COMMERCIAL GENERATOR 8.0'"'DPM 8.0 DP 8.0 DPR 8.5 DIV-3 ENGINE PARTS LIST. I~l WESJ'ERBEKE. r Marine Engine Products

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1 COMMERCIAL GENERATOR 8.0'"'DPM 8.0 DP 8.0 DPR 8.5 DIV-3 ENGINE PARTS LIST I~l WESJ'ERBEKE r Marine Engine Products

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3 CONTENTS PAGE Alternator Group :..." ,.,.:.....: Camshaft Group ".9 Crankcase Group... 2" 3 Cylinder Head Group... 6" 7 Engine Stop Lever Group " 2 Flywheel Group Fuel Camshaft Group " 35 Fuel Filter Group " 39 Gear Case Group :... e" 9 Governor Group " 3 \ Head Cover Group... 2 " 3 ManHold Group... 4 " '5 Main Bearing Case Group... 0 ", Nozzle Holder " 4 Nozzle Holder Group " 27 Oil Pan Group... 4" 5 Piston Crankshaft Group Gaskets Sets Speed Control Plate Group Valve Rocker Arm Group '7 Water Flang:e Group... ::... :... :.L " 33 ';: : Water Pump Group... :: " 37

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5 MODEL S.5DIY-3 S.5KW GEN-SET 3 PHASE 230 YOLT PARTS LIST PART NO DESCIPTION QUANTITY S.5KW Diesel Generator 3 Phase 230 Yolt, i J KW DIESEL GEN-SET 3 PHASE /8 Flat Washer (Zinc Plated /8-6 x 3-2 Hex Head Cap Screw (Zinc Plated /4-20 Kep Nut (Zinc Plated /4-20 x 2 Hex Head Cap Screw (Zinc Plated /4-20 x 5/8 Hex Head Cap Screw (Zinc Plated /4-20 x 3/4 Hex Head Cap Screw (Zinc Plated /4-20 x Hex Head Cap Screw (Zinc Plated /6-8 x 3/4 Hex Head Cap Screw (Zinc Plated xhi2 Hex Head Cap Screw (Zinc Plated /8-6 x 3/4 Hex Head Cap Screw (Zinc Plated '6 6 x 2 Hex Head Cap Screw (Zinc Plated /S 6 x 2-/4 Hex Head Cap Screw (Zinc Plated /S-6 x 2-/2 Hex Head Cap Screw (Zinc Plated 052SS 4-20 x 3/4 Soc Head Cap Screw Black Flat Washer (Zinc Plated /6 Standard Flat Washer (Zinc Plated #8 Medium Spring Lock Washer (Zinc Plated /4 Medium Spring Lock Washer (Zinc Plated /6 Medium Spring Lock Washer (Zinc Plated /S Medium Spring Lock Washer (Zinc Plated #8 32 Hex Nut (Zinc Plated /S 6 Hex Nut (Zinc Plated /8-24 Hex Nut (Zinc Plated #0 32 Kep Nut (Zinc Plated /6-8 Kep Nut (Zinc Plated Pipe Reducer Bushing /2 to 3/S Black /8 6 x -4 Hex Head Cap Screw Black Guard /6-S x /2 Hex Head Cap Screw (Zinc Plated x 3/ Ball Bearing KW Shield & Seal Ad~tor Union Male 3/8- Mpt 9/6 8 JIC (Aeroquip Elbow Adaptor 90 F 3/S- Mp! to 9/6 JIC (Aeroquip Swivel Ftg Hose 9/6 JIC Aeroquip # Pipe Plug 3/4- Solid. Square Head (Black Iron #8 32 x 3/4" Fillister Head Machined Screw (Steel 2303 #0 32 x 3/4- Hex Head Cap Screw (Steel

6 30379 Inlet Pipe Air Silencer & Injector Instruction Label 3048 Rad;ator Mounting Pad Fuel Hose-Filter to Engine 3067 #8-32 x 5/8 Truss Head Screw M0 Diameter x.25mm P x 20MM Long Hex Cap Screw Oil Pressure Sending Unit M6 Diameter x MM P x 65MM Long Hex Head Cap Screw Fuel Return Bracket Assembly. M F Exhuast Flange Machined Muffler Mounting Band Oil Une 5/6 0 x 4 Long Fuel Return Hose 35 0 x 5 Long Post Terminal Block Remote Oil Filter Bracket Dip Stick Dual Filter Remote Mount Base Oil Une 5/6 0 x 3-/4 Long Fan Blade Caution Decal M6 x MM P x 5SMM Long Hex Head Head Cap Screw MM x lmm P x 25MM Long Soc Head Cap Screw M-25XP Diesel Engine Alternator Mount M-25XP Alternator Adjustable Arm M-25XP Exhuast Manifold 80P /60 Grommet 3027 AC Box Air Intake Connector AC Box Top Cover Post Terminal Block V-5A Alternator AMP 3 Pole Circuit Breaker /8" 0 Cushioned Clamp AC Box End Cover Radiator 8KW Diesel PSI 2 Volt Fuel Pump F Temperature Sender Overload & Rebound Washer Magnetic Pick-Up Magnetic Pick-Up Boot Unear Actuator - Governor Controller - Governor Clevis - Actuator KW 3 Phase Pancake Jr Generator 8_50IV-3 Decal Rod End Ball Joint #0-32 Threads M Duro Metacone Mount Drip Par] & Mount Tray Control Box Mount Housing - Generator Adapter 8.5DIV IV-3 \ 3

7 30307 Generator Mount Bracket Generator Mount Spacer Actuator Mounting Bracket Fan Mount Radiator Mount Pad Radiator Mount Side Pad Mounting Rubber - Controller Radiator Shroud Radiator & Engine Mount Throttle Rod 8.50IV Cooling Fan 2 5/8" Diameter Plastic Tee 5/6" 0 Hose Water Tube Assembly Expansion Bottle Mount Hose Adapter To Manifold " 0 Molded Hose Lower Radiator Radiator Brace Fuel Filter Bracket 8.5DIV Square - Ring 2-/2" ID x 2-3/4" OD x / Remote Filter Adaptor Kit Stop Lever Plate PSI Radiator Cap Adaptor Union Male /2" Npt to 96-8 JIC (Aeroquip Elbow Adaptor 90 3/8" Mpt to 9/6-8 Male 37 Flare Stop Lever Assembly 8.50IY Fuel Filter \, Oil Filter 2 4

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9 CRANKCASE GROUP Itom Pert No. Unit Description \, A A Complete Crankcase Complete Block Orde' by Item No. 3 Expansion Plug Expansion Plug 5 Sealing Cap Sealing Cap 6 Plug 3 Plug Plug 2 Straight Pin 2 Straight Pin 2 Pipe Pin Pipe Pin 3 Cylinder Uner Cylinder Liner M 25XP O-Ring Water Cover Water Cover Gasket 2 Bolt Drain Cock Plug Oil Pump Assembly Oil Pump Packing 4 Bolt Drain Cock Oil Pump Drive Gear Feather Key Nut Claw Washer Oil Switch 3

10 OIL PAN GROUP 4

11 OIL PAN GROUP Item Pari No. UnH Description 'I / Gauge Oil Bracket Bolt Washer Plain Gauge Oil Guide Nut Gasket Oil Pan Bolt Gasket Oil Gauge Oil Pan O Ring Filter Oil Split Washer Bolt Drain Kit Bolt Washer Spring Plug , Oil Drain Plug Gasket Drain Plug Adapter (For Hose Kit Drain Plug Only Dip Stick (For Block Mtg GEN'S Washer Oil Drain Kit 50' 5

12 CYLINDER HE" 0 A GROUP \ 6

13 CYLINDEF\ HEAD GROUP \ Item I A A 7 7A Part No Unit Description 2 Engine Hook I Stud I 80lt I Nut 2 Spring Washer I Cylinder Head Assembly Cyfinder Head Assembly M 25XP Order by Item No. 6 5 Sealing Cap Sealing Cap 2 Plug 3 Inlet Valve Guide 3 Exhaust Valve Guide 2 Cylinder Head 80t 2 Cylinder Head Stud 2 Cylinder Head Nut Cylinder Head Gasket Cylinder Head Gasket M-25XP AR Cylinder Head Gasket Shim Cylinder Head Gasket Shim M-25XP 7

14 GEAR CASE GROUP.., (~ f,\! \.!.J 4 I... '\.~ 8

15 GEAR CASE GROUP Item Pan No. Unit Description Gear Case Assembly Order by Item No. 2 Plug 3 O-Ring Stan Spring Pin Gear Case Gasket 7 Bolt 5 Bolt Boll Boll Oil Seal Relief Valve Assembly Order by Item No. 4 O-Ring Gasket W.P. MTG. 4 Stud 4 NUl 4 Spring Washer '\ 9

16 MAIN BEARING CASE GROUP 0

17 MAIN BEARING CASE GROUP Item Part No. Unit Description 'I / I Main Bearing Case Asse'Tlbly 2 Order by Item No. I 3 Order by Item No. I Bearing Case Bolt e Bearing Case Washer I Bearing Case Gasket I Bearing Case Cover I Bearing Case Cover, Oversize I Bearing Case Cover Gasket Bolt Bolt I I I Oil Seal I Oil Seal, Oversize I Main Bearing 2 Case Assembly 3 Order by Item No. 2 4 Order by Item No Bearing Case Bolt Bearing Case Washer I Main Bearing 3 Case Assembly 8 Order by Item No. I 7 9 Order by Item No. I I Sheeve Wear Ring I'

18 HEAD COVER GROUP 2

19 HEAD COVER GROUP Item Pan No. Unit Description Cylinder Head Cover Head Cover Gasket Cap Nut Gasket Decompression Hole Cover Cover Gasket lt Oil Filler Plug O Ring Decompression Shaft Compression Bolt Nut O Ring Decompression Wire Holder lt Decompression Spring lt Spring Washer reather Element Plate reather Element 2 Plate reather Element reather Oil Shield Screw Breather Elbow Pipe Clamp - Hose , Breather Hose Lever Shaft 3

20 MANIFOLD GROUP \. ~.. 4

21 MANIFOLD GROUP Item Pan No. Unit Description Inlel Manifold Gaskel Inlet Manifold 2 Gaskel Inle' Manifold 2 4 Boll Bolt Boll 2 Washer Spring 3 Gaskel Exhaust Mar.ifold 6 Studs Manifold 6 NUl Radiator Cap - 4 P.S.I. Manifold - Exhausl Plug Pipe / \, 5

22 VALVE ROCKER ARM GROUP \ 6

23 VALVE ROCKER ARM GROUP Item Part No. Unit Description Inlet Valve Exhaust Valve Valve Spring Valve Spring Retainer Valve Spring Collet Valve Stem Seal Valve Cap Rocker Arm Shaft Assembly 9 Order by Item No Set Screw Rocker Arm Bracket Stud Nut ~ Plain Washer Set Screw Rocker Arm Washer Rocker Arm Spring External Cir-Clip Rocker Arm Assembly 20 Order by Item No Rocker Arm Bushing Adjusting Screw Nut 7

24 CAMSHAFT GROUP \ },~ \J 8

25 CAMSHAFT Gi=lOUP Item Pa" No. Unit Description B BO 2994Bl Tappet 6 Push Rod Camshaft Assembly Campshaft Order by Item No. 3 2 Blind Plug Camshaft Gear Feather Key Campshaft Stopper External Cir-Clip 2 Bolt Idler Gear Assembly Order by Item No. 2 Idler Gear Bushing Idler Gear Collar Idler Gear Collar 2 External Cir-Clip Idler Gear Shaft 3 Bolt 2 Spring Washer \ 9

26 ENGINE STOP LEVER GROUP \ ( ~ ~~ \CJ \.,;---- 0"---..J --",',/ (\ -,/' cc~ -" \j ~ '\ ' i( I I (\ \ \ " II ". 20

27 ENGINE STOP LEVER GROUP \ J Item Part No. Unit Description Cover Pump Gasket Bolt Idling Apparatus Assembly Adjusting Bolt Assembly Order by Item No.5 Adjusting Bolt Order by Item No.5 Spring Nut Cap Nut Gasket 3047 Cap Engine Stop Lever Assembly Injection Pump Cover Order by Item No. 27 Shaft Lever Order by Item No. 27 Engine Stop Lever O Ring Spring Pin Spring Stopper Nut Non Sale Wire Non Sale Lead Sealing Breather Gasket Bolt Belt Wire Helder Lever Shaft Assembly Belt 2

28 PISTON, CRANKSHAFT GROUP \ a~-~' \ e'-----<> red >:::~JJ_---_c, \ 22

29 PISTON, CRANKSHAFT GROUP Item Pa" No. Unit Description Piston. Std. la Piston Standard M-25XP Piston A Piston Ring Assembly M 25XP Piston Ring Assembly Piston Pin Piston Pin Cir-Clip Connecting Rod Assembly 6 Order by Item No Piston Pin Bushing Connecting Rod Bolt Rod Bearing Std Rod Bearings..2 mm Rod Bearings. 4 mm Crankshaft Assembly loa Crankshaft Assembly M-25XP Order by Item No. 0 2 " Pin Plug Crankshaft Gear Feather Key Crankshaft Oil Slinger Crankshaft Collar O-Ring Bearing Bearing.02 mm Oversize Bearing.04 mm Oversize Bearing Metal Main Bearing,.2 mm Main Bearing..4 mm Side Metal Side Metal Crankshaft Sleeve Bearing Oil Seal 23

30 FLYWHEEL GROUP \, 2 24

31 FLYWHEEL GROUP Item Pan No. Unit Description Assembly Flywheel Bolt Flywheel Washer Flywheel Washer 2 Flywheel Bolt Spring Washer Pin Straight Rear End Plate Washer Spring Bolt Assembly Starter Solenoid wl.tuds 2A Solenoid w/screws 25

32 NOZZLE HOLDER GROUP \ i 26

33 NOZZLE HOLDeR GROUP Item Pan No. Unit Description Nozzle Holder Assembly No Nozzle Holder Assembly No Gasket Injection Pipe No Injection Pipe No Injection Pipe No Pipe Clamp No Pipe Clamp No Screw. with Washer Glow Plug Glow Plug Code Fuel Overflow Hose 2A Fuel Retum Assy-Metal Pipe Clip Fuel Retum Hose Mounting Bracket Fuel Retum Connector Fuel Retum Kit 27

34 SPEED CONTROL PLATE GROUP \ j ~ -CD f--,;mfo'------icd r---qf ~~ ~---@ '~I \ 28

35 SPEED CONTROL PLATE GROUP Item Pan No. Unit Description 3050 Adjusting Bolt Nut Gasket Cap Nut Cap Speed Control Lever Feather Key O Ring Plain Washer Nut Friction Plate Speed Control Plate 29S!545 Control Plate Gasket lt Stud Nut Spring Washer Stopper Non Sale Wire Non Sale Lead Sealing \ 29

36 GOVERNOR GROUP / 30

37 ELECTRONIC GOJERNOR - f'\tijor fu.ponents & PART Nil'IBERS Typical Wiring e Diagram.,.. -See color code on. tront of 90ntroller.... o CONTROLER "" PN.30300B \ I 2 VDe Supply Linear "Actuator PN;,! ' SENSOR. PNi!

38 GOVERNOR GROUP hem Pan No Unit Description Stan Spring Governor Spring Govemor Spring 2 Governor Lever Assembly Fork Lever Assembly Fork Comp Lever Fork Lever Order by Item No.6 Order by Item No. 6 Order by Item No. 6 Order by Item No.6 Order by Item No.6 Fork Lever 2 Fork Lever Shaft Bolt 2 Spring Washer Fork Lever Holder Bolt 2 Bolt \ i 3

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40 WATER FLANGE GROUP CDr-~ I j 'I.. 32

41 WATER FLANGE GROUP Item Pert No. Unit Description Drain Cock 8 MPT Thermostat Housing Temperature Sender Gasket Thermostat Housing Thermostat 60" Pipe Hose Clamp (USA Hose Thermostat Mounting Bolts (6mm x 50mm Bolt Nut Spring Washer Flange Water Gasket Water Range Stud Hose Clamp No Wire Flex Hose 7/8.0. x 27-/2 Lg. e Hose Connector 3/4 MPT to 7/8.0. Hose ' Wire Fie.. Hose 7/8.0. x 7" Lg. [;zo Hose Connector EL-90 3/4 MPT to 7/8 Hose /8 x 5/8 Hose Adapter (Heater By Pass 33

42 FUEL CAMSHAFT GROUP ~--.,.. M-25 EARLY MODEL J 34

43 FUEL CAMSHAFT GROUP liem Part No. Unil Descriplion 3009 Pump Injection Shim Pump Injection Bolt Stud Nut Washer Spring Camshaft Fuel Camshaft Fuel Bearing Ball Gear Injection Key Feather Sleeve Governor Cir-Clip Case Governor Ball Ball Cir-Clip Ball Cir-Clip External Bearing Ball Cir-Clip External Stopper Fuel Camshaft Bolt Lock Washer Stud Packing Fuel Pump Cover Washer Spring Nut Gasket 8eed Screw Bleed Screw 30A Bleed Screw Adaptor (M-2SXP Gasket Screw S0 Bleed Valve Assy. :l Fuel Inlet Joint 35

44 WATER PUMP. GROUP,,"" ~~ I, \ \ /' \ 36

45 WATER PUMP GROUP Item Pen No. Unit Description Water Pump Assembly 2 Order by Item No Water Pump Glange Bearing Mechanical Seal Assembly S 30 SO Water Pump Impeller Water Return Pipe Water Pump Gasket Stud Nut Spring Washer Fan Drive Pulley Feather Key Crankshaft Nut Crankshaft Washer. S Pulley Fan Bolt Fan Washer Belt 37

46 FUEL FILTER GROUP 38

47 FUEL FILTER GROUP hem Pan No. Unit Description Cap Screw Flat Washer Fuel Filter Cover Washer Lock Nut Bracket Fuel Filter Clamp Adjustable Fuel Hose Electric Fuel Pump Fuel Filter Element Bleed Screw O-Ring Fuel Filter Assembly Filter & GskL Gasket Cap \ 39

48 NOZZLE HOLDER 8 \ t:ref.no. 40

49 NOZZLE HOLDER Item Part No. Unit Description Nozzle Holder Assembly Nozzle Holder Assembly Nut Eye Joint Eye Joint Plain Washer 7 Order by Item No Adjusting Washer Nozzle Spring Distance Piece 3052 Push Rod Nozzle Nut Nozzle Piece NOT!:: Item No's Available in Sizes from.00 to.95 in.05 Increments. 4

50 ALTERNATOR MOUNT 0 0-." ~ /'..,~ -..." " " "<' erl 4." 2 46

51 ALTERNATOR MOUNT Item Pa" No. Unit Description /8-6 x 3-2 Hex HD Cap Screw / 6-8 x 3/4 Hex HD Cap Screw / 6-8 x Hex HD Cap Screw / 6 FL T Washer /6 Med SPR Lock Washer /8 Med SPR Lock Washer /8-6 Hex Nut Hose Clamp MMIDxll.8MMODx/6MM SPR Lock Washer MM DIA x 97 MM LG Stud Elbow 90 3/ ,.. ID x 90 Model Hose Alternator Mount Alternator ADJ Arm MM x MM x 20 MM LF Hex HD Cap Screw 6' V-8elt 47

52 EXfWJST l'wlifold 8ID GROOP. 48

53 DJ-iA.UST r-ia.~ifold HID GROUP liem Pari No. Unit Description , Gasket - Exhaust Flange 30769, Exhaust Flange 25 de.gle.e Stud 3/8 '6& 24 x ' 7' Hex Nut 3/ , Hose Connector 3/4 MPT 90de.gLe.e Hose Clamp No , Stud 3/8-'6 & 24 x 2 5/8 I \ } 49

54 # " X 20" EXHAUST INSULATION WRAP " THICK # " X li6" X 25FT INSULATION WRAP Top Gasket Set Complete Gasket Set , 63

55 ... CUT7 Ht r I. ", VR~ VOl. TAGE REGULIITOR ;03462Z. ''''---/ ,-- ~~~~~il~~~=l5:---- I REMOTe PANELuOPTION I #-30Z8S ~," lj., ~...,..,!~ r~====]~~!~~~"j~~ J' OIL PK.:lO:'. t03siz3 I tf"'30t40 iz;:. i : ;: J LiD 8.C. VOL 7 It!!! '~,r.;/..r~ r2.~iihp FIlla 4"0,39Z4' ;.!::!rr.!.!i :O~D'~ CIRCUIT 8R'~I ~O'Z49. I~I '" Il~l"". I- /'~J6f+JU33" F 4 nvaa. "30Z90Z. "' IAcwnOR I R.C. GENERATOR :a PHASe '30300 purl'" PU~"" # ,, ~ /!ONrROLUR f..8!!!lej o -l'~" ~wj rn "",,,,,--,,:!!,u"'c!s : MAA"'-TlC@ el!!k~lip 'Z99l.B IQ...d...S. TERMINAL 8toCIL 3-5" AMP. fuse :t OIL PRESS. ~. SCNDING UNt.,. "l30b8 T VATER TEMP. e! UNP "Z9906(, INA UNIt., ; "C~+J- I N GWT ~o... PLuG switeh S"fIl.~.r"TtJP ' :ti.:!!:!l Br ~ ~ ~ F0 "'" ~r' G.l' 00...s:I ~ (p;j fi rli-,,' <<R,U" S_gp BR""R ~ l(.;l -7 ~~ ~, \ <l ~ lib " OIL PRESSURE RELA... #30049" SHUT OOWN JtEUY '30049& I~~;::;.,"'RY (sa: J I ~ ~ L~' I- 2G'~,H 0 SIr COMMON TtAMINAt.. SLOC/( t:=k\l;\iis r m'ip,~"" Ttl 6W. rc.ri 3 Dz.Zl 0... ~c;.~. SUPPLIE,D nem II'I(Q'O otscftiploii ~", PMIOO ',' ~ -... ""'.~ IY 000tE <0. fviish(s.f:!...ll PAM ~.~'" ~, ~ '... 00' /l,;8 '... I~.'IM "'~_I..,. AtFlflEJIC& -... _ft".'''....," :PoIJuI«H.lBEn ~ -., c

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UNIVERSAL ATOMIC DIESEL MODEL (16 H.P.) PARTS MANUAL. Universal Motors

UNIVERSAL ATOMIC DIESEL MODEL 20 5416 (16 H.P.) PARTS MANUAL Universal Motors This copy of the Universal Motors Owners Manual has been re-created using images computer scanned from a manual rather than