in the housing Fit the oil seal into the end cover so that its sealing lip fJcs towards the bearings SmeJr the joint face of the end cover with sealing compound and relit the end cover to the drive housing being caeful not to damage the oil seal Refit the coupling key and driving flange Inject a liberal quantity of clean engine oil through Fig Aa34 the hole in the top of the drive housing to provide initial Checking the camshaft endfloat lubrication un til the oil in the engine is circulating Section Aa27 REMOVING AND REPLACING TIlE INJECTION PUMP DRIVE Section Aa29 Remove the injection pump Section Da Remove the blanking plate from the timing gear case REMOVING AND REPLACING cover and unlock and unscrew the nut from the THE CAMSHAFT injection pump drive shaft Remove the six set bolts securing the injection pump drive to the timing gear case and withdraw the injection pump drive using tool 18G loo8B to Remove the timing gear case cover Section Aa22 separate the drive shaft from its drive gear Withdraw the camshaft drive gear Section Aa23 When replacing the drive housing ensure that the joint faces of the timing gear case and the drive housing Remove the rocker cover and slacken fully the valve are clean Smear the joint face on the rear of the rocker adjusting screws Withdraw the pushrods timing gear case with jointing compound and fit a new Remove the fuel lift pump drive housing gasket Disconnect the external oil pipe from the main oil Replace the remaining components by reversing the gallery and cylinder head removal procedure Remove the tappet and pushrod cover and the oil Bleed the fuel system as described in Section Da level indicator guide from the side of the cylinder blockSection Aa28 Lift out the tappets Remove the camshaft thrust plate and withdraw the DISMANTLING AND REASSEMBLING camshaft being careful to avoid damage to the bearing THE INJECTION PUMP DRIVE surfaces as the camshaft is withdrawn Slacken the clamp bolt nut on the coupling driving Thoroughly clean and inspect all the and withdraw the flange from the drive shaft parts Extract the coupling key from the drive shaft and Check the camshaft bearing clearance against theremove the end cover complete with oil seal from the dimensions in GENERAL DATAdrive housing Fit the thrust plate and the drive gear to the Remove the cover plate from the front of the drive camshaft tighten the camshaft nut and check thehousing and press the shaft out of the housing in a camshaft endBoat as shown in Fig Aa34 against theforward direction The large bearing will be ejectedfrom the housing as the drive shaft is pressed out dimension given in GENERAL DATA Extract the drive gear key from the drive shaft If necessary remove the locating bolt and withdraw Press the small ball bearing out of the rear of the the camshaft front bearing from the cylinder blockhousing and remove the oil seal from the end cover Press a new bearing into position plain edge first Clean and inspect all the dismantled components aligning the rwo holes in the bearing with the two holes Commence reassembly by pressing the large ball in the bearing housing When the bearing is in into the front of the housing Refit the front the holes can be tapped into final alignment using a 69 DIESEL ENGINE soft drift against the aligning notch in the bearing Fit Section Aa31 the locating bolt and lineream the bearing to the REMOVING AND REPLACING dimension given in GENERAL DATA THE ENGINE SANDWICH PLATE Replace the remaining components lubricating all the bearing surfaces with clean engine oil by reversing Remove the Transmission Section and the removal procedure the flywheel Section Aa30 Remove the starter motor Adjust the valve rocker clearance as described in Unscrew the set bolts securing the sandwich plate to Section Aa11 and bleed the fuel system of air I the cylinder block and pull the sandwich plate off the three dowels which locate it on the cylinder block Remove the sandwich plate joint washer Replacement is a reversal of the foregoing procedure Section Aa30 using a new joint washer between the sandwich plate and the cylinder block REMOVING AND REPLACING THE FLYWHEEL AND STARTER RING Remove the Transmission Section Aa32 Unlock and remove all but two of the bolts securing REMOVING AND REPLACING the flywheel to the crankshaft flange Unscrew the two THE CRANKSHAFT AND MAIN BEARINGS remaining bolts sufficiently to allow the flywheel to bedrawn off the crankshaft flange Withdraw the flywheel by screwing two tin UNFbolts into the withdrawal holes in the flywheel andremove the two remaining flywheel bolts Remove the sump Remove the oil pump Examine the flywheel face and the starter ring teeth Section Aa6 and the timing gear case cover Sectionfor wear against the figures given in GENERAL Aa22DATA Remove the oil thrower from the front end of the If necessary remove the starter ring by drilling a hole crankshaft and withdraw the oil pump driving gear andin the ring and splitting it across the hole with a hammer the crankshaft gear using tool 18G 231 and adaptorsand chisel 18G 231 B Withdraw the two halves of the crankshaft Ensure that the bore of the new starter ring and its thrust washer from the front main bearingmating surface on the flywheel are perfectly clean and Remove the flywheel Section AL30 and the enginefree from burrs Heat the starter ring uniformly to the sandwich plate Section given in GENERAL DATA The stripof paint on the starter ring willchange from greyblue to buff colour when thetemperature is correct Place the heated starter ring bore chamfer foremost squarely on the flywheel The expansion should allowthe ring to be readily fitted by placing a piece ofhardwood across the ring and pressing or tapping ituntil the starter ring is hard against its register Whenthe ring is cold the shrink fit will be and no further treatment is necessary When replacing the flywheel check that the locatingdowels are not a loose fit in their holes and that theyare free from burrs The dowels are diagonally offsetto ensure correct positioning of the flywheel Tighten the flywheel bolts in diagonal sequence tothe torque figure given in GENERAL DATA Check the flywheel alignment with a clock gaugeagainst the figure given in GENERAL DATA Fig Aa35 Lock the flywheel bolts and replace the rem a Checking the crankshaft rear oil seal cover to oilcomponents by reversing the removal procedure return thread clearance 70Aa DIESEL ENGINE Fig Aa36 The arrow indicates the gauge paper used whell Fig Aa37 checking the diametrical clearance of a crankshaft Checking the crankshaft endfinat main bearing Remove the connecting rod bearing caps and shells Before attaching the connecting rods to the crankkeeping the shel1s with their respective caps for correct shaft align the marks on the timing gears as and separate the connecting rods from the in Section Aa23crankshaft Replace the remaining components by reversing the Unscrew the two bolts holding the two halves of the removal procedure refill the sump with new engine oilcrankshaft rear oil seal cover together Remove the and bked the fuel system of air as described in Sectionbolts securing the bottom half of the cover to the Dacrankcase and remove the bottom half cover takingcare not to damage the gasket If the gasket is damaged Section Aa33in any way the top half of the cover should be removed MODIFIED INLET VALVE LOCATINGand a new gasket fitted DETAILS Remove the main bearing caps complete with the A new type inlet valve locating key and thimble andbottom halves of the main bearings The crankcase a modified valve guide locating dowel have beenand caps are marked for correct assembly and the introduced on later engines These parts whichbearings and caps should always be replaced in their facilitate the assembly of the valves to their guides areoriginal positions in sets with their equivalent parts referred to in Section Aal3 Lift the crankshaft out of the crankcase and removethe remaining halves of the bearings and the thrustwashers Thoroughly clean and inspect all the and examine all bearing surfaces for wearor scoring Check the crankshaft endfioat and main bearing clearance against the figures given in GENERAL fDATA New bearings are prefinished to size and do notrequire any scraping or fitting r1 When replacing the crankshaft lubricate all the bearings with clean engine oil and ensure that the hollow locating dowels are in position over the mainbearing studs before fitting the bearing caps 1 Refit the crankshaft rear oil seal cover and checkthat the clearance between the cover and the oil return t lthread on the crankshaft is in accordance with the figurein GENERAL DATA The ftat surface of the bottom Fig Aa38half of the oil seal cover should be perfectly level with Modified inlet valve locating detailsthe crankcase surface to which the sump is mounted I Thimble 2 Key 3 Dowel 71 TRANSMISSION HYDRAULIC TRANSMISSIONS 74 INTRODUCTION 75 INSTALLA TION 75 OPERATION 76 MAINTENANCE 77 TROUBLE SHOOTING CHART 78 REDUCTION GEARS 85WARNER HYDRAULIC TRANSMISSIONS 91 73I SPECIFICATIONS A Description Chart MODEL P200 P300 P400 REDUCTION RATIO DIRECTION OF ROTA TION P21R P31R P41R DIRECT RIGHT P21L P31L P41L DIRECT LEFT P22R P32R P42R 1 51 RIGHT P22L P32L P42L 1 51 LEFT P23R P33R P43R 20 1 RIGHT P23L P33L P43L 201 LEFT P24R P34R P44R 251 RIGHT P24L P34L P44L 251 LEFT P25R P35R P45R 301 RIGHT P25L P35L P45L 301 LEFT B Model and Serial Numbers Each reverse gear has a model number and a serial number These numbers are on the name plate located on the housing of the transmission MODEL AND SERIAL NUMBER CHART DIRECT DRIVE MODEL AND SERIAL NUMBERS P2 Gear Size 1 Direct Drive R Right Hand Rotation Unit 5J 1234 Transmi asion Seriol No L L ft H and Rotation Uni t REDUCTION GEAR MODEL AND SERIAL NUMBERS L 5J5678 P 2 Gor Size I Rdu ction Gear 15 1 j 20 1 cion R Right Hand Rotation Unit L Left Hand Rotaion Unit 5J5678 Trons Sitn Si Ztt 25 1 Roio No 30 174 TRANSMISSIONII INTRODUCTION ward drive is through a multiple disc clutch arrangement while the reverse drive utilizes The Models P200 P300 and P400 hydraulic a reverse clamp band and planetary gear transmissions have been designed for smooth train The transmission oil is circulated and operation and dependability in marine use The cooled through a separate external oil cooler transmission is se1 contained having an oil core which is in turn cooled by the engine pressure system and oil supply completely water Paragon transmissions are furnished separated from engine lubricating oil systems with either direct drive or reduction gears Gear reduction ratios and corresponding Transqlission oil under pressure is used to model identification numbers are listed in engage a forward or reverse drive The for Section I under INSTALLATION 4 Install and tighten four bolts with lock washers through the transmiSSion A The installation instructions below are for housing flange into the engine adapter use when the original transmi ssion has been plate Remove the 312 studs Install removed for servicing and must be re and tighten the two remaining bolts installed or when the transmission unit with lockwashers through the trans is to be adapted as nonoriginal eqUip mission housing flange ment to a marine engine D The transmission and propeller shaft cou B It is important that the engine and trans pling must be carefully aligned before the mission rotations are matched The direc propeller shaft is connected to the trans tion of rotation of an engine is defined in mission in order to avoid vibration and this manual as the direction of rotation consequent damage to the transmission of the engine crankshaft as viewed from the engine and boat hull during operation output end of the transmission A clock To align the coupling move the propeller wise rotation of the engine is a right hand shaft with attached coupling flange toward rotation and a rotation of the transmission so that the faces of the the engine is a left hand rotation propeller shaft coupling flange and trans miSSion shaft coupling flange are in con A letter R or L appearing on the tact The coupling flange faces should be transmission serial number plate illus in contact throughout their entire circum trated in Section It SPECIFICATIONS ference The total runout or gap between indicates whether the transmission is for the faces should not exceed 002 at any use with a right or left hand rotating point If the runout exceeds 002 reposi engine tion the engine and attached transmission by loosening the engine support bolts and C The hydraulic transmission is attached to adding or removing shims to raise or lower the engine in the following manner either end of the engine If necessary move the engine sideways to adjust the 1 Insert two 312 studs in opposite runout or to align the coupling flange transmission mounting holes in the faces laterally Tighten the engine support engine adapter plate bolts and recheck the alignment of the coupling before bolting the coupling flanges 2 Place the transmission against the studs together Connect the coupling flanges with so that the studs go through two of the bolts lockwashers and nuts matching holes in the transmission E Connect the oil cooler lines to the trans housing flange mission 3 Slide the transmission along the studs F Connect the shift control cable from the toward the engine so that the spline on cockpit control station to the transmission the shaft at the front of the transmission control valve lever shown in Figure on enters the matching splined hole in the page 5 Place the transmiSSion control engine vibration dampener valve lever in the neutral position and 75 adjust the shaft control cable length until or reverse position and should return the cockpit control station hand lever is exactly to the neutral position when the in the neutral position Move the cockpit hand lever is in the neutral position control hand lever to forward and reverse positions several times while observing the G Remove the oil dipstick shown in Figure transmission control valve lever motion on page 5 and fill the transmission with The transmission control valve lever should Type A transmission fluid to the mark on move fully into forward or reverse position the dipstick Replace the dipstick in the when the hand lever is moved into forward transmission housingIV OPERATION Starting Procedure 1 Always start the engine with the trans Principle of Operation mission in NEUTRAL to avoid moving the boat suddenly forward or back The transmission forward and reved drives 2 When the engine is first started allow it are operated by transmission oil undar pres to idle for a few moments Stop the engine sure An internal gear type oil pump C1elivers and check the transmission oil level Add the transmission oil under pressure to the oil if necessary to bring the oil level up external oil cooler The transmission oil is to the mark on the transmission dipstick returned still under pressure to the oil distribution tube and relief valve The relief valve maintains the oil pressure by remaining NOTE closed until the oil pressure reaches 60 PSI ON SUBSEQUENT START UPS THE When the control lever is shifted to the TRANSMISSION OIL LEVEL MAY BE forward pOSition oil under pressure is de CHECKED BEFORE RUNNING THE livered to the multiple disc clutch piston ENGINE WHEN ENGINE OIL IS which moves to clamp the clutch discs and CHECKED planetary reverse gear case together The 3 Start the engine again with the transmission discs and case then revolve as a solid cou in NEUTRAL and allow the enginetowarm pling in the direction of engine rotation The up to operating temperature reverse drive is engaged by shifting the control lever to the reverse poSition so that 4 Shift the transmission into FORWARD or oil under pressure is delivered to the reverse REVERSE as desired If the engine should piston The reverse piston moves to clamp stall when the transmission is shifted to the reverse band around the planetary gear FORWARD or REVERSE place the trans case preventing the planetary gear case mission in NEUTRAL before restarting the from moving but allowing the planetary gears engine to revolve to drive the 9utput or propeller It is recommended that shifting be done at shaft in a direction opposite to the rotation speeds below 1000 RPM and preferably in of the engine With the control levr in the the 800 RPM or idle engine range to pro neutral poSition pressurized oil is prevented long the life of the engine transmission from entering the clutch piston or reverse and boat EMERG ENCY shifts may be at band piston and the propeller shaft remains higher engine speeds but this is not a stationary recommended practice76 TRANSMISSIONv MAINTENANCE are full If necessary refill to the mark on the dipstick to ensure proper operation A Lubrication of the transmission The transmission oil level should be checked each time the engine The Models P200 P300 and P400 trans oil level is checked before running the missions are selfcontained units indepen engine dent of the engine lubricating systems The units are lubricated by pressure and by The oil in the transmission should be splash from its own oil The type of oil changed every 100 hours or each season recommended is Transmission Fluid under normal conditions However the Type A commonly used for automatic number of hours that can be run between transmissions in automobiles oil changes varies with the operating condi tions Drain plugs are located at the The quantity of oil depends upon the angle bottom of the reverse gear housing and the of installation as well as the reduction reduction gear housing model The level must be maintained at the mark on the dipstick and should be checked periodically to ensure satisfac B Adjustments tory operation No adjustment is necessary for the FOR When filling for the first time or refilling WARD drive multiple disc clutchesandthe after an oil change check the level after reverse band is self adjusting to compen running for a few minutes to mnke certain sate for lining wear so that no external that the oil cooler and the various passages reverse band adjustment is necessary OIL TO COOLER COUPLING FLANGE PARAGON TRANSMISSION 77C Trouble Shooting Chart PROBLEM POSSIBLE CAUSES AND METHODS OF CORRECTIONGEAR INOPERATIVE Drive Shaft does not operate with selector valve in forward 1 Low Oil Pressure a Low oil supply Add oil refer to or reverse lubrication b Faulty oil gauge Replace Sauge Oil gauge slow to register air or obstruction in oil gauge line Clean and bleed oil gauge liLe c Plugged oil lines or passages Clean lines or passages d Oil pressure relief valve scored and sticking Remove relief valve Clean valve and valve bore in control val ve housing with crocus cloth to free valve or replace e Defective pistons and oil distributor seal rings Replace seal rings f Defective oil pump Check for wear and replace if necessary 2 High Oil Temperature a Low oil supply Add oil refer to lubrication b Low water level in cooling system Add ater and check for leaks c Plugged raw water inlet screen Clean screen d Collapsed or disintegrated water inlet hose Replace hose e Air leak in cooling water suction line Replace suction line f Raw water pump impeller worn or damaged Replace impeller g Clogged or dirty oil cooler element Remove and clean 3 Reverse Band not engaging Planetary a Reverse bo1d lining worn out Gear Cage Replace lining b Defective reverse piston 0 ring Replace 0 ring 4 Failure of Planetary Remove gear case assembly and check Assembly for defective or damaged parts Replace defective or damaged parts 5 Failure of Reduction Remove reduction gear assembly and Gear check for defective or dunaged parts Replace defective or damaged parts78 TRANSMISSION PROBLEM POSSIBLE CAUSES AND lfiETHODS OF CORRECTIONGEAR DRAGGING Drive Shaft rotates either forward or reverse with Forward clutch plates warped and Selector Valve in neutral 1 Defective forward sticking Remove clutch plates and position Clutch Plates replace 2 Defective forward Forward clutch piston release spring Clutch Piston Release broken or weak Replace spring Spring 3 Binding in Planetary a Bearings and gears worn excessively Assembly in gear case Replace necessary parts b Input shaft bearings worn excessively causing misalignment of input shaft Replace necessary partsGEAR SLIPPING OR SLOW TOENGAGE With Selector Valve in forward or reverse position 1 Low Oil Pressure See Gear Inoperative 1 2 Worn forward Clutch Remove forward clutch plates and check Plates for wear excessively replace clutch plates 3 Reverse Band not See Gear Inoperative 3 engaging Gear CaseINTERNAL AND EXTERNALLEAKS 1 Water in Lubricating a Hole in oil cooler element permitting Oil water to seep into oil compartment Replace oil cooler element b Oil cooler gaskets Check gaskets and replace 2 Excessive Oil in Engine Crankcase or Defective front end plate oil seal Flywheel Housing Replace on seal 3 Oil on Exterior of Marine Gear a Oil seeping from breather Check for too high oil level b Defective rear end oil seal Replace oil seal 4 Loss of on from Transmission a Check for defective gaskets and seal 79VI PARTS Each part illustrated in the exploded views ALWAYS GIVE THE PART NUMBER PART has a key number and an arrow pointing from NAME TRANSMISSION MODEL NUlBER the key number to the part Refer to the key AND TRANSMISSION SERIAL NUl1BER VHEN number in the parts list to determine the part ORDERING PARTS number and name80 PARTS LIST KeyNo Description No Description 1 Gear Case Needle Bearing 67 Hod Down Spring 2 Gear Case 68 Socket Head Pipe Plug 3 Long Pinion 69 Pipe Plug 4 Pinion Thrust Pad 70 Control Lever Pin 5 Roller Bearing 71 Capscrew 6 Long Pinion Bearing Spacer 72 Lockwasher 7 Pinion Shaft 73 Plain Washer 8 Engine Gear Roller Bearing 74 Control Lever 9 Engine Gear 75 Control Lever Bushing 10 Short Pinion 76 Control Lever Pawl 11 Roller Bearing 77 Control Valve 0 Ring 12 Short Pinion Bearing Spacer 78 Control Valve 13 Short Pinion Spacer 79 Control Valve Retaining Ring 14 Pinion Shaft Locking Tab 80 Cover 15 Case Clip 81 Reverse Piston 0 Ring 16 Capscrew 82 Reverse Piston and Shaft Assembly 17 Engine Gear Thrust Washer 83 Piston Back Up Plate 18 Direct Drive Tailshaft 84 Reverse Piston Shaft Pin 19 Propeller Gear 85 Retaining Ring 20 Propeller Gear Thrust Washer 86 Reverse Band Roll Pin 21 Steel Clutch Plate 87 Reverse Band Lever 22 Bronze Clutch Plate 88 Reverse Band Roll 23 Screw Collar Spring 89 Piston BackUp Plate 0 Ring 24 Screw Collar Needle Bearing 90 ReliM Valve Plug 25 Screw Collar 91 Relief Valve Spring 26 Forward Piston 0 Ring Outer 92 Relief Valve Retaining Ring 27 Forward Piston 0 Ring Inner 93 Relief Valve 0 Ring 28 Forward Piston 94 Relief Valve Pin 29 Clip Screw Collar 95 Relief Valve Housing 30 Lockscrew 96 Front Plate Oil Seal 31 Oil Distributor Seal Rings 97 Front Plate 32 Tailshaft Thrust Washer 98 Front Plate Thrust Washer 33 Tailshaft Seal Washer 99 Roller Bearing 34 Woodruff Key 100 Pump Pert Plate 35 Spring Retainer 101 Pump Housing Pin 36 Retaining Ring 102 Inner Pump Gear 37 Cover Gasket 103 Outer Pump Gear 38 Distributor Tube 104 Pump Housing 39 Tailshaft Needle Thrust Race 105 Lockwasher 40 Tailshaft Needle Thrust Bearing 106 Capscrew 41 Retaining Ring 107 Dipstick 42 Ball Bearing 108 Flat Head Socket Capscrew 43 Reduction Pinion Tailshaft 109 Breather 44 Reduction Adapter Plate 110 Pump Key 45 Adapter Plate Seal 111 Reverse Band 46 Capscrew 112 Pipe Plug 47 Gasket 113 Brass Washer 48 Crescent 114 Brake Band Support Screw 49 Plain Steel Washer 115 External Socket Head Cap Screw 50 Lockwasher 116 Detent Seal Washer 51 Capscrew 117 Detent Ball 52 Locknut 118 Capscrew 53 Lockwasher 119 Detent Spring 54 Capscrew 120 Lockwasher 55 Lockwasher 121 Capscrew 56 Ball Bearing 122 Reduction Gear Housing 57 Direct Drive Plate 123 Pipe Plug 58 Oil Seal 124 Oil Seal 59 Gear Half Coupling 125 Gear Half Coupling 60 Rear Gasket 126 Lockwasher 61 Housing 127 Loelmut 62 Dipstick Tube 128 Internal Gear 63 Front Gasket 129 Bearing Assembly 64 Reverse Band Housing Pin 130 Retaining Ring 65 Baffle 131 0 Ring 66 Flat Head Socket Capscrew 132 Suction Tube 133 Washer BJ GEAR CA SE ASSEMBLY REVEJ r 24 31 1 J FRONT END PLATE AND PUM P ASSEMBLY 116 117 100 101 102 103 119 E 118 104 105 106 82 TRANSMISSION SE GEAR HOUSING ASSEMBLY COVER ASSEMBLY 71 72 73 74 RELIEF VALVE 75 76 ASSEMBLY S 2 I I I 70 77 B i 78 91 79 92 jl 93 94 80 95 SI 1 109 81tr Q 82 40 41 42 ROUCTION DAlvE 44 5 6 83 89 I I yl 86 87 88 87 MPLETE ASSEM BL Y REDUCTION GEAR ASSEMBLYe 128 I I J 0 113 4 127 83 REDUCTION Disassembly of Reduction UnitThe Westerbeke Paragon reductiongears consist of an internal ring gear This manual is intended to serve as aand a drive gear that offers a variety guide in servicing the reduction gearsof reduction ratios The reduction since these units are similar in mostunits are used integrally with either details except for sizemanual or hydraulic reverse gears As in any servicing operation cleanModel and Serial Numbers liness is a must and all rules for good and Part Numbers workmanship apply Some of these rulesThe model and serial numbers are on are as followsa plate affixed to the cover of thetransmis sion 1 Use only clean fluid in any cleanThe parts list accompanying the dia ing or washing of partsgrams are intended only to identify theparts in regards to disassembly and 2 Use only clean oil for when pressing parts togetherTo order parts refer to Parts ListManual giving complete description 3 Neverpress a ball bearing so thatand part number with Model and Serial the force is carried through thenumbers of the transmission 4 Never use a hammer to drive ballThe reduction gears are lubricated bearings in jllacewith the same oil as used in the reversegears Refer to General Data 5 Use only properly sized in removing or securing nuts and capscrewsThere are no adjustments necessaryto maintain the reduction gears inproper rUJIling condition 6 Replace gaskets with DeW ma terial ALWAYS GIVE MODEL NUMBER AND SERIAL NUMBER OF TRANSMISSION WHEN ORDERING PARTS 85 7 Work on a clean bench and protect 6 Remove retaining ring 4 from groove gear teeth and oil seal surfaces next to ball bearing 3 inside reduction from nicks and scratches gear housing and press ball bearing 3 from housing Before removing the reduction unit from the reverse gear drain all of the lu 7 If necessary to replace remove oil bricating oil from the transmission and seal 5 the reduction unit 8 Remove Woodruffkey 13 from flanged shaft and remove seal washer 12 and DISASSEMBLY NEED BE CARRIED spacer 11 OUT ONLY AS FAR AS NECESSARY TO CORRECT THOSE DIFFICULTIES 9 Press ball bearing 10 from flanged WHICH INTERFERE WITH PROPER shaft using two holes in flange MARINE GEAR OPERATION 10 Remove caps crews 9 and lockwashers 8 from rim of flanged shaft and re DISASSEMBLY OF REDUCTION UNIT move ring gear 7 from flanged shaft 61 Remove oil drain plug 1 from bottom of reduction gear housing 2 and drain INSPECTION oil from unit Make certain that all lubricating oil is removed from reverse All parts should be thoroughly cleaned gear unit before inspection Parts showing ex cessive wear should be replaced2 Remove capscrews 18 and lockwash ers 17 from flange of reduction gear 1 Ball bearings should be examined for housing and slide entire reduction unit indications of corrosion and pitting on straight back approximately 3 inches balls and races until reduction unit clears reduction drive pinion 2 All gear teeth should be examined for pitch line pitting uneven wear pat I3 Bend tang of from tern or excessive wear locknut 16 Remove locknut using 3 Examine oil seal for rough or charred suitable wrench and lift lockwasher from shaft lips4 Remove gear half coupling 14 with 4 Hetaining rings should be checked for gear type puller or by supporting en burrs or deformities tire assembly under flange of gear half coupling and press against shaft to force 5 All gaskets should be replaced coupling from assembly ASSEMBLY OF REDUCTION UNITS Support reduction gear housing so that flanged shaft assembly can drop free 1 Replace oil drain plugl Into reduction approximately 2 inches and press gear housing 2 flanged shaft assembly from reduction gear housing 2 Press ball bearing 3 into reduction 86 TRANSMISSION gear housing 2 and install retaining 10 Support unit on inside of flanged shaft ring 4 into groove next to ball bearing with large end of unit down and press gear half coupling 14 onto shaft end3 If removed for replacement press new and into ball bearing 3 until coupling oil seal 5 into reduction gear housing is seated against ball bearing Care must be taken to line up keyway in coup4 Place flanged shaft 6 over ring gear ling and key in shaft before pressing to 7 and line up holes in flange with those gether in ring gear 11 Place lockwasher 15 over end of5 Place lockwasher 8 over caps crew flanged shaft with tang on inside of lock 9 and insert capscrew into hole in washer in slot on flanged shaft Place flanged shaft and secure flanged shaft locknut 16 onto shaft and secure using to ring gear suitable wrench6 Press ball bearing 10 onto flanged 12 Bend one tang of lockwasher into slot shaft Place spacer 11 over shaft on locknut next to ball bearing and place seal washer 12 over shaft next to spacer 13 Install two studs 3 12 inches long into two OPPOSite holes in reduction adapter7 Install Woodruff key 13 into keyway in plate flanged shaft8 Place reduction gear housing over small 14 Position reduction gear assembly over end offlanged shaft and start ball bear studs with oil drain plug at bottom of ing 10 on flanged shaft into bore in housing and Slide onto reduction drive housing by tapping housing with a soft gear It may be necessary to rotate reduction gear slightly to properly mesh mallet gear teeth9 Turn unit over with small end of housing down and press on center of flanged shaft 15 17 and capscrews until spacer 11 is seated against ball 18 around flange of reduction gear bearing 3 in reduction housing housing and tighten uniformly 87 REDUCTION ASSEMBLY DRAWING 8 4 3 5 I I NOTE SEE APPROPRIATE SERVICE MANUAL FOR OTHER REVERSE GEAR PARTS II 14 10 12 13 1688 TRANSMISSION PARTS LIST AND EXPLODED VIEW 7 6 8 9 10 II 12 i 4 3 i IIto 13 J I 14 I rfJ I 16 Fig 2KEY KEYNO DESCRIPTION NO DESCRIPTION1 Drain Plug 10 Ball Bearing2 Reduction Gear Housing 11 Spacer3 Ball Bearing 12 Seal Washer4 Ball Bearing Retaining Ring 13 Woodruff Key5 Oil Seal 14 Gear Half Coupling6 Flanged Shaft 15 Lockwasher7 Ring Gear 16 Locknut8 Lockwasher 17 Lockwasher9 Caps crew 18 Capscrew 89 TRANSMISSION WARNER HYDRAULIC be shifted to the point where it coversThe Westerbeke Six346 and Four230 the letter F on the case casting andEngines are also furnished with Warner is located in its proper position by thehydraulic direct drive and reduction poppet ball The Warranty is cancelledgear assemblies if the shift lever poppet spring and or ball is permanently removed or if theThe direct drive transmission consists control lever is changed in any mannerof a planetary gear set a forward or repositioned or if linkage betweenclutch a reverse clutch an oil pump remote control and transmission shiftand a pressure regulator and rotary lever does not have sufficient travel incontrol valve All of these are con both directions This does not apply totained in a cast iron housing along with transmissions equipped with shafts and connectors to Gear electrical shift controlprovide forward reverse and A direct drive ratio is used LUBRICATIONfor all forward operation In reversethe speed of the output shaft is equal to The properties of the oil used in theinput shaft speed but in the opposite transmission are extremely Helical gearing is used to to the proper function of the quieter operation than can be system Therefore it is extremely important that the recommended oilobtained with spur gearing automatic transmission fluid ATFOil pressure is provided by the cres Type A be usedcent type pump the drive gear ofwhich is keyed to the drive shaft and PROCEDURE FOR at transmission input speed TRANSMISSION WITH OILto provide screened oil to the pressure When filling the transmission oilregulator should be added until it reaches theFrom the regulator valve the oil is full mark on the dipstick The quandirected through the proper circuits tity of oil depends upon the angle ofto the bushings and antifriction bear the installation The unit should beings requiring lubrication A flow of turned over at engine idle speed for alubricant is present at the required short time in order to fill all circuitsparts whenever the front pump is turn including the cooler and cooler pipinging and it should be noted that supplyis positive in forward neutral and PROCEDURE FOR CHECKING OILreverse conditions LEVELThe unit has seals to prevent escape The oil level should be checked imof oil mediately after shutting off engine and sufficient oil added to again bring theBoth the input and output shafts arecoaxial with the input shaft splined transmission oil level to the full mark on the dipstick assembly The dipstickfor the installation of a drive damper assembly need not be threaded into theand the output shaft provided with a case to determine the oil level Itflange for connecting to the propeller need only be inserted into the caseshaft until the cap or plug rests on the sur face surrounding the oil filler holeCONTROL LEVER POSITION The transmission should be checkedThe position of the control lever on periodically to assure proper oil when in forward should and oil should be added if necessary 91CHANGING OILIt is recommended that the transmission oil be changed once each seasonAfter draining oil from the unit theremovable oil screen should bethoroughly cleaned before refillingthe transmission with the recommended oil ATF Type AREDUCTION GEAR BOXThe reduction gear box operates inconjunction with the direct drive unitThe reduction gear box consists of aplanetary gear set which reduces theinput revolutions to a fixed ratioIt is recommended that all installations using a reduction gear have asuitable locking device or brake toprevent rotation of the propeller shaftwhen the boat is not under direct propulsion If the marine gear is not inoperation and the forward motion ofthe boat causes the propeller shaft torotate lubricating oil will not be circulated through the gear because theoil pump is not in operation Overheating and damage to the marine gearmay result unless rotation of the propeller shaft is in an emergency shift fromforward to reverse drive throughneutral at engine speeds below1000 rpm to prevent damage to theengine or marine gear 9293 TABLE OF 1GENERATOR SECTIO General 4 Component Location 4 Visual Inspection 6 Question and Answer Guide 7 A No Output Voltage 7 B Unstable Output Voltage 8 C High or Low Output Voltage 8 D Field Circuit Breaker Trips 9 E Unbalanced Generator Terminal Voltages 9 Flow Chart Guides 10 No Voltage Buildup 10 Voltage Builds Up But Circuit Breaker Trips 11 Output Voltage Too High lr Too Low 12 Voltage 150 or More Than Rattd 13 Unstable Output Voltage 14 Cycling Buildup 15 Unbalanced Terminal Voltages 16 Procedures B Flashing the Field i C No AC Power to Exciter 18 D Testing Ll Reactor 18 E Testing Diodes 18 F Testing SCRs 19 G Testing Transistors 20 H Testing Generator Rotor 21 J Testing Generator Stator 22 K Testing Brushless Exciter Rotor 22 L Testing Brushless Exciter Stator 23 M Reconnection 23 N Voltage Reference Circuit 24 P Generator Disassembly 25 Q Voltage Adjustment 2594 LIST OF 1 Static Exciter Design 2 RntClting Brush less Exciter Design 3 Top View of Chassis Assembly 4 Voltage Regulator Printed Circuit Board Location J 7 Flashing the Field 17 8 Testing Diodes 18 911 Testing SCRs 19 1217 Testing Transistors 20 18 Testing Rotor for Grounds 21 19 Test ing Rotor for an Open Circuit 21 20 Testing Stator Windings 22 21 Testing Exciter Armature 22 22 Testing Exciter Field 23 23 Connecting Lead From Terminal 63 23 24 Reconnection Diagram 23 25 VR21 Printed Circuit Board 24 26 Generator Disassembly 24 27 Adjusting Voltage on VR21 2S LIST OF TABLESTable 1 Resistance Values for Rotors 21Table 2 Resistance Values for Stators 22 95 are two generator aeslgns usu un ln UK senes 1 U giim access to generator remove gnue sectionThey are basically the same except for the method of below control boxfield excitation 1 chassis assembly VR22 mounts on the rear portion of the generator SCRs siliconThe Static Exciter brush type design uses a brush controlled rectifiers and diodes are easily acrig and collector rings for field excitation This design cessible for testing See Figures 13was used on some of the earlier models within the 2 On staticexcited generators brushes attach torange of 25 KW 90 KW the brush rig inside of end bell housing inspect through large access holes in the end belL SeeThe Brushless design uses a rotating rectifier exciter Figure 1assembly i place of the brush rig for field excitation 3 On brushless models rotating exciter assemblyThe brushless design is standard on all models from mounts directly behind chassis25 KW 175 KW assembly with all diodes accessible for servicing See Figure 2 4 PC Board VR21 Printed Circuit Board mounts inside the control box on the rearNOTE Unless otherwise specified the tests In this panel left side turn 14 turn fasteners on frontsection apply to both designs of control box to gain access See Figure 4 VR22 EXCITER REGULATOR CHASSIS ASSEMBLV ENDBELL AC STATOR oII 4 208240 VOLTS AC RESIDUAL MAGNETISM IN ROTOR STARTS PROCESS SOLID STATE EXCITER ND VOLTAGE REGULATOR C I REVOLVING FIELD OVERSPEED SWITCH GENERATOR END VIEW GRILLE REMOVED EXCITATION SCHEMATIC FIGURE I STATIC EXCITER DESIGN96 AL STATORCHASSIS ASSEMBL Y 208240 VOLTS AC EXCITER ARMATURE VOL TAGEOVERSPEED SWITCH REGULATOR WITH RECTIFIERS SENERATOR END VIEW SRILLE REMOVED EXCITATION SCHEMATIC FIGURE 2 ROTATING BRUSHLESS EXCITER DESIGN CHECK THESE DOUBLE LEAD SCRS ACCORDING TO PROCEDURE F o LCHECK THESE SINGLE LEAD RECTIFIERS ACCORDING TO PROCEDURE E FIGURE 3 TOP VI EW OF CHASSIS ASSEMBL Y VR21 VOLTAGE REGULATOR PRINTED CIRCUIT BOARD FIGURE 4 VOLTAGE REGULATOR PRINTED CIRCUIT BOARD LOCATION 97VISUAL INSPECTION nections dust dirt or moisture If dirty cleanBefore proceeding with the on the with a suitable solvent and compressed airfollowing pages a few simple checks can be made 3 Visually inspect the chassiswhich could directly indicate the cause of trouble assembly VR22 for burned components broken wires loose connections carbon tracks caused 1 Always be sure that connection of generator leads by arcing between parts or between parts and is correct Whenever leads are reconnected for a ground Also check for shorted paths between different voltage check the output with an inde terminals caused by dust dirt and moisture pendent voltmeter Do not use the control panel 4 Large banks of SCR Silicon Controlled Rectifier meter since it could indicate that the voltage is regulated loads can cause the generator voltage correct even if connection is wrong to increase as load is applied If such loads exist 2 Visually inspect the voltage regulator printed and the voltage increases more than 5 or 10 circuit board assembly VR21 in the control box consult the factory an additional filter is available for burned components broken wires loose con for the regulator circuit to correct the situation THE QUESTION AND ANSWER GUIDE BEGINNING ON PAGE 7 GIVES A STEPBYSTEP PROCEDURE FOR CHECKING THE GENERATOR THE FLOWCHART GUIDES ON PAGES 10 TO 16 ARE GIVEN AS A GENERAL GUIDE TO RE SOLVE VARIOUS GENERATOR PROBLEMS ALL CHARTS REFER TO PROCEDURES SHOWN AT THE END OF THIS SECTION PAGES 17 TO 2598 QUESTION AND ANSWER GUIDETo correct a particular problem answer the qJestion either yes or no then proceed to the next step given inwhichever column question wac answered A NO AC OUTPUT VOLTAGE ENGINE RUNNING YES NO 1A Is the circuit breaker on the meter panel in the on position 3A 2A 2A Switch the circuit breaker to the on position Does the AC voltage build up 3A NOTE If voltage builds up but is high low or unstable or causes the circuit breaker on the meter panelto trip refer to section B c or 0 of the guide 3A Is the AC voltage at terminals 1 and 2 on VR21 voltage regulator printed circuit board SA 4A and at terminals 9 and 10 on VR22 chassis assembly S to 10 volts 4A Check continuity of wires and connections between terminal 1 on VR21 printed circuit lOA board and terminal 9 on VR22 chassis assembly and between terminal 2 on VR21 printed circuit boaed and terminal 10 on VR22 chassis assembly Is there continuity between these connections SA Check for broken wires and loose connections on VR22 chassis assembly 6A Replace or repair any that are defective and clean all dust dirt and other foreign material from the assembly Does the AC voltage now build up 6A Is the DC voltage at terminals 4 and S on VR22 chassis assembly S to 13A 7A 10 volts 7A Are diodes CR I CR2 and CR3 on VR22 chassis assembly OK 8A See Method E in Procedure section for checking diodes 8A Are SCRs Q4 and Q5 on VR 22 chassis assembly OK 9A See Method F in Procedure section for checking SCRs 9A The trouble is probably caused by a defective component on the voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD See Figure 4 lOA With the circuit breaker on the meter panel in the off position is the AC voltage at 14A llA terminals 62 and 63 on terminal board TB21 on the left side of control box S to 10 volts llA With the circuit breaker on the meter panel in the off position flash the exciter field l2A 13A See Method B in Procedure section for field flashing Is the AC voltage at terminals 62 and 63 now 5 to 10 volts 12A Turn the circuit breaker on the meter panel to the on position Does the AC output ISA voltage build up NOTE If voltage builds up but is high low or unstable or causes the circuit breaker to trip refer to section B C or 0 of this guide 13A Is the brushless exciter stator winding OK See Method L in Procedure section for 17A checking exciter l4A With a jumper wi re connected across the terminals of the circuit breaker on the meter ISA panel does the voltage build up NOTE If the voltage does build up the circuit breaker CB21 is defective and MUST BE REPLACED 1SA Is Ll commutating reactor mounted on the back side of VR22 chassis 16A assembly OK See Method 0 in Procedure section for checking Ll reactor 16A Check continuity of wires and connections between TB21 terminal 62 on left side of control box and terminal 1 on VR21 printed circuit board Also check between TB21 terminal 63 on the left side of control box and terminal 2 on VR21 printed circuit board 99 A NO AC OUTPUT VOLTAGE ENGINE RUNNING CONTINUED YES NO 17A Are the rotating diodes CRl CR2 CR3 CR4 CRs and CR6 on the brushless exciter 18A rotor OK See Method E in Proedure section for checking diodes 18A Is the main generator field winding OK See Method H for checking generator field 19A 19A Is the brushless exciter rotor winding OK See Method K for checking exciter rotor winding 20A 20A Are the generator stator windings OK See Method J for checking stator windings B AC OUTPUT VOLTAGE BUILDS UP BUT IS UNSTABLE ENGINE RUNNING OK YES NO lB Are there any loose or broken wires or connections at VR2l printed circuit board 2B terminals 2B Does adjustment of R26 damping control pot on VR2l printed circuit board result in 3B stable generator voltage See Method Q 3B The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board REPLACE VR2l PRINTED CIRCUIT BOARD See Figure 4 R26 is used on brushless generators only C AC OUTPUT BUILDS UP BUT IS HIGH OR LOW ENGINE RUNNING OK YES NO lC Does adjustment of R21 Voltage Adjust knob on the meter panel result in the correct 2C voltage 2C Does adjustment of R18 potentiometer on VR21 printed circuit board result in the correct 3C voltage See Method Q in Procedure section 3C Is the correct voltage reference transformer tap on TB21 being used See Method M 4C for choosing correct tap 4C Are generator output leads properly connected See Method M for proper connection of SC output leads SC The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD100 D GENERATOR VOLTAGE BUILDS UP BUT CAUSES THE CIRCUIT YES NO BREAKER ON CONTROL PANEL TO TRIP ENGINE RUNNING OK 10 Does the AC output voltage LoJild up to 150 or more of rated voltage before CB21 circuit 20 70 breaker trips 20 Are there any loose or broken terminals or connections at VR21 voltage regulator printed 3D circuit board terminals 3D Is diode CR3 on center heat sink of VR22 chassis assembly OK 40 See Method E for checking diodes 40 Are the voltage regulator transformer T21 windings and connections OK 50 50 Are stator leads connected properly See Method M for correct connections 60 60 The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD See Figure 4 70 Does the AC output voltage build up to rated voltage or less before tripping CB21 circuit 80 breaker on the meter panel 80 Are the rotating diodes CR1 CR2 CR3 CR4 CR5 and CR6 on the brushless xciter 90 rotor OK See Method E for checking rotating diodes 90 Is the brushless exciter stator winding OK See Method L for checking exciter stator 100 winding 100 Is the main generator field winding OK See Method H for checking generator rotor 110 110 Is the brush less exciter rotor winding OK See Method K for checking exciter rotor winding E UNBALANCED GENERATOR TERMINAL VOLTAGES YES NO IE Remove load from generator terminals Are generator terminal voltages still unbalanced 2E 4E 2E Are generator leads properly connected andor grounded 3E 3E Is continuity of thp generator stator windings OK See Method J for checking stator windings 4E Is grounding procedure of generator and load correct 5E 5E Check for ground faults in load NOTE Unbalanced voltages of up to 5 will occur if unbalanced loads are applied to the generator terminals 101ot NO VOLTAGE BUILDUP I I I I I I CB21 NO AC LOW FAUL T IN DEFECTIVE DEFECTIVE FAULTY FAULT IN CIRCUIT POWER RESIDUAL GENERATOR COMPONENT COMPONENT ROTATING BRUSHLESS BREAKER TO VOLTAGE FIELD ON ON DIODE EXCITER ON METER EXCITER FLASH WINDING REGULATOR VOLTAGE ON ROTOR OR PANEL IN FIELD PC BOARD REGULATOR BRUSH LESS STATOR OFF VR21 CHASSIS EXCITER WINDING POSITION ASSEMBLY RESET VR22 DEFECTIVE CIRCUIT BREAKER ON METER PANEL BUILDUP 04 OR 05 RELAY KI OPEN OPEN In CRa OR CR9 OPEN DEFECTIVE DIODE CRI CR2 OR CR3 RI R2 OR R3 OPEN OPEN LEAD OPEN LEAD AT AT TERMINAL REGULATOR I 2 5 PC BOARD I OR 9 TERMINALS I OR 2 NOTE Whenever a letter appears near the boxa separate procedure corresponding to that letter is given at the end of this section Check SCRs 04 and 05 on VR22 voltage regulator chassis assembly and replace if defective before repairing or replacing VR21 voltage regulator printed circuit board Static excited generators only VOLTAGE BUILDS UP BUT CB21 CIRCUIT BREAKER ON METER PANEL TRIPS DEFECTIVE FAULT IN FAULT INROTATING DIODE EXCITER ROTOR GENERATOR CR I CR2 CR3 OR STATOR MAIN FIELDCR4 CRS OR CR6 WINDING WINDING ON EXCITER ROTOR E HNOTE Whenever a letter appears near the box a separate procedure correspond ing to that letter is given at the end of th i s sect ion 103 OUTPUT VOLTAGE TOO HIGH OR TOO LOW I INCORRECT I INCORRECT DEFECTIVE I DEFECTIVE REFERENCE SETTING OF COMPONENT ON COMPONENT ON TRANSFORMER TAP VOLTAGE ADJUST VOLTAGE VOLTAGE ON Tli POT R21 ON REGULATOR CHASSIS REGULATOR PC METER PANEL ASSEMBL Y VR22 BOARD VR21 INCORRECT OPEN LEAD OR R2 R3 OR R4 SETTING OF CONNECTION AT OPEN I VOLTAGE ADJUST TERMINALS 3 4 POT RI8 ON S 7 OR 8 VR21 PC BOARD t 1 CR8 OR CR9 OPEN IN OPEN Q4 OR QS VOLTAGE 1 SHORT IN RI8 CAUSES HIGH VOLTAGE BREAKDOWN OF Q4 OR Q5 I 1 MINIMUM VOLTAGE SETTING ON RI8 NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Causes low voltage as load is applied Wi II cause voltage to increase after warmup or voltage adjustment Check SCRs 04 and OS on VR22 voltage regulator chassis assembly replace if defective before repairing or replacing VR21 voltage regulator printed circuit board104 VOLTAGE 150 OR MORE THAN RATED 1 I 1 I OPEN TRANSFORMER OPEN WIRE OR DEFECTIVE COMPONENT DEFECTIVE COMPONENT T11 WINDING CONNECTION AT ON VOLTAGE ON VOLTAGE VOLTAGE REGULATOR REGULATOR CHASSIS REGULATOR PRINTED CHASSIS ASSEMBLY ASSEMBLY VR12 CIRCUIT BOARD VR11 VR12 TERMINALS 4 5 OR 6 OPEN WIRE OR CONNECTION AT PRINTED CIRCUIT BOARD VR11 TERMINALS 5 6 9 10 II OR 11 H CRIIOPEN H CR4 CR5 CR61 OR CR7 OPEN VOLTAGE BREAKOOWN OF t Q4 OR Q5 H CR 15 SHORTED ill K It NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Malfunction occurs after warmup or voltage adjustmenton UNSTABLE OUTPUT VOLTAGE I DEFECTIVE COMPONENT BROKEN WIRES OR 1 INCORRECT SETTING ON VR21 VOLTAGE LOOSE CONNECTIONS OF R26 POT ON VR21 REGULATOR PRINTED AT VR21 VOLTAGE PRINTED CIRCUIT CIRCUIT BOARD REGULATOR PRINTED BOARD BRUSHLESS ONLY CIRCUIT BOARD TERMINALS I C6 C7 RI4 OR RIS OPEN r I C II C 12 R27 OR R28 OPENNOTE Whenever a letter appears near the box a separate procedure correspondin to that letter is given at the end of this section106 CYCLING BUILDUP I OPEN LEAD AT OPEN IN R21 1 DEFECTIVE COMPONENT VR21 PRINTED CIRCUIT VOLTAGE ADJUST POT ON VR21 PRINTED BOARD TERMINALS ON METER PANEL CIRCUIT BOARD I 2 5 7 OR 8 OPEN IN RI8 VOL TAGE ADJUST POT ON VR21 PRINTED 1 CRIO CRI2 CRI3 OR CR 14 OPEN I CIRCUIT BOARD 1 R4 R6 R 17 OR R21 OPEN I 1 CI C2 OR CI3 OPEN I H QI SHORTED J Lf Q2 OR Q3 OPEN INOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Generator voltage builds uP then collapses builds uP etc 107 UNBALANCED TERMINAL VOLTAGES J I INCORRECT RECONNECTION INCORRECT GROUNDING FAULTY GENERATOR ANDIOR GROUNDING OF OF LOAD OR GROUND STATOR WINDING GENERATOR LEADS FAUL T IN LOAD fANOT E Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section108 PROCEDURES 3 After starting the plant touch the positive FLASHING THE FIELD NO VOLTAGE lead to TBs and the negative lead to TB4If output voltage will not build up it may be necessary hold on terminals just long enough until voltageto flash the field to restore residual magnetism starts to build up or damage may occur to the 1 Remove end grille to obtain access to exciter system regulator chassis assembly 2 Use a six volt dry cell lantern battery with a ten ohm resistor as shown in Figure 7 If a lantern battery is not available a 12 volt automotive I WARNING I Be cautious when workin on a battery can be used by increasing the lOohm enerator that IS runnin resistor to 20ohms or a 24 volt automotive battery can be used by increasing the resistor to 40ohms VR22 CHASSIS ASSEMBLY n0L0U1 HOLD ON TERMINALS UNTIL VOLTAGE STARTS TO BUILD UP LAD e VOLT ORV CELL FIGURE 7 FLASHING THE FIELD 109 Resistance between 13 23 14 or 24 should be infinity Resistance from any terminal to reactor frame should be infinityNO AC POWER TO EXCITER If any of the above conditions are not met installNOT E Residual should be checked before the circuit a new reactorbreaker the best place to check it is at the fhe leads61 through 65 coming directly out of the stator Thecombination of leads should be chosen by the of the stator ie 120240 Delta 120208Parallel Wye 277430Series Wye After proceed to VR21 PC board and then checkthe circuit breaker CB21 TESTING DIODESIf residual voltage is present check AC voltage at Diodes mount on the center heat sink of the 1 and 2 on VR21 voltage regulator printed regulator chassis assembly They are labeled CR tcircuit board Voltage should be 510 volts The AC CR2 and CR3 as shown in Figure 3 On at terminals 9 and 10 on VR22 generators six diodes mount on the rotating exciterchassis assembly should be the same 5 to 10 volts assembly as shown in Figure 2 These six diodes areIf not check continuity between these points If labeled CRt CR2 CR3 CR4 CRs and CR6 Testvoltage is low check Lt reactor diodes as follows 1 Disconnect lead from only one diode at a time or remove diode from heat sink Test that diode and reconnect lead before proceeding to the next one 2 Use an accurate ohmmeter to check the L 1 REACTOR of the diode Connect one lead to the top of theThe Lt reactor mounts on the rear of VR22 exciter diode and the other lead to the heat sink chassis assembly Terminals are marked 1 reading2 3 and 4 3 Now reverse leads and again observe reading A good diode should have a higher reading in one direction than the other If both readings are high IlI11J2 or if both readings are low diode is defective and must be replaced with a new identical part 3nIT4 tssnsn oncesOr dIITerminals 12 and 34 are wound on the same iron heating and eentual failure Keep these assembliescore Resistance between 12 and 34 should be equal clean GOOD DIODE WILL HAVE HIGH RESISTANCE READING IN ONE DIRECTION AND LOW READING WHEN OHMMETER LEADS ARE REVERSED FIGURE 8 TESTING DIODESno OHMM ETER 4iia OHMMETER SHORT BETWEEN GATE AND ANODE CATHODE FIGURE 9 TESTING SCRs FIGURE 10 TESTING SCRs FIGURE II TESTING SCRs REPLACING RECTIFIERS SCRS AND DIODES 1 Unsolder leadwires from SCRs 2 Use proper size wrenches to hold the body whileSCRs mount on the outer heat sinks of the exciter removing the nutregulator chassis assembly They are labeled Q4 and 3 Push the rectifier free of its mounting hole inQ5 as shown in Figure 3 the heat sink 1 Remove the leads from both SCRs 4 Insert new rectifier into its mounting hole in the 2 Determine polarity of ohmmeter leads Connect heat sink Using nut and washer provided secure the ohmmeter leads to the anode and cathode as rectifier to heat sink shown in Figure 9 Use the high scale on the 5 Torque the two large diodes on the center heat ohmmeter The resistance should be 1 megohm sink of chassis assembly to or greater 2025 in lb NOTE The cathod i the longer lead the gate 6 Torque the small diode on center heat sink of is the shorter lead The anode is the threaded chassis assembly to 1215 in lb stud 7 Torque SCRs on outer heat sinks to 2025 in lb 3 Reverse the leads as shown in Figure 10 The 8 On brushless generators torque diodes on rotating resistance again should be 1 megohm or greater exciter assembly ttl 15 in lb 4 With the leads connected as in Step 3 and using 9 Solder leadwires to new rectifiers the low scale on the ohmmeter short the gate to the anode as shown in Figure 11 The resistance should drop to a low value r I Ut a 40 watt soldering ron and also hold a needlenose pllCrs betwpn 5 Remove the short between the anode and the gate rectifier and soldering point to pretnt destructip The resistance should remain at the same low heating Excessie hpJt on theool components will value destroy them 111 Checking Unijunctin Transistors shown on rculat or diagram as Q3 1 With the negative lead on E the resistance from E to Bl or from E to B2 should exceed 1 megohmTESTING TRANSISTORS See Figure 15In each of the following tests it will be necessaryto determine the polarity of the ohmmeter leads This PICTORIAL TOPis not necessarily the same as when used with voltage HI Q3Checking NPN Transistors shown on regulator diagramas Ql and Q2 1 Place ohmmeter leads between E and C as shown in Figure 12 The resistance should be high 8YE 82 0 62 PICTORIAL TOP IQ1 AND Q21 be C E E OHM METER FIGURE IS 2 With the positive lead on E the resistance to either Bl or B2 should be between 500 and 10000 ohms See Figure 16 FIGURE 122 Leave ohmmeter connected as in Figure 12 but OHM METER short Band C as shown in Figure 13 The re sistance should become less than it was in step 1 FIGURE 16 OHM 3 Connect as shown in Figure 17 The resistance 8 METER between Bl and B2 should be between 4000 and 10000 ohms Reversing the leads should not change this value FIGURE 13 3 Leave ohmmeter connected as in Figure 12 but E OHM now short Band E as shown in Figure 14 The METER resistance should be higher than in step 1 FIGURE 17 OHM METER FIGURE 14112TESTING GENERATOR ROORFor these tests use an For Grounds remove Fl and F2 rotor leadsfrom heat sink assembly Check for grounds betweeneach field lead and rotor shaft Refer to Figure 18Testing for an Open Circuit disconnect and test be CONTACT ONE PROD TO EACH OF THE FIELD LEADS AND THE OTHER PROD TO THE ROTORtween Fl and F2 leads as shown in Figure 19 SHAFTReplace the rotor if it is grounded or has an open IF ROTOR IS GOOD THERE SHOULD BE NO READING ON OHMMETERor short FIGURE 18 TESTING ROTOR FOR GROUNDS OHMMETER TABLE 1 RESISTANCE VALUES FOR ROTORSAll resistances should be lOo of the values specified at2SC 77F This includes readings between slip rings onstatic excited rotors and between field leads with on brushless rotors Use an ohmmeter fortesting CONTACT ONE PROD TO ONE FIELD LEAD AND THE SECOND PROD TO THE OTHER FIELD LEAD i RESISTANCE VALUES ARE GIVEN IN TABLE 1 FIGURE 19 TESTING ROTOR FOR AN OPEN CIRCUIT 113 TABLE 2 RESISTANCE VALUES FOR STATORS All resistances should be 1W of value shown at 2SC 77F Use an accurate instrument for this test such as a KelvinTESTING GENERATOR STATOR Bridge Test hetween the following coil leadsUsing an ohmmeter or 1500 volt hypot check each TIT4 T7Tl0 T3T6 T9T12 T2TS TSTl1winding of thE stRtor for grounding to the laminationsof the frmeNOTE Some entrators have ground connections totht frame Check wiring diagramTest each stator winding for shorts to laminations TESTING BRUSHLESS EXCITER ROTOR ARMATUREA reading less than infinity indicates a short Use a Wheatstone Bridge for this test Disconnect main rotor field leads which connect to heat sinks F 1Test for continuity between coil leads shown in Figure and F2 Unsolder leadwires from diodes CR1 CR220 all shculd have equal resistance Use an accurate CR3 CR4 CRs and CR6 Test between exciter leadinstrument for this test such as a Kelvin Bridge The pairs TlT2 T2T3 and TlT3 Resistance shouldproper resistance values are given in Table 2 according be S2Sohms 10 at 77Fto KW ratings and voltage codes CR1 CR4If any windings are shorted open or grounded replacethe stator assembly Before replacing the assemblycheck the leads for broken wires or insulationNOTE Stator output leads T4 T7 T8 T9 and Tl0are interconnected within the stator to five stranded 10 aircraft control wires These wires are labeled4 7 8 9 and 10 respectively and terminate at TB21terminals 6165 CRe CR5 FIGURE 21 TESTING EXCITER ARMATURE TEST BETWEEN WIRE PAIRS T1T4 T7T10 T3T6 T9T12 T2T5 T8T11 VALUES ARE GIVEN IN TABLE 2 FROM KELVIN BRIOGE FIGURE 20 TESTING STATOR WINDINGS114 voltage be SUrf to also reconnect lead fron terminal 63 inside control box to either H3 H4 Hs or Hti See Figures 23 and 24TESTING BRUSHLESS EXCITER STATORCheck between F 1 and F2 field leads with an ohmmeterThe resistance should be 202ohms 10 at 77 c F H24 0i 1I2 H 1I3 144 1 115 116 I 116 61 6t 61L1 62 63 tiJ CON NECT LOOSE WIRE 64 4 FRO M TERMINAL 63 OHMMETER RESISTANCE BETWEEN U 6S TO E ITHER H3H4H5 OR F1 AND F2 SHOULD BE 66 66 H6 D EPENDING ON 202 OHMS I 10 VOL TAGE SELECTED 67 67 FIGURE 22 TESTING EXCITER FIELD 68 68 g 69 70 71 id 11 24 shows reconnect ion possibilities for the UR FIGURE 23 CONNECTING LEAD FROM TERMINAL 63series generators When reconnecting for a different HII DIGI PPlIn TO 12 LEAD GINIIOIS ONLY I INIIAT COMNICTION WING DAOI IWIT CUIIINT nANSf 111 w UIID fI ft T 11 II TI T TS II fli I I I no so1 I n 712 TS 71 TlO T6 Til U II U 120201 I 1272 201 ji 140 nooi I 1 so MJ 111001 SOl i D 11 I T n i l TS n FIGURE 24 RECONNECTION DIAGRAM 115 OF SIDE OF VOLTAGE REGULATOR WHEN MOUNTED UNSOLDER THIS WRE FROM E1 AND CCNNECl TO E2 FOR A NONFRE QUENCY SENSITVE VOLTAGE REFERENCE CIRCUIT FIGURE 25 VR21 PRINTED CIRCUIT BOARD sensitive voltage dips with speed to nonfrequency sensitive voltage remains constant as frequency is reduced by unsoldering one lead and connecting it to another terminal See Figure 25 Following REFERENCE CIRCUIT change readjust R18 rheostat on voltage regulatorUR series regulators can be changed from frequency printed circuit board for correct voltage 9 23 2 BRUSHLESS GENERATOR FIGURE 26 GENERATOR DISASSEMBLY116 4 Torque drive disctoflywheel capcrews to 45 50 lb ft 5 Torque generator throughstud nuts to 3035 lb ftGENERATOR DISASSEMBLY 6 Refer to parts catalog for replaceable parts andIf generator testing determines that generator needs assemblies Refer to wiring diagram for reasrepair remove and disassemble according to Figure26 semblyand the following instructions 1 Disconnect and remove load wires 2 Disconnect leadwires from the control box Check wire markings for legibility to ease assembly Arrange leads so they can be withdrawn easily from the control box VOLTAGE ADJUSTMENT 3 Remove front grille 14 and sheet metal work If VR21 voltage regulator printed circuit board has 4 Remove the four capscrews securing voltage reg been replaced it may be necessary to center the ulator chassis 23 to end bell 9 and remove voltage adjust rheostat R21 on meter panel chassis assembly 1 Center the voltage adjust knob so pointer is in 5 Remove the centrifugal switch 8 from end bell a vertical position and rotor shaft 2 Open meter panel doors Start unit 6 Block the rear of the engine in place by supporting 3 Using a screwdriver turn R18 potentiometer on the flywheel housing Remove the narrow generator printed circuit board VR21 to band 10 Remove the large capscrews securing increase the voltage or clockwise to decrease the generator mounting pad 11 to the skid base voltage Observe voltmeter on meter panel while Remove the capscrews securing the stator as making adjustment Set voltage with no load sembly 4 to the engine flywheel housing connected to generator Example For a 120240 7 Using an overhead hoist and sling slide the stator volt connection set at noload voltage or ap assembly off the rotor assembly proximately 246 volts 8 Remove end bell from stator assembly disconnect and remove brush rig from end bell on static If voltage is unstable or tends to hunt turn R26 excited generators On brush less models remove potentiometer on VR21 in the direction shown on exciter field 24 from end bell assembly if re printed circuit board to increase voltage sensitivity quired 9 Attach the hoist and sling to the rotor assembly 1 and apply a slight lift to support the rotor Remove the capscrews securing the flexible drive coupling 13 to the engine flywheel and remove rotor from the engine10 Remove bearing capscrew 18 and washer 17 and remove bearing from shaft If required remove blower 2 from the rotor11 Disconnect rotor field leads from heat sinks F 1 and F2 on the exciter armature Remove exciter armature 25GENERATOR assembly is the reverse of 1 Always replace bearing with a new one apply a layer of grease on end bell bearing hole before inserting bearing 2 Torque bearing capscrew to 6070 lb ft FIGURE 27 ADJUSTING VOLTAGE ON VR21 3 Torque drive disctorotor capscrews to 200240 lb ft 117 EII r JQQSR I HI XI TI T4 TIl T8 STATIONARY 5 CHART IELDI PHASE 3 MDlL I I IIID H I VRZI VOLTAoE REo PCBOARD Ii STATIONARY EXTATION I COIL H I on I U 10 EI00 llOS Ta ro J w TJ o 120 6 4 flo U1 D ARuATURE 8 RIETIIE o ENGINE CONTROL 5 DRAWING 10 NO 117 VillI o SCRIIECULATOII r T8J FIELD ATTACHD en IT1 LAD T8 SEE TABLE or AC l 0 IT1 CONNECTIONS en C r II 2 3 4 1 2 CD L J J o 0 TA8LE OF AC CONNECTIONS 120 C GENERATOR FRO POWEll vOLTS MAl ML LIMIT 0 JuulfR STATNlNA6r LI C MODEL HZ KW A IVA LIN 11 o 18 ONE PHASE PIKED I OUR 50 00 110 240 17 J 1160 Ho 0062 I TO 1 OUTPUT CONNEcTION I 3NI o 250 115Z30 JIZ 0 6 0063 d 0 IE 40 UR flO 4t0 120240 l61 2140 H5 e64 T2 00 IT1 0 INI 50 n5 1151210 2010 H 6 ACLIH BLOCK C 100 UA 60 0 0 240 17 520 H5 T6 TlO r LI n o 4 o 21N18 IS 0 230 112 0 H6 TJ TI T L I z 0rttr Z l 40 c C 450UR IltNI 60 to ns 240 ZIO HI2 70 680 t 6 Tt I T i l V I I T T2 00 LJ IT1 n t 300 IZOI20 17 7 1040 HI I o z en 300UR 60 JOO JOO 127220 139240 17b 54 00 HS T4 TI Ta r LI V THREE PHASE I IISMIB 0 20 110 190 II 10 I RICONNUTA8LE oJ 250 450 5z08 120 201 112 HZ 100 160 H4 HI Tl TIO IS I LZ LI U1 U1 oUR 10 40 121 220 62 0 H4 Tt 112 I ZISN 4S0 11 240 562 1150 HS LO U1 U1 SO US 110 NO 5 14J0 HI TI TI I ns liS ZOO 1180 H4 100 240 46 315 S20 H3 OouA 21Nla 60 300 JOO 254 0 217 4eO 35 0 450 H4 H T 8 Z I r LI I 50 250 220 380 112 41S HJ T7 T5 2 ILl 4OUR 21NIB 60 450 2t4 440 7749 562 L 740 680 H4 H5 1 T U TlZ I LO 0 375 ZO o 7S 120 I J u d4 400 75 60 H4 T6 3045 KW MANUAL STARTER DISCONNECT ROTARY SWITCH BATTERY 12VDC BATTERY RETURN STARTER MOTOR START SOL RELAY r t G AMP th It CRN 140 I OUT J CI REO 7 ALTERNATOR oJ FUSE IASLOW SLOWI It WITH SUPPRESSORS IiiUil GllfC eAMP PANEL GROUND FEAT MOM I ISTAR MOIol rh 0 MANUAL SWITCH 1 wTS I I 1 I I I OPS 1 V HOUR METER EXCITATION DIODE I I rUEL OL I OSR K2 I I I 3 1 SUPPRESION DIODE START SOL RELAY I t I IJ 4 I I NC KI I 8 I OSRELAY OEN OVERSPIED B 1 SWITCH 6 V 7 Drawing 15227 119 MANUAl CONTROL The Manual Control series of Westerbeke marine diesel generatorsis equipped with a bar handle rotary control switch on the engine paneland optionally at a remote panel The following instructions and methodsof correcting minor problems apply to the following manual control REFERENCE DIAGRAMSWPDS 100 Four107JC 15123 15687WPDS 125 Four107JC 15123 15687WPDS 150 Four107JC 15123 15687WPDS 200 Four154JC 15123 15687WPDS 300 Four230UR 15227 15555WPDS 450 Six346UR 15227 15555The five rotary switch positions on the panel and on the remote panel aremarked to indicate the functional state of the control circuit1 SAFETY The 12 volt DC power to control circuit is interrupted wheneither the panel or remote switch is in the SAFETY position Its purposeis to positively shut down the set from either station A running engine willstop and cannot be restarted when either switch is in SAFETY Turn panel switchto SAFETY when servicing engine to prevent an attempted startup at the remotestation2 OFF The normal stopping position is OFF When a remote panel is the usualstation from which the generator is operated the engine panel switch is leftin the OFF position which allows full control by the remote switch3 RUN The normal operating position When the set is running a red lightemitting diode LED is illuminated above the RUN position on the remote panelThis is a warning to operators not to engage the starter on a running engine4 OP CIRCUIT DEFEAT momemtary spring return When the set is not runningthe low oil pressure shutdown switch is open preventing the fuel solenoid fromoperating The DEFEAT position provides direct energization of the fuel solenoidat full battery voltage by bypassing the oil pressure switch In addition the instrument panel independently of the oil pressure switch an oilpressure switch provides power to the panel when the engine is running Thetemperature gauge may be checked without starting the engine by use of this switchposition At the remote panel the LED is illuminated when either panel or remoteswitch is positioned to DEFEAT This checks the RUN light and more that there is sufficient charge in the batteries to crank the engine5 START momentary spring return This position energizes the cranking motorthrough a solenoid relay The bypass and LED connections activated by the DEFEATposition are maintained in the START position When ignition occurs the startingmotor is disengaged by releasing the switch from the START position At the remotestation the LED is extinguished by the drop in system voltage as the crank motoris engaged Relighting of the LED signifies that ignition has OPERATION1 STARTING AT THE ENGINE PANEL Installations with remote stations must set the remote switch to OFF A Turn switch to DEFEAT and pause to allow the fuel solenoid to operate Check panel lights and instruments for appropriate indications and the hour meter blinking The ammeter shows a momentary large discharge and a small sustained discharge depending on the use of preheaters Preheat twenty seconds in the DEFEAT position on Model WPDS 20 B Turn the switch from DEFEAT to START and hold there while the engine cranks When engine ignition occurs allow the switch to return to DEFEAT and hold until the oil pressure indicator rises Then release to the RUN position2 STARTING AT THE REMOTE PANEL Check that the LED is not illuminated due to the engine already running A The engine mounted switch must be on OFF B Turn the switch to DEFEAT and hold Verify that LED illuminates Hold briefly for fuel solenoid engagement to occur On Model WPDS 20 which is preheated hold DEFEAT twenty seconds C Turn the switch to START Observe that LED extinguishes momentarily When LED again flares up brightly ignition has occurred Release to DEFEAT holding there sufficiently long for the oil pressure to rise Then release the switch to RUN3 SHUT OFF To shut the engine off simply turn the switch to OFF or SAFETY When there is a remote panel shut off requires that both switches be in the OFF position or either switch be placed in the SAFETY positionAC GENERATORS Once the diesel generator sets have been placed in operationthere is little or no control adjustment required by the AC GeneratorWhen starting the generator it is always a good plan to switch off all ACloads especially large motors until the engine has come up to speed and incold climates starts to warm up These precautions will prevent damage operation of AC machinery and prevent a cold engine from CONTROLS ON WPDS 30 AND WPDS 45The engine panels on these generators have four additional fpatures1 OVERSPEED If the engine governor loses control and the engine speed ac celerates a relay is actuated that deenergizes the fuel solenoid and stops the engine A red light on the panel illuminates and remains lighted To extinguish the light reset the overs peed relay switch to the OFF or SAFETY condition When the reason for the overspeed shutdown is corrected the engine is ready to be restarted 121 2 FIELD BREAKER The generator automatically monitors its power output A sustained overload or short circuit in the output lines causes the FIELD BREAKER to open This removes the generator excitation and the output ceases The engine will continue to run with no AC output After de termining and correcting the cause of overload the FIELD BREAKER can be reset with the engine still running 3 AC VOLTAGE ADJUSTMENT This rheostat allows the output voltage to be adjusted a few percent in relative value A second adjustment can be made using a potentiometer mounted on the printed circuit voltage regu lator in the cabinet 4 5A SLOW BLOW This fuses principle function is the protection of the fuel solenoid which rapidly overheats if its ability to complete its stroke and bottom is impeded A second function is general protection of th 12 volt control wiring against inadvertant overload The set shuts off and gives no indication of panel power in the DEFEAT and START position when the fuse blows Replace only with slow blow 5 ampere fuses The slow blow feature allows the initial solenoid surge currents to pass Permanent damage to the fuel solenoid can result from overfusing122 MANUAL CONTROL TROUBLE SHOOTING HINTSNature of trouble Probable cause Verification1 No panel A Remote or engine switch 1 Visual check indications or on SAFETY switch response B Engine panel fuse 1 Check replace 5 amp slow blow 2 Repeated blowingcheck for short circuits and fuel solenoid bottoming C Battery 1 Check connections and disconnect switch 2 Jump B to start solenoid coil If cranks battery is OK D Continuity grounding 1 Check voltage point by pOint or shorted circuits from battery through ammeter Tighten loose connections and locate any faults2 Doesnt crank A Start solenoid 1 Bypass solenoid with heavy wire panels and If cranks OK start solenoid or voltages are OK coil input at fault B Crank by encine switch 1 Remote cable wire too small for but not hy remote panel length of run Open circuit C Starter jmmed 1 Voltage drops and starter motor heats Remove motor Check pinion ring gear and engagement mechan ism Replace as required D Starter engagement 1 Apply voltage to B and S on solenoid and switch starter No response Check starter motor return lines R Both connected to battery3 No ignition A Fuel solenoid l Check 12V on terminals at DEFEAT cranks doesnt position Check for free mechani start fueled and cal action Adjust spring and link primed ages Replace solenoid if weak overheating or dead 2 No voltage Test with bypassed oil pressure switch then bypassed tem perature switch If no voltage check wiring B Overspeed relay l Check solenoid return circuit 30 and 45 KW through relay Check relay move ment and contacts 2 A faulty overspeed ci rcui t wi 11 hold relay closed Reset with switch and isolate cause 123 C Faulty fueling system 1 See englne maintenance section D Preheat not working 1 Check preheat solenoid relay 20 KW and glowp1ugs 2 G10wp1ugs burned out Replace and check pressure switch shut off operation 4 Fai 1ure to shut A Fuel solenoid return 1 Stop engine by freeing fuel pump cOtn spring lever That failing shut off fuel Check fuel solenoid linkage and repair for free movement B Control ci rcui t or 1 Stop engine by removing fuse switch failure Locate malfunction by voltage test after removing wire from the start solenoid relay and replacing fuse C Fuel injection pump 1 Stop engine with fuel line shut failure off Repair or replace pump D Major engine fault 1 Stop engine with fuel line cutoff That failing plug air inlet with rags Put maximum load on genera tor to attempt to stall engine 5 Engine stops A Low oi 1 pressure or 1 Check oil fresh water and sea in RUN overheated water cooling B Low oi 1 pressure switch 1 Check for satisfactory operation fails to close with switch bypassed C High water temperature l Same as above switch open at too low a temperature D Switch and wiring l Inspect all wlrlng for loose con nections and short ci rcui ts 6 Not charging A Alternator drive 1 Check drivebelt and its tension battery Be sure alternator turns freely Check for loose connections B Regulator unit and 1 With engine running momentarily alternator connect B to field A good alter nator will produce a high charge 50 amps If no response replace alternator Check for shorting of alternator output connections to ground 7 Battery runs A Oi 1 pressure sli tch 1 Observe if gauges and panel light down are on when engine is not running Test the normally open oil pressure switch by disconnecting one lead If lights go out replace oil pres124 sure switchB High resistance leak 1 Check iring Insert sensitive to ground 025 amp meter in battery lines Do not start engine Remove con nections and replace until short is locatedC Low resistance leak 1 Check all wires for temperature to ground rise to locate faultD Al ternator 1 Disconnect alternator at output after a good battery charging If leakage stops replace alternator protective diode plate That fail ing replace alternator 125

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