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Westerbeke Diesel W 50 Parts Manual



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   TECHNICAL MANUAL




        WESTERBEKE 50
   Marine Diesel Engine




              Publication #23156
                   Edition Two
                  January 1981




~r-.v- 'WESTERBEKE
        WESTERBEKECORPORATION
    ~   MYLES STANDISH INDUSTRIAL PARK
        150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319
   TECHNICAL MANUAL




        WESTERBEKE 50
   Marine Diesel Engine




              Publication #23156
                   Edition Two

                  January 1981




~r-.v- 'WESTERBEKE
        WESTERBEKECORPORATION
    ~   MYLES STANDISH INDUSTRIAL PARK
        150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319
                      INTRODUCTION
    IMPORTANT
    THIS MANUAL IS A DETAILED GUIDE TO THE INSTALLATION,
    START-UP, OPERATION AND MAINTENANCE OF YOUR WESTERBEKE MARINE
    DIESEL ENGINE.    THE INFORMATION IT CONTAINS IS VITAL TO THE
    ENGINE'S DEPENDABLE, LONG TERM OPERATION.
          READ IT
          KEEP IT IN A SAFE PLACE !
          KEEP IT HANDY FOR REFERENCE AT ALL TIMES
    FAILURE TO DO SO WILL INVITE SERIOUS RISK, NOT ONLY TO YOUR
    INVESTMENT BUT YOUR SAFETY AS WELL.


UNDERSTANDING THE DIESEL ····
    The 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 of the same general type
as that of a gasoline engine; it has the same sort of valves,
camshaft, pistons, connecting rods, lubricating system and reverse and
reduction gear.
    Therefore, it follows to a great extent that a diesel engine
requires the same preventative maintenance as that which any intelli-
gent operator would give to a gasoline engine.       The most important
factors are proper maintenance of the fuel, lubricating and cooling
systems.    Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for con-
tamination (i.e. water, sediment,etc.) in the fuel system is also
essential.    Another important factor is the use of the same brand of
"high detergent" diesel lubricating oil designed specifically for
diesel engines.
    The diesel engine does differ from the gasoline engine, however,
in the method of handling and firing its fuel.      The carburetor and
ignition systems are done away with and in their place is a single
component - the Fuel Injection Pump - which performs the function of
both.
    Unremi tting care and attention at the factory have resulted in a
Westerbeke engine capable of many thousands of hours of dependable
service. What the manufacturer cannot control, however, is the treat-
ment it receives in service. This part rests with you!

ORDERING PARTS
    Whenever replacement parts are needed, always include the complete
part description and part number (see separate Parts List furnished,
if not part of this publication).    Be sure to include the engine's
model and serial number. Also, be sure to insist upon Westerbeke fac-
tory packaged parts, because "will fit" parts are frequently not made
to the same specifications as original equipment.
 GENERATOR SETS
    Westerbeke diesels are used for both the propulsion of boats and
for generating electrical power. For generator set applications, all
details of this Manual apply, except in regard to certain portions of
the Installation, Operation and Maintenance sections.       Additional
information is provided in the section titled Generator Sets,
Section T.


                                  3
YOUR NOTES




     4
                       INSTALLATION
    FOREWORD
          Since the boats in which these engines are used are many
    and varied, details of engine installation are equally so.
    It is not the purpose of this section to advise boatyards and
    eng ine installers on the generally well understood and well
    developed procedures for installation of eng ines.    However,
    the following outline of general procedure is included
    because it is valuable in explaining the functions of each
    component, the reasons why, the precautions to be watched and
    the relationship of the installation to the operation of the
    eng ine.   There are details of the installation which should
    have a periodic check and of which the operator should have a
    thorough understanding to insure good operating cbndi tions
    for the engine and correct procedure for its servicing.

INSPECTION OF EQUIPMENT
    The engine is shipped from the factory mounted securely and pro-
perly crated. Accessory equipment is shipped in a separate small box,
usually packed with the engine crate.
    Before accepting shipment from the transportation company, the
crate should be opened and an inspection made for concealed damage.
If either visible or concealed damage is noted, you should require the
delivering agent to sign nReceived in damaged condition n · Also check
contents of the shipment against the packing list and make sure note
is made of any discrepancies. This is your protection against loss or
damage. Claims for loss or damage must be made to the-carrier, not to
J. H. Westerbeke Corporation.
RIGGING AND LIFTING
     The engine is fitted with lifting rings.
     Rope or chain slings should be attached to the rings and the
engine lifted by means of tackle attached to this sling. The lifting
rings have been designed to carry the full weight of the engine;
therefore, auxiliary slings &re not required or desired.
     CAUTION:   Slings must not be so short as to place the engine
lifting eyes in significant sheer stress.        Strain on the engine
lifting eyes must not be in excess of 10· from the vertical. A spacer
bar must be placed between the two lifting eyes, if supported by valve
cover studs.
     The general rule in moving engines is to see that all equipment
used is amply strong and firmly fixed in place.      Move the engine a
little at a time and see that it is firmly supported.         Eliminate
possibility of accidents by avoiding haste. Do not lift from the pro-
peller coupling, or pry against this with crowbar, as you may distort
the coupling.
     In some cases it may be necessary to lift the engine in other than
the regular horizontal position.     It may be that the engine must be
lowered endwise through a small hatchway which cannot be made larger.
If the opening is extremely restricted, it is possible to reduce, to
some extent, the outside clearances such as generator, cooling piping,
water tank, filters, mounting lugs, etc.      This\accessory equipment
should be removed by a competent mechanic and special care should be


                                  5
taken to avoid damage to any exposed parts and to avoid dirt entering
openings.   The parts which have been removed should be returned to
position as soon as the restriction has been passed.
    In case it is necessary to hoist the eng ine either front end··
upwards or reverse gear end upwards, the attachment of slings must be
done very carefully to avoid the possibility of damage to the parts on
which the weight may bear. It is best if special rigging work be done
by someone experienced and competent in the handling of heavy machi-
nery.

ENGINE BOLTS
    It is recommended that bronze hanger bolts of appropriate size be
used through the engine flexible mounts.    Lag screws are less pre-
ferred because their hold on the wood is weakened every time they are
moved, whereas the lag bolt stays in position and the nut on top is
used to tighten the engine down or is removed to permit the engine to
be lifted. The bolt itself stays in position at all times, as a stud,
and the bond between the bolt and the wood is not weakened by its
removal.
FOUNDATION FOR ENGINE
    A good engine bed contributes much toward the satisfactory opera-
tion of the engine. The engine bed
must be of rigid construction and
neither deflect nor twist when sub-
jected to the engine weight or the
position the boat may have to take
under the effects of rough seas.                       GOOD
The bed must keep the engine within
one or two thousandths of an inch
of this position at all times.   It
has to withstand the forward push                             A
of the propeller which is applied
to the propeller shaft, to the
thrust washer bearing in the engine
and finally to the engine bolts and
engine bed.
     In fiberglas hulls, we recom-
mend that similar wooden stringers                   BAD
as in wooden hulls be formed and
fitted, then glassed to the hull
securely. This allows hanger bolts
to be installed firmly in wood,
thus reducing noise and transmitted                           B
vibration.
    The temptation to install the
engine on a pair of fiberglas
"angle irons" should be resisted. Such construction will allow engine
vibrations to pass through to the hull.     Flexible mounts require a
firm foundation against which to react if they are to do their job.
When possible, follow bed design "A" and avoid bed design liB".

PROPELLER COUPLING
    Each Westerbeke Diesel engine is regularly fitted with a suitable
coupling connecting the propeller shaft to the engine.


                                 6
    The coupling must not only transmit the power of the engine to
turn the shaft, but must also transmit the thrust either ahead or
astern from the shaft to the thrust bear ing which is built into the
reduction gear housing of the engine. This coupling is very carefully
machined for accurate fit.
    For all engine models, a propeller half-coupling, bored to shaft
size for the specific order, is supplied.   The coupling either has a
keyway with set screws or is of the clamping type.
    The forward end of the propeller shaft has a long straight keyway.
Any burrs should be removed from the shaft end.    The coupling should
be a light drive fit on the shaft and the shaft should not have to be
scraped down or filed in order to get a fit.     It is important that
the key be properly fitted both to the shaft and the coupling.     The
key should fit the side of the keyway very closely, but should not
touch the top of the keyway in the hub of the coupling.
    If it seems difficult to drive the coupling over the shaft, the
coupling can be expanded by heating in a pail of boiling water. The
face of the propeller coupling must be exactly perpendicular to the
centerline or axis of the propeller shaft.

PROPELLER
    The type and size of propeller varies with the gear ratio and must
be selected to fit the application based upon boat tests. To utilize
the full power of the engine, and to achieve ideal loading conditions,
it is desirable to use a propeller which will permit the engine to
reach its full rated speed at full throttle under normal load.

ALIGNMENT OF ENGINE
    The engine must be properly and exactly aligned with the propeller
shaft.   No matter what material is used to build a boat it will be
found to be flexible to some extent and the boat hull will change its
shape to a greater extent than is usually realized when it is launched
and operated in the water.    It is therefore very important to check
the engine alignment at frequent intervals and to correct any errors
when they may appear.
    Misalignment between the engine and the propeller shaft is the
cause of troubles which are blamed often on other causes.      It will
create excessive bearing wear, rapid shaft wear and will, in many
cases, reduce the life of the hull by loosening the hull fastenings.
A bent propeller shaft will have exactly the same effect and it is
therefore necessary that the propeller shaft itself be perfectly
straight.
    One particularly annoying result of misalignment may be leakage of
transmission oil through the rear oil seal.    Check to make sure that
alignment is within the limits prescribed.
    The engine should be moved around on the bed and supported on the
screw-jacks or shims until the two halves of the couplings can be
brought together without using force and so that the flanges meet
evenly all around.    It is best not to drill the foundation for the
foundation bolts until the approximate alignment has been accurately
determined.
    Never attempt a final alignment with the boat on land.    The 'boat
should be in the water and have had an opportunity to assume its final
water form.   It is best to do the alignment with the fuel and water
tanks about half full and all the usual equipment on board and after
the main mast     has   been stepped   and  final   rigging has been


                                  7
accomplished.
    Take pLenty of time in making this alignment and do not be
satisfied with anything less than perfect results.
    The alignment is correct when the shaft
can be slipped backward and forward into the
counter bore very easily and when a feeler
gauge indicates that the flanges come exactly
together at all points.      The two halves of
the propeller coupling should be parallel
within 0.002 inches (A).
     In making the final check for alignment,
the eng ine half coupling should be held in
one position and the alignment with the pro-
peller coupling tested with the propeller
coupling in each of four positions, rotated
90· between each position. This test will also check whether the pro-
peller half coupling is in exact alignment on its shaft.          Then,
keeping the propeller coupling. in one position, the alignment should
be checked rotating the engine half coupling to full position each 90·
from the next one.
    The engine alignment should be rechecked after the boat has been
in service for one to three weeks and, if necessary, the alignment
remade.    It will usually be found that the engine is no longer in
alignment.    This is not because the work was      improperly done at
first but because the boat has taken some time to take its final
shape, and the engine bed and engine stringers have probably absorbed
some moisture.     It may even be necessary to re-align at a further
period.
    The coupling should always be opened up and the bolts removed whe-
never the boat is hauled out or moved from the land to the water, and
during storage in a cradle. The flexibility of the boat often puts a
very severe strain on the shaft or the coupling or both when it is
being moved.    In some cases the shaft has actually been bent by these
strains.    This does not apply to small boats that are hauled out of
the water when not in use, unless they are dry for a considerable
time.

EXHAUST SYSTEM
    Exhaust line installations vary considerably and each must be
designed for the particular job. The general requirements are to pro-
vide an outlet line with a minimum of restrictions and arranged so
that sea water, rain water or condensation cannot get back into the
engine.   There should be a considerable fall in the line between the
exhaust manifold flange and the discharge end. This slope in the pipe
makes it difficult for water to be driven in very far by a wave, and a
steep drop followed by a long slope is better than a straight gradual
slope.   Avoid any depression or trough to the line which would fill
with water and obstruct the flow of exhaust gas. Also avoid any sharp
bends.
    Brass or copper is not acceptable for wet exhaust systems, as the
combination of salt water and diesel exhaust gas will cause rapid
deterioration.   Galvanized iron fittings and galvanized iron pipe are
recommended for the exhaust line.    The exhaust line must be at least
as large as the engine exhaust manifold flange and be increased in
size if there is an especially long run and/or many elbows. It should
be increased by 1/2" in I.D. for every 10 feet beyond the first

                                  8
10 feet.
    Most exhaust systems today use a water lift type muffler such as
the Westerbeke "Hydro-Hush".    In most installations there is a dry,
insulated high loop after the engine manifold and before the muffler
to prevent water flowing backwards into the engine during cranking.
     It is essential not to hang too much weight in the form of exhaust
system components rigidly from the engine manifold. Generally, it is
permissable to directly connect a pipe nipple and a water jacketed
exhaust elbow, which two components weigh about 8 pounds (4 kg).     If
there are more components to be rigidly connected to each other than
will weigh 8 pounds, then a flexible exhaust section must be installed
between the manifold outlet and the exhaust system.


                                         WAT(~   DISCIo4ItR.G£




                                                                                                    WATEA. Llrr O''"IAUS,T      !.YSTEM

                                                                                                    WI TH   HYOtl;O-,",U~   MUFF"LE:j




                                                                                                       1-3/"" 0,0.




                                                                      '-3/~" o.o~_ _...--,-_S-3/8"
                                                                                         , 1-1/2"
                                                                                           OIA.
                                                                 !'4UFFLER.. PH 131710



EXHAUST SYSTEM WITH WATER JACKETED               WATER LIFT EXHAUST SYSTEM WITH
            STANDPIPE                                "HYDRO-HUSH MUFFLER"
    The exhaust system must be supported or suspended independently of
the engine manifold, usually using simple metal hangers secured to the
overhead.
    All dry portions of the exhaust system should be wrapped in
suitable insulation material to keep surface temperatures as low as
possible.
    Many installations use flexible rubber exhaust hose for the water
cooled section of the exhaust line because of the ease of installation
and flexibility. Provide adequate support for the rubber hose to pre-
vent sagging, bending and formation of water pockets.
    Always arrange the rubber hose section so that water cannot
possibly flow back into the engine. Also make sure that entering sea
water cannot spray directly against the inside of the exhaust piping.
Otherwise, excessive erosion will occur.

MEASURING EXHAUST GAS BACK PRESSURE
    Back pressure must be measured on a straight section of the
exhaust line and as near as possible to the engine exhaust manifold.
The engine should be run at maximum load during the measurement
period. Set-up should be as shown below.
1. For normally asperated engines:
         Pressure Test       Mercury Test     Water Column
         1-1/2" Max PSI      3" Mercury         = 39"
2.   For turbo-charged engines:
          Pressure Test       Mercury Test                       Water Column
          0.75 Max PSI        1-1/2" Mercury                      = 19-1/2"
                                     9
Checking The Back Pressure
1. Exhaust pipe flange
2. Exhaust line
3.     Transparent   plastic  hose,
partly filled with water.
Measurement "A" may not exceed 39"
for normally asperated engines and
19.5" for turbo-charged engines.




WATER CONNECTIONS
    Seacocks and strainers should be of the full flow type at least
one size greater than the inlet thread of the sea water pump.     The
strainer should be of the type which may be withdrawn for cleaning
while the vessel is at sea.
    Water lines can be copper tubing or wire-wound, reinforced rubber
hose.   In any case, use a section of flexible hose that will not
collapse under suction, between the hull inlet and engine and between
the outlet and the exhaust system.   This takes up vibration and per-
mits the engine to be moved slightly when it is being re-a1igned. Do
not use street elbows in suction piping. All pipe and fittings should
be of bronze. Use sealing compound at all connections to prevent air
leaks. The neoprene impeller in the sea (raw) water pump should never
be run dry.

FUEL TANK AND FILTERS
    Fuel tanks may be of fiberglas, monel, aluminum, plain steel or
terne plate.   If made of fiberglas, be certain that the interior is
gel coated to prevent fibers from contaminating the fuel system.
Copper or galvanized fuel tanks should not be used.         It is not
necessary to mount the tank above the eng ine level as the fuel lift
pump provided will raise the fuel from the tank.    The amount of lift
should be kept minimum (6 feet being maximum).    If a tank is already
installed above the engine level, it can be utilized in this position.
Great care should be taken to ensure that the fuel system is correctly
installed so that air10cks are eliminated and precautions taken
against dirt and water entering the fuel.
    A primary fuel filter of the water collecting type should be
installed between the fuel tank and the fuel lift pump. A recommended
type is available from the list of accessor ies.    The secondary fuel
filter is fitted on the engine between the fuel lift pump and the
injection pump and has a replaceable element.
    As the fuel lift pump has a capacity in excess of that required by
the injection pump, the overflow is piped to the fuel tank and should
be connected to the top of the tank or as near the top as possible.
    To insure satisfactory operation, a diesel engine must have a
dependable supply of clean diesel fuel.   For this reason, cleanliness
and care are especially important at the time when the fuel tank is
installed, because dirt left anywhere in the fuel lines or tank will
certainly cause fouling of the injector nozzles when the engine is
started for the first time.

FUEL PIPING
    We recommend copper tubing together with suitable fittings,   both

                                  10
for the supply line and the return line.       Run the tubing in the
longest pieces obtainable to avoid the use of unnecessary fittings and
connectors. The shut off valve in the line between the fuel tank and
eng ine should be of the fuel oil type, and it is important that all
joints be free of pressure leaks.
     Keep fuel lines as far as possible from exhaust pipe for minimum
temperature, to eliminate "vapor locks".
     The fuel piping leading from the tank to the eng ine compartment
should always be securely anchored to prevent chafing.     Usually the
copper tubing is secured by means of copper straps.
     The final connection to the eng ine should be through flexible
rubber hoses.

ELECTRIC PANEL
    The Westerbeke all-electric panel utilizes an electronic tacho-
meter wi th a built-in hourmeter.    Tachometer cables are no longer
required, except for the Skipper mechanical panel.     Mounted on the
panel are a voltmeter, water temperature gauge and ~il pressure gauge.
Each instrument is lighted.   The all-electric panel is isolated from
ground and may be mounted where visible. It is normally pre-wired.

ELECTRICAL EQUIPMENT
    Most Westebeke eng ines are supplied pre-wired and wi th plug-in
connectors.     Never make or break connections while the engine is
running.    'Carefully follow all instructions on the wiring diagram
supplied, especially those relating to fuse/circuit breaker require-
ments.
    Starter batteries should be located as close to the engine as
possible to avoid voltage drop through long leads. It is bad practice
to use the starter batteries for other services unless they require
low amperage or are intermittent.     In cases where there are substan-
tial loads (from lights, refrigerators, radios, depth sounders, etc.),
it is essential to have a complete, separate system and to provide
charging current for this by means of a second alternator or
"alternator output splitter".
    Starter batteries must be of a type which permits a high rate of
discharge (Diesel starting).
    Carefully follow the recommended wire sizes shown in the wiring
diagrams. Plan installation so the battery is close to the engine and
use the following cable sizes:
         #1        for distances up to 8 feet
         #1/0       for distances up to 10 feet
         #2/0       for distances up to 13 feet
         #3/0       for distances up to 16 feet

MECHANICAL CONTROLS
    The recommended practice is to have the stop-run lever loaded to
the run posi tion and controlled by a sheathed cable to a push-pull
knob at the pilot station. The throttle lever should be connected to
a Morse type lever at the pilot station by a sheathed cable.
    The transmission control lever may be connected to the pilot sta-
tion by a flexible, sheathed cable and controlled by a Morse type
lever.   The single-lever type gives clutch and throttle control with
full throttle range in neutral position. The two-lever type provides
clutch control with one lever and throttle control with the other.
    Any bends in the control cables should be gradual.    End sections


                                  11
at engine and transmission must be securely mounted.    After linkages
are completed, check the installation for full travel, making sure
that, when the transmission control lever at the pilot station is in
forward, neutral and reverse, the control lever on the transmission
i~ on the respective detent.  Check the throttle control lever and the
stop-run lever on the fuel injection pump for full travel.
    Some models do not require a stop cable because they have either a
fuel solenoid or an electric fuel pump.   Examples of such models are
the W58 and the W52.




                                  12
                          OPERATION
PREPARATION FOR FIRST START
    The engine is shipped "dry" ··· with lubricating oil drained from
the crankcase and fluid from the transmission. Therefore, be sure to
fOllow these recommended procedures carefully before starting the
engine for the first time.
    1.   Remove oil filler cap and fill oil sump with heavy duty,
diesel lubricating oil to the highest mark on the dipstick. See table
under Maintenance for an approved lubricating oil.    Do not overfill.
Select an approved grade from the listing and continue to use it.
    2. Fill the reverse gear to the highest mark on the dipstick with
TYPE A transmission fluid.      Do not overfill.        Refer to the
Transmission Section of this manual for details.
    Engine oil is not recommended because it can foam, and it can con-
tain additives harmful to some transmissions.
    If the engine is equipped with a V-drive, fill to the full mark on
the dipstick with the recommended lubricant specified on the data tag
on the V-drive housing.
    3. Fill fresh water cooling system with a 50-50 antifreeze solu-
tion only after opening all petcocks and plugs until all entrapped air
is expelled.
    Fill surge tank to within one inch of the top. Check this level
after engine has run for a few minutes.    If trapped air is released,
the water level may have dropped.    If so, refill tank to within one
inch of top and replace filler cap.
    4. Ensure battery water level is at least 3/8" above the battery
plates and battery is fully charged so that it is capable of the extra
effort that may be required on the first start.
    5. Fill fuel tank with clean diesel fuel oil~ No. 2 diesel fuel
oil is recommended. The use of No. 1 is permissible but No. 2 is pre-
ferred because of its higher lubricant content.
    NOTE:   I f there is no filter in the filler of the, fuel tank, the
recommended procedure is to pour the fuel through a funnel of 200 mesh
wire screen.
    6. Fill grease cup on the sea water pump, if present, with a good
grade of water pump grease.
FUEL SYSTEM
    The fuel injection system of a compression ignition engine depends
upon very high fuel pressure during the injection stroke to function
correctly. Relatively tiny movements of the pumping plungers produce
this pressure and, if any air is present inside the high pressure
line, then this air acts as a cushion and prevents the correct
pressure, and therefore fuel injection, from being achieved.
     In consequence, it is essential that all air is bled from" the
system whenever any part of the system has been opened for repair or
servicing.


                                  13
BLEEDING PROCEDURES BY MODEL

     1.   Initial Engine Start-up (Engine stoppage due to lack of fuel)
           a.   Insure that the fuel tank (s) is filled with the proper
           grade of diesel fuel.
           b.  Fill any large primary filter/water separator with clean
           diesel fuel that is installed between the fuel tank and
           engine.   To attempt to fill any large primary filter using
           the manual priming lever on the engine mounted fuel lift pump
           may prove futile or require a considerable amount of priming.
           c. Turn the fuel selector valve to "On".    Systems with more
           than one tank insure that fuel returning is going to the
           tanks being used.
The above procedures are basic for all initial engine start-ups or for
restarting engines stopping due to lack of fuel.

WESTERBEKE W7 AND WPD4 GENERATOR (3600 RPM)   (Figure 1)

1.   with the use of a 5/16 box wrench or common screw driver, open the
     bleed screw one or two turns on the outgoing side of the engine
     mounted secondary fuel filter (Bleed point A). with firm strokes
     on the lift pump priming lever, bleed until fuel free of air
     bubbles flows from this point.    Stop pr iming and gently tighten
     the bleed screw.

2.   With a 5/8 open end wrench loosen one to two turns the          nut
     securing the injector line to the injector (Bleed point B).

     Decompress the eng ine with the lever on the top of the cylinder
     head.  Crank the eng ine over with the starter.   (W7: ensure that
     the engine stop lever is in the run position and the throttle is
     full open.)  (4KW: use the defeat position while cranking.) Crank
     the engine until fuel spurts by the nut and line.    Stop cranking
     and tighten the 5/8 nut and proceed with normal starting proce-
     dures.

WESTERBEKE W30 (Figure 2),  W40 & WPOlO, l2~, 15 (Figure 3),   W50     &
WEO 15 (Figure 4), W80 & BR 30 (Figure 5), W120 & BR 45 (Figure 5)
1.   Open the banjo bolt on top of the engine mounted secondary fuel
     fil ter 1-2 turns (Bleed Point A).  Wi th firm stroke on the fuel
     lift pump priming lever, bleed until fuel free of air bubbles
     flows from this point. Stop priming and tighten the bolt.

2.   On the fuel inj ection pump body is a 5/16 bleed screw (Bleed
     Point B).   This may be mounted on a manifold with a pressure
     switch.   Open this one or two turns (do not remove it) and with
     the pr iming lever bleed until fuel free of air bubbles flows.
     Stop priming and tighten the bleed screw.

3.   On the control cover of the inj ection pump (Bleed Point C) is a
     5/16 bleed screw. Open this screw one to two turns and proceed as
     in Step 2.   (Note: Bypass this bleed point on the W30 inj ection
     pump. )



                                   14
4.   W50 injection pump only.      Open the 5/16 bleed screw (Bleed
     Point D) on the injector line banjo bolt one or two turns and,
     with the throttle full open and the engine stop lever in the run
     position, crank the engine over with the starter until clear fuel
     free of air flows from this point. Stop cranking and tighten this
     bleed screw.

5.   with a 5/8 wrench loosen one to two turns the injector line
     attaching nuts at the base of each injector and, with the throttle
     full open and the engine stop control in the run position, crank
     the engine over with the starter until fuel spurts by the nuts and
     injector line at each injector. Stop cranking and tighten the nut
     and proceed with normal starting procedures.

WESTERBEKE W13, 4.4KW, W21, 7.7KW, W27, 11.lKW, W33, 12.5KW (Figure 6)

These units are self-bleeding.
1. Turn the ignition to the ON position and wait 15--20 seconds.
2. Start the engine following normal starting procedures.

WESTERBEKE W58 & WTO 20 (Figure 7)

1.   Open the bleed screw on the top inboard side of the engine-mounted
     secondary fuel filter one to two turns using a 10mm box wrench
     (Bleed Point A).     This fuel filter is equipped with a hand-
     oper ated pr iming pump.  Wi t.h the palm of your hand, pump this
     primer until fuel free of air flows from this point. Stop pumping
     and tighten the bleed screw.
2.   With bleed screw A tightened, pump the hand primer several more
     times.   This primes the injection pump which is self-bleeding.
     The injection pump incorporates a feed pump which keeps the fuel
     system primed when the eng ine is running: thus, no external lift
     pump is required.

3.   Loosen the four injector line attaching nuts at the base of each
     inj ector (Bleed Point B) one to two turns with a 16mm open end
     wrench.   Place the throttle in the full open position and crank
     the engine over with the the starter until fuel spurts by the nut
     and injector lines.    stop cranking and tighten each of the four
     nuts and proceed with normal starting procedure.




              Figure 1                            Figure 2
                                     15
Figure 3               Figure 6




Figure 4               Figure 7




Figure 5        Typical Mechanical Fuel
           16          Lift pump
PREPARATION FOR STARTING
1.   Check water level in expansion tank.      It should be    l~   to 2 in.
     below the top of the tank when cold.

2.   Check the engine sump oil level.

3.   Check the transmission fluid level.

4.   See that there is fuel in the tank and the fuel shut-off is open.

5.   Check to see that the starting battery is fully charged, all
     electrical connections are properly made, all circui ts in order
     and turn on the power at the battery disconnect.

6.   Check the seacock and ensure that it is open.

STARTING THE ENGINE (COLD)

Most Westerbeke marine diesel engines are equipped with a               cold
starting aid to ease in the starting of your engine when cold.

1.   Check to see that the "stop" lever    (if installed)   is in the "run"
     position.

2.   place the throttle in the fully open position.

3.   Press the "Preheat" button in and hold for 15 to 20 seconds.

4.   While holding the "Preheat" button in, turn the keyswitch to the
     "ON" or "Run" position. This activates the panel gauges, lights
     and fuel solenoid or electric fuel pump if so equipped.   Continue
     to turn the keyswitch to the "Start" position and hold for no more
     than 20 seconds. Some units may be equipped with a pushbutton to
     start rather that the keyswitch and in these cases the electrical
     system is activated by fuel pressure.

5.   If the engine fails to start in 20 seconds, release start switch
     and preheat for an additional 15 to 20 seconds, then repeat
     step 4.

6.   As soon as the eng ine starts, release the start switch and the
     preheat button and return the throttle to the "idle" position
     immediately.

CAUTION:  Do not crank the engine more than 20 seconds when trying to
start. Allow a rest period of at least twice the cranking period bet-
ween the start cycles.   Starter damage may occur by overworking the
starter motor and the backfilling of the exhaust system is possible.

STARTING THE ENGINE (WARM)
I f the eng ine is warm and has only been stopped for a short time,
place the throttle in the partially open position and engage the
starter as above, eliminating the preheat step.



                                   17
NOTE:   Always be sure that the starter plnlon has stopped revolving
before again re-engaging the starter ~ otherwise, the flywheel ring
gear or starter pinion may be damaged.                                     ,/



Ensure that the electr ical connection to the cold starting aid is
correct.
Extended use of the cold starting aid beyond the time periods stated
should be avoided to prevent damage to the aid.
NEVER under any circumstances use or allow anyone to use ether to
start your engine.    If your engine will not start, then have a
qualified Westerbeke'marine mechanic check your engine.

WHEN ENGINE STARTS
1.   Check for normal oil presure immediately upon engine starting. Do
     not continue to run engine if oil pressure is not present within
     IS seconds of starting the engine.
2.   Check Sea Water Flow.   Look for water at exhaust outlet.   Do this
     iwthout delay.
3.   Recheck Crankcase Oil. After the engine has run 3 or 4 minutes,
     subsequent to an oil change or new installation, stop the engine
     and check the crankcase oil level. This is important as it may be
     necessary to add oil to compensate for the oil that is required to
     fill the engine's internal oil passages and oil filter.    Add oil
     as necessary. Check oil level each day of operation.
4.   Recheck Transmission Fluid level.    (This applies only subsequent
     to a fluid change or new installation.) In such a case, stop the
     engine after running for several minutes at 800 RPM with one shift
     into forward and one into reverse, then add fluid as necessary.
     Check fluid level each day of operation.
S.   Recheck Expans ion Tank Water Level, if engine is fresh water
     cooled.   (This applies after cooling system has been drained 'or
     filled for the first time.)     Stop engine after it has reached
     operating temperature of l7S·F and add water to within one inch of
     top of tank.
WARNING: The system is pressurized when overheated, and the pressure
must be released gradually if the filler cap is to be removed. It is
advisable to protect the hands against escaping steam and turn the cap
slowly counter-clockwise until the resistance of the safety stops is
felt. Leave the cap in this position until all pressure is released.
Press the cap downward against the spring to clear the safety stops
and continue turning until it can be lifted off.
6.   Warm-up Instructions. As soon as possible, get the boat underway,
     but at reduced speed, until water temperature gauge indicates
     l30-lS0·F.    If necessary, engine can be warmed up with the
     transmission in neutral at 1000 RPM.       Warming up with the
     transmission in neutral takes longer and tends to overheat the
     transmission.
                                   18
7.   Reverse Operation.    Always reduce      engine to idle speed when
     shifting gears.   However, when the      transmission is engaged, it
     will carry full engine load.
NOTE: The SAO transmission requires that when backing down, the shift
lever must be held in the reverse position, since it has no positive
overcenter locking mechanism.


STOPPING THE ENGINE

1.   position shift lever in neutral.

2.   Idle the engine for 2 to 4 minutes to avoid boiling and to dissi-
     pate some of the heat.

3.   If equipped with a stop lever, pull the knob and hold in this
     position until the engine stops.   This stops the flow of fuel at
     the injection pump. After the engine stops, return the control to
     the run position to avoid difficulty when restarting the engine.

4.   Turn off the keyswitch.  Some models do not use the stop lever as
     they are equipped with a fuel solenoid or electric fuel pump which
     shuts off the fuel supply when the keyswitch is turned to the OFF
     position.

5.   Close the seacock.

6.   Disconnect power to system with battery switch.


OPERATING PRECAUTIONS

1.   Never run eng ine for extended per iods when excessive overheating
     occurs, as extensive internal damage can be caused.

2.   DO NOT put cold water in an overheated engine.      It can crack the
     cylinder head, block or manifold.

3.   Keep intake silencer free from lint, etc.

4.   Do not run engine at high RPM without clutch engaged.

5.   Never Race a Cold Engine as internal damage can occur due to ina-
     dequate oil circulation.

6.   Keep the engine and accessories clean.

7.   Keep the fuel clean.   Handle it wi th extreme care because water
     and dirt in fuel cause more trouble, and service life of the
     injection system is reduced.

8.   Do not allow fuel to run low, because fuel intake may be uncovered
     long enough to allow air to enter the injection system, resulting
     in engine stoppage requiring system bleeding.



                                   19
9.   Do not be alarmed if temperature gauges show a high reading
     following a sudden stop after engine has been operating at full
     load.   This is caused by the release of residual heat from the
                                                                          /
     heavy metal masses near the combustion chamber.     Prevention for
     this is to run engine at idle for a short period before stopping
     it.   High temperature reading after a stop does not necessar ily
     signal alarm against restarting.   If there is no functional dif-
     ficulty, temperatures will quickly return to normal when engine is
     operating.




                                   20
                       TEN MUST RULES

IMPORTANT                       IMPORTANT                     IMPORTANT
··· for your safety and your engine's dependability.

ALWAYS -
    1.   Keep this Manual handy and read it whenever in doubt.
    2.   Use  only filtered fuel oil and check lube oil level daily.
    3.   Check  cooling water temperature frequently to make sure it is
         190· or less.
    4.   Close all drain cocks and refill with water before starting
         out.
    5.   Investigate any oil leaks immediately.

NEVER -
    6.      Race the engine in neutral.
    7.      Run the engine unless the gauge shows proper oil pressure.
    8.      Break the fuel pump seals.
    9.      Use cotton waste or fluffy cloth for cleaning or store fuel
            in a galvanized container.
   10.      Subject the engine to prolonged overloading or continue to
            run it if black smoke comes from the exhaust.




                                    21
                           MAINTENANCE
PERIODIC ATTENTION:
    After you have taken delivery of your engine, it is important that
you make the following checks right after the first fifty hours of its
operation.
    Note:   Transmissions generally require fluid change after the
first 25 to 30 hours of operation. Refer to the Transmission section
of this manual for details.

FIFTY HOUR CHECKOUT (INITIAL)
Do the following:
1.     Retorque the cylinder head
bolts.
2.    Retorque the rocker bracket
nuts    and    adjust    valve     rocker
clearance.
3. Check and adjust, if necessary,
the forward drum assembly and the
reverse band on manual SAO and SA-l
transmissions.
4. Change engine lubricating oil
and oil filter.
s. Check for fuel and lubr icating
oil leaks. Correct if necessary.
6. Check cooling system for leaks
and inspect water level.
7.   Check     for    loose    fittings,
clamps, connections, nuts, bolts,
vee belt tensions, etc.         Pay par-
ticular      attention      to      loose
engine mounts engine mount fit-
tings.      These could cause mis-
alignment.


DAILY CHECKOUT
Do the following:
1. Check the sea water strainer, if one has been installed.
2. Check water level in cooling system.
3.   Check lubricating oil level in sump.    Fill to highest mark on
dipstick.
4. Turn down grease cup on water pump, if used, one full turn.
5.   Check fluid level in transmission.     Fill to highest mark on
dipstick with proper fluid.

SEASONAL CHECK-OUT (MORE OFTEN IF POSSIBLE)
Do the following:
1.   Check gener ator , alternator and sea water pump "V" belts for
proper tension.
2. Check water level in battery.
3. Change oil in sump. See Note.
4. Replace lubricating oil filter, Figure 2. See Note.
5. Fill sump with diesel lubricating oil to highest mark on dipstick.
Refer to Specification page for proper quantity of oil.       Do Not
Overfill. See Note.


                                       22
CAUTION:   The use of different brands of lubricating oils during oil
changes has been known to cause extensive oil sludging and may in many
instances cause complete oil starvation.
6.   Start engine and run for 3 or 4 minutes.    Stop engine and check
oil filter gasket for leaks. Check oil sump level. This is important
as it may be necessary to add oil to compensate for the oil that is
required to fill the eng ine' s internal oil passages and oil filter.
Add oil as necessary. See Note.

IMPORTANT NOTE
IT IS MANDATORY THAT THE CHECKS 3, 4 ,    5 AND 6 BE ATTENDED TO WHEN
TOTAL OPERATING TIME REACHES 150 HOURS.   IN SOME INSTANCES, THIS TOTAL
IS REACHED BEFORE END OF SEASON.

7.   Clean Air Filter if supplied.   (Most models have an air silencer
that does not require cleaning.)    The time per iod for replacing the
air filter depends on operating conditions; therefore, under extremely
dirty conditions, the seasonal frequency should be increased.      The
correct time periods for replacing the filter will greatly assist in
reducing bore wear, thereby extending the life of the engine.
8. Check engine for loose bolts, nuts, etc.
9. Check sea water pump for leaks.
10. Wash primary filter bowl and screen.      If filter bowl contains
water or sediment, filter bowl and secondary oil fuel filter need be
cleaned more frequently.
11. Replace secondary fuel filter element.
12. Replace air filter.
13. Change the fluid in the transmission.    Refer to the Transmission
Section of this manual for details.

END OF SEASON SERVICE
1.    Drain fresh water cooling system by removing the surge tank
pressure cap and opening all water system petcocks.
2.  Remove zinc rod (usually located in heat exchanger) and see if it
needs replacing. The zinc rod will take care of any electrolysis that
may occur between dissimilar metals. Insert new zinc if necessary.
3.    Fill fresh water cooling system with antifreeze of a reputable
make.   (Refer to Cold Weather Precautions.)
4. Start engine. When temperature gauge indicates l7S·F, shut engine
down and drain lubricating oil. Remove and replace filter. Fill sump
with High Detergent Lubricating Oil.
5.   Carefully seal air intake opening with waterproofed adhesive tape
or some other suitable medium.                                      .
6.   Seal the exhaust outlet at the most accessible location as close
to the engine as possible.
7. Remove injectors and spray oil into cylinders.
8.    Replace injectors with new sealing washer under each injector.
Turn engine slowly over compression.
9. Top off fuel tank completely so that no air space remains, thereby
preventing water formation by condensation.
10. Leave fuel system full of fuel.
11. Change fuel filters before putting the engine back in service.
12. Wipe engine with a coat of oil or grease.
13. Change fluid in transmission.    Refer to the Transmission Section
of this manual for details.
14. Disconnect battery and store in fully charged condition.    Before


                                  23
storing the battery, the battery terminals and cable connectors should
be treated to prevent corrosion. Recharge battery every 30 days.
15. Check alignment.




                                  24
                           LUBRICATING OILS

Lubricating oils are available for Westerbeke Diesel engines which
offer an improved standard of performance to meet the requirements of
modern operating conditions such as sustained high speeds and tem-
peratures.
These   oils   meet   the  requirements   of   the   U.  S.   Ordnance
Specifications MIL-L-2l04B (API Service CC).     Any other oils which
also conform to these specifications, but are not listed here, are, of
course, also suitable.



                                                 S.A.E. DESIGNATION
       COMPANY              BRAND             0·/4S·F 4S·/80·F OVER 80·F

American Oil Co.     American Supermil
                     Motor Oil                  lOW    20W/20     30
BP Canada Ltd.       BP Vanellus                lOW    20W/20     30
                     BP Vanellus              10W/30   10W/30   10W/30
Chevron Oil Co.      RPM DELO Multi
                     service Oil                lOW    20W/20     30
Cities Service Oil
Co.                  CITGO Extra Range          lOW    20W/20     30
Continental Oil
Co.                  CONOCO TRACON OIL          lOW    20W/20     30
Gulf Oil             Gulflube Motor Oil
Corporation          X.H.D.                     lOW    20W/20     30
Mobil Oil Company    Delvac 1200 Series        1210     1220     1230

Shell Oil Company    Shell Rotella T Oil        lOW    20W/20     30

Sun Oil Company      Subfleet MIL-B             lOW    20W/20     30

Texaco, Inc.         Ursa Oil Extra Duty        lOW    20W/20     30




                                      2S
YOUR NOTES




    26
                                              A1




  ENGINE OVERHAUL
                   p

The following sections contain detailed
information relating to the proper operat-
ing characteristics of the major components
and systems in the          engine. In-
cluded are disassembly, rework and reas-
sembly instructions for the guidance of
suitably equipped and staffed marine engine
service and rebuilding facilities. The
necessary procedures should be undertaken
only by such facilities.

Additional operating characteristics are
included in the Operation Section of this
manual.

Any replacements should be made only with
genuine Westerbeke parts.
A2

     GENERAL SPECIFICATION DATA
     ENGINE - Diesel 1.8 litre
       Type . . · · . . . . . . . . . . . . . . . . . . .    18V----D
       Number of cylinders .·.....·.....                     4
       Bore .......· ' . . . . . . . . . . . . . . .         3.16 in (80.26 mm)
       Stroke . . · . . . . . . . . . . . . . . . . . . .    3.5 in (88.9 mm)
       Capacity ..........·.....·.·.·                        109.8 in 3 (1799 cm 3 )
       Injection order . . . . . . . . . . . . . . . . .     1,3,4,2
       Valve operation . . . . . . . . . . . . . . . .       Overhead by push-rod
       Compression ratio . . . . . . . . . . . . . .         21.47: 1
       Torque (gross) . . . . . . . . . . . . . . . . .      79'lbf ft (10.92 kgf m) at 2,400 rev/min
     Crankshaft
        Main journal diameter . . . . . . . . . . . .        2.1262 to 2.1270 in (53.992 to 54.012 mm)
        Minimum regrind diameter . . . . . . . . .           2.1162 to 2.1170 in (52.742 to 53.762 mm)
        Crankpin journal diameter . . . . . . . . .          1.8759 to 1.8764 in (47.64 to 47.65 mm)
        Minimum regrind diameter ..·......                   1.8659 to 1.8664 in (47.39 to 47.40 mm)
        Crankshaft end-thrust · . . . . . . . . . . .        Taken on thrust washers at centre main
                                                                bearing
        Crankshaft end-float . . . . . . . . . . · . .       0.001 to 0.0055 in (0.025 to 0.139 mm)
     Main bearings
       Number and type . . . . . . . . . . . . . . .         5 Steel backed lead indium
       Length: Front, centre and rear .. . ·..               1.120 to 1.130 in (28.45 to 28.70 mm)
                Intermediate ·..·.......·                    0.760 to 0.770 in (19.30 to 19.55 mm)
       Diametrical clearance . . . . . . . . . . . .         0.001 to 0.0027 in (0.03 to 0.07 mm)
       Undersizes .... '. . . . . . . . . . . . . . .        0.010 in (0.25 mm)
     Connecting rods
       Type . . . . · . . . . . . . . . . . . . . . . . .    Horizontally split big-end, plain small end
       Length between centres ......·....                    6.220 to 6.222 in (157.9 to 158.0 mm)
     Big·end bearings
        Type .··.··..·..............                         Steel backed lead indillm
        Length . . . . . . . . . . . . . . . . . . . . . .   0.775 to 0.785 in (19.68 to 19.93 mm)
        Diametrical clearance . . . . . · . . . . . .        0.001 to 0.0027 in (0.03 to 0.07 mm)
        Undersizes . . . . . . . . . . . . . . . . . . .     0.010 in (0.25 mm)
     Gudgeon pin
       Type . . . · · · . . . . . . . . . . . . . . . . .    Fully floating with circ1ip location
       Fit in piston . . . . . . . . . . . . . . . . . .     0.0001 to 0.0003 in (0.002 to 0.007 mm)
                                                                clearance
        Fit in connecting rod . . . . . . . . . . . .        0.0002 to 0.0009 in (0.02 to 0.04 mm)
                                                                clearance
        Diameter (outer) . · . . . . . . . . . . . . .       0.9998 to 1.0000 in (25.39 to 25.40 mm)
     Pistons
        Type ..···.·................                         Aluminium alloy, solid skirt, with open
                                                               combustion cavity
        Clearances:
           Top land . . . . . . . . . . . . . . . . . . .    0.0171 to 0.0211 in (0.43 to 0.57 mm)
           Bottom land . . . . · . . . . . . . . . . .       0.0137 to 0.0172 in (0.35 to 0.44 mm)
           Bottom of skirt . . . . . . . . . . . . . .       0.004 to 0.005 in (0.10 to 0.13 mm)
        Oversizes . . . . . . . . . . . . . . . . . . . .    0.020 in and 0.040 in (0.51 mm and 1.02
                                                                mm)
     Piston rings
        Compression:
           Type: Top ·...·....·..·....                       Chrome-faced
                  Second . . . . . . . . . . . . . . .       Tapered, cast iron alloy
          ,Width . . . . . . . . . . . . . . . . . . . . .   0.0771 to 0.0781 in (1.96 to 1.98 mm)
           Fitted gap: Top . . . . . · . . . . . . . .       0.012 to 0.017 in (0.30 to 0.43 mm)
                        Second . . . . . . . . . . . .       0.009 to 0.014 in (0.23 to 0.35 mm)
           Ring to groove clearance: Top ... .               0.0025 to 0.0045 in (0.06 to 0.11 mm)
                                           Second ..         0.0015 to 0.0035 in (0.04 to 0.09 mm)
        Oil control
           Type . . . . . . . . . . . . . . . . . . . . .    Slotted scraper
           Fitted gap . . . . . . . . . . . . . . . . . .    0.012 to 0.017 in (0.30 to 0.43 mm)
           Ring to groove clearance ....... .                0.0015 to 0.0035 in (0.04 to 0.09 mm)
                                                                                                         A3
Camshaft
  Journal diameteIS: Front . . . . . . . . . .            1.78875 to 1.78925 in (45.43 to 45.44 mm)
                       Centre ..·......                   1.72875 to 1.72925 in (43.91 to 43.93 mm)
                       Rear ·..........                   1.62275 to 1.62325 in (41.22 to 41.23 mm)
  Bearing liner inside diameter (reamed
     after fitting):
     Front.·. · . . . . . . . . . . . . . . . . . .       1.79025 to 1.79075 in (45.47 to 45.48 mm)
     Centre . . . . . . . . . . . . . . . . . . . .       1.73025 to 1.73075 in (43.95 to 43.96 mm)
     Rear · · . . . . . . . . . . . . . . . . . . .       1.62425 to 1.62475 in (40.26 to 40.27 mm)
  Diametrical clearance .·..........                      0.001 to 0.002 in (0.02 to 0.05 mm)
  End-thrust ......··.......·...                          Taken on locating plate
  End-float . . . . . . . . . . . . . . . . . . . .       0.003 to 0.007 in (0.08 to 0.18 mm)
Rocker gear
  Rocker shaft diameter . . . . . . . . . . . .           0.624 to 0.625 in (15.85 to 15.87 mm)
  Rocker bush inside diameter (reamed in
     position) . . . . . . . . . . . . . . . . . . .      0.6255 to 0.6260 in (15.89 to 15.90 mm)
Tappets
  Type . . . . . . . . . . . . . . . . · . . . . . .      Bucket
  Outside diameter . . . . . . . . . . . . . . .          0.8125 in (20.65 mm)
  Length ... ',' ··...·..·........                        1.495 to 1.505 in (37.97 to 38.23 mm)
Valves
  Seat angle: Inlet ....··..........                      45°
                Exhaust ·..··........                     45°
  Head diameter: Inlet .·.....·.·...                      1.434 to 1.439 in (36.42 to 36.55   mm)
                     Exhaust ..··.·....                   1.207 to 1.212 in (30.64 to 30.78   mm)
   Stem diameter: Inlet .....··......                     0.3428 to 0.3433 in (8.71 to 8.73   mm)
                     Exhaust .·.·.·....                   0.3422 to 0.3427 in (8.69 to 8.70   mm)
   Stem to guide clearance: Inlet ...... .                0.0008 to 0.0020 in (0.02 to 0.05   mm)
                             Exhaust ... .                0.0014 to 0.0026 in (0.03 to 0.06   mm)
   Valve lift: Inlet and exhaust ....... .                0.384 in (9.75 mm)
  Valve: Stand down .····.........                        0.0445 to 0.0505 in (1.13 to 1.28   mm)
Valve guides
   Length: Inlet and exhaust ....·....                    2.22 in (56.39 mm)
  Outside diameter: Inlet and exhaust ...                 0.5635 to 0.5640 in (14.31 to 14.33 mm)
   Inside diameter (reamed after fitting):
      Inlet and exhaust ..·..........                     0.3441 to 0.3448 in (8.74 to 8.76 mm)
   Fitted height above spring seat: Inlet
      and exhaust . . . . . . . . . . . . . . . . .       0.55 to 0.56 in (13.9 to 14.2 mm)
   Interference fit in head: Inlet and
      exhaust . . . . . . . . . . · . · . . . . . .       0.0005 to 0.00175 in (0.01 to 0.04 mm)
Valve springs
   Free length · . . . . . . . · . . . . . . . . . .      1.92 in (48.77 mm)
   Fitted length . . . . . . . . . . . . . . . . . .      1.44 in (36.57 mm)
   Load at fitted length . . . . . . . . . . . . .        821bf (37.19 kgf, 364 N)
   Load at top of lift .·.·..·.......                     1421bf (64.4 kgf, 631 N)
   Number of working coils . . . . . . . . . .            4Ya
Valve timing
  Timing marks . . . . . . . . · . . . . . . . ·          Dimples on timing wheels, marks on
                                                             flywheel
   Rocker clearance: Running ....... .                    0.017 in (0.43 mm) cold
                       Timing ....... ..                  0.024 in (0.61 mm)
   Inlet valve: Opens ..·.....··.....                     8° B.T.D.C.
                Closes ...·..·........                    42° A.B.D.C.
   Exhaust valve: Opens . . . . . . . . . . . .           60° B.B.D.C.
                   Closes .··.........                    12° A.T.D.C.
Lubrication
  System . . . · . . . . . . . . . . . . . . . . . .      Wet sump, pressure fed
  System pressure: Running . . . . . . . . .              Between idle and running speed the
                                                          pressure will vary from 45-85 psi.
   Oil pump . . . . . · . . . . . . . . . . . . . .       Rotor type
   Oil filter . . . . . . . . · . · . . . . . . . . . .   Full flow; disposable cartridge type
   Oil pressure relief valve . . . . . . . . . . .        50lbf/in2 (3.52 kgf/cm 2 )
   Relief valve springs: Free length .... .               3 in (76 mm)
                             Fitted length ... .          2.156 in (54.77 mm)
   Load at fitted length .··..........                    15.5 to 16.51bf (7.0 to 7.4 kgf, 69 to 73 N)
A4
        FUEL SYSTEM
          Fuel injection pump . . . . . . ..·....               C.A.V
            Type . . . . . . . . . . . · . . . . . . . . .      DPA
            Injection timing . . . . . . . . . . . . . .        18° B.T.D.C.
          Fuel lift pump . . . . . . · . . . . . . . . . .      A.C. Mechanical
          Fuel injectors . . · . . . . · . . . . . . . . .      C.A. V. Pintaux
            Nozzle type . . . . . . . . . . . . . . . . .       BDN.OSPC.6651
            Nozzle holder type . . . . . . . . . . . .          BKB.35SD.5188
            Opening pressure . . . . . . . . . . . . .          135 Atm
          Main fuel filter . . . . . . . · . . . . . . . . .    C.A.V.
            Type . . . . . . . . . . . . . . . . . . . . .      FS5836B130
          Heater plugs
            Champion . . . . . . · . . . . . . . . . . .        AG32

       TORQUE WRENCH SETTINGS
                                                                1bf ft        kgfm     Nm
        Cylinder head nuts ·..··.·.........                     75            10.4     102
        Rocker bracket nuts . . . . . . . . . . . . . . .       25            3.5      34
        Manifold nuts . . . . · . . . · . . . · . . . . . .     15            2.1      20
        Big-end nuts . . . · . . . . . · . . . . . . . . . .    35            4.8      47
        Main bearing set screws . . . . . . . . . . . . .       75            10.4     102
        Flywheel bolts . . · . . . . . . . . . . . . . . . .    40            5.5     .54
        Timing cover bolts: ~ in . . . . . . . . . . . .        14            1.9      19
                               fe- in . . . . . . . . . . . .   30            4.1      41
        Rear plate bolts: fe- in . . . . . . . . . . . . . .    20            2.8      27
                           -& in . . . . . . . . . . . . . .    30            4.1      41
        Camshaft nut . . . . . . . . . . . . . . . . . . . .    65            9.0      88
        Crankshaft bolt . . . . . . . . . . . . . . . . . .     75            10.4     101
        Idler gear hub bolt . . . . · . · · . . . . . . . .     30            4.1      41
        Cylinder side cover set screws . . . . . . . . .        4             0.5      5
        Rocker cover nuts . . . . . . . . . . . . . . . .       4             0.5      5
      . Sump bolts . . . . · . . . . . . . . . . . . . . . .    6             0.8      8
     . Oil filter adaptor . . . . . . . . . . . . . . . . .     30            4.1      41
        Oil pump nuts . . . . . . . . · . . . . . . . . . .     16            2.2      22
        Oil release valve - domed nut . . . . . . . . .         45            6.2      61
        Starter motor bolts . . . . · . . . . . . . . . . .     35            4.8      47
        Clutch to flywheel . . . . . . · . . . . . . . . .      25            3.5      34
        Fuel lift pump nuts · . . . . · . . . . . . . . . .     12            1.7      16
        Injector nozzle nut . . . . . . . . . . . . . . . .     50            6.9      68
        Injection pump nuts . . . . . . . . . . . . . . .       18            2.5      24
        Injector nuts . . . . . . . . . . . . . . . . . . . .   12            1.7      16
        Injection pump driving flange set screws ..             10            1.4      14
        Water pump bolts . . . . . . . . . . . . . . . . .      17            2.3      23
        Water pump pulley set screws. . . . . . . . . .         18            2.5      24
        Alternator pulley nut . . . . . . . . . . . . . .       27            3.7      36
        Thermal transmitter . . . . . . . . . . . . . . .       16            2.2      22

       TRANSMISSIONS
           Type SAO Westerbeke/Paragon Manual
           Type SAOV with RVIOS Vee Drive
           Short Profile Sailing Gear
           Paragon Hydraulic
           Warner Hydraulic
           Propeller rotation is left hand except Warner 1.91 to 1

       ENGINE MOUNTS
           Type .·.·.····..·..···.····.·                        Flexible Adjustable

       COOLING SYSTEM
           Type ·..···..···..·..····.····                        Centrifugal Pump, Thermostat
           Thermostat Setting ...··..·.··                        82C (180F)
           Water Capacity (Fresh) ..·.···                        7 Quarts
FUEL INJECTION PUMP HUB                                          OIL PUMP DRIVE SHAFT
  Remove and refit                12.10.26            3            Remove and refit              12.10.30
  Fuel injection pump gear I to 5                                  Oil pump                      12.60.26
  and 12 to 18                    12.10.25                       Removing
                                                                 1   "'A'
Removing                                                         2  Drain the sump.
1 Remove the timing chain, see                                   3  Disconnect the oil cooler pipe from
   12.65.14.                                                        the LH side of the crankcase.
2 Remove the injection pump, see                                 4  Release the oil pipe clip. from the
   19.30.07.                                                        gearbox mounting plate and move the
3  Remove the four bolts from the                                   oil pipe aside.
   injection pump driving flange.                                5  Remove the sump.
4 Withdraw the driving flange and                                6  Remove the oil strainer and gasket.
   collect the two locating half plates.                         7 Remove the three oil pump securing
5 Withdraw the injection pump gear.           9                     nuts.
6  Remove the injection pump drive oil                           8 Withdraw the oil pump and its drive
   feed pipe.                                                       shaft.
7  Remove the countersunk screw from                             9 Withdraw the drive shaft from the oil
   the injection pump hub.                                          pump.
8  Remove the upper bolt from the chain                          10 Remove the oil pump gasket.
   vibration damper.
9  Remove the injection pump hub.                                Refitting
10 Remove the hub gasket.                                        II Reverse the procedure in 1 to 10,
11 Remove the oil pipe union from the                                tightening the oil pump securing nuts
   hub.                                                              to 161bf ft (2.2 kgf m, 22 Nm).
Refitting
I 2 Reverse the procedure in 5 to II.
13 Ensure that the circlip is correctly
    located in its groove in the splined              /'
    bore of the injection pump driving            /         3    TAPPETS
    flange.                                       z~               Remove and refit              12.29.57
14 Fit one of the locating half plates to                          Camshaft 1 to 17 and 20 to 32 12.13.02

                                                                                                                  ~AJ(~
    its groove in the injection pump hub,             SHe "'53
                                 n
    and position it by inserting a in (5.5                       Service tool: 18G 694
    mm) peg through the timing hole in
                                                                 Removing



                                                                                                             : ~Lo .(Ii~"~
    the locating plate and into the timing
    hole in the gear.                                            1   NA
15 Fit the second locating half plate and                        2   Drain the sump.
                                                                 3   
                                                                                                                                                          U1
                                                                                                                                                                                  ~
                                                                                                                                                                                  0)



I 2 Lay the engine on its side with the                                    2       5       12      17 Lift off the front mounting plate,                  IBGI24F
    cylinder head slightly downwards.                                                                 complete with injection pump, front




                                                                                                                                                ,
13 Withdraw the dipstick.                                                                             mounting brackets, chain tensioner
14 Remove the sump.                                                                                   stop-pin, and chain tensioner shoe.
15 Remove the oil pump and its drive                                                               18 Remove the fuel lift pump.
    shaft.                                                                                         19 Withdraw the dipstick.
16 Rotate the camshaft to position all the                                                        20 Release the dipstick tube from the
    tappets away from their cams.                                                                     cylinder head nut and withdraw the
17 Withdraw the camshaft.                                                                             tube from the crankcase.
18 Withdraw the tappets and retain their                                                          21 Disconnect and remove No. I heater                                INC49BC

    order for refitting.                                                                              plug.
                                                    14                                            22 Remove the rocker cover and gasket.
                                                                                                  23 Remove the rocker shaft assembly,
                                                                                                      noting the locking plate on the rear
Refitting                                                                                             bracket and the shim under each
19 Fit the tappets with their open ends                                                               centre bracket.
     towards the cylinder head.                                                                   24 Withdraw the push-rods, retaining
20 Fit the camshaft.                                                                                  their order for refitting.
21 Fit the oil pump and its drive shaft,                                                          25 Remove the cylinder head nuts.
     tightening the retaining nuts to 16 Ibf    CAMSHAFT BEARINGS                                 26 Lift off the cylinder head.
     ft (2.2 kgf m, 22 Nm).                                                                           NOTE: The combustion chamber
22 Fit the sump.                                  Remove and refit             12.13.13
                                                                                                      inserts may drop out of the cylinder
23 Fit the dipstick.                            Service tools: 18G 55 A, 18G 123 A, 18G               head as it is lifted; they MUST be
24 Place the engine in an upright               123 B, 18G 123 E, 18G 123 F, 18G 123 L,               refitted in their original positions.
     position.                                  18G 123 T, 18G 123 AB, 18G 123 AC,                27 Remove the cylinder head gasket.
25 Fit the push-rods.                           18G 123 AD, 18G 124 A, 18G 124 B, 18G             28 Lay the engine on its side with the
26 Fit the rocker shaft assembly, noting:       124 C, 18G 124 F, 18G 124 H, 18G 134,                 cylinder head face slightly downwards.
     a     Ensure that the shim is fitted       18G 134 CQ, 18G 284, 18G 284 A, 18G               29 Remove the sump.
           under both centre brackets.          284 AC, 18G 694, 18G 1108, 18G 1195               30 Remove the oil pump and its drive
     b     Fit the locking pia te to the rear                                                         shaft.
           bracket.                             Removing                                          31 Remove the big-end bearing caps and
     c    Tighten the cylinder head nuts to     I        NA                                           bearing halves.                                        IBGI24B
          75 Ibf ft (l0.4 kgf m, 102 Nm) in     2        Drain the sump.                          32 Remove the main bearing caps and
          the sequence shown, using tool        3        NA                                           bearing halves, using tools 18G 284,
           18G 694 to reach the centre row.     4        Remove the                                   18G 284 A, and 18G 284 AC.
    d     Tighten the rocker bracket nuts       5        Remove the flywheel.                     33 Lift out the crankshaft and remove
          to 25 Ibf ft (3.5 kgf m, 34 Nm).      6        Remove the crankshaft rear oil seal          the bearing and thrust washer halves.
27 Fit the fuel lift pump.                               retainer.

                                                                                                                                                                           i
                                                                                                   34 Withdraw the connecting rod and
28 Fit the camshaft locating plate.             7        Remove the bolts securing the gearbox        piston assemblies.
29 Fit the camshaft gear, timing chain,                  adaptor plate and pull the adaptor        35 Rotate the camshaft to position all the
     and timing gear cover, see·12.65.12.                plate off its two locating dowels.           tappets away from their cams.                                    INC497C.
     NOTE: Do not leave the crankshaft          8        Remove the two adaptor plate gaskets.     36 Withdraw the camshaft.
     pulley in position.                        9        Remove the alternator.                    37 Withdraw the tappets and retain their     IBGI24C      IBGI24H
30 Adjust the valve rocker clearance, see       10       Remove the high-pressure pipes from          order for refitting.
     12.29.48.                                           the injectors and pump.                  "38 Remove the camshaft front bearing
31 Fit the rocker cover and its gasket.         II       Remove the injection pump drive oil          liner, using tools 18G 124 A and 18G
32 NA                                                    feed pipe.                                   124 F as shown.
33 Run the engine for a minimum of 5            I2       Remove the timing chain and the           39 Remove the camshaft rear bearing
     miles, 8 km or I 5 mins and on return               camshaft gear, see 12.65.12.                 liner, using tools 18G 124 A and 18G
     slacken the cylinder head nuts             13       Remove the camshaft locating plate.           I 24 B as shown.
     approximately 1 of a turn in the           14       Remove the chain vibration damper.       40 Remove the camshaft centre bearing
     sequence shown before retightening         15       Remove the bolt securing each front          liner, using tools 18G 124 A, 18G 124
     them to 75lbfft (lO.4kgfm, 102 Nm)                  mounting bracket to the crankcase.           C, and 18G 124 H as shown.                                        INC496E
     in the sequence shown. Check the           16       Remove the two bolts securing the
     valve rocker clearances.                            front mounting plate to the crankcase.
Refitting                                                                                                       18GI23AC
NOTE: When fitting each new bearing liner
ensure that its oil holes are lined up with
those in the crankcase.
41 Fit a new camshaft front bearing liner,
     using tools I SG 124 A and ISG 124 F
     as shown.
42 Fit a new camshaft rear bearing1iner,
     using tools 18G 124 A and 18G i 24 B
     as shown.                                                                      INC495C
                                                                                                                                                                      INC492E
43 Fit a new camshaft centre bearing                                                                                    18G 123AD             18GI23F   18G 123T
     liner, using tools ISG 124 A, ISG 124
     C, and ISG 124 H as shown.
NOTE: Lightly lubricate the arbor before
assembling the cutters and pilots to it.
Feed the reamers very slowly and keep the
cutters dry.
Keep the cutter flutes clear of swarf during
reaming.                          .
44 Ream the front and rear bearing liners
     using tools ISG 123 A, ISG 123 L,
                                                                                     I
                                                                                     INC494£
                                                                                                                                                                   INC49tE

     ISG 123 E (in position '10' on the                    18GI24C   18GI24H
     arbor), ISG 123 AB, ISG 123 B (in
     position '6' on the arbor), and ISG
     123 AC as shown.
45 Ream the centre bearing liner, using                                                         59 Position the front mounting plate
     tools ISG 123 A, 18G 123 T, ISG                                                               assembly on the engine and locate it
     123 F (in position '9' on the arbor),                                                         by fitting the camshaft locating plate
     and ISG 123 AD as shown.                                                                      bolts and the chain tensioner retaining
46 Ensure that the oil holes of the                                                                screw.
     bearing liners are still lined up with                                          INC493E
                                                                                                60 Fit the two bolts to secure the
     those in the crankcase.                                                                       mounting plate to the crankcase.
47 Thoroughly clean all swarf from the                                                          61 Fit the two bolts to secure both front
     cylinder block and crankcase.                                                                 mounting brackets to the crankcase.
4S Fit the tappets with their open ends                                                         62 Fit the chain vibration damper.
     towards the cylinder head.                                                                 63 Fit the camshaft locating plate.
49 Fit the camshaft.                                                                            64 Fit the camshaft gear, timing chain,
50 Fit the connecting rod and piston                                                               and timing gear cover, see 12.65.12.
     assemblies with the combustion                  d     Tighten the main bearing bolts to       NOTE: Do not leave the crankshaft                e  Tighten the rocker bracket nuts
     cavities on the R.H. side of the engine,              75 Ibf ft (l0.4 kgf m, 102 Nm).         pulley in position.                                 to 25 Ibf ft (3.5 kgf m, 34 Nm).
     using tool ISG 55 A.                       53   Check the crankshaft end-float against     65 Reverse the procedure in 18 to 27,             f    Adjust the valve rocker clearance,
5 I Fit the crankshaft main bearings, and            the figure in DATA, and fit alternative       noting:                       ,                     see 12.29.4S.
     thrust washers (grooved side towards            thrust washers if necessary.                  a    Fit the cylinder head gasket with         g    Apply Loctite to the bottom of
     the crankshaft) to the crankcase.          54   Fit the big-end bearings and caps,                 the face marked 'TOP'                          the dipstick tube.
52 Fit the main bearing caps, noting:                ensuring that the connecting rod and               uppermost.                             66 Reverse the procedure in 4 to II,
     a    Caps Nos. 2 and 4 are each                 cap markings are aligned.                     b    Ensure that the combustion                noting:
          stamped with their number.            55   Tighten the big-end nuts to 35 Ibf ft              chamber inserts are fitted flush          a    Use tools 18G 134 and 18G 134
     b    Fit caps 2, 3 and 4 with the cast          (4.S kgf m, 47 Nm).                                with the cylinder head face.                   CQ to fit the new rear oil seal.
          word 'FRONT' towards the front        56   Fit the oil pump and its drive shaft,         c    Leave the cylinder head nuts              b Use tool 18G 11 OS to protect the
          of the engine.                             tightening the retaining nuts to 16 Ibf            finger tight until the rocker shaft            seal 'when fitting the adaptor
     c    Using a straight-edge, align t,he          ft (2.2 kgf m, 22 Nm).                             assembly has been fitted.                      plate.
          front and rear bearing caps with      57   Soak the cork sealing strips in engine        d Tighten the cylinder head nuts to            c    Tighten the adaptor plate bolts to
          the front and rear faces of the            oil, then fit them to the front and rear           75 Ibf ft (10.4 kgf m, 102 Nm) in              30 Ibf ft (4.2 kgf m, 41 Nm).
          crankcase.                                 main bearing caps.                                 the sequence shown, using tool                 NOTE: Fit the two longer bolts
                                                58   Fit the sump.                                      18G 694 to reach the centre row.               in the two top holes.


                                                                                                                                                                                            »
                                                                                                                                                                                            "'"
                                                                                                                                                                                          l:-
                                                                                                                                                                                          eo

     d    Tighten the oil seal retainer bolts         68   Run the engine for a minimum of           Refitting
          to 20 Ibf ft (2.8 kgf m, 27 Nm).                                  I 5 mins and on return   13 Reverse the procedure in 8 to 12,
     e    Tighten the flywheel bolts to 40                 slacken the cylinder head nuts                noting:
           Ibf ft (5.5 kgf m, 54 Nm).                      approximately t of a turn in the              a     Assemble the pistons to the
67   Fit the engine.                                       sequence shown before retightening                  connecting rods with the
                                                           them to 75 Ibf ft (10.4 kgf m, 102                  combustion cavities on the oil
                                                           Nm) in the sequence shown. Check                    hole side of the connecting rods.
                                                           the valve rocker clearances.                  b     If new piston rings are being used
                                                                                                               ensure that the ring gaps are
                                                                                                               correct, see 12.17.10.
                                                                                                         c     Use tool 18G 55 A to compress
                                                                                                               the piston rings.
                                                                                                         d     Fit the connecting rod and piston
DATA                                                                                                           assemblies with the combustion
Camshaft bearing inside diameters (reamed                                                                      cavities on the R.H. side of the
in position):                                                                                                  engine.
   Front . . . . . . . . . . . . . . . . . . . . .    1.79025 to 1.79075 in (45.47 to 45.48 mm)      14 If the connecting rods or piston(s)
   Centre . . . . . . . . . . . . . . . . . . . .     1.73025 to 1.73075 in (43.95 to 43.96 mm)          have been renewed, rotate the
   Rear . . . . . . . . . . . . . . . . . . . . . .   1.62425 to 1.62475 in (40.26 to 40.27 mm)          crankshaft and measure the amount
Crankshaft end-float . . . . . . . . .                0.001 to 0.0055 in (0.03 to 0.14 mm)               by which each piston stands proud of
Thrust washer thicknesses . . · . . . · . . . .       0.0885 to 0.0905 in (2.25 to 2.30 mm),             the cylinder block face at T.D.C.
                                                      0.091 to 0.093 in (2.31 to 2.36 mm) and        IS If piston stand-proud is outside the
                                                      0.0935 to 0.0955 in (2.37 to 2.43 mm)              limits given in DATA, fit suitable
                                                                                                         alternative piston(s) from the range
                                                                                                         available.
                                                                                                         NOTE: It is not necessary for the
                                                           12                            13a             pistons in an engine to be of the same
CONNECfING RODS AND                                                                                      height grade.



                                                           ~
PISTONS                                                                                              16 Tighten the big-end nuts to 35 Ibf ft
                                                                                                         (4.8 kgf m, 47 Nm).
  Remove and refit                  12.17.01                                                         17 Reverse the procedure in I to 7.
Service tool: 18G 55 A
Removing
I    NA                                                                                              DATA
2    Drain the sump.
3    Drain the cooling system.                                                                       Piston stand-proud                             0.013 to 0.021 in (0.33 to 0.53 mm)
4    Remove the cylinder head gasket, see                       13a
     12.29.02.
5    Disconnect the oil cooler pipe from
     the L.H. side of the crankcase.
6    Release the oil cooler pipe clip from
     the gearbox mounting plate and move
     the oil pipe aside.
7    Remove the sump.
8    Remove the big-end nuts.
9    Remove the big-end caps and bearing
     halves.
10 Withdraw the connecting rod and
     piston assemblies.
II Mark the pistons and connecting rods
     for reassembly.
12 Remove the circlips and the gudgeon
     pins and separate the pistons from the
     connecting rods.                                                                4NC09lA
                                                        ~r1I'·
CONNECTING RODS AND                                                                                    CRANKSHAFT REAR OIL SEAL
PISTONS                                                                                                  Remove and refit              12.21.20
    Overhaul                       12.17.10                                                              Gearbox adaptor plate         12.53.03
    Connecting rods 1 to 5 and 10 to 12                                                                  Flywheel I to 8 and IS        12.53.07


                                                        O;=II~~
    Pistons 1 to 9 and 12                                                                              Service tools: ISG 134, ISG 134 CQ, ISG
I     NA                                                                                               IIOS
2    Drain the sump.

                                                         J~LJ~
3    Drain the cooling system.                                                                         Removing
4    Remove the cylinder head gasket, see                                                              I  NA

                                                        ) B o~
     12.29.02.                                                                                         2  Remove the gearbox.
5    Remove and separate the connecting                                                                3  Remove the dllllller
     rods and pistons, see 12.17.0 I.                                                         4NCQ1,   4  Remove the flywheel securing bolts.
6    Remove the rings from the pistons.                                                                5  Lift off the flywheel.
7    Check the jJiston ring gaps, in an                                                                6  Remove the oil seal retainer.
     unworn part of the cylinder bore,                  9  Check the piston ring groove clearance      7  Remove the - - bolts securing the
     against the figures' in DAT A. If                     against the figures in DATA.                   gearbox adaptor plate.
     necessary, increase the gap(s) by filing           10 Check the gudgeon pin clearance in          S Pull the adaptor plate off its two
     the end of the ring(s).                               the connecting rod bush (see DATA).            locating dowels.
S    Fit the piston rings, noting:                         If the clearance is excessive, renew the    9  Remove the two adaptor plate gaskets.
     a    Fit the oil control ring expander                bush, noting:                               10 Remove the oil seal from the adaptor
          spring first, ensuring that the                  a    Position the bush with its hole           plate.
          latch pin enters both ends of the                     and oil grooves towards the top.
          spring.                                          b    Finish-ream the bush to the            Refitting
     b    Fit the oil control ring with its                     dimension given in DATA.               II Fit the new oil seal flush with the rear
          gap ISO o from the expander latch             II Ensure that the connecting rod                  face of the adaptor plate, using tools      S,.,C   ~18A

          pin.                                             alignment is within the figure given in          ISG 134 and ISG 134 CQ.
     c    Fit the second ring with the word                DATA.                                       12 Reverse the procedure in I to 10,
          'TOP' uppermost.                              12 Reverse the procedure in I to 5.                noting:
                                                                                                           a     Use tool ISG II OS to protect the
                                                                                                                 oil seal when fitting the adaptor
DATA                                                                                                             plate.
Connecting rod alignment                                                                                   b Tighten the adaptor plate bolts to
  Maximum out-of-parallel of big-end and                                                                         30lbfft (4.2 kgfm, 41 Nm).
     little-end . . . . . . . . . . . . . . . . . . .   0.004 in per inch (0.004 cm per cm)                      NOTE: Fit the two longer bolts
                                                        effective mandrel length                                 in the two top holes.
                                                                                                           c     Tighten the oil seal retainer bolts
Connecting rod bush                                                                                              to 20 Ibf ft (2.S kgf m, 27 Nm).
  Clearance on gudgeon.pin . . . . . . . . .            0.0002 to 0.0009 in (0.02 to 0.04 mm)              d     Tighten the flywheel bolts to 40
  Inside diameter (reamed after fitting) ..             1.0002 to 1.0007 in (25.41 to 25.42 mm)                  Ibf ft (5.5 kgf m, 54 Nm).

Piston rings
   Fitted gap:
      Top compression                                   0.012 to 0.017 in (0.30 to 0.43 mm)
      Second compression .                              0.009 to 0.014 in (0.23 to 0.35 mm)
      Oil control . . . . . . . . .                     0.012 to 0.017 in (0.30 to 0.43 mm)
   Ring to groove clearance:
      Top compression . . . . . . . . . . . . .         0.0025 to 0.0045 in (0.06 to 0.11 mm)
      Second compression . . . . . . . . . . .          0.0015 to 0.0035 in (0.04 to 0.09 mm)
      Oil control . . . . . . . . . . . . . . . . .     0.0015 to 0.0035 in (0.04 to 0.09 mm)




                                                                                                                                                                      l>
                                                                                                                                                                      CD
                                                                                                                                                                                        ...
                                                                                                                                                                                        »
                                                                                                                                                                                        o
CRANKSHAFT END-FWAT
    Check and adjust                    12.21.26
1     NA
2  Check the crankshaft end-float using a
   dial gauge against the crankshaft
   pulley bolt. If end-float is outside the
   limits given in DATA, change the
   thrust washers as described in the                                                                            33
   following paragraphs.
3  Drain the sump.
4  Release thtl. oil pipe clip from the
   gearbox mounting plate and move the
   oil pipe aside.
5  Remove the sump.
6  Remove the oil pump and its drive
   shaft.
7  Remove the two bolts from the centre
   main bearing cap.
8  Remove the centre main bearing cap.
9  Remove the bottom halves of the
   thrust washers from the cap or
   crankshaft.
10 Slide the upper halves of the thrust                                              SNC4778
   washers around the crank and remove
   them.
11 Select a set of thrust washers to give                c   Tighten the main bearing cap
   the correct end-float (see DATA).                         bolts to 75 Ibf ft (lOA kgf m,
12 Reverse the procedure in 3 to 10,                         102 Nm).
   noting:                                               d   Ensure that the end-float is
   a    Fit the thrust washers with their                    correct after tightening the main
        grooved sides towards the                            bearing cap bolts.
        crankshaft.                                      e   Tighten the oil pump securing
   b    Fit the main bearing cap with the                    nuts to 16 Ibf ft (2.2 kgf m, 22
        'FRONT' mark towards the front                       Nm).
        of the engine.
                                                                                                                                            9  Remove the alternator.
                                                                                                 CRANKSHAFT                                 10 Disconnect the high-pressure pipes
DATA                                                                                               Remove and refit              12.21.33      from the injectors.
Crankshaft end-float . . . . . . . . . . . . . . .   0.001 to 0.0055 in (0.03 to 0.14 mm)                                                   II Remove the injection pump drive oil
                                                                                                 Service tools: 18G 134, 18G 134 CQ, 18G       feed pipe.
Thrust washer thicknesses . . . . . . . . . . .      0.0885 to 0.0905 in (2.25 to 2.30 mm)       284, 18G284AC, 18G 1108, 18G 1195
                                                     0.091 to 0.093 in (2.31 to 2.36 mm) and                                                12 Remove the timing chain and the
                                                     0.0935 to 0.0955 in (2.37 to 2.43 mm)                                                     camshaft gear, see 12.65.12.
                                                                                                 Removing                                   13 Remove the camshaft locating plate.
                                                                                                 1  NA                                      14 Remove the chain vibration damper.
                                                                                                 2  Drain the sump.                         IS Remove the bolt securing each front
                                                                                                 3  Remove the engine.                         mounting bracket to the crankcase.
                                                                                                 4  Remove the daMper                       16 Remove the two bolts securing the
                                                                                                 5  Remove the flywheel.                       front mounting plate to the crankcase.
                                                                                                 6  Remove the crankshaft rear oil seal     17 Lift off the front mounting plate,
                                                                                                    retainer.                                  complete with injection pump, front
                                                                                                 7  Remove the bolts securing the gearbox      mounting brackets, chain tensioner
                                                                                                    adaptor plate and pull the adaptor         stop-pin, and chain tensioner shoe.
                                                                                                    plate off its two locating dowels.      18 Withdraw the dipstick.
                                                                                                 8  Remove the two adaptor plate gaskets.   19 Remove the sump.
20 Remove the oil pump and its drive                32 Fit the oil pump and its drive shaft,      OIL PUMP
   shaft.                                              tightening the retaining nuts to 161bf       Overhaul                        12.60.32
21 Remove the big-end bearing caps and                 ft (2.2 kgf m, 22 Nm).
   bearing halves.                                  33 Soak the cork sealing strips in engine     Dismantling
   NOTE: If the crankshaft has to be                   oil, then fit them to the front and rear   I   Remove the oil pump, see 12.10.30.
   rotated, be careful not to apply any                main bearing caps.                         2   Remove the cover from the pump
   force which could cause damage if a              34 Fit the sump.                                  body.
   piston touches a valve.                          35 Fit the dipstick.                              NOTE: The cove.r is located by two
22 Remove the main bearing caps and                 36 Position the front mounting plate              dowels.
   bearing halves, using tools 18G 284                 assembly on the engine and locate it       3   Remove the rotors from the pump
   and 18G 284 AC on the front and rear                by fitting the camshaft locating plate         body.
   caps if necessary.                                  bolts and the chain tensioner retaining
23 Lift out the crankshaft and remove                  screw.
   the bearing and thrust washer halves.            37 Fit the two bolts to secure the front      Inspection
24 Remove the crankshaft gear.                         mountig plate to the crankcase.            4 Clean the components.
25 Remove the crankshaft keys and lift              38 Fit the two bolts to secure both front     5 Fit the rotors to the pump body with
   off the shim(s}.                                    mounting plate to the crankcase.               the chamfered end of the outer rotor
                                                    39 Fit the chain vibration damper.                at the closed end of the body.
Refitting                                           40 Fit the camshaft locating plate.           6 Check the end-float of the inner and
26 Fit the shim(s}, keys and gear to the            41 Fit the camshaft gear, timing chain,           outer rotors.
    crankshaft.                                        and timing gear cover, see 12.65.12.       7 Check the outer rotor to pump body
27 Fit the crankshaft, main bearings, and              NOTE: 00 not leave the crankshaft              diametrical clearance.
    thrust washers (grooved side towards               pulley in position.                        8 Check the rotor lobe clearances.




                                                                                                                                                           ~
    the crankshaft) to the crankcase.               42 Reverse the procedure in 4 to II,          9   Renew the pump assembly if the
28 Fit the main bearing caps, noting:                  noting:                                        clearances or end-floats in 6 to 8
    a     Caps Nos. 2 and 4 are each                   a     Use tools 18G 134 and 18G 134            exceed the figure given in OATA.
          stamped with their number.                         CQ to fit the new rear oil seal.
    b     Fit caps 2, 3, and 4 with the cast           b     Use tool 18G 1108 to protect the     Reassembling
          word 'FRONT' towards the front                     seal when fitting the adaptor        10 Lubricate all components with clean
          of the engine.                                     plate.                                   engine oil.                                                    'HC4MA

    c     Using a straight-edge, align the             c     Tighten the adaptor plate bolts to   II Reverse the procedure in I to 3,
                                                                                                      ensuring that the outer rotor is fitted




                                                                                                                                                       ~lIIl
          front and rear bearing caps with                   30 Ibf ft (4.2 kgf m, 41 Nm). .
          the front and rear faces of the                    NOTE: Fit the two longer bolts           with its chamfer at the closed end of
          crankcase.                                         in the two top holes.                    the body.
    d Tighten the main bearing bolts to                d Tighten the oil seal retainer bolts
          751bfft (l0.4 kgf m, 102 Nm).                      to 20 Ibf ft (2.8 kgf m, 27 Nm).
29 Check the crankshaft end-float against              e     Tighten the flywheel bolts to 40
    the figure in OAT A, and fit alternative                 Ibf ft (5.5 kgf m, 54 Nm).
    thrust washers if necessary.
30 Fit the big-end bearings and caps,
    ensuring that the connecting rod and
    cap markings are aligned.
31 Tighten the big-end nuts to 35 Ibf ft
    (4.8 kgf m, 47 Nm).
DATA
Main journal diameter . . . . . . . . . . . . . .   2.1262 to 2.1270 in (54.01 to 54.03 mm)
Crankpin diameter .·.·.·....·.....                  1.8759 to 1.8764 in (47.64 to 47.66 mm)       DATA
Clearance in bearings Uournals and crank-                                                         Outer rotor end-float .··.·.........          0.005 in (0.13 mm)
  pin} .··.......··.··..·......                     0.001 to 0.0027 in (0.03 to 0.07 mm)          Inner rotor end-float .··.· ~ ..·......       0.005 in (0.13 mm)
Undersizes Uournals and crankpins} .....            0.010 in (0.25 mm)                            Outer rotor to pump body diametrical
Crankshaft end-float ..···..........                0.001 to 0.0055 in (0.03 to 0.14 mm)            clearance ···.··...··..........             0.010 in (0.25 mm)
Thrust washer thicknesses . . . . . . . . . . .     0.0885 to 0.0905 in (2.25 to 2.30 mm),        Rotor lobe clearance ...··..··.....·          0.006 in {0.15 mm}
                                                    0.091 to 0.093 in (2.31 to 2.36 mm) and
                                                    0.0935 to 0.0955 in (2.37 to 2.43 mm)


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                                                                                      18   Remove the front mounting plate
                                                                                           gasket
                                                                                      Refitting
                                                                                      19 Fit the front mounting plate gasket.
                                                                                      20 Position the front mounting plate
                                                                                          assembly on the engine and locate it
                                                                                          by fitting the camshaft locating plate


                                                                                                                                           ~ · t
                                                                                           bolts and the chain tensioner retaining         "                      M
                                                                                          screw.
                                                                                      21 Reverse the procedure in I to 16,
                                                                                          noting:
                                                                                                                                                                                                  1
                                                                                          a     With the throttle cable connected            J\I f> Q                                   "'~4ft'
                                                                                                       ensure that the injection           Pilots
                                                                                                pump throttle lever is operated                Pressing-out       A. 3.25    8:~ in
                                                                                                through its full range of                      pilot:                (82.55' 0·13   mm)
                                                                                                                                                                                0'00
                                                                                                movement by the throttle pedal.                                                 0'000
                                                                                          b     When the stop control cable is                                    B. 3. IS 7   -0'005 in
                                                                                                connected, ensure that the stop                                       (80.19   :"g:r: mm)
                                                                                                control has sufficient travel
                                                                                                                                                                  C. 1.75 in (44.45 mm)
                                                                                      22 Bleed the fuel system, see 19.50.07.
                                                                                                                                                                  D. 0.75 in (19 mm)
                                                                                                                                                                  E. 34 in B.S. W. thread
                                                                                                                                               Pressing-in        F. 3.625 in (92.07 mm)
                                                                                                                                               pilot:             G.3.312in(84.14mm)
                                                                                                                                                                              , 0'000
                                                                                                                                                                  H. 3.133 -0'005 in
                                                                                      CYLINDER LINERS                                                                (79.58 :::g:r: mm)
                     16        16                                                        Remove and refit               12.25.26                                  J. 1.25 in (31.75 mm)
                                                                                         NOTE: If the condition of the cylinder                                   K.0.75in(l9mm)
                                                                                      bores is such that they cannot be cleaned
                                                                                      up to accept oversize pistons, dry cylinder                                 L. 0.015 in (0.38 mm)
ENGINE FRONT MOUNTING                     10 Disconnect the throttle cable from the
                                             injection pump                           liners can be fitted (see DATA).                         Pilot extension:   M. 14.50 in (36.83 em)
PLATE GASKET                                 lever.                                      Pilots should be made to the dimensions                                  N. 0.875 in (22.22 mm)
                                          II Remove the injection pump drive oil      given, from case-hardening steel and
  Remove and refit             12.25.10      feed pipe.                               case-hardened.                                                              P. 0.625 in (15.87 mm)
                                          12 Disconnect the high-pressure pipes          The pilot extension should be made                                       Q. 0.625 in (15.87 mm)
Removing                                     from the injectors.                      from 55-ton hardening and tempering steel,
                                                                                      hardened in oil, and then tempered at                                       R. Two flats I in (25.4
I  Remove the timing chain and the        13 Remove the two bolts and washers                                                                                        mm) across
   camshaft gear, see 12.65.12.              securing the front moullting plate to    550°C (l020°F).
2  Remove the camshaft locating plate.       the crankcase.                                                                                                       S. 34 in B.S.W. thread
3  Remove the chain vibration damper.     14 Lift off the front mounting plate,                                                                                   T. 1.25 in (31.75 mm)
                                             complete with injection pump, front      DATA
4  Remove the alternator.
5  Disconnect the thermal transmitter        mountings, chain tensioner stop-pin,     Cylinder block
   and move the wiring harness aside.        and chain tensioner shoe.                  Bore: Standard . · . . . . . . . . . . . . . . .   3.1595 to 3.1606 in (80.25 to 80.28 mm)
6  Disconnect the supply lead from the                                                        Oversize maximum (without
   heater plugs.                          IS.,                                                   cylinder liner) . . . . . . . . . .       0.040 in (1.02 mm)
7  Disconnect the fuel return pipe from                                                       To accept cylinder liner                     3.2615 to 3.2620 in (82.84 to 82.86 mm)
   the injection pump.                    16   NA
8  Disconnect the fuel supply pipe from   17'/                                        Cylinder liners                            n
   the injection pump.                                                                  Outside diameter . . . . . . . . . . . .           3.2645 to 3.2660 in (82.92 to 82.96 mm)
9  Disconnect the stop control cable                                                    Bore: Standard (machined after fitting)            3.1595 to 3.1606 in (80.25 to 80.28 mm)
   from the injection pump.                                                                   Oversize (maximum) . . . . . . . . .         0.020 in (0.51 mm)
                              CYLINDER HEAD GASKET                                                          5       12
                                Remove and refit               12.29.02
                              Service tool: 18G 694
                              Removing
                              I    NA
                              2    Drain the cooling system.
                              3    Disconnect the hoses from the water
                                   outlet elbow.
                              4    Disconnect the breather hose from the
                                   cylinder side cover.
                              5
                              6    NA
                              7    Disconnect the lead from the thermal
                                   transmi tter.
                              8    Disconnect the supply lead from the     Refitting
                                   heater plugs.                           21 Reverse the procedure in l to 20.
           4                  9    Disconnect the spill rail and return        noting:
                                   pipe from the injectors and lay the         a     Fit the cylinder head gasket with
                                   spill rail aside.                                 the face marked 'TOP'
                              10   Remove Nos. 3 and 4 injector pipes.               uppermost.
                              II   Remove Nos. I and 2 injector pipes.          b    Ensure that the combustion
                              12   Remove the oil dipstick.                          chamber inserts are fitted flush
               H
               C!)   15   I   13   Release the dipstick tube from the
                                   cylinder head nut and withdraw the
                                                                                     with the cylinder head face.
               ~~                  tube from the crankcase.
                                                                               c     Leave the cylinder head nuts
                                                                                     finger tight until the rocker shaft
                              14   Disconnect and remove No. I heater                assembly has been fitted.
                                   plug.                                       d Tighten the cylinder head nuts to
                              15   Remove the rocker cover and gasket.               75 Ibf ft (10.4 kgf m, 102 Nm) in
                              16   Remove the rocker shaft assembly,                 the sequence shown, using tool

               ~i
       ~
                                   noting the locking plate on the rear              18G 694 to reach the centre row.
                                   bracket and the shim under each             e     Tighten the rocker brackets nuts
                                   centre bracket.


               ~
                                                                                     to 25 Ibf ft (3.5 kgf In, 34 Nm).
                              17   Withdraw the push·rods, retaining.



=&
                                                                               f     Adjust the valve rocker clearance,
                                   their order for refitting.                        see 12.29.48.
                              18   Remove the cylinder head nuts.              g     Bleed the fuel system, see
                              19   Lift off the cylinder head.                       19.50.05.
                                   NOTE: The combustion chamber                h     Apply Loctite to the bottom of
                                   inserts may drop out of the cylinder              the dipstick tube:
I;g)                               head as it is lifted; they ·MUST be     22 Run the engine for a minimum of
                                   refitted in their original positions.                          I 5 mins and on return
                              20   Remove the cylinder head gasket.            slacken the cylinder head nuts
                                                                               approximately 1 of a turn in the
                                                                               sequence shown before retightening
                                                                               them to 75 Ibf ft (10.4 kgf m, 102
                                                                               Nm) in the sequence shown. Check
                                                                               the valve rocker clearances.




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CYLINDER HEAD                                                                                          g    18G 167 A Glaze breaker for
                                                                                        \'J{)                              exhaust seats.
  Overhaul                            12.29.19                                                         h    18G 167 Cutter for exhaust seats.
Service tools: 18G 27, 18G 29, 18G 45,                                                                      18G 167 B Top narrowing cutter
18G 167, 18G 167 A, 18G 167 B, 18G 167                                                                                     for exhaust seats.
C, 18G 174, 18G 1741\, 18G 174 B, 18G                                                                  k    18G 167 C Bottom narrowing
174 C, 18G 174 D, 18G 284, 18G 284 P                                                                                       cutter for exhaust
                                                                                                                           seats.
I    Remove the cylinder head gasket, see                                                         19   Lap the valves onto their seats, using
     12.29.02.                                                                                         tool 18G 29.
2    Remove the three remaining heater                                                            20   Check the valve stand-down against
     plugs from the cylinder head.                                                                     the figure in DATA. If stand-down is
3    Remove the injectors, usinl: tools 18G                                                            excessive, even with a new va1ve fitted,
     284, and 18G 284 P.                                                                               renew the valve seat insert(s) and cut
4    Remove the two sealing washers from                                                               their seats.
     each injector position.                                                                      21   Renew the valve springs if they are not
5    Remove the heater hose from the                                                                   as specified in DATA.
    cylinder head ·..                                                                             22   Renew the sealing washers for the
6    Remove the manifolds and gasket.                                                                  injectors.
7    Mark the combustion chamber iriserts                                                         23   Renew the sealing washers for the
     for refitting jn their original positions.                                                        injector heat shields;
8    Remove the combustion chamber                                                                24   Reverse the procedure in I to 12.
     inserts, if necessary using a soft drift
     through the injector holes.
9    Push out the injector heat shields and                                                       DATA
     their sealing washers.
10 Remove the water outlet elbow and its                                                          Cylinder head
     gasket.                                                                                        Depth after refacing                                  3.16 in (80.26 mm) minimum
II Lift out the thermostat.
12 Remove the valves and their                                                                    Valve guides
     components, using tool 18G 45.                                                                  Inside diameter (reamed after fitting)               0.3441 to 0.3448 in (8.74 to 8.76 mm)
     NOTE: Seals are fitted to the inlet                                                             Protrusion (from bottom of
     valve guides.                          -                                                       counterbore) . . . . . . . . . . . . . . . . . .      0.550 to 0.560 in (13.97 to 14.22 mm)
13 If the valve guides are worn (see
     DATA), press them out in the                                                                 Valves
     direction of the valve seats.                                                                   Seat angle . . . . . . . . . . . . . . · . . . . .   45°
14 To fit new valve guides, press them in                                                           Stand-down . . · . . . . . · . . . . . . · . . .      0.0445 to 0.0505 in (1.13 to 1.28 mm)
     from the top of the cylinder head                                                              Stem diameter: Inlet . . . . . . . . . . . . .        0.3428 to 0.3422 in (8.71 to'8.73 mm)
     until they protrude by the amount            17 If necessary, reface the valves to the                           Exhaust . . · . . . . . . .         0.3422 to 0.3427 in (8.69 to 8.70 mm)
     stated in DATA. Protrusion is                   angle given in DATA, removing the
     measured from the top of the valve              minimum of material.                         Valve springs
     guide to the bottom of the counter           18 If necessary, recut the valve seats in          Free length (approximate) . . . . . . . . .          I it in (48.75 mm)
     bore for the valve spring.                      the cylinder head, using the following          Load when compressed to 1.44 in
15 Ream new valve guides to the size                 tools:                                            (36.58 mm) ....··.·...·.....                       82 Ibf (37.195 kgf, 364N)
     given in DATA.                                  a    18G 27     Handle.
16 Check the cylinder head face for                  b    18G 174 DPilot.
     flatness and, if necessary, reface the          c    18G 174 A Glaze breaker for inlet
     cylinder head without reducing its                                 seats.
     depth below the figure given in                 d    18G 174 Cutter for inlet seats.
     DATA.                                           e    18G 174 B Top narrowing cutter
     NOTE: The combustion chamber                                       for inlet seats.
     inserts must be faced level with the                 18G 174 C Bottom narrowing
     cylinder head o                                                    cutter for inlet seats.
VALVE CLEARANCE                                                                              Refitting                                                                               6         12
  Check and adjust                 12.29.48                              4                   7 Reverse the procedure in I to 6,
                                                                                                 noting:
Checking                                                                                         a     Tighten the cylinder head nuts to
I   Remove the rocker cover ana gasket.                                                                75 Ibfft (10.4 kgf m, 102 Nm) in
2 Check, and if necessary adjust, the                                        3                        .the sequence shown, using tool
    clearance between the rocker arms and      2, I    be...j                                           ISG 694 to reach the centre row.
    valve stems against the figure in                                                            b Tighten the rocker bracket nuts
    DATA, working in the following                                                                     to 251bf ft (3.5 kgf rn, 34 Nm).
    order:                                                                                       c     Adjust the valve rocker clearance,
    Check:                                                                                             see 12.29.4S.
    No. I valve with No.8 valve fully open.                                                  S Run the engine for a minimum of
        3             " 6                                                        4HC104A                         115 mins and on return
     " 5                4                     Adjusting                                          slacken the cylinder head nuts
        2               7                     3 Slacken the locknut.                             approximately t of a turn in the           13b            PM·   6       W\I1       MIt        13b
                                              4   Rotate the adjusting screw to set the          sequence shown before retightening

                                                                                                                                            I~Q~ I~Q I~ IQ~Q.II
     " S              " I                                                                        them to 75 Ibf ft (10.4 kgf rn, 102
     ,,6              ,,3                         clearance.
        4             " 5                     5 Hold the adjusting screw against                 Nm) in the sequence shown. Check
     " 7              " 2                         rotation and tighten the locknut.              the valve rocker clearances.
                                              6   Fit the rocker cover and gasket.
                                                                                             ROCKER SHAFf ASSEMBLY                          2          4                        .                   2
                                                                                               Overhaul                       12.29.55
DATA                                                                                         Service tools: ISG 226, ISG 226 A
Valve rocker clearance (cold)                 0.017 in (0.43 mm)                                                                                  t.                     _                .1
                                                                                             Dismantling
                                                                                             I   Remove the rocker shaft, see
                                                                                                                                                                     I
                                                                                                                                                                     6                    INC ....
                                                                                                 12.29.54.
                                                                                             2   Remove the split pin from each end of
                                                                                                 the rocker shaft.
                                                                                             3 Slide the components off the shaft.
                                                                                             4   Remove the locating screw from the
                                                                                                 rocker shaft rear bracket and remove
                                                                                                 the bracket.
                                                                                             5 Remove the adjuster screws.
                                                                                                                                                                                           _10311
                                                                                             Inspection
                                                                                             6 Clean the oilways of the rocker shaft.
                                                                                             7 Examine the rocker to valve contact          II  Drill a hole in the bush, through the
                                                                                                 faces for wear, and renew the                  hole in the top of the rocker barrel,
ROCKER SHAFf ASSEMBLY                                                                            rocker(s) if necessary.                        using a 1.95 mm drill.
   Remove and refit               12.29.54                                                   S Renew the rocker adjusting screws if         I 2 Burnish-ream the bush to the
                                                                                                 they are worn or if the threads are            dimension given in DATA.
Service tool: ISG 694                                                                            damaged.                                   13 Reverse the procedure in I to 5,
                                                                                             9 Press out worn rocker bushes, using              noting:
Removing                                                                                         tools ISG 226 and ISG 226 A.
I   NA                                                                                                                                          a    The locating screw engages the
2   Drain the cooling system.                                                                Reassembling                                            larger of the two diametrically
3   Remove the rocker cover and gasket.                                                      10 Press in new rocker bushes, using tools              opposite holes.
4   Slacken evenly and remove the eight                                                           ISG 226 and ISG 226 A, and ensuring           b The doubl&ocoil spring washers
    nuts retaining the rocker shaft                                                              that the bush joint and oil groove are              are fitted inside the plain washer
    brackets.                                                                                    in the positions shown.                             at each end of the shaft.
5   Remove the locking plate from the                                                        DATA
    rocker shaft rear bracket.                                                               Rocker shaft diameter ..··...···.·..           0.624 to 0.625 in (15 .S5 to 15.S7 mm)
6   Remove the rocker shaft assembly and                                                     Rocker bush inside diameter (reamed in
    the shim under each centre bracket.                                           'SNC .,7
                                                                                               position) .....·....····.......              0.6255 to 0.6260 in (l5.S9 to 15.90 mm)



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OIL PRESSURE RELIEF VALVE                                                                           TIMING GEAR COVER OIL SEAL
  Remove and refit
Service tool: 18G 69
                                   12.60.56                                                       Remove and refit             12.65.05
                                                                                                Service tools: 18G ·98 A, 18G 134, 18G             ~~-~;;                             -,



                                               t~~~)
Removing                                                                                        134 BD                                                                      J

.1   INA                                                                                        Removing
 2   Remove the valve cap washer from the                                                       I    lNA
     rear of the L.H. side of the crankcase.                                                    2     Slacken the alternator mounting boIts
 3   Withdraw the spring from the                                                                     and remove the fan belt.
     crankcase.                                                                                 3     Remove the              . water pump
4    Withdraw the valve plunser, using tool                                                           pulley.
     18G 69.                                                                                    4     Remove the crankshaft pulley, using

                                                                           ~
                                                                                                      tool 18G 98 A.
Refitting
5 If the valve plunger is pitted, or is not       Qg)i&m-;l                                     5     Remove the timing gear cover and
                                                                                                      gasket.
    seating correctly, lap the plunger onto        4   -..." I                      INC   oue   6     Remove the oil seal from the timing
    its seating, using tool 18G 69. If                                                                cover.
    lapping fails to correct the fault,
    renew the plunger and ensure that the                                                       Refitting
    new plunger seats correctly.                                                                7    Fit the new oil seal to the timing gear
6    Renew the spring if it is not as                                                                cover, using tools 18G 134 and 18G
    specified in DATA.                                                                               134 BD.
7    Reverse the procedure in 1 to 4.                                                           8    Fit the timing gear cover and gasket,
                                                                                                     using the crankshaft pulley to            TIMING CHAIN AND GEARS
                                                                                                     centralize the oil seal on the              Remove and refit               12.65.12
                                                                                                     crankshaft.                                 Timing chain tensioner
DATA                                                                                            9 Fit the timing gear cover boIts in the
Relief valve spring:                                                                                 following illustrated positions.            1 to 14, 16 to 19, 34 to 40,
  Free length .......·.·.··...·..              3 in (76 mm)                                                                                      and 43 to 47                   12.65.28
  Load when compressed to 2.16 in                                                                    Position            Bolt size               Timing chain 1 to 14, 16 to
     (54.77 mm) .··.··.··.·..·...              15.5 to 16.51bf (7.0 to 7.4 kgf, 69 to 73 N)          A fa- in x I % in (44.5 mm) long            22,29 to 41, and 43 to 47       12.65.14
                                                                                                    B 1\ in x 2 in (50 mm) long                Service tools: 18G 98 A, 18G     134, 18G
                                                                                                    l'lOTE: An '0' ring is fitted on this      134 BD
                                                                                                    'bolt.
                                                                                                    C 1\ in x 2 in (50 mm) long                Removing
                                                                                                    D 1\ in x 2Y.. in (57 mm) long             I   NA
                                                                                                    E Y.. in x 1% in (44.5 mm) long            2  Drain the cooling system.
                                                                                                    F Y..inxlY..in(31.75mm)long                3  Slacken the alternator mounting bolts
                                                                                                10 Reverse the procedure in I to 4,               and remove the fan belt.
                                                                                                    tightening the crankshaft pulley boIt      4  Remove the                water pump
                                                                                                    to 751bf ft (10.4 kgf m, 102 Nm~              pulley.
                                                                                                                                               5  Remove the crankshaft pulley, using
                                                                                                                                                  tool 18G 98 A.
                                                                                                                                               6  Remove the timing gear cover and
                                                                                                                                                  gasket.
                                                                                                                                               7  Remove the crankshaft oil thrower.
                                                                                                                                               8 If the camshaft gear is to be removed,
                                                                                                                                                  slacken the camshaft nut using tool
                                                                                                                                                  18G 98 A.
                                                                                                                                               9  Rotate the crankshaft until the timing
                                                                                                                                                  marks are positioned as shown.
                                                                                                                                               10 Hold the chain tensioner and chain
                                                                                                                                                  together by hand and remove the
                                                                                                                                                  tensioner retainer screw.
                                                                                                                                               11 Lift away the chain tensioner.
                                                               12 If the chain tensioner shoe is to be              27 Fit the chain tensioner shoe and
                                                                  renewed, remove the circlip from the                 circlip to the pivot pin.
                                                                  pivot pin and lift off the shoe.                  28 Fit the spring, pressure block, and
                                                               13 Remove the idler gear bolt.                          centre pin to the chain tensioner
                                                               14 Lift away the idler gear and its hub.                body. Compress the ~ringand rotate
                                                                  NOTE: The idler gear hub is located                  the centre pin 180 to retain the
        o                                                         by a roll-pin dowel.                                 compressed position.
                                                               15 Remove the timing chain.                          29 Fit the pressure lever to the chain
                                                               16 Remove the camshaft nut and·gear.                    tensioner with the lever legs forward
                                                               17 Remove the crankshaft gear.                          of the tensioner body, i.e. the
                                                                                                                       tensioner body will contact the engine
                                                               Refitting                                               front plate when fitted.
                                                               18 Fit the camshaft gear and secure it               30 Fit the retaining screw through the
                                                                    with its nut.                                      pressure lever and tensioner body.
                                                               I 9 Check the camshaft end-float against             31 Fit the compressed chain tensioner
                                                                    the figure in DATA. If end-float is                and tighten its retaining screw.
                                                                   excessive, remove the camshaft gear              32 Rotate the centre pin 1800 to release
                                                                   and renew the camshaft locating plate.              the tensioner.
                                                               20 Fit the camshaft gear and crankshaft              33 Ensure that the timing marks are still
                                                                   gear to their shafts.                               correctly positioned.
                                                               21 Place a straight-edge across the tooth            34 Remove the peg from the injection
                                                                   face of the gears and check their'                  pump gear.
                                                                   alignment; the crankshaft gear face              35 Tighten the camshaft nut to 65 Ibf ft
                                                                   should be rearward by the amount                    (9 kgf m, 88 Nm).
                                                                   stated in DATA. If necessary, add or             36 Fit the crankshaft oil thrower with its
                                                                   remove shims behind the crankshaft                  dished side towards the gear.
                                                                   gear to set the alignment as near as             37 Renew the timing gear cover oil seal,
                                                                   possible to the DATA figure.                        using tool 18G 134 and 18G 134 BD.
                                                               22 Position the injection pump gear with             38 Fit the timing gear cover and gasket,
                                                                                           *
                                                                   its timing hole at approximately 7
                                                                   o'clock and insert a in (5.5 mm) peg
                                                                   through the hole to engage the hole in
                                                                                                                       using the crankshaft pulley to
                                                                                                                       centralize the oil seal on the
                                                                                                                       crankshaft.
 ~~
            ~f?11
                      ~;;~                                         the engine front plate.
                                                               23 Position the camshaft gear and
                                                                   crankshaft gear with their timing
                                                                                                                    39 Fit the timing cover bolts in the
                                                                                                                       following illustrated positions.

1--\.               - I   },                                       marks in the positions shown.

                               39
                                                               24 Fit the timing chain and place the
                                                                   idler gear (without its hub) in position
                                                                   on the chain.
                                                                                                                       Position
                                                                                                                                    *  Bolt size
                                                                                                                       A ·rw in x I in (44.5 mm) long
                                                                                                                       B -A. in x 2 in (50 mm) long
                                                               25 Adjust the position of the chain,                    NOTE: An '0' ring is fitted on this
                                                                   without rotating the gears, to permit               bolt
                                                     29            the idler gear hub to be fitted. without            C *in x 2 in (50 mm) long
                                                                                                                       D * in )( 2U. in (57 mm) long
                                         /
                                                                   chain slack between the idler and its
                                                                   adjacent gears.
                                                                   NOTE: The idler gear hub is located
                                                                                                                                    *
                                                                                                                       E U. in x I in (44.5 mm) long
                                                                                                                       F U.inxlU.in(31.75mm)long

                                     !.~
                                     . .;;:~
                                                                   by a roll-pin dowel.                             40 Reverse the procedure in I to 5,
                                                               26 Fit the idler gear bolt and tighten it to            tightening the crankshaft pulley bolt
                                                                   30 lbf ft (4.1 kgf m, 41 Nm).                       to 75lbf ft (10.4 kgf m, 102 Nm).
                                                           C
                                    30
                                                               DATA
                                             SHe   "56 A       Camshaft end-float . . . . . . . . . . . . . . . .   0.003 to 0.007 in (0.08 to 0.18 mm)
                                                               Timing gear alignment ...·.·.·...·.·                 Crankshaft gear 0.005 in (0.13 mm) rear-
                                                                                                                       ward of camshaft gear

                                                                                                                                                                 »
                                                                                                                                                                 ....
                                                                                                                                                                 .....
                                                                                                                                                                                       ,..
                                                                                                                                                                                       ....
                                                                                                                                                                                       00

                                              HYDRAULIC TYPE ONLY
                                              INJECfION PUMP
                                                  Remove and refit              19.30.07
                                                  Ti'lliUg - check and adjust
                                                  1 to 16 and 21 to 38        19.30.01
                                              Service tools: AMK 9990, MS 67 A
                                              Removing                                                                                   24 Assemble the long scribing guide of
                                              I  Slacken the alternator mounting bolts                                                      tool MS 67A to the tool body, set it
                                                 and remove"the fan belt.                                                                   on the 2040 position and lock it with
                                              2  Remove the alternator.                                                                     its knurled screw.
                                              3  Disconnect the fuel return pipe from                                                    25 Insert the assembled tool into the
                                                 the injection pump.                                                                        injection pump position on the engine,
                                              4  Disconnect the fuel supply pipe from                                                       engaging the injection pump drive
                                                 the injection pump.                                                                        splines.
                                              5  Disconnect the stop control cable                                                       26 Slide the body of the tool along its
                                                 from the injection pump.                                                                   centre bar until the body engages the
                                              6  Disconnect the throttle cable from the                                                     injection pump drive gear hub. Lock
                                                 injection pump      "                      ~~                               SN::46S
                                                                                                                                            the centre bar with the knurled screw.
                                              7  l>isconnect the lead from the fuel                                                      27 Apply gentle clockwise (viewed from
                                                    preSSIre ulte.                                                                          the rear) pressure to the tool and
FUEL FILTER ELEMENT                           8   Remove the injection pump stop lever                                                      check that the scribed line (timing
  Remove and refit                 19.25.07       return spring.                                                                            mark) on the drive gear hub lines up
                                              9   Remove Nos. 3 and 4 injector pipes.                                                       with the scribing guide of the tool. If
Removing                                                                                                                                    necessary, scribe a new mark.
1  Support the filter base and unscrew        10 Remove Nos. I and 2 injector pipes.
                                              II  Remove the three nuts and washers                                                      28 Remove tool MS 67A.
   the centre bolt in the filter head.                                                     Refitting                                     29 Remove timing pin AMK 9990.
2  Detach the filter base.                       securing the injection pump and
                                                  withdraw the injection pump from the                                                   30 Fit the injection pump gasket to the
3  Remove the element, using a twisting                                                    21 Rotate the crankshaft until the master        drive gear hub.
   motion.                                       engine.
                                                  NOTE: The lower nut also secures the        spline in the injection pump drive is in   31 Fit the torsion bar in to the drive
4  Remove the seals from the filter base                                                      the 12 o'clock position.                      flange on the engine.
   and filter head.                              anchor bracket for the stop lever         22 Insert timing pin AMK 9990 into the
                                                  return spring.                                                                         32 Position the injection pump drive
                                                                                              timing hole in the gearbox adaptor            shaft so that its master spline lines up
Refitting                                     12 Withdraw the injection pump torsion          plate. The hole is situated below the
                                                  bar.                                                                                      with that on the drive flange.
5   Clean the filter base.                                                                    sump flange on the RH side.                33 Fit the injection pump drive shaft over
6    Reverse the procedure in I to 4, using   13 Remove the injection pump gasket.         23 Maintain a light pressure on the timing       the end of the torsion bar and VERY
    a new element and seals.                  14- 20 IIA                                      pin and rotate the crankshaft in the          GENTLY engage the drive shaft
7   Bleed the fuel system, see 19.50:07.                                                      normal direction of rotation until the        splines with the drive flange splines.
                                                                                              timing pin engages the timing hole in      34 Push the injection pump as far into
                                                                                              the flywheel. The master spline in the        position as possible and fit the spring
                                                                                              injection pump drive should now be in         anchor bracket, washers, and nuts.
                                                                                              the 8 o'clock position when viewed         35 Progressively tighten the three nuts to
                                                                                              from the rear. "                              pull the injection pump fully into
                                                                                                                                            position, ensuring that the timing
                                                                                                                                            marks on the pump and drive flange
                                                                                                                                            are aligned.
                                                                                                                                         36 Reverse the procedure in I to 10
                                                                                                                                         37 Bleed the fuel system, see 19.50.07.
LIFT PUMP
  Remove and refit                 19.45.09
Removing
I    NA
2    Disconnect the two pipes from the lift
     pump.
3    Plug the supply pipe from the fuel
     tank.
4    Remove the securing nuts and
     washers.
5    Remove the lift pump and gasket.
Refitting
6    Reverse the proced ure in I to 5.
7    Bleed the fuel system, se.e 19.50.07.

LIFT PUMP
  Overhaul                         19.45.16
DismantlinR
1
2
    Remove the lift pump, see 19.45.09.
    Scribe a reassembly mark across the
    body joint flanges.                                 17     3
                                                                                  8


                                                'ccCO~-=--""
                                               3~
3   Remove the domed cover and sealing
    ring.                                               _----0--'
4   Remove the filter.
5   Remove the securing screws and
    separate the top and bottom halves of      4
    the pump.
6   If the valves require renewing, lever
    them out carefully.
7   Remove the valve gaskets.
8   Press the diaphragm downwards,
    rotate it through 90° and withdraw it.         7~<§>-7
9   Lift out the diaphragm spring.
10 If the diaphragm rod seal is to be
    renewed, carefully withdraw the seal               ~


                                                   ~
    retainer.
11 Lift out the seal.
12 If the rocker arm pin or linkage is to
    be renewed, secure the rocker arm in a
    vice and tap the face of the pump
    mounting flange to dislodge the rocker
    arm pin and its components.
Reassembling
13 Renew any components which are
    worn or damaged.
14 Reverse the procedure in 1 to 12,               b    If the valves are renewed, enS\lre
    noting:                                             that they are fitted to operate in
    a    If the diaphragm spring is                     the correct directions and staked
         renewed, ensure that the new                   in.
         spring is of the same colour as the       NOTE: The inlet port is indicated by
         original.                                 an arrow on the pump body.



                                                                                             ~
                                                                                             CD
                                                                                                                         l>
                                                                                                                         I\)
                                                                                                                         o
FUEL SYSTEM
 Bleeding            19.50.07

NOTE: After renewing the fuel filter element it will only
be necessary to bl~ed the fuel filter as described in 1
and 2, provided that the engine has not been cranked while
the filter is dismantled.
1. Slacken the bleed screw at banjo fitting in the fuel
    filter head. Operate the lift pump by means of its
    priming lever and, when the fuel flowing from the
    screw is free of air bubbles, tighten the screw.            C    2_-K-~~~
2. Slacken the union nut at the injection pump end of
    the fuel feed pipe. Operate the lift pump, and                                         2
    when the fuel flowing from the union is free of
    air bubbles, tighten the nut.                               C:2
3. Slacken the air bleed screw on the fuel pressure
    switch adapter. Operate the lift pump and when
    the fuel flowing from the bleed screw is free of
    air bubbles, tighten the screw.
4. Slacken the air bleed screw on the injection pump


                                                                       ~=l
    governor housing. Operate the lift pump until the
    fuel flowing from the bleed screw is free of air
    bubbles, leave the bleed screw slack.

                                                                                 C)~~~
5. Slacken the air bleed screw on the injection pump
    high-pressure banjo bolt. Operate the starter motor
    with full throttle in the full run position and
                                                                                 ~-~~
    when the fuel flowing from the high-pressure bleed
    screw is free of air bubbles, tighten the bleed                      .'        ~7~7~7
    screw.
6. Continue cranking the engine with the starter motor
    to expel any air trapped in the governor and when
    the fuel flowing from the governor housing bleed       8.   Start the engine and allow it to run until it is
    screw is free of air bubbles, tighten the bleed             firing on all cylinders or repeat step 7 if necessary.
    screw.                                                 9.   Note:
7. Slacken the union nut at the injector end of any             If difficulty in starting occurs, the sea water in-
    two high-pressure pipes. Operate the starter motor          take valve must be closed to prevent filling of the
    with throttle in the full run position and when             exhaust system with sea water. Immediately when
    the fuel flowing from both pipes is free of air             the engine starts, open the sea water intake valve
    bubbles, tighten both union nuts.                           to prevent damage to the pump and engine.
                                                                             20°   fiq               12   Renew the nozzle assembly if the
                                                                                                          pintle clearance allows an angle of
                                                                                                          more than 20° when checked as
                                                                                                          shown.
                                                                                                     13   If necessary, restore the nozzle and
                                                                                                          valve seats to the angles given in
                                                                                                          DATA.
                                                                                                     14   Check the needle lift against the figure
                                                                                                          in DATA.
                                                                                                     I5   Reverse the procedure in 2 to 7,
                                                                                                          tightening the nozzle nut to 50 Ibf ft
                                                                                                          (6.9 kgf m, 68 Nm).
                                                                                                     16   Test and set the injectors to the
                                                       ~              I   cu.                             specification given in DATA, using
                                                                                                          tools 18G 109 A and 18G 109 B.
                                                                                                     17   Fit the injectors, see 19.60.0 I.
                                                   4~
                                                    5~
INJECTORS
  Remove and refit               19.60.01                                                            DATA
Service tools: 18G 284, 18G 284 P                                                          7           Auxiliary hole diameter . . · . . . . . . . .          0.2 mm



                                                    6~1
                                                                                                       Needle lift . . . · . · . . · . . . . . . . . . . '.   0.70 to 0.75 mm
Removing                                                                                               Nozzle seat angle . . . . . . . . . . . . . . .        59° 0'
I INA                      .                                                                           Valve seat angie . . . . . . . . . . . . . . . .       60° 0'
2    Disconnect the spill rail from the
     injectors.
3    Disconnect the high-pressure pipes                                                              Testing
                                                                                         5NC480
     from the injectors.
4    Remove the nuts and washers securing
     the injectors.                                                                                  TEST                NOZZLE SET           ADAPTOR           STROKES         REQUIREMENTS
5    Withdraw the injectors, using tools                                                                                 TO OPEN AT           (18G 109 B)         PER
     18G 284 and 18G 284 P if necessary.                                                                                                    SET TO OPEN AT       MINUTE
6    Remove the two sealing washers from        INJECTORS
     each injector position.                                                                              Auxiliary          135 Atm               220 Atm          60     Spray free of distortions.
                                                  Overhaul                          19.60.08
                                                                                                                                                                           Slight core permissible.
Refitting                                       Service tools: 18G 109 A, 18G 109 B, 18G          Spray
7    Fit two new sealing washers to each        1091::;, 18G 210, 18G 388, 18G 487
     injector position, fitting the smaller                                                               Main               135 Atm               220 Atm         140     Spray free of distortions.
                                                I    Remove the injectors, see 19.60.0 I.                                                                                  Slight core permissible.
     washer as shown.                           2    Mount the injector in tool 18G 388.
8    Reverse the procedure in I to 5,           3    Remove the cap nut and sealing
     tightening the injector securing nuts to        washer.                                      Seat tightness             100 Atm                   -            -      Dry nozzle after 10
     121bfft (1.7 kgf m, 16 Nm).                4    Remove the spring cap and shim.                                                                                       seconds at 90 Atm pressure·
9    If more than two injectors have been       5    Remove the spring.
     removed, crank the engine with the         6    Lift out the spindle.
    starter motor and bleed at least two of                                                       Back-leakage                160 to                   -            -      Initial pressure 160 Atm.
                                                7    Remove the nozzle nut and nozzle,                                       170 Atm                                       Time for pressure drop
     the high-pressure pipes.                        using tool 18G 210.                                                                                                   from 150 to 100 Atm to       !
                                                8    Renew the spring if it shows any sign                                                                                 be between 6 and 140
                                                     of weakness or distortion.                                                                                            seconds
                                                9    Renew the spindle if it is not perfectly
                                                    straight.
                                                10 Clean the nozzle and valve, using kit          Final setting              135 Atm*                  -            -               -
                                                     18G 487.
                                                II Reverse-flush the nozzle, using tools
                                                     18G 109 A and 18G 109 E.                     * Add 5 Atm when setting new injectors or after fitting new springs.


                                                                                                                                                                                                            »
                                                                                                                                                                                                            ...
                                                                                                                                                                                                            III
                                                                                                                                                                   l>
                                                                                                                                                                   N
                                                                                                                                                                   N

SERVICE TOOLS


                                                                                                                                        ~
All Service Tools mentioned in this Manual
must be obtained direct from the tool
manufacturers :
   Messrs V L Churchill & Co. Ltd.
   PO Box No.3                                                                                                              18G 123 B   Cal1L'lhaft   Liner   Reamer
   London Road                                                                                                                          Cutter
   Daventry
   Northants NNll 4NF
   England



                                                                                                                                        ~."
                                             18G SSA    Piston Ring Compressor
                                                                                  18G 109 A   Injector   Nozzle   Testing
                                                                                              Machine

                                                                                                                            18G 123 E   Cal1L'lhaft   Liner   Reamer
                                                                                                                                        Cutter



                                                                                                                                                 /-
                                                                                                                                        ~
18G 27       Valve Seat Cutter and Pilot
             Handle


                                                                                                                                        a-~""""
                                             18G 69     Oil Pump Release Valve
                                                        Grinding-in Tool '


                                                                                  18G 109 B   IJijector Nozzle Testing      18G 123 F   Camshaft      Liner' Reamer
                                                                                              Adaptor                                   Cutter




                                                                                                                                        ~
                              18G 29



18G 29       Valve Grinding-in Tool
                                             18G 98 A   Starting Nut Handle

                                                                                  18G 109 E
                                                                                              ~
                                                                                              Injector Nozzle     Reverse   18G 123 L   Camshaft      Liner   Reamer
                                                                                              Flush - Adaptor                           Pilot




                                                                                                          ~
                                              18G99"



                                             18G 99 A   Clutch Assembly Gauging                                             18G 123 A   Camshaft Liner Reamer -
18G4S        Valve Spring Compressor                    Fixture                                                                         Basic Tool
                                                     @                                            ~
             Gl)""                                                                                                                          /JM\,,"
                                                                                                 U
                                                                        18G 124B

18G 123 T    Camshaft   Liner   Reamer   18G 124 B   Camshaft      Lin e r
             Pilot                                   Remover /Replacer
                                                     Adaptor                                                                    18G 167 C   Valve Seat Narrowing
                                                                                                                                            Cutter - Bottom



             ~t                                      @ . ,"
                                                                                     18G 134 BD   Timing Case Oil        Seal




                                                                                                                                            ~."
                                                                                                  Replacer - Adaptor

18G 123 AB   Camshaft   Liner   Reamer
             Pilot                       18G 124 C   Camshaft        Lin e r
                                                     Rem over / Replacer
                                                     Adaptor                                   ~- ·..~~

             ~
                                                                                                                                18G 174     Valve Seat Finishing Cutter




18G 123 AC   Camshaft
             Pilot
                        Liner   Reamer

                                         18G 124 F
                                                     @ ."
                                                     Camshaft         Liner
                                                     R e mover / Replacer                                                                   ~                 laG 174-'




             ~
                                                     Adaptor                         18G 134 CQ   Crankshaft Rear Oil Seal
                                                                                                  Replacer - Adaptor            18GI74A     Valv Seat Glaze Breaker




                                                     ~                                                                                      ~
18G 123 AD Camshaft     Liner   Reamer
           Pilot



                                         18G 124 H
                                                           18(i 120tH


                                                     Camshaft       Liner
                                                     Remover / Replacer
                                                     Adaptor
                                                                                     18G 167
                                                                                                  Q)".
                                                                                                  Valve Seat Finishing Cutter
                                                                                                                                18GI74B
                                                                                                                                                   lP.(,



                                                                                                                                            Valve Seat
                                                                                                                                            Cutter - Top
                                                                                                                                                           17~[




                                                                                                                                                                          Narrowing


  'V
                                                ...,...... ~
  0~
               f'
18G 124 A    Camshaft         Liner
             Remover/Replacer - Basic    18G 134     Bearings and Oil Seal
                                                                          lfiG 134


                                                                                     18G 167 B
                                                                                                  ~      laG 1618


                                                                                                  Valve Seat        Narrowing   18G 174 C
                                                                                                                                            /JM\,,"
                                                                                                                                            Valve Seat Narrowing
             Tool                                    Replacer - Basic Tool                        Cutter - Top                              Cutter - Bottom


                                                                                                                                                                                  l>
                                                                                                                                                                                  N
                                                                                                                                                                                  Co)
                                                                                                                                                                                   ~
                                                                                                                                                                                   N
                                                                                                                                                                                   .Jio




                                                18G 284 A
                                                            ~laG 284A


                                                             Main Bearing Cap Remover
                                                                                                                                                           6,. .
                                                                                                                                             18G 636     Transfer Pressure - Adaptor
18G 174 D   Valve Seat Cutter Pilot                          - Adaptor




18G 210
             O?,
            I njector    Nozzle           Nut
                                                18G 284 P    I nj ector
                                                             Adaptor
                                                                             Remover
                                                                                                  18G 487     Injector Nozzle Cleaning Kit

                                                                                                                                             18G 637     Assembly Rod

            Spanner

                                                             ~
                                                             ~
                                                18G 284 AC   Main Bearing Cap Remover
                                                             - Adaptor




                                                   ~~~
                                                                                                  18G 633 A   D.P.A. Assembly Base

                                                                                                                                             18G 638 B   Automatic Advance Gauge




18G 226 l Valve Rocker Bush
18G 226 A f Remover/Replacer                                   ~
                                                18G 284 AAF Crankshaft Spigot
                                                            Remover - Adaptor
                                                                                    .
                                                                                ,,,,, ,,
                                                                                           Bush

                                                                                                  18G 634     Assembly Box Spanner
                                                                                                                                             18G 639
                                                                                                                                                         6?
                                                                                                                                                         Head Locating
                                                                                                                                                         Protection Cap
                                                                                                                                                                             Fitting




18G 284     Impulse Extractor -
            Tool
                                laG 284


                                      Basic     18G 388
                                                             ~
                                                             Injector
                                                             Fixture
                                                                        ~Q
                                                                          lflG3AA



                                                                               Dismantling        18G 635
                                                                                                              ~
                                                                                                              Hydraulic Drive
                                                                                                              Protection Cap
                                                                                                                                     Shaft   18G 640
                                                                                                                                                         ~
                                                                                                                                                         Automatic Advance
                                                                                                                                                         Protection Cap
                                                                                                                                                                               Plug
                                                                                                                                                        '\
                                                                                                                                                       )




                                                                                    18G 691 A
                                                                                                ~
                                                                                                Pilot Guide
                                                                                                                             L;;J
                                                                                                                             18G 1195
                                                                                                                                           1                 t::=ID
                                                                                                                                        Clutch Plate Centralizer

18G 641     Assembly       Drive    Plate   18G 651     Drive Shaft Holding Tool
            Spanner




18G 643 A
            ~"
            Metering Valve
            Protection Cap
                                   Pinion   18G 653 A
                                                      ~."
                                                        Relief Valve
                                                        Adaptor
                                                                        Timing
                                                                                                                             AKM 9990   Timing Pin




                                                                                    18G 694 A   Cylinder Head Nut




            ~
                                                                                                Crowfoot Wrench (Special)
                                                                                                - Alternative Tool 18G 694



18G 646     Torque Spanner Socket
                                            18G 655 A   Drive Plate Screw Torque-
                                                        Adaptor
                                                                                                                                                                   HS6,.




            6Y.
                                                                                                                             MS67A      Injection Timing Gauge

                                                                                                              186 1004

                                                                                    18G 1004    Circlip Pliers - Small
18G 647     Assembly Cap



                                            18G 656     Maximum Fuel Adjusting
                                                        Probe




18G 648 A   Universal
            Gauge
                        Flange Marking
                                            18G 690
                                                        P::
                                                        End Plate Adjuster
                                                                                    18G 1108    Crankshaft Rear Oil Seal
                                                                                                Protector Sleeve


                                                                                                                                                                           »
                                                                                                                                                                           I\)
                                                                                                                                                                           (II
                                                                                                Q.l




                 OTHER OVERHAUL

        CONTENTS                                                               SECTION   PAGE
MARINE ENGINE ELECTRICAL SySTEM.............                                      Q
     Activation by Keyswitch (1980 onwards) ...·..............· Q.2
     Activation by Fuel Pressure .···.·.............·.......... Q.4
     Acti vati on by Lube Oi 1 Pressure.......................... Q. 6

COOLING SYSTEM (EXTERNAL)...................                                       R

TRANSMI SS IONS. · . . . . . · . . . . . . . . . . . . . . . . . . . . . . .       S
     Type SAO Manual.......................................... S. 9
     SAl and SAO Clutch Adjustments .......................·... S.21
     SAl and SAO Reduction Units ......·....................... S.23
     Paragon P-21 Series, Hydraulic ............·.............. S.29
     Warner Hydrau1 i c ......................................... S. 35
     Short Profile Sailing Gear .....................··.·...... S.41
Q.2
SECTION Q

            MARINE ENGINE ELECTRICAL SYSTEM

                     ACTIVATION BY KEY SWITCH
               Thjs system is supplied on most Wester-
               beke engines beginning May. 1980. Essen-
               tially activation of the circuit is
               accomplished by the ignition position of
               the key switch. No oil pressure switch
               is required. The engine is preheated
               by depressing the preheat push button.
               The engine is cranked by turning the
               key switch to the right-most momentary
               position.
               Voltage is maintained to the instruments,
               fuel solenoid or fuel lift pump if sup-
               plied, and to other electrical devices via
               the ignition position of the key switch.
               Models which have a fuel solenoid or elec-
               tric fuel pump may be turned off via the
               key switch. Models with mechanical fuel
               lift pumps or no fuel solenoid are stopped
               by pulling a stop cable.
               The circuit is protected by a circuit
               breaker located near the starter. Any
               time excessive current flows. the circuit
               breaker will trip. This is a manually
               resettable breaker, and must be reset
               before the engine will operate electrically
               again.
               CAUTION - the builder/owner must ensure
               that the instrument panel, wiring and
               engine are installed so that electrical
               devices cannot come in contact with sea-
               water.
               The latest information regarding your
               engine's electrical system is included
               on the wiring diagram shipped with the
               engine. Be sure to study this wiring
               diagram and all the notes thereon.
                                                                                                                                                                                   Q.3
                                                                              ACTIVATION BY KEYSWITCH                                                    SECTION Q



                                                                                                                                               SCHEMATIC DIAGRAM.


                                                                                                                                     ~ 1 Z VDC BATTERY                &AT'TERY M'TU,,"




                                                                                                                                                          @
                                                                                                                                                         PRE-ICAT
                                                                                                                                           "


                                            WI RI NG DIAGRAM.



                                                                   NOT USED    OC"
                                                  ®.5U NOT!- D

                                                W.T.5ENDER           ORN
                                                                               ··
       WATtR TtMPT.
       ~IT'H              Olt. PR!S!.URe
                                                                      RN             @
           @             @SWITCH                                                     ALTERNATOR

           i~    ~I
            '¥----~ j
       ..L.     '                    I
       -        I
       =              @
                                   ...L..
                                   =                                       @
              tt"\.   Of=lTIONAL     -
           W          ALARM                                                                                                                                         ALARM   @ o. P, sw.
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                                                                                                               ".                        W T
Q.4


      MARINE ENGINE ELECTRICAL SYSTEM




       ACTIVATION BY FUEL PRESSURE
       (Push Button Start)
              This system is supplied on all four and
           six cylinder Westerbeke engines beginning
           January 1975. Basically, the system is
           very simple and eliminates the need for a
           separate switch position to activate the
           engine alarm system, when supplied.
              Starting is accomplished by operation
           of the start push button which causes the
           starting motor to crank.
              Once the engine is running, fuel pres-
           sure developed in the low pressure side of
           the fuel injection pump operates a fuel
           pressure switch. Voltage is then applied
           to the alarm system (if supplied) and to
           the alternator for excitation and for all
           instruments.
              When the engine is stopped, fuel pres-
           sure drops and the fuel pressure switch
           removes voltage from these devices.
              When an engine is supplied with a pre-
           heating device, the device is energized by
           a separate push button.
           NOTE: It is important that your engine
           installation includes fuses or circuit
           breakers, as described under "Ownership
           Responsibility" on the wiring diagram
           supplied with your engine.
                                                                                                                                                                                                               Q.5
                                                            ACTIVATION BY FUEL PRESSURE
                                                                (PUSH BUTTON STARn




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                                                                                                                                                             Drawing No. 19201
Q.6

         Marine Engine Electrical System




      ACTIVATION BY LUBE OIL PRESSURE
      (Keyswitch Start)
             This system is supplied on all 4 and 6
          cylinder Westerbeke diesels produced prior
          to January 1975. Operation is very simple.
          Putting the start switch in the Run posi-
          tion energizes an alarm system (when sup-
          plied). Returning the start switch to Off
          position de-energizes the alarm.
             Turning the start switch to Crank posi-
          tion operates the starting motor and starts
          the engine. Upon starting, the start
          switch is released to the Run position.
             When the engin~ develops oil pressure,
          voltage is supplied to the alternator for
          excitation and to all instruments. When-
          ever the engine stops, loss of oil pres-
          sure removes voltage from these devices.
             When an engine is furnished with a pre-
          heating device, it is energized by a sep-
          arate push button at the key switch panel.
             When an engine is furnished with an
          electric stop solenoid, it is energized by
          a separate push button at the key switch
          panel.
          NOTE: It is important that your engine in-
          stallation includes fuses or circuit
          breakers, as described under "Owner's Res-
          ponsibility" on the wiring diagram supplied
          with your engine.
                                                                                                                                                                                                              Q.7
                                 ACTIVATION BY LUBE OIL PRESSURE
                                        (KEYSWITCH START)




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                                                                                                                                                  Drawing No. 15245
Q.8

      YOUR NOTES
                                                                  SECTION R
                    COOLING SYSTEM (EXTERNAL)
1. DESCRIPTION:                           charge of the sea water pump to the
Westerbeke marine diesel engines are      heat exchanger sea water inlet. After
equipped with fresh water cooling.        passing through the tubes of the heat
Transfer of heat from engine fresh        exchanger, the sea water may enter a
                                          tran~mission oil cooler if present
~ater to sea water is accomplished
1n a heat exchanger, similar in func-     and 1f sea water cooled. Ultimately,
tion to an automotive radiator. Sea       the sea water enters a water injected,
water flows through the tubes of the      wet exhaust system, the most popular
heat exchanger while fresh water          type of exhaust system in use. In
flows around the tubes. The sea           the case of larger engines the sea
water and fresh water never mix           water flow is divided prior to enter-
with the result that the cooling          ing the exhaust systems so that a
water passages in the engine stay         portion is dumped directly overboard
clean. .                                  and a portion is used to cool the
                                          exhaust system~ Full sea water flow
2.   FRESH WATER CIRCUIT:                 entering the exhaust system would
                                          create unnecessary exhaust back
Heat rejected during combustion, as       pressure.
well
.     as heat developed by friction.
1S absorbed by the fresh water whose      4.   SEA WATER PUMP:
flow is created by a fresh water cir-
                                          The.s~a wa~er  pump is self priming and
culating pump. The fresh water flows      pos1t1~e dlsplacement. It is a rotary
from the engine through a fresh water     pump w1th a nonferrous housing and a
cooled exhaust manifold, a heat ex-       neoprene impeller. The impeller has
changer, in most cases an oil cooler,     flexible vanes which wipe against a
and returns to the suction side of        curved cam plate within the impeller
the fresh water circulating pump.         housing, producing the pumping action.
The flow is not necessarily in this       On no account should this pump be run
order in every model. When starting       dry. There should always be a spare
a cold engine, most of the external       impeller and impeller cover gasket
flow to the heat exchanger is pre-        aboard.
vented by the closed thermostat.
Some amount of by-pass is maintained      5. SEA WATER PUMP IMPELLER REPLACEMENT:
to prevent overheating in the exhaust
manifold. As the engine warms up, the     The ~ol!owi~g instructions are general
thermostat begins to open up allowing     and lnd1cat1ve only. Specific instruc-
full flow of engine fresh water thru      t~ons where applicable may be packaged
the external cooling system.              w1th your replacement impeller.
3. SEA WATER CIRCUIT:                     a. Remove the front cover taking care
The sea water flow is created by a           to salvage the gasket.
positive displacement neoprene inpeller
pump (gear pump in certain special        b. Remove the impeller by pulling
cases). Normally the pump draws sea          straight outwards, parallel to
water directly from the ocean via the        the pump shaft. This is best
sea cock and sea water strainer. Some-       done with a pair of pliers ap-
times a transmission oil cooler, or          plied to the impeller hub.
pehaps a V drive will be piped on the     c. Coat the replacement impeller
suction side of the sea water pump.          and the chamber into which it
Generally it is better to have as few        mounts with grease.
devices on the suction side of the sea
water pump as possible to preclude        d. Carefully align the impeller key
priming difficulties. Usually sea            way, or other locking mechanism,
water flows directly from the dis-
R.2
           with the shaft. Take care that      8.   THERMOSTAT:
           all the impeller blades bend in
           the same direction and trailing.    Generally thermostats are of two types.
                                               One is simply a choking device which
     e.    Inspect the front cover for wear.   opens and closes as the engine tempera-
           A worn front cover should ulti-     ture rises and falls. The second type
           mately be replaced. Sometimes       has a by-pass mechanism. Usually this
           it can be reversed as an emer-      is a disc on the bottom of the thermo-
           gency measure, but not when         stat which moves downward to close off
           stamped markings would break the    an internal by-pass passage within the
           seal between the cover and the      head. Both types of thermostats, from
           i'mpel1er blades.                   1980 onward, have a 0.06" diameter
                                               hole punched through them to serve as
     f.    Reinstall the end cover with a      a by-pass while the engine is warming
           new gasket.                         up. This prevents overheating in the
                                               exhaust manifold during engine warm-up.
     g.    Be doubly sure to check quickly     The hole is critical and replacement
           for sea water flow when starting    thermostats must be equal in this
           the engine. The absence of flow     design characteristic.
           indicates that the pump may not
           be priming itself properly.         When replacing a thermostat, be sure
           This situation must be investi-     that it is rotated so as to not
           gated immediately or damage to      strike the thermostat housing, pro-
           the new impeller will result        jections inside the head, temperature
           from overheating.                   senders or temperature switches
                                               which may be installed close to the
6.        ENGINE FRESH WATER:                  thermostat.
It is preferable to fill your engine           A thermostat can be checked for prop-
with a 50% antifreeze-water mixture.           er operation by placing it in a pan
This precludes the necessity of drain-         of cold water and then raising the
ing coolant in the winter. Since most          temperature of the water to a boil.
antifreezes contain preservative agents        The thermostat should open notice-
of one kind or another, rusting within         ably (with travel on the order of
the engine is minimized. Also the anti-        1/4" - 1/2") and be fully opened when
freeze mixture boils at a higher tem-          the water is boiling.
perature than water, giving cooling
system "head room.      II
                                               9.   ENGINE LUBE OIL COOLER:
When draining the engine, open the
pressure cap first to relieve the              Lubricating oil carries heat away from
vacuum created by draining.                    the engine bearings and other friction
                                               surfaces. The oil circulates from the
                                               lube oil pump, through the engine,
7.        FILLING THE FRESH WATER SYSTEM:      through the engine oil cooler, and back
                                               to the oil pump.
It is very important to completely fill
the fresh water system before starting         The oil cooler may be cooled either by
the engine. It is normal for air to            engine fresh water or by sea water.
become trapped in various passages so
all high points must be opened to atmos-       10. TRANSMISSION OIL COOLER:
phere to bleed entrapped air. When an
engine is started after filling with           Certain transmissions require oil cool-
coolant, the system may look deceptively       ing. In these cases, the transmission
full until the thermostat opens. At this       oil cooler is usually cooled by sea
time when water flows through the exter-       water.
al cooling circuit for the first time,
pockets of air can be exposed and rise         Normally sea water enters this cooler
to the fill point. Be sure to add cool-        after exiting the heat exchanger, but
ant at this time.                              not always.
                                                                              R.3




                    TWO PASS MANIFOLD


 Note:   Drawing is indicative only.   Specific models may vary in detail ·




                                                             . - - - TO EXHAUST
                                                                     5YSTE/v1




         FRESH
         WATt':?




PUMP
R.4



                       SINGLE PASS MANIFOLD


      Note:   Drawing is indicative only.        Specific models may vary in detail.




      SURGE                        EXHAUST
      TANK                         MANIFOLD
                                                                 - -~
                                                                                  i\lER
                                                                     BOARD
                                                                       H J"
                                                                       EXCHANGER
              FRESH                                                         -..                         FROM
              WATER                                                     I         ~C          c::I                   >         FRESH WATER
                                                                .... - - · -                  ENG'NE 01 L

                                                    'lL"t:X.P
                                      HYDRAULIC GEAR/
                                                                     I"-'-..-L
                                                                                      t:l
                                                                                            IUSED   ON HYD-
                                                                                             RAU L Ie GEAR
                                       Q1b COOLER     'If                                       ONLY·
                SECTION S




TRANSMISSIONS
S.8

      YOUR NOTES·
                                                                                                                                       S.29

                     PARAGON P-21 SERIES HYDRAULIC

I. SPECIFICATIONS


  A. Description Chart




               MODEL               REDUCTION RATIO                           DIRECTION OF ROTATION
                 P21L                          DIRECT                                 ALL LEFT HAND
                 P22L                          1. 5: 1                                AS VIEWED FROM
                 P23L                          2:1                                    THE OUTPUT END
                 P24L                          2. 5: 1                                OF THE TRANS-
                 P25L                          3:1                                    MISSION




 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


                                   P21- L             5J-1234
   ~~
 P2 -   Gear. Size         1-   Direct Drive                                                   5J-1234 -     Transmission Serial No.
                                                      L-   left Hand Rotation Unit




                                     REDUCTION GEAR MODEL AND SERIAL NUMBERS


                                 P 23 L               5J-5678
  ~
 P2 -   Gear Si ze   2)
                     3 ,     Redu ction
                           . Gear
                                                --------=:::::---------
                                                 1. 5: 1 ·t
                                                 2 . 0 -1
                                                       ·
                                                              Reduction
                                                              Gear
                                                                            L ..   Left Hand Rotation Unit
                                                                                                                 5J-5678 -   Trans-
                                                                                                                             mission
                                                                                                                             Seriol
                     :   \ Si ze                 2.5:1 \      Ratio                                                          No.
                                                 3.0: 1 .
S.30



   II. INTRODUCTION                                        ward drive is through a multiple disc clutch
                                                           arrangement, while the reverse drive utilizes
                                                           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 sep&.rate external oil cooler
       transmission is self- 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
       Translllission oil under pressure is used to        model identification numbers are listed in
       engage a forward or reverse drive. The for-         Section I, under "SPECIFICATIONS".




   III. 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 transmission has been           plate. Remove the 3-1/2" 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 non-original 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 counterclockwise 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 I, "SPECI FICA TIONS",           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 3-1/2" 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
     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 housing.




IV. 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 reverse drives
                                                   2. When the engine is first started, allow it
   are operated by transmission oil under pres-
                                                      to idle for a few moments. Stop the engine
   sure. An internal gear type oil pump delivers
                                                      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' r;ontrol lever is shifte1 to the       TRANSMISSION OIL LEVEL MAYBE
  forward position, oil under pressure is de-       CHECKED BEFORE RUNNING THE
  li vered 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 nnd case then revolve as a solid cou-         in NEUTRO\L, 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 ()utput 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 lever 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. EMERGENCY shifts may be at
  band piston :md the propeller shaft remains         higher engine speeds, but this is not a
  stationary.                                         recommended practice.
8.32


V. 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 self-contained 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 automobHes.                     oil changes varies with theoperatingcondi-
                                                           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 clutches, and the
          after an oil change, check the level after       reverse band is self adjusting to compen-
          running for a few minutes to make certain        sate for lining wear, so that no external
          that the oil cooler and the various passages     reyerse band adjustment is necessary.




                                                                               OIL TO COOLER




          COUPLING
          FLANGE
                                                                                                       S.33
C. Trouble Shooting Chart

    PROBLEM                            POSSIBLE CAUSES AND METHODS OF CORRECTION
GEAR INOPERATiVE

 Drive Shaft does not operate
 with selector valve in forward   1.   Low Oll Pressure.      a.   Low oil supply. Add oll, refer to
 or reverse.                                                       lubrication.

                                                              b.   Faulty oil gauge. Replace gauge.
                                                                   Oil gauge slow to register, air or
                                                                   obstruction in oll gauge line. Clean
                                                                   and bleed oil gauge line.

                                                              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 valve 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 v'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 watar 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 band 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 damaged parts.
                                                              Replace defective or damaged parts.
S.34



       PROBLEM                         POSSIBLE CAUSES AND METHODS OF CORRECTION
GEAR 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 parts.

GEAR SLIPPING OR SLOW TO
ENGAGE
 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 Case~

INTERNAL AND EXTERNAL
LEAKS                             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 oil 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 Oil from
                                       Transmission.          a.   Check for defective gaskets and
                                                                   seal.
                                                                                  S.35


                          WARNER HYDRAULIC


DESCRIPTION                                 be shifted to the point where it covers
                  VVesterbeke Four-107      the letter" F" on the case casting, and
Engines are also furnished with VVarner     is located in its proper position by the
hydraulic direct drive and reduction        poppet ball. The VVarranty is cancelled
gear assemblies.                            if the shift lever poppet spring and/ or
                                            ball is permanently removed, or if the
The direct drive transmission consists      control lever is changed in any manner,
of a planetary gear set, a forward          or repositioned, or if linkage between
clutch, a reverse clutch, an oil pump,      remote control and transmission shift
and a pres sure regulator and rotary        lever does not have sufficient travel in
control valve. All of these are con-        both directions. This does not apply to
tained in a cast iron housing along with    transmissions equipped with VVarner
necessary shafts and connectors, to         Gear. electrical shift control.
provide forward, reverse and neutral
operation. A direct drive ratio is used     LUBRICATION
for all forward operation. In reverse,
the speed of the output shaft is equal to   The properties of the oil used in the
input shaft speed, but in the opposite      transmission are extremely important
direction. Helical gearing is used to       to the proper function of the hydraulic
provide quieter operation than can be       system. Therefore, it is extremely
                                            important that the recommended oil,
obtained with spur gearing.                 automatic transmission fluid (ATF),
Oil pressure is provided by the cres-       Type "A" be used.
cent type pump, the drive gear of
which is keyed to the drive shaft and       PROCEDURE FOR FILLING
operates at transmission input speed          TRANSMISSION VVITH OIL
to provide screened oil to the pressure     VVhen filling the transmission, oil
regulator.                                  should be added until it reaches the
From the regulator valve the oil is         full mark on the dipstick. The quan-
directed through the proper circuits        tity of oil depends upon the angle of
to the bushings and anti-friction bear-     the installation. The unit should be
ings requiring lubrication. A flow of       turned over at engine idle speed for a
lubricant is present at the required        short time in order to fill all circuits,
parts whenever the front pump is turn-      including the cooler and cooler piping.
ing and it should be noted that supply
is positive in forward, neutral and         PROCEDURE FOR CHECKING OIL
reverse conditions.                            LEVEL
The unit has seals to prevent escape        The oil level should be checked im-
of oil.                                     mediately after shutting off engine and
                                            sufficient oil added to again bring the
Both the input and output shafts are
                                            transmission oil level to the full mark
coaxial, with the input shaft splined
                                            on the dipstick assembly. The dipstick
for the installation of a drive damper,     assembly need not be threaded into the
and the output shaft provided with a        case to determine the oil level.· It
flange for connecting to the propeller      need only be inserted into the case
shaft.                                      until the cap or plug rests on the sur-
                                            face surrounding the oil filler hole.
CONTROL LEVER POSITION                       The transmission should be checked
The position of the control lever on         periodically to assure proper oil level,
transmission when in forward should          and oil should be added if necessary.
S.36


 CHANGING OIL
 It is recommended that the transmis-
 sion oil be changed once each season.
 After draining oil from the unit. the
 removable oil screen should be
 thoroughly cleaned before refilling
 the transmission with the recom-
 mended oil (ATF) Type "A".

 REDUCTION GEAR BOX
 The reduction gear box operates in
 conjunction with the direct drive unit.
 The reduction gear box consists of a
 planetary gear set which reduces the
 input revolutions. to a fixed ratio.
 It is recommended that all installa-
 tions using a reduction gear have a
 suitable locking device or brake to
 prevent rotation of the propeller shaft
 when the boat is not under direct pro-
 pulsion. If the marine gear is not in
 operation and the forward motion of
 the boat causes the propeller shaft to
 rotate, lubricating oil will not be cir-
 culated through the gear because the
 oil pump is not in operation. Over-
 heating and damage to the marine gear
 may result unless rotation of the pro-
 peller shaft is prevented.
 Except in an emergency. shift from
 forward to reverse drive through
 neutral   at  engine speeds below
 1000 rpm to prevent damage to the
 engine. or marine gear.
                                                                         S.41

      SHORT PROFILE SAILING GEAR
1.    Description


1.1   Brief description

      The Short Profile Sailing Gears are equipped with a positively
      driven, mechanically operated helical gearing system. The
      servo-operated multiple-disc clutch requires only minimum
      effort for gear changing, making the transmission suitable
      for single-lever remote control via a rod linkage, Morse or
      Bowden cable.
      The torque transmission capacity of the clutch is exactly rated,
      preventing shock loads from exceeding a predetermined value and
      thus ensuring maximum protection of the engine.

      The transmission units are characterized by low weight and small
      overall dimensions. The gearbox castings are made of a high-
      strength, corrosion-resistant aluminum alloy, chromized for
      improved sea water resistance and optimum adhesion of paint.

      The transmissions are immersion-lubricated. Maintenance is
      restricted to oil level checks (see "Maintenance").




                              AIR VENT HOLE




                                                        LEVER
                                                       NING SCREW
5.42
       1.2   Gear casing

             The rotating parts of the HBW transmission are accomodated in an oil-tight casing
             divided into two halves in the plane of the vertical axis. Amply dimensioned cool-
             ing ribs ensure good heat dissipation and mechanical rigidity.

             An oil filler screw with dipstick and an oil drain plug are screwed into the gear
             casing. The filler screw is provided with a breather hole.

             The shaft for actuating the multiple-disc clutch extends through a cover on the
             side of the gear casing.

       1.3   Gear sets

             The transmission is equipped with shaved, casehardened'helical gears made of
             forged low-carbon alloy steel. The multi-spline driving shaft connecting the trans-
             mission with the engine is hardened as well.

             The driven shaft (propeller side) of the transmission is fitted with a forged coupling
             flange.
                                                                                              S.43
1.4   Multiple-disc clutch including operation - power train

      The engine torque is applied to the input shaft (36) in the specified direction of
      rotation and, in shifting position A (see item 1.2), via gear (44), the frictionally
      engaged clutch discs (51 and 52) to the external disc carrier (57) and from there
      via the guide sleeve (59) to the output shaft (66).

      In shifting position B (see item 1.2), the torque is transmitted from the input
      shaft (36) via intermediate gear (26), gear (65), clutch discs (51 and 52) to the
      external disc carrier (57), the guide sleeve (59) and the output shaft (66).

      - Function

      The transmission uses a positively driven, mechanically operated multiple-disc
      clutch system mounted on the output shaft.

      The thrust force required for obtaining positive frictional engagement between the
      clutch discs is provided by a servo system. This essentially comprises a number of
      balls which, by the rotary movement of the external disc carrier, are urged against
      inclined surfaces provided in pockets between the guide sleeve and the external
      disc carrier and in this manner exert axial pressure. The thrust force and, as a
      result, the transmittable friction torque are thus proportional to the input torque
      applied. Due to the cup springs (48) supporting the clutch disc stack and a limita-
      tion of the range of axial travel of the external disc carrier (57), the thrust force
      cannot exceed a predetermined value, so that the torque transmission capacity of
      the clutch is limited.

      The actuating sleeve (60) is held in the middle position by spring-loaded pins. To
      initiate the shifting operation, the actuating sleeve (60) need merely be displaced
      axially by a shifting fork until the arresting force has been overcome. Then the
      actuating sleeve (60) is moved automatically by the spring-loaded pins, while the
      external disc carrier, which follows this movement, is rotated by the frictional
      forces exerted by the clutch discs, and the shifting operation is completed as de-
      scribed above.




       Input




         36
                                                                           Output
5.44
       1.5   Shaft beari ngs

             Both the input and the output shafts are carried in amply dimensioned taper roller
             bearings.                                                                              \
                                                                                                        \


             The intermediate gear and the movable gears are carried in sturdy needle roller
             bearings.




       1.6   Shaft seals

             External sealing of the input and output shafts is provided by radial sealing rings.
             The running surfaces on the shafts are casehardened.


       1.7   Lubrication

             The transmissions are immersion-lubricated. The bearings are generously supplied
             with splash oil and oil mist.
                                                                                               S.45
2.    Installation


2.1   Delivery condition

      For safety reasons, ~~e gearbox is NOT filled with oil for
      shipment. The actuating lever is mounted on the actuating
      shaft.

      Before leaving the factory, each transmission is subjected to a test run with the
      prescribed ATF oil. The residual oil remaining in the transmission after draining
      acts as a preservative and provides reliable protection against corrosion for at least
      1 year if the units are properly stored.


2.2   Painting the gearbox

      Before painting the gearbox, take care to remove any oil films by means of suit-
      able agents (e.g. HST safety cleansing fluid).

      Always cover the running surfaces and sealing lips of the radial sealing rings on
      both shafts before painting. Make certain that the breather hole on the oil filler
      screw is not closed by the paint. Indicating plates should remain clearly legible.


2.3   Connection of gearbox with engine

      A torsio-elastic damping plate between the engine and the
      transmission is to compensate for minor alignment errors
      and to protect the input shaft from external forces and
      loads. Radial play should be at least O.Smm.


2.4   Suspension of engine-gearbox assembly in the boat

      To protect the gearbox from detrimental stresses and loads, provision should be
      made for elastic suspension of the engine-gearbox assembly in the boat or craft.

      The oil drain plug of the gearbox should be conveniently accessible.


2.5   Position of -gearbox in the boat

      The inclination of the gearbox unit in the direction of the shafts should not per-
      manently exceed an angle of 20 degrees (see illustration).

      The gearbox can also be mounted with the output shaft in the upward position.
      Interchange the oil dipstick and the oil drain plug in this case.
S.46




       2.6   Operation of gearbox

             Gear changing requires only minimum effort. The gearbox is suitable for single
             lever remote control. Upon loosening the retaining screw, the actuating lever (see
             illustration) can be moved to any position required for the control elements (cable
             or rod linkage). Make certain that the lever does not contact the actuating lever
             cover plate (9): the minimum distance between lever and cover should be 0.5 mm.

             The control cable or rod should be arranged at right angles to the actuating lever
             in the neutral position of the lever.

             The shifting travel, as measured at the pivot point of the actuating lever, between
             the neutral position and end positions A and B should be at least 35 mm for the
             outer and 30 mm for the inner pivot point.

             A larger amount of lever travel is in no way detrimetal.

             However, if the lever travel is shorter, proper gear engagement might be impeded
             which, in turn, would mean premature wear, excessive heat generation and result-
             ing damage.

                                                    o
                                                              Minimum shifting movement




                    Clamping screw to be
                    tightened to torque
                    of 18 Nm




                                                                            Oil drain plug
                                                                                           S.47
            Oil dipstick and
            oil filler screw
            17 mm width across flats


                               A




                           8

                                                             Min. distance of
                                                             actuating lever 0.5 mm


      The position of the cover plate underneath the actuating lever is factory-adjusted
      to ensure equal lever travel from neutral position to A and B.

      When installing the gearbox, make certain that shifting is not impeded e.g. by
      restricted movability of the Bowden cable or rod linkage, by unsuitably positioned
      guide sheaves, too small bending radius, etc.


2.7   Engine-gearbox compartment

      Care should be taken that the engine-gearbox compartment is properly ventilated.

3.    Operation


3.1   Initial operation

      Fill the gearbox with oil of the recommended grade (see items 4.1 and 4.2). The
      oil level should be the index mark on the dipstick (see illustration).


                                       Casi ng su rface




                                                                   Dipstick




            Correct readings up to             Oil level
            200 inclination in
            direction of shafts

                                                     --::~~~~Jlrr~~~~A~TF'or
                                                                           Type A

                                                                              Dexron II

      To check the oil level, just insert the dipstick, do not screw in. Retighten the
      hex screw with the dipstick after the oil level check.
S.48
       3.2   Operating temperature

             The max. permissible temperature of the transmission oil is 130 0e.


       3.3   Operation of gearbox

             Shifting is initiated by a cable or rod linkage via the actuating lever and an actuat-
             ing cam. The completion of the gear changing operation is automatic and cannot
             be influenced by external control. The actuating lever is mounted on an actuating
             shaft and fixed by means of a retaining screw.

             Gear changing should be smooth, not too slow, and continuous (without inter-
             ruption). The multiple-disc clutch permits gear changing at high engine rpm, in-
             cluding sudden reversing at top speeds in the event of danger.


       3.4   Operation without load

             Rotation of the propeller without load, e.g. while the boat is sailing, being towed,
             or anchored in a river, as well as idling of the engine with the propeller stopped,
             will have no detrimental effects on the gearbox.

             Locking of the propeller shaft by an additional brake is not required. since lock-
             ing is possible by engaging the reverse gear.


       3.5   Lay-up periods

             If the transmission is not used for periods of more than 1 year it should be com-
             pletely filled with oil of the same grade to prevent corrosion. Protect the input
             shaft and the output flange by means of an anticorrosive coating if required.


       3.6   Preparation for re-use

             Drain the transmission of all oil and refill to the proper
             level with the prescribed oil.
                                                                                            5.49
4.    Maintenance


4.1   Transmission oil

      To ensure trouble-free operation of the clutch, only use oil of the recommended
      type.

      Under no circumstances should the oil contain any additives such as molybdenum
      sulphite.

      We recommend commercial Automatic Transmission Fluid (ATF), Type A
      or Dexron II.

4.2   Oil quantity

      H BW 5 approx 0.4 Itr
      HBW 10 approx 0.6 Itr
      H BW 20 approx 0.8 Itr
      Use the index mark on the dipstick as a reference.


4.3   Oil level checks

      Check the oil level in the transmission daily. Correct
      oil level is the index mark on the dipstick (see item 3.1) .
      Always use the same oil grade when topping up.


4.4   Oil change

      Change the oil for the first time after about 25 hours of operation, then at inter-
      vals of at least 1 year.


4.5   Checking the Bowden cable or rod linkage

      The Bowden cable or rod linkage should be checked at shorter time intervals.
      The minimum lever travel from the neutral position to operating positions
      (O-A = O-B) should be 35 mm for the outer and 30 mm for the inner pivot point.
      Make certain that these minimum values are safely reached. Check the cable or
      rod linkage for easy movability (see item 2.9).


4.6   OVERHAUL

      Disassembly of the transmission in the field is not recom-
      mended. If an overhaul or repair is needed, the work should
      be done by Westerbeke or an authorized Westerbeke service
      center.
                                               SECTION V




         SERVICE BULLETINS
The following Bulletins contain supplementary and
updated information about various components and
service procedures which are important to the
proper functioning of your eng ine and its support
systems.
You should familiarize yourself with the subjects
and make sure that you consult the appropriate
Bulletin (s) whenever your eng ine requires service
or overhaul.




                        127
 V2
                SERVICE BULLETIN
DATE:        6/15/69                                                       BULLETIN NUMBER:                20
MODEL:       All Engines
SUBJECT:     Connecting Pressure Sensing Devices to Oil Galleries


                  Oil pressure sensing devices, such as senders and switches, must
             never be connected directly to any oil gallery of an engine.                            The
             reason is simply that continued engine vibration causes fatigue of
             the fittings used to make such a connection.                  If these fittings fail,
             the engine loses its oil pressure and very quickly seizes.

                   Such pressure sensing devices must be bulkhead mounted and
             connected to the oil gallery using an appropriate grade of lubricating
             oil hose. Any fittings used to connect the hose to the gallery must
             be of steel or malleable iron.        Brass must not be used fo"r this
             purpose .                                                                                          '..~j




                                   J. H. WESTERBEKE CORP.
                                    AVO" ",O«Ie.",'A' NIt«, AIIOII, MAee. o.~ ·.·'.17/ . . . -7700
                                                CA.'.: " ·· TCOIt~, AVO"· r.'.Il: ·· -····

PIN: 11967
                         SERVICE BULLETIN                                                                 V3


/.-",
        DATE:        5/6/74                                                       BULLETIN NUMBER: 69
        MODEL:       All marine generators and marine engines
        SUBJECT:     Exhaust system failures


                 When engine sea water is fed into an exhaust system so that the full
                 stream strikes a surface, erosion may cause premature failures.
                 Proper design of either a water jacketed or ~ water injected {lIwet)1I
                 exhaust system to prevent this problem requires that the sea water
                 inlet be positioned so that the entering stream of sea water does not
                 strike a surface directly. Also, the velocity of the entering sea
                 water stream should be as low as possible which is achieved by having
                 inlet fittings as big in diameter as possible.
                 In addition to the above design considerations, it is usually advan-
                 tageous to divide the sea water flow at the point of entry to the
                 exhaust system so that only a portion of it enters the exhaust system.
                 The remainder is normally piped directly over the side. The proper
                 proportion of the sea water flow to pass through the exhaust system
                 can only be determined by trial and error. The goal is to prevent
                 excessive exhaust temperatures with the least amount of sea water.




                                           J. H. WESTERBEKE CORP.
                                           AVON 'NDU.TR'AI. ,.AR", AVON, iliA ··· 02322· '8f71 588-7700
                                                      CA.I..: Mi·· TCOR,., AVON· T.I..1C: .2-4444

        PIN:     19149
 V4
                        SERVICE BULLETIN
DATE:             May 29, 1974                                                 BULLETIN NUMBER: 72

MODEL:            All
SUBJECT:          Non-Interchangeabil ity between Manufacturers of Gauges and Senders

 In recen't years we have purchased gauges and senders from four di fferent
 manufacturers.
 In no case may the gauge of one manufacturer be used with the sender of another
 manufacturer. In some cases the wiring of either or both the gauge and the
 sender varies by manufacturer.
 Thus it becomes important, when ordering a replacement gauge or ordering a
 replacement sender, to order a matched set or to know conclusively who the
 manufacturer is.

Ammeters are electrically interchangeable.
                            STEWART-WARNER VOO             FARIA                             NOVOX
                            2" OIA CASE    2 3/8" OIA CASE 2" OIA CASE                       2" OIA CASE
Ammeter                     11581              11931                    16550                 19165
Oil pressure gauge          11544              11914                    16548                 19166
Oil pressure sender         11542             11916                     16551                 19167
Water temp. gauge           11545             11913                     16549                 19168
~Ja ter   temp. sender      11543              11915                    16552                 19169
Adapter ri ng to i n- 16023                 LAMP ...                    16023                16023
stall 2" dia gauge in and                                               and                  and
2 3/8" dia panel      S8 #44                   __-...... __ AMP-        S8 #44               S8 #44
cut-out
                      GND             B+                 SND          LAMP'"
                      ~
                                                             SND~B'"
Wiring diagram                                                                              LAMP+

                    SND~B+                    GND
                                                                       ~ SN .... _·,...                 B+
                                              Also see                  (;ND
                                              S8 #36
                                                                                              (;ND




                                           J. H. WESTERBEKE CORP.
                                           AIION INDUSTRIAL PARK, AIION, MAS.S. 02322· (517} 588-7700
                                                       CABLE: WESTCORP, AIION· TELEX: .2-4444


PIN:      19190
                 SERVICE· BULLETIN                                                                V5




DATE:        August 27, 1975                                          BULLETIN NUMBER: 76

MODEL:       Four-9l, W-30 ; W-50 (If fitted with thi s type pump)
SUBJECT:     Proper bleeding procedure for hydraulically governed fuel injection
             pumps incorporating an engine anti-stall device

An anti-stall device is incorporated on fuel injection pumps fitted to the                   Four-91
engines. This device is located on top of the fuel pump governor housing,                    just
beneath the air vent bleed screw. In fact, the bleed screw and anti-stall                    device
are a complete assembly incorporating parts #1, #2, and #3 as shown on the                   dia-
gram.
The anti-stall device has a spring loaded pin which comes in direct contact,
with the top end of the fuel injection pump (metering valve) preventing rapid
upward movement of the metering valve to the fuel cutoff position, during rapid
engine deceleration. Rapid deceleration or rapid retarding of the throttle
without this device installed would normally cause engine stalling and/or
stoppage.
It should be noted here that under normal bleeding procedures, it is only neces-
sary to bleed the bleed screw #5 shown on the diagram.
However, if excessive air entering the injection pump makes it necessary to
bleed screw #1 in the diagram during the fuel pump bleeding procedure, when
loosening or tightening the bleed screw #1, two wrenches should be used. One
is to loosen the bleed screw and one is to hold the anti-stall device body #2
to prevent it from turning and upsetting the adjustments. If during the bleed-
ing procedure screw #2 shown in the diagram is inadvertently turned in or clock-
wise during bleeding the result will be excessive engine RPM which cannot be
controlled by retarding the throttle.
If the adjustment of the anti-stall device has been disturbed or when installing
a replacement pump, the procedure for resetting it is as follows:
     1. Loosen the locknut (#3) sufficiently to enable the anti-stall device
        body (#2) to be unscrewed two complete turns.
     2. Set engine idle speed with idling stop screw (#4) to 800 RPM.
     3. Turn the anti-stall device body (#2) clockwise until there is a barely
        perceptible increase in the idling speed. Now hold device body (#2)
        with wrench and tighten locknut (#3).
     4. Accelerate the engine to maximum no load RPM and return the throttle
        rapidly to the idling position. Should the period of return from
        maximum RPM to idling RPM speed exceed three seconds, this is an
        indication that the device has been screwed in too far. However,
        should engine stalling occur, this is an indication that the device




                                    J. H. WESTERBEKE CORP.
                                    AVON INDUSTRIAL PARK, AVON, MASS. 02322· (8171588-7700
                                               CABLE: WESTCORP, AVON· TELEX: 112- ........

PIN: 19329
V6



                                  SERVICE BULLETIN #76 conlt.

               has not been screwed in far enough.   In either case, re-adjustment
               should be made accordingly.     .
     CAUTION: Use extreme caution when tighteniny the locknut or the bleed screw
     because the "threaded boss" that the assembly is screwed into is pressed
     into the governor housing. It is not an integral part. Therefore, if it is
     loosened or turned through over-torquing, replacement of the complete governor
     housing may become necessary .




                         ·




     On all prewired engines dating from early 1975 onwards bleed screw (#5) has
     been relocated to the opposite side of the fuel injection pump.


     PN19329   8/27/74                                                        Page 2/2
                                                                                                      V.7
                  SERVICE BULLETIN
DATE:           May 19, 1980                                                BULLETIN NUMBER: 82

MODEL:          All
SUBJECT:        Battery Recommendations
                                   BATTERY RECOMMENDATIONS
        MODEL                       BATTERY AMPERE HOURS                               VOLTAGE

        W-7, & WPD4                         60-90                                    12 V.D.C.
        W-13 & 4.4 KW                       90-125                                   12 V.D.C.
        W-21 & 7.7 KW                       90-125                                   12 V.D.C.
        W-27 & 11 KW                        90-125                                   12 V.D.C.
        W-33                                90-125                                   12 V.D.C.
        W-30                                125-150                                  12 V.D.C.
        W-40, & WPD-l0-15 KW                125-150                                  12 V.D.C.
        W-50                                125-150                                  12 V.D.C.
        W-58 & WTO-20 KW                    125-150                                  12 V.D.C.
        W-60 &WBO-20 KW                     150-170                                  12 V.D.C.
        W-80 & 30KW                         170-200                                  12 V.D.C.
        W-120 & 45 KW                       200 minimum                              12 V.D.C.

        The ampere hour range shown is minimum.           There is no real maximum.




                                     J. H. WESTERBEKE CORP.
                                     AIION INDUSTRIA&. PARK, AIION, IIfASS. 02322 . (ts.71 588-7700
                                                  CAS&.E: WESTCORP, AIION·TE&.E/(: 112- ····


PIN:   20442
 V.8
                   SERVICE BULLETIN
 DATE:                 September 4, 1975                                  BULLETIN NUMBER: 84
 MODEL:                All
 SUBJECT:              Heat Exchanger Rubber End Cap

            Many heat exchangers supplied on our various products incorporate a
            molded rubber end cap to facilitate inspection of the tubes.
            There have been occasions on which engine overheating has been caused
            by the improper positioning of this rubber end cap.
            It is absolutely essential that the molded channel running across the
            inside of the cap be positioned over the baffle of the heat exchanger,
            according to the drawing below.
            In any cases of engine overheating where such a rubber end cap is used,
            it should be checked for proper positioning along with other routine
            troubleshooting.




                                     J. H. WESTERBEKE CORP.
                                     AVON 'NDUsrR'AL "AR", AVON, MASS. 02322· '.,71 5 ·· -7700
                                                CA.L.: w.srCOR", A.,Olt·r.L.1C: .2-4444

PIN:     20684
                  SERVICE BULLETIN                                                                  V.9


DATE:        April 4, 1983                                                 BULLETIN NUMBER: 87
MODEL:       All Marine Engines
SUBJECT:     Alternator Output Splitter
        GENERAL DESCRIPTION: The splitter is a solid state device which allows
        two batteries to be recharged and brought to the same ultimate voltage
        from a single alternator as large as 120 amp and, at the same time, iso-
        lates each battery so that discharging one will have no effect on the
        other. Charging rates are in proportion to the batteries' voltage (state
        of discharge). This method precludes the necessity, and even the desira-
        bility of a rotary switch for selecting which battery is to be charged.
        It also assures that ships services cannot drain the engine starting
        battery.
        INSTALLATION:
        1. Mount splitter on a metal surface other than the engine, preferably
           in an air stream if available. Do not install near engine exhaust
           system. Install with cooling fins aligned vertically.
        2. Be sure to use a wire size appropriate to the output of the associated
           alternator. In full power systems number 4 wire is recommended from
           the alternator to the splitter and from the splitter to the batteries.
        3. Connect the alternator output terminal to the center splitter terminal.
        4. Connect one splitter side terminal to one battery (s) ..
        5. Connect the other splitter side terminal to the other battery(s).
        6. When the splitter is installed, both batteries will see a charging
           voltage 8/10 volts less than usual. This voltage drop can be regained,
           if desired, by connecting the regulator wire directly to the alternator
           output terminal instead of the regulator terminal.
        TEST INFORMATION: When the engine is not running, the side splitter ter-
        minals should read the voltage of the respective battery. The center
        splitter should read zero voltage.
        With the engine running and alternator charging, the side splitter ter-
        minals should read the same voltage which should be the voltage of the
        regulator or somewhat less. The center splitter terminal should read .82
        volts higher than the readings of the side terminals.




                                                                                   Continued ...




                                    J. H. WESTERBEKE CORP.
                                    AI/ON INDueTRIAL ,.AR/(, AI/ON, MAee. 02322·,ef7} 5 · · -7700
                                                CA.L~; WtEeTCOR,., AI/ON· T~L~1C: .2-4444



PIN:     20745
V.10



 This unit is sealed for maximum life and is not repairable.
 BY .. PASSING SPLITTER: In the event of fai1ure~ batteries may be charged directly
 from alternator by connecting either splitter terminal #l or #2 to terminal A,
 bypassing the splitter itself. This should not be done simultaneously for
 both batteries unless they are~ and will remain at, the same voltage (state
 of charge.)




                             S?LITTER                                        .sTARTER
                                                  POWER DISC. SW.
                                 I ,).--+-.......e 8+
                                                  STARTING
                                                  BATTERY(S)             -
                                           POWER DISCONNECT
                                                             -
                         r---+-o. A         SWITCH

                              PN20.6S4                                            SHI P',s
                                                                                  SERVICE
                                2 (.;..-......._ .....0 8 +                       LOADS
                                                        .5ERVI CE
                                                        BATTERY(S)
                                                            -o-......~        -
   SEE NOTE

       DRWG Jl 20 70 I                                               -

 NOTE: On Alternators which have an isolation     diode between their output
 and regulator terminals, such as the Motorola    units used with most WESTERBEKE
 engines, the regulator wire should be removed    from the REG terminal and
 reconnected to the OUTPUT terminal as shown.     The diode in the splitter will
 provide an equivalent voltage drop.
                                                                                                     V.ll
                     SERVICE BULLETIN
DATE:              Apri 1 28, 1976                                          BULLETIN NUMBER: 92

MODEL:             All
SUBJECT:           Troubleshooting Water Temperature and Oil Pressure Gauges

        Given a presumably faulty gauge indication with the instrument panel ener-
        gized, the first step is to check for 12 VDC between the ign. (8+) and
        neg. (8-) terminals of the gauge.
        Assuming there is 12 volts as required, leave the instrument panel ener-
        gized and perform the following steps:
              1.     Disconnect the sender wire at the gauge and see if the
                     gauge reads zero, the normal reading for this situation.
              2.     Connect the sender terminal at the gauge to ground and
                     see if the gauge reads full scale, the normal reading for
                     this situation.
        If both of the above gauge tests are positive, the gauge is undoubtedly
        O.K. and the problem lies either with the conductor from the sender to
        the gauge, or with the sender.
        If either of the above gauge tests is negative, the gauge is probably
        defective and should be replaced.
        Assuming the gauge is O.K., preoceed as follows. Check the conductor from
        the sender to the sender terminal at the gauge for continuity.
        Check that the engine block is connected to ground. Some starters have
        isolated ground terminals and if the battery is connected to the starter
        (both plus and minus) the ground side will not necessarily be connected
        to the block.
        If the sender to gauge conductor is O.K. and the engine block is grounded,
        the sender is probably defective and should be replaced.




                                        J. H. WESTERBEKE CORP.
                                        AVON INDIJSTRIAL PARI<, AVON, MASS. 02322· (fS'7} 588-7700
                                                    CABLE: WESTCORP, AVON· TELEX: 92 - ........


PIN:     21616
V.12
                   SERVICE BULLETIN
 DATE:           June 22, 1976                                             BULLETIN NUMBER: 93
 MODEL:          All
 SUBJECT:        Adjusting Paragon P200 Series Reverse Band


         If the boat moves forward when the gear is in neutral at proper idle
         speed, the reverse band may be out of adjustment. When adjusting,
         be very careful not to get reverse band too tight or it will burn out.
         If the boat goes backwards when in neutral, it may be too tight.
         The following adjustment procedure should only be carried out when it
         is not possible to obtain the service of an authorized Paragon trans-
         mission service dealer.
         To Adjust:
         On the outside left side of the gear there is a bolt in the mounting
         pad. Under its head are 1 to 3 washers. Remove one washer. This
         should stop forward boat movement. But under NO circumstances use
         fewer than one washer nor more than three.




                                     J. H. WESTERBEKE CORP.
                                     AI/ON 'NDuaTR'AL PARIC, AI/ON, "A.a. 02322 - (8171 588-7700
                                                 CABLE: WE.TCORP, AI/ON-TELEX: .2-4444


PIN:     21683
                                                                                                                  V.13
                                   SERVICE BULLETIN
    ~~.
!         \
              DATE:          September 9, 1976                                            BULLETIN NUMBER:94
              MODEL:         All
              SUBJECT:       Fuel Pressure Switch Installation

                             Overleaf is a parts list and an illustration showing the proper
                             installation of the fuel pressure switch used on most of our
                             engine products.




                                                    J. H. WESTERBEKE CORP.
                                                    AVON INDUSTRIAL PARK, AVON, IfASS. 01131111· (8171 588-7700
                                                               CABLE: WESTCO"P, AVDN· TELEX: .11- ····


              PIN:   21564
                                                                                                                                         .
                                                                                                                                         <
                                                                                                                                         ....
                                                                                                                                          ,J:...

                                                                                              OAT.   1"'1   ".VISION ".CO"D   rUTHID" lete




                                FUEL INJECTION   PUMP.
                                  (ON EN~INE)




                                                          9 I 19/87           I    flE..t' HD. SCREW
                                                          8'/9442.                 ;::-t..~T WASHER                                      I
                                                          7    /~320              "O"Rlr'IIt::;   l1"O.D.                                I
                                                          ~    11383               FUEL PRESSURE SWITCH                                  I
                                                           5   1I~/5               PLUG                                                  ,
                                                          4    /9321              '0" RINt;       9/1" O. D.                             I
                                                          .3   /9185"              ADAPTER                                               I
                                                          2    1f}261              COPPeR Wt4SHee                                        I
                                                           I   19204              SCReW ASs')" (Bl.eCD)                                  I
                                                         ITEU PART NO.                     DESCRiPTION                               aT)"

                                                               ,!?~".~~~,    IJ· H. WESTERBEKE     CORP.
                                                                                     AVON. MA. 02322
                                                               OKelMAL


                                                                  ~

                                                               P"",CTIO"AL


                                                                  ~

                                                               AHGULA"


                                                               t~
                                                                             o;:!:, -7,   rUW'NG NUMm       21 7 4 3
                                                                                                                              MAD. IN U_ ·. A.

K·E :~::::.".·.~.~~~~!"D po""
                SERVICE BULLETIN                                                            V.15

DATE:      7 July 80 Rei ssued                                            BULLETIN NUMBER: 95

MODEL:      All
SUBJECT:   Domesti c Hot Water Heaters
   PRINCIPLE
   The heater is connected in series with the engine's freshwater circuit. This
   allows full water flow for maximum heat transfer to the heater. The series
   installation also avoids several potential pitfalls of installations in which
   the heater is in parallel with either the engine's by-pass or its internal
   freshwater circuit.
   The only potential disadvantage of a series installation is flow restriction
   due either to a restrictive heater design, a large engine water flow (such
   as models W58, W80, W120), or a combination of both.
   Installation
   The shorter the length of piping to and from the heater, the better. The
   elevation of the heater should assure that the top of its internal coil is
   no higher than the engine pressure cap. If the heater must be higher than
   this at any heel angle, then the optional remote fill tank must be installed
   to be the highest point of the c~rcuit.
   Piping between the engine and heater should           rise continuously from the heater
   to the engine so that trapped air will rise           automatically from the heater to
   the engine. If trapped air can rise to the            heater, then a petcock or other
   convenient method of bl~eding that air is a           necessity.
   Study the attached sketches. A convenient place to interrupt the engine cool-
   ing circuit is between the thermostat housing outlet and the exhaust manifold
   inlet. This is also the hottest water available. CAUTION: While most owners
   want the hottest water available, it is possible for scalding water or even
   steam to come from the faucets.
   Since the heater is in series with the engine cooling water, any other conven-
   ient point of the circuit can also be interrupted for heater installation.
   Some engine/heater combinations require that a "by-pass" nipple be installed
   in parallel with the heater. This is required to maintain an adequate fresh
   water flow for cooling capability. The table below shows the minimum diameter
   of "by-pass" nipples in these situations:
                                    HEATER
              MODEL            SENDURE          ALLCRAFT        RARITAN
                W30
            '----
                                                               3/8" NPT
                W40                                            3/8" NPT
                W 50                                           1/2" NPT
                \0158          1/2" NPT         1/2" NPT       3/4" NPT
            ___ HaQ            1/2" l{p'L_      1/2" NPT       3f~NPT
               l.-Hm           1/2" IJPT        1/2" NPT       3/4" ~IPT
                                                        Please see sketches on overleaf.

                                 J. H. WESTERBEKE CORP.
                                 AVON INDUSTRIAL PARK, AVON, MASS. OZ3ZZ - (.f7/ 5.8-7700

PIN:    21814                               CABLE: WESTCORP, AVON - TELE 1C: 8Z - ~~~~
  V.16

                                                                EN(;I NE

                                                             THERMOSTAT
                                                             HOUSING




                                                                   .... ---
                                                             DUAL PASS MANIF'OLD
             * INTERRUPT
                ~LTERNATE
                                ~.- CES
                              p' A
                                           TO
               ~ONNECT~IRU'T             AND
                I          HEATER
                    N SERIES.  -                                  ENGINE

                                                             THERMOSTAT
                                                             HOUSING



                            BYPASS
                           NIPPLE
                           ...... _...



                                      E~URE
                                 PR                            SINGLE   PA
                                           CAP (MUST   MANIFOLD              55
                                       ESSURE T/;AN  8E HIGHER
                                     REMOn          ENGINE' CAP).

                                     TANK   . FILL




      WATER H
ALrERNATf     EATER
HIGHER
   --      INST
      _~ ENGINE
        TH'-
          EN    . IF HEATf
                      PR-
                        ESSURE      IS --
                          - R COIL CA
                                      P.    -----foi~-   I



                     BYPASS NIPPLE



                                                                                     UNPRESSURIZED
                                                                                   ~~~....C_AP




                                                               OPTIONAL COOLANT
                  SERVICE BULLETIN                                                             V.17



DATE:      January 22, 1980                                              BULLETIN NUMBER: 104
MODEL:     Westerbeke 30 and 50
SUBJECT: Sea Water Pump Pulley Set Screw P.N. 11357



       The sea water pump pulley on the Westerbeke 30 and 50 engines is keyed to the
 sea water pump shaft and locked in position with a heat treated 5/32" Allen head set
 screw, Westerbeke P.N. 11357.
       Particular attention should be paid to this set screw at the time of commission-
 ing of the engine and during regular servicing of the engine.                 Ensure that it is tight.
 If not, remove the set screw and apply a good locking liquid to the set screw threads
 and reinstall and tighten with the aid of a 5/32" Allen wrench.



           PULLEY                                                       SEA        WATER
                                                                             PUMP




                                                             ~S~.~ SCREW
                                                             __ ~N. 11357




                                     J. H. WESTERBEKE CORP.
                                     AVON INDUSTRIAL PARK, AVON, MASS. 02322· (S17) 588-7700
                                                CABLE: WESTCORP, AVON· TELEX: 92- · · · ·


PIN:     24293
V.18
                   SERVICE BULLETIN
DATE:              May 1, 1980                                              BULLETIN NUMBER:        107 /
MODEL:             All Models
SUBJECT:           Thermostats


                Beginning approximately May, 1980, thermostats supplied by the
                factory have a by-pass hole sufficient to allow adequate water
                flow through the exhaust manifold, head, and block, during engine
                warm-up.


                This flow is mandatory, especially in the case of marine engines
                and generator sets which have significant load applied soon
                after start-up.


                We strongly recommend that only genuine WESTERBEKE thermostats
                be used in WESTERBEKE products to assure proper design in this
                regard.




                                      J. H. WESTERBEKE CORP.
                                      AVON INDUSTRIAL PARK, AVON, IIIASS. 0:1322· (fl171 .88-7700
                                                 CA8LE: WESTCORP, AVON· TELE 1C: 82 - 4444

PIN:    24707
                  SERVICE BULLETIN                                                                 V.19


DATE:             May 5, 1980                                               BULLETIN NUMBER:         108
MODEL:            ALL
SUBJECT:          Circuitry Change for Marine Propulsion Engines

 With the W58 we introduce a new electrical circuit which will eventually be used
 on most models.
 Some features of the new circuit are as follows:
                 1. A voltmeter is substituted for an ammeter. Naturally
                    an ammeter can still be installed separately.
                 2. All wires between the engine and the instrument panel
                    need not be heavier than 14 AWG.
                 3.     The panel contains controls for preheating and starting
                        the engine, eliminating the necessity for a separate
                        control panel. Of course the controls can be installed
                        remotely from the panel by the builder if desired.
                 4.     The circuit allows commonization of the instrument panel
                        across the broadest possible range of engine models,
                        simplifying the distribution of spare parts.
                 5.     The circuit allows commonization of engine wiring harnesses
                        across the broadest range of engine models, simplifying
                        the distribution of spare parts.
  The same connectors and color coding of the connector poles are used on both new
  and old harnesses and cables. Functional color codesare not necessarily the same
  in new and old circuits. The new panel will not operate wit~ an older engine, and
  new engines will not operate w~th an older panel. Because the connectors are the
  same, a physical mating of old and new components is possible, but neither the
  panel nor the engine will operate and no harm can be done by accidental mismatching.




                                                                        Please see diagram on overleaf.




                                        J. H. WESTERBEKE CORP.
                                        AVON INOUSTRIAL PARI(, AVON, MASS. OZ3ZZ· (8f7/ 5B8-7700
                                                   CABLE: WESTCORP, AVON· TELEX: '2-4444


PIN:     24720
V.20




                         SCHEMATIC DIAGRAM.




       WIRING DIAGRAM.
                            SERVICE BULLETIN                                                                 V.21


/"" \
.
        DATE:             May 5, 1980                                               BULLETIN NUMBER: 109
        MODEL:            W58
        SUBJECT:          Two Pass Manifold

           The W58 employs a two pass manifold, It is a key feature of a new cooling
           system first appearing on the W58. The system is vented by the pressure cap
           at the return side of the fresh water circulating pump, the point of the
           lowest pressure within the system. This has the advantage of increasing
           cooling capacity by preventing cavitation at the fresh water pump under higher
           temperature conditions.
          This system will ultimately be incorporated on most models.
          The schematic on the overleaf shows the water flow.                  Operation of the circuit
          is as follows:
                 1.      The thermostat has a permanent by-pass port of .06 square inches
                         to assure water flow through the manifold while the engine is
                         warming up. Replacement thermostats must have this permanent
                         by-pass port.
                 2.      Hot water leaving the engine thermostat housing passes through
                         the inside half of the water jacketed exhaust manifold to the
                         heat exchanger inlet.
                 3.   Water lea~ing the heat exchanger enters a fresh water cooled
                      oil cooler, if used.
                 4. Water leaving the oil cooler or heat exchanger enters the outside
                    half of the water jacketed manifold.
                 5.   The outside half of the manifold is comprised of two sections:
                      a cooling path adjacent to the exhaust passage and an air removal
                      path which allows entrained air to rise to the top of the manifold.
                 6.   The pressure cap is located at the top of the air removal path.
                 7. From the manifold, coolant returns to the suction side of the
                    fresh water pump.
          The system is designed to accept an optional coolant recovery tank. This
          useful accessory offers several advantages, including:
                 1. A remote fill point for the circuit, in which case it should
                    be located slightly higher than the engine's pressure cap.


                                                                                     Continued ···.·.

                                                J. H. WESTERBEKE CORP.
                                                AVON INDUSTRIAl. "ARIC. AVON. MASS. 02322· (fl17} 588-7700
                                                           CABI.E: WESTCOR". AVON·TEI.EX: 82-4444
                 24721
        PIN:
V.22
       2. A means of conveniently observing the water level in the
          circuit.
       3. A means of assuring that the circuit is always completely
          full of cooling water.
       4. The coolant recovery system operates without diverting
          engine cooling water. It is a one-way connection to the
          system which provides a place for expanding water to go
          while the engine is warming up and, conversely, a source
          of water to refill the system as the engine cools down.




                                                                      TO EXHAUST
                                                                      S'yST£M
                     EtlGINE




  SeA WATER
   PUMP
                                                                                                         V.23
                        SERVICE BULLETIN
DATE:                  May 20, 1980                                            BULLETIN NUMBER: 110
MODEL:                 All
SUBJECT:               Ammeter Wire Sizes

       Ammeters may be installed in conjunction with any Westerbeke marine diesel
       engine or diesel generator set. The range of the ammeter must be appropriate
       for the maximum output of the alternator.
    Additionally, the wire size for the alternator output circuit,·inc1uding the
    ammeter, varies with the total length of that circuit. The table below shows
    the maximum current that can be carried various total distances by various
    wire sizes, to and from source to load.
                                      WIRE SIZE TABLE
            Total Length                     MAXIMUM CURRENT(AMPS)
   System of wire in        I
    Vol ts      feet        35        40        55       60      70      85    120
        12           1 to 5           12       12           12             8          8              8    6
        12           5 to 10          10       10            8             6          6              6    4
        12           10 to 20          6        6            6             6          3              2    1
        12           20 to 30          6        4            4             2          1              1    1
        12           30 to 40          4        2            2             1          1              0    0

        24           1 to 5           14       14           12           12          10          10       8
        24           5 to 10          12       12           10           10           8           8       6
        24           10 to 20         10        8            8            6           6           4       4
        24           20 to 30          8        6            6             4          4           4       2
        24           30 to 40          6        6            4             4          2           2       0

        32           1 to 5           14       14           12           12          10          10       8
        32           5 to 10          12       12           10           10           8           8       6
        32           10 to 20         10        8            8            6           6           4       4
        32           20 to 30          8        6             6           4           4              4    2
        32           30 to 40          6        6             4           4           2              2    0




                                            J. H. WESTERBEKE CORP.
                                            AVON INDUSTRIAL PARK, AVON, MASS. 02322· (5171588-7700
                                                       CABLE: WESTCORP, AVON· TELEX: 82 -4444


PIN:         24737
V.24
                          SERVICE BULLETIN
 DATE:              December 8, 1983
                                                                               BULLETIN NUMBER:     130
 MODEL:             W50
 SUBJECT: On Engine Fuel System- Bleed Procedure


       (REFER TO THE ILLUSTRATION WHEN FOLLOWING THE PROCEDURE BELOW)
       1.     After air has been bled from that portion of the fuel system between the
              fuel tank and engine, the use of the manual primer on the fuel lift pump
              can aid in accomplishing this, proceed to bleed point #1 with a 5/8" box
              wrench. Loosen this banjo bolt 1 - 2 turns. (Do not remove the bolt
              from the filter.) Work the manual priming lever on the fuel lift pump
              and purge all air out of the secondary filter until fuel free of air
              bubbles flows from around this banjo bolt. Once fuel free of air flows
              from around the bolt, retighten the bolt.
              NOTE #1:    You may want to place a small plastic garbage bag
                          around and under the secondary filter with a few
                          paper towels to catch the fuel.
              NOTE #2:    When working the manual priming lever on the fuel lift
                          pump, move it with long and deliberate strokes - NOT
                          rapidly. In some rare instances, the lift pump may
                          internally be at or near the maximum pump stroke
                          and no pumping action will be achieved using the
                          manual external priming lever, making it necessary
                          to turn the engine over slightly with the starter
                          to reposition the pump internally.

       2.     With the aid of a 5/16" box wrench, or socket (1/4" Drive), open the
              bleedscrew #2 on the side of the fuel injection pump, 1 or 2 turns.
              DO NOT remove the screw. Again work the manual priming lever on the
              engine-mounted fuel lift pump; purge all air from this area of the
              fuel injection pump and when fuel free of air flows, retighten the
              bleedscrew #2.
              NOTE:       Models with pushbutton starting refer to the inset
                          for point #2A located on the fuel pressure switch
                          manifold mounted at bleed point #2 on the injection
                          pump. Bleed #2A as above.

       3.     With the aid of 5/16" box wrench or socket (1/4" Drive) open the
              bleedscrew #3 and bleed this portion of the injection pump as in
              Step #2.
              NOTE:       Ensure that the throttle is full open and the engine
                          shut-off lever is in the RUN position when proceeding
                          to Step #4.                                      over ....... .
                                           J. H. WESTERBEKE CORP.
                                           AVON INDUSTRIAL PARK, AVON, MASS. 02322· (617/588-7700
                                                      CABLE: WESTCORP, AVON· TELEX: fl2- · · · ·

PIN:        33547
                                                                              V.25
                                        -2-
4.   With the aid of a 5/16 box wrench or socket (1/4 Drive), open the
                            11                         11

     bleedscrew #4 located at the base of the high pressure line 1 to 2
     turns.
     NOTE:   DO NOT remove this bleedscrew. At the same time with a
             5/8 open-end wrench, loosen all four high pressure
                  11

             injector line nuts #5 at the base of each fuel injector
             1 to 2 turns. With the engine starter, bleed Point #4
             on the high pressure line by cranking the engine over
             with the starter motor and when fuel free of air flows
             from bleedscrew #4, stop cranking with the starter and
             retighten bleedscrew #4.

5.   Again crank the engine over with the starter until fuel spurts between
     the 5/8 nut and the high pressure injector line at the base of each
             11

     injector Bleed Point #5. When fuel spurts between the line and nut
     at each of these four points, stop cranking and re-secure these nuts
     with the 5/8 open-end wrench.
                       11



     NOTE:   Extensive torque is not required on these nuts to properly
             seat the high pressure injector lines to the base of the
             injectors.

6.   The engine is now ready to start. Leaving the throttle in the
     FULL OPEN position and ensuring that the engine STOP lever is in
     the RUN position and the transmission is in NEUTRAL, proceed to start
     the engine. Preheat as required and crank the engine over with the
     starter. Once the engine fires, return the throttle to IDLE position,
     and ensure that proper engine oil pressure is achieved, and that
     raw water is being discharged with the ex~aust.
     Allow the engine to run at 1000-1200 RPM for five minutes, to be sure
     that all air has been bled from the fuel system.
     NOTE:   When routine servicing of the on-engine secondary fuel
             filter is being accomplished, bleed points #1 and #2
             should only be bled to ensure that all air has been removed
             from the system. No other bleed points need be bled at this
             time.
             Owners may find it advantageous to daub white paint onto
             each of the bleed points, so if an unexpected problem
             arises requiring engine fuel system bleeding, these points
             will be readily visible.
V.26
                                                                                                V.27
                  SERVICE BULLETIN
DATE:       December 5, 1984                                             BULLETIN NUMBER:        139
MODEL:      All Propulsion and Generator Models
SUBJECT:       Hydro-Hush Muffl er Install ations
       The illustrations shown with this text should be used as a guide when making
       an installation of a Hydro-Hush Muffler.
       When used in conjunction with propulsion engine, the Hydro-Hush Muffler should
       be mounted close to the fore-aft center line of the boat. When used with a
       generator unit, the muffler should be as close as possible to the generator.
       All installations should be such that the entry of water into the engine exhaust
       manifold and cylinders is prevented while under sail and at various angles of
       heel, from following seas, when backing down, or any other condition.
       Units installed with the exhaust manifold/water injected exhaust elbow at or
       below the water line of the vessel must install a vent or syphon break in the
       sea water supply line to the water injected exhaust elbow. The seawater supply
       line must be looped above the water line a minimum of six (6) inches with the
       vent or syphon break installed at the top of this loop.
       The vented loop, when used, can be a mechanical syphon break as shown in the
       illustration or a simple tee arrangement with a small hose or tube (3/16-1/4
       inch 1.0.) routed to the transom exhaust discharge or to a separate thru-hull
       fitting located above the water line. This hose or tube must be routed in such
       a way that it will drain of water when the engine is shut down and allow air
       into the sea water supply hose and injection elbow.
       The syphon break or vent is installed to break the vacuum in the sea water
       cooling circuit and thereby discourage syphoning of sea water through this
       circuit, and subsequently filling of the exhaust and engine cylinders with
       sea water. When used, syphon breaks should be checked periodically for proper
       operation and should be installed in a location where, should they leak sea
       water, it would not leak onto the engine or its accessories.
       The syphon break or vent must be located above the vessel's water line high
       enough so as to remain above the water line at..2llangles of vessel heel and
       pitch.
       The Hydro-Hush Muffler remains approximately 30% full of water after engine
       shut-down when there is a maximum of 48 inches of lift on the discharge side.
       The installation information given in this text is to be used as a guide only.
       Westerbeke cannot be responsible in any way for muffler installations. Wester-
       beke presumes the installer to have a basic knowledge of marine installation
       requirements.




                                      J. H. WESTERBEKE CORP.
                                      AVON INDUSTRIAL PARK, AVON, MASS. 02322· (6f7J 588-7700
                                                 CABLE: WESTCORP, AVON· TELEX: 92-4444
          33934
PIN:
V.28




   Hydro-Hush Muffler Installations                                   Page 2


   Use as few right angle fittings as possible. The use of wire reinforced
   hose is recommended and the hose should be routed to produce the bends
   needed.
   The use of 90° and 45° fittings contribute to the rise of engine exhaust
   back pressure. (Refer to the Unit Technical Manual for back pressure
   specifications.)
   The exhaust hose diameters shown are minimums. Exhaust hose diameter for
   the discharge hose will have to be increased if the length of run from
   the Hydro-Hush Muffler to the thru-hull discharge is excessive (25' to 30'
   depending on the number of bends).

                                      CAUTION
       THE SEA WATER PUMP WILL CONTINUE TO FILL THE EXHAUST SYSTEM WITH
       SEA WATER DURING CRANKING. THE ENGINE EXHAUST PRESSURE DURING
       CRANKING ~~Y NOT BE STRONG ENOUGH TO EXPEL THE WATER FROM THE
       MUFFLER AND PREVENT THE SYSTEM FROM FILLING UP WITH SEA WATER
       AND ENTERING THE EXHAUST MANIFOLD AND CYLINDERS.
       IF ENGINE CRANKING EXCEEDS 30-40 SECONDS APPROXIMATELY, CLOSE
       THE SEA WATER THRU HULL AND OPEN IT IMMEDIATELY AFTER THE ENGINE
       STARTS.
                                                                         Page 3         V.29

                                           ENGINE INSTALLATIONS




~~
  .-~-.,-.~~~
 Insulate __"{t




 ENCINE INSTALLATIONS WITH EXHAUST MANI-
 FOLD/WATER INJECTED ELBOW AT OR BELOW
 VESSEL WATER LINE




                                                                  max.

ENCINE INSTALLATIONS WITH EXHAUST MANI-
                                                                             12" min.
FOLD/WATER INJECTED ELBOW MINIMUM OF 6
INCHES ABOVE VESSEL WATER LINE.
V.30                                                                                               Page 4
                                   GENERATOR INSTALLATIONS




                                    _...   --:,---   "-   ~.;,:........--    -_.   ---

                                                                                                            Raw Water
                                                                                                              Pump




                                                       Raw Water
       Generator Installations with                   Intake - Thru
       exhaust manifold/water injected                 Hull Fitting
                                                                                            --'-
       elbow at or below vessel water
       line.                                              Generator Below Water Line




                                                                                                              Raw Water
                                                                                                                Pump




                                                                             Raw Water
       Generator Installations with                                         Intake - Thru
                                                                             Hull Fitting
       exhaust manifold/water injected
       elbow minimum of 6 inches above                    Generator Above Water Line
       vessel water line.
                                  SERVICE BULLETIN                                                               V.31

-, ..   '-'



              DATE:           1/23/85                                                     BULLETIN NUMBER: 148
              MODEL:          ALL PROPULSION ENGINES
              SUBJECT:        FIELD TROUBLESHOOTING TACHOMETER/HOURMETER PN 11917
                     The tachometer/hourmeter used in propulsion engine instrument panels contains
                     two separate electrical circuits with a common ground. One circuit operates
                     the hourmeter, and the other the tachometer. The hourmeter circuit operates
                     on 12 volts/alternator charging voltage supplied to the (+) terminal on the
                     back of the instrument.
                     The tachometer circuit operates on AC voltage 6-8 volts, fed from one of the
                     diodes in the alternator and supplied to the "tach inp.1I terminal while the
                     engine ,is running, and the alternator producing battery charging voltage
                     13.0-14.8 volts D.C.                                   '
                     The following are procedures to follow when troubleshooting a fault in
                     either of the two circuits in the tachometer/hourmeter.
                     HOURMETER
                     FAULT                                           CHECK
                     1. Inoperative             1. Check for proper DC voltage between (+) and (-)
                                                   terminals.
                                                   A. Voltage present - meter defective - repair
                                                       or replace.
                                                   B. Voltage not present - trace (+) and (-)
                                                       electrical connections for fault. (Jump
                                                       12 Volts DC to meter (+) terminal to
                                                       verify operation.)
                     TACHOMETER
                     FAULT                                            CHECK
                     1. Inoperative            1. Check for proper AC voltage between "Tach Inp.1I
                                                  terminal and, (-) terminal with engine running.
                                                  A. Voltage present - attempt adjusting meter
                                                      through calibration access hole. No results,
                                                      repair or replace meter.
                                                  B. AC voltage not present - check for proper
                                                      alternator D.C. output voltage.
                                                  C. Check for A.C. voltage at tach terminal
                                                      on alternator to ground.
                                                  D. Check electrical connectio'ns from "tach
                                                      Inp." terminal to alternator connection.




                                                       J. H. WESTERBEKE CORP.
                                                       AVON INDUSTRIAL PARK, AVON, MASS. 02322· (6f7} 5BB-7700
                                                                  CABLE: WESTCORP, AVON· TELEX: 92-4444


              PIN:    34791
V.32

                                            -2-

   2.   Sticking     1.   Check for proper A.C. voltage between "tach inp."
                          terminal and (-) terminal.
                     2.   Check for good ground connection between meter
                          (-) Terminal and alternator.
                     3.   Check alternator is well grounded to engine
                          block at alternator pivot bolt.
   3.   Inaccurate   1.   With hand-held tach on front crankshaft pulley
                          retaining nut or strobe type tach read front
                          crank shaft pulley R.P.M. Set engine R.P.M.
                          with hand or strobe tach at 1500-1800 R.P.M.
                     2.   Adjust tachometer with small Phillips type
                          screwdriver through calibration access hole
                          in rear of tachometer covered with translucent
                          plug. Zero tach and bring to R.P.M. set by
                          strobe or hand tach. (Verify R.P.M. at idle
                          and at high speed 2500-3000 R.P.M.) (Adjust
                          tach as needed.)




                                                    Tachometer Input
                                                      (AC Voltage)




                         ( + ) Terminal
                     (Battery Voltage-DC)
                                                                                        V.33

        Page 3                                          SERVICE BULLETIN #148

                             LATE MODEL TACHOMETER

                 Replaces Earlier Model as Shown on Page 2 of this Bulletin




                                                              Access Hole for
                                                           Tachometer Calibration




                                                                ( - ) Ground Terminal



/
    /


                                                                   'Tachometer Input
                                                                      (AC Voltage)


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