Universal M3-20A, M-25XPA, M-25XPB, M-35A, M-35B Operator's Manual
...
• •
OPERATORS
MARINE
M3·20A
MANUAL
Unlvarsal
DIESEL
M3·20B
M·35A
PUBUCATION 200494
1
ST
EDITION I
M·25XPA
M·35B
APRIL
ENGINES
M·25XPB
1997
WESTERBEKE CORPORATION· AV
AVON,
N
---
MA
02322 • TEL: (508) 588
"'~~~
MMA
M~mMr
I~
ON
INDUSTRIAL PARK
-n
oo • FAX: (508) 559-
N
aJ;
olllll
Marin
~
Manuf
octurrrs Association
93
23
OPERATORS
MANUAL
Univarsal
MARINE
DIESEL
ENGINES
M3-20A M3-20B
M-25XPA
M-25XPB
M-35A
M-35B
PUBLICATION 200494
1
ST
EDITION I
APRIL
1997
I~
WESTERBEKE
CORPORATION·
AVON INOUSTRIAL PARK
AVON,
MA
02322 • TEL: (508) 588-7700 • FAX: (508) 559-9323
....
iIIr~~
NMMA
Member
Nalional Marine Maflujacluren;Assocullion
...,.".,..,
CALIFORNIA
PROPOSmON
Diesel engine exhaust and some
of
its
constituents are known
the State
of
California
cancer, birth defects, and other
reproductive harm.
65
WARNING
to
to
cause
SAFETY
INSTRUCTIONS
UNIVERSAL
DIESEL
ENGINES
INTRODUCTION
Rem! this safety manlllll carefully. Most accidents are caused
IJy
failure to follow juruiJlmenJal rules
Know
when
dangerous conditions erist
necessary
and
The
the
PREVENT
A
nile
power.
• Do not operate this machinery without electrical
• Shut
•
• Make sure your clothing and skin are dry, not damp
• Remove wristwatch and all jewelry when working
• Do not connect utility shore power to vessel's
• Electrical shock results from handling a charged capacitor.
precautions to protect yourself, your
your
machinery.
foUuwing safety instructions are in compliance with
American
WARNING:
enclosures
equipment.
Use
equipment.
(particularly shoes) when handling electrical equipment.
electrical equipment.
circuits, except through a ship-to-shore double throw
transfer
result if this procedure is not followed.
Discharge capacitor by shorting terminals together.
Boat
and
Yacht Council (
ELECTRIC
engine
is
Lethal
roltage
and
off
electrical power before accessing electrical
insulated
switch. Damage
SHOCK
Do
nat
running,
covers
mats
whenever
touch
IX
nen
is present
in
place
to
vessel's AC ge
and
ABYC)
AC
electrical
connected
at
these
.
working
precautions.
and
take the
personnel,
staruiJlrtis.
CI1IIIIIiCtions
to
shore
connections!
on
electrical
AC
nerator
on
may
PREVENT
A
exhaust
vert
• Always check the engine coolant level at the coolant
recovery
I A
• In case
before touching the engine
PREVENT
I A
• Prevent flash fires. Do not smoke
sparks
pump, or
vapors. Use a suitable container to catch all fuel when
removing
•
Do
arrester
death.
• Do n
Backfire can cause severe
•
Do
fuel system. Keep the compartment and the engine/gener-
ator
fire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will bum.
BURNS -HOT
WARNING:
system
hat!
WARNING:
of
Do
components. A running
tank.
Steam
an engine overheat, allow the engine to cool
not
ENGINE
much
hat
engine
can
cause
injury
or
checking the coolant.
BURNS -ARE
WARNING:
to
not operate with the
removed. Backfire
ot
operate
not
smoke
clean
Steam
occur
near
other
potential sources
the
fuel
with
or
perm
and
free
can
cause
injury
or
the
carburetor, fuel
of
line, carburetor, or
Coast
Guard Approved flame
can
cause severe
the
air
cieaner/siJencer
injury
or
it
flames
or
sparks
of
debris
to
minimize
permit flames or
spilled fuel
fuel
death
parts
engine
or
death!
or
death!
line,
filter,
filters.
injury
removed.
.
to
occur
the
chances of
or
gets
or
fuel
near
fuel
or
the
PREVENT
A
injury
BURNS -EXPlOSION
WARNING:
Dr
death!
Explosions
from
fuel
raptllS
can
cause
SAFETY
INSTRUCTIONS
PREVENT
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling.
after fueling. Check below for fumes/vapor before running
the blower. Run the blower for four minutes before starting your engine.
• All
handling and storing fuels. Store fuel in a well-ventilated
area away from spark-producing equipment and
reach
• 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.
sources
Ensure proper ventilation exists when servicing the fuel
system
• Do not alter
•
Be
•
Be
free
• Make sure a fire extinguisher is installed nearby
properly maintained.
Extinguisher.; rated
for all applications encountered in
ACCIDENTAL
A
·
ar
death!
I
• Disconnect the battery cables before servicing the engine!
generator.
it last.
• Make certain all personnel are clear
starting.
BURNS -EXPLOSION
fuel
vapor.; are highly explosive. Use extreme care when
of
children.
DO NOT allow any smoking, open flames,
of
fire
near
the fuel system
.
or
modify the fuel system.
sure all fuel supplies have a positive shutoff valve.
certain fuel line firtings are adequately tightened and
of
leaks.
Be
familiar with its proper use.
ABC
by the NFPA are appropriate
(continued)
Open and ventilate cabin
out
of
or
other
or
engine when servicing.
and
is
this environmenL
STARTING
WARNING:
Accidetrtal
Remove
the
slaTting
negative
can
cause
lead
first
and
of
the engine before
iajuty
reconnect
the
BATTERY
A
·
ardeath!
I
• Do not smoke
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which
arcing
equipment
seJVicing.
• Never connect the negative
tive
test the battery condition by shorting the terminals
together. Sparks could ignite battery
Ventilate
accumulation
disturb the battery charger connections
being cbarged.
•
Avoid
bums
wristwatch, rings,
the battery.
• Always tum the battery cbarger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY
A
sereTe
• When servicing the battery
level,
tion. Batteries contain sulfuric acid which is destructive.
it
comes
with water. Acid may splash on tbe skin
inadvertently when remo ving electrolyte caps.
EXPLOSION
WARNING:
or
(+) connection terminal
contacting
or
sparks
Battery
or
allow an open flame near the battery
by lit tobacco products. Shut
in
the
vicinity
any
compartment
of
explosive gases. To avoid sparks, do not
the
terminals
that
could cause
and
any other jewelry before handling
ACID
WARNING:
iajury
wear
rubber
in
contact
Sulphuric
/If
death!
gloves, a
with
explasian
to
can
cause
can
be ignited by electrical
off
prevent
(-)
electrical
battery cable to the posi-
of
the starter solenoid. Do not
gases
containing
acid
or
checking the electrolyte
rubber
your
skin,
with
tools, etc
an
explosion.
in
batteries
apron, and
wash
baneries
while the battery is
it
or
injury
all electrical
arcing
during
or
fuel vapor.;.
to
prevent
.,
to
prevent
Remove
can
cause
eye
protec-
off
at
once
into the eyes
If
• Make certain all covers, guards, and hatches are reinstalled before starting the engine.
ii
SAFETY
INSTRUCTIONS
TOXIC
I A
• Ensure that the exhaust system is adequate to expel gases
• Be
•
•
• Do not use copper tubing in diesel exhaust systems. Diesel
• Do not install exhaust outlet where exhaust can be drawn
• Although diesel engine exhaust
EXHAUST
WARNING:
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
exhaust pipe nipple.
sure
the
In
addition
install a carbon
builder
or
For
additional informati
tional information
A
WARNING:
odOfless
nausea
gas_
Of
death!
fumes can rapidly destroy copper tubing
tems. Exhaust sulfur
tubing resulting in exhaust/water leakage.
through portholes, vents,
exhaust
enter tbe exhaust discharge outlet and close
flow
exhaust fumes from gasoline engines, carbon monoxide
gas is present
toms
are:
discharge
of
exhaust. Avoid overloading the craft.
or signs
Vomiting
GASES
Cal'llon
to
the
manifold,
unit
and
to
routine
monoxide
dealer for installation
Carbon
Inhalation
in
diesel exhaust fumes. Some
of
carbon monoxide inhalation
monoxide
water
its
surroundings
inspection
detector. Consult
on
refer to
on
Carbon Monoxide).
monoxide
produces
causes
rapid deterioration
or
air conditioners.
outlet is
near
(CO)
is a
deadly
injection
of
of
the
gases
elbow,
are
well
ventilated.
the
exhaust
your
approved detectors.
ABYC
T-22 (educa-
(CO)
is
an
invisible
flu-like
symptDms,
in
exhaust sys-
If
waterline, water
or
restrict the
are not as toxic
of
or
and
system,
boat
of
copper
the engine
the symp-
poisoning
gas!
could
as
AVOID
·
I
• Do
• Do not wear loose clothing or jewelry when servicing
• Make sure all attaching hardware is properly tightened.
• Do not check fluid levels
• Stay clear
HAZARDOUS
· loss!
I
• Never
•
• Do not run engines for long periods with their enclosures
MOVING
A
WARNING:
or
death!
not
service
arises
in which it is absolutely necessary to make operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, neckJaces
moving parts.
Keep protective shields and guards in their respective
places
at all times.
the
engine is
when
the
be caught in these rotating parts.
PARTS
Rotating
the
or
operating.
of
the drive shaft and the transmission coupling
engine is
parts
engine while
bracelets
running; hair
that
or
the drive belt's tension while
can
cause
injury
it
is
running
compone~ts.
could
and
be
caught
clothing
. If a
can
in
situation
easily
NOISE
A
WARNING:
operate
Do
not run an engine with the air intake (silencer)
removed.
OpeD.
A
WARNING:
are
mentally
High
an
engine
Do
or
physically
noise
/ere/s
without
not
work
incapacitated
can
its
muffler
on
machinery
cause
installed
when
by
fatigue!
hearing
you
.
Dizziness
in
Throbbing
Muscular twitching
Intense headache
Weakness and sleepiness
temples
OPERATORS
Many
of
in
your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain
procedures.
MANUAL
the preceding safety tips and warnings are repeated
your
equipment, and follow all safety
iii
SAFETY
RECOMMENDED
INSTALlATION
INSTRUCTIONS
CODES
AND
SAfETY
STANDARDS
ENGINE
Preparations to install an engine should begin with a thor-
ough
(ABYC)
sources including the USCG
Sections
All installations must
Regulations (FCR).
INSTALlATIONS
examination
standards.
of
H-2 Ventilation
P-l
P-4 Inboard engines
E-9
of
the
American
These
the
ABYC
standards
Exhaust systems
DC
Electrical systems
comply
Boat
and
Yacht
Council
standards are a combination
and
the NFPA.
of
particular interest are:
with the Federal Code
of
of
's
ABYC,
INSTAWNG
Read the following
for safety codes
tions when installing
ABYC
"Safety Standards for Small Craft"
Order From:
NFPA (Na
"Fire
Order From:
USCG
"USCG
Order From:
NFPA
AND
USCG
PUBUCATIONS
DIESEL
(American Boat and Yacht Council)
ABYC
15
East
26th Street
New York,
Protection Standard for Motor Craft"
NFPA
1 Banerymarch Park
P.O.
Quincy.
U.S. Government Printing Office
Washington, D.
NY
ti
onal Fire Protection Association)
Box 9101
MA
02269-9101
(United States
33CFR183"
ENGINES
ABYC
. NFPA
and
standards. Follow their recommenda-
your
UNIVERSAL
10010
Coast
Guard)
C.
20404
and
USCG
engine
FOR
publications
TABLE
OF
CONTENTS
Introduction
.......................................................................
2
Description ............ . ...................................... 20
Warranty
Procedures
..
__
............................................
__
..
2
Alternator Troubleshooting .................................
20
Typical
Customer
Identification Card .......................... 2
Checking
for Propcr Voltage ..............................
.20
Product Software .......... _ ........... _ ........... _ ....................... 2
Engine
12
Volt
DC
Control Circuit ............................
21
Notes, Cautions
and
Warnings ..................................... 2
Drivc Belt Adjustmcnt ..............................................
.21
Serial Number Location ............................................... 3
Battery Care ...............................................................
21
Understanding the Diesel Engine ................................. 3
Glow
Plugs ................................................................
21
Ordering
Parts .............................................................. 3
Wiring
Diagram
..............................................................
.22
Spares and Accessories ................................................ 3
Wiring
Schematic
...........................................................
23
Protecting Your Investment .......................................... 3
Engine
Adjustments
......................................................
.24
Admiral
Control
Panel
....................................................
.4
Throttle
and
Stop
Assembly ....................................... 24
Captain
Control
Panel
....................................................
.5
Diesel
Fuel,
Engine
Dil
and
Engine
Coolant
...............
6
Diesel Fuel ................................................................... 6
Valve
Clearance
.......................................................... 24
Water
Heater
Connections
............................................
25
Water Heater Installations .......................................... 25
Care
of
the Fuel Supply ........................................ 6
Engine
Troubleshooting
................................................
.26
Engine
Oil ............................................................. 6
Control
Panel
Troubleshooting
....................................
28
Engine Coolant ............................................................. 6 Manual Starter Disconnect (Toggle Switches) .......... 28
Coolant and Recovery Tank ......................................... 6
Troubleshooting
Water Temperature
and
Preparations
for
Initial
Start-Up
...................................
7
Prestart Inspection ........................................................ 7
Oil Pressure
Gauges
................................................... 28
Tachometer
Troubleshooting
........................................
29
StartingJStopping
Procedure
..........................................
8
Starting Procedure ........................................................ 8
Preheat .......................................................................... 8
Tachometer/Hourmeter
............................................... 29
Hourmeter
Inoperative ........................................ 29
Tachometer
Inoperative ...................................... .29
Start .............................................................................. 8
Tachometer
Sticking ........................................... 29
Starting
Under
Cold
Conditions ................................... 8
Stopping Procedure ...................................................... 8
Break-In
Procedure
..........................................................
9
Calibration .......................................................... 29
HBW
Transmission
.........................................................
.30
Initial
Operation
.........................................................
30
The
First
50
Hours ....................................................... 9
Gearbox
Operation
.....................................................
30
The
Daily
Routine
...........................................................
10
Check
List .................................................................. 1 0
Start
Your Engine ....................................................... I 0
Maintenance
Schedule
..................................................
11
When
Under
Sailor
Being Towed .............................
30
Locking
the Prop .......................................................
.30
Control Cables ...........................................................
.30
Maintenance ...............................................................
31
Transmission
Fluid ..............................................
31
Engine
Cooling
Circuit...
................................................
13
Description ................................................................. 13
To
Refill With Coolan!... .....................................
13
Capacity
..............................................................
31
Fluid
Change
......................................................
.31
Checking
the Bowdin Cable
or
Rod Linkage .....
31
Thermostat .................................................................. 14
Propeller
Shaft Alignment ................................
.31
To Replace the Thermostat ................................. 14
Lay-Up/Winterize ...............................................
.31
Raw Water
Cooling
Circuit ........................................ 14
Raw Water
Pump
................................................ 14
Changing the Raw Water
Impeller. ..................... 15
Heat Exchanger ...................................................
15
Zinc Anode .......................................................... 15
Engine
Oil
Change
..........................................................
16
Lay-Up
and
Recommissioning
......................................
32
Lay-Up
.......................................................................
32
Propeller
Shaft
Coupling
........................................... .32
Fresh Water
Cooling
System ......................................
32
Lubrication
System
................................................... .32
Fuel
System
................................................................
32
Drain the
Sump
.......................................................... 16
Raw Water Circuit ..................................................... .32
Replacing the
Oil Filter.. ..................................... 16
Intake Manifold ......................................................... .32
Refill the Oil
Sump
............................................. 16
Starter Motor .............................................................. 33
Remote
Oil
Filter
............................................................
17
Cylinder
Lubrication ................................................. 33
Installation .................................................................. 17
Transmission
.............................................................. 33
Fuel
System
....................................................................
18
Fuel Filters ................................................................ 18
Fuel Water
Separator .................................................. 18
Fuel Additivcs ............................................................ 19
Spares
......................................................................... 33
Batteries
...................................................................... 33
Recommissioning
....................................................... 33
Specifications
.................................................................
34
Spares ......................................................................... 19
Parts
Identification
.......................................................
.36
Primary (Blecding/The Fuel System) ........................ 19
Metric
Conversions...................................... . .........
37
Air Cleaner/Silencer ............................................ 19
Standard
Hardware
Torques
....................... . .........
3R
DC
Electrical
System
.................................................
20
Spare
Parts
...................................................................
.39
1
INTRODUCTION
These new high perfonnance
UNIVERSAL
marine diesel
engines are a product of
UNIVERSAL/WESTERBEKE's
design technology and their
combined
years
of
experience
manufacturing quality marine engines. We take great pride in
the superior durability and dependable performance
of
our
marine engines.
Thank
you for selecting UNIVERSAL.
In
order to
get
the full use and benefit from your engine,
it
is
important that you operate and maintain it correctly.
This
manual
is
designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout
An
extensive network
of
UNIVERSAL!
\VESTERBEKE distributors. dealers and service centers are
available worldwide. Should your
engine
require servicing,
contact your nearest dealer for assistance.
This
is
your operators manual. A Parts Catalog
is
also
provided and a Technical Manual
is
available from
your
UNIVERSAL dealer. Also,
if
you are planning to instal! this
equipment, contact your
UNIVERSAL
dealer for
UNIVERSAL'S installation manual.
WARRANTY
PROCEDURES
Your
UNIVERSAL
Warranty
is
included
in
a separate folder.
If
you have
not
received a
customer
identification card regis-
tering your warranty
60 days after submitting the warranty
registration
fonn,
please contact the factory in writing with
model information, including the unit's serial number and
commission date.
Customer Identification
UNIVERSAL OWNER
MAIN
STREET
HOMETOWN, USA
Model
M-35B Sec
#XXXX-D704
Expires
7/20/97
TYPICAL
CUSTOMER
IDENTIFICATION
CARD
The
UNIVERSAL
serial
number
is
an alphanumeric
number that
can
assist
in
determining the date
of
manufacture
of your
UNIVERSAL
engine.
The
first character after the
dash
indicates the decade [A=1960s, B=1970s, C=1980s,
D:::::!
990s,
etc.:.],
the second
character
represents the
year
in
the decade, and the fourth and fifth numbers represent the
month
of
manufacture.
2
PRODUCT
SOFTWARE
Product software (tech data,
parts
lists, manuals, hrochurcs
and
catalogs) provided
from
sources
other
than
liNTVERSAL
arc
not
within UNIVERSAL'S CONTROL
UNIVERSAL
CANNOT
BE
RESPONSIBLE
FOR
THE
CONTENT
OF
SUCH
SOFTWARE,
MAKES
NO
WAR-
RANTIES
OR
REPRESENTATIONS
WlTH
RESPECT
THERETO,
INCLUDING ACCURACY,
TIMELINESS
OR
COMPLETENESS
THEREOF
AND
WILL
IN
NO
EVENT
BE
LIABLE
FOR
ANY
TYPE
OF
DAMAGE
OR
INJURY
INCURRED
IN
CONNECTION
WITH
OR
ARISING OUT
OF
THE
FURNISHING
OR USE
OF
SUCH
SOFTWARE.
UNIVERSAL
customers should also keep in mind the time
span between printings
of
UNIVERSAL product software
and the unavoidable existence
of
earlier
UNIVERSAL
manuals. In summation, product software provided with
UNNERSAL
products, whether from
UNIVERSAL
or other
suppliers, must not and cannot be
relied upon exclusively
as
the definitive authority
on
the respective product. It not only
makes good sense but
is
imperative that appropriate represen-
tatives
of
UNNERSAL or the supplier in question be con-
sulted to
detennine
the accuracy and currentness
of
the
product software being consulted
by
the customer.
NOTES,
CAUTIONS
AND
WARNINGS
As
this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of
your marine
engine, critical information will be highlighted by
NOTES.
CAUTIONS,
and WARNINGS. An explanation follows:
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,
AWARNING:
Procedures,
which
if
not
properly
fol-
lowed,
can
result in
personal
injury or
loss
of
life,
INTRODUCTION
SERIAL
NUMBER
LOCATION
An identification nameplate that displays the engine model
number and engine serial number
is
mounted on the side
of
the
engine's manifold. Take the time to enter this information
on
the
blank decal provided below. This will provide a quick
reference when seeking technical information and/or ordering
parts.
• MODE'-
SPEC
SER.NO. •
UNDERSTANDING
THE
DIESEL
ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism
is
essentially
the
same. The cylinders
are arranged above a closed crankcase; the crankshaft
is
of
the same general type as that
of
a gasoline engine, and the
diesel engine has the same types
of
valves, camshaft, pistons,
connecting rods and lubricating system.
To
a great extent, a diesel engine requires the same preven-
tive maintenance
as
a gasoline engine. Most important are
proper ventilation and proper maintenance
of
the fuel, lubri-
cating and cooling systems. Replacement
of
fuel and lubri-
cating filter elements
at
the time periods specified and
frequent checking
for
contamination (water, sediment, etc.)
in
the
fuel
system are essentiaL Also important
is
the consistent
usc
of
a brand
of
high detergent diesel lubrication
oil
designed specifically
for
diesel engines.
The diesel engine does differ from
the
gasoline engine, how-
ever,
in
its method
of
handling and firing
of
fuel. The carbu-
retor and ignition systems are done away with and
in
their
place
is
a single component (the
fuel
injection pump) which
pcrfonns the function
of
both.
3
ORDERING
PARTS
Whenever replacement parts are needed, always provide the
engine model number and engine serial number
a,
they
appear
on
the
silver and black identification nameplate
located
on
the manifold.
You
must provide
us
with
this infor-
mation so we can identify your engine.
In
addition, include a
complete part description and part number
for
each part
needed (see the separately furnished
Parts Catalog). Also
insist upon UNIVERSAUWESTERBEKE packaged parts
because will
fit
or generic parts are frequently not made
to
the same specifications as original equipment.
SPARES
AND
ACCESSORIES.
Certain spares will be needed
to
support and maintain
your
UNIVERSAL marine engine. Your UNIVERSAU
WESTERBEKE dealer will assist you
in
preparing
an
on
board inventory
of
spare parts. See the UNIVERSAL SPARE
PARTS page
in
this manual for a suggested
list.
PROTECTING
YOUR
INVESTMENT
Care at
the
factory during assembly and thorough testing
have resulted
in
a UNIVERSAL diesel engine capable
of
many thousands
of
hours
of
dependable service. However the
manufacturer cannot control how
or
where the engine is
installed
in
the vessel
or
the manner
in
which
the
unit
is
operated and serviced
in
the
field. This
is
up
to the
buyer/owner-operator.
NOTE:
Six important sleps to ensure long engine bfe:
o Proper engine installation and alignment.
o An efficient well-designed exhaust system that includes
an anti-siphon break
to
prevent water from entering the
engine.
o Changing the engine oil and oil filters every
JOO
operating
hours.
o Proper maintenance
of
all
engine components according
to the maintenance schedule
in
this manual.
o Use clean. tiltered diesel fucl.
o Winterize your engine according to the LAY-UP AND
RECOMMISSIONING section
in
this manual.
ADMIRAL
CONTROL
PANEL
UNIVERSAL
offers two optional panels. Refer to the
instruction page that applies to the panel you purchased.
ADMIRAL
PANEL
This manually-operated control panel is equipped with a Key
Switch and
RPM
gauge with an
ELAPSED
TIME
metcr
which measures the engine's running time
in
hours and in
1110
hours.
The
panel also includes a WATER
TEMPERA·
TURE
gauge
which
indicates
water
temperature
in
degrees
Fahrenheit, an
OIL
PRESSURE
gauge
which measures the
engine'5 oil pressure in
pounds
per square
inCh,
and a
DC
control circuit VOLTAGE gauge
which
measures the sys-
tem'5 voltage.
All
gauges
are illuminated when the key
switch is turned
on and remain illuminated while the engine
is
in
operation. The panel also contains two rubber-booted
pushbuttons,
one
for
PREHEAT
and
one
for START.
When the engine is shut down with the Key
Switch turned
off, the water temperature gauge
will continue to register the
Ja~t
temperature rcading indicated hy the gauge bctllfC elec-
tncal power
was
turned off.
The
oil pressure gauge will fall
to zero when the Key
Switch is turned oft·.
The
temperature
gauge
will
once
again register the
engine's
true temperature
when electrical power
is
restored
to
the gauge.
A
se~aratc
alarm buzzer with harness is supplied with every
Admiral
Panel.
The
installer is responsible for electrically
connecting the
buzzer
to the
four~pin
connection on the
engine's electrical harness.
The
installer is also responsible
~or
installing the buzzer
in
a location where
it
will
be
dry and
where
it
will be audible 10 the operator should
it
sound while
t~eengin.e
is
running. The buzzer will sound when the igni-
hon key IS turned on and should silence when the engine has
started and the engine's oil pressure rises above
15
psi.
WATER
TEMPERATURE GAUGE:
THIS
GAUGE
IS
GRADUATED
IN
DEGREES
fAHRENHEIT
AND
IS
ILLUMINATED
WHILE
THE
KEY
SWITCH
IS
TURNED
ON.
THE
ENGINE'S
NORMAL
OPERATING
TEMPERATURE
IS
170°·190° f 177°·BBOC).
OtL
PRESSURE
GAUGE:
THIS
GAUGE
IS
GRADU-
ATED
IN
POUNDS
PER
SQUARE
INCH
(PSI)
AND
IS
ILLUMINATED
WHILE
THE
KEY
SWITCH
IS
TURNED
ON.
THE
ENGINE'S
NORMAL
OPERATING
OIL
PRESSURE
RANGES
BETWEEN
30·60
PSI
RPM
GAUGE:
REGIS·
TERS
REVOLUTIONS
PER
MINUTE
OF
THE
ENGINE
AND
CAN
BE
RECALIBRATEO
FOR
ACCURACY
FROM
THE
REAR
Of
THE
PANEL
HOURMETER:
REGISTERS
ElAPSED
TIME,
AND
SHOULD
BE
USED
AS A GUIDE
FOR
THE
MAINTENANCE
SCHEDULE.
PREHEAT
BUTTON:
WHEN
PRESSED.
ENERGIZES
THE
ALTERNATOR'S
REGUlATOR,
THE
FUEL
LIFT
PUMP,
THE
fUEL
SOLENOID
ON
THE
INJECTION
PUMP,
AND
THE
ENGINE'S
GLOW
PLUGS,
AND
BYPASSES
THE
I
OIL
PRESSURE
AlARM
SWITCH.
IN
ADDITION,
I
BUDON
ENERGIZES
THE
START
BUDON.
START
BUTTON:
WHEN
STARTER'S
SOLENOID
I
THIS
BUDDN
WILL
NOT
OPERATE
ELECTRICALLY
UNLESS
THE
PREHEAT
BUDON
IS
PRESSED
AND
HELD
ATTHE
SAME
TIME.
4
AUTOMATIC
ALARM
SYSTIM
KEY
SWITCH:
PROVIDES
POWER
ONLY
TO
THE
INSTRUMENT
PANEL
CLUSTER.
INDICATES
THE
AMOUNT
THE
BATTERY
IS
BEING
CHARGED
SHOULD
SHOW
13V
TO
14V.
HIGH
WATER
TEMPERATURE
ALARM:
AN
ALARM
BUZZER
HAS
BEEN
SUPPLIED
WITH
THE
INSTRUMENT
PANEL
If
THE
ENGINE'S
FRESH
WATER
COOLANT
REACHES
210° f 19BOC),
THIS
SWITCH
WILL
CLOSE
SOUNDING
THE
AlARM
WHICH
WILL
EMIT
A
CONTINUOUS
SIGNAL.
LOW
OtL
PRESSURE
AlARM: A LOW
OIL
PRESSURE
AlARM
SWITCH
IS
LOCATED
OfF
THE
ENGINE'S
OIL
GALLERY
THIS
SWITCH
MONITORS
THE
ENGINE'S
OIL
PRESSURE.
SHOULD
THE
ENGINEiS
OIL
PRESSURE
FALL
TO
5·10
PSI,
THE
SWITCH
WILL
CLOSE
SOUNDING
THE
ALARM.
IN
THIS
EVENT,
THE
AlARM
WILL
EMIT
A
PULSATING
SIGNAL
CAPTAIN
CONTROL
PANEL
CAPTAIN
PANEL
This
manually~operated
control panel
is
equipped with a
Key
Switch, an RPM gauge, PREHEAT and START buttons,
an
fNSTRUMENT TEST button and three indicator lamps, one
for ALTERNATOR DISCHARGE, one for low
OlL
PRES·
SURE,
RPM
GAUGE:
REGISTERS
REVOLUTIONS
PER
MINUTE
Of
THE
ENGINE
AND
CAN
BE
RECALIBRATED
fOR
ACCURACY
fROM
THE
REAR
Of
THE
PANEl.
Oil
PRESSURE
ALTERNATOR
ALARM
ALARM
LIGHT
LIGHT
WATER
TEMPERATURE
ALARM
LIGHT
START
BUTTON:
WHEN
PRESSED.
ENERGIZES
THE
STARTER'S
SOLENOID
WHICH
CRANKS
THE
ENGINE
THIS
BUTTDN
WILL
NOT
OPERATE
ELECTRICALLY
UNLESS
THE
PREHEAT
BUTTON
IS
PRESSED
AND
HELD
AT
THE
SAME
TIME.
5
and one for high
ENGINE
COOLANT
TEMPERATURE. ft
also includes
an
alarm buzzer for low OfL PRESSURE or
high WATER TEMPERATURE. The RPM gauge
is
illumi·
nated when the Key Switch
is
turned
on
and remains illumi-
nated while the engine
is
in
operation.
ALARM:
THE
ALARM
WILL
SOUND
If
THE
ENGINES
OIL
PRESSURE
fALLS
BELOW
15
PSI.
IN
THIS
EVENT.
THE
ALARM
WILL
EMIT
A
PULSATING
SIG·
NAl.
THE
ALARM
WILL
ALSO
SOUND
If
THE
WATER
TEMPERATURE
IN
THE
fRESHWATER
COOLING
CIRCUIT
RISES
TO
20S'f.
IN
THIS
EVENT.
THE
ALARM
WILL
EMIT A SIGNAl.
NOTE:
THE
ALARM
WILL
SOUND
WHEN
THE
KEY
SWITCH
IS
TURNED
ON.
THIS
SOUNDING
IS
NORMAl.
ONCE
THE
ENGINE
STARTS
AND
THE
ENGINE'S
OIL
PRESSURE
REACHES
15
PSI,
THE
ALARM
WILL
SILENCE.
TEST
BUTTON:
WHEN
PRESSED,
TESTS
THE
ALTERNATOR.
THE
OIL
PRESSURE.
AND
THE
WATER
TEMPERATURE
CONTROL
CIRCUITS
WHEN
PRESSED.
THE
ALTERNATOR.
THE
OIL
PRESSURE,
AND
THE
WATER
TEMPERATURE
INDICATOR
LIGHTS
ILLUMINATE
IN
ADDI·
TION
TD
SOUNDING
THE
ALARM
BUZZER
KEY
SWITCH:
PROVIDES
POWER
TO
THE
INSTRUMENT
PANEL
CLUSTER
AND
THE
DC
ALTERNATOR
REGULATOR
TERMINAL.
PREHEAT
BUTTON:
WHEN
PRESSED.
ENERGIZES
THE
fUEL
LIfT
PUMP
AND
THE
ENGINE'S
GLOW
PLUGS.
ANa
BYPASSES
THE
ENGINE'S
OIL
PRESSURE
ALARM
SWITCH.
IN
ADDITION.
THIS
BUTTON
ENERGIZES
THE
START
BUTTON
DIESEL
FUEL,
ENGINE
OIL
AND
ENGINE
COOLANT
DIESEL
FUEL
Use fuel that meets the requirements or specification
of
Class
2-D (ASTM), and has a cetane rating
of
#45 or better.
Care
Of
The
Fuel
Supply
Use only clean diesel fuel! The clearance
of
the components
in
your fuel injection
pump
is
very critical; invisible dirt
par~
tides
which might pass through the filter can
damage
these
finely finished parts.
It
is important to buy clean fuel, and
keep
it
clean. The best fuel can be rendered unsatisfactory
by
careless handling or improper storage facilities. To assure that
the fuel going into the tank for
your
engine's daily use
is
clean and pure, the following practice
is
advisable:
Purchase a well-known brand
of
fuel.
Install and regularly service a good,
visual~type
filter/water
separator between the fuel tank and the engine. Raycor
500
FG or
900
FG
is
a good example
of
such a filter.
ENGINE
OIL
Use a heavy duty engine oil with
an
API classification
of
CF
or
CG4
or
better, Change the engine oil after
an
initial 50
hours
of
break-in operation, and every 200 hours
of
operation
thereafter. For recommended oil viscosity, see the
following
chart:
Operating
Temperature
Oil
Viscosity
Above
68"F
(2D"C)
SAE
30
or 1 OW-3D
41
"-68"F
(5-2D"C)
SAE
20
or
1DW-3D
Below
41"F
(5"C)
SAE
1DW-3D
A
CAUTION:
00
not allow
two
or
more
brands
of
engine
oil
to
mix,
Each
brand
contains
its
own
additives;
additives
of different
brands
could
react
in
the
mixture
to
produce
properties
harmful
to
your
engine.
6
ENGINE
COOLANT
UNNERSAL
recommends a mixture
of
50%
antifreeze and
50%
distilled water. Distilled water
is
free from the chemi-
cals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine
to
run at proper temperatures
by
transferring heat away from
the
engine
to
the coolant, and lubricates and protects the cooling
circuit from rust and corrosion. Look for a good quality
antifreeze that contains Supplemental Cooling Additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE:
Look
for
the
flew
environmenwl(v-jriendiy
IOllR
la.l'finf!,
antifreeze that is
nol1.'·
available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial to the engine's cooling system. They
retard rust and add to the life
of
the circulating pump seal.
ANTIFREEZE
PROTECTION
Antifreeze
concen1ration
Freezing
Temperature
23%
WF
(-5"C)
COOLANT
RECOVERY
TANK
30%
8"F
(-13"C)
35%
-4"F
(-20"C)
50%
-40"F
(-40"C)
A coolant recovery tank kit
is
supplied with each
UNIVERSAL diesel engine. The purpose
of
this recovery
tank
is
to allow for engine coolant expansion and contraction
during engine operation, without the loss
of
coolant and
without introducing air into the cooling system. This
kit
is
provided and must be installed before running the engine.
COOLANT
RECOVERY
TANK
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