Westerbeke ATOMIC 4 Operation And Maintenance Manual
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Westerbeke ATOMIC 4 Operation And Maintenance Manual

Westerbeke ATOMIC 4 Operation And Maintenance Manual

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ATOMIC 4
OPERATION AND
MAINTENANCE
MANUAL
PART NUMBER
200156
jJ~
'WESTERBEKE
WESTERBEKECORPORATION
~
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

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  • Page 1 ATOMIC 4 OPERATION AND MAINTENANCE MANUAL PART NUMBER 200156 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 ATOMIC 4 OPERATION AND MAINTENANCE MANUAL PART NUMBER 200156 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 3 INSTALLATION, OPERATION MAINTENANCE INSTRUCTIONS UNIVERSAL MARINE ENGINES BLUE JACKET TWIN, ATOMIC FOUR, UTILITY FOUR, SUPER-FOUR, UNIMITE FOUR, ARROW (SIX), BLUEFIN (SIX), MARLIN (SIX), . TARPON (SIX), KNIGHT (SIX), LITTLE KING V-8 and BIG KING V-8 MODELS MARINE ENGINE WARRANTY PRODUCT WARRANTY SELLER WARRANTS ALL PRODUCTS AND PARTS OF ITS MANUFACTURE AGAINST DEFECTS IN MATERIAL OR WORKMANSHIP FOR A PERIOD OF ONE (1) YEAR FROM...
  • Page 4 WARRANTY REGISTRATION ENCLOSED WITH EACH ENGINE IS A WARRANTY REGISTRATION CARD. THIS CARD MUST CONTAIN THE OWNER'S NAME, ADDRESS, SERIAL NUMBER OF THE ENGINE, V-DRIVE AND REVERSE GEARS AND RETURNED TO MEDALIST BEFORE THE WARRANTY BECOMES EFFECTIVE. THIS WARRANTY REGISTRATION MUST TAKE PLACE WITHIN 24 HOURS AFTER RECEIPT OF THE ENGINE.

  • Page 6: Table Of Contents

    TABLE CONTENTS SECTION GENERAL INFORMATION Paragraph Title Introduction Factory Preparation for Shipment Treatment of Engine on Arrival Engine Rotation Engine Identification SECTION INSTALLATION Preparation for Installation Installing the Propeller Shaft Installing Engine Stringers and Beds Aligning the Engine Exhaust Piping Cooling Water System and By-Pass Valve Th~rmostat...
  • Page 7 TABLE OF CONTENTS (Cont.) Paragraph Title Stopping Engine Break-In Starting Magneto Models Starting FUel Oil-Kerosene Models Operation of Standard Reversing Gear Operation of Hydraulic Reversing Gear Cold Weather Operation Preparing Engine for Storage SECTION IV THEORY OPERATION General Theory of Operation Theory of Ignition Systems Lubrication System Fuel System...
  • Page 8 TABLE OF CONTENTS (Cont.) SECTION VI MAINTENANCE Paragraph Page Title Distributor Maintenance Timing Procedure General Maintenance starter Maintenance Magneto Maintenance Carburetor ~mintenance Valve Adjustment ~appet Reversing Gear Adjustment - Joes Models Reversing Gear Adjustment - Paragon Manual Reversing Gear Adjustment - Paragon Hydraulic Sta-Nu-Tral Manual Transmission Oil Pressure Regulator Adjustment Spark Plug Maintenance...
  • Page 9 LIST ILLUSTRATIONS Fig. Description Page Location of Underwater Gear Method of Locating Shaft Hole Shaft Log Method of Drilling Shaft Hole Photo of Drilling Operation Photo of Engine Stringers Engine Bed Construction Photo of Exhaust Piping Method of Cooling Water Discharge Suggested Battery Installation Methods of Engine Temperature Control Typical Shaft Location...
  • Page 10 LIST OF ILLUSTRATIONS (Cont.) Fig. Description Distributor Body Sanding Distributor Brushes Bendix Drive Magneto - American Bosch Magneto - Fairbanks-Morse Carburetor - 63M and 263M Series Carburetor - 61M Series Carburetor - Adjustments Carburetor - Adjustments Valve Tappet - Adjustment Reverse Gear - Adjustment - Joes Model Reverse Gear - Cam Adjustment - Joes Model Sta-Nu-Tral - Reverse Gear...
  • Page 11 TABLES LI ST Table Description General Engine Data Installation Data Electric System Wire Sizes Lubrication Requirement Data Fuel Oil Specifications Trouble Shooting Procedures Valve and Piston Data Torque Tensions ~Vrench Bearing Data Spark Plug Data Valve Timing...

  • Page 12: Introduction

    SECT ION GENERAL INFORMATION d. Every modern facility is employed 1. INTRODUCTION in building these marine engines. Yet metals will wear, and as time This instruction book gives general goes on, certain adjustments will instructions for the installation, be necessary. It is, tberefore, the oper'ation and maintenance of all cur- rent production models of UNIVERSAL purpose of this book to show you the...

  • Page 13: Engine Rotation

    wise to check accessible use left hand propellers. Opposite nuts and bolts for tightness. The rotation engines are available in various tags and decals attached to all of the six and eight cylinder the engine contain important informa- series and in every case utilize a t ion which should be carefully noted.
  • Page 14 Table 1- GENERAL DATA Piston Reduction Standard Max. Reversing Standard Disp. Engine Gear Propeller Standard Gea1:' Ignition Coupling Cyl. Bore Stroke In. RPM Ratie.. Rotat ion Model HP Manual Magneto Blue Jacket Twil AFT 2200 R.H. 7/8" 49.5 3" 3-1/2" 6 V.

  • Page 15: Installation

    SECT ION INSTALLATION 1. PREPARING FOR INSTALLATION moving the rudder is more satisfac- tory. It is, of course, also neces- Remember that as much of the work sary to know the exact location of of installing an engine takes place tbe engine and tbe manufacturer's...

  • Page 16: Installing The Propeller Shaft

    justed to obtain proper propeller clearances and crankcase and fly- wheel clearance for the engine. When the position of the string has been accurately determined, the place it passes each of the sticks is care- fully marked and the jig placed back in the boat.

  • Page 17: Method Of Drilling Shaft Hole

    A drill 1/8 inch larger than the any ribs which might interfere. The shaft diameter should be used wedge is then screwed into position provide opel' c-learance. Any type over the locat ion of the shaft hole. Use a good grade bedding compound of drill may be...

  • Page 18: Installing Engine Stringers And Beds

    gine beds. They should rest firmly shaft and move it along the pro- on the hull ribs and be cross-braced peller shaft with the base pressed at intervals by notching into 2" by firmly against the keel until the 8-" members .Lunning at right angles shaft is approximately in the center to them.

  • Page 19: Aligning The Engine

    from the string, which represents tightened. washers under all center of shaft, to nuts. The position of the engine position of the hangers using the hold-down bolts is marked on figures given on the engine scale the top surface of the engine beds. drawing.

  • Page 20: Exhaust Piping

    to direct cooling_ uater from engine into the exhaust line. so doing, two purposes are served: the hot exhaust line is cooled be- low the point and the daI.lg~r ~7ater quiets the ,,-,.:haust. In this type of installation, two precautions must ENGINE be oTJserved.

  • Page 21: Th~Rmostat And By-Pass Valve

    Installation of the water scoop is 3" a simple process. square by 3/4" thick block" is fastened to tbe inside of tbe bottom of tbe bull witb four wood screws and set in bedding compound. A bole is then drilled tbrougb the block and bull the same diameter as outside...

  • Page 22: Fuel System

    of restriction to flow offered by the valve. the piping. It is quite common to find engine operating temperatures installations using hand as low as 90 F. in these installa- control valve, water should be noted issuing from the exhaust pipe soon t ions.

  • Page 23: Electrical System

    discharged harmlessly over the side. with most engines or one of several Connection from the tank to types of controls available. These engine should be made with copper controls operated from a tubing of a size recommended by the remote lever, either mechanically engine manufacturer.

  • Page 24: 11. V-Drive Installation

    11. V-DRIVE INSTALLATION In this case, keel should be leveled from the transom to about In recent years two factors have six feet forward to aid in deter- had a great influence on power for mining the shaft bole location outboard type hulls.

  • Page 25: Drill Block Details

    STERN OF BOAT BLOCK "A" KEEL BLOCK "8" MATERIAL - MAPLE OR OAK MATERIAL MAPLE OR OAK ,.---_ _ ---,-L t& "ND [±] ===Lt -= - 1--,0,,---1 5·:..j ~'Z"--l f-5~ DETAIL OF BLOCK "B" DETAIL OF BLOCK "A" Fig. 14 Drill Block Details distance from tbe prop sbaft center an angle to the shaft line equal to...

  • Page 26: Typical V-Drive Layout

    dimensions typical wedges two-thirds the length of the hull for varying keel thickness. are now installed and fastened se- curely transom, Afte~ installation of the wedge, rudder installed and braced to the preparations can be made for dril- stringers. A typical installation ling the shaft hole.

  • Page 27: Special Equipment

    temporarily, beds slid into place Because of installation at the ex- under the engine and clamped treme stern, the engine can be en- closed by building a seat over or marking of the mounting bolts. engine is then removed, beds fas- in front of the engine with the seat tened in place...

  • Page 28: Photo Of 3-Unit Instrument Panel

    SPARK PLUG'S NOTES :- LEAD IS CUSTOMER INSTALLED. USE MIN. OF "I HEAVY DUTy BATTERY CASLE. THIS WIRE MUST BE GROUNDED BACK TO ENGINE. Wiring Diagram - Motorola LEAD IS CUSTOMER INSTALLED. USE MIN. OF MI Alternator - 12 volt - HEAVY OUT { BATTERY CABLE.

  • Page 29: Wiring Diagram - 3-Unit Panel

    Figure 8 TO ALT. OUTPUT TERM. ON ALT ORG. TO DIST.HTERM. AT COIL GRAY ,GROUND TO ENG. BOCK BLACK ~P~RATURE SENDER AMMETER 01 L PRESSURE SENDER BLUE PURPLE TERM. OF IGN. COIL TO·S"TERM. OF START MOTOR SOL. WHITE TO BAT TERM ON START MOTOR..sQL f...lI::Ull..

  • Page 30: Wiring Diagram - 5-Unit Fanel

    BACK SmEOF 5 UNIT PANEL BACK ~UNlT SIDE PANEe NOTE: "I>.' SIZE WIRE "B" SIZE - - - - WIRE TACHOMETER ' * ' HEAT GROUNDED TO " ENG. BY CUSTOMER ______ ...J .., " ,\G~WON A SIZE WIRE W'RE ror.

  • Page 31: Wiring Diagram - Std. 12 Volt And 12 Volt 24 Amp

    THE ELECTRICAL SYSTEM OF ENGINE MUST REGULATOR IS TO BE MOUNTED HAVE NEGATIVE GROUNDED BATTERY WHEN SEPARATE FROM ENGINE 12 VOLT 24 AMP. GENERATOR IS USED. I,zj PREFERABLY IN A VERTICAL ..REGULATOR FURNISHED WITH STANDARD 12 POSITION • VOLT GENERATOR CAN BE EITHER POSITIVE OR NEGATIVE GROUND.

  • Page 32: Engine Scale Drawings

    INSTALLATION DRAWl NGS ------~----------------~BLUE JACKET TWIN SERIES----------------~------ PIPE TAP WATER OUTLET BORE K["fWAY 1"< Fig. 23 BOLT 3y .. ~ ~~ 8!J:.j. 8~'" lZ2 : -?I~- 3~ - .. 16 ----------------------------ATOMIC FOUR SERIESi-------------------------- t-----I7"* - - - - I -8li--+---- BORE KtYWAY Fig.
  • Page 33 ----------------------~ATOMIC FOUR SERIES (Cont.)---------------------- Fig. 26 & AQUA-PAX V-DRIVE 1:1, 1.29:1, 1.67:1 2:1 RATIO --------------------------UTILITY FOUR SERIES-------------------------- tPIPE TAP WATER OUTLET Fig. 27 .)4~ DIRECT DRIVE -rP1Pr TAP _TtR OUTLET Fig. 28 REDUCTION DRIVE -22-...
  • Page 34 ----------------------------SUPER-FOUR SERIES--------------------------- DIRECT DRIVE RIGID MOUNTINGS Fig. 29 DIRECT DRIVE RUBBER MOUNTINGS Fig. 30 REDUCTION DRIVE RIGID MOUNTINGS Fig. 31 H I . : L ' _ .3IJ..-+--'-::~ _, ' " " --"'~ '---I~~-------'--12l-- -Il-- --~ ..i.. __ - 4 7 - - - - - - REDUCTION DRIVE RUBBER MOUNTINGS Fig.
  • Page 35 -----------------------UNIMITE FOUR SERIES-------------------------- DIRECT DRIVE RUBBER MOUNTINGS Fig. 2:1 REDUCTION DRIVE RUBBER MOUNTINGS Fig. ,CENTER OF GRAVITY -2"L._,. AQUA-PAK V-DRIVE & ALL REDUCTION RATIOS DRIVE RUBBER MOUNTINGS Fig. -24-...
  • Page 36 ---------------------------------ARROW 8~Hl~8------------------ ____________ __ Fig. 36 -~~--- "'5 !--~-~ ,---.---- STA-NU-TRAL GEAR - DIRECT DRIVE ~llHA.UST EITHEI1 2Fp. FOI1 TU&IN6 SIZE Fig. 54~-------- -~------ ----~-----, ST.!-NU-TRAL GEAR 1.88:1 REDUCTION RATIO /EXHAUST EITHeR END 2Fp. II--~/ FOR 2! 5IZE TLJeINb Fig. ----42~-- ---~541--~------- ST.!-NU-TRAL GEAR - 2.44:1 REDUCTION RATIO...
  • Page 37 ------------------------------BLUEFIN SERIES----------------------------- EXHAUST EITHER END FOR 3 TUBING, PIPE OR TUBE & 1.5:1 DIRECT DRIVE Fig. MANUAL REVERSING GEAR EXHAUST EITHER END FOR TUBE-.------''-<d--,.-,~ TUBING, 2- 2 ' PIPE OR <to EXHAUST li~~; .8~O OFFSET I.S:I RED. OIA. BOLTS -RUBBER MOUNTS , 12jb OFFSET , 21 /...
  • Page 38 -----------------------------MARLIN SERIES----------------------------- Fig. ~111--"~-i--:#-~ eNG!tL~WffiUI'!we(11-~2l ~!US;oP"'I~ JaOx.\ 1!0.5 KeV "'4-~- JiOalK~V ~--------~A STA-NU-TRAL REVERSE GEAR, 1.88:1 REDUCTION GEAR Fig. ----46i----------------------~ ------se~ -------------------------------1 STA-NU-TRAL REVERSE GEAR, 2.44:1 REDUCTION GEAR Fig. ~-------45i-----------------------~ ~--------------------~5ge-------------------~ 3.32:1 STA-NU-TRAL REVERSE GEAR, REDUCTION GEAR -27-...
  • Page 39 ------------------------------TARPON SERIES----------------------------- EXHAUST fITH~R EXHAUST DIA. BOLTS - RUBBER MOUNTS /ADIA.IOLTS -SOLID MOUNTS CRANKSHAFT L"l\::::t:::t- MIN. BORE Ii MAX. BORE Direct Fig. MANUAL REVERS ING GEAR EXHAUST L=----4~,----------- Direct Drive 1.05 OFFSET 1.5:1 RED. 1.5:1 & HYDRAULIC REVERSING GEAR Fig. -28-...
  • Page 40 -----------------------------.KNIGHT SERIES----------------------------- flHAUST EITHf.R END FOR t~+--+:::: 0R 3 PIPE OR TUBE - lr-':'-~ EXHAUST lJif +-II-,------~ ADIA. BOLTS -SOLID MOUNTS ~---------4~----------------~ Direct Drive Fig. 47 MANUAL REVERS ING GEAR ._ •. _ _ _ _ "' I :<i.=EX="=AU=S""' T _ _ _ _ _ 1.05 OFFSET DIA.
  • Page 41 ----------------------~,LITTLE KING - V-B SERIES------------------------ nNUA.L REVERSING GEAR Fig. DIRECT DRIVE Fig. 51 REDUCTION DRIVE, 1.5:1 RATIO Fig. 52 REDUCTION DRIVE, 2:1 RATIO Fig. 53 REDUCTION DRIVE, 2.5:1 RATIO -30-...
  • Page 42 ------------------------LITTLE KING SERIES (Cont.)---------------------- HYDRAULIC REVERSING GEAR Fig. DIRECT DRIVE Fig. RED0CTION DRIVE, 1.5:1 RATIO Fig. 56 REDUCTION DRIVE, 2:1 HATI( Fig. REDUCTION DRIVE, 2.5:1 RATIO -31-...
  • Page 43 ------------------------~BIG KING - V-8 SERIES------------------------- . I.",·, . • , •. ".t AA"'~ Fig. DIRECT DRIVE HYDRAULIC REVERSING GEAR ' ... - -- -1 - -1- ------ - ~,~ .."'" .'!>1.~ ..REDUCTION 1 P.ATIO DRIYJ<~, 2.~;: HYDRAULIC REVERSING GEAR -32-...

  • Page 44: Operation

    SECT ION III OPERATION j. Open shut-off valve below fuel 1. PRELIMINARY CHECKS tank. Operate hand primer, models so equipped, to fill feed a. Check to be sure the engine is line and sediment bowl with fuel. filled with "full" mark bayonet stick.
  • Page 45 in your locality and with the fuel h. Check oil pressure gauge for op- available. If readjustment is at- eration of oil pump. If gauge does tempted it should be done by a com- not indicate oil pressure, stop en- petent mechanic.
  • Page 46 Table LUBRICATION REQUIREMENTS Herringbone S.A.E. VISCOSITY NUMBERS FOR Average Reduct ion Gear ENGINE CRANKCASE OIL Surrounding Surrounding Surrounding Engine Lubricant S.A.E. p..ressure Viscosity Number Air Temp. Air Temp. Air Temp. MODEL Over (Hot Engine) .Separately F. and Below NAME Maximum Service Average Service Average Service Lbs.
  • Page 47 Table FIRING ORDER CYLINDERS STANDARD ROT. OPPOSITE ROT. 1-2-4-3 1-5-3-6-2-4 1-4-2-6-3-5 V-8 LEV 1-2-7-5-6-3-4-8 1-8- +-3-6-5-7 -2 V-8 SEVH 1-2-7-5-6-3-4-8 1-8-4-3-6-5-7-2 V-8 NKEV 1-5-6-3-4-2-7-8 1-8-7-2-4-.3-6-5 gear positions are stamped on the OPERATION OF STANDARD REVERSING GEAR top cover. See Paragraph Section IV for detailed operation.

  • Page 48: Preparing Engine For Storage

    shafting and propeller caused b. Manifold the shock of rapid shifting at high Open drain cocks in exhaust manifold engine speeds. and drain watet from the manifold. 9. COLD WEATHER OPERATION c. Water Pump Water pumps are particularly sus- Special precautions must be taken ceptible...

  • Page 49: General Theory Of Operation

    commutator and brushes. Do not oil Battery the commutator. Remove battery and store in a warm dry place. Battery sbould be fully i. Generator cbarged wben placed in storage and cbecked periodically. Occasional Oil bearings. Seal moisture tight to prevent corrosion. cbarging may be desirable to pro- long battery life.

  • Page 50: Lubrication System

    (2) Two separate circuits, primary (2) The high tension type magneto and secondary, make up the ignition used UNIVERSAL engines has a secondary winding, comprIsIng system. The primary low tension cir- cons ists of the battery, great number of turns of fine wire, voltage distributor points, primary superimposed upon the primary wind- coil...
  • Page 51 (2) The gear driven oil pump, lo- working an eccentric cated in the oil base, draws camshaft. through an intake screen. Oil is forced to all main, connecting rod As the high point of the cam is and camshaft bearings; through jet reached, the plunger is forced down, holes...
  • Page 52 curved plates, dissipates the heat Super-Four series engines only. prevents fire from extending through the arrestor. (2) The forward .d.r ive on this unit is a double friction clut9h. On the COOLING SYSTEM propeller end are a series of fric- tion discs of steel and bronze which a.

  • Page 53: Reduction Gears

    a ser ies of fr ict ion discs , alternate reversing gears is provided by the ones held in the reverse gear drum transmission oil pump mounted in- and on the tailshaft clutch carrier. side the reversing gear case This group of discs can be clamped driven continuously by the engine...

  • Page 54: General

    ratios varying from the heavy axial propeller thrust 1.5:1 to Reduction gears in addition to the radial load ic- supplied J..j,.12:1. various model engines posed by the helical gear. are shown with in l'able 1. The propelter shaft coupling is keyed to the end of the reduction...

  • Page 55: One Hundred Hour Check

    engines having separately sediment. oiled reduction gears, check oil level and if necessary refill. b. Inspect flame arrestor Table 4 for engine requirements. sure clean and pass~ges free from oil. If dirty remove and c. On engines equipped with wash with kerosene.

  • Page 56: Maintenance

    Paragraph Section VI. e. Lubricate and repack bearings on magneto. See Paragraph Section VI. Check generator starter brushes for wear. If worn replace. THREE THOUSAND HOUR CHECK See Paragraphs Section VI. At the end of three thousand hours of operation the engine should be c.

  • Page 57: Timing Procedure

    Engine Hodel loct.;,ticD scale reading is No. 1 Cylinder within the above limits, loosen the terminal post, holding the end spring (Fig. Blue Jacket Twin Flywheel End slide the end of the spring in or Atomic Four " " out as necessary. Ut il i ty Four "...

  • Page 58: General Maintenance

    rotor points to slot in distributor fully pull generator auay from case when distributor drive gear is housing. re-engaged. Rotate distributor body 1 breaker po ints are just begin- On model:: belt driven from fly- ning to open. wheel, remove belt, remove nut hold- ing generator pulley to shaft, f.

  • Page 59: Starter Maintenance

    Disconnect start ing motor wir ing. b. Lubrication (-1) The generator should be lubricated (2) Remove bolts holding starting every 100 hours of operation. Place motor to housing. fl~vheel three to five drops of light gine oil in the oil cups at each ~otor Remove...

  • Page 60: Magneto Maintenance

    it from the engine. b. Inspection and Cleaning Loosen screws and ~emove the end cap from the magneto. careful not to damage the gasket betueen the end cap and the magneto body. (2) Remove the distributor cap from the end cap. (J) Inspect magneto for worn or bro- Fig.62 Bendix Drive...

  • Page 61: Carburetor ~Mintenance

    (2) Further lubrication of the mag- d. Adjustment of POints, neto by the operator is not recom- Fairbanks-Uorse mended. (1) Inspect the points for evidence of pitting or burning. g. Timing, American Bosch If points are badly pitted, re- Remove distributor plate place.
  • Page 62 (9) Hold adjusting screw covered by these instructions are place and tighten the packing nut. supplied with Zenith marine type safety non-drip carburetors, cept the V-8 models (See special Return throttle to idle (10) instruction books.) With position and readjust idle needle exception following...

  • Page 63: Carburetor - 63M And 263M Series

    IDLE ADJUSTING NEEDLE IDlE MAIN JET ADJUST 63~1 263~I Fig.66 Carburetor - Series Fig.65 Carburetor - Series desired idling speed and repeat the jet size is No. 42 (2.1 mm.) This adjustment of idling jet "A". jet size should be correct for all applications., However, if the oper- th the boat...

  • Page 64: Carburetor - Adjustments

    small, round brass disc riveted fully observe the reaction of the ,to the car!Juretor. tachometer. If the tachometer shows a steady decrease as the throttle Zenith carburetor supplied is retarded, the stop screw is not on the l.Iodel 250, 155 II. P. Knight needed in adjusting the carburetor.

  • Page 65: Valve ~Appet Adjustment

    7. VALVE TAPPET ADJUSTIlENT plate. a. Valve tappet adjustments ere to (2) Loosen the screw (2) 17hich holds be made with the piston on top dead the clip in the notcQes cut in center of the compression stroke the gear case housing until the clip with both valves closed.

  • Page 66: Reversing Gear Adjustment - Paragon Hydraulic

    to the reverse position. Fig. (2) Back out lockscreu until 74 (A. and the end is free of the Detch in the adjusting collar. See Fig. 74 (A and B). Tighten the adjusting bolt (2) until the brake band prevents the gear case from revolving.

  • Page 67: Sta-Nu-Tral Manual Transmission

    the reverse band evenly Gbout the STA-NU-TRAL l1ANUAL TRANSI.IlSSION drurr. 1\'i th the reverse gear in the The adjustments that for the forward or neutral position the re- follo~ manual transmission Sta-~u-Tral should be made periodically. They are especially important 't7here re- mote control type of eqniIrnent...

  • Page 68: Spark Plug Maintenance

    Fig. 7 Reverse Gear - Adjustr:Jent - Paragon pressure regulat ing scre'rl in SPARK PLUG INTENANCE I) • l.lA or out until the proper pressure sho-rm in Table 4 is reached. Spark plugs should inspected cleaned from time to time ano Hold the regulating screw...

  • Page 69: Fuel Pump Maintenance

    and gap setting each engine Check diaphragm return springs. covered by these instructions. Check cam roll and cam arm for worn parts. 14. FUEL Pma' 1IA.INTENANCE (See Fig.77) c. Replacement of Parts a. DiE assembly (1) Replace parts '7hich are (1) Disconnect fuel lines and re-...

  • Page 70: Maintenance Of V-Drive Units

    /NL£T JCPEEN Jf DIMEN! "'4---!-~ BOWL PRIMER LEVER Fuel Fump Fig.?? b. Lubrication n~INTENANCE OF V-DRIVE UNITS (1) The unit must be kept filled to a. General the full mark on the bayonet sticko (1) The Universal V-Drive unit is Use a good grade EP-90...

  • Page 71: Repair Parts Kit

    REPAITI PARTS KIT engine l]C'.,intenance. con- A factory repair parts tains parts most likely to require pack~ged !cit is C1vailable for all models of replaceoent through normal engine engines covered by these instruc- operction. .c:ach part is carefully tions. Parts included in the ':Tapped 17aterproof ,n'apping...
  • Page 72 Table TROUBLE SHOOTING PROCEDURES (Cont.) .-------------r-----------------,--- .-- ---- -----------.-----.---.-- ----- ---- -.-L r_r~:,·' f-T_r_o_u_b_l_e ___________ +-_p_r_o_b_a_b_l_e_C_a_u_s_e ____________ .;1) Engine will not start Water in fuel system . 1< ' II II " " , lIt" (Defective fuel system) lilj(·...; "l;·~'~. l~·r.
  • Page 73 Table 6 TROUBLE SHOOTING PROCEDURES (Cont. ) Trouble Correction Probable Cause - - - - - - - - - - - - - - - - - f Check for leak by squirting oil around Engine will not start Air leak around intake mani- (Poor compression and intake connections.
  • Page 74 Table TROUBLE SHOOTING PROCEDURES (Cont. ) Trouble Probable Cause Correction Sludge in oil Drain and refill with proper weight oil Infrequent oil changes Water in oil Drain and refill. If trouble persists, check for cracked block, defective head gasket and cracked head Dirty oil filter Replace filter Loss of RPM...

  • Page 75: Repair

    SECT ION V III REPAIR Method of shipment desired: 1. MAJOR REPAIRS parcel post, express, truck, or rail freight. If freight shipment a. It is not recommended that operator perform any repairs more is desired, give name of truck complex than those covered under line...
  • Page 76 Table VALVE AND PISTON DATA VALVE STEM MODEL PISTON PISTON VALVE SEAT VALVE TAPPET CLEARANCE CLEARANCE IN GUIDE NAME CLEARANCE RING ANGl.E INTAKE AND (!C I,D INTAKE EXHAUST EXHAUST INT. EXH. Blue Jacket Twin 45 0 .008" .010" .0015 - .002" .0015 - .002"...

  • Page 77: Index

    SECTION IX INDEX Page Aligning the Engine Bearing Data (Table 9) Break-in Carburetor Maintenance Cold Weather - Operation Cooling Sy stem Cooling Water System - Installation of Crankshaft Data Distributor Maintenance Electrical System - Installation of Engine Identification Engine Models - General Data (Table 1) Engine Rotation &...
  • Page 78 Page INDEX (Cont.) Instrument Panels Introduction Lubrication Chart (Table lubrication System Magneto Maintenance Major Repairs Oil Pressure Regulator Adjustment Once a Season Check One Hundred Hour Check One Hundred Fifty Hour Check Periodic Service - General Preliminary Checks - Operation Pre-Operational Cbeck Preparation for Shipment - Factory Preparation for Storage...
  • Page 79 INDEX (Cont.) Spark Plug Maintenance Special Equipment Sta-Nu-Tral Manual Gear Starter Maintenance Starting - Electric Ignition Models Starting - Fuel Oil and Kerosene Models Starting - Magneto Models Stopping Engine Theory of Operation & Thermostat By-Pass Valve - Installation of Three Thousand Hour Check Timing Procedure - Ignition Torque Wrench Tensions (Table 8)

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