Universal M3-20B Service Manual Download

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Summary of Contents for M3-20B

Page 1: ...0B PUBLICATION NO 200562 1st Edition July 2001 WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A TEL 508 823 7677 FAX 508 884 9688 WEBSITE www WESTERBEKECOM IlIMMA Member National Marine Manufacturers Association ...

Page 2: ...he Throbbing in Temples Muscular Twitching Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANYOF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the unit and do not restart until it has been inspected and repaired This WARNING DECAL is providedby UNIVERSAL andshould be fixed to a bulkhead nea...

Page 3: ...e or permit flames or sparks to occur near the fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause s...

Page 4: ...skin or into the eyes inadvertently when removing electrolyte caps ii TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifold water injected exhaust elbow is securely attached Be sure the unit and its surroundings are well vent...

Page 5: ...rs Manual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety pro cedures ENGINE INSTALLATIONS Preparations to install an engine should begin with a thor ough examination ofthe American Boat and Yacht Council s ABYC standards These standards are a combination of sources including the USCG and the NFPA Sectio...

Page 6: ...age to the engine and possible flooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under any of the vessel s various operating conditions or when the vessel is not underway install a siphon break This precaution is necessary to protect your engine NOTE A siphon break requires periodic inspection and cleaning to ensure ...

Page 7: ...cription 58 Fuel System Disassembly Reassembly 63 Fuel System Service 64 Admiral Control PaneL 67 Captain Control PaneL 68 Control Panel Troubleshooting 69 Glow Plug Service 71 Starter Service 72 Mando Alternator Service 78 Prestolite Alternator Service 88 Wiring Diagram 39144 100 Wiring Schematic 39144 101 Wiring Diagram 200360 Catalina yachts 102 Wiring Schematic 200360 Catalina yachts 103 Hurth...

Page 8: ...res and troubleshooting of your marine engine critical informa tion will be highlighted by NOTES CAUTIONS and WARN INGS An explanation follows NOTE An operating procedure essential to note A CAUTION Procedures which ifnot strictly observed can result in the damage or destruction of your engine A WARNING Procedures which if notproperly fol lowed can result in personal injury or loss oflife CUSTOMER...

Page 9: ...OIL FILTER PARTS IDENTIFICATION MODEL M3 20B STARTER SOLENOID FUEL LIFT PUMP 3 ALTERNATOR yr I COOLANT PUMP SHEAVE ...

Page 10: ...2 68 in 67 x 68 mm Spherical type three vortex combustion system 43 8 cu in 0 7177 liters 23 1 1 2 3 Counterclockwise as viewed from flywheel end 33 ft Ibs 4 6 kg m 2500 rpm 241 Ibs 110 kg Length 26 4 in 670 6 mm Width 18 8 in 477 5 mm Height 20 1 in 510 6 mm Not to exceed 14 24 rad Not to exceed 25 44 rad Idle speed 1 000 1 200 rpm Cruise Speed 2 500 3 000 rpm Maximum Speed 3 500 3 600 rpm 18 0 3...

Page 11: ...ow 7 0 gal min 26 5 liters min ELECTRICAL SYSTEM Starting Battery 12 volt DC negative ground Battery Capacity 400 600 cold cranking amps CCA Alternator Regulator Mando 51 amp 12 volt belt driven with internal regulator Starter Motor 12 volt reduction gear actuated shift with solenoid Starting Aid 12 volt sheathed type glow plugs TRANSMISSION Model HURTH HBW 50 2R Type of Transmission Case hardened...

Page 12: ...engine overhaul it is important to measure the engine com pression pressure regularly At the same time the engine speed at which the measurement ofcompression pressure is made should be checked because the compression pressure varies with engine rpm The engine rpm can be measured at the front end of the crankshaft 6 Measuring Compression Pressure To check the compression pressure see ENGINE COMPRE...

Page 13: ...ve stem seized e Weak or broken valve spring f Bent push rod g Compression leaks through cylinder head gasket h Cracked or worn piston i Piston ring seized j Worn piston ring or cylinder liner It Cracked or distorted cylinder head I Fuel camshaft worn 2 Carbon accumulation in combustion chamber UnlvQI sal 7 VERIFICATION REMEDY 1 Replace engine oil with less viscous oil 2 Recharge battery 3 Replace...

Page 14: ... or fuel filter 3 Clean fuel line or replace fuel filter 4 Leak in fuel line or fuel filter 4 Repair fuel line or replace fuel filter 5 Air in injector fuel line injection pump fuel filter or fuel filter water separator 5 Bleed air 6 Seized or leaky delivery valve 6 Clean or replace delivery valve 7 Faulty injection starting pressure 7 Adjust starting pressure 8 Injection nozzle malfunction 8 Clea...

Page 15: ...crease engine compartment air supply KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles 1 Check a and b a Overheated cylinder a See ENGINE OVERHEATS SHUTS DOWN LOW OUTPUT b Carbon deposits in cylinder b Clean 2 Injection timing too early 2 Correct the timing 3 Injection pressure too high 3 Correct the pressure 4 Improper fuel 4 Replace with proper fuel KNOCKING WITH DARK SMOKE 1 Poor...

Page 16: ...uck open OTHER 1 Coolant pump bearing worn or seized 2 Improper drive belt tension 3 Malfunction of alternator bearing 4 Exhaust gas leakage INJECTION PUMP 1 Uneven injection 2 Inadequate injection nozzle spray GOVERNING SYSTEM 1 Governor lever malfunctioning 2 Fatigued governor spring Unlvanal 10 VERIFICATION REMEOY 1 Replace bearing 2 Grind crankshaft 3 Correct bend or replace 4 Repair or replac...

Page 17: ...KISH OR DARK GRAYISH 1 Poor compression 1 See Low Compression under HARD STARTING 2 Improper valve clearance 2 Adjust valve clearance 3 Improper injection timing 3 Adjust injection timing 4 Improper fuel 4 Replace with proper fuel 5 High back pressure in exhaust 5 Check for restrictions in exhaust system 6 Insufficient intake air 6 Increase engine compartment air supply 7 Overload 7 Reduce load BL...

Page 18: ...ctive oil seals 2 Broken gear case gasket 3 Loose gear case attaching bolts 4 Loose drain plug 5 Loose oil line connector 6 Broken rocker cover gasket 7 Loose rocker cover attaching bolts Unlvarsal 12 VERIFICATION REMEDY 1 Clean or replace filter 2 Retighten fuel line joints or replace fuel line 3 Replace fuel 1 See KNOCKING 2 See SMOKY EXHAUST 3 Repair or replace 4 See Low Compression under HARD ...

Page 19: ...on pump malfunction 1 Defective cylinder head gasket 2 Defective cylinder head or cylinder block 1 V belt slackening or slippery with oil 2 Low oil level or poor oil quality 3 Knocking 4 Moving parts seized or damaged 5 Lack of coolant 6 Raw water not Circulating Unlvarsal 13 VERIFICATION REMEDY 1 Correct ring gap positions 2 Replace connecting rod 3 Replace ring or piston 4 Replace oil ring 5 Rep...

Page 20: ...lvarsal 14 VERIFICATION REMEDY 7 Check a through d a Thermostat remove and test in hot water Replace thermostat b Loss of cpolant check hoses hose clamps drain plug etc for leaks c Broken or loose belt tighten replace d Air leak in system run engine and open the pressure cap to bleed air Add coolant as needed ...

Page 21: ...35 rad BTDC Intake Valve Closed 45 0 79 rad ABDC Exhaust Valve Open 50 0 87 rad BBDC Exhaust Valve Closed 15 0 26 rad ATDC LIMIT 0 002 in 0 05 mm 327 psi 23 kgf cm2 2 26 MPa 0 011 in 0 30 mm 0 003 in 0 10 mm Valve Spring DESCRIPTION Free Length Setting Loadl Setting Length Tilt Rocker Arm Clearance between Rocker Arm Shaft and Shaft Hole Rocker Arm Shaft 0 0 Rocker Arm Shaft Hole 1 0 Tappet Cleara...

Page 22: ... Crankshaft 0 0 0 15 mm 0 005 in Crankshaft 0 15 mm Bearing No 1 1 0 Oil Clearance between 0 005 in Crankshaft and 0 15 mm Crankshaft Bearing No 2 10 023 in 0 60 mm Crankshaft 0 0 0 0039 in Crankshaft 0 10 mm Bearing No 2 1 0 Oil Clearance between Crankshaft and Crankshaft Bearing No 3 Crankshaft 0 0 Crankshaft Bearing No 3 1 0 Oil Clearance between 2 644 in 67 169 mm Crank Pin and Crank Pin Beari...

Page 23: ...05 in 0 03 0 14 mm 0 002 0 005 in 0 07 0 15 mm 0 002 0 005 in 0 075 0 135 mm 157 1 162 5 F 69 5 72 5 C 185 F 85 C 20 22 BTDC 0 35 0 38 rad 1991 2133 psi 14O 150 kgf crn2 3 73 14 71 MPa When the pressure is 1849 psi 130 kgf crn2 12 75 MPa the valve seat must be fuel tight SERVICE STANDARDS LIMIT 14 psi 1 0 kgf cm2 98 kPa 2133 psi 150 kgf cm2 14 71 MPa 5 seconds 2133 1990 psi 50 140 kgfIcm2 14 7 13 ...

Page 24: ... cylinder head Because the overlaps of the intake and exhaust ports are smaller than in the ports of other types of engines which have their openings on one side the intake air is protected from being heated and expanded by the heated exhaust air The cool high density intake air has high volume efficiency and increases the power of the engine Distortion of the cylinder head by heated exhaust gas i...

Page 25: ...an oil gallery through which engine oil is fed to the crankpin to lubricate it 0 1 DO DO s J f PISTON AND PISTON RINGS The piston is made of an aluminum alloy Two recesses for the valves are provided on top of the piston A fan shaped depression is also on top of the piston in order to allow com bustion gas to flow smoothly The piston pin is slightly off center With this design the run out of the p...

Page 26: ...HAFT ASSEMBLY 20 FUEL CAMSHAFT The fuel camshaft controls the reciprocating movement of the injection pump The fuel camshaft is made of carbon steel and the cam sections are quenched and tempered to provide greater wear resistance FUEL CAMSHAFT ASSEMBLY FLYWHEEL The flywheel stores the rotating force of the combustion stroke as inertial energy reduces crankshaft rotating speed fluctuation and main...

Page 27: ... mix bolts and nuts Both metric and S A E bolts are used on various engine assemblies 21 Replace plain bearings if they are peeling burned or otherwise damaged Reassemble parts e g pistons piston rings bearings bearing caps in their proper order positions and directions relative to the engine block Avoid reversed orientation note that the cylinder head gasket head bolt washers and thermostat are a...

Page 28: ...EAT EXCHANG ER under COOliNG SYSTEM for inspection and servicing information 6 Remove the starter motor 7 Remove the engine bellhousing 8 Remove the transmission damper plate 9 Remove the flywheel and flywheel washer 10 Remove the engine back plate DAMPER PLATE 11 Remove the exhaust manifold When Reassembling Retighten the exhaust manifold using the same torque after idling for 20 minutes 12 Remov...

Page 29: ...rnator bracket 25 Remove the crankcase breather hose CYLINDER HEAD COVER 26 Remove the glow plugs CYLINDER HEAD AND VALVES Cylinder Head Cover 1 Remove the cylinder head cover cap nuts 2 Remove the cylinder head cover When Reassembling 1 Check the cylinder head cover gasket if it is defective replace it Tightening torque Cylinder head cover nuts Nozzle Holder Assembly 2 9 4 3 ft Ibs 0 4 0 6 kgf m ...

Page 30: ...wdriver three or four times in each direction While turning the screwdriver slowly pull the heat seal out together with the injection nozzle copper washer c If the heat seal drops repeat the above procedure The heat seal and injection nozzle copper washer must be changed when the injection nozzle is removed for cleaning or for service PHILLIPS SCREWDRIVER When Reassembling Tightening torque FUEL I...

Page 31: ...re a proper fit VALVE ALVE TIMING GEARS AND CAMSHAFT Injection Pump and Speed Control Plate 1 Remove the socket head screws and nuts and remove the injection pump NOTE The fuel injection pump is a very important com ponent ofthe diesel engine requiring the utmost care in handling It has been thoroughly bench tested and the owner operator is cautioned not to attempt to service it If the fuel inject...

Page 32: ...ealant to both sides of the soft metal gasket shim Liquid gasket is not required 2 The addition or subtraction of a shim 0 0020 in 0 05 mm delays or advances the injection timing by approx OS 0 0087 rad 3 In disassembling and replacing shims be sure to use the same number of new gasket shims having the same thickness Tightening Injection pump 7 23 7 32 ft Ibs torque retaining screws and nuts Drive...

Page 33: ...r assembly to the crankcase 27 RETAe I0ffNING Pl INJECTION PUMP GEAR FUEL CAMSHAFT Oil Pump and Crankshaft Gears 1 Unscrew the flange nut and remove the oil pump gear 2 Unscrew the mounting screws and remove the oil pump 3 Remove the collar O ring and oil slinger 4 Remove the crankshaft gear with a puller When Reassembling 1 Install the collar after aligning the marks on the gears see illustration...

Page 34: ... rod cap 2 Tum the crankshaft to bring the piston to top dead center 3 Push the connecting rod out from the bottom of the cylinder block with a handle of a hammer then pull out the piston and connecting rod NOTE Do not change the combinations ofcylinder and piston Make sure ofthe location ofeach piston by marking it For example mark 1 on the No 1 piston When Reassembling 1 Before inserting the pis...

Page 35: ...tes then insert the piston pin into the piston 5 Install the connecting rod to the piston so that the align ment mark on the connecting rod is on the opposite side of the alignment mark on the piston head see illustration 29 6 When inserting the piston into the cylinder place the gap of compression ring No 1 on the side opposite the combustion chamber and stagger the gaps of compres sion ring No 2...

Page 36: ...t and threads of bearing case screw 2 then tighten it Tightening torque Bearing case 19 5 22 4 ft Jbs screws 2 2 7 3 1 kgf m 26 5 30 4 Nm CRANKSHAFT Main Bearing Case Assembly 1 Remove the two main bearing case screws 1 and remove the main bearing case assembly 1 being careful with the thrust bearings and crankshaft bearing 2 2 Remove the main bearing case assemblies 2 and 3 When Reassembling 1 Cl...

Page 37: ...Flaw 1 Prepare an air spray red check 2 Clean the surface of the cylinder head with detergent 3 Spray the cylinder head surface with red permeative liquid Wait five to ten minutes after spraying 4 Wash away the red permeative liquid on the cylinder head surface with the detergent 5 Spray the cylinder head surface with white developer 6 If the surface is flawed the flaws will be identified as red m...

Page 38: ...968 5 980 mm Valve guide 1 0 0 236 0 237 in 6 010 6 025 mm 32 Replacing Valve Guide When removing 1 Using a valve guide replacing tool see SPECIAL TOOLS press out the existing valve guide When installing 1 Clean a new valve guide and apply engine oil to it 2 Using a valve guide replacing tool see SPECIAL TOOLS press in a new valve guide until it is flush with the cylinder head as shown in the illu...

Page 39: ...d be sure to check the valve recession and adjust the valve clearance after o LAPPING THE VALVE Correcting Valve and Valve Seat NOTE Before correcting the valve and seat check the valve stem and the J D ofthe valve guide and repair them ifnec essary After correcting the valve seat be sure to check the valve recession 1 Correcting the Valve a Correct the valve with a valve refacer STANDARD VALUE Va...

Page 40: ...a square on the side of the spring and check to see if the entire side is in contact with the square Then rotate the spring and measure the maximum tilt see illustration If the measurement exceeds the limit replace the spring 34 3 Check the entire surface of the spring for scratches and replace the spring if there are any STANDARD VALUE LIMIT Free length 1 244 in 1 118 in 31 6 mm 28 4 mm Tilt 0 04...

Page 41: ...cracks damage and unusual wear 2 Measure the bending of the push rod with a dial indicator 3 If the measurement exceeds the limit replace the push rod Oil Clearance between Tappet and Tappet Guide Bore 1 Measure the tappet 0 0 with an outside micrometer 2 Measure the 1 0 of the tappet guide bore with a cylin der gauge and calculate the oil clearance 3 If the oil clearance exceeds the limit or the ...

Page 42: ...VALUE UMIT Oil Clearance 0 0005 0 0029 in 0 0039 in between piston pin and small end 0 015 0 075 mm 0 10 mm bushing PRESSING OUT EXISTING BUSHING PRESSING IN NEW BUSHING REPLACING CONNECTING ROD SMALL END BUSHING Piston Ring Gap 1 Insert the piston ring into the lower part of the liner the least worn out part of the liner using a piston ring compressor and the piston 2 Measure the ring gap with a ...

Page 43: ...h 1 Set a dial indicator lever type with its tip on the gear tooth 2 Move the gear to measure the backlash holding its mating gear 3 If the backlash exceeds the limit check the oil clearance of the shaft and gear 4 If the oil clearance is correct replace the gear STANDARD VALUE Backlash between 0 001 0 004 in idler gear and crank 0 043 0 124 mm gear Backlash between 0 001 0 004 in idler gear and c...

Page 44: ...easure the height of the cam at its highest point with an outside micrometer 2 If the measurement is less than the limit replace the camshaft STANDARD VALUE LIMIT Intake and exhaust 1 058 in 1 056 in cam heights 26 88 mm 26 83 mm MEASURING INTAKE AND EXHAUST CAM HEIGHT Idler Gear Side Clearance 1 Set a dial indicator with its tip on the idler gear 2 Measure the side clearance by moving the idler g...

Page 45: ...7 19 980 mm Idler gear bushing 0 787 0 789 in I D 20 000 20 051 mm MEASURING OIl CLEARANCE BETWEEN IDLER GEAR SHAFT AND IDLER GEAR BUSHING LIMIT 0 0039 in 0 10mm 39 Replacing the Idler Gear Bushing 1 Using an idler gear bushing replacing tool see SPECIAL TOOLS press out the existing bushing 2 Clean a new idler gear bushing and the idler gear bore and apply engine oil to them 3 Using the idler gear...

Page 46: ... 5 mm C 0 071 0 087 in radius 0 071 0 087 in radius 1 8 2 2 mm radius 1 8 2 2 mm radius O 4 S The crankshaft journal must be fine finished to higher than VV V V o c Oil Clearance between Crankpin and Crankpin Bearing 1 Clean the crankpin and crankpin bearing 2 Put a strip of plastigauge on the center of the crankpin A CAUTION Never insert the plastigauge into the crank pin oil hole 3 Install the c...

Page 47: ...ARING NO 1 3 If the oil clearance exceeds the limit replace crankshaft bearing No 1 4 If a same size bearing is too big because of crankshaft journal wear replace it with an undersize bearing see illustration and table STANDARD VALUE LIMIT Oil Clearance 0 001 0 004 in 0 007 in between crankshaft 0 034 0 106 mm 0 20 mm journal and crank shaft bearing No 1 STANDARD VALUE Crankshaft journal 1 5722 1 ...

Page 48: ...rankshaft bearing No 2 or No 3 5 If a same size bearing is too big because of the crank shaft journal wear use an undersize one see illustra tion and table STANDARD VALUE UMIT Oil Clearance 0 001 0 003 in 0 007 in between crankshaft 0 034 0 092 mm 0 20 mm journal and crank shaft bearing No 2 and NO 3 Crankshaft journal 1 729 1 730 in 0 0 flywheel side 43 934 43 950 mm Crankshaft bearing 1 731 1 73...

Page 49: ... If deep scratches are found the cylinder should be bored see Correcting Cylinder below 43 STANDARD VALUE LIMIT Cylinder I D 2 637 2 638 in 67 000 67 019 mm Maximum Wear 0 005 in 0 15 mm Correcting Cylinder 1 When the cylinder is worn beyond the limit bore and hone it to the specified dimension STANDARD VALUE LIMIT Oversize 2 647 2 648 in Cylinder I D 67 250 67 269 mm 0 005 in Maximum Wear 0 15 mm...

Page 50: ... in the timing hole The piston in Cylinder No I is now at IDC Adjust the valves in Cylinder No 1 Proceed to the next cylinder in the firing order Rotate the crankshaft 2400 in the normal direction of rota tion and adjust the No 2 Cylinder s valves Rotate the crankshaft another 2400 and adjust the No 3 Cylinder s valves 44 Valve clearance engine cold TOP CLEARANCE VALVE CLEARANCE t STANDARD VALUE 0...

Page 51: ...l oil pressure gauge in its place 2 Start the engine After warming up to operating temper ature measure the oil pressure at both idling and rated speeds STANDARD VALUE LIMIT Engine oil pressure At idle speed 15 psi 1 05 kgf cm2 103 4 kPa At rated speed 40 60 psi 15 psi 2 8 4 2 kgf crn2 1 05 kgf cm2 276 414 kPa 103 4 kPa 3 If the oil pressure is less than the specified limit check the following a E...

Page 52: ...the cylinder through the glow plug hole Allow the oil to settle Install the pressure gauge and repeat the above test If the compression reading rises dramatically the fault is with the rings If the compression value does not rise the problem is with the valves A slight rise in compression would indicate a problem with both the rings and the valves DRIVE BELT ADJUSTMENT The drive belt must be prope...

Page 53: ...eter onto the reflecting tape to confirm the engine speed Check the instrument panel tachometer reading Adjust the tachometer in the panel by using the instrument calibration pod as needed to bring the instrument panel tachometer into the same rpm reading as the engine 4 Adjust the idle speed if the engine speed is not within the specified value Normal idle speed 1000 1200 rpm 47 Adjusting the Idl...

Page 54: ... 1 If the manifold was removed as an assembly and left intact it can be replaced on the cylinder head in the reverse order of removal Do not reuse the gaskets install new ones a Loosely attach the manifold elbows to the cylinder head using new gaskets Do not use any gasket seal ant on these gaskets h Gradually tighten each fitting to ensure proper alignment of all the parts This should be done in ...

Page 55: ... ROCKER ARM VALVE IDLER GEAR CRANKSHAFT OIL PUMP Some of the oil that lubricates these components or is splashed by the crankshaft also reaches and lubricates the pistons cylinders small ends of the connecting rods tap pets pushrods intake and exhaust valves and timing gears The oil then returns to the oil sump to repeat the continu ous cycle When the oil pressure exceeds the specified pressure th...

Page 56: ...he lobes The relief valve prevents damage to the lubrication system due to high oil pressure This relief valve is a ball type direct acting relief valve and is best suited for low pres sures When oil pressure exceeds the upper limit the ball is pushed back by the oil pressure and the oil escapes While the rotors rotate from A to B see illustration the space leading to the inlet port increases whic...

Page 57: ...DlL FILTER When the filter element accumulates an excessive amount of dirt and the oil pressure in the inlet line builds up by 14 psi 1 0 kgf cm2 98 kPa more than the outlet line the bypass valve opens and the oil flows from the inlet to the outlet bypassing the filter element FILTER ELEMENT BYPASS VALVE 51 OIL PRESSURE SWITCH The oil pressure switch is mounted on the cylinder block to warn the op...

Page 58: ... PRESSURE STANDARD VALUE LIMIT At idle speed 15 psi 1 05 kg cm2 103 4 kPa At rated speed 40 60 psi 15 psi 2 8 4 2 kg cm2 1 05 kg cm2 276 414 kPa 103 4 kPa 3 If the oil pressure is less than the specified limit check the following a Engine oil insufficient b Oil pump defective c Oil strainer clogged d Oil filter clogged e Oil gallery clogged f Excessive oil clearance of bearing g Foreign matter in ...

Page 59: ...ody with a feeler gauge 2 If the clearance exceeds the standard value replace the oil pump rotor assembly STANDARD VALUE Clearance between 0 0028 0 0059 in outer rotor and pump body 0 07 0 15 mm 53 Clearance Between Inner Rotor and Cover 1 Put a strip of plastigauge onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully measure the amount of the fla...

Page 60: ...tat gradually opens The thermostat is accessible and can be checked cleaned or replaced easily WATER TEMPERATURE SWITCH The water temperature switch is located on the thermostat housing see illustration This switch is normally open When activated it will close and sound an alarm WATER TEMPERATURE SENDER Optional The water temperature sender if supplied is located on the thermostat housing see illu...

Page 61: ...rom the freshwater coolant To keep the heat exchanger operating efficiently it should be removed from the engine every 1000 hours to be thorough ly cleaned and pressure tested ZINC ANODE A zinc anode or pencil is located in the raw water cool ing circuit within the heat exchanger The purpose of the zinc anode is to sacrifice itself to electrolysis action taking place in the raw water cooling circu...

Page 62: ...Read the temperature at this moment on the thermometer 4 Continue heating the water and read the temperature when the valve has completely opened about 0 236 in 6 mm S If these temperatures are not within the standard values as shown in the chart below replace the thermostat STANDARD VALUE Thermostat s valve 157 1 162 50 F opening temperature 69 5 72 50 C Temperature at which 1850 F thermostat com...

Page 63: ...he pump assembly mounting screws 16 Start and run the engine check for leaks and check for a normal operating temperature RAW WATER PUMP 57 COOLANT PUMP 1 Loosen the alternator mounting bolts and remove the drive belt 2 Remove the coolant pump pulley 3 Remove the coolant pump assembly from the gear case cover 4 Remove the flange 5 Press out the shaft with the impeller on it 6 Remove the impeller f...

Page 64: ... fuel filter water separator FUEL RETURN LINE FROM FUEL INJECTORS TO INJECTIDN PUMP TO FUEL TANK c INJECTION PUMP FUEL RETURN LINE FROM FUEL INJECTORS TO FUEL TANK FUEL FILTER The fuel injection pump is a Bosch MD type mini pump It is small lightweight and easy to handle The plunger with a right hand lead reciprocates via the tap pet roller by means of the fuel camshaft causing the fuel to be deli...

Page 65: ...lunger also lowers and fuel is drawn into the delivery chamber through the feed hole from the fuel chamber 2 Beginning ofDelivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole the pressure in the delivery chamber rises to push the relief plunger open Fuel is then force fed into the injection line 3 Delivery While the plunger is rising the delivery of fue...

Page 66: ...bricating oil For this reason it is extremely important to completely remove any water and dirt contained in the fuel The fuel filter cartridge will require occasional replacement to maintain an adequate flow of fuel to the injection pump The frequency of this service will vary according to the cleanliness of the available fuel and the care used in its storage The fuel filter eliminates any foreig...

Page 67: ...tated by the fuel camshaft At Start The steel balls have no centrifugal force Fork lever 1 is pulled by the start spring and the control rod moves to the maximum injection position for easy starting At Idling When the speed control lever is set at the idling position the governor spring is pulled slightly As the camshaft rotates the steel balls increase their centrifugal force and push the governo...

Page 68: ...el delivered to the injection nozzle is increased to produce the higher engine torque required for the load SPEED CONTROL At Maximum Speed Running with an Overload When the engine is overloaded at a high speed and the engine speed drops the centrifugal force of the steel balls decreases and the governor spring pulls fork levers 1 and 2 When fork lever 2 contacts the adjusting screw the spring that...

Page 69: ...NDER PLUNGER B I PLUNGER SPRING I IU TAPPET INJECTION PUMP 63 INJECTION NomE Nozzle Holder 1 Secure the nozzle retaining nut in a vise 2 Remove the nozzle holder and take out the parts inside the nozzle holder When Reassembling 1 Assemble the nozzle in clean fuel oil 2 Install the push rod noting its direction 3 After assembling the nozzle be sure to adjust the fuel injection pressure NOZZLE HOLDE...

Page 70: ...the injection nozzle to a nozzle tester 2 Raise the fuel pressure and keep it at 1849 psi 130 kgf cm2 12 75 MPa for 10 seconds 3 If any fuel leak is found replace the nozzle piece STANDARD VALUE Valve seat tightness No fuel leak at 1849 psi 130 kgf cm2 12 75 MPa Fuel Injectors Service In case of severe vibrations and detonation noise have the injectors checked and overhauled by an authorized fuel ...

Page 71: ...0 026 rad 3 After adjusting the injection timing apply a liquid type gasket Three Bond 1215 or equivalent to both sides of the injection pump shim before reassembling Shim Specifications Engine Serial Number 489291 on up 1 The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling 2 Shims are available in thicknesses of 0 0079 in 0 20 mm 0 0...

Page 72: ...G 0 472 in 12 mm c Data for Adjustment Control rack position Camshaft Amount of fuel from stop position speed 0 1969 in 1800 rpm 0 0714 0 0751 cu in l100 st 5 0mm 1 17 1 23 cc 100 st 0 0591 in 1800 rpm less than 0 006 cu in l100 st 1 5 mm less than 0 1 cc 100 st Delivery Valve Fuel Tightness 1 Remove the injection lines and injection nozzles 2 Install a pressure tester to the injection pump 3 Set ...

Page 73: ...hen the engine has started and the engine s oil pressure rises above 15 psi Note Refer to the WIRING DIAGRAM in this manual for the installation of two engine sendors WATER TEMPERATURE GAUGE THIS GAUGE IS GRADUATED IN DEGREES FAHRENHEIT AND IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED ON THE ENGINE S NORMAL OPERATING TEMPERATURE IS 170 190 F 77 88 C OIL PRESSURE GAUGE THIS GAUGE IS GRADU ATED IN ...

Page 74: ...he engine is in operation ALARM THE ALARM WILL SOUND IF THE ENGINE S OIL PRESSURE FALLS BELOW 5 10 PSI IN THIS EVENT THE ALARM WILL EMIT APULSATING SIGNAL THE ALARM WILL ALSO SOUNO IF THE WATER TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 210 F IN THIS EVENT THE ALARM WILL EMIT A SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STA...

Page 75: ...Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a With a hand held tach on the front of the crankshaft pulley retaining nut or with a strobe type tach read the front crankshaft pulley rpm at idle h Adjust the tachometer with a small Phillips type screw driver through the calibration access hole in the rear of the tachometer Zero the tach and br...

Page 76: ...round 2 Check the wiring Insert sensitive 0 25 amp meter in battery lines Do NOT start engine Remove connections and replace after short is located 3 Low resistance leak to ground 3 Check all wires for temperature rise to locate the fault 4 Faulty alternator 4 After agood battery charging disconnect alternator at output If leakage stops Remove altemator and bench test Repair or replace TROUBLESHOO...

Page 77: ...s will become vary hot to the touch Be careful not to burn your fingers when testing the plugs 1 Disconnect the leads from the glow plugs 2 Measure the resistance with the ohmmeter across the glow plug terminal and the body of the glow plug see illustration 3 If 0 ohm is indicated the screw at the tip of the glow plug and the body of the glow plug are short circuited 4 If the standard value is not...

Page 78: ...It consists of a pull in coil a holding coil and a plunger Starter Operation When Main Switch is Turned to START Position The contacts of the main switch close and the holding coil is connected to the battery to pull the plunger The pull in coil and the starting motor are also connected to the battery The pinion is pushed against the ring gear with the overrun ning clutch by the drive lever and th...

Page 79: ...entarily between the starter body and the negative battery terminaL 3 If the motor does not run check the motor 73 Magnet Switch NOTE Each test should be carried out for a start time 3 to 5 seconds and at halfofthe rated voltage 6V Checking Pull In Coil 1 Connect jumper lead from the battery s negative termi nal post to the C terminaL 2 The plunger should be attracted strongly when a jumper lead i...

Page 80: ...ER SERVICE Armature Coil 4 3 DRIVE LEVE 19 BRUSH 7 Remove the brush holder 20 8 Draw out the yoke 18 from the starter drive housing 2 9 Draw out the armature 9 with the drive lever 3 NOTE Do not damage the brush or commutator When Reassembling Apply grease to the following parts shown in the illustration a Joint of solenoid switch d Collar b Bushing e Teeth of pinion gear c Drive lever f Armature ...

Page 81: ...e 12 55 12 60 mm MEASURING BUSHING 1 0 MEASURING ARMATURE SHAFT 0 0 Commutator and Mica 1 If the commutator surface is dirty or dusty clean it with sandpaper 2 Measure the commutator O D with vernier calipers at several places 3 If the difference of the O D s exceeds the limit correct the commutator on a lathe to the standard value 4 If the minimum O D is less than the limit replace the armature 5...

Page 82: ...easure the brush spring tension required to raise the spring from contact position with the commutator 3 If the tension is less than the limit replace the spring DESCRIPTION STANDARD VALUE LIMIT Spring Tension 3 1 5 7 Ibs 2 0Ibs 1 4 2 6 kg 0 9 kgf 13 7 25 5 8 8 N 76 Brush Holder 1 Check the continuity across the brush holder and the holder support with an ohmmeter 2 If it conducts replace the brus...

Page 83: ...cting leads unconnected 2 Connect a cable from the negative terminal of the bat tery to the starter body and a cable from S terminal of the starter to the positive terminal of the battery to force out the pinion 3 Push back the pinion slightly to kill the play and measure the pinion clearance 4 If the clearance is not within the specified values add or remove the washer between the solenoid switch...

Page 84: ...g battery positive to positive negative to negative TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ib H Ib in Location Nm Nm Alternator front 25 35 Ib in housing screws 2 8 4 0 Nm Alternator end 35 65 Ib in frame screws 4 0 7 3 Nm Alternator 35 50 Ib H pulley nut 47 68 Nm Regulator 25 45 Ib in mounting screws 2 8 5 1 Nm PREPARING TO CHECK ALTERNATOR Before starting the alternator tests check...

Page 85: ... rotor field circuit probably is shorted or grounded Disas semble the alternator and test the rotor as described under CLEAN AND TESTALTERNATOR COMPO NENTS in this section 4 If the reading is between 6 0 and 7 0 volts the rotor field circuit probably is open Remove the regulator and inspect it for worn brushes or dirty slip rings Replace the brushes if they are less than 114 in 6 rom long If the b...

Page 86: ... LEAD ALTERNATOR OUTPUT TEST 1 6 If the reading is low stop the engine and connect a jumper lead between the alternator output terminal and the indicator light terminal Repeat Steps 4 and 5 see illustration 7 If the reading is now within the specifications the diode trio is faulty Disassemble the alternator and replace the diode trio as explained in this section 8 If the reading is still low with ...

Page 87: ...Remove the regulator cover f Temporarily install Jumper A and all associated nuts Leave Jumper B installed g Remove the plastic plug from the side of the regulator h Connect a jumper between the top brush lead from the brush and ground see illustration SENSING TERMINAL PLASTIC PLUG I _r I JUMPER END VIEW OF REGULATOR WITH COVER REMOVED i Repeat steps 1 and 2 NOTE Do not let the voltage exceed 16 v...

Page 88: ...UT INSULATOR ALTERNATOR DISASSEMBLY 10 Place an oversized V belt around the pulley and fasten the pulley in a vise 11 Use a 7 8 in box wrench to loosen and remove the pulley nut PULLEY REMOVAL 12 Remove the pulley nut lockwasher pulley fan and spacer see illustration FAN NUT PULLEY AND FAN COMPONENTS A CAUTION DO NOT insert screwdriver blades more than 1 16 in 1 6 mm Damage to the stator winding c...

Page 89: ... RECTIFIER REMOVAL CLEAN AND TEST ALTERNATOR COMPONENTS 1 Inspect and test the brush regulator assembly The brush set may be reused if the brushes are 114 in 6 mm or longer The brushes must not be oil soaked cracked or grooved Test for continuity between 1 and 2 and 3 and 4 using a test lamp or an ohmmeter These checks will indicate a good brush regulator assembly replace the complete assembly if ...

Page 90: ...t the front housing for cracks stripped or damaged threads in the adjusting ear or an out of round bore in the mounting foot If possible correct slightly damaged threads using a tap Replace the housing if necessary c If the housings are to be reused clean them in solvent and dry with compressed air 5 Clean and inspect the rotor shaft bearings NOTE Do not use a solvent on the rear rotor bearing sin...

Page 91: ...using a crocus cloth Thoroughly wipe the slip rings clean after polishing removing all grit and dust d Check for a grounded slip ring or rotor winding by measuring the resistance from each slip ring to the rotor body or pole finger B An open circuit should be indicated in both cases for a good rotor see illus tration TESTING ROTOR e If the windings are defective or physical damage cannot be correc...

Page 92: ...ligned with the four through bolt holes in the housing h Align the scribe marks you made In the stator and front and rear housings during disassembly c Slip the rear housing into place over the rotor shaft Align the mounting holes and put the stator leads through the holes at the top of the rear housing d Install the four bolts and tighten them see illustration NOTE If the front housing is new the...

Page 93: ...all the Phillips screw for the brush regulator assembly cover 17 Install the capacitor 18 Install the terminal nuts 19 Install the jumper 20 Install the last terminal nut INSTALL ALTERNATOR 1 Install the alternator screws and washers 2 Connect the wiring leads 3 Put the belt on the alternator crankshaft and coolant pump pulleys 4 Adjust the alternator belt s tension see DRIVE BELT ADJUSTMENT under...

Page 94: ...em Test Equipment Requirements The alternator and regulator tests described in this section require electrical test equipment to measure voltage only however most commercial test equipment incorporates several testing devices in a single unit The following test equipment will be necessary DC VOLTMETER 0 20 volt scale HYDROMETER Any commercial type having a temperature correction scale Storage Batt...

Page 95: ...y 6000 alternator rpm at an ambient temperature of 75 P 23 8 C The alter nator is designed to operate in an ambient temperature range of 40 to 212 P 40 to 100 C To ensure proper cooling of the rectifier bridge and internal components of the alterna tor it must be used with the proper cooling fan EXCITE REGULATOR ICI 0 B GROUND a ACTAP TACH ALTERNATOR SENSE INTEGRAL REG SENSE EXCITE REGULATOR ICI 0...

Page 96: ...n belt 2 Check belt Indicator lamp remains on 3 Worn or broken brushes 3 Replace brush assembly 4 Defective alternator system 4 Refer to LOCATING THE PROBLEM section B Battery undercharged 1 Indicator lamp burned out or 1 Check bulb and harness Indicator lamp off with key defective wire harness on and engine stopped 2 Broken brush 2 Replace brush assembly Normal condition is lamp on 3 Defective al...

Page 97: ...Y REMaTE BATI SENSE ONLY JUMPER NOT ATIACHED OPEN DIODE TRIO TEST 91 Test No 2 Open Regulator Test NOTE This test requires the removal ofthe back cover of the alternator To remove disconnect the wiresfrom the terminals extending through the back cover Remove the back cover two screws and reconnect all wires With the ignition on and the engine not running and the jumper not attached check for batte...

Page 98: ...eldom if ever be required In cases where the causes of the mal function are known it will only be necessary to follow that portion of the procedure directly related to resolving the problem Similarly when the reasons for the malfunction are uncertain it will be necessary to follow the procedure in greater depth in order to isolate and correct the problem The following troubleshooting diagram shoul...

Page 99: ...R BRUSH TEST TEST CONTINUITY FROM ATO B FROM C TO D NO CIRCUIT FROM A OR B TO C OR D 4 Remove the integral voltage regulator Remove the two screws securing the integral voltage regulator to the rear housing REGULATOR MOUNTING SCREWS 2 REMOVING VOLTAGE REGULATOR 5 Remove the diode trio field diode and rectifier diode bridge The diode trio and rectifier diode bridge are detached as an assembly Remov...

Page 100: ... only and all diodes should check alike see illustration If any diode is defective replace the entire diode rectifi er bridge assembly e Q TESTING RECTIFIER BRIDGE e 9 8 Separate the stator rear housing assembly from the front housing Remove the four thru bolts see illustration Carefully insert two screwdriver blades in opposite openings between the stator and the front housing as shown in the ill...

Page 101: ...driver Inspect the fan for cracked or broken fins and note the condition of the mounting hole If it is worn from run ning loose replace the fan to insure balance Inspect the pulley for possible faults as shown in the illustration PULLEY REMOVAL CHECK FOR WORN DRIVE SURFACES __ CHECK FOR POLISHED SURFACE HERE NOTE CONDITION OF t KEY GROOVE to CHECK BORE FOR WEAR 12 Separate the rotor from the front...

Page 102: ...xception of item D S NOTE New rotors include a new rear bearing and new slip rings as part ofthe assembly Ifthe rear bearing requires replacement follow the instructions for this operation 16 Remove the slip rings from the rotor assembly Unsolder the rotor leads from the slip ring terminals Carefully unwind the ends of the rotor coil leads from the slip ring terminals as shown in the illustration ...

Page 103: ...R BEARING ROTOR INSTALLING REAR BEARING 2 Install the slip ring assembly Guide the rotor leads through one of the oval passages in the slip ring assembly Be sure the oval passage is in line with the groove in the rotor shaft Place the rotor on a press as shown in the illustration Choose a driver sleeve having a diameter that clears the leads Press the slip ring assembly onto the shaft Solder the r...

Page 104: ...re it with a cone locknut Apply a thin film of heat sink compound to the back of the diode rectifier bridge and to the mating area on the rear housing Install the assembly to the rear housing four screws Place the strap AC tap in position and connect the stator leads three screws Install the capacitor where applicable 8 Install the integral regulator Install the brush mounting screws two though th...

Page 105: ...ts Starting with the carbon pile off slowly increase the load while observing the ammeter and maintaining 5000 rpm Increase the load until a minimum output voltage of approximately 13 7 volts is obtained Record the output current at this point and refer to the chart for minimum acceptable ratings MINIMUM ACCEPTABLE OUTPUT VALUES AT 70 80 F 21 27 C RATING OUTPUT 51 AMP 46 AMP 99 RED EXCITE TO IGN S...

Page 106: ...PANEL are diagramed below When an ADMIRAL PANEL is installed two additional instrument senders are assembled to the engine 10 provide data for the panel gauges refer to the illustra tions below REMOVE THE PLUG AND INSTALL THE SENDER NOTE An on off switch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat Twelve volt diesel engin...

Page 107: ...44 STARTER f t it H ___________J_______ s ALTUU OIl I I I I I I I I I I 1 M i iU i J I 2i S2 i I I FUEl 1_lItlil r 1r s 1 208 c lial B iQNlY ______ 1 CJ ALARM o p SENDU TACttCMETEft S GNO VOLTMETeR 0 W T GAUGE ADMIRAL MITSUBISHI 50 AMP AIT PANE L __ 51 MP CAPTAIN PANEL I TERNAIQR STANDARD ALTERNATOR ON THE 6lS Cl 6lC 01 716 01 B26 01 1088 lZJ 10BC JZ 101 NOTE W RE roll AnERY ATTACNN 1iIT WILL NEtO...

Page 108: ...eaving the boat Aswitch with acontinuous rating of 175 amps at 12 volts will serve the function This switch should not be used to make or break this circuit Q u z 0 t GRA 0 NOT USEO tI PINK 0 x u t 14 BRN Il 0 RED 0 pRESTOI ITE 12 AMP ALT l co u 0 Z 0 19 CL u z s co 0 0 Z Z 0 Z 0 0 102 110 RED z co u z co c 0 Z 0 E U x 0 OIL PRESS rn KH z u 0 Z a 0 i a 0 e 0 4 9 51A CL 1FT PUMPS 21 0 III 114 GRA I...

Page 109: ... 0 l o U 0 u sl l RESISTOR IK 112W AL TERNATOR OUTPUT 1 r J LIFT PUMP P WATER TEMP S ER C J WATER TEMP SWITCH r H IH 1 _ I I TO THE B TO THE TO THE S TO THE I TO THE TO THE P TO THE S TO THE S TO THE C TO THE TACH TERN OF START TERN OF TERN OF TERN OF TERN OF TERN OF TERN OF TERN OF KETS ITCH SWITCH KETSWITCH KETS ITCH THE ALARN THE ALARN THE TACH T GUAGE THE ALARN GROUND _ BUllER BUZZER BUZZER 10...

Page 110: ...on bearing provided the value specified under SPECIFICATIONS is not exceeded However the output shaft should be protected from additional loads Special care should be taken to prevent tor sional vibration When using a universal joint shaft make certain to observe the manufacturer s instructions Even with the engine solidly mounted the use ofa flexible cou pling or DRIVESAVER will reduce stress in ...

Page 111: ...eller shaft by an additional brake is not required use the gear shift lever position opposite your direction oftravel for this purpose Never put the gear shift in the position corresponding to the direction oftravel of the boat WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without a load such as when the boat is being sailed being towed or anchored in a river as well as opera tion of th...

Page 112: ... months or more o Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges and spray with lubricant o Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the cable rods Lubricate all moving parts NOTE Ifthe transm...

Page 113: ...n needs professional attention gear but fails to propel 2 Propeller shaft is not turning Output 2 The coupling bolts are sheared or the coupling is Slipping the boat coupling is turning on the propeller shaft Tighten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and propeller shaft are 3 Inspectthe propeller it may be missing or damaged A both turning folding pr...

Page 114: ... mm I 0 236 0 240 in dia 6 0 6 1 mm dia J 0 71 in dia 18 mm dia K 0 417 0 421 in dia 10 6 10 7 mm dia L 0 276 in 7 mm C1 Chamfer 0 039 in 1 0 mm C2 Chamfer 0 079 in 2 0 mm CO 3 Chamfer 0 012 in 0 3 mm Crankshaft Bearing No 1 Replacing Tool Application Use to press out and to press fit the crank shaft bearing No 1 A 5 12 in 130 mm B 2 56 in 65 mm C 1 57 in radius 40 mm radius D 0 39 in 10 mm E 0 87...

Page 115: ...amfer 0 039 in 1 0 mm C2 Chamfer 0 079 in 2 0 mm C3 Chamfer 0 118 in 3 0 mm C4 Chamfer 0 157 in 4 0 mm A B C Idler gear Bushing Replacing Tool Application Use to press out and to press fit the idler gear bushing A B C D E F C1 C2 CO 3 C2 5 91 in 150 mm 1 18 in 30 mm 0 79 in 20 mm 0 98 in dia 25 mm dia 0 862 0 864 in dia 21 90 21 95 mm dia 0 783 0 785 in dia 19 90 19 95 mm dia Chamfer 0 039 in 1 0 ...

Page 116: ... 1 8 M12 x 1 5 M8 When the tightening torques are not specified tighten the screws bolts and nuts according to the following table ft Ib kg m 2 9 4 3 0 4 0 6 28 9 32 5 4 0 4 5 9 4 11 6 1 3 1 6 19 5 22 4 2 7 3 1 39 8 43 4 5 5 6 0 19 5 22 4 2 7 3 1 7 23 8 32 1 00 1 15 7 23 8 32 1 00 1 15 86 8 94 0 12 0 13 0 7 2 8 3 1 00 1 15 5 8 10 8 0 8 1 5 36 2 50 6 5 0 7 0 10 8 14 5 1 5 2 0 18 1 25 3 2 5 3 5 6 5 ...

Page 117: ...65 M30 46mm 402 545 568 170 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 140 774 1050 1500 2035 2139 2900 M36 55 mm 700 950 992 1345 1925 2610 2744 3720 SEALANTS LUBRICANTS GASKETS SEALANTS Oil based PERMATEX 2 and irs HIGH TACK equivalent are excellent all purpose sealers They are effective in just about any joint in contact with coolant raw water oil or fuel...

Page 118: ...09361 6 6 56168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER VALUES e g 6 000 METERS 6 561 68 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0 454 6 2 722 1 2 205 6 13 228 2 0 907 7 3 175 2 4 409 7 15 432 3 1 361 8 3 629 3 6 61...

Page 119: ...28 35 Grams g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13 783 H20 Inches of Water H20 x 03613 psi x 27 684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4 026 H20 TORQUE Po...

Page 120: ... 54 57 Gears 27 Coolant Recovery Tank 55 Glow Plug 71 Cooling System Governor 61 Description 54 Heat Exchanger 22 55 Service 56 Hourmeter 67 69 Crankcase Breather Hose 23 Hurth HBW Transmissions 104 Crankshaft 19 29 30 39 40 Idler Gear Bushing 39 Crankshaft Bearing No 1 42 Idler Gear 27 38 Crankshaft Gears 27 Idler Gear Shaft 39 Cylinder 43 Idle Speed Adjustment 47 69 Cylinder Block 18 Injection P...

Page 121: ...ification 3 Control Panel 70 Piston and Piston Rings 19 27 28 29 35 36 Engine 7 Preheat Button 67 68 Transmission 107 Prestolite Alternator Service 88 Valves 23 25 31 Pumps Clearance Adjustment 44 Coolant 25 54 57 Guide 32 Fuel Lift 26 58 60 Lapping 33 Injection 58 63 65 Recession 31 Oil 27 50 53 Seating 33 Raw Water 54 Spring 34 Push Rod 24 35 Stem to Valve Guide Clearance 32 Raw Water Pump 54 56...

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