Westerbeke WMD 12.5 User manual

SERVICE MANUAL
4-CYLINDER
MARINE DIESEL ENGINES
& GENERATORS
MARINE DIESEL ENGINES
38B FOUR W-33 42B FOUR
W-27 W-33A
R08D
W-27A
MARINE DIESEL GENERATORS
WMD 11.0-60Hz
WMD 8.3-50Hz
11.0 BTO
WMD 12.5-60Hz 12.5 BTDA
WMD 9.4-50Hz 9.4 BTDA
12.5 BTD
8.3 BTD 9.4 BTD
PUBLICATION NO. 43440
2nd Edition / April 1998
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State
of California to cause
cancer, birth defects, and other
reproductive harm.
A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
-Nausea
-Headache
- Weakness and Sleepiness
- Throbbing in Temples
- Muscular Twitching
- Vomiting
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF 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.

SAFETY INSTRUCTIONS
INTRODUCTION
Read these safety instructions carefully. Most accidents are
caused byfailure tofollow fundamental rules
and precau-
tions. Know when dangerous conditions exist
and take the
necessaryprecautions to protect yourself,
your personnel,
and your machinery.
The following safety instructions are in compliance with
theAmerican
Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers
in place.
• Shut off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage
to vessel's AC generator may
result if this procedure is not followed.
• Electrical shock results from handlinga charged capacitor.
Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, 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, carburetor,
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 severe injury
or death.
• Do not smoke or permit flames or sparks to occur near the
fuel system. Keep the compartment and the engine/gener-
ator clean and free
of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care when
handling and storing fuels. Store fuel in a well-ventilated
area away from spark-producing equipment and out
of
the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care
in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources
of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free
of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated
ABC by the NFPA are appropriate
for all applications encountered
in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explostve gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal
of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases
or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BAnERY ACID
A WARNING: Sulphuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
If
it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin
or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• 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 manifolds
are securely attached and
no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder
or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration
of copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close
or restrict the
flow
of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some
of the symp-
toms
or signs of carbon monoxide inhalation or poison-
ing are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situation
arises in which it is absolutely necessary to make operat-
Engines &Generators
ii

SAFETY INSTRUCTIONS
ing adjustments, use extreme care to avoid touching
moving parts and hot exhaust system components.
• Do not wear loose clothing orjewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught
in
moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine
is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught
in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you
are mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor·
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination
of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
PA Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine/generator.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines &Generators
iii

Engines & Generators

TABLE OF CONTENTS
Introduction ......................................................................... 3
Engine Shutoff ................ ~ ................................................. 32
Product Software....................................................................3 Engine with Manual Stop (Standard) ..................................
32
Engine/Generator Model Designations................................. .3
Optional Key Switch Shutoff (38B and 42B only) .............32
Notes, Cautions and Warnings..............................................
.3
Installing and Adjusting the Key Switch
Ordering Parts/Serial Number Location ................................3 Shutoff Solenoid ........................................................
32
Engine/Generator Specifications ........................................ 5
Testing for Overhaul ............................................................ 6
How to Judge Engine Overhaul Period .................................6
Cause of Low Compression...........................................6
Measuring Compression Pressure..................................6
Overhaul Conditions ..............................................................6
Key-Stop Solenoid System Operation
Checking Procedure...................................................
32
Engine Adjustments ........................................................... 33
Tightening the Cylinder Head..............................................33
Adjusting Valve Clearance...................................................33
Adjusting Fuel Injection Timing..........................................33
Disassembly ...................................................................6
Reassembly ....................................................................7
Adjusting No-Load Engine Speeds......................................
34
Lubrication System Service ............................................... 35
Service Standards ............................................................... 8 Description ...........................................................................35
Technical Data ................................................................... 11
Tightening Torque ..... ~ .......................................................... 11
General Screws.....................................................................l1
Sealants................................................................................. 11
Engine Troubleshooting . .................................................... 12
Disassembly .........................................................................35
Oil Filter and Oil Pump ...............................................35
Inspection .............................................................................35
Oil Pump ......................................................................35
Reassembly ..........................................................................
36
Testing the Oil Pressure ....................................................... 36
Engine Parts Identification ............................................... 16 Oil Pressure Switch..............................................................36
Cylinder Head ... .................................................................. 17
Construction.........................................................................17
Fuel System ... .. , .................................................................. 37
Description........................................................................... 37
Cylinder Head Service ....................................................... 18
Disassembly .........................................................................18
Inspection .............................................................................18
Cylinder Head ..............................................................18
Valve Guide..................................................................18
Fuel System Service .......................................... ' ............... .39
Disassembly ......................................................................... 39
Fuel Filter..................................................................... 39
Fuel Lift Pump............................................................. 39
Fuel Injection Pump..................................................... 39
Valve Seat.....................................................................18 Injector .........................................................................
40
Valve.............................................................................19 Inspection .............................................................................
40
Valve Spring.................................................................19
Rocker Arm and Rocker Shaft.....................................19 Fuel Filter.....................................................................
40
Fuel Lift Pump ............................................................40
Reassembly ..........................................................................19
Partial Reassembly.......................................................20
Installation of Cylinder Head Assembly......................20
Valve Clearance Adjustment........................................20
Cylinder Block .. .................................................................. 21
Construction......................................................................... 21
Cylinder Block Service ...................................................... 23
Disassembly .........................................................................23
Inspection .............................................................................23
Cylinder Block.............................................................23
Piston, Piston Pin and Piston Rings.............................24
Connecting Rod............................................................25
Crankshaft ....................................................................25
Main Bearings and Connecting Rod Bearings ............25
Gearcase .......................................................................
26
Fuel Injection Pump.....................................................40
Nozzle ..........................................................................40
Reassembly ..........................................................................40
Fuel Filter.....................................................................40
Fuel Lift Pump.............................................................40
Injection Pump.............................................................40
Installation and Adjustment of Fuel
Injection
Pump ........................................................... 41
Injector .........................................................................42
Adjustment and Installation
of Nozzle
Holder Assembly........................................................
42
Raw Water Cooling Circuit ............................................... .44
Description ...........................................................................44
Raw Water Pump Service ................................................. .45
Pump Overhaul -Raw Water Pump PN 33636...................45
Timing Gears and Lube Oil Pump Gear......................
26
Camshaft ...................................................................... 26
Disassembly .................................................................45
Inspection .....................................................................45
Fuel Injection Pump Camshaft ....................................
26
Ball Bearings................................................................ 26
Tappets ......................................................................... 26
Push Rods..................................................................... 26
Reassembly ..................................................................45
Pump Overhaul- Raw Water Pump PN 24143...................46
Disassembly .................................................................46
Inspection .....................................................................46
Reassembly ..........................................................................
26
Reassembly ..................................................................46
Governor ............................................................................ . 31
Fresh Water Cooling Circuit ............................................. .47
Description ...........................................................................31 Description ...........................................................................47
Disassembly .........................................................................31
Fresh Water Cooling Service ............................................ .48
Inspection .............................................................................31 Disassembly .........................................................................48
Governor Lever............................................................
31
Inspection .............................................................................48
Governor Spring...........................................................
31
Water Pump..................................................................48
Needle Bearing.............................................................31 Thermostat....................................................................48
Reassembly and Adjustment................................................31 (continued)
Engines & Generators
1

TABLE OF CONTENTS
Reassembly ..........................................................................48 Engine Wiring Diagram.#36467..........................................70
Drive Belt Adjustment .................................................48 Engine Wiring Schematic #36467 ....................................... 71
Admiral Control Panel ...................................................... .49
Description ...........................................................................
49
Captain Control Panel ................... ................................... .50
Description ........................................................................... 50
Control Panel Troubleshooting ......................................... .51
Tachometer/Hourmeter ........................................................ 51
Engine Wiring Diagram #36844..........................................72
Engine Wiring Schematic #36844 .......................................73
Engine Wiring Diagram #39144..........................................74
Engine Wiring Schematic #39144 .......................................75
Standard Hardware Torques .............................................. 76
Metric Conversions ............................................................ 77
Hourmeter Inoperative .................................................
51
Generator Information ....................................................... 78
Tachometer Inoperative................................................
51 Use of Electric Motors.........................................................78
Tachometer Sticking ....................................................
51
Required Operating Speed ...................................................78
Tachometer Inaccurate .................................................
51 Generator Frequency Adjustment ........................................78
Manual Starter Disconnect (Toggle Switches) ...................
52
Generator Maintenance........................................................78
Troubleshooting Water Temperature Generator Troubleshooting ..................................................78
and Oil Pressure Gauges....................................................52
WMD Generator .................................................................. 79
Control Panel - Early Models . .......................................... 53 Description ...........................................................................79
Activation by Key Switch....................................................
53
Disassembly .........................................................................79
Starter/Solenoid Service ................................................... 54
Description ........................................................................... 54
Adjustment and Repair ........................................................ 54
Inspection .............................................................................79
Reassembly ..........................................................................79
WMD Generator Troubleshooting ...................................... 80
Pinion Gap Inspection.................................................. 54
No Electrical Output ............................................................80
No-Load Test................................................................ 54
Flash Field Coils ..................................................................80
Solenoid........................................................................ 55 Replacement of Field CoiJ(s)............................................... 81
Starter Disassembly..............................................................55 Low Voltage Output.............................................................
81
Starter Inspection ................................................................. 56 High VOltage Output ............................................................82
Solenoid........................................................................
56
Solenoid with Throttle Linkage ...........................................82
Inspecting the Armature............................................... 56
Brush and Brush Holder Inspection............................. 56
Field Coil Inspection....................................................57
Starter Adjustment and Reassembly .................................... 57
DC Electrical System .. ....................................................... 58
Description ........................................................................... 58
Engine 12- Volt Control Circuit.................................... 58
Charging System .................................................................. 58
Alternator Troubleshooting.................................................. 58
Checking for ~roper Voltage........................................ 58
Battery Maintenance ............................................................ 59
WMD Generator AC Internal Wiring Diagrams .. ................ 83
WMD Generator DC Electrical System .............................. 84
WMD Generator Wiring Diagram #24700 ..........................84
WMD Generator Wiring Schematic #24700 .......................85
BT Generator .................................................................. .... 86
Description ...........................................................................86
BT Generator Troubleshooting ............................................. 87
Residual Voltage Check .......................................................89
Bridge Rectifier....................................................................89
Testing the Bridge Rectifier for Faults with
Glow Plugs........................................................................... 59
Alternator/Regulator Service ............................................ 60
Description ...........................................................................60
Alternator Troubleshooting..................................................60
Testing the Charging Voltage .......................................60
Output Test................................................................... 61
Disassembly ......................................................................... 61
Inspection .............................................................................62
Diode............................................................................62
Checking for Short Circuit...........................................62
Checking for Open Circuit...........................................62
Checking Diode Trio....................................................62
Stator............................................................................63
an Ohmmeter..............................................................90
Internal Wiring Diagram ......................................................90
Component Resistance Values ............................................. 91
Models 11.0 & 12.5(A) BT.......................................... 91
Component Resistance Checks............................................ 91
Exciter Stator Windings ............................................... 91
Exciter Rotor/Field...............................................................92
Main Stator Windings ..........................................................93
Compound Transformer.......................................................93
Selector Switch ....................................................................93
Bridge Rectifier Wiring........................................................93
No-Load Voltage Adjustment...............................................94
Voltage/Hertz Connection Bar.............................................94
Field Coil (Rotor).........................................................63
BT Generator AC Voltage Connections ................................ 95
Checking Brush and Brush Spring ..............................63 Generator Frequency............................................................95
Checking the Slip Ring................................................63
BT Generator 6 Terminal Block .............................................. 96
Regulator..............................................................................63
Reassembly ..........................................................................64
Transmissions . ................................................................... 65
Wiring Connections .............................................................96
BT Generator DC Electrical System ...................................... 98
BT Generator Wiring Diagram #34651 ...............................98
DC Electrical System ......................................................... 66 BT Generator Wiring Diagram #36412 ............................
.100
Engine Wiring Diagram #24666..........................................66
BT Generator Wiring Schematic #36412........................... 101
Engine Wiring Schematic #24666 .......................................67
Engine Wiring Diagram #33685 ..........................................68
Engine Wiring Schematic #33685 .......................................69
Engines &Generators
2

INTRODUCTION
This service manual contains detailed information relating to
the proper operation
of the major components and systems of
the engine or generator. Included are disassembly, inspection,
service, and reassembly instructions for the guidance
of suit-
ably equipped and staffed marine engine service and rebuild-
ing facilities. The necessary procedures should be undertaken
only by such facilities and their personnel. Refer also to your
Westerbeke parts catalog when performing an engine over-
haul.
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures
and catalogs) provided from sources other than WESTER-
BEKE are not within
WESTERBEKE'S control.
WESTERBEKE CANNOTBE RESPONSIBLE FOR THE
CONTENTOFSUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOFAND
WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OFDAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF
THE FURNISHING OR USE OFSUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings
of WESTERBEKE product soft-
ware and the unavoidable existence
of earlier WESTER-
BEKE manuals. In summation, product software provided
with WESTERBEKE products, whether from WESTER-
BEKE or other suppliers, must not and cannot be relied upon
exclusively as the definitive authority on the respective prod-
uct.
It not only makes good sense but is imperative that
appropriate representatives
of WESTERBEKE or the sup-
plier
in question be consulted to determine the accuracy and
currentness
of the product software being consulted by the
customer.
ENGINE/GENERATOR MODEL DESIGNATIONS
This manual contains certain descriptions, procedures and
specifications that vary depending on the engine/generator
model. Where references to specific models are necessary,
three basic model group designations are used:
A MODELS
B MODELS C MODELS
ENGINES
GENERATORS
ENGINES
GENERATORS
ENGINES
GENERATORS
60Hz 50Hz 60Hz 50Hz
60Hz
50Hz
388 Four 11.0 BTD 8.3 BTD W·33 WMO 12.5 WMD9.4 42B Four 12.5 BTDA 9.4 BTDA
W27 WMD11.0
WMD8.3 W·33A 12.5 BTD 9.4 BTD
R080
W27A 11.0 BTD 8.3 BTD
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the service procedures,
maintenance schedules, and troubleshooting
of your marine
engine/generator, critical information will be highlighted by
NOTES, CAUTIONS, and WARNINGS. An explanation fol-
lows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine/generator.
A WARNING: Procedures, which if not properly fol·
lowed, can result in personal injury or loss of life.
ORDERING PARTS/SERIAL NUMBER LOCATION
Whenever replacement parts are needed for engines, always
provide the engine model number and engine serial number
as they appear on the silver and black identification name-
plate located on the manifold. For generators, provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black decal
located on the generator end.
The engine serial number can also be found stamped into the
engine block just above the injection pump.
The generator
serial number is stamped into the generator housing on the
flat surface on the left side
of the generator.
You must provide us with this information so we may prop-
erly identify your engine/generator.
In addition, include a
complete part description and part number for each part
needed (see the separately furnished Parts List). Also insist
upon WESTERBEKE packaged parts because will fit
or
generic parts are frequently not made to the same specifica-
tions as original equipment.
NOTE: Component locations in this manual are referenced
from the front
of the engine which is the pulley/drive belt end.
Left and right sides are determined as follows: imagine
straddling the engine, facing
in the same direction as the
front
of the engine: the left side is at your left, the right side
is atyour right.
Engines &Generators
3

INTRODUCTION
Owners mayfind it convenient to fill in the data on the decal or identification
nameplate shown below to provide a quick reference when using this service manual.
SPECIFICATION
MODEL _______ _
RPM ... _________ _
KW _____ ... _____ _
KVA __________ _
VOLTS _ ... __ ......... __
AMPS ____ .......... ..
ENG. HP _ ...... ___ _
ENG. SER. NO.
GEN. SER. NO.
PF IPHASE ___ _
WIRES ________ _
RATING ....... __ ...... _
INSUL CLASS __
TEMP. RISE ...........
BAlTERY _____ _
C.'.D. _________ _
50 HZ. 60
/
GENERATOR DECAL
PROPULSION ENGINE IDENTIFICATION NAMEPLATE
Engines & Generators
4

ENGINE/GENERATOR SPECIFICATIONS
A MODELS B MODELS C MODELS
ENGINES
GENERATORS
ENGINES
GENERATORS
-
ENGINES
GENERATORS
60Hz 50Hz
60Hz
50Hz
60Hz 50Hz
38B Four 11.0 BTD 8.3 BTD W-33 WMD 12.5 WMD 9.4
428 Four 12.5 BTDA
9.4 BTDA
W27
WMD 11.0
WMD 8.3
W-33A
12.5 BTD 9.4 8TD
RD80
W27A
11.0 BTD 8.3 BTD
Engine Type
Vertical, inline, 4-cycle, QHV, freshwater-cooled with heat exchanger, diesel engine.
Cylinders
4
Bore & Stroke
2.87 x 3.07 in. (73 x 78 mm)
3.07 x 3.07 in. (78 x 78 mm)
Total Displacement
79.6 cu. in. (1.30 liters)
90.9 cu. in. (1.49 liters)
Combustion Chamber Swirl chamber type
Compression Ratio
23:1
Injection Order 1-3-4-2
Injection Timing Engines: 23° ± 1.5°; Generators: 19° ± 1.5°
Injection Pump
Bosch M type
Injection Nozzle
Throttle type
Governor Centrifugal flyweight type
Fuel Diesel #2 cetane rating 45 or higher
lubrication Forced lubrication (trochoid pump)
Oil Filter Paper-element filter (full flow type) .5 liter capacity
Sump Capacity
5.0 quarts (4.8 liters) not including filter.
Filter requires approximately .5 quarts (.5 liters)
Fresh Water Pump
Centrifugal type
Fresh Water Coolant
Capacity (approximate)
8.0 quarts (7.5 liters)
Raw Water Pump
Positive displacement (Neoprene impeller)
Starter Motor 12 volts - 1.6 kW reduction type
DC Alternator 12 volt - 50 amp - internal voltage regulator
Inclination Angle
15° Continuous (in all directions)
20° Temporary (20 minutes)
Starting Battery
12 volt 300 C.C.A. or greater
Compression Value
Standard 455 psi at 280 rpm (32 kg/cm2)
Minimum 370 psi at 280 rpm (26 kg/cm2)
Overhaul 312 psi at 280 rpm (22 kg/cm2)
Difference between
Cylinders
35.5 psi (2.5 kg/cm
2)
Engines & Generators
5

TESTING FOR OVERHAUL
HOW TO JUDGE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output,
in the case of diesel engines, is not necessarily due to trouble
with the engine itself, but is sometimes caused by injector
nozzle wear or injection pump wear. It is most reasonable to
judge by a decrease
in compression pressure. The decrease in
compression pressure is caused by many factors. It is, there-
fore, necessary to determine a cause or causes on the basis
of
data of periodic inspection and maintenance. Oil analysis on
a seasonal basis is a good means
of monitoring engine inter-
nal wear. When caused by worn cylinders or piston rings, the
following symptoms will occur:
Low engine power output
Increased fuel consumption
Increased oil consumption
Hard engine starting
Noisy engine operation
These symptoms often appear together. Increased fuel con-
sumption and hard engine starting can result also from exces-
sive fuel injection, improper injection timing, and wear
of
plugs and nozzles. They are caused also by defective electri-
cal devices such as the battery, alternator, starter and glow
plugs. Therefore
it is desirable to judge the optimum engine
overhaul time by the lowered compression pressure caused
by worn cylinders and pistons plus increased oil consump-
tion.
In diesel engines, satisfactory combustion is obtained
only under sufficient compression pressure. Ifan engine
lacks compression pressure, incomplete combustion
of fuel
will take place even
if other parts of the engine are operating
properly.
To judge the period of engine overhaul, it is impor-
tant to measure the engine compression pressure regularly. At
the same time, the engine speed at which measurement
of
compression 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.
Measuring Compression Pressure
To check the compression pressure, follow this procedure:
1. Warm the engine.
2. Remove all the fuel injectors or all the glow plugs from
the cylinder block.
3. Disconnect the fuel solenoid from the throttle arm (gen-
erator models only).
4. Place the stop lever
in the OFF position (propulsion mod-
els only).
5. Install a pressure gauge adapter
in the first injector hole
or glow plug hole to be tested.
6. Connect the pressure gauge to the adapter.
7. Crank the engine with the starter motor until the pressure
reaches a maximum value. Read the engine rpm and the
pressure gauge when the starter rotation has become sta-
ble.
8. Repeat the above procedure for each cylinder.
9. If the compression differs
by more than 42.7 psi (3.0
kglcm2) at 200 rpm, then determine the cause of the low
pressure, and repair as necessary.
NOTE: Do not guess the conditions of other cylinders from a
result
of testing one cylinder. Be sure to measure the com-
pression pressure for each cylinder. Lookfor cylinders with
dramatically (at least 20%) lower compression than the aver-
age
of the other cylinders. If the weak cylinder is flanked by
healthy cylinders, the problem is either valve-
or head-gasket
related. Very low compression in an adjacent cylinder points
to gasketfailure. Abnormally high readings on all cylinders
indicate heavy carbon accumulations, a condition that might
be accompanied by high pressures and noise.
NOTE: In case of severe vibrations and detonation noise,
have the injectors overhauled by an authorizedfuel injection
service center. Poorfuel quality, contaminates, and loss
of
positivefuel pressure to the injection pump will result in
injectorfaults.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter,
it decreases gradually with the progress of wear
of these parts.
When decrease
of compression pressure reaches the repair
value, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blowby evident, and
compr~ssion valves at minimum or
below. Engine compression should be 32 kglcm2 (at 280
rpm). See SERVICE STANDARDS chart.
NOTE: The SERVICE STANDARDS chart gives the values for
repair
or replacement of the engine components. Refer to
these values
and measurements during engine overhaul.
Disassembly
1. Before disassembly and cleaning, carefully check for
defects which cannot be found after disassembly and
cleaning.
2. Drain water, fuel and oil before disassembly.
3. Clean
or wash the engine exterior.
4. Do not remove
or disassemble the parts that require no
disassembly.
Engines & Generators
6

TESTING FOR OVERHAUL
5. Perfonn disassembly in a proper order using proper tools.
Keep disassembled parts
in order. Apply oil when neces-
sary. Take special care to keep the fuel system parts free
from the intrusion
of dust and dirt.
Reassembly
1. Prepare all parts necessary for reassembly.
2. Clean or wash the parts. Apply oil on surfaces where
needed or specified.
3. Carefully check gaskets, packings and oil seals even
if
not specified to check. Replace with new ones ifdefec-
tive.
4. Be sure to install
in proper directions and positions.
(Pay attention to dowel pins, mating marks and specified
directions.) Where tightening torque is not specified,
tighten evenly to an ordinary torque. Apply sealant where
specified.
5. After completion of the reassembly, manually rotate the
engine crankshaft two complete revolutions
to ensure
there is no binding
or obstructions. Prepare for starting
the engine and idle the engine sufficiently for a test run.
Engines & Generators
7

SERVICE STANDARDS
These SERVICE STANDARDS specify the values at which
the engine components will require REPAIR (replacement is
optional), or REPLACEMENT (due to maximum component
wear). It is important to observe these standards for your
engine/generator, and to take action when necessary to main-
tain a high level
of safety, dependability and performance.
A MODElS
ENGINES
GENERATORS
60Hz 50Hz
388 Four 11.08TD 8.3 BTO
W27 WMD11.0
WMO 8.3
RD80
All measurements are in mm unless otherwise noted.
To convert mm to inches,
multiply by .03937
DESCRIPTION
ENGINE COMPRESSION PRESSURE
INTER-CYLINDER DIFFERENCE (max)
INJECTION ORDER
INJECTION TIMING
(BTDC on compression stroke)
CYLINDER HEAD
Bottom surface distortion
Valve seat angle (IN and EX)
Valve seat width (IN and EX)
Valve seat sinkage
VALVE CLEARANCE (IN and EX)
VALVE
Stem 0.0.
Stem to guide clearance
Intake
Exhaust
Valve face angle
Valve head thickness (margin width)
VALVE SPRING
Free length
I nstalled load/length
Squareness
ROCKER ARM
Arm to shaft clearance
CYLINDER BLOCK
Camshaft hole 1.0.
Front bushing
Cylinder bore
Cylinder bore oversize finish tolerance
Taper of cylinder
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
W27A 11.0 BTO 8.3 BTD
MODELS STANDARD VALUE
B C
32 kg/cm2 (at 280 rpm)
B C 2.5 kg/cm
2
B C
1-3-4-2
B C 23°± 1.5° (Propulsion)
19° ± 1.5° (Generator)
B C Within 0.05
B C
45°
B C
1.3 -1.8
B C .12-.13
B C 0.25 (when engine is cold)
C
6.6
B 8
B C .012
B C .025
B C 45°
C
1.0
B
1.5
C
43
8 45.85
C
14.0 kg ± 0.7 kg/36 mm
8 27.9 kg ± 1.4 kg/37.3 mm
8 C 1.5°
B C
B C
45
C 73
B 78
8 C o to 0.03 for each oversize
8 C within 0.01
B MODELS
ENGINES
GENERATORS
60Hz
50Hz
W-33 WMD 12.5
WMD9.4
W-33A 12.SBTD
9.4 BTD
REPAIR (or
replacement)
Required at:
26 kg/cm
2
0.1
2.5
41.7
44.5
+0.2
+0.2
NOTE: Valve seats are apart of the cylinder head. A machine shop can install valve seats andcut the seats to properly fit the valves.
Engines & Generators
8
C MODELS
ENGINES
GENERATORS
60Hz 50Hz
428 Four
12.5 BTDA 9.4 BTDA
REPLACEMENT
Required at:
-1
0.10
0.15
0.5
0.5
-15%
-15%
3°
-0.2
+.95 Replace block
or sleeve
+.95 Replace block
or sleeve
(continued)

All measurements are in mm unless otherwise noted.
To convert mm to inches, multiply by .03937
DESCRIPTION
PISTON
0.0. (skirt end)
Piston to cylinder clearance
Oversize
PISTON PIN
Type
0.0.
Piston to pin clearance
Pin to connecting rod clearance
Piston protrusion above block surface
PISTON RINGS
Number of compression rings
Number of oil rings
Ring side clearance
Compression
No.1
No.2 &3
Oil ring
Ring gap
CONNECTING ROD
Bend and distortion
Sideplay clearance
CONNECTING ROD BEARING
Standard Type
Oil clearance
Undersize
CRANKSHAFT
Bend
End play
Main 0.0.
Conn.O.O.
Undersize finish tolerance
Main (common to all)
Conn. (common to all)
MAIN BEARING
Standard type
Oil clearance
Undersize
SERVICE STANDARDS
REPAIR (or
MODELS STANDARD VALUE
replacement)
REPLACEMENT
Required at: Required at:
A
73
B C
78
A B C 0.07-0.08 .178 0.3 BIO
A B C 0.25, 0.50, 0.75
A C
Semi-floating type
B Full-floating type
A C
19
B
23
B -.002 (slight force fit-heat)
0.08
A C
Press-fit load: 500 - 1500 kg
B
.014 - .038
.015
.015
A B C 0.6 -1.1
A B C 3
(No.1: chrome plated barrel type, semi-
keystone. No.2 and NO.3: taper ring.)
A B C 1 (chrome plated with coil expander)
A B C .06 .11
0.3
A B C
.05 - .09
0.2
A B C .03 - .07 0.2
A B C
.22 - 040
1.25
1.5
A B C
0.15
A B C 0.1 - 0.35
0.5
A B C Kelmet metal with back metal
A B C
0.035 - 0.05 0.06 0.15
A B C 0.25, 0.50, 0.75
A B C
0.05
A B C
0.06 - 0.3
-0.3
A C
52
-0.15 -0.90
B 57
-0.15 -0.90
A C
42
-0.15 -0.90
B
48
-0.15 -0.90
A C 0-0.015
B
0.040 - 0.055
A B C -0.035 --0.050
A B C Kelmet metal with back metal
(flanged metal for center bearing only)
A
B-
e 0.04 - 0.05
.06 0.10
A B C 0.25,0.50,0.75
(continued)
Engines & Generators
9

SERVICE STANDARDS
All measurements are in mm unless otherwise noted.
11 . hi' I 0393
o convert mm to mc es, mu tlply bv . 7
REPAIR (or
DESCRIPTION
MODELS STANDARD VALUE
replacement) REPLACEMENT
Required at:
Required at:
CAMSHAFT
Front bearing
A B C
Lead bronze alloy with back metal
Oil clearance
A B C 0.04 - 0.08
0.10 0.15
Cam lobe height (IN and EX)
A B C
35.6 - 35.7
-1.0
PUMP CAMSHAFT
Front bearing A B C Ball bearing
Cam lobe height
A B C
44
-1.0
TAPPET
0.0.
A B C 23
Tappet to cylinder block clearance
A B C .025 - .050
0.15
PUSH ROD
Bend
A B C
Within 0.3
LUBRICATION
ENGINE OIL
Oil specification
API service classification
A B C
Class CF or CG-4
Viscosity
above 20°C A B C
SAE30 or 10W-30
5° to 20°C A B C SAE20 or 10W-30
below 5°C A B C
SAE 10W-30
OIL PUMP
Trochoid type
A B C
Check valve opening pressure A B C 4±
0.4 kg/cm
2
(at 500 rpm of pump speed)
Outer rotor to body clearance A B C
0.15 - 0.2 0.3
Outer rotor to inner rotor clearance A B C 0.05 0.12
0.25
Rotor to cover clearance A B C 0.03 - 0.07 0.20
OIL PRESSURE SWITCH
Contact closing pressure
Engine A B C 4- 6 psi normally open
Generator A B C 4- 6 psi normally open
FUEL SYSTEM
FUEL INJECTION PUMP
Model: NO-PFT4M A B C
At smoke set (SS)
Pump speed
A C 1500 rpm: 27.5 ± 1.0 mm
3
/st
Pump speed
B 1500 rpm: 38 ± 1.0 mm
3
/st
At start set (MS)
Pump speed A C
150 rpm: 34 ± 5 mm
3
/st
Pump speed B
150 rpm: 36 ± 7.5 mm
3
/st
Difference from reference cylinder
A B C
Within 2 mm3/rev. cylinder
Prestroke
A B C
2.2 ± 0.1
NOZZLE
Throttle type A B C
Model: NO-ON4S024
A B C
Injection start pressure A B C
120 ± 10 kg/cm
2
Engines &Generators
10

TECHNICAL DATA
TIGHTENING TORQUE
DESCRIPTION
MODELS
TYPE/QUANTITY
TIGHTENING TORQUE (kg-m)
CYLINDER HEAD BOLT
A C
M12 bolt
(10)
11.5 - 12.5 (wet)
A C
M10 bolt
(4)
6.5 - 8.0 (wet)
B M14 bolt
(10) 15 -16
B M14 bolt
(4) tappet side 10 -11
CRANKSHAFT PULLEY NUT A C
M18t
15 -20
B M20
20-25
MAIN BEARING CAP BOLT
A B C 5 -5.5
CONNECTING ROD CAP NUT A C 3.2 -3.5
CONNECTING ROD CAP BOLT B 5.5 - 6.0
FLYWHEEL MOUNTING BOLT (with flange) A B C
13 -14
(8T) (WITH WASHER: OLD)
A B C
11.5 12.5
OIL DRAIN HOSE BANJO BOLT A B C
5-6
OIL FILTER
A B C
1.1 -1.3
FUEL INJECTION PUMP
Delivery valve holder A B C 4 5
NOZZLE HOLDER
Holder mounting bolt A B C
1.5 -2
Holder body and retaining nut A B C
6-8
GLOW PLUG
A B C
1.5 -2
GENERAL SCREWS
BOLT DlA.
BOLT HEAD MARK
4 7
10
M6
0.3 - 0.5 0.8 -1.0
1.0 -1.3
M8
1.0 -1.3 1.5 - 2.2 2.5 -3.5
M10
1.8 - 2.5
3.0 -4.2
5.0
7.0
M12
3.0
4.2
5.5
7.5
9.5 -12.0
M14
5.0 -7.0 8.0 -11.0
16.0 -19.0
SEALANTS
PARTS REQUIRING SEALANT SURFACES REQUIRING SEALANT SEALANT
(where to mount sealant coated parts)
Taper screw 1/2 /I
Thread portion (Gear case)
Liquid Teflon
Taper screw 1/4 1/
Thread portion (Cylinder block right side, pump cover)
Liquid Teflon
Taper screw 1/8 1/
Thread portion (Cylinder head rear surface)
Liquid Teflon
Water drain plug Thread portion (Cylinder block right side, rear middle portion) Liquid Teflon
Oil pressure switch
Thread portion (Cylinder block right side surface)
Liquid Teflon
Side seal
Periphery (Main bearing caps No. 1 and No.5)
Permatex #6B
Bearing cap No. 1 Contact surface with cylinder block
Permatex #6B
Engines & Generators
11

ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain
problems relating to engine service, the probable causes
of
these problems, and the recommendations to overcome
these problems.
Note: The engineselectric..al system is protected by a 20-
ampere manual reset circuit breaker located on a bracket on
the left front side
of the engine. The preheat solenoid is
mounted on the same bracket.
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
HARD STARTING LOW CRANKING SPEED
1. Engine oil viscosity too high. 1. Replace engine oil with less viscous oil.
2. Run-down battery.
2. Recharge battery.
3. Worn battery.
3. Replace battery.
4. Battery terminals loosely connected. 4. Clean terminals and correct cables.
5. Defective starter. 5. Repair or replace starter.
6. Defective main drive section. 6. Check clutch for disengagement.
DEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
1. Bleed air from fuel system.
2. Clogged fuel filter.
2. Clean or replace filter.
3. Low injection pressure. 3. Adjust injection pressure.
4. Inadequate spray.
4. Clean or replace nozzle.
5. Injection pump delivering insufficient fuel.
5. Repair or replace injection pump.
6. Injection too early.
6. Adjust injection timing.
MAIN ENGINE TROUBLES
1. Low compression.
a. Incorrect valve clearance. a. Adjust valve clearance.
b. Inadequate contact of valve seat. b. Lap valve.
C. Valve stem seized. c. Replace valve and valve guide.
d. Broken valve spring. d. Replace valve spring.
e. Compression leaks through cylinder head gasket.
e. Replace gasket.
f. Piston ring seized. f. Replace piston and piston ring.
g. Worn piston ring and cylinder. g. Overhaul engine.
2. Burnt glow plug.
2. Replace glow plug.
3. Faulty glow plug operation. 3. Check glow plugs and solenoid.
4. Incorrect governor lever position.
4. Set lever to starting position.
LOW OUTPUT
LOW COMPRESSION
See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1. Incorrect injection timing. 1. Adjust injection timing.
2. Insufficient injection. 2. Repair or replace injection pump.
3. Low injection pressure. 3. Check injection nozzle and adjust pressure.
INSUFFICIENT FUEL
1. Air trapped in fuel system. 1. Check and retighten connector.
2. Clogged filter.
2. Clean or replace filter.
3. Contaminated fuel tank. 3. Clean tank.
INSUFFICIENT INTAKE AIR
1. Clogged air cleaner.
1. Clean or replace air cleaner.
(continued)
Engines & Generators
12

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VEmFICATION/REMEDY
LOW OUTPUT (cont.)
OVERHEATING
1. Low coolant level. 1. Add coolant.
2. Loose V-belt.
2. Adjust or replace V~belt.
3. Incorrect injection timing. 3. Adjust injection timing.
4. Low engine oil level. 4. Add engine oil.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION
1. Defective oil seals.
1. Replace oil seals.
2. Broken gear case gasket. 2. Replace gasket.
3. Loose gear case attaching bolts. 3. Retighten bolts.
4. Loose drain plug.
4. Retighten plug.
5. Loose oil pipe connector. 5. Retighten oil connections.
6. Broken rocker cover gasket. 6. Replace gasket.
7. Loose rocker cover attaching bolts. 7. Retighten attaching bolts.
OIL LEVEL RISING
1. Incorrectly positioned piston ring gaps.
1. Correct ring gap positions.
2. Displaced or twisted connecting rod.
2. Replace connecting rod.
3. Worn piston ring. 3. Replace ring.
4. Worn piston or cylinder.
4. Replace piston and rebore cylinder.
OIL LEVEL FALLING
1. Defective stem seal.
1. Replace stem seal.
2. Worn valve and valve guide.
2. Replace a valve and valve guide.
EXCESSIVE FUEL
ENGINE BODY TROUBLES
CONSUMPTION
1. Noisy knocking. 1. See KNOCKING.
2. Smoky exhaust. 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn.
3. Repair or replace.
4. Poor compression.
4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing. 5. Adjust.
6. Improper valve clearance. 6. Adjust.
INSUFFICIENT INTAKE AIR
1. Air intake obstructed.
1. Clean or remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle.
1. Replace.
2. Worn nozzle.
2. Replace.
IMPROPER FUEL
Replace with proper fuel.
FUEL LEAKS Find fuel leaks.
SMOKY EXHAUST WHITISH OR PURPLISH
1. Excessive engine oil. 1. Correct oil level.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact. a. Check.
b. Seized piston ring. b. Replace or clean.
c. Excessive piston-to-cylinder clearance.
c. Replace or correct.
(continued)
Engines & Generators
13

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERtFICATION/REMEDY
SMOKY EXHAUST (cont.,
WHITISH OR PURPLISH (cont.,
d. Worn valve stem and valve guide. d. Replace.
e. Low engine oil viscosity.
e. Replace.
f. Excessive oil pressure. 1. Correct.
3. Injection timing is too late. 3. Adjust.
4. Insufficient compression.
4. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAYISH
1. Engine body troubles.
a. Poor compression. a. See LOW COMPRESSION; HARD STARTING.
b. Improper valve clearance. h. Adjust.
2. Insufficient intake air (air cleaner clogged). 2. Clean air cleaner.
3. Improper fuel. 3. Replace with proper fuel.
ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE
1. Badly worn bearing.
1. Replace bearing and grind crankshaft.
2. Badly worn crankshaft. 2. Grind crankshaft.
3. Melted bearing.
3. Replace bearing and check lubrication system.
CONNECTING ROD AND CONNECTING ROD BEARING
1. Worn connecting rod big end bearing. 1. Replace bearing.
2. Worn crankpin. 2. Grind crankshaft.
3. Bent connecting rod. 3. Correct bend or replace.
PISTON, PISTON PIN, AND PISTON RING
1. Worn cylinder. 1. Rebore cylinder to oversize and replace piston.
2. Worn piston pin.
2. Replace piston.
3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and rings worn or damaged. 4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft.
1. Replace.
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing. 4. Replace.
ROUGH OPERATION
INJECTION PUMP SYSTEM
(HUNTING) 1. Uneven injection.
1. Adjust injection or replace parts.
2. Control rack malfunctioning. 2. Disassemble, check and correct injection pump.
3. Worn delivery valve. 3. Replace.
4. Inadequate injection nozzle spray. 4. Replace injection nozzle.
GOVERNING SYSTEM
1. Governor lever malfunctioning.
1. Check governor shaft and correct operation.
2. Fatigued governor spring. 2. Replace.
(continued)
Engines &Generators
14