Installation manual

TABLE OF CONTENTS
Introduction ................................................................................. 2 Cooling System (continued)
Warranty Procedures ............................................................ 2 Raw Water Pump ................................................................. 22
Product Software ................................................................. 2 Inspecting/Changing the Raw Water Pump Impeller
... 22
Notes, Caution and Warnings .............................................. 2 Raw Water Intake ................................................................. 22
Model No.lSerial No. Location ........................................... 2 Raw Water Intake Strainer ................................................... 22
Component Locations .......................................................... 3 Siphon-Break ....................................................................... 23
Understanding the Diesel Engine ........................................ 3 Draining the Cooling
System ............................................... 23
Ordering Parts ...................................................................... 3 Air Intake Filter ............................................................................ 24
Spares and Accessories ........................................................ 3 Description ........................................................................... 24
Protecting Your Investment ................................................. 3 Air Filter ....................................................................... 24
7A-1 Diesel Engine Specifications ............................................. 4 Maintenance ................................................................. 24
7A-1 Diesel Engine Parts Identification ..................................... 5 Water Heater ................................................................................ 24
11A-1 Diesel Engine Specifications ............................................ 6 Water Heater Installations .................................................... 24
11A-1 Diesel Engine Parts Identlfication ................................... .7 Fuel System ................................................................................. 25
Preparations for Initial Start-Up ................................................. 8 Diesel FueL .......................................................................... 25
Diesel FueL .......................................................................... 8
Fuel Additives ...................................................................... 25
Care
of the Fuel Supply ............................................... 8
Care
of the Fuel Supply ........................................................ 25
Fuel Additives ............................................................. 8 Fuel Lift Pump ..................................................................... 25
Engine OiL .......................................................................... 8 Fuel Filter ............................................................................. 25
Transmission Fluid .............................................................. 8 Replacing the Fuel Filter .............................................. 25
Pre-Start Inspection ............................................................. 8
Fuel Lines ............................................................................. 26
Starting/Stopping Procedure ....................................................... 9
Fuel FilterlWater Separator .................................................. 26
Electric Starting ................................................................... 9
Fuel Injection Pump ............................................................. 26
Electric Starting Procedure .......................................... 9
Fuel Injector ......................................................................... 26
Low Battery Electric Starting Procedure ..................... 9
Bleeding the Fuel
System .................................................... 26
Manual Starting (Hand Cranking) ....................................... 9
Spare Parts ............................................................................ 26
Automatic Decompression Device ............................
IO DC Electrical System ................................................................... 27
Cold Starting Device ..................................................
10 12 Volt DC Control Circuit... ............................................... 27
Manual Starting Procedure ........................................
11 Control Panel. ....................................................................... 27
Starting Under Cold Conditions ................................
12 Engine Circuit Breaker ......................................................... 27
Operating the Engine ......................................................... 12 Battery .................................................................................. 27
Initial
Start-Up Check List... ..................................... .12 Battery Care ................................................................. 27
Stopping the Engine ...........................................................
12
Checking the Service Battery ....................................... 27
Engine Break-In Procedure ....................................................... 13
Alternator Troubleshooting .................................................. 28
Engine Break-In Procedure ................................................
13
Testing the Alternator ................................................... 28
Break-In Check List. ..........................................................
13
Checking the Service Battery ....................................... 29
Transmission Break-In .......................................................
13 7A-I Marine Diesel Engine Wiring Diagram #45593 ......... 30
Daily Operation .......................................................................... 13
7 A-I Marine Diesel Engine Wiring Schematic #45593 ...... 31
Daily Operation Check-List. ...................................... 13
11A-1 Marine Diesel Engine Wiring Diagram #44542 ....... 32
Transmission ..............................................................
13 11A-l Marine Diesel Engine Wiring Schematic #44542 .... 33
Maintenance Schedule .............................................................. 14
Glow Plugs (ModeI7A-1 only) ................................................... 34
Exhaust System ......................................................................... 16
Engine Adjustments ..................................................................... 35
Description .........................................................................
16
Tightening the Cylinder Head .............................................. 35
Siphon-Break .............................................................
16
Valve Clearance Adjustment. ............................................... 35
Exhaust
System Precautions .............................................. 16
Engine Compression Test. .................................................... 35
Carbon Monoxide ......................................................
16
Testing the Fuel Injector ...................................................... .36
Carbon Monoxide Warning Decal .............................
16
Removing the Fuel Injector .......................................... 36
Carbon Monoxide Detectors ......................................
17
Fuel Injector Components ............................................ 36
Insulation ...................................................................
.17
Checking the Injection Starting Pressure ..................... 36
Overcranking .............................................................. 17
Tightness of the Valve Seat. ......................................... 37
Lubrication System .................................................................... 18
Inspecting the Spray Pattern ........................................ 37
Description .........................................................................
18
Checking the Nozzle Body and Needle Valve ............. 37
Oil Pressure ReliefValve ........................................... 18
Reassembly ................................................................... 37
Low
Oil Pressure Alarm Switch ................................ 18
Injector Installation ...................................................... 37
Engine
OiL ......................................................................... 18
Drive Belt Adjustment. ........................................................ 38
Checking the
Oil ................................................................ 18
Checking Belt Tension ................................................. 38
Changing the
OiL .............................................................. 19
Adjusting Belt Tension ................................................. 38
Removing the
Old Oil ............................................... .19
Engine Troubleshooting ............................................................... 39
Changing the
Oil Filter (Model llA-l only) ............ 19
Hurth HBW Transmission ............................................................. 42
Adding the New
Oil... ............................................... 20
Hurth HBW Transmission Troubleshooting .................................. 45
Testing the
Oil Pressure ..................................................... 20
Lay-Up and Recommissioning ..................................................... 46
Cooling System ......................................................................... 21
7A-1 & 11A-1 Torque Specifications ........................................... 48
Raw Water Cooling
System .............................................. 21
Standard Hardware/Sealants & Lubricants ................................ 49
Thermostat. ........................................................................
21
Metric Conversions ...................................................................... 50
CheckinglReplacing the Thermostat... ...................... 21
Standard and Metric Conversion Oata ........................................ 51
Coolant Temperature Switch ............................................. 21
Suggested Spare Parts Kits ......................................................... 52
Engines & Generators
1