Universal M-25XPB(C), M-408, M3-20B, M-35B(C), M-508 Operator's Manual

OPERATORS

MANUAL

4.Unlvarsal

-

·

MARINE

DIESEL

ENGINES

M3·20B

M-25XPB(C)

M·35B(C)

M-408 M-508

- -

PUBLICATION

REVISION

AUGUST

NO.

3:

2015

200550

Westerbeke

150

John

JS!j

Corporation-

Hancock

Website:

Member

...

·

Myles

Road-

Taunton,

www.westerbeke.com

National

Marine

Mamifacturen

...

Standish Industrial

MA

02780-7319

Association

Parle

U.S.A.

A

wARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF

GET

seek

until

gasses

gas. can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

Carbon

include:

and

THE

attention.

·WARN

.

Engfrles

Produce

Regular

CARBON

Maintenance

f'W./'fP'S!BeiCl!

-·-

contain

IN

Required

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

A bulkhead

CARBON living/sleeping

G·

MONOXIDE

obtainable

.

Monoxide,

is

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability

IMMEDIATELY. down

and

repaired.

WARNING

WESTERBEKE WESTERBEKE

They

are

CALIFORNIA

PROPOSITION

65

an

odorless

poisonous

ANY

the

near

MONOXIDE

inexpensive

of

carbon

in

Twitching

to

Think

OF

If

unit

and

DECAL

and

your

also

quarters

at

your

and

Temples

THESE

should

recommends

local

WARNING

and

can

cause

Monoxide

Coherently

SYMPTOMS,

symptoms

do

Is

provided

engine DETECTORS

and

persist,

not

restart

be

fixed

or

generator.

of youi

easily

marine

by

installing in vessel.

store.

to

the

a

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

gasoline

its

constituents

of

California

birth

defects,

harm.

engine

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

precautions.

take

the

peJ:sonne4

The

following safety instructions are in compliance with

the

American

PRMNT

A

while these

•

Do

\

enclosures

•

Shut equipment.

•

Use equipment.

•

Make

(particularly

•

Remove electrical

PREVENT

A

exhaust

Know

necessary precautions to protect yourself, your

and your machinery.

Boat and

ELECTRIC

WARNING:

engine

Is

connections!

not

operate

and

off

electrical

insulated

sure

your

shoes)

wristwatch

equipment.

BURNS -HOT

WARNING:

system

veryhotl

•

Monitor

coolant

location

when

engine

recovet}l

on

the

engine

AWARNINll:

•

l1'1

case

of

an

before

touching

carefully.

to

follow

fundamental

when dangerous conditions exist and

Yacht

Most

accidents

rules

Council (ABYC) standards.

are

and

SHOCK

Do

not

touch

AC

electricaf

running.

this covers

mats

Lethal

voltage

machinery without electrical

in place.

power before accessing electrical

·

whenever working on electrical

clothing and skin are dry, not damp

when

handling electrical equipment.

and

all jewelry when working on

connections

is

present

at

·

ENGINE

011

n11t

flluch

hot

engine

c11mponents. A running

ani:i.freezP/coolantieveht the

·tartk

and Periodicaly

water

iS

COLD;

jacketed

~J.Ihaustmiinifold~

· · · . . · .

S~Hm:can,l:at~Se,:JnJiiry"or

,':'

...

tmgine

twerhe&.t,

the

~ngine

·anow

or

cbeeklrig

parts

engine

at

the

...

.-.·.,:

....

_.,.;,.

the

engm¢

the cobiant

11r

gets

plaStic

filler

cap

but

deSthi

··-··'

· ..... .

to

cool

t)nly

PREVENT

A

• Prevent flash sparks to occur near the fuel injector, fuel line, pump, or other potential sources of spilled fuel or vapors. Use a suitable container to catch

. removing the fuel lines or fuel filters.

•

Do Backfire can cause severe injury or death.

• Do not smoke or permit flames or sparks the fuel

et~.gine

.

chances of

• Be aware - diesel fuel will burn.

PREVENT

A

fnjury.or

•

Follow hatches

after the your

• All

when well-ventilated area away from spark-producing equipment and out of the reach of children.

•

Do

• Shut off

•

· • Be sure all fuel supplies have a positive shutoff

• Be certain fuel line fittings are adequately tightened

• Make sure a fire extinguisher is-installed

BURNS

WARNING:

not operate with the air cleaner/silencer

sysfe~.

'clean and free

-FIRE

Fire

can

cause

injury

or

fires.

Do not smoke or pennit

J(eep

t11e

compartment

of

debris to minimize the

fire.

Wipe up all spilled fuel and engine

death!

flames

all

fuel

removed.

to

occur

8lld

the

filter,

BURNS -EXPLOSION

WARNING:

de;#/.1!

re-fueling safety instructions.

fueling.

blciwer.

engine.

fuel

handling and storing fuels. Store fuel in a

not

the fuel system. Take care in catching spill. DO NOT allow any smoking, sources servicing. the fuel system.

Do

not alter or modify the fuel system.

free

of leaks.

properly maintained. Be familiar with its proper Extinguishers rated ABC by the

for

all

applications encountered in this environment.

Explosions

closed

when

Check below for

Run

the

blower per four

vapors

are highly explosive.

fill

the fuel tank(s) while the ,engine while it

the

fuel service valve at

of fire near the

Ensure proper ventilation exists

fueling.

fuel

from

fuel

Open

and

fumes/vapor

the

system or

NFPA

vapors

Keep

the

ventilate

refore

minutes

before

Use

extreme

engine

when

any

fuel

open

flames,

engine

when

nearby

are appropriate

can

vessel's

when

the

that

servicing

valve.

or

fuel

near.

oil.

cause

cabin

running

starting

care

is

running.

servicing

might

or other

and

is

use.

I

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

w

Thin

unit's battery selector switch to engine.

• Make certain. all personnel are clear

starting.

•

Make certain all covers, guards, and hatches are re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke or allow an open flame near the battery being serviced. highly explosive gas, which can arcing or by lit tobacco products. Shut equipment in the vicinity to prevent electncal arcmg during servicing.

• Never connect the negative(-) battery cable to the positive ( Do not test the battery condition by shorting the termmals together. Sparks could ignite Ventilate any compartment contammg battenes to prevent

accumulation 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.

wristwatch, rings, and any other jewelry before handlmg the battery.

• Always tum the battery charger off before .disconnecting

the battery connections. Remove the and reconnect it last when servicing the battery.

BATTERY

A

WARNING:

severe

• When servicing the battery or checking the electrolyte

level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain destructive.

it off at once with water. Acid may splash on the skin

into the eyes inadvertently when removing electrolyte caps.

STARTING

Accidental

OFF

the

DC

breaker on the control panel

EXPLOSION

Battery

Lea~

acid batteries

+) connection terminal

of

explosive gases. To avoid sparks, do not

ACID

Sulfuric

injury

or

death!

If

it comes in contact wtth your skin, wash

starting

OFF

explosion

acid

can

be

of

batt~ry

in

batteries

sulfuri~

can

cause

injury

or

turn the

before servicing the

of

the engine before

_

cause

injury

~mi!

hydrogen,

1gmted by

o~

all

the starter

gases

o~

negative lead first

can

acid

whic~

~

elec~cal

ele~tncal

solenoi~.

fuel vapors.

Remo~e

cause

is ·

or

TOXIC

• Ensure that the exhaust system is adequate to expel gases

11

• Do not run the generator set

• For additional information, refer to ABYC TH-22

·A

• Do not use copper tubing in diesel exhaust systems.

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not as toxic as

AVOID

• Do not service the engine while it is running.

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifold/

water-injected elbow is securely attached.

Be

sure the unit and its surroundings are well ventilated.

Run blowers when running the generator set

equipped with a functioning marine carbon monoxide

detector that complies with ABYC A-24. Consult your boat builder detectors.

(educational information on Carbon Monoxide).

WARNING:

odorless nausea

gas.

or

death!

Diesel fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration copper tubing resulting in exhaust/water leakage.

through portholes, vents, or

exhaust discharge outlet is near the waterline, water could

enter the exhaust discharge outlet and close or restrict the

of

flow

exhaust fumes from gasoline engines, carbon monoxide gas is present symptoms poisoning are:

exhaust. Avoid overloading the craft.

Vomiting· Dizziness Headache Nausea Weakness and sleepiness

MOVING

A

WARNING:

or

death!

situation arises in which it is absolutely necessary to make operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components.

GASES

Carbon

or

dealer for installation

Carbon

Inhalation

in diesel exhaust fumes. Some

or

signs

monoxide

monoxide produces

of

carbon monoxide inhalation or

Inability to

Throbbing in temples

Muscular twitching

(CO)

or

engine unless the boat is

(CO)

flu·like

air conditioners.

think coherently

PARTS

Rotating

parts

can

cause

is a deadly

or

engine.

of

approved

is

an

invisible

symptoms,

If

the engine

of

the

injury

If

gas!

of

a

,...,

...

Unlvanal

5 2

M·1;J@:WP•

i i

1

59:t;•

•

Do

not

wear

loose

equipment;

rings, moving

.

•

Make Kf!ep places

•

Do

not

.

the

engine

•

Stay

when be

caught

HAZARDOUS

A

WARNING:

avoid

necklaces

parts.

sure

all

protective

at

all

times.

check

is

clear

of

the

engine

in

tliese

NOISE

or bracelets that could

attaching

shields

fluid

operating. the

drive is

High

loss/

•

Never

operate

•

Do

not

removed.

A

WARNING:

mentally

OPERATORS

Many

of

the

in

your

Operators

notes

to

highlight carefully, procedures.

maintain

an

run

an

engine

Do

or

physically

MANUAL

preceding

Manual critical

your

SAFETY

clothing or jewelry when servicing

wearing

rotating

engine without

not

loose

jackets, shirts,

hardware and

guards

levels

or

the

drive

shaft

and

the

running;

noise

hair and clothing can easily

parts.

levels

its

with

the air intake (silencer)

work

on

machinery

incapacitated

safety

tips

and

along

with other cautions

information. Read

equipment,

and

sleeves,

be

caught in

is

properly tightened.

in

their

respective

belt's tension

transmission

can

cause

hearing

muffler installed.

when

by

fatigue!

warnings

follow

are

your

all safety

repeated

manual

t:oupling

you

and

INSTRUCTI·ONS

while

are

ABYC,

.

INSTALLING

Read for safety codes

tions

ABYC

"Safety Standartls for Small Craft" ·

Order

ABYC

613

Annapolis,

- (

41

·

www.abycinc.~rg

NFPA

"Fire Protection Standard for Motor Craft" Order NFPA

1 Batterymarch Park

P.O.

Quincy,

USCG "CPR Code

Order

U.S. Washington,

NFPA

AND

MARINE

the

following

when

installing your UNIVERSAL engine

(American Boat and

From:

Third Dtreet, Suite

MD

0)

990-4460

(National

From:

Box

9101

MA

02269-9101

(United States Coast Guard)

33

AND

CFR46"

of

Federal Regulations

From:

Government Printing Office

D.C.

USCG

PUBLICATIONS

ENGINES

ABYC,

and

21403

Frre

20404

NFPA

standards. Follow their

Yacht

10

Protection Association)

FOR

AND

GENERATORS

and

USCG

publications

recommenda-

Council)

ENGINE

Preparations ough

(ABYC)

sources

Sections

All Regulations

AND

examination

standards.

including

of

the

H-32

Ventilation

H-33

Diesel

P-1

Installatiion

and

P-4

Marine

E-11

AC & DC

TA

Batteries

installations

GENERATOR

to

install

an

engine should begin

of

the

American

These

standards are a combination of

the

USCG

and

ABYC

Auxilliary

(FCR).

standards for

boats using diesel

Fuel

Systems

of Exhaust Systems for Propulsion

Engines

Inboard

must

Engines

Electrical Systems

and

Battery

comply

INSTALLATIONS

with

a thor-

Boat and

the

of particular interest

and Transmissions

Chargers

with

the

NFPA.

on

Federal

Yacht

fuel

Boats

Code

Council's

are:

of

When

installing WESTERBEKE engines

to

the

attention be paid

following

.INSTALLATION

and

generators it

information:

is

important that strict

CODES

Strict when

AND

REGULATIONS

federal

regulations,

installing engines

SIPHON-BREAK

For installations

or

will

be

break

in

the

minimum

the

exhaust

raw

water

If

you

have

to

the

vessel's waterline under

siphon-break.

NOTE:

A siplton-break operation. engine

damage.

EXHAUST

The

exhaus·t

Exhaust Hose

and

turns

and

turns

system

MUST

under

any

where

below

the vessel's waterline, provisions must be made

raw

water supply hose

of20"

above

manifold

damage

Failure

to

any

doubt about the positi9n of the water-injected exhaust elbow relative

to

Consult

SYSTEM

system's hose

is

recommended:.

withoutthe

.In

this

regard,

be designed to prevent

sea conditions

.

ABYC

and

the exhaust manifold/water injected exhaust elbow is close

the vessel's waterline.

injection

the

requires

properly maintain a siphon-break

ne~d

guidelines,

generators in a marine environment.

to

port

engine

and

the

vessel's various operating conditions,

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

MIJST:o~·celtified

The use of

of additiinal

a single

and

at

length

any

and

safety codes must be complied

the exhaust

is

at

or

possible

fitting

of corrugated exhaust hose

the

angle

Failure

below

flooding

for

this

type

and

entry of

of

vessels

elbow.

This hose must be looped a

to

use a siphon-break'when

the

load

of

can·

marine use.

of hose

clamps

wat~r

into the exhaust system

heal.

to

install a siphon-

waterline

the

boat.

result

Con11gated

a,llows

to

accomplish these bends

will

to

ensure proper

in

catastrophic

for

extreme

can

be

result

install

Marine

used.

with

to

in

a

bends

The

AVAILABLE YOUR.

DEALER

SIPHON-BREAK LOOP PART

FROM

WESTERBEKE

FOR NO.

WITH

1"

HOSE

044010

STAINLESS

.

A

detailed engines .is

Website:

and

also

available

www.westerbeke.com

Marine

Installation

generators

in

pdf

is

supplied

format

Manual

on

with

our

website

covering

every

unit

to

g;~soline

sold.

and This

download

~Univcarsal

2&

M·l;l1~1JA•£t'13;W

.

IV

diesel

manual

TABLE

Parts

Identification

lntroduction

Warranty Procedures ........................................ .3

Serial Number Location ..................................

Admiral Captain Diesel Preparations

.............................................................

Control Control

Fuel,

Engine

for Starting/Stopping Break-In The

Alarms and Circuit Breakers ..........................

Maintenance Engine

Raw Water Pump ............................................

Changing the Raw Water Impeller .................

Raw Water Intake Strainer .............................. 16

Thermostat ...................................................... 16

Heat Exchanger .............................................. 16

Engine Remote Fuel

Air Cleaner/Silencer ....................................... 19

Priming the Fuel Fuel Lift

Fuel Filters ......................................................

DC

Drive Belt Adjustment ....................................

Battery Care ....................................................

Glow Plugs .....................................................

Alternator Troubleshooting ............................

Wiring Wiring Wiring

Procedure

Daily

Routine

Cooling

Oil

Change

Oil

Filter

System

.......................................................

Pump ................................................ 19

Electrical

Diagram Schematic Diagram

Schedule

System

................................................ 2 Wiring

Panel

............

..................

Oil

and

Initial

Start-Up

Procedure

.............................

.......................

Engine

Coolant..

......................

...............................

...........................................

..............................................

.....................................

Circuit

......................................

.............................................

...............................................

Pump ................................... 19

........................................

................................................

..............................................

(Catalina)

..................................

OF

.4

.....

...

10

11

11 12 14

15 15

17

18

19

20

.

21 21 21 21

22

..

23

24 25

CONTENTS

Schematic

3

5

6

?

8

9

Engine

Engine Control

Adjustments

Throttle and

Valve Clearance ............................................. 27

Testing Oil Pressure ........................................ 28

Fuel Injectors .................................................. 28

Troubleshooting

Panel

Troubleshooting Water Temperature .............

Troubleshooting Oil Pressure Gauges ............

Tachometer Water

PRM

Heater

Transmission

Changing the Fluid ........................................ .34

Gear Shifting .................................................. 34

Daily

Control Cables ................................................ 35

Maintenance .................................................... 35

Operation .............................................. 35

Transmission HBW

Transmission

Shaft Couplings .............................................. 37

Shift Lever ...................................................... 37

Fluid Change .................................................. 38

Specifications .................................................. 38

Operating Temperature ................................... 39

Transmission Cooler ....................................... 39

Maintenance .................................................... 39

Transmission

Control Cables ...............................................

Lay-up

and Specifications Spare

Parts Standard Metric

Conversions

(Catalina)

..............................

.............................................

Stop Assembly ........................... 27

(Chart)

Troubleshooting

........................

(Chart)

............

............................

.....................................................

............................................

Troubleshooting

........................

Troubleshooting

Recommissioning

(Chart)

..............

.....................

(Chart)

.............

..........................

...................................................

........................................................

Hardware

Torques

Chart

..............................

................................

26

27

29

.31 .31

31

32 33

.

34

36

37

.40 .40

.42

44

45

46

.4

7

PARTS

IDENTIFICATION

HEAT

EXCHANGER----'->~

TRANSMISSION CONTROL BRACKET

REAR

TRANSMISSION FLUID

DRAIN

OIL

MANIFOLD !COOLANT

ZINC

FILL

PRESSURE

FILL]

RIGHT

CAP

SIDE

COOLANT

PUMP

OIL

FILL

SHEAVE

WATER TEMPERATURE SEND

OR

INJECTION

PUMP

M·40BILLUSTRATED

'AIR

FILTER

SILENCER

MANIFOLD PRESSURE

ALTERNATOR

CAP

MANIFOLD

PREHEAT SOLENOID

~~~~~~~~~~£;::.~~~b.::-:__COOLANT

FUEL

REAR

FILTER

M-50BILLUSTRATED

ALTERNATOR

OIL

FILTER

DRAIN

RAW PUMP

WATER

FLEXIBLE MOUNT

MANIFOLD

!COOLANT

COOLANT DRAIN

PRESSURE

FILL]

OIL

CAP

PAN

I.D.

NAME

PLATE

START MOTOR

FRONT

,.,

Unlvarsal

4

5 6

COOLANT DRAIN

FLEXIBLE

MOUNT

M·1;1@!M•'W3;W

2

LEFT

SIDE

OIL

DRAIN

HOSE

INTRODUCTION

These new high performance UNIVERSAL marine diesel engines are a product design technology and their combined years manufacturing quality marine engines. We take great pride in

the superior durability and dependable performance 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. manual carefully and observe all the safety precautions throughout. WESTERBEKE distributors, dealers and service centers are available worldwide. contact your nearest dealer for assistance.

This is

provided

Universal

are planning Installation

An

your

Operators Manual. A Parts List is also

and

Dealer

to

Manual

WARRANTY

Your UNIVERSAL Warranty is included in a separate folder.

If

you have not received a customer identification card registering your warranty registration form, please contact the factory in writing with model information, including the unit's serial number and commission date.

of

UNIVERSALIWESTERBEKE'S

of

experience

Please read this

extensive network

Should your engine require servicing,

a Service Manual is available from

or

in

pdf

install this equipment, reference the

supplied with the unit.

form

of

UNIVERSAL

off

our

website.

PROCEDURES

60

days after submitting the warranty

your

If

of

you

our

ts

PRODUCT

Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than UNIVERSAL are not within UNIVERSAL'S CONTROL.

UNIVERSAL CONTENT RANTIES THERETO, INCLUDING ACCURACY, TIMELINESS COMPLETENESS THEREOF

BE

LIABLE INCURRED IN OF

THE UNIVERSAL customers should also keep in mind the time

span between printings and the unavoidable existence manuals. In summation, product software provided with UNIVERSAL products, whether from UNIVERSAL or other suppliers, must not and cannot the definitive authority on the respective product. makes good sense but is imperative that appropriate representatives consulted to determine the accuracy and currentness product software being consulted by the customer.

NOTES,

As this manual takes you through the operating procedures, maintenance schedules, and troubleshooting

engine, critical information will be highlighted by CAUTIONS, and WARNINGS. An explanation follows:

SOFTWARE

CANNOT

OF

SUCH SOFTWARE, MAKES NO WAR-

OR

REPRESENTATIONS

FOR

CONNECTION WITH

FURNISHING

of

UNIVERSAL or the supplier in question be

CAUTIONS

BE

RESPONSIBLE

WITH

AND

WILL

ANY

TYPE

OF

DAMAGE

OR

USE

OF

SPCH

of

UNIVERSAL product software

of

earlier UNIVERSAL

be

relied upon exclusively

AND

WARNINGS

FOR

RESPECT

IN

OR

ARISING

SOFTWARE.

of

THE

OR

NO EVENT

INJURY

OUT

as

It

not only

of

the

your marine

NOTES,

Unlvarsal

Customer Identification

UNIVERSAL OWNER MAIN HOMETOWN, USA

Model M-358

Expires. 7/20/2000

TYPICAL

Your UNIVERSAL Warranty Statement is included in the product documentation package. There is a Warranty Registration Card you can fill out and mail to Westerbeke Corporation register your products warranty a Customer Identification card in the mail within registering. your model number, serial number and in service date available.

STREET

Ser. #6C442E711

CUSTOMER

or

go to our website: www.westerbeke.com and

If

you do not, please contact the factory and have

IDENTIFICATION

on

line. You should receive

CARD

60

days

of

NOTE:

An

A

CAUTION:

observed,

your

engine.

A

WARNING:

followed,

operating procedure essential to note.

can

Procedures,

result

in

Procedures,

result

in

which

the

damage

which

personal

if

or

if

injury

not

strictly

destruction

not

properly

or

loss

of

life.

Nnlvarsal

*

Ml;!IIIJ#•I119;W

3

INTRODUCTION

SERIAL

An identification nameplate that displays the engine model number and engine serial number the engine's manifold. Take the time to enter this information on reference when seeking technical information and/or ordering parts.

Fili

UNDERSTANDING

The diesel engine closely resembles the gasoline engine, since the mechanism is essentially the same. The cylinders are arranged the same general type diesel engine has the same types of valves, camshaft, pistons, connecting rods and lubricating system.

To tive proper ventilation and proper maintenance cating and cooling systems. Replacement cating filter elements at the time periods specified and frequent checking for contamination (water, sediment, etc.) in the fuel use designed specifically for diesel engines.

The diesel engine does differ from the gasoline engine, however, retor and ignition systems are done place performs the function of both.

NUMBER

the blank decal provided

in

the.

information for your

a great extent, a diesel engine requires the same preven-

maintenance

~ystem

of

a brand of high detergent diesel lubrication oil

in its method of handling and firing of fuel. The carbu-

is

a single component (the fuel injection pump) which

LOCATION

is

mounted on the side

below.

This will provide a quick

SEA. NO.

rejer(mce.

THE

DIESEL

above

a closed crankcase; the crankshaft is

as

that

of

a gasoline engine, and the

as

a gasoline engine. Most important are

are essential. Also important is the consistent

·

/lJJ

ENGINE

of

the fuel, lubri-

of

fuel and lubri-

away

with and in their

of

ORDERING

Whenever replacement parts are needed, always provide the engine model number and engine serial number appear on the silver and black identification nameplate located on the manifold. mation complete part description and part number for each part needed (see the separately furnished insist upon UNIVERSAIJWES1ERBEKE packaged parts because will fit or generic parts are frequently not made the same specifications

SPARES

. Certain spares will be needed

your UNIVERSAL marine engine. WES1ERBEKE dealer will assist board inventory

PARTS page in this manual for a suggested list.

PROTECTING

Care

have resulted in a UNIVERSAL diesel engine capable many thousands manufacturer cannot control how or where the engine is installed in the vessel or the manner in which the unit operated and serviced in the field. This is up to the buyer/owner -operator.

NOTE:

PARTS

as

they

You

must provide

so

we can identify your engine.

as

original equipment.

AND

ACCESSORIES.

to

support and maintain

Your

you

of

spare parts. See the UNIVERSAL SPARE

YOUR

INVESTMENT

at the factory during assembly and thorough testing

of

hours

of

dependable service. However the

Six important steps to ensure long engine life:

us

with this infor-

In

addition, include a

Parts Catalog). Also

UNIVERSAl)

in preparing an on

is

of

to

0 Proper engine installation and alignment. 0 An efficient well-designed exhaust system that includes

to

an anti-siphon break engine.

prevent water from entering the

0 Changing the engine oil and oil filters every 100 operating

hours.

0 Proper maintenance

to the maintenance schedule in this manual.

of

all engine components according

0 Use clean, filtered diesel fuel.

0 Winterize your engine according

RECOMMISSIONING section in this manual.

to

the LAY-UP AND

ADMIRAL

CONTROL

PANEL

DESCRIPTION

This

manually-operated

KEY

switch

and

meter

which

measures

in

1110

hours.

The ATURE Fahrenheit, engine's

control

tem's

switch is pushbuttons,

RPM TERS PER ENGINE

RECALIBRATED ACCURACY REAR

gauge

an

oil

pressure

circuit

voltage.

is

turned

in

operation.

gne

GAUGE:

REGIS-

REVOLUTIONS

MINUTE

OF

THE

AND

CAN

BE

FOR

FROM

OFTHE

THE

PANEL.

OIL

VOLTAGE

All

The

control panel

RPM

gauge with an ELAPSED TIME

the engine's running time

panel

also includes a

which

indicates water temperature

PRESSURE gauge

in

pounds per square inch,

gauge which measures the

gauges

are

illuminated

on

and

remain illuminated while the engine

.panel

also contains

for

PREHEAT

and

WATER

TEMPERATURE

GRADUATED

ILLUMINATED

TURNED

ON.

TEMPERATURE

is

equipped

WATER

which

when

two

one

for

IN

DEGREES

WHILE

THE

ENGINE'S

IS

170"

with

a

in

hours

TEMPER-

in

degrees

measures the

and

a DC

sys-

the

key

rubber-booted

START.

GAUGE:

THIS

FAHRENHEIT

KEY

-190" F (77"-

GAUGE

SWITCH

NORMAL

AND

IS

OPERATING

88"C).

and

IS

When

the

engine

is

shut

down

with

the

water temperature gauge will continue temperature reading indicated power

was

turned

off

The oil pressure

when

the

key

switch is turned

will

once

again

register the engine's true temperature

electrical A

Admiral

necti~g

..

electncal the be running. on engine's

separate

Panel

the

buzzer

audible

The

and

should

oil

po"";"er

is

alarm

buzzer

The

buzzer to

harness.

The installer

in a location

to

the

operator

buzzer

silence

pressure

restored

installer

the

will

when

rises

OIL ATED ILLUMINATED ON. PRESSURE (2.1-4.2

by

off

to

the

with

harness

is

responsible

four-pin

is

where

it

should

sound

when

the

engine

above

PRESSURE

IN

POUNDS

THE

ENGINE'S

RANGES

kg/cm

the

key

to

the

gauge

The temperature

gauge.

is

supplied

for

connection

also

responsible

will

be

dry

and

it

sound

while

the

ignition

has

started

15

psi

(1.1

kg/cm

GAUGE:

THIS

PER

SQUARE

WHILE

THE

KEY

NORMAL

OPERATING

BETWEEN

2

).

switch

turned

register

before

electrical

will

fall

with

electrically

on

the

engine's

for

where

the

engine

key

and

2

).

GAUGE

IS

INCH

(PSI)

SWITCH 30-

60

psi

off,

the

last

to

zero

gauge

when

every

con-

installing

it

will

is

turned

the

GRADU-

AND

IS

TURNED

OIL

·

HOURMETER: REGISTERS TIME,

USED THE SCHEDULE.

PREHEAT THE POWER THE THIS DC BUTTON.

START STARTER'S THIS UNLESS AT

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

BUTTON:

CONTACTS

TO

THE

PREHEAT

IS

TRANSMITTED

POWER

IS

BUTTON:

SOLENOID

BUTTON

WILL

THE

SAME

PREHEAT

TIME.

THE

BE

FOR

IN

THE

PREHEAT

GLOW

PLUGS.

SOLENOID ALSO

ALSO

TO

TRANSMITTED

WHEN

PRESSED,

WHICH

NOT

OPERATE

BUTTON

DEPRESSED,

THE

IT

SOLENOID

THE

"I"

TERMINAL

RECEIVES

ELECTRIC

TO

THE

ENERGIZES

CRANKS

THE

ELECTRICALLY

IS

PRESSED

CLOSES

SENDING

POWER

FUEL

PUMP.

START

THE

ENGINE.

AND

·

ON AND

HELD

SWITCH:

THE SWITCH ON

SUPPLIES

TO

THE

INSTRUMENT

PANEL

CLUSTER,

SWITCH,

TERMINAL

CHARGING

AND

TO

THE

BUZZER

A

PULSING

I

•

AUTOMATIC

·.

·--~····'

.

,'/.

"/~

'

COOLANT

SUPPLIED REACHES ALARM

OIL LOCATED THE FALL ING SIGNAL.

ALARM

TEMPERATURE

WITH

210" F (99"C),

WHICH

WILL

PRESSURE

ENGINE'S

TO

THE

ALARM:

OFF

THE

OIL

10-5

psi

ALARM.

SYSTEM

ALARM:

THE

INSTRUMENT

THIS

EMIT

A

AN ENGINE'S PRESSURE.

(0.7-

0.4

IN

THIS

EVENT,

AN

ALARM

PANEL.

SWITCH

WILL

CONTINUOUS

OIL

PRESSURE

OIL

GALLERY.

SHOULD

THE

THE THE ALARM

kg/em'),

BUZZER

IF

THE

CLOSE

SIGNAL.

ALARM

THIS

SWITCH

ENGINE'S

SWITCH

WILL

DC

VOLTMETER:

INDICATES

.BAmFW

SHOULD

HAS

ENGINE'S

SOUNDING

SWITCH

MONITORS

OIL

PRESSURE

WLL(OPEIN:

EMIT

A

PIJl.SATJNG

KEY

WHEN

TURNED

DC

POWER PREHEAT

EXCITATION

OF

THE

DC

ALTERNATOR

ALARM

ENERGIZING

MODE.

THE

IS

SHOW

BEEN

COOLANT

IS

AMOUNT

BEING

CHARGED.

13VTO

THE

'SOUND-

IT

IN

THE

14V.

5

CAPTAIN

CONTROL

PANEL

DESCRIPTION

This manually-operated control panel is equipped with a

KEY

switch,

tons,

an lamps, OIL

PRESSURE,

TEMPERATURE.

RPM

GAUGE:

PER

MINUTE RECALIBRATED THE

REAR

an

RPM

gauge,

PREHEAT and

INSTRUMENT TEST button and

one

for AL1ERNATOR DISCHARGE, one for low

and

one for high ENGINE COOLANT

REGISTERS

OFTHE

FOR

OF

THE

REVOLUTIONS

ENGINE

AND

ACCURACY

PANEL.

CAN

FROM

BE

START

three

indicator

but-

The panel also PRESSURE or high RPM

gauge is illuminated

includes

COOLANT

and remains illmninated

ALARM:

THE

ALARM

WILL

BELOW

10-5 psi

PULSATING

TEMPERATURE 210"F

NOTE:

SOUNDING

PRESSURE

SIGNAL

(99"C). THE

ALARM

IS REACHES

IN

THIS

NORMAL

SOUND

(0.7

-

0.4

THE

ALARM

THE

FRESHWATER.

EVENT,

WILL

SOUND

ONCE

15

psi

an

alarm

when

while

IF

kg/em").

WILL

THE

ALARM

WHEN

THE

ENGINE

(1.1

kg/em"),

buzzer for low TEMPERATURE.

the

KEY

switch is

the engine is

THE

ENGINE'S

IN

THIS

ALSO

COOLING

THE

OIL

EVENT,

THE

SOUND

IF

CIRCUIT

WILL

EMIT A CONTINUOUS

KEY

SWITCH

STARTS

AND

ALARM

WILL

TEST

PRESSED,

ALTERNATOR,

PRESSURE, COOLANT

TURE

CUITS. THE OIL THE TURE LIGHTS ADDITION

ING

BUZZER..

on.

The

turned

in

operation.

PRESSURE

ALARM

THE

RISES

THE

PRESSURE,

THE

FALLS

WILL

COOLANT

TO

IS

SILENCE.

BunDN:

CONTROL ALTERNATOR, WATER

INDICATOR

SIGNAL.

TURNED

ON.

ENGINE'S

WHEN

TESTS

THE

AND

THE

TEMPERA-

CIR-

WHEN

PRESSED,

AND

TEMPERA-

ILLUMINATE

TO

SOUND-

ALARM

EMIT

THIS

OIL

THE

OIL

THE

IN

on

A

START

BUTTON: STARTER'S BUTTON PREHEAT TIME.

SOLENOID

WILL

BUTTON

WHEN

NOT

OPERATE

IS

PRESSED,

WHICH

CRANKS

ELECTRICALLY

PRESSED

AND

ENERGIZES

THE

HELD

THE

ENGINE.

UNLESS

AT

THE

4 4

£ 6 mN;!I§Ij#•M!;M

THIS

THE

SAME

Unlvarsal

~-----~~swrr~:THEKEY

BUTTON:

THE

CONTACTS POWER PREHEAT TRANSMITTED IS

ALSO

IN

TO

THE

GLOW

SOLENOID

TO

TRANSMITTED

WHEN

THE

PREHEAT

PLUGS.

ALSO

THE

ELECTRIC

TO

SWITCH

WHEN SUPPLIES INSTRUMENT CWSTER, EXCITATION

DC

AND

ENERGIZING MODE.

DEPRESSED,

THE

RECEIVES

THE

DC PREHEAT

CHARGING

TO

THE

IT

SOLENOID

"I"

TERMINAL

POWER

FUEL

PUMP.

START

BUTTON.

TURNED

POWER

TO

PANEL

SWITCH,

TERMINAL

ALTERNATOR

ALARM

BUZZER

IT

IN A PULSING

CLOSES

SENDING

ON

THE

AND

THIS

DC

POWER

ON

OF

IS

THE

6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a diesel fuel that meets the requirements ofNo.2-D SAE

J 313 and has a Cetane rating

diesel fuel according to ASTM D975.

Care

Use only clean diesel fuel! The clearance in your fuel injection pump is very critical; invisible dirt particles which might pass through the filter can damage these finely finished parts. It

fuel, and keep it clean. The best fuel can be rendered

unsatisfactory by careless handling facilities. engine's daily use is clean and pure, the following practice advisable:

Purchase a well-known brand Install and regularly service a good, visual-type filter/water

separator between the fuel tank and the engine. Raycor 230

or 245 are good examples of

ENGINE

Use a heavy duty engine oil with an API classification CG-4, CH-4 the initial and filter change intervals as specified in the

MAINTENANCE SCHEDULE in this manual.

Westerbeke Corporation does not approve or disapprove

the use break-in must be performed using conventional oil. change intervals must be as listed in the MAINTENANCE

SCHEDULE

synthetic oils are used.

NOTE:

regarding synthetic oil.

FUEL

of

#45 or higher. Grade

Of

The

Fuel

Supply

of

the components

is

important to buy clean f

or

improper storage

To

assure that the fuel going into the tank for your

of

fuel.

of

such a filter. Micron filter rating

#10

is

recommended.

OIL

or

CI-4. Change the engine oil and filter after

50 hours

of

synthetic oils.

The infomwtion above supersedes all statements

of

break-in operation. Then follow the oil

If

synthetic oils are used, engine

section in this manual and not be extended

Oil

of

is

CF,

if

ENGINE

UNIVERSAL recommends a mixture 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces.

The antifreeze performs double duty.

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:

antifreeze that

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

Antifreeze

Freezing

COOLANT

A coolant recovery tank kit is supplied with each UNIVERSAL diesel engine. The purpose tank during engine operation, without the loss without introducing air into the cooling system.

COOLANT

of

50% antifreeze and

It

allows the engine to

Look

for

the new environmentallyjriendly long lasting

is now available.

of

the circulating pump seal.

ANTIFREEZE

concentration

Temperature

RECOVERY

is

to allow for engine coolant expansion and contraction

PROTECTION

23%

14oF

(-5°C)

TANK

30%

35%

of

this recovery

of

coolant and

50%

For recommended oil viscosity, see the following chart:

Operating

Above

41

°-68°F

Below

Temperature

68°F

(20°C)

(5-20°C)

41°F

(5°C)

Oil

SAE lOW-40 SAE lOW-40

SAE lOW-40

Viscosity

or

15W-40

or

15W-40

or

15W-40

COOLANT

~

,.,Unlvarsal

£ 6

&f.1;11S!JQ•i'tj3;M

7

RECOVERY

TANK

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting your engine for longed

D Check the engine oil level; add oil

the high mark on the dipstick.

INSPECTION

layoff-

check the following items.

the

first time or after a pro-

to

D Check the fuel supply and examine the

bowls

for

contaminants.

D Check the transmission fluid

NOTE:

Refer to the specifications pages in this manual

fuel,

oi~

and

transmission types

level.

and

quantities.

maintain the level at

fuel

filter/separator

for

D Check the DC electrical system. Inspect

and

battery cable connections.

wire

connections

D Visually examine the unit. Look for loose or missing

parts, disconnected wires, unattached hoses, and check threaded connections.

D Check the coolant level in the plastic recovery

the manifold.

NOTE:

If

the engine has

to the

ENGINE COOLING CIRCUIT section

not

yet

been filled with coolant, refer

tank

of

this manual.

and at

COOLANT RECOVERY

TANK

MANIFOLD

MANIFOLD (M-358

SHOWN)

~

8

STARTING/STOPPING

PROCEDURE

STARTING

Place the transmission control to slightly open.

A

neutral. to

your

Thrn the

PREHEAT:

panel lights, gauges and meters, and fuel solenoid will

activated. accordance with the following chart:

PROCEDURE

in

neutral and advance the throttle

CAUTION:

Starting

transmission,

KEY

Depress the PREHEAT switch. The voltmeter,

The

Make

certain

in

gear

your

SWITCH

PREHEAT switch should

could

boat,

to the

the

transmission

result

and

ON

position (2 o'clock)

in

serious

vessels

be

depressed in

is damage

nearby.

Temperature/Preheat

Atmospheric

¥WF(+5°C)

+41°F(+5°C)

+23°F(-5°C)

Limit

START:

While still depressing the PREHEAT switch, depress the START switch. This will engage the start solenoid. engine starting, release the START switch. PREHEAT switch until the oil pressure reaches

Temperature

or

to

23°F

of

continuous

hig~er

(-5°C)

or

lower

use

Approx. Approx. Approx.

30

seconds

Preheating

1 0

seconds

15

seconds

20

seconds

before

Do

not release the

15

Time

cranking

psi.

in

be

Upon

AcAUTION:

engine

starting

filling

with

pump

is cooling enter

manifold

from hull correcting Engine

warrantable

in

Once the engine starts, check instruments for proper oil pressure and battery charging voltage.

NOTE:

running.

NOTE:

Depressing will help stabilize the engine RPM until temperature reaches 150°- 170°F (60°propeller load running load

system

the

happening

shut-off,

damage

mind.

Never attempt

Some unstable running may occur

and

on

the

Prolonged can

raw

water.

pumping

raw

during

engine's

once

cylinders

the

exhaust

by

draining

the

cause

resulting

issue;

the

Preheat switch for 10-15 second

is

applied

the PREHEAT switch

DC alternator will

cranking

result

in

the

This

may

water

through

cranking.

by

way

sPfem

closing

the

raw

the

exhaust

·of

the

excessive

from

raw

owner/operator

to

engage

to

the

engine.

be

happen

intervals

engine

the

This

of

fills.

water

muffler,

water

starter

When

is

depressed, a charging

discernible.

exhaust

because

raw

water

the

exhaust

Prevent

supply

and

engine

entry

should

while

in a cold

the

operating

77°C)

the

without

system

the

water

can

this

through·

cranlcing.

is

not

keep

the

engine.

intervals

and

engine

a

the

a

this

is

VOLTAGE

DROP

NOTE:

When

starting:

A voltage

when is

depressed.

Should the engine not start when the START switch is depressed for wait longer.

drop

will

occur'

the

preheat switch

10 to

20

seconds, release both switches and

30 seconds; repeat the procedure above and

Never

run

the

starter

for

more

than

30

seconds.

prehe~t

STARTING

Make certain the lubricating oil conforms with the ratings for the prevailing temperature. Check the table on the engine oil

~ction

The battery should drep.

a sufficient amount

Use

Temperature/Preheat chart elsewhere in this section.

STOPPING

To stop the engine, bring the throttle to an idle position and place the transmission in neutral. Allow the engine to idle for

a

few moments

to shut down the engine.

l~ver

Made certain the

12

o'clock).

( discharge.

operator of

preventing the battery from from the should be stowed

UNDER

of

this manual.

COLD

CONDITIONS

be

fully charged to minimize voltage

of

preheat to aid in starting, see

PROCEDURE

to

stabilize temperatures. Pull the STOP lever

Onee the engine stops, return the

to the run position. Then turn OFF panel key switch.

key

switch

is

in

the

OFF

position

1f

the

Key

_Switch}!tkft-QN,

An engine alarm buzzer

of

this condition

Key

Switch after stopping

in

(Key

a safe place).

Switch

discharge

the

battery

wfll

iso.providedro·wam

ON).

The

best

method

is

to

remOve

the

engine.

(The

extra

the

key

9

BREAK-IN

PROCEDURE

THE

FIRST

Although your engine has experienced a minimum hour

of proper operation The service life engine is operated and serviced during its initial use.

Your new engine requires approximately 50 hours conditioning operation to break in each moving part in order to maximize the performance and service life Perform this conditioning carefully, keeping in mind the following:

1.

Start the engine according to the Starting Procedure

section in this manual; run the engine at fast idle while checking that all systems (raw water pump, oil pressure, battery charging) are functioning.

2.

Allow the engine to warm up (preferably by running at fast

idle) until the water temperature gauge moves into the

130° -140°F range.

3.

While using the vessel, run the engine at varying engine

rpms for the first 25 hours.

4. Avoid rapid acceleration, especially with a cold engine.

5. Use caution not to overload the engine. The presence

gray or black exhaust, and the inability reach its full rated rpm, are signs

50

HOURS

test operations

of

all systems, break-in time is required.

of

your engine is dependent upon how the

to

ensure accurate assembly and

50

of

the engine.

of

the engine to

of

an overload.

of

hours

of

initial

one

of

a

Breaking-in a new engine basically involves seating the piston rings to the cylinder walls. This cannot be accomplished by long periods rpm. Idle running may glaze the cylinder walls, resulting in

excessive oil consumption and smoky operation. Excessive

or

speed may cause scoring

results. Operate the engine in moderation during the

break-in period. (Don't baby the engine, but do not abuse it.)

MODEL

M3-20B M25XPB

M358 M408 M50B

NOTE:

Attempting

may

shown

NOTE:

The

the

allow throttle underway rated horsepower when

NOTE:

See

break-in information

of

running at idle, nor by early running at full

heavy over-loading, especially with a cold engine,

of

the cylinder walls, producing similar

50-hour

RECOMMENDED

IDLE RPM

1000-1200 1000-1200

800-1000 800-1000 800-1000

to

reduce

produce unstable engine operation and

propeller should

engine

to

reach

in

forward gear

RPM

CRUISE

RPM

2500-3000 2000-2500 2000-2500 2000-2500 2000-2500

idle

speed below

be

either 2 or 3

its

maximum rated

to

RANGES

the

blade.

rpm

ensure

the

MAXIMUM

RPM

3500-

3600

2900-

3000

2900-3000 2900-3000 2700-2800

minimum

stalling.

It should

at full

open

availability

needed.

the

TRANSMISSION section ofthis manual for

on

your transmission.

of

6. During the next 25 hours, the engine may be operated at varying engine rpms, with short runs at full rated rpm. Avoid prolonged idling during this break-in period.

10

THE

DAILY

ROUTINE

CHECK

Each day before starting your engine, take a few moments to

run this check list:

LIST

D Visually inspect the engine for fuel, oil, coolant and

exhaust leaks.

D Check the oil level.

D Check the transmission fluid level.

D Check for loose wires at the alternator.

D Check for loose wires and electrical connections at the

DC

alternator and elsewhere on the engine's

DC

harness.

D Check the starting batteries level (weekly)

D Check drive belts for wear and proper tension (weekly). D Log your engine running time. These hours relate to

scheduled_maintenance.

D Check fuel supply; always keep fuel tank(s)

possible.

as

full as

D Look for clean fuel in the fueVwater separator bowl.

. D Check the coolant level in the plastic recovery tank.

D Check for any obviously loose components

bolts.

NOTE:

Excessive

leak.

Check

tem

pressure tester

the

area

of

the

system as outlined

section

in

the

entire

leakage.

this

manual.

loss

of

coolant indicates a cooling system

system.

to

pressurize the cooling system

In

If

necessary,

cases

of

excessive coolant

in

the

ENGINE COOLING CIRCUIT

or

use

nuts or

a cooling

to

locate

loss,

refill

sys-

START

NOTE:

manual for

1.

2.

3.

4. While pressing PREHEAT, push the START.

5.

NOTE:

above

6.

YOUR

See

Put

transmission in neutral, throttle advanced.

Tum

Depress PREHEAT (10 to

As engine fires - release START and PREHEAT.

Observe the panel gauges, check the oil pressure, DC charges, etc. Check for water discharge with the exhaust.

Should engine fail procedure,

Allow a few minutes for the engine to warm at a comfortable high idle rpm to the normal idle position, shift into gear, and get underway.

A

CAUTION:

always

transmission

slight

pause

Shifting

transmission/damper

ENGINE

STARTING STOPPING PROCEDURE

more

detailed·

KEY to the

and PREHEAT

reduce

the

firmly

in

neutral

at

high

rpm

instructions.

ON

position (2

to

start,

(1400- 1500 rpm), then reduce the

When

shifting

engine

from

one

will

damage

15

seconds).

wait 30

longer.

rpm

to

direction

allow

0'

clock)

seconds,

the

transmission,

idle,

then

to

another.

the

propeller

the

plate.

in

repeat

shift

to

this

the

A

slow.

ENGINE

The

mounted manual reset circuit breaker Excessive current draw the instrument panel wiring breaker to trip. In this event most engines will shut down because the open breaker disconnects the fuel supply.

this should occur, check and repair the source After repairing the fault, reset the breaker and restart the engine.

LOW

A low oil pressure alarm switch is located off the engine's oil gallery. This switch's sensor monitors the pressure. Should the engine's oil pressure fall to 5

(0.4 - 0.7 kg/cm

CIRCUIT

DC

harness on the engine is protected by an engine-

OIL

PRESSURE

OIL

[M-508

BREAKER

or

electrical overload anywhere in

or

engine wiring will cause the

ALARM

2

),

this switch will activate a pulsating alarm.

GALLERY

SHOWN]

SWITCH

ALARMS

(20 amps DC).

eugine's oil

OIL

PRESSURE

AND

If

of

the problem.

-1.Q

ALARM

+ '

psi

SWITCH.

Univarsal

4

a a

CIRCUIT

COOLANT

A coolant temperature switch is located on the thetmostat . housing. This switch will activate a coolant's operating temperature reaches approximately 210"F (99°C).

&f.1;'@1P·NI#i•

'11

BREAKER

TEMPERATURE

THERMOSTAT

SWITCH

[M·50B

continuous

ASSEMBLY

SHOWN]

alarm

if

the

ll

WARNING:

and

gloves,

control

panel,

and

or

Never

use

turn

attempt

the

correct

off

the

to

perform

tools

battery

MAINTENANCE

any

service

while

the

engine

for

each

job.

When

switch.

servicing/rep/acing

SCHEDULE

is

running.

Wear

DC

components,

the

proper

turn

safety

off

the

equipment

DC

circuit

such

as

breaker

goggles

on

the

SCHEDULED

I

DAILY

Coolant Engine Fuel/Water

Fuel

VIsual

Drive

I

INITIAL

Engine

Exhaust

Engine

and Inlet

·

Fuel Engine Transmission Heat

MAINTENANCE

CHECK

Level

Oil

level

Separator

Supply

Inspection

Belts

50

HOURS

011

and

System

Throttle,

Shutoff

Lever

Fuel

Filler

Idle

Speed

Exchanger

BEFORE

(owner

of

Engine

OF

Filler

Transmission

Cables

Fluid

START-UP

Installed)

OPERATION

EXPLANATION

Check

at

Oil

level

Check hours

or

Use

properly

there

is

Check

for securing connections.

Inspect

Initial

engine

Initial

check

Check

that Check

the

Check

Initial

change,

Initial

change,

Refer

to

Initial

change,

Open

end

interval

OF

recovery

should

indicate

for

water.and

once a year.

filtered

adequate

fuel,

oil

v-clamp

Look

for

frayed

oil

and

at

50

the

exhaust

integrity/mounting

all

connections

then then

Specifications.

then

caps

and

for

your.

area.

SCHEDULED

tank,

if

empty,

between

dirt

in

fuel.

#2

diesel

with a Cetane

fuel

for

the

vessel's

and

water

tight.

loose

filter

hoses

every every

at

300

clean

Belts

then

250 250

out

and

No

exhaust

bolts/hardware

change

every

are

security

are

hours hours

hours

debris.

is

for

edges.

hours,

MAINTENANCE

check

at

manifold.

MAX

and

LOW

Drain

filter

if

necessary.

rating

needs.

exhaust

leaks.

leaks

around

and

must

be

properly

at

50

hours

then

250

hours

properly

attached

of

the

water

secure,

proper

or

once a year.

or

once a year.

or

once a season.

Change

zinc

Add

coolant

on

dipstick.

Do

Replace

of

#45

or

higher.

Check

that

the

elbow.

as

needed.

that

exhaust

and

lubricate

if

necessary.

water

Inspect

Carefully

the

correct

tensioned

change both every

or

once a year.

and

injected

travel

anode

if

needed.

not

overfill!

filter

every

Check

injected

wiring

inspect

securing

elbow.

with

Determine

250

operating

that

exhaust

and

electrical

200

hours or yearly.

for

clamps

are

WD-40.

zinc

elbow

leaks.

tight.

service

.,

i

I

EVERY

50

OPERATING

'Drive

Belt

(Fresh

Water/Raw

Starling

Batteries

··Electric

Fuel

Zinc

Anode

I

EVERY

100

Air

Intake

Filter

Heat

Exchanger

Key

Switch

(Instrument

Drive

Belts

(Fresh

Water/Raw

Starling

Batteries

Electric

Fuel

Raw

Water

Pump

•

Unlvarscil

HOURS

Water

Pumps)

Pump

OPERATING

Pump

recommends

Water

HOURS

Panel)

Pumps

this

OR

as

applicable)

service

MONTHLY

YEARLY

be

performed

by

an

knowledgeable

Inspect

for

proper

for

slipping,

cracking

Check

electrolyte

off

corrosion Inspect, Inspect

your

Inspect, Inspect

anode Replace

Lubricate Inspect

for

slipping, Check

off

corrosion Inspect, Inspect

if

no

leaks.

and

clean

own

inspection

clean

and

clean

needs

replacing,

zinc

if

with

for

proper

cracking

electrolyte

if

no

leaks.

impeller,

and

mechanic

• •

unlvarsctl

MARINE POWER

tension

and

levels

Make

needed.

Apply Connections zinc

anode.

schedule.

replace

zinc

anode.

you

necessary.

"lockeze".

tension

and

levels

Make

needed.

Apply

Connections

check

drive

.

(3/8"

wear.

sure

petroleum

are

Replace

as

needed.

Note

should

(3/8"

wear.

sure

petroleum

are

shaft

to

1/2"

Adjust

cables

clean

the

remove

to

1/2"

Adjust

cables

clean

security.

deflection)

tension

or

and

connections

jelly

to

and

tight.

if

necessary.

condition,

the

end

deflection)

tension

or

and

connections

jelly

to

terminals

and

tight.

Inspect

and

adjust

replace

as

terminals

are

for

Clean/replace

Note

the

then

determine

cap

and

adjust

replace

as

are

for

Clean/replace

there

is

no

if

needed.

in

good

corrosion

filter

condition,

your

clean

out

if

needed.

in

good

corrosion

filter

shaft

water

Check

Replace

order.

protection.

element

then

determine

own

schedule.

the

debris.

Check

Replace

order.

protection.

element

or

belt

cover.

Clean

if

applicable.

belt

cover. Clean

if

applicable.

oil

seal

If

zinc

leaks.

12

NOTE:

Use

the

engine hourmeter gauge

MAINTENANCE

to

log

your engine hours or

SCHEDULE

rec;"ro

your

eng~ne

hours running

time.

SCHEDULED

I

EVERY

·

Transmission

Engine Fuel Inlet

DC 'Electric 'Vibration

Heat

·

Exhaust

I

EVERY

*Fuel

Coolant

•valve

•starter

Raw

·Preheat

Engine/ShaH

Crank

MAINTENANCE

250

OPERATING

011

Filter

and

Fuel

Filter

Alternator

Fuel

Pump

Isolators/Engine

Exchanger

Elbow/Exhaust

500

OPERATING

Injectors

System

Clearances

Motor

Water

Pump

Circuit

Alignment

Case

Vent

D·Rings

HOURS

Mounts

System

HOURS

OR

YEARLY

OR

YEARLY

EXPLANATION

Change Change Remove Remove Check

mounting Inspect, Check

vibration Inspect Check

the of

the

exhaust chaffing. NOTE:

An

Check

and

Drain,

flush Adjust

valves.

Check

solenoid

motor

pinion

Remove components Lubricate

Check

operation

compounds Check

security

Clean

crank

Replace

fluid

at

the

engine

and

replace

and

replace

no

leaks.

zinc

anode

structural

No

exhaust

adjust

and

(Incorrect

drive.

from

engine,

showing

when

on

case

filter

element

system

of

OF

SCHEDULED

300

operating

oil

bracket,

Connections

isolators,

replace

integrity

leak

injection

re-fill

and

motor

re-assembling.

of

the

threads.

the

vent

hours.

and

oil

filter

fuel

filter

and

inlet

fuel

filter.

tighten

are

brackets

if

necessary.

of

the

attached

leaks.

wear.

shaft

as

to

Hoses

will

cause

opening

the

cooling

valve

clearance

for

corrosion.

remove

cover

If

needed,

pre-heat.

components

Remove

coupling

needed.

MAINTENANCE

Lubricate (always all

electrical

clean and

water the and

exposure

pressure

system

and

located

together)

sealing

0-rings:

connections.

and

tight.

mounting

injected

elbow.

All

muffler

to

diesel

and

with

will

result

Remove

inspect

replace

and

clean

check

inside

control

every

Clean/replace

hardware.

exhaust

hose

are

in

good

exhaust!

spray

appropriate

In

and

cam

impeller

the

shaft

alignment.

the

cable

and

check

200

hours

filter

Replace

elbow

connections

poor

lubricate.

and

rocker

casting.

serviceable

conditions.

antifreeze engine

Clean

wear

plate&.

gasket.

glow

plugs.

cover.

attachment.

or

yearly.

element

if

as

needed.

Check

should

condition.

mix.

performance)

and

Replace

Re-Install

the

be

secure.

lubricate

any

with

applicable.

integrity

No

the

starter

anti-seize

I

EVERY

1000

OPERATING

*Heat

Exchanger

•

Adjusting

*Positive *Fuel *Transmission

•starter *Transmission

NOTE:

the

Crankcase

Injectors

Motor

Keep

the

Valve

011

Damper

•:lJnlvGnGl

Clearances

Ventilation

Cooler

(as

Plate

engine

surface

recommends

HOURS

OR OR

Valve

applicable)

clean.

Dirt

this

service

and

be

EVERY

oil

will

inhibit

performed

FIVE

the

YEARS

Remove antifreeze

Adjust

Disassemble Pressure Remove Remove,

Inspect indication

engine's

by

an

knowledgeable

the

and

the

ability

and

valves.

test

clean

damper

of

to

heat

exchanger

flush

and

clean.

injectors/re-build

have

and

damper

remain

mechanic.

for

the

system.

Replace

professionally

lubricate

the

plate,

replace

spring

wear).

cool

professional

as

needed.

at

1500

hours.

tested

and

drive.

if

necessary

cleaning

cleaned.

(damper

and

plate

pressure

chatter

testing.

at

Idle

Change

speed

Is

the

an

ENGINE

COOLING

CIRCUIT

DESCRIPTION

The engine engine-mounted heat exchanger. through placement impeller pump. After engine coolant in the heat exchanger, it engine's charges

The gal-type engine. controlled.

The engine's coolant tenance become contaminated,

AcAUTION:·

crif!cal; a traced

A coolant and cant loss of coolant ing manifold

is

fresh

water cooled (engine coolant)

Raw

water

the

heat.

exchanger

eXhaust

overboard.

engine's coolant

metal

The engine's coolant temperature

schedule·

gases,

impeller pump mounted

in this

Proper

substantial-number

back

to

cooling

recovery

contraction during engine operation, without

system.

This

level,

tank

and should

. .

by a gear-driven,

the

raw water cools the

cools the exhaust gases, and dis-

is

circulated

must

manual.

it

can

cooling

system

tank allows

and

without introducing air into the

is

best located at

by

a belt-driven centrifu-

be

changed according

If

the coolant

lead

to

overheating problems.

system

of

engine

corrosion.

for

engine coolant expansion

be

easily

accessibie.

M-508

COOLANT

THE

RIGHT

by

an

is

pumped

positive dis-

mixes with the

on

the front

is

thermostatically

maintenance

failures

or

above the engine

FRONT

to

is

allowed

any

DRAIN

ENGINE

of

the

can

signifi-

JUST

MOUNT

main-

is

be

cool-

ABOVE

~

to

Drain the engine coolant

engine block and opening the

system with fresh

the

Parts Identification photos in this manual for locations.

·

NOTE:

The

petcock

help

drain

engine

A

wARNING:

protective

To

Refill

With coolant into the manifold.

NOTE:

exchanger

flow

water

manifold exchanger

Monitor the coolant

the

manifold cap.The petcock when refilling

Remove the cap on

coolant

replace the cap. Run observe the coolant expansion flow into the recovery

After checking Coolant engine cools needed. Clean

gloves.

With

the engine running

Open

the

petcocks

to

help

of

coolant

drain

appears

plug

remains

when

antifreeze

to

the filler neck and install the pressure

on

to

allow

mix

to

halfway between

for

shouii draw back into the cooling system

do·vn.

t1P

by

loosening the drain plug

the

manifold pressure

water,

then start the refill process. See

on

the

heat exchanger

coolant.

Beware

of

the

Coolant

in

idle, slowly pour clean premixed

on

the

remove

air from

at

the

drain

and

continue

full.

Close

in

the manifold and add

the

leaks,

Add

.''lilY

spilled coolant.

to

'the

flows from

thermostat should

trapped air

coolant recovery tank,

engine, close

stop

the engine and

coolant

can

also

hot

engine

thennostat

the

plug

fill

the

petcock on

to

LOW

to

the recovery tank if

housing

system.

opening,

system until

the

it.

also

escape.

and

MAX,

all

petcocks

coolant.

When a steady

as

be

fill

allow

heat

needed. Fill

cap.

be

close

·

opened

with

and

as

on

the

Flush

used

Wear

and heat

the

tank.

it

to

cool.

the

to

MANIFOLD

PRESSURE

CAP

NOTE:

Periodicq.lly

Ensure

that

the

upper condition and check tightly.

Carry a spare

check

the

condition

and

lower rubber seals

that

the

vacuum

cap.

of

valve

the

pressure

opens

are

PRESSURE

in

good

and

closes

CAP

cap.

ENGINE

COOLING

CIRCUIT

RAW

WATER

The raw water flow is created by a positive displacement impeller pump. This pump draws water directly from the ocean, lake, or river from a through-hull opening through a hose to the water strainer. The raw water passes from the strainer through the pump to a heat exchanger (through the heat exchanger tubes) where it cools the engine's circulating fresh water coolant. The raw water is then discharged into the water injected exhaust elbow, mixing with, and cooling the exhaust gasses. This mixture

driven through the stem tube and overboard.

Raw

Water

The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate within the On no account should this pump be run dry lubticant for the impeller. There should always be a spare impeller and impeller cover gasket aboard (an impeller kit). Raw water pump impeller failures occur when lubricant (raw

is

water)

are not warrantable, and operators are cautioned to make sure

raw water flow is present at start-up.

Changing

1.

Close the raw water intake.

2. Remove the inlet and outlet port hoses from the pump, noting the port location and positioning.

3.

Remove the pump assembly and its gasket from the engine.

4.

Remove the three hex head screws that hold the housing to the cover.

5.

Remove the impeller cover exposing the impeller.

COOLING

CIRCUIT

of

exhaust gas and raw water is

Pump

impell~r

not present during engine operation. Such failures

housing, producing the pumping action.

the

Raw

Water

Impeller

as

water acts as a

7. Check the cam and inner wear plate for wear. Replace as needed.

A

CAUTION:

impeller

cooling

they

circuit.

If

must

They

any

be

often

of

the

found

can

vanes

to

prevent

be

have

blockage

found

broken

in

the

off

in

heat

the

exchanger.

8. Slide the new impeller onto the shaft taking care to engage the impellers slot with the key on the shaft.

9. Apply a film surface

NOTE:

Just coat the surface, do not over apply.

10. Install the sealing the gasket and wear plate and install the impeller housing

and secure in position with the 3 retaining bolts and washers.

11.

Mount the pump to the engine taking care that the end seal and gasket are in place. mounting screws,

12. Reassemble the hose connections and water

13. Crank the engine a few revolutions to allow the pump to center on its drive slot.

14. Stop cranking and secure the pump to the gear case.

15. Start and run the engine, check for leaks and check for a

normal operating temperature.

NOTE:

Should a failure occur with the pumps intemal parts (seals and bearings) it may be more cost efficient to purchase a new pump. The price match the price

of

petroleum jelly or silicone to the inner

of

the impeller housing.

0-ring

just

finger tight.

intake.

of

individual pw1s would almost

of

a new pump.

in the impeller cover. Position

Do

not tighten the pump

open

the

raw

6.

Pull the impeller off the shaft. Observe that the key on the

shaft is not lost.

GASKET

HOUSING

·

WEAR

PlATE

NOTE:

Keep the slotted weep holes

and open. Water found coming from these openings indicates

must

a shaft seal leak and

RAW

WATER

0-RING

be attended to wit/rout delay.

PUMP

in

the pump housing clear

15

ENGINE

COOLING

THERMOSTAT

A thermostat, located near the manifold at the front engine, controls the coolant temperature as it continuously flows through the closed cooling circuit. When the engine is first started the closed thermostat prevents coolant from ing (some coolant is by-passed through a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up the thermostat gradually opens. The thermostat is accessible and can be checked, cleaned, or replaced easily. Carry a spare thermostat and gasket.

of

the

flow-

CIRCUIT

HEAT

EXCHANGER

ZINC

ANODE

Zinc

Anode

A zinc anode (or pencil) is located in the raw water cooling circuit within the heat exchanger. The purpose anode is to sacrifice itself to electrolysis action taking place in the raw water cooling circuit, thereby reducing the effects electrolysis on other components of

the zinc anode should cleaned carried onboard. The area in the exchanger where the anode is located should periodically

or

replaced, as required. Spare anodes should be

be

of

the system. The condition

checked monthly and the anode

be

cleaned

of

REPLACE

of

the zinc

anode debris.

CLEAN & REUSE

of

THERMOSTAT

(M-358

To

Replace

Remove the two cap screws and disassemble as illustrated. When assembling the new thermostat and gasket put a thin coat

of place. Run the engine and check for normal temperatures and that there are no leaks at the thermostat housing.

Heat

Exchanger

The heat exchanger is a copper tube which encloses a number

of small copper tubes and the freshwater coolant from the engine is circulated around the copper tubes. The raw water removes heat from the freshwater coolant. exchanger operating efficiently, it should be removed from the engine every pressure tested.

the

Thermostat

sealant on both sides

small copper tubes. Raw water is pumped through the

1000 hours to be thoroughly cleaned and

of

the gasket before pressing in

To

ASSEMBLY

SHOWN)

keep the heat

RAW

WATER

NOTE:

Always install

the

strainer will always

A clean raw water intake strainer is a vital component engine's cooling system. Include a visual inspection

strainer when making your periodic engine check.

in the glass should be clear.

Perform the following maintenance after every I 00 hours operation:

1.

Close the raw water seacock.

2.

Remove and clean the strainer filter.

3. Clean the glass.

4. Replace the sealing washer

5. Reassemble and install the strainer.

6.

Open the seacock.

7. Run the engine and check for leaks.

NOTE:

Also follow

INTAKE

STRAINER

the

strainer at or below

be

the

above

the

self-priming.

if

necessary.

procedure after having

waterline

of

this

The water

run

hard

the

aground.

If

the engine temperature gauge ever shows a higher than normal reading, the cause may be that silt, leaves or grass may have been caught up in the strainer, slowing the flow water through the cooling system

SEACOCK

of

raw

so

of

'sEALING

··WASHER

.,Unlvarsal

4

MARINE POWER

16

RAW

WATER

[TYPICAL].

INTAKE

STRAINER.

'.

ENGINE

OIL

CHANGE

DRAIN

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil to drain, hose and pump out the old oil. Make sure the oil drain hose is oil has been drained.

NOTE:

114NPT.

Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic present in the oil. Raw water present in the oil can result and/or a siphoning

ing circuit into the exhaust, filling the engine. This problem

is often caused

siphon valve. See UNIVERSAL'S Installation Manual.

THE

SUMP

or

attach a pump to the end

capped and properly secured in its holder after all the old

Thread size

of

a fault in the exhaust system attached to the engine

for

the lube oil drain hose capped end is

of

water in the oil. Although

of

raw water through the raw water cool-

by

the poor location

or

the lack

of

if

be

an

the drain

water is

the

anti~

Replacing

When removing the used oil filter, you may find it helpful and cleaner to punch a hole in the upper and lower portion the old filter to drain the oil from it into a container before removing it. This helps to lessen spillage.

NOTE:

to

make

An automotive filter wrench should be helpful in removing

the old oil filter. around the filter when unscrewing it to catch any oil left in the filter. Inspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes filter. engine block, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the engine block free oil to the rubber gasket on the new oil filter. onto the threaded oil filter stub, and tighten the filter firmly by

hand.

NOtE:

are

not

REFILL

the

Oil

Filter

Do

not

punch

this

hole

without first loosening the filter

certain

it

will come off!

Place some paper towels and a plastic bag

off

with the old oil

If

this rubber sealing gasket remains sealed against the

of

Use genuine

recommended.

THE

OIL

oil and apply a thin coat

UNNERSAL

oil

filters - generic filters

SUMP

of

clean engine

SCrew the filter

of

AWARNING:

mlnants.

nalls

thoroughly

card

clothing

oil

properly.

Avoid

or

Used

prolonged

using rags

for

engine

containing

NOTE:

the model M50B is located

of

the top

oil

contains

skin

contact.

soap

and

water.

used

Not illustrated. The block drain hex plug

of

the engines lube oil dipstick.

hannful

Clean

Launder

o/1.

Discard

skin

or

just

conta·

and

dis-

used

to the right

Add fresh oil through the filler cap. After refilling, run the engine for a few moments while checking the engine's oil pressure. Make sure there is no leakage around the new oil filter

or

from the oil drain system, and then stop the Then check the quantity the engine requires additional oil, fill to, but not over, the

high mark on the dipstick.

of

oil with the lube oil dipstick.

e~~

If

M-25XPB M-358 M-408 M3-20B

BLOCK

DRAIN

OIL

FILTER

TIGHTEN

BY

HAND

THE

NEW

WHEN

SPIN-ON

---

WITH

OIL

FILTER

MOISTEN

FILTER

GASKET

CLEAN

OIL

INSTALLING

17

REMOTE

OIL

KIT

PN

INSTALLATION

This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as an engine room bulkhead.

NOTE:

Refer

to

the

ENGINE

manual for instructions

To install, simply remove the oil filter thread

on

WESTERBEKE'S remote oil filter as shown. Try to install the remote filter facing down to help reduce oil spillage when changing.

OIL

on

removing

APPLY A THIN INSTALLING TIGHTEN CONTACTS

AN

THIS

THE

CHANGE page

the

oil

filter.

off

the engine and

COAT

OF

CLEAN

KIT.

THREAD

ADDITIONAL

BASE.

3/4

TURN

OIL THE

in

TO

KIT

ARER

this

THE

D-RING

ON,

THEN

THE

D-RING

THE

IN

CONNECTION

MUST

ATTACH CONNECTION REMOTE

FILTER

(OPTIONAL

#040078

NOTE:

incorrect installation

A

co"ectly. by-pass

from failure. immediately

WHEN

HAND

HOSE

TO

THE

DDT

AT

THE

OIL

FILTER.

Westerbeke

is

not responsible for engine failure

of

CAUTION:

valve

reaching

If

the

in

there

and

It oil

the

is

check

is

flows

engine no

the

Remote

vital

filter

oil

pressure

the

Oil

to

install

in

the

reverse

assembly

causing

reading,

hose

connections.

Filter.

the

will

an

internal

FASTEN

(SCREWS

oil

lines

direction,

prevent

engine

shutdown

SECURELY

ARE

OWNER

due

to

the

oil

TO A BULKHEAD

SUPPLIED)

THE

DDT

CONNECTION

MUST

ATTACH

OIL

TO

AT

FILTER.

CONNECTION REMOTE

THE

HOSE

IN

APPLY A THIN GASKET

WHEN CONTACTS 3/4

THE

TURN.

COAT

OF

CLEAN

INSTALLING.

BASE,

TIGHTEN

OIL

ARER

IT

TO

THE

FILTER

THE

FILTER

AN

ADDITIONAL

18

FUEL

ADDITIVES

If

fungus or bacteria have an authorized dealer correct these problems. Then use a diesel fuel biocide to sterilize the fuel (follow the manufacturer's instructions).

SPARES

While the likelihood sea is slini, the possibility does mend that banjo washers, injector seat washers, and a fuel filter be carried on board at all times. Purchase needed spares

from your local should develop at a banjo washer that cannot be corrected by a simple tightening

FUEL

LIFT

PUMP

The on-engine fuel system is virtually self priming. Under ordinary circumstances the engine's electric fuel lift pump, which is energized by the key switch/preheat button, will

supply a continuous flow

drawn through the fuel/water separator to the

·pump, the primary spin-on fuel filter, and the injection pump.

is

causing fuel problems, you should·

of

having to service the fuel system at

exist

Therefore, we recom-

UNIVERSAL dealer or distributor.

of

the fitting, replace the sealing washer.

of

fuel from the tank. This fuel is

engine lift

If

a leak

·

SYSTEM

FUEL

RETURN

A shut-off valve is located on the fuel return line near the injection pump. This valve

FUEL

Air

Cleaner/Silencer

Some p:NIVERSAL engines use a replaceable air filter ele-

w~;apped

ment removed and brushed off or cleaned with an it become too contaminated it can be replaced. The with its interior element should also periodically. mable cleaning solvent Use this same cleaning procedure for

other

UNIVERSAL air cleaners that use a similar type canis-

ter.

LINE

SHUT-OFF

must

SHUT·OFF

VALVE

around a metal canister. This element can be

Simply wash the assembled unit in a non-flam-

VALVE

be

[M-508]

fully open.

air hose. When

be

removed and cleaned

canister

A

WARNING:

near

the

fuel

proper

ventilation.

FUEL

SYSTEM

If

it becomes necessary to bleed air from the engine fuel

system, tum the panel key seconds). Activate the preheat circuit This activates the fuel which draws fuel into the engine fuel system and drives out via the fuel return.

If

the high pressure injector lines need to be bled, loosen the injector line nut at each injector, open the throttle and crank the engine over until fuel spurts from the nut and line. Then secure the nuts and start the engine as normal

NOTE:

Do

not attempt this procedure

A

JIIARNING:

safety

glasses

injector

lines.

Do

not

system

when

BLEEDING

ON

Always

and

gloves-when

allow

smoking

servicing.

and interrnitently

wear

Also

on

a hot

protective

bleeding

or

open

provide

(5

engine.

clothing,

high

pressure

flames

'•

- 10

air

~·

NOTE:

To

operate efficiently a diesel engine must continuous volume and black exhaust smoke intake.

FILTER

ELEMENT

of

clear

air.

Hard starting,

are

all symptoms

intake

a

an

erratic

of

a restricted air

AIR

CLEANER/SILENCER

[M·35B

SHOWN]

idle,

Unlvanal

44

MARINE POWER

19

ELEMENT

AIR

CLEANER/SILENCER

[M·50B

SHOWN]

.A.

WARNING:

ssrvlclng

that or v/clng. the

may

other

Ensuffl

fuel

the

spill.

sources

system.

Shut

fuel

system.

DO

NOT

of

proper

off

the

Take

allow

fire

near

ventilation

fuel

valve

ca111

any

smoking,

the

fuel

exists

at

the

in

catching

open

system

whflll

FUEL

tank

when

any

fuel

tlamtiS

whflll

ssr-

servicing

SYSTEM

FUEL

WATER

A primary fuel filter installed between the fuel water and other contaminants be

carried to the fuel system on the engine.

Most

installers include a type the installation package as they are aware that contaminants in the fuel can cause.

SEPARATOR

of

the water separating type must be

tank

and

the engine to remove

from

the fuel before they can

of

filter/water separator with

of

the problems

FUEL

FILTERS

The fuel injection pump and the fuel injectors are precisely manufactured and they must receive clean diesel fuel, free

from water and dirt. To ensure this flow

at

must pass through

rator and the

clean, and change these filters according to the maintenance

schedule in this manual.

1.

Shut fuel supply off.

2. Loosen the fuel filter, turning counterclockwise with a filter wrench.

Using a rag, wipe clean the sealing face on the housing

3. bracket so the new filter

4. Lightly oil the sealing

stall, turn the filter assembly clockwise carefully until the 0-ring

Turn 2/3 further with the filter wrench.

5.

Turn on the fuel and start the engine.

function should quickly should start.

NOTE:

during

)YSTEM after

engine's

contacts the sealing surface

The

cartridge contains fuel.

disassembly.

least two fuel filters, a fuel/water sepa-

spin-on fuel filter. Visually inspect,

can

be

0-ring

prime

Perform

replacing

the

spin-on

of

clean fuel, the fuel

seated properly.

on

the

new filter. To rein-

of

the housing bracket.

The

normal preheat

the system

Take

PRIMING

care

and

not

THE

filter.

the engine

to

spill

it

FUEL

A typical fuel filter/water separator is illustrated below.

This is

the

RACOR

if

a water separator type filter is fuel supply in the fuel will affect the fuel pump, engine filter, and injection equipment. The owner/operator is responsible for making certain the fuel reaching the engine's injection equipment is free and

NOTE: completely servicing.

tank

of

impurities. This process is accomplished by installing

maintaining a proper filtration/separation system.

Fill

the

full

TO

ENGINE

Model

500

MA.

Keep

in

mind

not

installed between the

and engine-mounted fuel system, any water

RACOR after

FROM

FUEL

TANK

NOTE:

10 FILTER IS

MICRON

ELEMENT

RECOMMENDED

FUEL

FILTER

WAfER/SEPARATOR

that

FUEL

FILTER

BLEED.

SCREW

Unlvarsal

4

MARINE POWER

20

NOTE:

AFTER

BLEED

THE

SERVICING

FUEL

THE

DRAIN

SYSTEM

FUEL

FILTERS

AS

NEEDED

DC

ELECTRICAL

SYSTEM

ENGINE

The engine has a 12 volt DC electrical control circuit that is shown on the wiring diagrams that follow. Refer to these diagrams when troubleshooting trical system on the engine.

DRIVE

A

Loose

charging

Drive

of

maturely.

Belt tension adjustment is made by pivoting the alternator on its base mounting bolt.

1.

2.

3. Tighten the base mounting bolt and the adjusting strap

4.

12

VOLT

DC

CONTROL

BELT

ADJUSTMENT

CAUTION:

drive

and

belts

alignment

Loosen the alternator adjusting strap bolt and the base

mounting bolt. Pivot the alternator on the base mounting bolt to the left

or right as required.

bolt. Operate the engine for about 5 minutes at idle, then shut

down and recheck belt tension.

belts

will

that

and/or

Drive

belts

will not

eventually

are

too

cause

provide

tight will pull

CIRCUIT

or

when servicing the DC elec-

must

be

damage

the

alternator

/<;_

properly

proper

the

tensioned.

alternator

alternator.

alternator

to

wear

out

pre-

GLOW

The glow plugs are wired through the preheat solenoid. When should

PLUGS

PREHEAT is pressed at the control panel this solenoid

"click" on and the glow plug should begin to get hot.

Inspection

To

inspect the plug, remove the electrical terminal connections, then unscrew or unclamp each plug from the cylinder head. Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and bum erosion;

if

it has eroded too much, replace the plug.

Testing

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the

of

other to the body plug will have a used with the plug in or out

an ammeter to test the power drain

A

WARNING:

hot

to

the

when

testing

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to seconds. circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

If

the plugs don't heat up quickly, check for a short

the glow plug, as shown. A good glow

0.7-

0.8 ohm resistance. This method can be of

the engine.

(8

- 9 amps per plug).

These

glow

plugs

will

touch.

Be

the

careful

plugs.

not

to

bum

You

can also use

become,

your

fingers

very

15

BAnERYCARE

Review the manufacturer's recommendations and then

· establish a systematic maintenance schedule for your engine starting batteries and house batteries.

• Monitor your voltmeter for proper charging during engine

operation.

• Check the electrolyte level and specific gravity with a hydrometer.

• Use only distilled water to bring electrolytes to a proper level.

• Make certain that battery cable connections are clean and tight to the battery posts (and to your engine).

• Keep your batteries clean and free

of

corrosion.

+

Unlvarsal

4

A

WARNING:

than

3D

GLOW

PLUG

seconds.

TIGHTENING

Do

not

TORQUE:

keep a glow

7-

11

Ft-lb

TESTING A GLOW WITH

plug

on

for

(1.0

-1.5

AN

OHMMETER

more

m-kg)

__.--TIP

PLUG

21

DC

ELECTRICAL

DESCRIPTION

The charging system consists voltage regulator, an engine

DC circuit breaker, and a battery and connection wires. Because voltage regulator is very compact and is mounted internally or

Alternator

If

voltage to charge the engine's battery, check the following:

of

the use

of

integrated circuits (IC's) the electronic

on

the back

of

the alternator.

Troubleshooting

you suspect that the alternator is not producing enough

A

WARNING:

bot.

Oo

not

A

touch

failetl

until

D Make certain your alternator is securely mounted. D Check the drive belts for proper tension.

of

an alternator with a mounted

DC

wiring harness, a mounted

altematllr

the

altematllr

can

become

bas

cooled

very

down.

SYSTEM

A

WARNING:

that

everyone

sheaves

5.

6.

The

NOTE:

voltmeter

the R terminal if the previous test showed only battery

age at

and

Start the engine.

voltage reading for a properly operating alternator should be between 13.5 and 14.5 volts. is overservice shop.

Before removing

to

the

B output

Before

starting

is

clear

of

moving

belts

during

or

undercharging, have it repaired at a reliable

the

ensure that 12 volts

terminaL

the

engine

parts!

test

procetlures.

alternator for

DC

excitation is present at

make

Keep

away

If

your alternator

repair,

use your

certain

from

volt-

D Inspect for loose

NOTE:

An

isolator selector switch is batteries so the

house batteries. battery but not the house battery, the alternator is the

problem is in the battery charging

A

disconnect electrical

Checking

If

you suspect the alternator has failed perform the following

tests with the engine off:

1.

Using a voltmeter, connect the voltmeter red wire clip to the output terminal B+.

2. Connect the voltmeter negative wire to any ground engine.

3. Check the battery voltage.

4. Check the voltage between the alternator ( +) positive terminal B and any engine ground. voltage at the alternator should (unless there's an isolator in the circuit, then the reading would be zero).

the starting battery is not discharged along

WARNING:

system.

for

or

disconnected wires at the alternator.

with

a

usutllly mounted

If

the isolator is charging

Shut

off

from

the

battery

Proper

Voltage

diode,

a solenoid, or a battery

in

the circuit to isolate the

circuit.

the

engine

battery

when

working

It

should read 12 to

If

the circuit is good, the

be the same as the battery

the

starting

OK and

switch

on

the

13

with

or

engine

on

volts.

the

TYPICAL ALTERNATOR

UNIVERSAL

CONNECTIONS

51

AMP

A

CAUTION:

circuit, the

never

engine

To

shut

is

running!

avoid

off

the

damage

engine

to

the

battery

switch

charging

when

22

OPTIONAL

ALTERNATOR

72

CONNECTIONS

AMP

r-----

~~~~*

I I I

I

.J

I I I

+~

AAlliJI:L

Use

!l-electrfc

lllllen

m~tlle

engne

Ill

ilnWIII

gmase

hllmess.

a

tight

.110m

tin

ilsfroll!flllt

11lerr

l)<wnrp

n1

sacure

lh•

wiring

panel

~

oonnec/lcn.

connections

ham.ss

fo

plJgs

together

DC

ELECTRICAL

•1

~

=.::....:~

SYSTEM

··m

•

+

ALAIN

C IUlZEI

ADMIRAL

PANEL

WIRING

. ,

..

,

..

DIAGRAM

These

diagrams electrical the

diagramed When

instrument provide tions

circuit.

CAPTAIN

an

ADMIRAL

data

below).

THERMOSTAT HOUSING

REMOVE INSTALL

·#39144

illustrate

The

two

PANEL

and

below

.

PANEL

sendors

are

for

the

panel

\)

ATTACH FROM

(co/orcodedyeflow)

THE

PLUG

THE

OIL

TEMP.

the

12

volt

optional

the

ADMIRAL

is

installed,

assembled

gauges

REMOVE IN

THE

SPARE

THE

HARNESS

AND

SENDER

negative

instrument

PANEL

two

to

the

engine

(refer

to

THE

SENDER

WIRE

BUNDLE

·

ground

panels,

are

additional

to

the

illustra-

PLUG

AND

~

PLUG

SCREW

r--

-I

CAPTAIN PANEL

NOTE:

®

Denotes off

the

preheat

oil

pressure

afann

sofenoi~

circuit

resister

·I • tenninal

PN039806

,

I

*

NOTE:

An

on-off should circuit starter an

emergency leaving volt

diesel typically amps

when switch rating

of

VDC

Ill

ILK

Ill

11.11:

Ill

BLK

tit

I!ILII

will

this

function,

must

"make"

never

switch

be

installed

in

the

battery

and

when

boat.

Twelve

starters

200

to

cranking.

amps

serve

but a switch

be

used

starter

circuit.

at

the

to

this

300

A

12

to

disconnect

from

the

engine

draw

with a continuous

175

normally

the

in

Unlvarsal

4

MARINE POWER

23

DC

ELECTRICAL

+

IZ

VDC

SYSTEM

ITAITEit

r-+-+-1-----

WIRING

LIFT

PUMP

FUlL

...

O.P.

IUDtl

CWIIll

·~:.e-·.!•1!1-

SCHEMATIC

#39144

NOTE:

An

should

be

circuit

to

starter

from

an

emergency

leaving

the

volt

diesel

typically

draw

amps

when

switch

with a continuous

rating

of

VDC

will

normally

this

function,

must

never

"make"

the

IAT

KET

...

I 0

on-off

installed

disconnect

the

battery

and

boat.

engine

200

cranking.

175

amps

but a switch

be

used

starter

Pl-l

switch

in

this

the

in

when

Twelve

starters

to

300

A

at

12

serve

to

PREHEAT

SWITCH

LAlOP

TUT

...

circw~"t.-------------=-:--.,-::--..,.--=~.,...,..,~.,..--1

51

AMP

STANDARD

me~.

ALTERNATOR

'lc

I

Hd:l:~

ADMIRAL PANEL

CAPTAIN

PANEL

ON

THE

Dr.

8ZB

Dr.

HITSUBISHI

~PRESTOLITE

72

114 LT.

114

AMP

50

AMP

PI

ALI

BLU

IlK

1--------------------

114

BRN

'ALT

24

114

GRA

114

PINK

114

LT.

BL

~UNIVERSAL

PRESTOL

PROPULSION

I IE

51

AMP

ALI

WIRING

BATTERY

SWITCH*

r---,

r~-~----------

1

DIAGRAM

CATALINA

19

YACHTS

110

RED

OIL

ID.EH.

#200360

PRESS

......

...

L_~

BATTERY

*

An

on-off

switch

not

RED

to

at

be

should

disconnect

the

boat. A switch

12

volts

will

used

to

the

starter

when

leaving

175

amps

should

t14

GRA

!NOT

USED?(

110

@PRESIOL I IE

be

the

serve

make

installed

between

battery

in

an

with a continuous

the

function.

or

break

this

<

114

72

AMP

ttie

emergency

This

circuit.

tl4

LT.

114

PINK

BRN

ALI

battery

and

rating

switch

BLU

and

of

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26

ENGINE

~,~

·

.

NOTE:

UNIVERSAL recommends that 'the following engine

~adjustments

information below is provided to assist the mechanic.

The

ADJUSTMENTS

be performed by a competent engine mechanic.

THROTILE

MODEL

THROTTlE CONTROl

M3-208

MODELS

AND

STOP

CONTROLS

M-258,

M-358

THROTTlE lEVER

Remove the valve rocker cover to expose the engine's valve

train. Remove the glow plugs from each

enable the engine to be easily rotated by hand to position

each cylinder for valve adjustment. Valves are adjusted with the piston in the cylinder being

adjusted at TDC (Top Dead Center) stroke. Each cylinder is adjusted following the engine's firing order.

FIRING

ORDER 3 CYLINDER

4

CYLINDER

Adjust the valves beginning with Cylinder #1. Rotate the crankshaft slowly and observe the operation Cylinder

the piston is on its intake stroke (the piston is moving down in the cylinder). Continue to rotate the crankshaft slowly and look for the intake valve to close. The piston is now starting its compression stroke (the piston is moving up in the cylinder towards TDC).

Watch the timing hole in the bell housing for timing numbers to appear. Position the ITC Mark in_alignment with the notch in the timing hole. The piston in Cylinder Adjust the valves in Cylinder #1. Proceed to the next cylinder in the

Three

Rotate the crankshaft rotation and adjust the #2 cylinder's valves. Rotate the crankshaft another

#1. Watch for the intake valve to open indicating

firing order.

Cylinder

240

MODELS MODELS

Models

240

degrees in the normal direction

degrees and adjust the #3 cylinder's valves.

of

the cylinders

of

its compression

1-2-3 1-3-4-2

of

the valves for

#1

is

to

now at TDC.

of

MODEL

THROTTLE

The throttle and engine stop levers are located on the outboard side Brackets are provided for owner-installed push-pull cables that run to the steering station. The throttle high speed adjustment has been factory set and is wire locked. The throttle idle screw be periodically lubricated and checked for loose fastenings.

VALVE

M-508

AND

STOP

ASSEMBLY

of

the engine just below the fuel injection pump.

is

adjustable. These levers and brackets should

CLEARANCE

NOTE: Valve adjustment should not be necessary under normal operating conditions. These adjustments, when required, should be

performed by an authorized mechanic.

Four

Cylinder

Rotate the crankshaft 180° in the normal direction and adjust the #3 Cylinder's valves. Rotate the cr.ankshaft another crankshaft another 180° and adjust the #2 Cylinder's valves .

.

SOME

HAVE A COVER OVER HOLE

180° and adjust the

MODELS

THE

Models

~

#4

Cylinder-'s valves. Rotate the

VALVE

[COLD

0.0071 -0.0087

..__.__ _ _._

[0.18M-508

0.0057[0.145M3-208, M-358,

of

rotation

II'

CLEARANCE

ENGINE)

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27

ENGINE

NOTE:

UNNERSAL

adjustments be

The information below

OIL

PRESSURE

The engine's oil pressure, during operation, by the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 60 psi (2.8 and 4.2 kg/cm

NOTE:

A newly started, cold engine can have an oil pressure

reading

. an oil pressure reading as low as 35 psi (2.5 kg/cm

readings will vary depending upon the temperature engine and the rpms.

Low

The specified safe minimum oil pressure

gradual loss For additional information on low oil pressure the ENGINE

up

to 60 psi (4.2 kg!cm

Oil

Pressure

of

oil pressure usually indicates a worn bearings.

TROUBLESHOOTING chart.

LUBRICATION

2

).

DIAGRAM

2

).

A warmed engine can have

is

is 5-10

ADJUSTMENTS

peiformed by a competent engine mechanic.

indicated

40 and

2

).

These

of

psi. A

re~dings,

TYPICAL

recommends that the following engine

is

provided to assist the mechanic.

+

the

see

Testing

To

test the oil pressure, remove the oil pressure sender, then

install a mechanical oil pressure gauge in its place. After

warming up the engine, set the engine speed at idle and read the oil pressure gauge.

OIL

PRESSURE 7 psi

SENDER

AND

•

OIL

PRESSURE

Oil

Pressure

SWITCH

TORQUE

[49

KPal

at

idle

9 ·13

speed.

!l-Ib

(1.2

[M-508

NORMALLY

·1.8 m ·kg).

OIL

GALLERY

SHOWN]

OPEN 5 PSI

RATED

.

OIL

FUEL

INJECTORS

In case injectors checked and overhauled by injection service center. loss. in injector faults. Since fuel injectors must be serviced in a clean room enviroment, it is best to carry at least one extra injector as a spare should a problem occur.

Before removing the old injector, clean the base falling down into the injector hole.

out easily and

the injector side-to-side with the aid

free it, and then lift it out.

washer. This washer should be removed with the injector,

replace with a new washer when the new injector

of

severe vibrations and detonation noise, have the

an

authorized fuel

Poor fuel quality, contaminants and

of

positive fuel pressure to the injection pump can result

area around the

of

the injector to help prevent any rust or debris from

If

the injector will not lift

is

held in by carbon build-up or the like, work

of

the socket wrench to

The injector seats in the cylinder head on a copper sealing

is

installed.

INJECTOR

TO

CYLINDER

HEAD

TORQUE

40

± 4 !l-Ib

(5.5 ± 0.5

kgf-m)

28

ENGINE

TROUBLESHOOTING

The following trouble shooting chart describes certain problems, the probable causes

mendations to overcome the problems.

Problem

Key

switch

on, depressed: fuel

solenoid

Key

switch depressed: no

starter

Engine start

Engine

PREHEAT

no

panel

or

electrical

on,

PREHEAT

START

engagement

cranks,

but

can't

be

stopped.

stops.

indications;

switch

does

of

the problems, and the recom-

switch

fuel

pump

switch

depressed;

not

1.

Battery 2Q-Amp

2.

1

0-Amp

3.

4.

Loose

5.

Preheat

1.

Connection

2.

Faulty

3.

Faulty

4.

Loose

5.

Low

1.

Faulty Preheat

2.

3.

Low

1.

Faulty

2.

Push-pull station

Fuel

1.

2.

Switches or

3.

Fuel 20

4.

5.

Exhaust

·

Probable

battery

START solenoid.

battery

batteries.

fueling

compression.

shut-off

lift

disconnected.

starvation.

Amp

Switch

circuit

breaker

connections.

solenoid

to

solenoid

switch.

connections.

system.

solenoid

shut-off

to

engine

pump

failure.

and/or

circuit

system

Cause

not

breaker

tripped.

lever

wiring

breaker

is

on.

not

faulty.

at

cable

disconnected.

restricted.

tripped.

operating.

faulty.

engine.

from

steering

loose

tripping.

NOTE:

The engine's electrical system is protected by a

20-

Ampere manual reset circuit breaker located on the bracket

of

on the left side

mounted on the

the engine. The preheat solenoid is

same

bracket.

Verification/Remedy

1.

Check

switch

and/or

battery

connections.

2.

Reset

breaker,

if

breaker

trips

again,

check

preheat

circuit

3.

Check

4.

Check(+) engine

5.

Check

1.

Check

2.

Check

3.

Check connection.

4.

Check(+) engine

Check

5.

1.

Check

2.

Check

3.

Compression

1.

Reconnect

2.

Reconnect

1.

Fuel

lift

pump

2.

Inspect Inspect

3.

Check Check

4.

Ensure cause

Check

5.

exhaust

and

check

voltage

at

connection

ground

stud. solenoid. connection

switch

with

that

12

volts

connection

ground

stud. battery

charge

that

fuel

valves

solenoid.

test

shut

off

push-pull

pump

should

with

spare.

wiring

for

switches

fuel

supply,

for

high

DC

breaker

is

tripping.

for

blockage,

elbow.

circuit

for

and

after

to

starter

Check

at

solenoid.

ohmmeter.

are

present

to

starter

Check

state.

are

the

engine.

lever

cable.

make a distinct

short

circuits

for

proper

fuel

valves,

amperage

not

overly

collapsed

shorts

breaker.

solenoid

battery

at

solenoid

battery

open.

and

operation.

fuel

draw sensitive

hose,

to

ground.

cable

starter

cable

ticking

loose

lift

pump.

during

to

carbon

and

connections.

solenoid

and

connections.

heat

solenoid

(-)connection

activation

(-)connection

sound.

Replace

connections.

operation.

which

would

buildup

at

to

r

6.

Battery

not

charging

1.

Water

in

fuel.

Alternator

drive.

29

6.

1.

Pump bleed

Check for

loose

volts

water

from

fuel

system.

drive

belt

connections.

are

present

fuel

tank(s);

tension.

Check

at

the

change

Atemator

output

Exc

terminal.

filters

should

with

and

turn

freely.

voltmeter.

Check

Ensure

12

ENGINE

TROUBLESHOOTING

Battery

runs

down.

Engine

overheats.

NOTE:

Shut

engine

Exhaust

smoking

Transmission of

gear,

or

drive

Excessive

vibration

Problem

down

problems

will

not

shift

the

vessel.

immediately.

in

or

out

1.

Oil

Pressure

High

resistance

2.

Low

resistance

3.

4.

Alternator.

Poor

5.

1.

Raw

water

2.

Coolant

1.

Blue

smoke.

2.

White

3.

Black

1.

Transmission

1.

Faulty

2.

Cutless propeller

Probable

switch.

leak.

battery

connections.

not

circulating.

not

circulating.

smoke.

or

gray

smoke.

failure.

engine

alignment

bearings,

could

Cause

leak

to

support

all

be

suspect.

ground.

strut

and

1.

Observe

not

running.

2.

Check

(Do

not

is

located.

3.

Check

4.

Disconnect leakage

5.

Check

1.

Broken

2.

Raw

water

2a.

Obstruction

2b.

ThermostatReplace

2c.

Loss leaks.

2d.

Broken

2e.

Air

leak

heat

exchanger,

1.

Incorrect

1a.

Crankcase the

exhaust).

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel

bum insufficient exhaust

3b.

Improperly compression.

3c.

Lack ventilation.

3d.

Overload.

3e.

Propeller.

1a.

Check transmission

1

b.

Check

1c.

Check

1d.

Check

1.

Check

1a.

Inspect

2.

Inspect

Verification/Remedy

if

gauges

and

panel

Test

the

oil

wiring.

Insert

start

all

wires

stops,

cable

or

thermostat.

of

coolant...,...

or

in

grade

is

running

injector

grade incomplete

system;

of

air-

cable

transmission shaft

engine's

the

all

propeller

sensitive

engine.)

Remove

for

temperature

alternator

loose

pump

loose system;

is

air

timed

shafVtransmission

engine

at

remove

alternator

connections

belt

at

raw

failure.

at

raw

water

remove

and

check

belts-

run

engine

manifold,

of

engine

overfilled

with

cold.

or

incorrect

of

fuel.

due

for

proper

check

air

fuel

system,

check

air

intake

connections

lever.

fluid.

couplings

or

damper

mounts.

and

shaft.

lights

pressure

output,

Check

plate.

are

switch.

(0-

.25

amp)meter

connections

rise

to

after a good

and

bench

at

battery. water

pump.

impeller-

intake

or

raw

test

in

hot

water.

hoses,

hose

clamps,

tighten/replace.

and

open

etc.

to

bleed

oil.

engine

oil

(oil

injector

timing.

to

high

back

combustion

intake).

at

steering

engine

(Check

misadjusted

and

air

filter.

station

damper

coupling.

activated

and

locate

the

battery

test

replace.

water

filter.

drain

cooling

air.

Add

is

blowing

pressure

for

valves

Check

and

plate.

when

engine

in

battery

replace

fault.

charging.

Repair

plug,

system

coolant

as

out

in

exhaust

restrictions

or

poor

for

proper

at

is

lines.

after

short

If

or

replace.

etc.

for

petcocks,

needed.

through

or

in

30

NOTE:

located

CONTROL

MANUAL

The

engine control system

on

the

engine as close

PANEL

STARTER

DISCONNECT

is

protected by a 20 amop manual

as

possible

TROUBLESHOOTING

to

the

(TOGGLE

power

source.

SWITCHES}

reset

circuit breaker

PREHEAT

fuel preheat

START

engagement.

NO

NOT

BATTERY

ALARM

solenoid,

solenoid

SWITCH

IGNITION,

CHARGING

BUZZER

(Oil

pressure

depressed,

RUNS

Problem

no

electric

cranks,

normal)

panel

fuel

not

energized.

DEPRESSED,

does

BATTERY

DOWN

SOUNDING

indications

pump

no

not

and

starter

start.

Oil

1.

2.

20

amp

1.

Connection Faulty

2.

Faulty

3.

4.

Loose Low

5.

Faulty

1.

2.

Check

3.

Faulty

1.

Faulty

1.

Oil

High

2.

3.

Low Faulty

4.

1.

Resistor

2.

Fuel Oil

3.

Probable

Pressure

circuit

to

switch solenoid. battery

battery.

fueling

for

air

fuel

lift

alternator

pressure

resistance

alternator.

shorting.

pump.

pressure

Cause

switch.

breaker

tripped.

solenoid

faulty.

connections.

system.

in

the

fuel

system.

pump.

drive.

switch.

leak

to

ground.

leak

to

ground.

switch.

1.

Check

2.

Reset and

1.

Check Check

2.

3.

Check

4.

Check Check

5.

1.

Check Allow

2.

Replace

3.

Check

1.

turns output

regulator

1.

Observe

engine

2.

Check lines

after

3.

Check

4.

After a good If

leakage

replace. Check

1.

solenoid Fuel

2.

Oil

3.

Verification/Remedy

switches

and/or

breaker.

If

run

connection. switch

that

battery battery

for

system

the

freely.

the

(Do

short

pump

pressure

opens

circuit

for

shorts

with

ohmmeter.

12

volts

are connections. charge

fuel.

to

bleed.

fuel

lift

pump.

drive

belt

and

Check

terminal.

the

gauges

not

running.

wiring.

NOT

start

is

located.

wires

for

battery

stops.

1000

"I"

terminal

coils

shorting.

switch

for

Insert

engine).

temperature

charging,

Remove

ohm.

internal

with a voltmeter.

if

is

all

resistor

battery

again,

to

present

state.

its

loose

Ensure

and

Test

sensitive

alternator

and

ground.

panel

the

resistor

connections.

check

preheat

ground.

at

the

solenoid

tension.

Be

connections.

12V

are

lights

are

oil

pressure

(0-.25

Remove

connections

rise

to

locate

disconnect

and

found

contacts

not

solenoid

sure

the

Check

present

activated

switch.

amp)

the

alternator

bench

between

closing

circuit

connection.

alternator

the

at

the

when

meter

in

battery

and

replace

fault.

at

output.

test.

Repair

preheat

properly.

the

or

TROUBLESHOOTING

If

the gauge reading is other than what is normally indicated by the gauge when the instrument panel is energized, the step is to check for 12 volts and the Negative

(B-) terminals

Assuming that there is 12 volts as required, leave the instrument panel energized (key switch on) and perform the following steps:

1.

Disconnect the sender wire at the gauge and see gauge reads zero, which is the normal reading for this situation.

2. Connect the sender terminal at the gauge to ground and see

if

the gauge reads full scale, which is the normal reading

for this situation.

DC

between the ignition (B+) of

the gauge.

WATER

TEMPERATURE

if

the

4

AND

If

both

of

the above gauge tests are positive, the gauge is

first

undoubtedly conductor from the sender to the gauge

If

either

of

probably defective and should Assuming the gauge is

sender to the sender terminal at the gauge for continuity. Check that the engine block is connected to the ground.

Some starters have isolated ground terminals and battery is connected to the starter (both plus and minus terminals), the ground side will not necessarily be connected to the block.

,..Unlvarsal

31

OIL

PRESSURE

OK

and the problem lies either with the

GAUGES

or

with the sender.

the above gauge tests are negative, the gauge is

be

replaced.

OK, check the conductor from the

if

the

TACHOMETER

TACHOMETER/HOUR

The

tachometer/hour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the other the tachometer. The hour meter circuit operates on volts

alternator charging voltage supplied to the (

on

the back

The from tachometer input terminal while the engine is running, and the

alternator producing battery charging voltage 13.0-14.8

volts The

· a fault meter.

Hour

Check for the proper DC voltage between ( +) and (-) terminals.

1.

Voltage present- meter is defective- repair or replace.

2.

Voltage not present - trace ( +) and (-) electrical connections for fault. (Jump 12 volts terminal to verify the operation.)

Tachometer

Check for the proper AC voltage between tachometer input

terminal and

1.

Voltage present - attempt adjusting meter through calibration access hole. No results, repair or replace meter.

2.

AC

output voltage.

3.

Check for AC voltage at tach terminal on alternator ground.

4.

Check electrical connections from tachometer input terminal

Tachometer

1.

Check for proper AC voltage between "tach inp." terminal

2.

Check for good ground connection between meter(-) terminal and alternator.

3.

Check that alternator is well grounded to engine block at

alternator pivot bolt.

Tachometer

1.

With a hand-held tach on the front pulley retaining nut or using a strobe type tach, read the front crankshaft pulley rpm at idle.

2.

Adjust the tachometer using an 2mm Allen head wrench 5/64 (2mm) through the calibration access hole in the rear of indicated by the strobe or hand tach (verify rpm at idle and at high speed). Adjust the tach as needed.

of

the instrument.

tachometer circuit operates on

one

of

the diodes in the alternator and supplied

DC.

following are procedures to follow when troubleshooting

in

either

of

meter

Inoperative

(-)

terminal with the engine running.

voltage not present - check for proper alternator DC

to

alternator connection.

Sticking

and (-) terminal.

Inaccurate

the tachometer. Zero the tach and bring it to the rpm

METER

+)

terminal

AC

voltage 6-8 volts, fed

m.

the two circuits in a tachometer/hour

DC

to meter(+)

.

of

the crankshaft

the

to

12

NOTE:

Current model tac_hometers use a coarse adjustment dial to set the tachometer to the crankshaft pulley calibrating screw

IDLE

SPEED

&

TACHOMETER

Checking

NOTE:

In a new installation having new instrument panels,

the tachometer may

:S

engine installations.

1.

2. Start and idle the engine.

3.

4. Adjust the idle speed

rpm. This calibration should be checked

Warm up the engine to normal operating temperature. Remove any specks on the crankshaft pulley with a clean cloth and place a piece pulley to facilitate use

Aim the light

confirm the engine speed. Check the instrument panel tachometer reading. Adjust the tachometer in the panel using the instrument coarse adjustment to calibrate the instrument reading to the closest is showing. Then use the bring the instrument to the exact reading as the photo tach.

specified value.

NORMAL

MODEL

M3·20B M25XPB M35B M40B MSOB

NOTE:

Attempting to reduce idle speed below the minimum

shown

may

is

then used

for

fine tuning.

CALIBRATION

ADJUSTMENT

CHECK

the

idle

speed

not

of

the tachometer onto the reflecting tape to

IDLE

SPEED:

RECOMMENDED

1000

1000-1200

800-1000

800-1000 800-1000

produce unstable engine operation and stalling.

(New

Installation)

always be correctly calibrated

of

suitable reflecting tape on the

of

a photoelectric type tachometer.

R.P.M. that the photo tach

fine calibration adjustment to

if

the engine speed is not within the

RPM

RANGES

IDLE RPM

-1200

CRUISE

RPM

2500-3000 2000-2500 2000-2500 2000-2500 2000-2500

rpms.

in

all new

MAXIMUM

3500-3600 2900-3000 2900-3000 2900-3000 2700-2800

The

(+)

TERMINAL(l)

to

the

by

RPM

,.~,Univarsal

4

a a

m·,;l@tu·wia;•

32

WATER

HEATER

CONNECTIONS

WATER

This engine engine coolant heater should high or low'position necting hoses from the heater to the engine can sonably direct line without

Hoses should rise continuously from their low point at the heater

heater then ting

NOTE:

engine ized (aluminum) be remote higher heater,

the expansion tank coolant level

-tank plastic coolant recovery tank

expansion tank kit

HEATER

to

the engine

to

the engine.

an

air bleed petcock must be installed at the higher

on

the heater for bleeding air while filling the system.

If

any portion

j closed cooling system pressure

installed

expansion tank

of

the

and plumb a single

other back

will

now

INSTALLATIONS

is

equipped with connections for

to

heat an on-board water

be

mounted in a convenient location either in a

in

relation

so

that air will rise naturally from the

If

trapped air

of

remote

in

the

circuit

into

two

connections for

to

the

engines

in a c_onvenient

can

easily

serve

as

a check and system fill

is

installed, since

to

the engine,

any

loops which might trap

is

able

the

heating circuit

expansion tank

to

become

the

line

heater

the

up

to

return.

the

return. the Install

location

be

checked.

is

not used

The

this

the

heater.

so

run

to

rise

rises

above

cap,

then

(Kit

#024177) must

highest point.

circuit,

choosing

Tee

tanH location and

the

so

the

fresh water

remote

point.

when

the

tank serves

plumbing

The water

that the con-

in

a rea-

air.

to

the heater,

fit-

the

a pressur-

Tee

the

at

the

remote

expansion

The

remote

the

function.

of

the

same

The pressure cap on the engine's manifold should installed after the engine's cooling system coolant. Finish filling the cooling system from the remote tank after the system

good coolant circulation. During engine operation, checking the engine's coolant should not at the engine manifold cap. The hose connection heater

to

the remote expansion tank should supported enabling any air in the system

of the system.

NOTE:

so

it rises continuously from the heater

Air bleed petcocks exchanger and cocks when filling

in

the

air air

coolant circuit

is

removed.

is

filled and

be

done at the remote tank

to

rise

are

located

on

the

thermostat

the

engines fresh water system

to

escape.

is

housing.

is

free of air

up

to

on

the

Close

tightly after all

THERMOSTAT

HEATER

filled with

and

be

routed

the tank

engine

Open

these

BELOW

be

exhibits

and

from

and

to

the tank,

and

j heat

pet-

to

allow

HOUSING

THE

out

the

ENGINE

the

HEATER

ABOVE

THERMOSTAT

HOUSING

THE

ENGINE

NOTE:

The

is

for filling and coolant. need not

Water

go

remote

expansion tank

the

expansion

heater coolant flow

through

the

tank.

HOSE

CONNECTIONS

The hose adapters (nipples) corning off the'engine (thermostat housing and water pump housing) are sized for

3/8" I.D. hose. An adapter

will increase the size

to

is

available (#302391) that

5/8" I.D. hose.

of

ADAPTER

PN

302391

·33

PRM

NEWAGE

TRANSMISSIONS

THE

MO/JEl_

FITTING

ON

- -

12D

THE

MOD-ElS

liAS

A

BRfATHEI<~·

TOP

OF

TH£i

CASE

_ ·

. ·

..

...:.niJ"STII~K

_

MODEL

A

BMM

PRM

712"

80

(MODEL

HEX

80,,.__.

PLUG)

HEX

--6.:~~

PLUG

120

USES

SO

ANI:f12b

NOTE:

drain plug sealing this

sealing

A

WARNING:

engine dipstick

When

is

hole.

changing

washer.

Never

running.

This

VENTS·

DAILY

OPERATION

0 Check the transmission 0

Visually

check the gear shift linkage

0 Start the engine in neutral,

idle

to

warm the

SEJIIJNG

WASHER

LOW:

~

0 Shift into

NOTE

:

the

. from

the

idle

GEAR

The erigine must be selecting

120 are ideal for single lever controls, controlling

throttle

gear.

Too

low

an

idle speed will produce a chattering noise

transmission gear and damper

speed should

SHIFTING

ahead

or

astern, Transmission

and

the gear shift

the

fluid,

take

care

not

The

drain

plug will

pull

out

the

dipstick

Hot

fluid

will

splash

from

~:ould

cause

severe

bums.

fluid.

allowing a few

fluid.

be

increased.

at

idle. Pause in neutral before

at

one

time.

and

plate.

models

to_

lose

the

leak

without

while

the

transmission.

minutes

In

PRM

such

both

at

cases

80

the

and

NOTE

:

Keep

vent/vent holes clear and

INITIAL

Before transmission Dexron

Do Model

Model

NOTE

filling with

Run the

CHECKING

Thread the dipstick

·observe

CHANGING

Change the fluid for the first time after the first of engine oil and filter change. Check for leaks and make a visual inspection Insert a suction pump hose down through the dipstick opening to the bottom fluid. (If space allows, use the transmission drain plug). Remove the drain plug and the drain plug with sealing washer. Tighten securely. Properly dispose with new fluid and shift the trans then shut

OPERATION

starting

not

overfill.

PRM80PRM

: Always clean

the engine

engine,

break-in, then every 300 hours or yearly with your

allow the fluid to drain into a container, then reinstall

II

or

fluid.

re-check

the

engine,

with

automatic

Dexron

1.0

120 -1.4

Replace

to

warm

THE

FLUID

fluid

level.

THE

TRANSMISSION

of

to

full make on dipstick.

remove

ill.

Fill

U.S. U.S.

the

area

the

up

the

fluid

LEV~L

fully

into

the shift cable and shaft coupling.

of

the housing and suck out the

(1" hex plug with sealing washer)

the old fluid and refill the transmission

down

transmission

to

pints pints

around

dipstick

level.

the

unobstructed.

the

dipstick

the

mark

(0.6L)

(0.8L)

the

by

fluid

and

case,

then

FLUID

and

check fluid level.

and

fluid

(ATF)

on

the

dipstick.

dipstick plug

screwing

after

Run

it

shutting

unscrew

50

the engine

fill

down.

it

hours

_ -:

the

before

down

and

A

WARNING:

throttle

ahead

LO.CKING

Lqcking of the propeller shaft by

n(Cluired.

direction of travel for this purpose. Never put the

b~at.

WHEN

Rotation of boat is being sailed, being towed or well (forcharging the battery), will on the transmission.

to

or

astem.

THE

Use the gear shift lever position

position corresponding

UNDER

the

as

operation of

When

shifting

idle

and

pause

PROPELLER

to

SAIL

OR

BEING

propeller without a

the

engine

gears,

in

neutral

an

the

direction of

with

have

bring

before

additional

opposite

TOWED

load,

such

anchored

the

propeller

no

detrimental

the

engine

shifting

brake

your

the

gear shift

travel

as

when

in a

river,

stopped

effects

of

is

not

in

the

·

the

as

34

PRM

NEWAGE

TRANSMISSIONS

MODELS

CONTROL

The control cable or

to

the

position. The neutral position of

cockpit must coincide with

The shift lever travel must be such that the

internal stops for the lever when shifted into forward or reverse. Those stops can be determined the

shift lever with the cable disconnected. This important adjustment for proper engagement the

lever travel impeded which, in turn, would mean premature wear, excessive heat generation and premature clutch failure. would

engagement

NOTE:

cable

MAINTENANCE/SERVICE

Make the box suffers major mechanical damage, thoroughly correct specifications.

NEW

the

Atlantis

418

Topsfield, Tel:

Fax:

CABLES

rod

should be arranged

actuating shift lever

is

too short, proper engagement might

be

indicated

at

all.

Check for proper lever travel and

to

the

lever bracket at least each

certain the transmission

fluid

should become contaminated

flushed

AGE

TRANSMISSIONS

world.

Listed here are those

Marine

Gear

Boston

Street

MA

01933

978-887-0001

978-887-5599

with

the

.neutral

by

slow clutch engagement or

fluid

out

and

re-filled with

LTD.

in

Supply

Inc.

--

at

a right angle

lever

in

the

neutral

operating lever

position of

the

lever just strikes

by

manually moving

of

the

security

season.

is

changed

has

the

by

the

United

annually.

water or

gearbox

fresh

fluid

distributors

States.

in

this

is

an

the gear.

no

of

the

must be

to

80

the lever.

If

be

This

the

If

gear-

the

around

AND

120

NEUTRAL

N

WARRANTY

NEW

AGE TRANSMISSIONS Newage Transmissioms will be free and

workmanship under normal

of

24

months.

·

All

PRM

transmissions must be correctly installed,

and

maintained.

LTD.

use

warrants

from

and

service

defects

TROU.BLE~OTING

See

the

following

page.

that

for

all

in

material a period

aligned,

PRM

Harbor

Marine

Transmission

1402

West

Marine

View

Drive

EvereH,

WA

98021

Tel:

425-259-3285

Transmission

223

Southwest

P.O.

Box

Ft.

Lauderdale,

Tel:

954-467-1540

Fax:

954-467-1525

Newage Website:

If a major problem should dealer or a warranty rights,

without

a

NEW AGE distributor (listed

dealer.

Marine

33

Court

21086

FL

33335-1086

Transmissions,

www.Newage-PRM.co.uk

NEW

first

contacting NEWAGE TRANSMISSIONS

Limited.

occur,

AGE

distributor.

do

not

undertake repair work

contact your WESTERBEKE

To

avoid prejudicing

above)

or your WESTERBEKE

on

the

gearbox

LTD.

or

35

PRM

NEWAGE

TRANSMISSIONS

TROUBLESHOOTING

Excessive Excessive

Fluid

needs

Difficulty

in

Escape

of

when

dipstick

No

drive

ahead

Propeller

speed

with

engine

Propeller

speed

with

engine

Excessive at

low

speeds.

Excessive operating

Problem

noise

at

noise

at

constant

moving

pressure

is

removed.

or

does

speed

does

speed

noise

from

noise

throughout

range.

low

speeds.

all

speeds.

topping

lever

from

astern.

not

ahead

not

in

one

gearbox

off.

control.

gearbox

increase

and

astern.

increase direction

only.

Probable

1.

Engine

idle

speed

1.

Defective

coupling.

2.

Shaft

misalignment.

3.

Prop

out

of

balance.

1.

Power

too

high.

2.

Fluid

leak.

1.

Poor

installation

Faulty

2.

1.

cable.

Defective

breather

past

oil

seals.

Mechanical-damper Shift

cable.

Cone/clutch clutch

Engine

Faulty

Defective coupling Propeller installation

2.

Propeller poorly

cable

plates

or

idle

speed

adjustment.

input

worn/damaged.

shaft

or

out

matched.

Cause

too

low.

of

cable.

causing

leaks

plate

problem.

slippage.

clutch

cones.

set

too

low.

coupling.

Input

misalignment,

hull

flexing.

of

balance,

damaged

Damaged.

faulty

prop,

1.

Increase-idling

1.

Inspect/replace

2.

Check

alignment

3.

Remove,

1.

Compare

2.

Inspect

seals,

1.

Check

installation,

2.

Replace.

1.

Remove

2.

Unscrew with

solvent-

1.

Replace

1.

Remove move

correct

hand

to

1.

Remove shaft

and

Increase

1.

refer

to

coupling

Check

1.

2.

the necessary, engine

mounts

Remove

diameter

if

necessary.

Verification/Remedy

speed.

coupling

if

necessary.

with

feeler

gauge.

check

pitch,

balance

and

engine

and

transmission

0-rings,

drain

plug,

remove

sharp

dipstick/clean

vent

damper

control

check

and

replace

idling

engine

if

necessary.

alignment

rectify

the

propeller

and

vent assembly PRM

120.

plate.

cable

or

distance.

Remove

movement.

examine

clutch/clutch

if

necessary.

speed.

If

supplier.

of

by

adjusting

or

adjust

and

balance

of

holes -PRM

from

top

linkage

Adjust

not

cured

Remove,

the

propeller

the

engine·

check

all

the

weight.

data.

check

bends

and

of

transmission

not

allowing

cable

and

cable

if

cone

by

increasing

examine

shaft

the

shims

mounts

that

the

blades

are

for

fluid

leaks.

turns.

80.

F-N-R

operate

necessary

on

appropriate

idling

and

replace

coupling.

under

the

themselves.

pitch,

weight,

equal

and

to

lever

If

clean

by

speed,

rectify

Difficulty

in

moving

single

lever

control.

3.

Defective Worn

1.

Operating

bearing/bearing.

or

damaged.

control

cable.

3.

1.

Isolate

Check

defective

the

installation

bearing,

and

remove

and

eliminate

replace.

all

tight

bends

in

the

cable.

,.,Unlvarsal

4

s a

&N;f!PIY•M

3

36

;M

DESCRIPTION

The information below is specific Transmissions, the

SECTION

applies to all models.

TRANSMISSION TROUBLESHOOTING

HURTH

to

the HBW

HURTH ZF15M

HBW/Zf

HBW

150

TRANSMISSIONS

NOTE:

When installing the transmission, make certain that

not

shifting is or

rod linkage, by unsuitably positioned guide sheaves, too small a bending radius mount a support two threaded holes located above the cable bracket mounted on the gear housing. Refer to the WESTERBEKE parts

SHIFT

The transmission is suitable for single lever remote control.

Upon loosening the retaining screw, the actuating lever can be moved (cable or rod linkage). Make certain that the shift lever does not contact the actuating lever cover plate: the minimum distance between lever and cover should be 0.5mm.

The control cable or rod should be arranged at right angle to the actuating shift lever when in the neutral position. The neutral position should coincide with the neutral position

The shifting travel, ating lever, between the neutral position and end positions and B should

the inner pivot point. A greater amount

detrimental and is recommended. However,

travel is shorter, proper clutch engagement might be impeded which, in turn, would mean premature wear, excessive heat generation and clutch plate failure. This would be indicated by slow clutch engagement or

NOTE

Check

impeded by restricted movability

or

other restrictions. In order to

for

shift control cable connections, use the

LEVER

to

any position required for the control elements

of

the operating lever on the control console

as

measured at the pivot point

be

at least

35mm

for the outer and

of

to

the

for

pfOI)er

leverand

shift lever travel

lever

travel.

bracket

at

least

is

no

engagement at all.

Inspect

each

of

the cable

of

this lever. ·

of

30mm

in no way

if

the lever

the

security

of

season.

list.

the actu-

for

the

cable

A

CAUTION:

the

actuating

shift

lever

this

mechanism

transmission

SHAn

WESTERBEKE recommends a flexible connection between

the transmission and the propeller shaft bly mounted, The installation required, since the propeller thrust will be absorbed by the transmission bearing, provided the value specified under

SPECIFICATIONS is not exceeded. However, the output

shaft should be protected from additional loads. Special care should be taken to prevent universal joint shaft, make certain to observe the manufacturers instructions.

Even with the engine solidly mounted, the use coupling or box bearings caused by hull distortions, especially in wooden boats or where the distance between transmission output flange and stern gland

"Drivesaver" is a product Rockland, MA.

COUPLINGS

The

position

lever

is

factory-adjusted

travel

from

Is

In

any

warranty

in

order to compensate for angular deflections.

of

a special propeller thrust bearing

"DRIVESAVER" will reduce stress in the gear-

is

of

the

mechanism

to

neutral

position A and.B.

way

tampered

will

be

void.

torsional vibration. When using a

less than about 800mm.

Globe Marine

with,

if

the engine

behind

ensure

If

the

of

flexible

equal

is

flexi-

not

NEUTRAL

FORWARD

A

CONTROL CABLE

COVER

37

0.5mm

MINIMUM

DISTANCE

HURTH

HBWn.F

TRANSMISSIONS

INITIAL

All HBW/ZF marine transmissions are test-run on a test

stand with the engine at the factory prior to delivery. For

· safety reasons the fluid is drained before shipment.

(DEXRON II

up to the index mark on the dipstick. To check the fluid level, just insett the dipstick, do not screw it in. Screw the dipstick into the case after the fluid level is checked and tighten. Do

not forget the sealing ring

Check for leaks and change the fluid after the first 25 hours,

also make a visual inspection

hoses, and shift cables.

OPERATION

Fill the gearbox with Automatic Transmission Fluid

or

DEXRON

DIPSTICK

III). The fluid level should

uncjer the hexhead

of

the coupling, oil cooler and

VENT

FLUID

LEVEL

of

the dipstick.

OPERATING

be

LOCKING

Locking required: use the gear shift lever position opposite your direction the position corresponding to the direction

WHEN

Rotation when the boat is being sailed, being towed, or anchored in a river, as well as operation stopped (for charging the battery), will have detrimental effects on the transmission

DAILY

THE

PROPELLER

of

the propeller shaft by an additional brake

of

travel for this purpose. Never put the gear shift in

of

travel

UNDER

of

SAIL

OR

BEING

the propeller without load (in neutral), such

of

TOWED

the engine with the

no

prop~ller

OPERATION

is

not

of

the boat.

as

D Check the transmission fluid.

D Visually check the gear shift linkage and transmission.

d Start the engine in neutral, allowing a few minutes at

idle to warm the fluid.

D Shift into gear.

NOTE

:

Too

low

an

idle speed will produce a chattering noise

the

from

the

For additional information refer to the following text in this Transmission Section:

AND TRANSMISSION

transmission gear and damper plate.

idle speed should

be

increased

SHAFT

COUPLINGS,

TROUBLESHOOTING.

In

such

cases

MAINTENANCE

FLUIDDMI~

NOTE:

Keep

vent holes

FLUID

then every to

Removing

Push a suction pump hose down through the dipstick hole to the bottom allows, use the transmission drain). Remove the drain plug from the bottom drain into a container, then reinstall the plug with its sealing washer. Wipe down the transmission and properly dispose the used fluid. After running the engine, shut down and recheck the fluid level.

Drain

NOTE

drain plug sealing this

CHANGE

Change the fluid after the initial

300 hours

the service life

the

of

the housing and suck out the fluid. (If space

plug

torque

:

When

changing

sealing

A

engine dipstick

washe1:

WARNING:

is

running.

hole.

or

yearly. Fluid changes contribute

of

the transmission.

fluid

of

the transmission and allow the fluid to

20-

25

ft/lbs

the

fluid,

washe1:

Never

This

Hot

could

The

pull

fluid

cause

out

will

50

hours

of

break-in,

take

care

not

to

lose

drain plug will leak without

the

dipstick splash severe

while

from

the

burns.

the

clear.

of

General·

Gear

ratio

(optional)

Lubricating

Transmission

Capacity

Propeller

Fluid

Rotation

Sump

(Hurth/ZF

hardened operated

HBW HBW HBW HBW

ATF-

HBW HBW HBW HBW

Transmissions

Standard

helical

multiple

50/ZF

5M

100/ZF

10M

150V/ZF

150NZF

or

Dextran

50/ZF

5M

100/ZF

10M

150V/ZF

150NZF

Transmission)

gears,

with a servo-

disc

clutch.

(2.05 : 1)

(1.79:

15MIV

(2.13:

15MA

(1.88 : 1)

-If

or

/If

0.63pts

0.74pts 15MIV 15MA

turn

2.1pts

1.0pts

Right

1)

Hand

Case-

(0.3L)

(0.35L) (1.0L) (0.47L)

propellers

~

Unlvarsal

4

N&M·1;1@JM•WJ:J;W

38

HURTH

HBW/ZF

TRANSMISSIONS

OPERATING

A

WARNING:

is

too

transmission

Normal operating temperature should be in the range maximum temperature

·reached for a short time. Make certain there is enough space around the transmission

to provide good ventilation and cooling.

TRANSMISSION

Some

UNIVERSAL with an externally attached convection type transmission cooler.

The cooler is a separate part

prevents any possibilities fluid. However, the continued flow will, in time, erode the inside leaks.

A transmission cooler may last ten years some circumstances, depending waters, maintenance, etc. it might only last half that time.

WESTERBEKE recommends having a spare cooler aboard.

TEMPERATURE

If

the

transmission

high,

stop

the

engine.immedlately

fluid.

of

122"F (50°C) to 212"F (100°C). A

of

266°F ( 130"C) may be only

COOLER

model's transmissions are equipped

of

fluid

temperature

and

check

the

of

the transmission fluid

of

the transmission which

coolant diluting the transmission

of

coolant thru the cooler

of

the cooler causing external

or

more but, in

on

operating hours, tropical ·

MAINTENANCE

Transmission maintenance is minimal. Keep the exterior housing clean, check the fluid level as part routine, and change the fluid every

Periodically inspect the transmission and the cooler for leaks

and corrosion. Lubricate the cable connections.

300 operating hours.

Lay-up/Winterize

Storage requires special care. Follow these procedures:

D Drain water from the transmission oil cooler and replace

with a proper mixture

NOTE:

This

operation will normally occur

engine

raw

water cooling system

of

antifreeze coolant.

D Clean up the transmission and touch up unpainted areas

(use heat resistant paint).

D Fill the transmission with Dextron III ATF fluid to pre-

vent'internal corrosion (extended storage only, twelve months or more).

. D Loosen attaching hardware from the transmission output

flange and propeller shaft coupling flange before removing the boat from the water. Separate the flanges and spray with lubricant.

D Inspect the gear shift cable, linkage, and attachments.

Look for corrosion the conduit, and bending all moving parts.

of

the end fittings, cracks or cuts

of

the actuator rods. Lubricate

is

properly

of

your regular

when

winterized.

the

in

TRANSMISSION

COOLER

PERIODICALLY EROSION REPLACE

AND

LEAKAGE

AS

NEEDED

INSPECT

NOTE:

If

the

transmission

·(twelve months or fluid

to

prevent internal

before

putting

For additional information contact:

HURTH

ZF

Industries

Marine

FOR

3131

Fort Lauderdale,

Tel.: (954)

Fax: (954) 581-4077

the

MARINE

US Headquarters

SW

42nd Street

581-4040

is

to

be

more),

it should

corrosion.

engine back into

GEAR

FL

33312

stored for a

be

topped off

Reduce

the

service.

long

with

fluid

time

level

;,Unlvanal

4

£3

M'';'@IU•1W3;W

39

HURTH

HBW/ZF

TRANSMISSION

TROUBLESHOOTING

CONTROL

The majority improper clutch adjustments (manual transmissions)

CABLES

of

transmission difficulties arise as a result

of

or

. problems with control cables (hydraulic transmissions)

rather than from problems with the transmission itself.

HURTH!ZF clutches, in particular, are very sensitive to

improper cable adjustments. If

you experience operating problems with the transmission, shut the engine down. First check the transmission-fluid level, then have a helper move the cockpit shift lever through the full range - from neutral to full forward, back to neutral, into full reverse, and back to neutral observe the actuating lever on the transmission. is stiff to operate, break the cable loose at the transmission and try again.

If

it is still stiff, check the cable for kinks or

excessively tight bends, and check any linkage for binding.

Problem

Transmission

Fails

Transmission but

fails

Delay

only

Transmission

Chattering mainly

Boat

Oil

to

move

to

propel

of

gear

after

an

transmission

at

low

fails

to

Leakage.

gears

cannot

into

gear.

shifts

into

gear,

the

boat.

engagement

increase

in

speed.

noise

becomes

engine

speed.

attain

specified

be

or

noise,

shifted.

engages

louder.

max.

speed.

·

____;

while you

If

the remote

1.

Actuating Shifting

2.

unattached. Shift

3.

Output

1.

2.

Propeller Output

Output

3.

propeller

Lever

1.

Refer Shift

2.

Shift

3.

Damage

1.

to

wear misalignment drives

Beginning

2.

transmission running alignment

engine The

1.

vibrations a

"chattering"

Operating

1.

Operating

2.

Corrosion

1.

Damaged Misalignment

2.

Probable

lever

travel

to level lever

haft.

engine

lever

is

cable

is

Cable

is

binding

coupling

shaft

is

coupling

shaft

are

N

to

diagram.

travel

is

binding

starting

or

fatigue,

between

damage

due

without

of

transmission,

output.

or

propeller

in

the

noise

temperature without

at

radial

sealing

of

Cause

loose.

broken,

radius

is

not

is

turning.

and

turning.

B

not

in

insufficient.

on

possibly

of

to

fluid,

drive

cooling.

sealing

ring

output

bent

is

too

against

turning.

equal

against

flexible

engine

bearings

torsional

overload,

generates

unit

which

in

the

transmission.

is

high.

ring

..

flanges.

A new cable and perhaps a new linkage mechanism may be needed. out

While the cable is loose, shift the transmission

of

gear using the lever

on

the side

of

the transmission to

make sure there's no binding inside the case.

If

the transmission passes these tests, crank the engine and have a helper put it in forward and reverse while you observe the propeller shaft; needs professional attention. thrust, check the shaft or,

that

it

isn't

stuck in the

NOTE:

If

you suspect a major problem

if

the shaft

to

see you still have a propeller on the end

if

you have a folding

isn't

turning, the transmission

If

it does tum but there's no

or

feathering propeller,

"no

pitch" position.

in

your

transmission, immediately contact your WESTERBEKE dealer or authorized marine transmission

1.

Tighten

damping

or

severe.

cover

plate.

to

N

to

cover

plate.

coupling due

to

and

in

vibrations,

wrong

or

excessive

torsional

produces

and

A.

shaft.

due

2.

Check

3.

Detach Clearance

1.

Transmission

2.

The

coupling

on

the

pins

and

3.

Inspect A

folding

propeller

1.

Adjust Refer

to

2.

Check

3.

Check

1.

Check inspect engine.

2.

Transmission

1.

Mount a flexible between A

higher

2.

Inspect transmission.

1.

Wrong

2.

Check

1.

Transmission

2.

Check

the

propeller

coupling

the

propeller may

cover

SHIFT

shift clearance, alignment,

the

Replace

the

stiffness

the

type

cooler.

alignment.

Verification/Remedy

cable,

shift

should

bolts

propeller.

plate

lever

damper

transmission

damper

of

bolt

reattach

cable

be

0.02

needs

professional

are

shaft.

bolts

may

be

in

"no

until

LEVER

cable

adjust

inspect

plate

if

necessary.

needs

professional

coupling

factor

plate

Replace

fluid. Inspect needs

Must

facility.

on

shifting

lever.

or

replace.

and

operate

in

(O.Smm).

attention.

sheared

or

Tighten

as

It

may

be

pitch"

the

TEXT

length.

if

Use

coolant

professional

the

or

replace

necessary.

be

missing

jammed. A variable

position.

lever

is

AND

DIAGRAM.

See

necessary.

flexible

coupling.

between

attention.

with

another

coupling

might

be

between

necessary.

ATE

Check hoses

attention.

be

within

the

lever

coupling

set

or

damaged.

exact

mid-position.

SHIFT

LEVER

If

the

transmission

stiffness

with

and

sufficient. the

engine

fluid

level.

and

coolant

0.003

in

(O.OBmm).

by

hand.

is

screws,

pitch

noise

the

and

in

and

of

an

slipping

keys,

DIAGRAM.

persists,

and

the

factor

driveshaft.

the

flow.

NOTE:

If

you

suspect a major problem

in

your transmission, immediately contact your WESTERBEKE dealer or authorized marine transmission facility.

an

40

HURTH

HBW/ZF

TRANSMISSION

TROUBLESHOOTING

Problem

High

fluid

Fluid

on

Fluid

and

Slow

engagement.

No

movement

NOTE:

If

marine

temperature.

transmission

water

you

mixed;

of

the

boat.

suspect

housing.

transmission

shifts

a major

facility.

hard.

.

problem

Probable

Fluid

level

1.

2.

Fluid

level

Plugged

3.

4.

No

water

Riter

clogged

5.

1.

Loose

2.

Loose

3.

Loose Loose

4.

Ruid

level

5.

Damage

1.

2.

Selector

1.

Low

fluid

2.

Linkage.

3.

Selector

1.

Improper

2.

Low

fluid

3.

4.

Propeller

5.

Propeller

6.

·Transmission

7.

Engine

in

your

Cause

high

during

low.

or

restricted

in

cooling

system.

(if

applicable).

screws. screw

connections. dipstick. fluid

filter.

high

during

to

fluid

cooler

control

linkage.

control.

level.

control.

selector

position. level. missing. shaft

broken.

malfunction.

transmission,

operation.

fluid

cooler.

operation.

..

immediately

1.

Pump

2.

Add

fluid.

3.

Replace

4.

Check Replace

5.

1.

Tighten

2.

Tighten, Tighten,

3.

4.

Tighten,

5.

Pump

1.

Replace

2.

Refer

1.

Refer

2.

Add

fluid.

3.

Adjust

1.

Consult

2.

Adjust

3.

Add

fluid.

4.

Replace.

5.

Contact

6.

Contact

7.

Contact

contact your

Verification/Remedy

out

fluid

to

the

maximum

cooler

and

flush

cooling

system

element.

to

specification. replace. replace. replace.

out

fluid cooler

this

manual.

this

manual.

(refer

this

service

(see

this

marine manufacturer.

marine

WESTERBEKE

and

to

the

maximum

and

flush

manual.

station.

manual).

repair. repair.

water

repair.

transmission

dealer

and

mark

system.

and

mark

or

on

and

hoses.

an

authorized

dipstick.

.

+ ·

.unlvarsal

MARINE POWER

41

LAY-UP

AND

RECOMMISSIONING

LAY-UP

Many owners rely including engines and generators, for lay-up during the

off-season or for long periods accomplish lay-up preparation themselves.

The following procedures will allow you to perform your own lay-up and recommissioning, check list for others. These procedures should afford your engine protection during a lay-up and also help familiarize yo1,1

with the maintenance needs

If

you have any questions regarding lay-up procedures, call your local servicing dealer; he will provide assistance.

PROPELLER

The transmission and propeller be opened up and the bolts removed when the boat is hauled out

of

the water or moved from land to water, and during storage in a cradle. The flexibility severe strain on the propeller shaft while the boat is taken out the shaft has actually been bent

not apply to small boats that are hauled out when not in use, unless they have been dry for a considerable

of

period

FRESH

A 50-50 solution mended for use in the freshwater cooling system at all times.

This solution may require a higher concentration

antifreeze, depending on the area's winter climate. Check the solution to make sure the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture.

and mixture

cooling system. Now recheck the antifreeze solution's

strength.

time.

WATER

Operate the engine to ensure a complete circulation

LUBRICATION

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter. towels and a plastic bag around the filter to catch the oil

during its removal.) When installing the new oil filter,

amount

of filter. Fill the sump with the correct amount engine model. (Refer to the manual.)· Run the engine and check for proper oil pressure and make sure there are not leaks. Stop the engine, check oil level and add oil as needed to bring level to dipstick full mark.

on

their boatyards to prepare their craft,

of

inactivity. Others prefer to

or

you may use them as a

of

your engine.

be

more than willing to

SHAFT

of

COUPLING

half

couplings should always

of

the boat often puts a

or

coupling,

or

put in the water. In some cases,

by

these strains. This does

COOLING

of

antifreeze and distilled water is recom-

the antifreeze concentration throughout the

SYSTEM

or

of

the water

both,

of

SYSTEM

(Place some paper

be

sure to apply a small

oil on the rubber sealing gasket at the base

of

oil for your

SPECIFICATIONS section

of

the

of

this

A

CAUTION:

in

the

sump bustion chemicals internal

FUEL

Top off your fuel cetane rating

ASTM D975. Fuel additives should be added at this time to control bacterial growth and a fuel conditioner such as Diesel Kleen based additives). Change the element in your primary fuel filter/water separator, the separator sediment bowl.

Change the fuel filter elements system as needed. Start 5-l Check for any leaks that may have been created in the fuel system during this servicing, correcting them

RAW

Close the through-hull fitting. Remove the raw water intake

hose from the fitting. 5-gallon bucket engine, check the zinc anode found in the heat exchanger on the engine and clean water strainer,

Start the engine and allow the raw water pump to draw fresh water through the system. When the bucket is empty, stop the engine and refill the bucket with an antifreeze solution slightly stronger then needed for winter freeze protection in your area.

Start the engine again and allow all drawn through the empty, stop the engine. This antifreeze mixture should protect the raw water circuit from freezing during the winter

lay-up, as well as providing corrosion protection. Remove the impeller from your raw water pump (some

antifreeze mixture will accompany it, so catch it in a bucket). Examine the impeller. cover gasket. until recommissioning,

NOTE:

months two complete turns every additional 4 months to allow the injection pump components to move. This will help prevent their sticking during extended storage periods.

deposits

parts.

SYSTEM

0 minutes to make sure no air is left in the fuel system.

WATER

If

the engine storage is going to be a lengthy one,

and

Do

not

leave

the

over

the

lay-up

period.

combintrto

which

can

reduce

tanks

with No. 2-D (SAE J313) that has a

of

#45

or

higher grade

+ Cetane Boost (DO

if

the system contains one, and clean

the engine and allow it to run for

engine's

produce

the

life11f

of

NOT

on

the engine and bleed the

old

engine

Engine

oil

and

com·

harmful

the

engine's

diesel according to

use any alcohol

as

needed.

oil

CIRCUIT

Place the end

of

clean fresh water. Before starting the

or

replace it as required. Clean the raw

if

one is installed in the inside

raw

water system. Once the bucket is

A-cquire replacement,

Do

not replace the impeller (into the pump)

but

replace the cover and gasket.

beyond, it is wise to rotate the engine by hand

of

this hose into a

of

the hull.

of

this mixture to be

if

needed, and a

12

+

..~,Univarsal

a a

mN;l@tU·*?*•

42

LAY-UP

AND

RECOMMISSIONING

STARTER

Lubrication and cleaning

advisable,

sure the battery connections are shut off before attempting

to remove the starter. Take care in properly replacing any electrical connections removed from the starter.

CYLINDER

It

is not necessary to remove the glow plugs from the cylinder head to squirt light engine oil into the cylinders for the few months a longer lay-up period (12 months that this procedure be performed. cylinders will prevent the pistons' rings from sticking to the cylinder walls. With oil in the cylinders, by hand two revolutions.

MOTOR

of

the starter drive pinion is

if

access to the starter permits its removal. Make

LUBRICATION

of

normal lay-up. However,

or

The

if

you anticipate

more), we recommend

light oil in the

turn the engine over

TRANSMISSION

Check

or

change fluid in the transmission as required. the engine is to be layed up 12 months or more, fill the transmission to the very top to prevent corrosion. Lower the fluid to its normal level at recommissioning. Wipe off grime and grease and touch up unpainted areas. Protect coupling and output flange with anticorrosion coating.

If

SPARES

Lay-up time provides a good opportunity to inspect your

UNIVERSAL engine to see

belts or coolant hoses need replacement. Check your basic spares kit and order items not used during the lay-up, such as filters and zinc anodes.

if

external items such as drive

on

hand, or replace those items

RECOMMISSIONING

The recommissioning seasonal lay-up generally follows the same procedures as those presented in the section regarding preparation for starting and normal starts. However, some counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold

2. Remove the raw water pump cover and gasket. Discard the gasket. Install the raw water pump impeller removed during lay-up (or a replacement, raw water pump cover with a new cover gasket.

3. Reconnect the shaft coupling and check for proper ment.

4.

Reinstall the batteries that were removed during the layup, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check to make sure the batteries are fully charged.

5.

Check the condition circuit and clean it

is not necessary to flush the antifreeze/freshwater solution from the raw water coolant system. When the engine is put into operation, the system will self-flush period

of

time with no adverse affects.

6.

Start the engine in accordance with procedures in the PREPARATIONS this manual.

of

your UNIVERSAL engine after a

PREPARATIONS

of

the lay-up procedures will need to be

of

the zinc anode in the raw water

or

replace the anode as needed. Note that

FOR

INITIAL START-UP section

FOR

STARTING

if

required). Install the

align-

in a short

of

BATTERIES

If

batteries are to be left

make sure they are fully charged and will remain that way, to

prevent them from freezing.

batteries will not remain fully charged, subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

A

WARNING:

highly

explosive

arcing

or

lighted

allow

an

open

flame

Shut

off

all

electrical

prevent

electrical gloves, a rubber servicing

batteries.

on

Lead

acid

gas,

which

tobacco

near

equipment

arcing

apron

and

board during the lay-up period,

If

you have any doubt that the

or

that they will be

batteries

can

products.

the

battery

during

eye

emit

be

Ignited

Do

not

being

In

the

vicinity

servicing.

protection

hydrogen,

by

electrical

smoke

or

serviced.

to

Wear

rubber

when

a

43

UNIVERSAL

MARINE

ENGINES

SPECIFICATIONS

Description

M-358,

M-4118,

M-508

Description

M3-208, M·25XP8

Displacement

M3·208 M·25XP8 M·358 M-4118 M·508

Aspiration Combustion Bore & Stroke

M3·20B M·25XP8 M·358 M-4118 M-508

Compression Firing

M3·20B, M-358

Weight

M3·208 M·25XP8 M·358 M-4118 M·508

Direction

Description Lube Lubrication

M3·208 M·25XPB M·358

Order

M·25XP8

,M-4118,

of

Rotation

Oil

Filter

Capacity

Chamber

Ratio

M-4118

M-508

Operating

Oil

(engine

Grade

Fuel

Oil

hot)

Pressure

GENERAL

Diesel,

four-cycle,

fresh

water-cooled,

overhead

valve

Diesel,

four-cycle,

fresh

water-cooled,

overhead

valve

Cubic

Inches

43.8

61.2

81.47

91.41

113.32 Naturally

as

Spherical

type,

Inches

[mm]

2.64 X 2.68

2.99 X 2.90

2.09 X 3.09

3.15 X 3.64 23:1

M·508

1-2-3 1-3-4-2

Lbs

[Kg]

with

241

[110.0]

295

[134.0]

352

(159.0]

356

[161.5]

529

[240.0]

Clockwise

LUBRICATION

Forced

lubrication

Full

flow,spin

Quarts

[Liters)

3.4

[3.2)

3.5

(3.3)

4.0

[3.8)

4.0

[3.8]

8.0

(7.5]

42-

64

psi

at

rated

speed

API

Specification

SAE

15W-40

No.2

SAE J 313

diesel

accoording

four-cylinder,

Vertical,

mechanism.

three-cylinder,

Vertical,

mechanism.

[Liters]

[.7177] [1.000]

"[1.335]

[1.498] [1.857]

pi

rated

three

vortex

(67 X 68.0] (76 X 73.6] [76 X 73.6] (78 X 78.4] (80 X 92.4]

transmission

when

viewed

SYSTEM

by

gear

on

filter

element

(294-

441

Kpa)

CF,

CG-4,

all

season Cetane

to

ASTM

from

pump

oil.

#45

in-line

system

the

front

CH-4

or

higher

D975.

Cl-4

grade

of

Description

Operating Fresh Raw

Raw Coolant

M3·2DB M·25XP8 M-358 M-4118 M-508

Description-type Fuel Fuel Fuel Fuel

Starting Battery DC Starting Starter Alternator

Temperature

Water

Pump

Water

Row

Capacity

Nozzle

Type

Injection

Lift

Pump

Battery

Capacity

Charging

Aid

Pump

Alternator

TUNE-UP

Compression

[at

250

M3·208, M·358,

M·508

Injection Engine

Valve

(engine

M3·208 M·25XP8

M·358 M-4118

Pressure

RPM]

M·25XP8

M-4118

Pressure

liming

(spill)

Clearance

COLD)

J-

COOLING

Fresh

water-cooled

controlled 150°-170° F (66°Centrifugal

Positive

belt-driven.

Rate

8.0

GPM

Quarts

[Liters)

3.75

4.0

6.0

4.5

12.0

FUEL

SYSTEM

Open

flow, (Bosch] In-line

plunger

No.

2 Diesel (Cetane rating

12

volt

5'

ELECTRICAL

12

Volt,

600-

BOO

51

Amp

Glow

plugs,

12

Volt,

51

Amp

set

volts

SPECIFICATIONS

412 -469

512 • 540 1991

PSI

18°

·20°

Inches

[mm]

0.0057 -0.0072

0.0071

-0.0087

SYSTEM

block,

with

heat

exchanger.

type,

metal

displacement,

(30.2

litres)

[3.5) [3.8) [5.6) [4.3] [11.4]

self

priming

throttle

type

[Bosch)

lift capacity

SYSTEM

(-)

negative

ground.

Cold

Cranking

rated,

belt

driven

sheathed

reduction

gear

with

internal

at

14.7

max.

PSI

(2.84 -3.23

PSI

[35.3-

(13.73

MPa]

BTDC

in

(0.145 -0.185

in

(0.18-

thermostatically-

77o

C)

impeller,

belt-driven.

rubber

impeller,

at

3000

rpm.

of

45

(wet)

solid

Amps

(CCA).

type

regulation,

MPal

37.2

MPa]

static

timed

0.22

mm)

or higher).

state.

·

mm)

Transmission manual.

Specifications:

Refer

to

the

TRANSMISSION

SECTION

in

this

~Unlvarsal

5 0

&N;*'IM•Wt:!;M

44

SUGGESTED

UNIVERSAL

CONTACT YOUR UNNERSAL DEALER FOR SUGGESTIONS AND ADDITIONAL

. .

SPARE

MARINE

ENGINES

PARTS

INFORMAT/0~

~~

UNIVERSAL each Kit

"A"

Kit

"B"

;:.;au

packaged

includes is

for

KIT

A

Impeller Heat

Exchanger

Fuel

Filter

Fuel

Filter

Oil

Filter Belt Zinc

Anodes

oners

in a rugged

the

basic

more

extensive

Kit

with

two

Spare

hinged

spares.

off-shore

Gasket

Parts

Kits,

toolbox.

cruising.

UNIVERSAL

CARRYING ENGINE FOR AND A GALLON MIXED

OIL

AN

OIL

COOLANT.

KITB

Impeller Oil Water Zinc Heat Thermostat Complete Injector Fuel Fuel Belt Glow

Kit

Filter

Pump

Anodes

Exchanger

Kit

Gasket

Filter Filter

with

Plug

RECOMMENDS

ENOUGH

(YQUR CHANGE,

Repair

SPARE

BRAND)

OF

PRE-

Kit

Gasket

Kit

Gasket

45

BOLT

HEAD

MARKINGS

STANDARD

HARDWARE

Metric strongest.

bolt

class

numbers

identify

bolts

by

their

strength

with

10.9

the

NOTES:

1.

2.

3.

STANDARD

Capsrew

Body

1/4.20

•

28

5116·18

•

24

3/8

·16

•

24

7116

·14

•

20

112

·13

•

20

9/16

·12

·18

518·11

·18

314

·10

·16

7/8.

9

·14

1 • 8

·14

Size

(Inches) • (Thread)

Use

the

torque

These

torques

Reduce

torques

BOLT & NUT

SAE

Torque

A·Lb

110(149) 120

150 170

270 295

395 435

590 660

values

are

by

Grade

(Nm)

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(47)

49

(66)

55

(75)

75

(102)

85(115)

(163) (203)

(231) (366)

(400) (536)

(590) (800)

(895)

listed

based

on

30%

or

TORQUE

5

SAE

below

when

specific

clean,

dry

threads.

more,

when

threading

SPECIFICATIONS

Grade

Torque

FI-Lb

(Nm)

10

(14)

19

(26)

34

(46)

55

(75)

85(115)

120(163)

167

(226)

280

(380)

440

(597)

660

(895)

6-7

SAE

Torque

A·Lb

105 120

155 170

210 240

375 420

605 675

910 990

torque

Reduce

capscrews

Grade

8

(Nm)

12

(16)

14

(19)

24

(33)

27

(37)

44

(60)

49

(66)

70

(95)

78

(106) (142)

(163) (210)

(231) (285)

(325) (508)

(569) (820)

(915) (1234)

(1342)

values

torque

into

are

not

by

10% aluminum.

METRIC

BoH

Dla.

M3 M4 M5

M8 M9

M10

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33

M36

available.

when

Wrench

5.5mm 7mm

8mm

10mm 13mm 16mm

18mm 21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

engine

oil

is

BOLT & NUT

Grade

Size

A·Lb

(Nm)

0.3

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

used.

TORQUE

4.6 FI·Lb

774 992

Grade

(Nm)

0.5

(0.7)

1

(1.5)

2

(3)

4

(5.5)

10

(13)

18

(25)

33

(45)

55

(75)

85(115)

118

(160)

166

(225)

225

(305)

288

(390)

417

(565)

568

(770)

(1050) (1345)

SPECIFICATIONS

4.8

Grade

8.8 • 9.8

Ft·Lb

1

(1.3)

2

4.5

7.5 18 37

63

103 159(215)

225 321 435

553

811

(1100)

1103

1500 1925

(Nm)

(3)

(6)

(10) (25) (50)

(85) (140)

(305) (435) (590)

(750) (1495)

(2035) (2610)

Grade FI-Lb

97 151 232

321 457 620

789 1154 1571

2139 2744

1.5 3

(4.5)

6.5

11

(15)

35

(26)

55

(75)

(130)

(205)

(315)

(435) (620)

(840)

(1070)

(1565) (2130)

(2900) (3720)

10.9

(Nm)

(2) (9)

GASKETS/SEALANTS

Oil

based

purpose

sealers.

coolant,

rav;

A

light

coating

and

O·rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper ing

assembly.

PERMATEX

Specialized

ing

copper

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers

properties.

gaskets

and

ifs

effective

fuel.

LIQUID

should

oil

pan

seal

grease.

such

HYLOMAR

as

HIGH

TACK

in

just

TEFLON

be

gasket

with

around

are

useful

as

HYLOMAR

it

resists

equivalent

about

can

be

used

on

high

water

(coolant)

for

work

is

particlarly

fuel,

oil

any

used

holding

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

use

bolts

the

levels

grease

and

oil!

sealing

tape

sealants!

and

other

water

flywheel,

and

thread

yet

allows

of

locking

is

waterproof,

reciprocating

joint

oil

adapter

temp

well

and

are

excellent

in

contact

on

rubber

hoses

RED

SILICONE

passages,

gaskets

in

applications

effective

water.

all

with

gaskets

and

coat

in

position

on

the

oil

sealer.

both

dur-

requir·

passages.

Do

not

BOLTS & FASTENERS/ASSEMBUES

Lightly

oil

head

plugs

that

HIGH When Anti-seize

threaded

LOCTITE

LITHIUM ing

Heavily use

penetrate

TACK.

assembling

compounds components offers

based

boxes.

oil

all

clean

engine

sliding

46

pipe

plugs

fasteners

jacket

should

coat

the

locking

them

to

according

ideal

and

fillings

as

you

assemble

be

sealed

bolt

threads

adhesives

came

apart

to

the

job.

for

water

components

that

with

LOCTITE

such

as

when

pump

when

assembling.

connect

coolant

them.

Bolts

and

PERMATEX

#2

blue.

LOCTITE

protect

necessary.

bearings

and

Always

or

stuff·

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

METRIC

(mm)

(m)

x

3.281

(km)

x

CONVERSION

x

.0394

=

Feet

.0621

=

Miles

=

Inches

DATA

VOLUME

Cubic

Inches Imperial Imperial Imperial Imperial Imperial Fluid

Ounces

US

Pints

US

Quarts

US

Gallons

(in

Pints

(IMP Quarts Gallons Quarts Gallons

x

(US

pt)

(US

3

(IMP

29.573

qt)

MASS-WEIGHT

Ounces Pounds

(oz)

(lb)

x

.454

28.35

PRESSURE

Pounds Inches Inches Inches Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

In

)

x

16.387

pt)

(IMP

x

.473

x

gal)

x

=

(psi)

(Hg)

(Hg) (H20) (H20)

(H20)

.946

=Grams

=

Cubic

x

.568

=

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

= Milliliters x

=

Liters(L)

=

Liters

3.785

=Liters

(g)

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

Centimeters

Liters

(L)

x

=

Liters

(L)

=

Liters

=

US

Quarts

=

US

Gallons

.034

=

x

2.113

(L)

x

1.057

(L)

x

.035

=Ounces

(kg)

x

2.205

=

Kilopascals

=

psi

x

2.036

=

Kilopascals =Inches =

Kilopascals

psi

of

x

27.684

1.76 x.88

(L)

x

(US

Ounces =Pints

=

Quarts

.264

=Gallons

=

Pounds

(kPa)

=

Hg

(kPa)

Mercury

=

(kPa)

x

.061

=

IMP

=

.22

qt)

(US

H20

x

=in

IMP

=

IMP

x

gal)

x

.145

x

.2961

x

13.783

4.026

3

pt

qt

.833

x

=

gal

=

.833

psi

=

H20

IMP

=

Hg =

H20

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

Per

(Hp)

Hour

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree Degree

Fahrenheit

Celsius

(°C) = (°F

(in-lb)

(ft-lb)

x

x . 7

45

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(°F) = (°C

x

.113

x

1.356

1.609

=

Kilowatts

x

.354

x

2.352

x

2.352

X

-

32) x .56

=

Newton

=Newton

=

Kilometers

(Kw)

=

Kilometers

=

IMP

.425

=

Kilometers

=

US

1.8) + 32

Meters

Per

x

1.34

MPG

(Nm)

Hour

=

MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-lb

=

ft-lb

=

MPH

47

1210 ( 200550)

8/2015

Universal M-25XPB(C), M-408, M3-20B, M-35B(C), M-508 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual