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Lehman SP135, Owner'S Manual

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Lehman SP135 Owner'S Manual Download Page 24

CODE 

KEY 

1 

2 
3 
4 
5 
6 

7 

8 

9 

10 
11 
12 
13 
14 
15 
16 
17 
18 
19 

20 
21 

22 

23 
24 

25 

26 

27 

28 

29 
30 

31 
32 
33 
34 
35 
36 
37 
38 

40 

Turbo Charger Assembly 

51 

5 

Comprising Key 1-39 

Engine 

QTY 

1 
1 
1 

2 

1 

4 
2 

1 

4 

2 
2 

1 
1 

2 

1 

2 
2 
2 

1 

2 

1 
1 

4 
2 

1 
1 
2 
2 

2 
4 

2 

1 

1 
1 
2 

1 
1 
1 
1 

PART 

No. 

1456626 
1456620 

5007673 

1 C52 

C 

5009881 
60991 99 
6065031 
6087966 
6097079 

151 5382 

6087961 

OD61 

1 c43 

OA3 

2M6 

3L1 

1 c53 

6065050 

1549952 

DESCRIPTION 

TURBOCHARGER HOLSET 
HOSE 

CLAMP 
OIL RETURN GASKET 
WASHER 
SETSCREW 
OIL RETURN ELBOW 
CLAMP 

HOSE 
SLEEVE 

BANJO BOLT 

WASHER 
CONNECTOR 

OIL DRAIN 

NUT 
STUD 
GASKET 
OIL FEED PIPE 
PLUG 
ADAPTOR BLOCK 
ADAPTOR 
WASHER 
BOLT 

PLUG 

VENT HOSE 
SCREW 

LOCK WASHER 
CLIP 

WASHER 

BOLT 
PLUG 
OIL FEED BLOCK 
OIL FEED GASKET 

AIR 

CLEANER 

- 

SEE ALSO PAGE C42 

TUBE 

Not Shown 

on Drawing 

CLIP 

PIPE SUPPORT 
NUT 
SPRING WASHER 

ADAPTOR BLOCK 

Summary of Contents for SP135

Page 1: ......

Page 2: ...canmaketothe newengineowner is do nottinker Ifthe unitisrunningwell leaveitalone Adjustmentsand repairsshouldbe performed only by a competent diesel mechanic who has the proper knowledge and tools Manytimeswe are requestedtoassistanownerwho hasattempted hisown repairs Unless you know what you re doing please hands off Lehmanhasaworld wideService Networkof Distributorsand Dealers Getto knowyour loc...

Page 3: ...volt negativegroundandinsulatedreturn12or 24volt arealsoavailableat extracost STARTINGMOTOR 12volt electricalsolenoid 24volt also availableatextra cost ATLERNATOR 70 amp with voltage regulator RAWWATER COOLING SYSTEM cupro nickelheatexchangerwithzinc anti corrosion pencil RAW WATER PUMP gear driven high flow rubber impeller type FRESHWATER COOLINGSYSTEM pressurizedfreshwater circuitfor engine and ...

Page 4: ...alloy Gear driven OILTEMPERATURE range 165 230 F LUBRICANT Above 909ambient SAE 30 20to 90 f ambient SAE 20W 20 Below309ambient SAE 1OW OILCOOLER TIMING INJECTORS 4 hole t PRESSURE S P 2 7 5 Test Pressure 265 275 FUELLIFTPUMP OPERATINGTEMP 82 94 C MAXIMUMTEMP 99 C CIRCULATlON 159 liters min 180 liters min SUGGESTEDBATTERY 120 AMP HR LOCKTORQUE 37 5 ft lbs 1240 amp draw Max RUNNINGTORQUE HEATEXCHAN...

Page 5: ... In order to prevent errors please order any required items by exact part number and name of part When ordering parts please advise model number and serial number of the engine Index Section A Air bleeding the fuel system Before operation Bleeding the fuel system Break in Controls Cooling system Dimensions engine Draining engine Electrics Fault findingguide Filters fuel air Fuel system Identificat...

Page 6: ...m Oil level pressure low worn bearings Incorrect grade fuel oil Incorrect injection timing Faulty injector Sticking valve or rocker arm Piston slap ENGINE NOT DELIVERING FULL POWER Air fuel system Engine overheated Injection timing incorrect Incorrect valve clearances Dirty air cleaner s Faulty injectors Faulty injection pump Stop control partly engaged Sticking valves Worn piston rings or bores F...

Page 7: ...ngine stop lever is fully towards rear flywheel end of engine Set throttle lever to V4 open position Press starting button to operate starter As soon as engine starts release starting button to operate speed control lever to warm up idling speed of 700 800 RPM If engine fails to start within 5 seconds release starting button Try again after allowing sufficient time for all moving parts to stop Onc...

Page 8: ...ut of the rain Use a fine gauze filter funnel and always wipe the fuel tank around the filter cap before andafter filling and immediately replace the cap An efficient large size primary fuel filter and water separator coalescer is deemed a necessity in order to prevent foreign particles reaching the injection equipment on your engine Your engine is equipped with secondary fuel filters which filter...

Page 9: ...he bleed plugs on top and slowly pouring fuel into the filter until it overflows Occasionally after an extended run an engine may slow down or miss or lose RPM or stop Although there may be other causes air in the fuel system should not be overlooked Many times a tiny leak in a fuel line fitting may allow air to enter the system and accumulate until there is sufficient to cause the above mentioned...

Page 10: ...r jackets surrounding the cylinders cylinder head and exhaust manifold The heated water flows by thermo syphonicaction assisted by a pump at the front of cylinder block around the tubes of a heat exchanger located above the fuel lift pump on the starboard side of the engine Raw water from outside the boat flows through the heat exchanger tubes and the heat from the fresh water is thus transferred ...

Page 11: ...n the tank should just touch the water surface To assist in corrosion control a zinc pencil is installed in your heat exchanger This zinc pencil is sacrificial that is the raw water will attack and eat away the zinc before attacking metal of the heat exchanger It is suggested that the plug accommodating this pencil be removed each week while engine is in service in order to inspect zinc Replace zi...

Page 12: ...exchanger Raw water drains are found on both engine and transmission coolers as well as the heat exchanger To drain raw water pump loosen rear cover Keel Cooling yy Systems In some cases the installation of a keel cooling system may be preferred to the standard heat exchanger previously discussed This system employs a series of tubes mounted on the underside of the hull through which the engine co...

Page 13: ...tapping for connection to operate a matching electric tachometer see Fig 13 A special actuating switch located on side of engine block behind alternator automatically energizes the alternator from the battery when engine is started and oil pressure reaches7 Ibs Battery is disconnected by this switch when the engine is stopped This switch initiates operation of the alternator system without the nee...

Page 14: ...tuated in the pump Oil under pressure passes through the oil filter where it is cleaned prior to being circulated inside the engine The filter is a full flow disposable spin on type Itshouldbe replacedat eachoilchange and is readilyavailablefrom your Lehmandealer All marine installations should include an oil pressure gauge to register the lube system pressure and such gauge should be frequently c...

Page 15: ...d engines the oil should be checked prior to starting After several minutes shut engine down wait for oil to drain back for several minutes then check and add as required Add engine oil of the type and viscosity as follows Oil should meet Ford specification 2M 2C l017A API classification CC or equivalent FIG 14 ENGINE OIL DIPSTICK ooc 20 C 32OC FIG 15 OIL VISCOSITY CHART TURBO ENGINES API classifi...

Page 16: ...MEPLATE Transmission As there is such a wide variety of transmissions available with Lehman diesels it is not practical to cover all installations in this manual However due to the popularity of the Borg Warner PRM Newage and Twin Disc transmissions the following information is offered for those models BORG WARNER No attempt is made herein to instruct in the installation of engine in the boat The ...

Page 17: ...y to the maximum mark on the dipstick Daily Check oil leveland makevisualcheckfor oil leaksespeciallyattheoutputshaftoilsealandatgasketsealingsurfaces Annually Check oil cooler hoses and connections Check propeller shaft alignment Ensure that remote control operating linkage is adjusted to give the correct travel on the gearbox operating lever TWIN DISC MARINE TRANSMISSION All moving parts of the ...

Page 18: ...0hoursof operation Every1500hoursof operation Every3000 hoursof operation 1 Every3600hoursof operation Replacethermostats Zinc pencil should be checked every 2 weeks regardless of number of operating hours until owner determines how often zinc element must be replaced Replace after 50 deterioration Injectorsneed not be serviced at regular intervals but rather should be serviced after problem such ...

Page 19: ...on is correct when your thumb pressure on belt at a point between alternator or and water pump pulleys does not exceed 1h Tighten alternator mounting and adjustment strap bolts I FIG 19 BELT ADJUSTMENT JUSTING STRAP BOLT D B B MOUNTING BOLTS INTAKE AIR FILTER The air filtering element s on all naturally aspirated engines is polyurethane foam which traps and holds dust and foreign matter which coul...

Page 20: ...the fuel system Carefully fit new sealing rings to the filter heads and bowls assemble to the filter heads and replace and tighten securing bolts It will now be necessaryto bleedthe fuel system of air as described in separate section After running engine for a short time check filters for possible fuel leaks Winterizing In preparationfor freezing temperatures anti freeze should be provided in the ...

Page 21: ...ove all plastic seals covers exhaust plug etc and refit air filter s in place Do not neglect to replace all drain plugs tighten rear cover of raw water pump and turn on seacock Galley Hot Water Connections It is common marine practice to utilize engine coolant passed through a hot water heater to provide domestic hot water Connectionto engine is made with Lehman Kit D1496 A coolant feed to the hea...

Page 22: ...No 2J30 2J32 2D304 2J33 2J41 1c39 1C40 3L1 3K210 3K13 1G192 OE202C OE208 OE401 OE201C OC31 OC41 1D64 3L45 3L50 3E40 3K13 OE302 OC51 OC30 OEl04 oc21 3K220 1OCM IG193 3K215 3K12 DESCRIPTION INTERCOOLERBODY ENDRING 0 RING INTERCOOLERCORE SUPPORT GASKET GASKET PLUG HOSE HOSECLIP PIPE BOLT BOLT BOLT BOLT LOCKWASHER LOCKWASHER PIPEASSEMBLY ADAPTOR PLUG ADAPTOR HOSECLIP SETSCREW LOCKWASHER WASHER SETSCRE...

Page 23: ...c9 I1 SEE OVER ...

Page 24: ...031 6087966 6097079 1515382 6087961 OB45 OD61 1c43 3E903 3E905 3E910 3E230 OC51 OE408 3E915 3K790 OA3 OC5 2M6 OC31 OGE207 3L1 3E912 1c53 6065050 2M9A OB1 OC41 1549952 x DESCRIPTION TURBOCHARGERHOLSET HOSE CLAMP OIL RETURNGASKET WASHER SETSCREW OILRETURNELBOW CLAMP HOSE SLEEVE BANJOBOLT WASHER CONNECTOROILDRAIN NUT STUD GASKET OIL FEEDPIPE PLUG ADAPTOR BLOCK ADAPTOR WASHER BOLT PLUG VENT HOSE SCREW...

Page 25: ... ORDERING ASSEMBLIES CODE KEY QTY PARTNo DESCRIPTION I PISK 1 1 2J134 2 1 OGB28 3 1 OGC31 4 1 1500785 5 1 2J23 6 1 2J20 7 3 2J21 8 3 2J22 9 1 2J133 10 1 3L2 11 1 3K13 12 1 EW6424 13 1 3E859 14 1 2J131 15 1 2J132 S 16 1 2J129 P K 17 1 2J130 HEATSHIELD NUT LOCKWASHER STUD GASKET ADAPTOR CLAMP STEELGASKET RISER EXTENSION RISER PLUG 1 8 CLIP HOSE ELBOW RISER EXT 150mm Jacket notshown2J136 RISER EXT 30...

Page 26: ... 12 KEY QTY 1 1 2 4 3 6 4 6 5 2 6 2 7 1 a 1 9 1 10 1 11 1 12 1 L PARTNo 3K511 3K4 OEl01 oc21 OE202 oc21 1A409 1c47 1C46 2C250 1A410 3K2135 10 DESCRIPTION HOSE CLAMP BOLT LOCKWASHER BOLT LOCKWASHER THERMOSTATCOVER GASKET RUBBERSEAL 9 8 0 THERMOSTAT SPl60 225 275 THERMOSTATHOUSING HOSE ...

Page 27: ...1 6 6 7 1 8 1 9 1 10 1 11 2 12 2 13 2 14 1 15 1 16 1 17 1 18 1 NOTE USE P SUFFIX ON ALL I 1A393 1A465 2C304 3K860 1541317 3C27 3K4 1D73 3K2133 3K2133 3K825 OD71 OC31 3K826 3E860 3K2 1608027 IF63 OB26 HEADERTANK ANGLED HEADERTANK HORIZ0NTAL PRESSURECAP VENT HOSE GASKET HOSEBARB CLAMP TUBE HOSE HOSE HOSE OVER FLOW STUD WASHER NUT ELBOW CLAMP COLD STARTSWITCH FILLER NECK T REDUCING HOSE ...

Page 28: ... PARTNo 3K14 1A413 2D36 3K786 3K353 3K2133 3K12 OC41 OE307 5 OE302 2C272 3G38 3K801 3K802 IG191 OGE201 OC30 OGC32 6135883 3K3A 3K3A 3K209 2 DESCRIPTION HOSECLIP SPLIT FLOW RETURN GASKET PIPERUBBER WATER HOSE RADIATORHOSE HOSECLIP LOCKWASHER SOCKETSCREW SETSCREW OILCOOLER ENGINE ADAPTOR OILHOSEASSEMBLY OILHOSEASSEMBLY HOSE PIPE BOLT FLATWASHER LOCKWASHER HOSE HOSECLIP HOSECLAMP ...

Page 29: ...ASHER OE310 BOLT 1c54 RUBBERSTRIP 1c54 RUBBERSTRIP 3L1 PLUG 3K12 HOSECLIP 3K503 RADIATOR HOSE 1D56 18 PIPE 3K2133 HOSE OE303 SETSCREW 1D68 SUPPORTREAR 1D58 SUPPORTFRONT OE403 SETSCREW 1 1D67 CLAMPREAR OC51 LOCKWASHER EM21 ZINCANODE ASSEMBLY EM21A ZINCANODE NOT SHOWN SEPARATELY 2C269A ENDPLATESP185 225 2D26 RUBBERGASKETSP185 225 275 2C273A ENDPLATESP275 2C211A ENDPLATEALL 2D25 GASKETALL HEATEXCHANG...

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