Westerbeke M3-20B, M-50B, M-25XPB, M-35B, M-40B Operator's Manual

OPERATORS

MANUAL

U

MARINE

M3-20B

- .

DIESEL

M-25XPB

-

...

B

rsal

ENGINES

M-35B

-50B

PUBLICATION 200550

REVISION

FEBRUARY 2010

WE5TERBEKE CORPORATION.

150JOHN HANCOCK

TEl..:

(508)823-78710 FAX:

..4JJs!J

Member

ROAD,

(508}B84·9688· weBSITE:

NaluJlla[

MYLES

TAUNTON,

Marille

2

STANDISH

MA

INDUSTRIAL

02780·7319

WWW.WESTERBEIfE.COM

Manu/acturers

U.S.A.

.

Associalioll

PARK

A

WARNING

Exhaust colorless uncIIIISClousness

expDS1118

-Dizziness

-/Iaus8a

-Headache

IF

GET

seek

until

/

~!-!~~lII!Ii!i!IlI!"~~\

( ,

.

WA

Engi!Is

gasses

gas.

Carbon

can

include:

Weakness

YOU

BUT

OR

ANYONE

INTO

medical

It

has

been

and

THE

attention.

R N I N G

-..

AI9'ar"""""""

CARBON

contain

MONOXlDE

Req.ired

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

Monoxide,

Is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-

Inability

IMMEDIATELY. dllwn

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE

CARBON Ilving/sleeping

They

are

obtainabie

an

of

Carbon

In

Twitching

to

ANY

OF

the

unit

DECAL

and

near

your

also

MONOXIDE

quarters

inexpensive

at

your

odorless

and

Temp/es

Think

THESE

If

symptoms

and

is

should

engine

recommends

DETECTORS

locai

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

provided

be

fixed

or

of

you;

and

easily

marine

persist,

by

to

a

generator.

installing In

the

vessel.

store.

"'.1.-

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

01

State

WARNING

gasoline

Its

birth

engine

constituents

01

Calilornia

delects,

harm.

SAFETY

INSTRUCTIONS

Read this safety

manual

carefully. Most accidents are

caused by failure to follow

fundamental

rules

and

precau·

tions. Know

when dangerous conditions exist

and

take the

necessary precautions to protect yourself,

your

personnel,

and

your

machinery.

The following safety instructions are

in

compliance with

the American Boat

and

Yacht Council (ABYC) standards.

PREVENT

B.ECmIC

SHOCK

A

WARNING:

Do

not

touch

AC

electrical

connsetlollS

wfr/IB

tlllfl/ilfl

Is

fUnning,

or

when

connocted

to

shoro

p

__

LBlhBI

roltage

Is

prtlSBnt

at

thBSIJ

connections!

• Do not operate this machinery without electrical

enclosures and covers in place.

•

Shut

off electrical power before accessing electrical

equipment.

• Use insulated mats whenever working

on

electrical

equipment.

•

Make

sure your clothing and skin are dry, not damp

(particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working on electrical equipment.

•

Do

not connect utility shore power to vessel's

AC circuits, except through a ship-to-shore double throw transfer switch.

Damage

to vessel's

AC

generator may

result

if

this procedure is not followed.

• Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together.

PREVENT

BURNS -HOT

ENGINE

A

WARNING:

Do

not

touch

hot

onglne

parts

or

emaust

5JStIIm

compollllllts. A running

engine

gois

reryhot!

• Always check the engine coolant level at the coolant recovery tank.

A

WARNING:

Steam

can

cause

Injury

or

death!

• In case

of

an engine overheat, allow the engine to cool

before touching the engine

or

checking the coolant.

PREVENT

BURNS -FIRE

A

WARNING:

Flro

can

cause

injury

or

death!

• Prevent flash fires.

Do

not

smoke

or

pennit

flames

or sparks to occur near the carburetor, fuel line, filter, fuel pump, or other potential sources

of

spilled fuel or fuel

vapors.

Use a suitable container to catch

al1

fuel when

removing the fuel line, carburetor, or fuel filters.

•

Do

not operate with a Coast Guard Approved flame

arrester removed. Backfire can cause severe injury

or death.

•

Do

not operate with the air cleaner/silencer removed.

Backfire

can

cause severe injury or

death.

•

Do

not smoke

or

permit flames

or

sparks

to

occur near

the fuel system. Keep

the

compartment and the

engine/generator clean and

free

of

debris to minimize the

chances

of

fire. Wipe up all spilled fuel and engine oil.

•

Be

aware - diesel fuel will bum.

PREVENT

BURNS -EXPLOSION

A

WARNING:

Explosions

from

fuel

vapors

can

cause

Injury

or

death!

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before

run-

ning the blower. Run the blower for four minutes before

starting your engine.

• All fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a well-ven-

tilated area away from spark-producing equipment and out

of

the reach

of

children.

• Do not fill the fuel tank(s) while the engine

is

running.

• Shut off the fuel service valve at the engine when servicing the fuel system. Take care in catching any fuel that might spill.

DO

NOT

allow any smoking, open flames, or other

sources

of

fire near the fuel system

or

engine when servicing. Ensure proper ventilation exists when servicing the fuel system.

•

Do

not alter

or

modify the fuel system.

• Be sure all fuel supplies have a positive shutoff valve.

•

Be

certain fuel line fittings are adequately tightened and

free

of

leaks.

•

Make

sure a fire extinguisher

is

installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated

ABC

by the NFPA are appropriate

for all applications encountered

in

this environment.

SAFETY

INSTRUCTIONS

ACCIDENTAl

A

WARNING:

III

tItNIth!

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect it last.

• Make certain all personnel are clear

starting.

• Make certain all covers, guards, and hatches are re-

installed before starting the engine.

BAnERY

A

WARNING:

III

tItNIth!

•

Do

not smoke being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing

ing

servicing.

• Never connect the negative tive (+) connection terminal not test the battery condition together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation

disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.

• Always tum the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery.

BATTERY

A

WARNING:

_In/lIlT

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye

tion.

Batteries

If

it

comes

with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

STARTING

Accldtmtal

EXPLOSION

Battery

or

of

explosIon

allow an open flame near the battery

explosive gases.

ACID

SUlfuric

III

dtlath!

contain

in

contact

acid

suJfuric

with

stalflng

(-)

of

your

can

cause

of

the engine before

can

cauulnlury

battery cable to the posi-

the starter solenoid. Do

by

shorting the terminals

To

avoid sparks, do not

In

banerles

acid

skin,

which

wash

can

is

it off

In/ury

dur-

to

prevent

cauu

protec-

destructive.

at

once

TOXIC

• Ensure that the exhaust system is adequate

• Be

•

• For additional information refer to ABYC T-22 (educa-

• Do not use copper tubing in diesel exhaust systems. Diesel

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not

AVOID

A

• Do

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. attention to the manifold, water injection elbow, and

exhaust pipe nipple.

sure

the

In

addition

install a carbon

builder or dealer for installation

tional information on Carbon Monoxide).

A

WARNING:

odorless

nausea

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

through portholes, vents, or air conditioners.

exhaust enter

flow

exhaust

gas is present

toms are:

Vomiting

Dizziness

Throbbing in temples Muscular twitching Intense headache

Weakness

discharge

the

exhaust

of

exhaust. Avoid overloading the craft.

fumes

or

signs

MOVING

WARNING:

Dr

dllath!

not

service

tion

arises operating ing

moving

GASES

unit

to

gas.

Dr

death!

and

Carbon

routine

from

in

of

sleepiness

monoxide

and

its

surroundings

inspection

monoxide

Inhalation

outlet

discharge

diesel exhaust fumes. Some

carbon

detector.

Carbon

monoxIde

produces

is

near outlet

gasoline engines.

monoxide

PARTS

Rotating

the

in

which

adjustments,

parts

engine

it

and

parts

while

is

absolutely

use

extreme

hot

exhaust

(CO)

Is a deadly

are

well

of

the

exhaust

Consult

of

approved detectors.

(CO)

Is

"u-Ilke

the

waterline,

and

close

or

carbon

inhalation

can

causs

Inlury

it

is

running.

necessary

care

to

avoid

system

components.

to

expel gases

Pay close

ventilated.

system,

your

an

Invisible

symptoms,

of

If

the engine

water

restrict

as

toxic

monoxide

of

the symp-

or

poisoning

If

a

to

make

gas!

boat

sys-

copper

could

the

as

situa-

touch-

ii

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces or bracelets that

be

could

• Make sure all attaching hardware is properly tightened. Keep protective shields and guards

places at all times.

•

Do

!hi:

• Stay clear of the drive shaft and the transmission coupling

when the engine is running; hair and clothing can easily

be

HAZARDOUS

A

caught in moving parts.

in

their respective

not check fluid levels or the drive belt's tension while

engine

is

operating.

caught in these rotating parts.

NOISE

WARNING:

High

nl1lse

lewis

can

cause

hearing

II1tIsI

• Never operate an engine without its muffler installed.

• Do not run an engine with the air intake (silencer)

removed.

• Do

not

run

open.

A

WARNING:

mentally

I1r

engines

physically

for

long

011

nl1t

Wl1t1c

Incapacitated

periods

I1n

with

machinery

by

their

when

fatigue!

enclosures

Yl1u

are

ABYC, INSTAlLING

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their

tions

ABYC "Safety Standards for Small Craft"

Order from:

NFPA

"Fire Protection Standard for Motor Craft"

Order from:

USCG "USCG 33CFR183"

Order from:

NFPA

AND

USCG

PUBLICATIONS

DIESEL

when

installing

(American Boat and Yacht Council)

ABYC

15

East 26th Street

New York, NY

(National Fire Protection Association)

National

II Tracy Drive Avon Industrial Park Avon,

U.S. Government Printing Office

Washington, D.C.

Fire

MA

02322

(United States Coast Guard)

ENGINES

your

lOOlO

Protection

20404

engine.

Association

FOR

recommenda-

OPERATORS

Many

of

in

your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

ENGINE

Preparations to install an engine should begin with a thorough examination (ABYC) standards. These standards are a combination sources including the USCG and the NFPA.

Sections

H-2 Ventilation P-I P-4 Inboard engines E-9 DC Electrical systems

All installations must comply with the Federal Code Regulations (FCR).

MANUAl

the preceding safety tips and warnings are repeated

INSTAllATIONS

of

the American Boat and Yacht Council's

of

the ABYC standards

Exhaust systems

of

particular interest are:

of

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict

attention be paid to the following information:

CODES

AND

REGULATIONS

Strict federal regulations, ABYC guidelines, and safety codes must be complied with

when

installing

engines

and

generators

in a marine

environment.

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow

is

close to

or

will

be

below

the

vessel's

waterline,

provisions

must

be

made

to

install a siphon-

break

in

the raw water supply hose

to

the exhaust elbow. This hose must be looped a

minimum

of

20"

above

the

vessel's

waterline.

Failure

to

use

a siphon-break

when

the exhaust manifold byeclion port is at or below the load waterline will result in

raw water damage to the engine

and

possible flooding

of

the boat.

If

you have any doubt about the position

of

the water-injected exhaust elbow relative

to

the

vessel's

waterline

under

the

vessel's

various

operating

conditions,

ins/all a

siphon-break.

NOTE:

A

siphon~break

requires periodic inspection and cleaning to

ensure

proper

operation.

Failure

fa

pmperly maintain a siphon-break

can

result

in

catastrophic

engine damage. Consult

the

siphon-break manufacturer for proper maintenance.

EXHAUST

SYSTEM

The exhaust hose must be certified for marine use. The system must be designed

to

prevent

water

from

entering

the

exhaust

under

any

sea

conditions

and

at

any

angle

of

the vessels hull.

A

detailed

Marine

Installation

Manual

covering

gasoline

and

diesel

engine

and

generators

is

suppied

with

each

unit.

Additional

copies

can

be

obtained

from

our

website

in

pdf

form.

www.westerbeke.com.

,/,

.Univorsal

iv

AVAILABLE

FROM

YOUR

WESTERBEKE

DEALER

TABLE

Parts

Identification

Introduction

Warranty Serial

Admiral Captain DIesel

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

Procedures .................................................... 3

Number

Control Control

Fuel,

Engine Preparations StartlngJStopplng

Break-In The

Procedure

Dall,

Alarms

Routine

and

Maintenance EngIne

EngIne Remote Fuel

DC

WIrIng WirIng WirIng

Cooling

Raw

Water Changing Raw

Therrnostat... ............................................................... 16

Heat

s,stem

Air Priming

Fuel Lift

Fuel

the

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

Exchanger

011

Change

011

Filter

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

Cleaner/Silencer ...................................................

the

Pump

Filters ................................................................. 20

ElectrIcal

Drive

Belt Battery Glow

Alternator Troubleshooting ........................................ 22

Care

Plugs ................................................................ 21

DIagram Schematic DIagram

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

Location ..............................................

Panel Panel

for

Initial

Procedure

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

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

Oil

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

and

Engine

Start-Up

Coolant

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

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

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

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

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

Circuit Breakers .....................................

Schedule

Clrcuil...

Pump

Raw

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

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

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

Water Impeller. ............................ IS

.......................................................... 16

....

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

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

Fuel

System

........................................................... 19

Srstem

Adjustment ...............................................

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

............................................ 19

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

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

......

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

(Catalina)

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

OF

CONTENTS

.2

.3

9

1 0

11

.11

12 14

15

5

6

7

8

Wiring

Schematic

Engine

Throttle and Stop Assembly ....................................... 27

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

Testing Engine Compression ...................................... 28

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

Fuel Injectors .............................................................

Engine Control

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

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

Tachometer PRM

Transmissions

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

Gear

Daily Operation ......................................................... .35

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

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

Transmission HBW

Transmission

17

18 19

19

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

Shift Fluid

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

Operating Temperature ...............................................

Transmission

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

Transmission

2I 21 21

23 24

25

Control Cables ........................................................... .40

Lay-Up

SpeCifications

Spare

Parts

Standard

Metric

Conversions

European

(Catalina)

Adjustments

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

Troubleshooting

Panel

Troubleshooting

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

(Chart)

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

(Chart)

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

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

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

Shifting ............................................................. .34

Troubleshooting

(Chart)

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

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

Lever

.................................................................. 37

Change

and

.............................................................. 38

Cooler ........ " ............ , ............................ 39

Troubleshooting

Recommissioning

(Chart)

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

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

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

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

Hardware

Torques

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

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

Maritime

Council

Certificate

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

26 27

.28

29

.31

31 31

32

.34

34

35

36

37

39

.40

42

.44 .45

.46 .47 .49

1

PARTS

IDENTIFICATION

REAR

MANIFOLO'p'R.E.SSUI~E

ICOOLANT

OIL

C,~P

RIGHT

SIDE

~~~~:d

COOLANT

PUMP

FILL

THERMOSTAT ASSEMBLY

=::;>F\-\---j\lR

"\l!i-of-----OIL

.u«"'r-~

FIlTER

DRAIN

M-40BILLUSTRATED

SILENCER

HOSE

CAP

ALTERNATOR

PREHEAT SOLENOID

REAR

FUEL

PUMP

RAW

COOLANT SHEAVE

WATER

PUHIP---'''>',L

PUMP-~--->j1U1i

~m---.T,

/

MA."ULU

COOLANT DRAIN

PRESSURE

FILL]

OIL

CAP

PAN

1.0.

NAME

PLATE

START MOTOR

M-50BILLUSTRATED

OIL

FRONT

2

OIL

LEFT

SIDE

OIL

DRAIN

HOSE

INTRODUCTION

These

new

high performance UNIVERSAL marine diesel

of

engines are a product design technology and their combined years of experience

manufacturing quality marine engines.

the

superior durability and dependable performance

marine engines. Thank you for selecting UNIVERSAL.

In

order

to

get the full

important that you operate and maintain it correctly. This manual is designed to help you manual carefully and observe all

An

throughout. WESTERBEKE distributors, dealers and service centers are available worldwide. contact your nearest dealer for assistance.

is

your operators manual. A Parts Catalog is also

This provided and a UNIVERSAL dealer. Also, equipment, contact your UNIVERSAL dealer for UNIVERSAL'S installation manual.

WARRANTY

Your

UNIVERSAL Warranty is included

If

you

have not received a customer identification card regis-

tering your warranty

registration form, please contact the factory

model information, including the unit's serial number

commission date.

extensive network

Thchnical Manual

PROCEDURES

UNIVERSAUWESTERBEKE' S

We

take great pride

of

our

use

and

benefit

Should your engine require servicing,

if

you are planning

60 days after submitting the warranty

from

do

this.

Please read this

the

safety precautions

of

UNIVERSAL

is

available

in

your engine, it

from

your

to

install

this

a separate

in

writing with

folder.

and

is

in

PRODUCT

Product catalogs) within

UNIVERSAL CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE, MAKES RANTIES THERETO, COMPLETENESS THEREOF AND WILL IN BE LIABLE INCURRED IN CONNECTION WITH

THE FURNISHING OR USE OF SUCH SOFTWARE.

OF UNIVERSAL customers should also keep

span between printings of UNIVERSAL product software and

the unavoidable existence of earlier UNIVERSAL manuals. UNIVERSAL products, whether from UNIVERSAL suppliers, must not the

definitive authority makes good sense but sentatives of UNIVERSAL or

consulted to detennine the accuracy and currentness

product software being consulted

NOTES,

As

this manual takes you through

maintenance schedules,

engine, critical information CAUTIONS,

SOFTWARE

software

provided

UNIVERSAL'S

In

CAUTIONS

(tech

data,

parts

lists,

manuais,

from

sources

other

than

UNIVERSAL

CONTROL.

OR

REPRESENTATIONS WITH RESPECT

INCLUDING ACCURACY, TIMELINESS

FOR ANY TYPE OF DAMAGE OR INJURY

OR

ARISING OUT

in

summation, product software provided with

and

cannot

be

relied upon exclusively

on

the

respective product. It

is

imperative that appropriate repre-

the

and

WARNINGS.

AND

WARNINGS

and

troubleshooting

will

be

An

supplier

by

the

highlighted

in

the customer.

operating procedures,

of

explanation follows:

brochures

NO

WAR-

NO

EVENT

mind

the

or

not

question

of

your marine by

NOTES,

are

time

only

be

the

and

not

OR

other

as

Unlvarsal

Customer Identification

UNIVERSAL OWNER MAIN STREET HOMETOWN, USA

Model M-35B

Expires 712012000

TYPICAL

The

that can assist

UNIVERSAL engine. The first character indicates

[A=1960s, character represents the year in the decade, and

CUSTOMER

UNIVERSAL serial number is

in

determining the date

B=1970s, C=1980s, 0=1990, etc.],

fifth numbers represent the month

IDENTIFICATION

Ser. #D704XXXX

CARD

an

alphanumeric number

of

manufacture

the

and

the

of

manufacture.

of

the

decade

second

fourth

your

NOTE:

An

A

CAUTION:

observed,

your

engine.

A

WARNING:

followed,

operating procedure essential to note.

can

Procedures,

result

In

Procedures,

result

In

personal

the

damage

which

InJury

If

not

strictly

or

destruction

if

not

properly

or

loss

of

of life.

3

INTRODUCTION

SERIAL

NUMBER

LOCATION

An identification nameplate that displays the engine model

number

and

engine serial number

is

mounted on

the

side

of

the engine's manifold.

Take

the time

to

enter this information

on

the

blank decal provided

below.

This will provide a quick

reference when seeking technical information and/or ordering

parts.

IllJERSTANDING

THE

DIESEL

ENGINE

The diesel engine closely resembles the gasoline engine,

since the mechanism is essentially the same. The cylinders

are arranged above a closed crankcase; the crankshaft is of the same general

type

as

that

of

a gasoline engine, and the

diesel engine

has

the

same types

of

valves, camshaft, pistons,

connecting

rods

and lubricating system.

To

a great extent, a diesel engine

requires

the same preven-

tive maintenance

as

a gasoline engine. Most important are

proper ventilation and proper maintenance

of

the fuel, lubri-

eating and cooling systems. Replacement

of

fuel and lubri-

cating filter elements at the time periods specified and

frequent checking for contamination (water, sediment, etc.)

in

the

fuel system are essential. Also important is the consistent

use

of

a brand of high detergent diesel lubrication

oil

designed specifically for diesel engines. The diesel engine does differ from the gasoline engine, how-

ever,

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

retor

and

ignition

systems

are

done

away

with

and

in

their

place

is

a single component (the fuel injection pump) which

performs

the

function of both.

4

ORDERING

PARTS

Whenever replacement parts are needed, always provide

the

engine model number and engine serial number

as

they

appear on the silver

and

black identification nameplate

located

on

the manifold.

You

must provide

us

with this infor-

mation so we can identify your engine.

In

addition, include a complete part description and part number for each part needed (see the separately furnished Parts Catalog). Also insist upon UNIVERSAUWESTERBEKE packaged parts because will fit or generic parts are frequently not made

to

the

same

specifications

as

original

equipment.

SPARES

AND

ACCESSORIES.

Certain spares will be needed

to

support and maintain

your

UNIVERSAL marine engine.

Your

UNlVERSAU

WESTERBEKE dealer will assist

you

in

preparing

an

on

board inventory

of

spare parts. See

the

UNIVERSAL SPARE

PARTS

page

in

this manual for a suggested list.

PROTECTING

YOUR

INVESTMENT

Care at the factory during assembly

and

thorough testing

have resulted

in

a UNIVERSAL diesel engine capable

of

many thousands

of

hours

of

dependable service. However

the

manufacturer

cannot

control

how

or

where

the

engine is

installed

in

the

vessel

or

the

manner

in

which

the

unit

is

operated and serviced

in

the field. This is up

to

the

buyer/owner-operator.

NOTE:

Six important steps to ensure long engine life:

o Proper engine installation

and

alignment.

o An efficient well-designed exhaust system that includes

an

anti-siphon break

to

prevent water from entering the

engine.

o Changing the engine

oil

and

oil

filters every 100 operating

hours.

D

Proper

maintenance

of

all

engine

components

according

to

the

maintenance

schedule

in

this

manual.

o

Use

clean, filtered diesel fuel.

o Winterize your engine according

to

the LAY-UP

AND

RECOMMISSIONING section

in

this

manual.

ADMIRAL

CONTROL

PANEL

UNIVERSAL offers two optional panels. Refer

to

the

instruction page that applies to the

panel

you

purchased.

ADMIRAL

PANn

This manually-operated control panel

is

equipped with a

Key

Switch

and

RPM gauge with

an

ELAPSED TIME meter

which measures the engine's running time

in

hours and

in

1110

hoUIS. The panel also includes a WJ'JER TEMPERA·

TURE gauge which indicates water temperature in degrees

Fahrenheit, an OIL PRESSURE gauge which measures

the

engine's oil pressure in pounds per square

inch,

and a DC control circuit VOLTAGE gauge which measures the system's voltage. All gauges are illuminated when the key switch is turned

on

and remain illuminated while the engine

is

in

operation. The panel also contains two rubber-hooted

pushbuttons, one for

PREHEPJ

and one for

START.

When the engine

is

shut down with

the

Key

Switch turned

off, the water temperature gauge

will

continue

to

register

the

last temperature reading indicated

by

the gauge before elec-

trical power was turned off. The oil pressure gauge will fall

to

zero when the

Key

Switch is turned off. The temperature

gauge

will

once again register

the

engine's true temperature

when electrical power is restored

to

the gauge.

A separate alarm buzzer with harness

is

supplied with every

Admiral Panel. The installer is responsible

for

electrically

connecting

the

buzzer

to

the four-pin connection on the engine's electrical harness. The installer is also responsible for

installing

the

buzzer

in

a location where

it

will

be

dry

and

where

it

will be audible

to

the operator should

it

sound while

the engine

is

running. The buzzer will sound when

the

igni-

tion

key

is

turned on

and

should silence when the engine has

started and the

en~ine's

oil pressure rises above

15

psi.

Nole:

Refer to the WIRING

DIAGRAM

in this manual

for

the

installation

of

two engine sendors.

WATER

TEMPERATURE

GAUGE:

TliIS

GAUGE

IS

GRADUATED

IN

DEGREES

FAHRENHEIT

AND

IS

IllUMINATED

WHILE

TliE

KEY

SWITCH

IS

TURNED

ON.

TliE

ENGINE'S

NORMAl

OPERATING

TEMPERATURE

IS

170'-190' F (77'-aa'C).

OIL

PRESSURE

GAUGE:

THIS

GAUGE

IS

GRADU-

ATED

IN

POUNDS

PER

SQUARE

INGH

(PSI)

AND

IS

ILLUMINATEO

WHILE

THE

KEY

SWITCH

IS

TURNED

ON.

THE

ENGINE'S

NORMAL

OPERATING

OIL

PRESSURE

RANGES

BETWEEN

30·60

PSI.

RECAUBRATEO

FOR

ACCURACY

FROM

THE

REAR

OF

THE

PANEl.

I

THIS

BUTTON

PRBtfAT

BUTTON:

WHEN

PRESSED.

ENERGIZES

AlTERNATOR'S

REGULATOR,

THE

FUEL

LIFT

PUMP

AND

THE

ENGINE'S

GLOW

PLUGS,

AND

BYPASSES

THE'

ENGINI"S

OIL

PRESSURE

ALARM

SWITCH.

IN

ADDI-

TlDN,1HIS

BUTTON

ENERGIZES

THE

START

BUTTON.

5

KEY

SWtTCH:

PROVIDES

CLUSTER.

INDICATES

THE

AMOUNT

THE

BATTERY

IS

BEING

CHARGED.

SHOULD

SHOW

13VTO

14V.

HAS

BEEN

~~l!~INji~~!~CJIF.:~~~E~

FRESH

WATER

2tO' F (9S'C),

THIS

SWITCH

WILL

CLOSE

SOUNDING

THE

ALARM

WHICH

WILL

EMIT

A

CONTINUOUS

SIGNAl.

LOW

OIL

'PRESSURE

ALARM: A LOW

OIL

PRESSURE

ALARM

SWITCH

IS

LOCATED

OFF

THE

ENGINE'S

OIL

GALLERY.

THIS

SWITCH

MONITORS

THE

ENGINE'S

OIL

PRESSURE.

SHOULD

THE

ENGINE:S

OIL

PRESSURE

FALL

TO

5 -10

PSI,

THE

SWITCH

WILL

OPEN

SOUNDING

THE

ALARM.

IN

THIS

EVENT,

THE

ALARM

WILL

EMIT

A

PULSATING

SIGNAL.

CAPTAIN

CONTROL

PANEL

CAPTAIN

PANEL

This manually-operated control panel is equipped with a Switch, INSTRUMENT

an

RPM gauge, PREHEAT and START buttons,

TEST

button and three indicator lamps, one for AL1ERNATOR DISCHARGE, one for low On.. PRESSURE,

RPM

GAUGE: REGISTERS MINUTE RECALIBRATED THE

REVOLUTIONS

OF

THE

REAR

OF

ENGINE

FOR

THE

PANEl.

PER

AND

CAN

ACCURACY

FROM

BE

Key an

and one for high ENGINE COOLANT TEMPERATURE. also includes an alarm buzzer for low

on..

PRESSURE or high WA1ER TEMPERATURE. The RPM gauge is illuminated when the Key Switch

nated

while

the

engine

ALARM:

THE

ALARM

BELOW

5 -10

SIGNAl.

THE

FRESHWATER

ALARM

WILL

NOTE:

THE

THIS

SOUNDING

OIL

PRESSURE

WILL

PSI.

IN

THIS

ALARM

WILL

COOLING

EMIT A SIGNAl.

ALARM

WILL

IS

NORMAl.

REACHES

SOUND

15

is

in

SOUND

EVENT,

ALSO

SOUND

CIRCUIT

WHEN

ONCE

PSI,

THE

is

turned

operation.

IF

THE

ENGINE'S

THE

ALARM

IF

RISES

THE

ENGINE

ALARM

on

and remains illumi-

OIL

WILL

EMIT A PULSATING

THE

WATER

TO

210°F

KEY

SWITCH

STARTS

WILL

SILENCE.

PRESSURE

TEMPERATURE

IN

THIS

AND

TEST

PRESSED,

ALTERNATOR,

PRESSURE, WATER CONTROL WHEN ALTERNATOR, PRESSURE,

WATER

INDICATOR ILLUMINATE

TION THE

FALLS

EVENT,

IS

TURNED

THE

ENGINE'S

BUTTON:

TESTS

THE

AND

TEMPERATURE

CIRCUITS.

PRESSED,

THE

AND

TEMPERATURE

LIGHTS

IN

TO

SOUNDING

ALARM

BUZZER.

IN

THE

ON.

WHEN

THE

OIL

THE

OIL

THE

ADDI-

It

START

BUTTON:

STARTER'S

BUTTON

WILL PREHEAT TIME.

BUTTON

WATER LIGHT

WHEN

SOLENOID

NOT

OPERATE

IS

PRESSED

TEMPERATURE

PRESSED,

WHICH

ENERGIZES

CRANKS

ELECTRICALLY

AND

HELD

ALARM

THE

ENGINE.

UNLESS

AT

THE

THIS

THE

SAME

PREHEAT LIFT

PUMP

THE

ENGINE'S

THIS

BUTTON

BUTTON:

AND

THE

OIL

ENERGIZES

WHEN

PRESSED,

ENGINE'S

PRESSURE

ALARM

THE

KEY PROVIDES THE PANEL

THE

REGULATOR

ENERGIZES

GLOW

PLUGS, SWITCH.

START

BUTTON.

SWITCH:

POWER

INSTRUMENT

CLUSTER

DC

AND

ALTERNATOR

TERMINAL.

THE

FUEL

AND

BYPASSES

IN

ADDITION,

TO

6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use

J

diesel

Care

Use

in

particles which might pass through these

fuel,

unsatisfactory facilities. engine's daily advisable:

Purchase a well-known Install

separator between or of #

ENGINE

Use

CG-4,

the

and

MAINTENANCE SCHEDULE

Westerbeke the

break-in change intervals must

SCHEDULE section

synthetic oils are

NOTE:

regarding synthetic oil.

FUEL

a diesel

313

only clean

your

and keep it clean. The best

245

IO

fuel

that meets

and

has a Cetane rating of

fuel

according

Of

The

Fuel

diesel

fuel

injection pump

finely finished parts.

by

careless handling or improper storage

To

assure that

use

is

and

regularly service a good, visual-type filter/water

the are good examples of is

recommended.

the

to

ASTM

Supply

fuel!

The clearance of

is

It

is

the

fuel

clean

and

brand

of

fuel

tank

such a filter.

very

OIL

a heavy

initial 50

filter change intervals

use

duty

engine

oil

with

CH-4 or CI-4. Change

hours

of break-in operation.,

Corporation

of synthetic oils. If synthetic oils are

must

be

performed

in

used.

The

in/ormation above supersedes all statements

be

the

as

specified

does

not approve or disapprove

using

as

listed

this

manual

requirements of

0975.

important

fuel going

pure,

and

in

No.2-D

#45

or

higher.

critical; invisible dirt

the

filter

can

into

the

fuel.

the

engine. Raycor

an

API

engine

in

this

manual.

conventional

in

the

and

not

Grade

the

components

can

damage

to

buy

clean f

be

rendered

the

tank

following practice

Micron filter rating

classification of

oil

and

filter after

Then

follow

the

used,

oil.

MAINTENANCE

be

extended if

of

for

the

engine

Oil

SAE

your

230

CF,

is

oil

ENGINE

UNIVERSAL recommends a 50%

chemicals

The antifreeze performs double run the cooling circuit quality antifreeze that contains Supplemental Cooling Additives

balanced,

The distilled water

being

NOTE:

antifreeze that is now available.

Antifreeze

and retard

Antifreeze

Freezing

COOLANT

A coolant recovery UNIVERSAL diesel engine. The purpose of

tank during without

COOLANT

distilled

at proper temperatures

engine to

poured

they

water.

that

can

the

from

(SCAs)

crucial

into

Laokfor

rust

Temperature

the new environmentally-friendly long lasting

mixtures

are beneficial

and

add

concentralion

Distilled

corrode

coolant,

rust

that keep

to

long

and

antifreeze should

the

cooling

will

to

the

ANTIFREEZE

RECOVERY

tank

kit

is

to

allow

for

engine

operation,

introducing

air

into

mixture

water

is

internal

by

and

tenn

protect

the

life of

engine

duty.

transferring heat

lubricates

corrosion.

the

antifreeze chemically

protection.

circuit.

against

engine's cooling

the

circulating

PROTECTION

23% 14°F

30% 35%

WC)

TANK

is

supplied

coolant

without

the

expansion

the

loss of

cooling

of

50%

free

from

surfaces.

It allows

and

Look

be

premixed

an

unexpected

-4°F

(-20°C)

with

each

coolant

system.

antifreeze

the

engine

away

protects

for

a good

system.

pump

this

recovery

and

contraction

and

to from the

before

freeze

They

seal.

50%

-40°F

(-40"C)

and

For

recommended

Opendlng

Above

41°-6soF

Below

A

CAUTION:

II1I/Ilne

011

additives

til

of

prtJdllce

oil

viscosity,

Temperatu.e

6soF

(20°C)

(5-20°C)

41°F

(5°C)

Do

not

to

mix.

Each

different

prtJperties

allow

brand

brands

harmful

see

the

SAE SAE

two

contains

could

to

your

following

011

Viscosity

30

0.1

20

or

SAE

10W-30

or

more

its

react

engine.

OW-30

10W-30

brands

own

in

the

chart:

of

additives;

mixture

COOLANT

7

RECOVERY

TANK

PREPARATIONS

PREST

ART

INSPECTION

Before

starting

longed

layoff - check

o

Check the

high

o

Check

bowls

o

Check

NOTE:

Refer to the specifications pages in this manual

fuel, oil,

your engine

the

engine

mark

on

the

fuel

supply

for

contaminants.

the

transntission

and

transmission types and quantities.

for

the

following

oil

level;

add

the dipstick.

and

examine

fluid

the

oil

level.

first

items.

to

the

time

or

maintain

fuel

FOR

after a pro-

the

level

at

filter/separator

for

INITIAL

o

Check and

o

Visually parts, threaded

o

Check

the

NOTE:

to

the

START-UP

the

DC

battery

examine

disconnected wires, unattached

connections.

the

coolant

manifold.

If the engine has

ENGINE

electrical system. Inspect

cable connections.

the

unit. Look

level

in

not

yet been filled with coo/ant, refer

COOLING CIRCUIT section

for

loose or

the

plastic recovery

hoses,

wire

missing

and

of

connections

check

tank

and

at

this manual.

COOLANT RECOVERY

TANK

MANtFOLD

MANIFOLD

IM-35B

SHOWN)

(&J

8

STARTING/STOPPING

PROCEDURE

STARTING

Place control

A

1IIIIIIrBI.

'"

JOIIf

Thrn

PREHEAT:Depress panel PREHEAT

the following chart:

START:While

the STAKr

Upon release the

15

psi. Then

oil pressure protective circuits

remain energized

lUTE:

A voltage drop will occur

when the

is

depressed.

PROCEDURE

the

transmission

to slightly

CAUTION:

StartIng

transmission,

the

KEY

SWITCH

lights,

gauges

switch

...

"'

....

Ie

Tompondun

41"f(S'C)

41

"f(S'C) 23'F(-5'C)

UmH

engine starting,

When

or

to

23'F

or

of

conll.uou.

still depressing

button.

PREHEAT

as

long

and

starting:

preheat button

in

neutral

open.

Make

certain

In

gear

could

your

to

the

PREHEAT

and

meters

should

be

TemperatureJPreheat

higher

(-5'C)

lower

use

This

will

release

switch

as

the

high

continue

and

the

resun

boat,

and

ON

position

switch.

will

be

depressed

30

the

PREHEAT

engage

the

START

until

the

water

do

not

to

run.

advance

the

throttle

transmission

in

serious

vessels

activated. The in

Preheallng

Approx. Approx. Approx.

seconds

oil temperature

activate,

(2

o'clock).

The

voltmeter

accordance

10

seconds

15

seconds

20

seconds

before

switch,

starter

solenoid.

switch.

pressure

the

nearby.

TIme

Do

engine

is

in

damage

and

with

cranking

depress

not reaches and

low

will

VOLTAGE

DROP

A

CAUTION:

the

engine system the COOling enter

filling

pump

system

the manifold from

happening through·hull conecting Engine

damage

warrantable

Once

the

engine starts, check

oil

pressure

NOTE:

Never attempt

running.

NOTE:

Some unstable running may occur

Depressing

will

help stabilize temperature a propeller load is applied running and the PREHEAT switch load on the

STARTING

Make

certain

the

prevailing

section

of

this

The

battery

Use a sufficient

Temperature/Preheat

Prolonged

starting

is

pumping

with

can

raw

during

engine's

once

cylinders

the

exhaust

by

closing

shutoff,

the

cause

resulting

issue;

the

and

battery

to

the

PREHEAT switch for 10·15 second intervals

the

engine

of

the engine reaches 150·170

DC alternator will

UNDER

the

should

COLD

lubricating

temperature.

manual.

be

fully

amount

chart

cranking

result

water.

raw

water

cranking.

by system the

draining

of

the

excessive

from

owner/operator

the

charging

engage

the

rpm

10

the engine.

be

CONDITIONS

oil

conforms

Check

charged

of

preheat

elsewhere

intervals

in

the

engine

exhaust

This

may

happen

through

way

raw

the

raw

instruments

voltage.

starter while

until

is

discernible.

the

to

the

raw

This

raw

water

of

the

exhaust

fills.

Prevent

water

supply

exhaust

water

depressed, a charging

table

minimize

aid

in

engine

should

in

the

operating

When

with

on

in

this

entry

a cold

F.

starting.

section.

muffler,

cranking,

keep

for

the

(60-77 C) and

the

engine

voltage

without

because

water

can this

and

is

not

a

this

proper

engine

engine.

engine

ratings

oil

drop.

See

is

for

the

Should

depressed

wail

longer.

the

engine

not

for

10

to

20

30

seconds;

Never run the starler

repeat the procedure

start

when

seconds,

for

the

release

more than 30 seconds.

START

both

above

switch

switches

and

preheat

is

and

STOPPING

To

stop place a

few lever close

Make certain this key switch is

(12

o'clock).1fthe key switch is left discharge. operator of

preventing the battery from discharging is

key

from

key should

PROCEDURE

the

engine,

the

transmission

moments

to

shut

down

An engine alarm buzzer

of

this

the

be

bring

in

to

stabilize

down

the

engine.

the

electric

condition (Key Switch

Key

Switch after stopping the engine. (The extra

stowed

in

the

neutral.

temperatures.

fuel

pump

a safe place.)

9

throttle

to

an

Allow

the

Then

tum

and

accessories.

in

the OFF position

ON,

is

provided

ON).

idle

engine

Pull

the

OFF

the

battery will

The

to

position

to

remove

and

to

idle

STOP

key

to

warn

the

best method

the

for

BREAK-IN

PROCEDURE

THE

FIRST

Although hour

of

proper operation

The service life engine is operated and serviced during its initial

use,

Your

new

conditioning

to

maximize

Perform this conditioning carefully, keeping in mind the

following:

1.

Start the engine according

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

idle) until the water temperature gauge moves into the

130° -1400P range.

3.

While using the vessel, run the engine at varying engine

rpms for the

4.

Avoid rapid acceleration, especially with a cold engine.

S.

Use

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

your

test

operations

engine

caution

50

HOURS

engine

has

experienced a minimum

to

ensure

accurate

of

all systems, break-in time is required.

of

your engine is dependent upon how the

requires

operation

the

performance

first 25 hours.

not

to

overload

to

approximately

break

in

and

to

the Starting Procedure

the

assembly

50

hours

each

moving

service life of

by

engine.

The

of

an overload.

of

and

50 hours

of

initial

part

in

the

engine.

running at fast

presence

the engine

one

order

of a

to

of

Breaking-in a new engine basically involves seating the

to

piston rings by long periods

rpm. Idle running may glaze the cylinder walls, resulting in

excessive

speed or heavy over-loading, especially with a cold engine, may cause scoring results. Operate the engine in moderation during the break-in period. (Don't baby the engine, but

MODEL

the cylinder walls. This cannot be accomplished

of

running at idle, nor by early running at

oil

consumption

of

RECOMMENDED

and

smoky

operation.

the cylinder walls, producing similar

RPM

RANGES

IDLE

CRUISE

Excessive

do

not abuse it.)

MAXIMUM

50-hour

RPM RPM RPM

1000

M3-20B M25XPB M35B M40B M50B

NOTE:

Attempting

shown may produce unstable engine operation and stalling.

NOTE:

The propeller should be either 2

allow the engine to reach its maximum rated rpm

throttle underway in forward gear

rated horsepower when needed.

NOTE:

See the 1RANSMISSION section

break-in information

-1200

1000

-1200

800 -1000 800 -1000 800

-1000

to

reduce idle speed below the minimum

on

your

2500 -3000

3500 -3600 2000 -2500 2900 -3000 2000 -2500 2900 -3000 2000 -2500

2900 -3000 2000 -2500 2700 -2800

or

3 blade. It should

at

to

ensure the availability

of

this manual

transmission.

full open

for

full

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

LIST

Each day before starting your engine, take a few moments

to

run

this

check

list:

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

exhaust leaks.

o Check the oil level. o Check the transmission fluid level. o Check for loose wires at the alternator.

o Check for loose wires and electrical connections at the

DC altemator and elsewhere on the engine's

DC

harness.

o Check the staJiing batteries level (weekly)

o Check drive belts for wear and proper tension (weekly).

o

Log

your

engine

running

time.

These

hours

relate

to

scheduled_maintenance.

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

as

full

as

possible.

o Look for clean fuel in the fueVwater separator bowl.

. 0 Check the coolant level

in

the plastic recovery tank.

o Check for any obviously loose components or nuts or

bolts.

NOTE:

Excessive loss

of

coolant indicates a cooling system

leak.

Check

the

entire system. If necessary,

use

a cooling sys-

tem

presslire lester

to

pressurize

the

cooling system

to

locate

the

area

of

leakage.

In

cases

of

excessive coolant

loss,

refill

tlte

system

as

outlined

in

tlte

ENGINE COOLING CIRCUIT

section

il1

this

manual.

START

YOUR

ENGINE

NOTE:

See

STARTING STOPPING PROCEDURE

in

this

manual

for

more

detailed instructions.

I.

Put transmission in neutral, throttle advanced.

2. Turn

KEY

to

the ON position

(2

O'clock)

3.

Depress PREHEAT (10

to

15

seconds).

4.

While pressing PREHEAT, push the START. As engine fires - release START and

PREHEAT.

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

NOTE:

Should engine fail

fa

start,

wait 30

secollds,

repeat

tlte

above procedure,

alld

PREHEAT

longe!:

6.

Allow a few

minutes

for

the

engine

to

warm

at

a

comfortable high idle (1400 - 1500 rpm), then reduce the

rpm

to

the

normal

idle position,

shift

into

gear,

anci

get

underway.

A

CAUTION:

When

shifting

the

transmission,

always

reduce

the

engine

rpm

to

idle,

then

shift

the

transmission

firmly

from

one

direction

to

another.

A

slight

pause

in

neutral

will

allow

the

propeller

to

slow.

Shifting

at

high

rpm

will

damage

the

transmission/damper

plate,

ALARMS

AND

CIRCUIT

BREAKER

ENGINE

CIRCUIT

BREAKER

The

DC

hamess on the engine is protected by

an

engine-

mounted manual reset circuit breaker

(20 amps DC).

Excessive

CUiTent

draw

or

electrical

overload

anywhere

in

the

instrument

panel

wiring

or

engine

wiring

will

cause

the

breaker

to

trip.

In

this event most engines will shut down

because the open breaker disconnects the fuel supply.

If

this should occur, check and repair the source

of

the problem.

After repairing the fault, reset the breaker and

restrui the

engine.

LOW

OIL

PRESSURE

ALARM

SWITCH

Allow oil pressure alarm switch is located off the engine's

oil

gallery.

This switch's sensor

monitors

the

engine's oil

pressure. Should the engine's oil pressure fan to 5

-to

psi

(0.4 - 0.7 kg/cm'), this switch will activate a pulsating

alarm.

OIL

GALLERY

IM-50B

SHOWN]

PRESSURE

ALARM

SWITCH

11

COOLANT

TEMPERATURE

SWITCH

A coolant

temperature

switch

is

located

on

the

thermostat

hOllsing.

This

switch will activate a continuous alarm

if

the

coolant's

operating

temperature

reaches

approximately

21O'F

(99'C).

AIR

BLEED

PETCOCK

COOLANT

rEMI'ERI,TURE,

SEND

OR

THERMOSTAT

ASSEMBLY

IM-50B

SHOWN]

A

WARNING:

runnIng.

use

the

servIcIng

NOTE:

Many

difficult

and

MAINTENANCE

Never

attempt

Wear

the

proper

correct

tools

tor

any

of

the

engIne's

of

the following maintenance jobs are simple but others are more

may require the expert knowledge

safety

each

DC

to

pertonn

equIpment

Job.

DIsconnect

electrical

SCHEDULE

any

service

such

the

equIpment.

of

a service mechanic.

as

goggles

battery

whIle

and

tennlnals

the

engine

gloves,

when

is and

SCHEDULED MAINTENANCE

Fuel

Supply

Fuel/Waler

Engine

Coolant

Drive

Vlsuallnspectlon

Engine Transmission

Cables Adjust

Fuel

Starting (and

engine

'Torque

Hold

Lubricate Switch

Transmission

Air

Cleaner

Exhaust

011

Level

Belts

Throttle and

engine

Filter

Batteries

House

011

and

Cylinder

Down

Panel

wllh

System

Separator

Level

and

Control

Shutoff

Idle

Batteries)

Filter

Head

Bolts

Key

"Lockeze"

Fluid

of

Engine

Levers

Speed

CHECK

EACH

DAY

50

100

HOURS

250

OF

OPERATION

750

500

1000

0 0

0

NOTE:

Please

keep

engine

suiface

0

DirI to

0

and

remain

oil will inhibit

cool.

0

the

0

clean.

engine's ability

0 0

0

0 0 0

0

0 0 0 0 0 0 0 0

0

0 0 0

0 0

0

0 0

0 0 0

1250

0

EXPLANATION

Diesel

No.2

rating

Check

for

water

if

necessal)').

Oil

level

should

dipstick. Check

at

recovel)'

Add

coolant

if

Inspect

for

proper

and

adjust

if

needed.

Check

for

fuel,

and

electrical

Check

for

loose

Check

for

loose

Lubricate

Refer to page

Initial

EveI)' and excessive

Initial change

At

Initial or

Clean

Initial for exhaust on sal)'.

with

change 50

operating

make

sure corrosion.

engine

both

evel)'

engine

overhaul

first

100

hrs.,

fluid

change

once a year.

the

filter

check

at

leaks.

Check

elbow

inside

passages;

Check

that

MAINTENANCE

of

45

and

dirt

in

indicate

between

tank;

if

needed.

tension

Check

oil

and

water

connections.

belt

tension.

fittings,

cotter

WD-40

or

10.

at

50

hrs,

then

hours

connections

oil & filter

and

50 for

change

100

hours.

or

cylinder

then

each

at

50

hrs.,

element.

hrs

..

then

siphon

break

carbon

clean

all

connections

OF

SCHEDULED

cetane

or

higher.

fuel

(drain/replace

MAX.

empty,

check

(3/8"

to

1/2"

belt

edges

leaks.

Inspect

Keep

bolts & nuts

pins,

equivalent.

change

check

electrolyte

are

vel)'

at

50

head

year

at

winterizing.

then

every

evel)'

500

operation.

and/or

corrosion

and

replace

are

tight.

and

LOW

at

manifold.

depression)

for

wear.

wiring

etc.

every

250 levels

tight.

Clean

hrs.,

then

overhaul.

250

hrs.

Inspect

Check

buildup

as

neces-

filter

on

tight.

hrs.

off

the

12

MAINTENANCE

NOTE:

Use the engine hour meter gauge to log your engine hours

engine hours

by running time.

SCHEDULE

or

record your

SCHEDULED

MAINTENANCE

Engine

Hoses

Heat

Exchanger

Zinc

Anode

Electric

Fuel

Lift

Pump

Filter

(if

applicable)

Raw

Water

Pump

Coolant

System

'Fuel

Injectors

'Starter

'Preheat

'Engine

Motor

Circuit

Cylinder Compression Valve

Clearance

DC

Alternator

Heat

Exchanger

Transmission

Damper

Plate

and

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

1000

1250

0 0 0 0 0 0 0 0 0

0 0

0 0 0 0

0

0 0

0

0 0

0

0 0

0

EXPLANATION

Hose

should

be

spongy.

Check & tighten

Clean

or

replace

cap

and

clean

for

professional

Clean

at

50

hours,

Remove replace both wear,

Drain, appropriate

Check spray

Check and pinion

Check clean

Incorrect performance; and

Check bracket;

Remove, tested.

Chattering damper

pump

if

needed.

when

reassembled.

cover

plate

flush,

and

antifreeze

and

adjust

condition

solenoid

lubricate.

drive. operation

glow

plugs;

valve

check

adjust

valve

DC

charge

tighten

have

at

plate

idle

wear.

OF

MAINTENANCE

hard & tight

all

hose

anode.

Open

out

debris.

Remove

cleaning

cover

(see

and

Clean

of

clearance

clearances.

electrical

professionally

and

then

clean

and

inspect

Also

replace

Inspect

wear

and

cam

refill

cooling

mix.

injection

check

from

and

opening

Engine

motor

for

and

lubricate

preheat

solenoid.

resistance

will

compression

alternator.

connections.

low

rpms

Remove

SCHEDULED

Replace

pressure every

Adjustments).

result

cleaned

and

if

clamps.

heat

exchanger

every

testing.

250

impeller

gasket

Lubricate

pump

for

wear.

system

with

pressure

corrosion.

the

starter

Remove

(0.7-0.8

in

poor

pressure

Check

and

is

an

indication

replace.

soft

1000

hours.

for

Remove

and

mounting

pressure

or

end hours

wear;

internal

and

motor

and

ohms).

engine

timing,

of

'UNIVERSAL

recommends

this

service

be

performed

by

an

authorized

13

mechanic.

ENGINE

COOLING

CIRCUIT

DESCRIPTION

The

engine

is

fresh

water cooled

(engine

coolant)

by

an

engine-mounted

heat

exchanger.

Raw

water

is

pumped

through

the

heat

exchanger

by a gear-driven,

positive

dis-

placement

impeller

pump.

After

the

raw

water cools the

engine

coolant

in

the

heat

exchanger,

it

mixes

with the

engine's

exhaust

gases,

cools

the

exhaust

gases,

and

dis-

charges

overboard.

The

engine's coolant

is

circulated

by

a belt-driven centrifu-

gal-type

metal

impeller

pump

mounted

on

the

front of

the

engine.

The

engine's coolant temperature

is

thermostatically

controlled. The engine's coolant

must

be

changed

according

to

the

main-

tenance

schedulO'in

this

manual.

If

the

coolant

is

allowed

to

become

contaminated,

it

can

lead

to

overheating problems.

ACAUTlON:

Propllr

cooling

systBm

mainfBnanclI

is

critical; a substantia/numbllr

of

IInglnll

failures

can

bll

traced

back

to

cooling

systllm

corrosion.

A coolant

recovery

tank

allows

for

engine coolant expansion

and

contraction during engine operation, without

any

signifi-

cant

loss

of

coolant

and

without introducing air into

the

cool-

ing

system.

This

tank

is

best located

at

or

above

the

engine

manifold

. should

be

easily

accessible.

COOLANT RECOVERY TANK

MHOB.

M·!lJB

COOLANT

DRAIN

JUST

ABOVE

TH~E

MOUNT

M·40B M·25XPB

M·35B COOLAln

DRAIN

MANIFOLD

M·50B

COOLANT

DRAtN

CAP

HEAT

EXCHANGER

Drain

the

engine coolant

by

loosening

the

drain

plug

on

the

engine block

and

opening

the

manifold pressure

cap.

Flush

the

system

with

fresh

water,

then start

the

refill process.

See

the

Parts

Identification

photos

in

this manual for locations.

.

NOTE:

The

petcock

on

the

heat

exchanger

can

also

be

used

to

help

drain

engine

coolant.

AWARNING:

Beware

of

the

hot

engine

coolant.

Wear

protectiVII

gloves.

To

Refill

With

Coolant

With

the

engine running

in

idle, slowly pour

clean

premixed

coolant into

the

manifold.

NOTE:

Open

the

petcocks

on

the

thermostat

housing

and

heat

exchanger

to

help

remove

air

from

the

system.

When a steady

flow

of

coolant appears

at

the

drain

plug

opening,

close

the

water

drain

plug and

continue

to

fill

the

system

until

the

manifold

remains

full.

Close'lhe petcock

on

the

heat

exchanger

when

antifreeze

flows from

it.

.

Monitor

the

coolant

in

the

manifold

and

add

as

needed.

Fill

the

manifold

to

the

filler

neck and install the pressure

cap.The petcock

on

the

thermostat should

also

be

opened

when

refilling

to

allow

trapped air

to

escape.

Remove

the cap

on

the

coolant recovery tank,

fill

with

coolant

mix

to

halfway

between

LOW

and

MAX,

and

replace the cap.

Run

the

engine, close

all

petcocks

and

observe

the

coolant

expansion

flow

into

the

recovery

tank.

After checking for leaks,

stop

the engine

and

allow

it

to

cool.

Coolant

shoui:!

draw

back

into

the cooling system

as

the

engine

cools

do·vn.

Add

coolant to

the

recovery

tank

if

needed.

Clean

up

'ny spilled coolant.

PRESSURE

CAP

PRESSURE

CAP

NOTE:

Periodically

check

the

condition

of

the

pressure

cap.

Ensure

that

the

upper

and

lower

rubber seals

are

in

good

condition and check that the vacuum· valve opens and closes

tightly.

Carry a spare

cap.

ENGINE

COOLING

CIRCUIT

RAW

WATER

CODLING

CIRCUIT

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

of

exhaust gas and raw water is

driven through the stem tube and overboard.

Raw

Water

Pump

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

impell~r

housing, producing the pumping action.

On no account should this pump be run dry as water acts

as

a lubricant 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 water) is not present during engine operation. Such failures are.

not warrantable, and operators are cautioned

to

make sure

raw water flow is present at start-up.

Changing

the

Raw

Water

Impeller

I.

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.

6.

Pull the impeller off the shaft. Observe that the key on the shaft is not lost.

.

HOUSING

15

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

A

CAUTION:

If

any

of

the

vanes

have

broken

off

the

impeller

they

must

be

found

to

prevent

blockage

in

the

cooling

circuit.

They

often

can

be

found

in

the

heat

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

of

petroleum jelly or silicone to the inner

surface

of

the impeller housing.

NOTE:

Just coat the swiaee, do Ilot over apply.

10.

Install the sealing O-ring in the impeller cover. Position the gasket and wear plate and install the impeller housing

and secure in position with the 3 retaining bolts and

washers.

II.

Mount the pump to the engine taking care that the end seal and gasket are in place. Do not tighten the pump mounting screws, just finger tight.

12.

Reassemble the hose connections and

open

the

raw

water intake,

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 afai/ure occur with the pumps illtemal parts

(seals and bearings)

if

may

be more cost efficient to purchase

a new pump. The price

of

individual pans would almost

match the price

of

a new pump.

NOTE:

Keep the slotted weep holes

ill

the pump

hOllSillg

clear

and open. Water found coming from these openings indicates

a shaft seal leak alld

IIlllst

be aI/ended

to

withow delay.

RAW

WATER

PUMP

O-RING

COVER

ENGINE

COOLING

THERMOSTAT

A \hennostat, located near the manifold at the front

engine, controls the coolant temperature

flows through the closed cooling circuit. When the engine is flTSt

started the closed thennostat prevents coolant from flowing (some coolant is by-passed through a hole in the thennostat to prevent the exhaust manifold from overheating). As \he engine warms thennostat is accessible and can replaced easily. Carry a spare thennostat and gasket.

up

the thennostat gradually opens. The

be

as

it continuously

checked. cleaned. or

of

the

WATER TEMPERATURE SENDDR

CIRCUIT

HEAT

EXCHANGER

ZINC

ANODE

Zinc

Anode

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

the zinc anode should

or

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

replaced. as required. Spare anodes should be

is

located in the raw water cooling

The

purpose

of

the syslem. The condition

be

checked monthly and the anode

of

REPLACE

of

the zinc

anode debris.

CLEAN & REUSE

of

in

THERMOSTAT

(M-35B

To

Replace

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

of place. Run the engine and check for that there are

Heat

Exchanger

The beat exchanger is a copper tube which encloses a num-

of

small copper tubes. Raw water is pumped through the

ber small copper tubes and the freshwater coolant from the engine is circulated around the copper tubes. removes heat from the freshwater coolant. To keep the heat exchanger operating efficiently. it should be removed from

the engine every pressure tested.

the

Thermostat

sealant on both sides

no

leaks at the thennostat housing. .

1000 hours to be thoroughly cleaned and

of

the gasket before pressing in

nonnal

ASSEMBLY

SHOWN)

THERMOSTAT HOUSING

temperatures and

The

raw water

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A clean raw water intake strainer engine's cooling system. Include a visual inspection strainer when making your periodic engine check. The water in the glass should be clear.

Perfonn the following maintenance after every 100 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

7. Run the engine and check for leaks.

NOTE:

Also follow the above procedure after having

INTAKE

the

soacock.

STRAINER

the

strainer at or below

is

a vital component

if

necessary.

the

waterline

of

run

of

this

the

of

hard

aground.

If

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

SEACOCK

or

grass may

:If':-t----

of

raw

o!!£::::::l:2:f::!.

so

'SEALING

WASHER

STRAINER FILTER

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 capped and properly secured in its holder after all the old oil has been drained.

NOTE:

J/4NPT.

Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence

this

vent serious damage. Call a competent mechanic

present in the oil. Raw water present in the oil can be the

result and/or a siphoning ing circuit into the exhaust, filling the engine. This problem is often caused by the poor location siphon valve, See UNIVERSAL'S Installation Manual.

THE

SUMP

or

attach a pump to the end

Thread size

condition

of

a fault in the exhaust system attached to the engine

is

for

the lube oil drain hose capped end is

of

water in the oil. Although

rare,

it

does

require

of

raw water through the raw water cool-

prompt

or

the lack

attention

of

the drain

to

if

water is

an

anti'

pre-

Replacing

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

NOTE:

to

make certain

An

automotive filter wrench should be helpful in removing the old oil filter. Place some paper towels and a plastic bag 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. 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 recommended.

REFILL

the

Oil

Filter

it

helpful

Do

not punch this hole without first loosening the filter

it

will come off!

off

with the old oil

If

this rubber sealing gasket remains sealed against the

When

installing the new oil

of

oil and apply a thin coat

Use genuine UNIVERSAL oil filters - generic filters

THE

OIL

SUMP

of

clean engine

screw

the filter

AWARNING:

minants. nails

thofllugh/y

card

clothing

011

Pfllporly.

Avoid

Of

Used

prolongBd

using rags

BnglnB

skin

soap

011

contact.

and

water.

containing

contains

Clean

LaundBf

uS/ld

011.

haflllful

skin

Of

Discard

DRAIN

conta-

and

dis-

uS/ld

Add

fresh oil through the filler cap. After refilling, run the

engine for a few moments while checking the engine's oil

pressure.

filter or from the oil drain system, and then stop the engine. Then

HOSE

the

high mark on the dipstick.

--Smm

1/4"

NPT

Make

sure

check the quantity

engine

requires

!11n61

SOCKET

SPIN·ON

there

is

no

leakage

of

oil with the lube oil dipstick.

additional oil, fill

Oil

FIlTER

around

to,

but

not

...J.l.,~nl:-(

the

new

over,

M·25XPB M·35B

M·40B BLOCK

DRAIN

OIL

oil

If

the

FILTER

17

REMOTE

OIL

FILTER

(OPTIONAL

KIT

PN

#040078

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.

NIIlE:

Refer to the ENGINE OIL CHANGE page

ill

this

manual

for

instructions on removing the oil filter.

To

install, simply remove

the

oil

filter off

the

engine

and

thread

on

WESTERBEKE'S remote

oil

filter

as

shown.

Try

to

install

the

remote filter facing

down

to

help

reduce

oil

spillage

when

changing.

APPLY A THIN

COAT

OF

CLEAN

OIL

TO

THE

O-RING

WHEN

INSTALLING

THIS

KIT.

THREAD

THE

KIT

ON,

THEN

HAND

TIGHTEN

AN

ADDITIONAL

3/4

TURN

AFTER

THE

O-RING

CONTACTS

THE

BASE.

NOTE:

Westerbeke is not respollSible

for

ellgine failure due to

incorrect installation

oj

the Remote Oil Filter.

A

CAUTION:

It

is

vital

to

install

the

oil

lines

correctly.

If

the

oil

flows

in

the

reverse

direction,

the

by-pass

valve

in

the

filter

assembly

will

prevent

the

oil

from

reaching

the

engine

causing

an

internal

engine

failure.

If

there

is

no

oil

pressure

reading,

shutdown

immediately

and

check

the

hose

connections.

FASTEN

SECURELY

TO A BULKHEAD

(SCREWS

ARE

OWNER

SUPPLIED)

THE

IN

CONNECTION

HOSE

MUST

ATTACH

TO

THE

OUT

CONNECTION

ATTHE

REMOTE

OIL

FIlTER.

THE

OUT

CONNECTION

HOSE

MUST

ATTACH

TO

THE

IN

CONNECTION

AT

THE

REMOTE

OIL

FILTER.

18

APPLY A THIN

COAT

OF

CLEAN

OIL

TO

THE

FILTER

GASKET

WHEN

INSTALLING.

AFTER

THE

FIlTER

CONTACTS

THE

BASE,

TIGHTEN

IT

AN

ADDITIONAL

3/4

TURN.

,

FUEL

ADDITIVES

If

fungus

or

bacteria

have

an

authorized a diesel turer's instructions).

fuel

biocide

is

causing

dealer correct

to

sterilize

fuel

the

these

fuel

problems,

SPARES

While

the

likelihood of having to service

sea

is

SUnil

the

possibility

mend

that

banjo

washers, injector seat washers,

ter

he

carried

from

your should a simple tightening of the fitting, replace

FUEL

The

on-engine ordinary which

supply

drawn

'pump,

on

board at all times. Purchase

local

UNNERSAL dealer or distributor.

develop at a banjo washer that cannot

LIFT

PUMP

fuel

circumstances the engine's electric

is

energized

a continuous

through

the primary spin-on

the

does

system

is

by

the

key

flow

of

fueVwater

fuel

exist.

Therefore,

virtually self priming. Under

switch/preheat bulton,

fuel

from

separator

fIlter,

and

you

problems.

(follow

the

the tank. This

to

the the injection

Then

the

fuel

system

we

and a fuel

needed

be

corrected

sealing

fuel

lift

engine lift

FUEL

should

use

manufac-

at

recom-

fil-

spares

If

a leak

by

washer.

pump,

will

"

fuel

is

pump.

SYSTEM

FUEL

RETURN

A shut-off injection

Air

SomeUNNERSAL engines use a replaceable air ment

removed'

it become with periodically. mable other

ter.

pump.

FUEl

Cleaner/Silencer

Wrapped

and

its

interiQr

cleaning

UNIVERSAL

LINE

SHUT-OFF

valve

is

located

This valve must be fully open.

SHUT-OFF

around a metal

brushed

too

contaminated it can

element should

Simply

solvent.

on

the

fuel

VALVE

canister.

off

or

cleaned

he

also

wash

the

assembled

Use

this

same

air cleaners that

VALVE

with

be

use

IM-SOBl

retum line

1bis element

an

replaced. The canister

removed

unit

cleaning procedure

a similar

near

the

filter

can

air

hose.

When

and

cleaned

in a non-flam-

type

canis-

ele-

he

for

A

WARNING:

II/IaI

filii

tuBI

proper

wmtIlatlon.

FUEL

SYSTEM

.

If

it becomes necessary system, onds.

pump

drives

If

injector line

the line.

NOTE:

tum

the

Activate

which

draws

air out via

high

pressure injector

nut

engine over until

the secure

Do

'not

A

WARNING:

samty

glasses

attempt

injector/lnes.

0"

not

system

when

BLEEDING

to

bleed

panel

key

ON

the

pre-hear

fuel

into

the

fuel

return.

lines

at

each

injector,

fuel

sports from between

the

nuts

and

this

procedure on a hot

Always

and

gloves

allow

smoking

stmllclng.

air

from

and

intennitently 5-10

vircui!.

This activates

the

on

engine

need

to

be

open

start

the

engine

wear

p!otectlvB

when

blBBdlng

or

Also

provide

the

on

fuel

bled, loosen

the

throttle

as

engine.

clothing,

high

open

flames

engine

the

fuel

system

the

and

crank

the

nut

and

normal.

pressure

fuel

sec-

and

NOTE:

To

operate efficiently a diesel

continuous

and black exhaust smoke

intake.

volume

of

clear

air.

Hard

are

all symptoms

engine

must

intake

starting,

AIR

an

erratic

of

a restricted air

CLEANER/SILENCER

IM-35B

SHOWN)

a

idle,

TO

FUEL

19

ELEMENT

AIR

CLEANER/SILENCER

IM-50B

SHOWN]

AWARNING:

SBtrlclng that

may

01

athol

SOUICIIS

vtclng.

EnsUIB

tho

fuol

system.

tho

spill.

Shut

fU1I1

00

proPIII

off

system.

NOT

allow

of

flIB

vontllatlon

tho

Tako

neal

fuel

valvo

calo

any

smoking,

tho

fuol

oxists

at

tho

In

catching

opon

systllllJ

whon

FUEL

tank

whlln

any

fulll

flamllS

whon

SIll-

slIrvlclng

SYSTEM

FUEL

WATER

A primary fuel filter installed between the fuel tank and the engine water and other contaminants from the fuel before they can

be carried 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

to

the fuel system on the engine.

of

filter/water separator with

of

the problems

to

remove

be

FUEL

FILTERS

The fuel injection pump and the fuel injectors are precisely manufactured

from water and dirt.

must pass through at least two fuel filters, a

rator and the engine's spin-on fuel filter. Visually inspect, clean, and change these filters according to the maintenance schedule

I.

Shut fuel supply off.

2.

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

3.

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

bracket so the new filter can be seated properly.

4.

Lightly oil the sealing O-ring on the new filter. stall, tum the filter assembly clockwise carefully until the O-ring contacts the sealing surface Tum

5.

Thrn on the fuel and start the engine. The normal preheat

function should quickly prime the system and the engine should start.

NOTE:

The

during

'iYSTEM after

and

they must receive clean diesel fuel, free

To

ensure this flow

in

this manual.

213

further with the filter wrench.

cartridge contains fuel.

disassembly.

Perfonn the PRIMING

replacing

the

spin-on

of

clean fuel, the fuel

fueVwater sepa-

of

the housing bracket.

Take

Care

not

THE

filter.

To

to

spill

FUEL

rein-

it

fil-

A typical fuel filter/water separator is illustrated gram. TIris is the Raycor Model 500 MA. Keep if

a water separator type filter is not installed between the fuel supply tank and engine-mounted fuel system, in the fuel will affect the fuel pump, engine filter, and injection equipment. The owner/operator is responsible for making

certain

the

fuel

reaching

free

of

impurities.

and maintaining a proper filtration/separation system.

TO

ENGINE

the

engine's

TIris

process is accomplished

injection

FUEL

in

this dia-

in

mind that

any

equipment

by

installing

FILTER

water

is

WATER/SEPARATOR

FUELFILnR

BLEED

SCREW

TO

FUEL

TO

INJECTION

GASKET

PUMP

20

DC

ELECTRICAL

SYSTEM

ENGINE

12

VOLT

DC

CONTROL

CIRCUIT

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 or when servicing the DC electrical system on the engine.

DRIVE

BELT

ADJUSTMENT

A

CAUTION:

Drive

belts

must

be

properly

tensioned.

Looss

drille

belts

will

not

provide

proper

alternator

charging

and

will

eventually

damage

the

alternator.

DrllIB

belts

that

are

too

tight

will

pull

the

alternator

out

of

alignment

and/or

cause

the

alternator

to

wear

out

pre-

maturely.

Belt tension adjustment is made by pivoting the alternator on

· its base mounting bolt.

1.

Loosen the alternator adjusting strap bolt and the base mounting bolt.

2.

Pivot the alternator on the base mounting bolt

to

the left

or

right

as

required.

3. Tighten the base mounting bolt and the adjusting strap bolt.

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

down and recheck belt tension.

/'<-

~

BATTERY

CARE

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.

21

GLOW

PLUGS

The glow plugs are wired through the preheat solenoid.

When

PREHEAT

is

pressed at the control panel this solenoid

should

"click" on and the glow plug should begin

to

get hot.

Inspection

To

inspect the plug, remove the electrical terminal connections, then unscrew or unclarnp 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

burn 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

other to the body

of

the glow plug,

as

shown. A good glow

plug will have a

0.7 - 0.8 ohm resistance. This method can be

used with the plug in or out

of

the engine.

You

can also use

an

ammeter to test the power drain

(8

- 9 amps per plug).

.

A

WARNING:

These

glow

plugs

will

become

very

hot

to

the

touch.

Be

careful

not

to

bum

your

fingers

when

testing

the

plugs.

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7

to

15

seconds.

If

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

circuit. When reinstalling the glow plugs, use anti-seize

compound

on

the

threads.

A

WARNING:

00

not

keep a glow

plug

on

for

more

than

30

seconds.

GLOW

PLUG

TIGHTENING

TORQUE:

7 ·11

Ft·lb

(1.0·

1.5

m·kg)

TERMINAL END

TIP

TESTING A GLOW

PLUG

WITH

AN

OHMMETER

DC

ELECTRICAL

DESCRIPTION

The charging system consists voltage regulator,

DC

circuit breaker, and a battery and connection wires.

Because

voltage regulator or on the

of

back

Alternator

H

you

suspect that the alternator is not producing enough

voltage

to charge

A

WARNING:

IirIt.

110

/lilt

an

engine DC wiring harness, a mounted

the use

of

integrated circuits (lC's)

is

very compact and is mounted internally

of

the

alternator.

Troubleshooting

the

engine's battery, check

A failtld

trnu:II

untilllltl

of

an alternator with a mounted

the

following:

IJItBIJIatDr

aItemator

can

has

be_

cooled

o Make certain your alternator is securely mounted.

o Check the drive belts for proper tension.

o

Inspect

for loose or disconnected wires

.rE:

An

isolotor

stlector switch is usually mounted

boIteries tire

battery

tire

so

house batteries.

but

probkm

with

a diode, a solenoid,

the

sIDrting

not

the hause battery, the alternator is

is in the battery charging circuit

battery is not discharged along

If

tire

isolotor is charging the starting

in

at

the

alternator .

or

a banery

the circuit to isolate the

OK

electronic

VfIfY

down.

with

and

SYSTEM

A.

WARNING:

that

everyone

sheallBS

5. Start

6. The voltage reading for a properly operating alternator

NOTE:

voltmeter

the R terminal if the previous test showed only battery

age at

'14

PINK/BlUE

and

the

be

should

is over- or undercharging, have it repaired at a reliable

service shop.

Before removing the alternator for

to

the

B output terminal.

Before

stattlng

is

clear

of

moving

belts

during

test

engine.

between 13.5 and 14.5 volts.

ensure that 12 volts

the

paris!

procedures.

DC

engine

Keep

If

your alternator

repair,

excitation

make

away

use

is

present at

cettain

from

your

volt-

A

WARNING:

"'

__

ur:tt"""

,"cfJtat

Cllacldll far

H

you

suspect the alternator has failed perform the following

tests

with the engine off:

1.

Using a voltmeter, connect the voltmeter

the output terminal

2. Connect the volbneter negative wire

engine.

3. Check the battery voltage.

4.

Check

the

minaI

B and

voltage at the alternator should be

(unless

there's

would

be zero).

A

CAUTION:

dn:tIIt,

fair

- sIuIt

....

ShIIt

off

IIItI

battery

engine

when

battery

WlHfring

SJISfIm.

Proper

voltage between the alternator

Is

I'IIIIIIlng!

Voltage

B+.

It

should read

any

engine ground.

an

isolator in the circuit, then the reading

To

arrIId

damage

off

IIItI

engine

If

the

to

tIHJ

battery

DR

red

to

any

12

(+)

circuit is good,

same as the battery

battery

switch

swltt:h

Of

the

engine

wire clip

ground

on

to

13

volts.

positive ter-

t:hBlging

when

to

the

.14

'RO"N==9"'«~--

'10

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TYPICAL ALTERNATOR

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UNIVERSAL

CONNECTIONS

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ELECTRICAL

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two

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and

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Is

assembled

gauges

ATTACH

THE

FROM

THE

Installed,

HARNESS

are

panel

volt

negative

PANEL

10

the

(refer

REMOVE IN

THE

SENDER

SPARE

WIRE

are

two

additional

engine

to

the

THE

PLUG

~

PLUG

BUNDLE

ground panels,

to

iIIustra·

AND

SCREW

-,

,

CAPTAIN

ADMIRAL PANEL

PANEL

,

REMOVE

THE

PLUG

INSTALL

THE

OIL

AND

TEMP

SENDER

,

*

NOTE:

An

on-off

be

installed

disconnect

the

and

the

boat.

engine

draw

200

cranking.

175

amps

normally

but a switch

be

used

the

starter

switch

in

the

battery

when

Twelve

starters

to

at

serve

to

circuit.

this

in

300

A

12

should

circuit

to

starter

from

an

emergency

leaving

volt

diesel

typically

amps

when

switch

with a continuous

rating

of

vac

will

this

(unction,

must

never

"make"

23

DC

ELECTRICAL

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typically

draw

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when

switch

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will

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and

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boat.

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engine

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200

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••

Unlvarsal

MARINE POWER

26

-

L..

ENGINE

ADJUSTMENTS

. -

..

~

.

NOTE:

UNIVERSAL recommends

thanhe

following engine

~adjustments

be peiformed by a competent engine mechanic.

The information below is provided to assist the mechanic.

THROnLE

ANO

STOP

CONTROLS

MOOEL

M3-20B

THROTTLE

LEVER'

.

,

•

THROTTLE CONTROL

MODELS

M-2SB,

M-3SB

MODEL

M-SOB

THROTTLE

LEVER

THROrnE

AND

STOP

ASSEMBLY

The throttle and engine stop levers are located on the outboard side

of

the engine

just

below the fuel injection pump. 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 is adjustable. These levers and brackets should be periodically lubricated and checked for loose fastenings.

VALVE

CLEARANCE

NOTE:

Valve

adjustment should not be necessary under

normal operating conditions. These adjustments, when

required,

should be peiformed by an authorized mechanic.

Remove the valve rocker cover to expose the engine's valve train. Remove the glow plugs from each

of

the cylinders

to

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

TOC

(Top Dead Center)

of

its compression

stroke. Each cylinder is adjusted following the engine's firing

order.

FIRING

OROER 3 CYLINOER

MODELS

4

CYLINDER

MODELS

1-2-3 1·3-4-2

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

of

the valves for

Cylinder #1. Watch for the intake valve to open indicating

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

#1

is now at TOC.

Adjust the valves in Cylinder #1.

Proceed to the next cylin-

der in the firing order.

Three

Cylinder

Models

Rotate the crankshaft

240'

in the normal direction

of

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

240'

and adjust the #3 cylinder's valves.

Four

Cylinder

ModelS

Rotate the crankshaft

180'

in the nmmal direction

of

rotation

and adjust the #3 Cylinder's valves. Rotate the crankshaft

another

180'

and adjust the #4 Cylinder"s valves. Rotate the

crankshaft another

180'

and adjust the #2 Cylinder'S valves.

SOME

MOOELS

~0

HAVE A COVER OVER

THE

HOLE

27

VALVE

CLEARANCE

(COLO

ENGINE(

0.0071

·0.0087

tN [0.18 -0.22mml M·5DB

,,=,,=.=!=t

0.0057 -0.0072

IN

10.145 -0.185mml M3·20B,

M·25XP8

M-358,

M·40B

ENGINE

NOTE:

UNIVERSAL recommends that the following engine adjustments be performed The infonnation below is provided

TESTING

Make certain the oil level (dipstick) is the also

1. Warm the engine to normal operating temperature.

2.

3. Remove all the

ENGINE

air

intake filter is clean.

he

in good condition.

Move

the control lever to a position for shutting

(Disconnect

compression gauge/adapter combination to the cylinder on which the compression

COMPRESSION

The

battery

the

wires

if

a fuel

glow

plugs from the engine and install the

is

to be measured.

at

the correct level and

and

starter

shutdown

solenoid is used).

motor

off

MEASURING COMPRESSION

DIAL

GAUGE

ADJUSTMENTS

by

a competent engine mechanic.

to

assist the mechanic.

must

the fuel.

+

...

OIL

PRESSURE

Testing

To install a mechanical oil pressure gauge in its place. After warming the oil pressure gauge.

OIL

SENDER

Oil

Pressure

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

up the engine,

PRESSURE 7 psi

AND

SWITCH

TORQUE

LIFT

set

(49

KPal

PUMP

the engine

alldle

9 ·13

speed

speed.

R·lh

(1.2

OIL

IM-50B

NO!IMAI,LYI?PEIV 5 PSI

BATTERY

GROUND

at

idle and read

·1.8 m •

kg).

GALLERY

SHOWN]

RAfEO

4.

Close

the raw

5.

Crank maximum

6.

Repeat

COMPRESSION cranking

MAXIMUM OR

LESS.

NOTE:

If

the readings are below the limit, the engine needs an

overhaul.

Re-installthe

7.

the threads)

S.

Open

Ibe

OIL

PRESSURE

The

engine's

by the

oil

pressure

normal operation, the oil pressure will range between

60 psi (2.8

NOTE:

A newly staned, cold engine can have

reading up to

. an oil pressure

readings will vary depending upon the temperature

engine

and

water

the

engine

reading. Record the reading.

this process

PRESSURE

speed.

PERMISSIBLE

LIMIT

327

glow

and

reset the fuel shut-off to the run position.

raw

water soacock

oil pressure, during operation, is indicated

gauge

and

4.2

kg/cm').

60

psi (4.2 kg/ctri'J. A warmed engine can have

I~ading

the rpms.

~

seacock

and

allow

for

each

412 • 469

DIFFERENCE

psi

12.25

MPal

plugs

on

the instrument panel.

as low

(thru-hull).

the

gauge

cylinder.

psi

12.84·3.23

BElWEEN

(use

anti-seize

(lbru-hull).

as

35 psi (2.5 kg/cm'

to reach a

MPal

CYLINDERS

compound

an

oil pressure

at

IS

on

During

40

J.

These

of

the

10%

and

FUEL

INJECTORS

In case injectors checked injection service center. loss in clean room enviroment, injector as a

Before removing the old injector, clean the base falling

out easily and is held in by carbon build-up

the injector side-to-side with the aid free it, and then lift it out.

The washer. This washer should be removed with the injector, replace with a new washer

INJECTOR

of

severe vibrations and detonation noise, have the

and

overhauled by an authorized fuel

Poor

fuel quality, contaminants and

of

positive fuel pressure to the injection

injector faults. Since fuel injectors must be serviced in a

it is best to carry at least one extra

spare

should a problem occur.

of

the injector to help prevent any rust or debris from

down

into the injector hole.

injector seats in the cylinder head

when

TO

CYLINDER

HEAD

TORQUE

If

of

the new injector is installed .

pump

can

result

area around the

the injector will not lift

or

the like, work

the socket wrench to

on

a copper sealing

±4

R·lh

(5.5

±0.5

kgl·m)

Low

Oil

Pressure

The specified safe gradual loss For

additional infonnation on low oil pressure

the ENGINE TROUBLESHOOTING chart.

minimum

of

oil pressure usually indicates a worn bearings.

oil pressure is 5 - 10 psi. A

re~dings,

see

•

.Unlvarsal

28

FUEL

INJECTOR

ENGINE

TROUBLESHOOTING

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

mendations

to

overcome

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-

the

problems.

switch

fuel

pump

switch

depressed;

not

1.

Battery

2.

20-Amp

to-Amp

3.

4.

Loose

5.

Preheat

1.

Connection

Faulty

2.

3.

Faulty

Loose

4.

5.

Low

Faulty

1.

2.

Preheat

low

3.

1.

Faulty

Push~pull

2.

station Fuellifl

1.

2.

Switches or

3.

Fuel

4.

20

5.

Exhaust

Probable

battery

START

solenoid.

battery

batteries.

fueling

compression.

shut-off

to

disconnected.

starvation.

Amp

Switch

not

circuit

breaker

connections.

solenoid

to

solenoid

swfich.

connections.

system.

solenoid

lever

shut·off engine

pump

failure.

and/or

circuit

breaker

system

Cause

breaker

tripped.

not

faulty.

disconnected.

wiring

is

on.

operating.

at

cable

restricted.

tripped.

faulty.

engine.

from

steering

loose

tripping.

NOTE:

The

engine~

electrical system is protected by a 20-

Ampere manual reset circuit breaker located on the bracket

on the left side

mounted on the

of

the engine. The preheat solenoid is

same

bracket.

Verification/1lemedy

1.

Check

switch

and/or

battery

connections.

Reset

breaker,

if

breaker

trips

again,

check

preheat

(-)

connection

activation

(~)

connection

sound.

which

buildup

solenoid

Replace

would

at

2.

circuit

Check

3.

4.

Check

engine

5.

Check

1.

Check Check

2.

Check

3.

connection. Check

4.

engine

Check

5.

Check

1.

2.

Check

3.

Compression Reconnect

1.

Reconnect

2.

Fuel

lift

1.

pump

with

Inspect

2.

Inspect

Check

3.

4.

5.

fuel

Check

for

Ensure cause

tripping.

Check

for

exhaust

and

check

circuit

voltage

at

and

(+)

connection

ground

stud.

solenoid.

connection

switch

that

(+)

ground

battery

that

solenoid.

pump

wiring switches

breaker

elbow.

at

with

ohmmeter.

12

volts

connection

stud.

charge

fuel

valves

test

the

shut

off

push~pull

should

spare.

for

short

for

supply,

fuel

high

DC

amperage

is

not

blockage,

for

shorts

to

after

breaker.

to

starter

battery

present

starter

battery

are

open.

circuits

operation.

valves,

solenoid

cable

at

starter

solenoid

cable

and

fuel

lift

draw

during

sensitive

hose.

Check

solenoid.

are

to

Check

state.

engine.

lever

cable.

make a distinct

proper

overly

col~psed

ground.

and

connections.

solenoid

and

connections.

ticking

loose

connections.

pump.

operation.

to

heat

carbon

to

Battery

not

charging

Water

6.

1.

Alternator

in

fuel.

drive.

29

6.

1.

Pump

bleed

Check

for

loose

volts

are

water

from

fuel

system.

drive

belt

connections.

present

fuellank(s):

tension.

Aternator

Check

at

the

Exc

change

should

output

with

terminal.

filters

and

turn

voltmeter.

freely.

Ensure

Check

12

ENGINE

TROUBLESHOOTING

l'1li111_

Battery

runs

down.

Engine

overfleats.

IIOl!:

Shut

engine

Exhaust

smoking

Transmission

of

gear,

Excessive

will

or

drive

vibration

down

problems

not

shift

the

vesse\.

1.

2.

3.

4_

5_

1.

immed~te\y.

2.

1.

2_

3_

in

or

out

1.

2_

Probable

Oil

Pressure

switch.

High

resistance

Low

resistance

Altemator.

Poor

battery

connections.

Raw

water

not

Coolant

not

circulating.

Bluesmoke.

White

smoke,

Black

or

gray

smoke.

Transmission

Faulty

Cutless propeller

engine

beanngs,

could

failure.

alignment

Cause

leak

to

ground.

leak.

circulating.

support

be

suspect.

strut

all

and

Verillcatlon/Remedy

1.

Observe

if

not

2.

Check

(00

is

3.

Check

4.

Disconnect

leakage

5.

Check

1.

Broken

2.

Raw

2a.

Obstruction

2b.

Thennostat -remove

Replace

20.

Loss leaks.

2d.

Broken

2e.

Air heat

1.

Incorrect

la.

Crankcase the

2.

Engine

28.

Faulty

3.

Improper

3a.

Fuel

insufficient

exhaust

3b.

Improperly

compression.

3c.

lack

ventilation.

3d.

Ove

3 •.

Propeller.

la.

Check

transmission

lb.

Check

le.

Check

ld.

Check

1.

Check

1a.

Inspect

2.

Inspect

gauges

running.

Test

wiring.

not

start

all

wires

engine.)

altemator

located.

stops,

cable

connections

or

loose

water

pump

at

thermostat.

of

coolant ~ check

or

loose

leak

in

system;

exchanger,

grade

is

running

injector

grade

bum

incomplete

air

system;

timed

of

air -check

cable

connections

overtilled

exhaust).

noad.

lever.

transmission

shaft

couplings

engine's

the

shaMransmission

all

engine

propeller

and

panel

lights

the

oil

pressure

Insert

sensitive

Remove

for

temperature

at

output,

remove

alternator

at

belt

at

raw

failure.

Check

raw

water

intake

and

belts -tighten/replace.

run

engine

manifold,

of

engine

with

cold.

or

incorrect

of

fue\.

due

for

proper

combustion

check

air

fuel

system,

air

intake

at

fluid.

or

engine

damper

plate.

mounts.

and

shaft.

are

sWitch.

(0 -.25

connections

rise

after a good

and

battery.

water

pump. impeller -replace. or

raw

test

in

hot

hoses,

hose

and

open

etc.

to

bleed

oil.

engine

oil

injector

timing.

to

high

back

intake).

misadjusted

and

air

steering

station

damper

coupling.

activated

amp)meter

and

to

locate

bench

test.

water

water.

clamps,

cooling

air.

Add

(oil

is

blowing

pressure

(Check

valves

filter.

Check

and

plate.

when

in

battery

replace

the

fault.

battery

charging.

Repair

filter.

drain

plug,

system

coolant

out

in

exhaust

for

restrictions

or

poor

for

proper

at

engine

is

lines.

after

short

If

or

replace.

etc.

for

petcocks,

as

needed.

through

Or

in

30

CONTROL

PANEL

TROUBLESHOOTING

MANUAL

STARTER

DISCONNECT

(TOGGLE

SWITCHES)

NOTE:

The engine control system is protected by a

20

amop manual reset circuit breaker

located on the engine as close as possible to the power source.

Problem

Probable

Cause

Verificallon/Remedy

PREHEAT

depressed.

no

panel

indications

1.

Oil

Pressure

switch.

1.

Check

switches

and/or

battery

connections.

fuel

solenoid,

electric

fuel

pump

and

preheat

solenoid

not

energized.

2.

20

amp

circuil

breaker

tripped.

2.

Reset

breaker.

If

opens

again,

check

preheat

solenoid

circuil

and

run

circuit

for

shorts

to

ground.

START

SWITCH

DEPRESSED.

no

starter

1.

Connection

to

solenoid

faulty.

1.

Check

connection.

engagement.

2.

Faulty

switch

2.

Check

switch

with

ohmmeter.

3.

Faulty

solenoid.

3.

Check

that

12

volts

are

present

at

the

solenoid

connection.

4.

Loose

battery

connections.

4.

Check

battery

connections.

5.

Low

batteI)'.

5.

Check

battel)'

charge

state.

NO

tGNITION.

cranks.

does

not

start.

1.

Faulty

fueling

system.

1.

Check

for

fuel.

2.

Check

for

air

in

the

fuel

system.

2.

Allow

system

to

bleed.

3.

Faulty

fuel

lift

pump.

3.

Replace

fuel

lift

pump.

NOT

CHARGING

BATTERY

1.

Faulty

alternator

drive.

1.

Check

the

drive

belt

and

its

tension.

Be

sure

the

alternator

turns

freely.

Check

for

loose

connections.

Check

the

output

with a voltmeter.

Ensure

12V

are

present

at

the

regulator

terminal.

BATTERY

RUNS

DOWN

1.

Oil

pressure

switch.

1.

Observe

if

the

gauges

and

panel

lights

are

activated

when

the

engine

is

not

running.

Test

the

oil

pressure

switch.

2.

High

resistance

leak

to

ground.

2.

Check

the

wiring.

Insert

sensitive

(0-.25

amp)

meter

in

bat1ery

lines

(Do

NOT

start

engine).

Remove

connections

and

replace

after

short

is

located.

3.

Low

resistance

leak

to

ground.

3.

Check

all

wires

for

temperature

rise

to

locate

the

fault.

4.

Faulty

alternator.

4.

After a good

bat1ery

charging,

disconnect

alternator

at

output.

If

leakage

stops.

Remove

alternator

and

bench

test.

Repair

or

replace.

ALARM

BUllER

SOUNDING

1.

Resistor

shorting.

1.

Check

resistor

1000

ohm.

resistor

found

between

preheat

(Oil

pressure nonnal)

solenoid

"I"

terminal

and

ground.

2.

Fuel

pump.

2.

Fuel

pump

coils

shorting.

3.

Oil

pressure

switch.

3.

Oil

pressure

switch

internal

contacts

not

closing

properly.

TROUBLESHOOTING

WATER

TEMPERATURE

AND

OIL

PRESSURE

GAUGES

If

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

DC

between the ignition (B+)

and the Negative (B-) tenninals

of

the gauge.

Assuming that there is

12

volts as required, leave the instrument panel energized (key switch on) and perfonn the following steps:

1.

Disconnect the sender wire at the gauge and see if the gauge reads zero, which is the nonnal 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 nonnal reading

for this situation.

31

If

both

of

the above gauge tests are positive, the gauge

is

undoubtedly

OK

and the problem lies either with the

conductor from the sender to the gauge

or

with the sender.

If

either

of

the above gauge tests are negative, the gauge is

probably defective and should be replaced. Assuming the gauge

is

OK, check the conductor from the

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

Some starters have isolated ground tenninals and if the battery

is

connected to the starter (both plus and minus tenninals), the ground side will not necessarily be connected to the block.

TACHOMETER

TACHOMETER/HOUR

METER

The

tachometerlhour

meter

used

in

propulsion

engine

instru-

ment

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

12 volts alternator charging voltage supplied to the (+) terminal on

the back

of

the instrument.

The tachometer circuit operates on

AC

voltage 6-8 volts,

fed

from one

of

the diodes in the alternator and supplied to the

tachometer input terminal while the engine is running, and

the

alternator producing battery charging voltage 13.0-14.8

volts DC. The following are procedures to follow when troubleshooting

a

fault

in

either

of

the

two

circuits

in a tachometerlhour

meter.

Hour

meter

Inoperative

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 con-

nections for fault. (Jump

12

volts

DC

to

meter (+)

tenninal to verify the operation.)

Tachometer

Inoperative

Check for the proper AC voltage between tachometer input

tenninal and (-) tenninal with the engine running.

1.

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

2,

AC

voltage not present - check for proper alternator DC

output voltage.

3.

Check for

AC

voltage at tach tenninal on alternator

to

ground.

4.

Check electrical connections from tachometer input ter-

minal

to

alternator

connection.

Tachometer

Sticking

1.

Check for proper AC voltage between "tach inp." termi-

nal and (-) terminal.

2.

Check for good ground connection between meter

(-)

ter-

ntinal and alternator.

3.

Check that alternator is well grounded

to

engine block at

alternator pivot bolt.

Tachometer

Inaccurate

a.

With a hand-held tach

on

the front

of

the crankshaft

pulley retaining nut

or

using a strobe type tach, read the

front crankshaft pulley rpm at idle.

b.

Adjust the tachometer using an 2mm Allen head wrench 1164

(2mm) through the calibration access hole

in

the rear

of

the tachometer. Zero the tach and bring it

to

the rpm

indicated by the strobe

or

hand tach (verify rpm at idle

and at high speed). Adjust the tach as needed.

NOTE:

Current model tachometers use a coarse adjustment

dial to set the tachometer to the crankshaft pulley

rpms.

The

calibrating screw is then used

for

fine tuning.

CURRENT

CDARSE ADJUSTMENT

IDLE

SPEED

ADJUSTMENT

WIRE

TERMINAL

&

TACHOMETER

CHECK

(New

Installation)

Checking

the

idle

speed

NOTE:

In

a new installation having new instrument panels,

the tachometer

may not always be correctly calibrated to

the

engine's rpm. This calibration should be checked in all new

installations.

1.

Wann

up

the

engine

to

nonnal

operating

temperature.

Remove any specks

on

the crankshaft pulley with a clean

cloth and place a piece

of

suitable reflecting tape on the

pulley to facilitate use

of

a photoelectric type tachometer.

2.

Start and idle the engine.

3. Aim the light

of

the tachometer onto the reflecting tape

to confinn the engine speed. Check the instrument panel tachometer reading. Adjust the tachometer in the panel

by

using

the

instrument

coarse

adjustment

to

calibrate

the

instrument reading to the closest

R.P.M.

that the photo tach

is showing. Then use the fine calibration adjustment

to

bring the instrument

to

the exact reading as the photo tach.

4.

Adjust the idle speed if the engine speed

is

not within the

specified value.

NORMAL

IDLE

SPEED:

RECOMMEIIIED

RPM

IWIGES

MODEL

IDLE

CRUISE

MAXIMUM

RPM

M3-20B

1000 -1200

2500 -3000

3500 -3600

M25XPB

1000 -1200

2000 -2500

2900·3000

M35B

800-1000

2000

- 2500

2900 -3000

M40B

800

-1000

2000

- 2500

2900 -3000

M50B

800 -1000

2000·2500

2700 -2800

NOTE:

Attempting to reduce idle speed below the minimum

shown may produce unstable engine operation and stalling.

32

WATER

HEATER

CONNECTIONS

WATER

HEATER

INSTALLATIONS

This engine is equipped with connections for the plumbing

of

engine coolant

to

heat

an

on-board

water

heater.

The

water

heater

should

be

mounted

in

a convenient location

either

in

a

high or low'position

in

relation to the engine, so that the con-

necting

hoses

from

the

heater

to

the

engine

can

run

in a rea-

sonably direct line without any loops which might trap air. Hoses should rise continuously from their low point at the

heater to the engine so that air

wiII

rise naturally from the

heater to the engine.

If

trapped air is able to rise to the heater,

then an air bleed petcock must

be

installed at the higher fit-

ting on the heater for bleeding air while filling the system.

NOTE:

If

any ponion

of

the heating circuit rises above the

engine:r

closed

cooling

system

pressure

cap,

then a pressur-

ized (aluminum)

remote

expansion tank (Kit #024177) must

be

installed

in

the

circuit

to

become

the

highest

point.

Tee

the

remote

expansion

tank

into

the

heater

circuit,

choosing

the

higher

of

the

two connections for

the

retum.

Tee

at

the

heater,

and plumb a single

line

up

to

the tank's location and

the

other back

to

the

engine s return.

Install

the

remote

expansion

tank

in a c.ollvenient

location so

the

fresh

water

coplant level

can

easily

be

checked.

The

remote expansion

.tank

will now serve as a check and system fill point.

The

plastic coolant recovery

tank

is

not used

when

the

remote

expansion

tank

kit

is

installed, since

this

tank

serves

the

same

function.

HEATER

ABOVE

THE

ENGINE

WATER

HEATER

NOTE:

The

remote

expansion tank

is

for filling and

the

expansion

of

coolant.

Water

heater coolant flow

need not

go

through

the

tank.

33

The pressure cap on the engine's manifold should be instalJed after the engine's cooling system is filJed with

coolant.

Finish

filling

the

cooling system

from

the

remote

tank after the system is filled and is free

of

air and exhibits

good coolant

circulation.

DUling

engine

operation,

checking

the

engine's coolant should

be

done

at

the

remote

lank

and

not

at

the

engine manifold

cap.

The

hose connection

from

the

heater

to

the

remote

expansion

tank

should

be

routed

and

supported so it rises continuously from the heater

to

the tank,

enabling any air in the system

to

rise up

to

the tank and out

of

the system.

NOTE:

Air bleed petcocks

are

located

on

the

engine's heat

exchanger and

on

the

thennostat

housing.

Open

these

pet-

cocks

when

filling

the

engine's fresh water system

to

allow

air

in

the

coolant cin:uit

to

escape.

Close

tightly after all

the

air

is

removed.

HOSE

CONNECTIONS

~

TfIERMIOST.ITHOUSING

HEATER

BELOW

THE

ENGINE

WATER

HEATER

The hose adapters (nipples) coming off theengine

(thermostat housing and water pump housing) are sized for

3/8"

J.D.

hose. An adapter is available (#302391) that

will increase the size to

5/8" J.D. hose.

ADAPTER

PN

302391

PRM

NEWAGE

TRANSMISSIONS

MODELS

80

AND

120

THE

MODEL

120

HAS A BREATHER

~

FITTING

ON

THE

TOP

OF

THE

CASE~

SERIAL

NUll/BEl!.

---_""POI·lrK

1/2"

HEX

PLUG

MODEL

80

(MODEL

120

USES

A

BMM

HEX

PLUG)

PRM

8DI_.q;~e

VENTS

FULL

LOW

SEALING

WASHER

~

NOTE:

Keep

ventlvent holes clear and unobstructed.

INITIAL

OPERATION

Before starting the engine, remove the dipstick

and

fill

the

transmission with automatic transmission

fluid

(ATF)

Dextron

11

or Dextron

111.

Fill

to

the

mark

on

the

dipstick.

Do

not

overfill.

R~n

the engine

to

warm

up

the

fluid

and after shutting down

the

engine, re-check the

fluid

level.

Model

PRM 80-1.0 U.S. pints (0.6L)

Model

PRM

120-1.4

U.S.

pints (0.8L)

NOTE:

Always clean the area around the dipstick plug before

filling with fluid. Replace

the

dipstick by screwing

it

down

CHECKING

THE

FLUID

LEVEL

Thread the dipstick fully into the case,

then

unscrew it

and

observe

the

fluid

level.

CHANGING

THE

TRANSMISSION

FLUID

Change

the

fluid

for

the

first time after about

25

hours of

operation, then every

250 operating hours or

at

least once a

year or when

you

change engine

fluid.

Check

for

leaks

and make a visual inspection of the shift cables and shaft coupling. Push a suction pump hose down through

the

dipstick hole

to

the

bottom of

the

housing

and

suck out

the

fluid.

(If

space allows, use the transmission drain). Remove

the drain plug

from

the bottom of the transmission

(I"

with

sealing washer) and allow

the

fluid

to

drain into a container,

then reinstall

the

plug with

its

sealing

washer.

Wipe

down the

transmission

and

properly dispose of the

used

fluid.

After

running

the

engine, shut down

and

recheck

the

fluid

level.

NOTE:

When

changing

the

fluid, take

care

not

to

lose

the

drain plug sealing

washer.

The drain plug will leak without

this sealing

washer.

A

WARNING:

Never

pull

out

the

dipstick

while

the

engine

is

running,

Hot

"uid will

splash

from

the

dipstick

hole.

This

could

cause

severe

burns.

DAILY

OPERATION

o Check the transmission

fluid.

o Visually check the gear shift linkage

and

transmission.

o Start the engine in neutral, allowing a

few

minutes

at

idle

to

warm the

fluid.

o Shift into

gear.

NOTE:

Too

Iowan idle speed will produce a chattering noise

from

the

transmission gear and damper plate.

In

such cases

the idle speed should

be

increased.

GEAR

SHIFTING

The engine must be

at

idle. Pause in neutral before

selecting ahead or astern, Transmission models

PRM

80

and

120

are

ideal for single lever controls, controlling both

the

throttle

and

the gear shift

at

one time.

A

WARNING:

When

shifting

gears,

bring

the

engine

throttle

to

idle

and

pause

in

neutral

before

shifting

ahead

or

astern.

LOCKING

THE

PROPELLER

Locking

of

the propeller shaft

by

an

additional brake

is

not

required. Use

the

gear shift lever position opposite your

direction of travel for this

pUl]Jose.

Never put the gear shift

in

the

position corresponding

to

the direction

of

travel of

the

boat.

WHEN

UNDER

SAIL

OR

BEING

TOWED

Rotation of the propeller without a load, such

as

when

the

boat

is

being sailed, being towed or anchored

in a river,

as

well

as

operation of

the

engine with

the

propeller stopped

(for charging the battery), will have

no

detrimental effects

on the transmission.

MARINE

POWER

,\,

.UnivQrsal

34

PRM

NEWAGE

TRANSMISSIONS

CONTROL

The to

the actuating position. cockpit

The shift the

internal reverse. the

shift lever important

the

lever impeded excessive heat

be

indicated

all.

NOTE:

cable ta the

control

The

must

level

Those

adjustment is which,

Checkfor

CABLES

cable

or

rod

should

be

shift

lever

with

the

neutral

position of

coincide

stops

with

too

by

level

with

the

neutral position of

travel

must

be

such

for

the

lever

when

stops

can

be

determined

the cable

short,

in

tum,

generation

slow

clutch engagement

proper lever travel

bracket at least each season.

disconnected. for proper engagement of proper clutch engagement

would

mean

and

clutch

arranged

lever

the

operating lever

that

shifted

and

MAINTENANCE/SERVICE

Make

certain the transmission

the

fluid

should

box

suffers

major

thoroughly

correct NEWAGE

the

world.

Atlantis 418

Boston

Topsfield,

Tel:

978-887-0001

Fal:

flushed

specifications.

TRANSMISSIONS

Listed

Marine

Gear

Street

MA

01933

978-887-5599

become contaminated

mechanical

out and

here

are

Supply

fluid

damage,

re-filled

those

Inc,

LID.

in

the

is

with

MODELS

at

in

the

lever just strikes

into

by

manually This

premature

plate

failure.

or

no

the security

changed

by

water

the

gearbox

fresh

has

distributors

United

a right

angle

neutral

in

the

this

lever.

forward

moving

is

an

the

gear.

might

be

wear,

This

would

engagement

of

the

annually,

or

the

gear-

must

fluid

to

the

around

States.

or

If

be

80

at

AND

120

NEUTRAL

R~~D-

<./~

\ 0

,

,-,

ACTUATING

SHIFT

WARRANTY

NEWAGE

Newage and

workmanship

or

24

months.

All

PRM

and

maintained.

TROUBLESHOOTING

See

the

/""\;0'

LEVER

TRANSMISSIONS

Transmissioms

transmissions

following

'

under

page.

N

will

normal

must

--;

'')'

'''-'

_..w...'

SHIFT

warrants

from

and

service

I I

defects

/ ,

;';t

,/

LTD.

be

free

use

be

correctly installed.

__

CABLE

that

-=:;

all

in

for

aligned.

AND

BRACKET

PRM

material

a period

~.,.

HamlHonJet

1111

NW

Ballard

Way SeaHle, Tel:

Fal:

Transmission 223

P.O.

R.

Tel:

Fu:

Newage Website:

If

dealer or a warranty without a NEWAGE distributor dealer.

WA

98107

206-784-8400

206-783-7323

Marine

Southwest

BOl21086

Lauderdale,

954-467-1540

954-467-1525

a major

33

Cour!

FL

33335-1086

Transmissions,

www.Newage-PRM.co.uk

problem

NEWAGE

rights,

first

should

do

not

contacting NEWAGE TRANSMISSIONS LTD.

Limited.

occur.

distributor.

undertake (listed

above)

contact your WESTERBEKE

To

avoid

repair

or

prejudicing

work

on

the

your

WESTERBEKE

gearbox

or

35

PRM

NEWAGE

TRANSMISSIONS

TROUBLESHOOTING

Problem

Probable

Cause

VerlllcalionJRemedy

Excessive

noise

at

low

speeds.

1.

Engine

idle

speed

too

low.

1.

Increase·

idling

speed.

Excessive

noise

at

aU

speeds.

1.

Defective

coupling.

1.

InspecVreplace

coupling

if

necessary.

2.

Shaft

misalignment.

2.

Check

alignment

with

feeler

gauge.

3.

Prop

out

of

balance.

3.

Remove,

check

pitch,

balance

and

weight.

fluid

needs

constant

topping

off.

1.

Power

too

high.

1.

Compare

engine

and

transmission

data.

2.

fluid

leak.

2.

Inspect

seals.

O-rings.

drain

plug.

check

for

fluid

leaks.

Difficulty

in

moving

lever

control.

1.

Poor

installation

of

cable.

1.

Check

installation,

remove

sharp

bends

and

turns.

2.

faulty

cable.

2.

Replace.

Escape

of

pressure

from

gearbox

1.

Defective

breather

causing

leaks

1.

Remove

dipstick/clean

vent

holes -PRM

80.

when

dipstick

is

removed.

past

oil

seals.

2.

Unscrew

vent

assembly

from

top

of

transmission

and

clean

with

solvent -PRM

120.

No

drive

ahead

or

astern.

1.

Mechanical'damper

plate

problem.

1.

Replace

damper

plate.

Propeller

speed

does

not

increase

1.

Shift

cable.

1.

Remove

control

cable

or

linkage

not

allowing

f·N·R

to

with

engine

speed

ahead

and

astern.

move

correct

distance.

-Remove

cable

and

operate

lever

by

hand

to

check

movement.

Adjust

cable

if

necessary

Propeller

speed

does

not

increase

1.

Cone/clutch

cable

slippage.

Damaged.

1.

Remove

and

examine

clutch/clutch

cone

on

appropriate

with

engine

speed

in

one

direction

only.

clutch

plates

or

clutch

cones.

shaft

and

replace

if

necessary.

Excessive'

nOise

from

gearbox

1.

Engine

idle

speed

set

too

low.

1.

Increase

idling

speed.

If

not

cured

by

increasing

idling

speed,

at

low

speeds.

faulty

adjustment.

refer

to

engine

supplier.

Remove,

examine

and

replace

coupling

if

necessary.

Excessive

noise

throughout

1.

Oefective

input

coupling.

Input

1.

Check

the

alignment

of

the

propeller

shaft

coupling.

If

operating

range.

coupling

worn/damaged.

necessary,

rectify

by

adjusting

the

shims

under

the

Propeller

shaft

misalignment.

faulty

engine

mounts

or

adjust

the

engine

mounts

themselves.

installation

or

hull

flexing.

2.

Propeller

out

of

balance.

damaged

prop.

2.

Remove

the

propeller

and

check

that

the

pitch.

weight.

poorly

matched.

diameter

and

balance

of

all

the

blades

are

equal

and

reclify

if

necessary.

3.

Defective

bearing/bearing.

3.

Isolate

defective

bearing,

remove

and

replace.

Worn

or

damaged.

Difficulty

in

moving

single

lever

control.

1.

Operating

control

cable.

1.

Check

the

installation

and

eliminate

all

tight

bends

in

the

cable.

,I,

,I,Univarsal

MARINE

POWER

36

HURTH

HBW/ZF

TRANSMISSIONS

DESCRIPTION

111e

information below

is

specific

to

the HBW

Transmissions, the

TRANSMISSION TROUBLESHOOTING

SECTION applies to all models.

HURTH

HBW

150

ZF

15M

A

CAUTION:

The

position

of

the

mechanism

behind

the

actuating

lever

Is

factory-adjusted

to

ensure

equal

shift

lever

travel

from

neutral

posit/on A andB.

If

this

mechanism

Is

In

any

way

tampered

with,

the

transmission

wa"anty

will

be

void.

SHAFT

COUPLINGS

WESTERBEKE recommends a flexible connection between

the

transmission and the propeller shaft

if

the engine is flexi-

bly

mounted, in order

to

compensate for angular deflections.

The installation

of

a special propeller thrust bearing is not

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

torsional

vibration.

When

using

a

universal

joint

shaft,

make

certain

to

observe

the

manufacturers

instructions.

Even

with

the

engine solidly

mounted,

the

use

of

flexible

coupling or "DRNESAVER" will reduce stress in the gear-

box.

bearings

caused

by

hull

distortions,

especially

in

wooden

boats

or

where

the

distance

between

transmission

output

flange and stem gland

is

less than about 800mm.

NOTE:

When

installing

the

transmission,

make

cel1ain

that

shifting is not impeded by restricted movability

of

the cable

or

rod linkage,

by

unsuitably positioned guide sheaves, too

small a bending radius

or

other restrictions,

In

order

to

mount a

suppon

for

shift control cable connections, use

the

two threaded holes located above

the

cable bracket mounted

on the gear housing. Refer

to

the WESTERBEKE parts

list.

SHIFT

LEVER

The

transmission

is

suitable

for

single

lever

remote

control.

Upon

loosening

the

retaining

screw,

the

actuating

lever

can

be

moved

to

any

position

required

for

the

control elements

(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 O.5mm. The control cable or

rod

should be arranged

at

light angle

to

the

actuating

shift lever

when

in

the

neutral

position. The

neutral position

of

the operating lever

on

the control console

should coincide with the neutral position

of

this lever.

The shifting travel,

as

measured at the pivot point

of

the actu-

ating lever, between the neutral position and end positions A and B should be at least

35mm

for the outer and

30mm

for

the

inner

pivot

point.

A greater amount

of

shift lever travel

is

in no way

detrimental and is recommended. However,

if

the lever

travel is shorter, proper clutch engagement might be impeded

which,

in

turn,

would

mean

premature

wear,

excessive

heat

generation

and

clutch

plate

failure.

1bis would

be

indicaled

by slow clutch engagement or no engagement at all.

NOTE

Check

for

proper lever travel at least each season.

CONTROL CABLE

FORWARD

A

SHIFT

LEVER

NEUTRAL

COVER

REVERSE

B

"Drivesavcr" is a product

of

Globe Marine

Rockland,

MA.

,I,

,I,Univanal

O.5mm

F

MINIMUM

DISTANCE

MARINE POWER

37

HURTH

HBW

nF

TRANSMISSIONS

INITIAL

OPERATION

All

HBWIZF

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.

Fill

the

gearbox

with

Automatic Transmission Fluid

(DEXRON

II

or DEXTRON

III).

The

fluid

level should be

up

to

the index

mark

on

the dipstick.

To

check the

fluid

level,

just insert

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

under the

hex

head

of

the

dipstick.

Check for

leaks

and

change

the

fluid

after

the

first

25

hours,

also

make a visual

inspection

of

the

coupling,

oil

cooler

and

hoses,

and shift cablcs.

FlUID

LEVEL

NOTE:

Keep vent holes

clear.

FLUID

CHANGE

Change the

fluid

for

the

first

time

after about

25

hours

of

operation,

then

every

250

operating

hours

or

at

least

once

a

year

Of

when

you

change

engine

oil.

Removing

the

fluid

Push

a suction

pump

hose

down

through

the

dipstick hole

to

the

bottom of the housing and suck out

the

fluid.

(If space

allows,

use

the

transmission drain). Remove the drain

plug

from

the

bottom of the transmission and allow

the

fluid

to

drain

into a container,

then

reinstall

the

plug

with

its

sealing

washer.

Wipe

down

the

transmission

and

properly dispose of

the

used

fluid.

After

I1lnning

the

engine, shut

down

and

recheck

the

fluid

level.

Drain

plug

IOTQue

20 -25

Mbs

NOTE:

When changing

the

fluid, take

care

not

to

lose

the

draill plug sealing washer.

The

drain plllg will leak without

this

sea/il1g

washa

A

WARNING:

Never

pull

out

the

dipstick

while

the

engine

is

running_

Hot

fluid

will

splash

from

the

dipstick

hole.

This

could

cause

severe

burns.

LOCKING

THE

PROPELLER

Locking of

the

propeller shaft

by

an

additional brake

is

not

required:

use

the gear shift lever position opposite your

direction

of

travel

for

this

purpose.

Never

put

the

gear

shift

in

the

position

corresponding

to

the

direction

of

travel

of

the

boat.

WHEN

UNDER

SAIL

OR

BEING

TOWED

Rotation of the propeller without

load

(in

neutral),

such

as

when

the

boat

is

being sailed, being

towed,

or

anchored

in

a

river,

as

well

as

operation

of

the

engine

with

the

propeller

stopped (for charging

the

battery),

will

have

no

.

detrimental

effects

on

the

transmission

DAILY

OPERATION

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

Iowan

idle speed will produce a chollering liaise

from the transmission

gear

and

damper plate.

III

silch cases

the

idle speed should be increased

For additional infonnation refer

to

the

following

text

in

this

Transmission Section: SHAFT COUPLINGS. MAINTENANCE

AND

TRANSMISSION TROUBLESHOOTING.

'.

HBWJZF

TRANSMISSIONS

SPECIFICATloNSHli

General

Gear

ratio

(oplional)

Lubricaling

Fluid

Transmission

Sump

Capacity

Propeller

Rotalion

(Hurth/ZF

Standard

Transmission)

Case-

hardened

helical

gears,

with a servo-

operated

multiple

disc

clulch.

HBW

50lZF

5M

(2.05 : 1)

HBW

100lZF

10M

(1.79:

1)

HBW

150VIZF

15MIV

(2.13:

1)

HBW

150NZF

15MA

(1.88:

1)

ATF -or

Dextran

- /I

or

/II

HBW

50lZF

5M

0.63pts

(0.3L)

HBW

100lZF

10M

0.74pts

(0.35L)

HBW

150VIZF

15MIV

2.1pts

(1.0L)

HBW

150NZF

15MA

1.0pts

(0.47L)

Transmissions

turn

Right

Hand

propellers

...

.Univarsal

38

HURTH

HBWJZF

TRANSMISSIONS

OPERATING

TEMPERATURE

A

WARNING:

If

the

transmission

fluid

temperature

is

too

high,

stop

the

engineimmedlatelyand

check

the

transmission

fluid.

NOlmal

operating

temperature of

the

transmission

flUId

should be

in

the range

of

122°F (50°C) to 212"F (100°C). A

maximum temperature

of

266°F (l30°C) may be only

reached

for a short

time.

Make

certain

there

is

enough space

around

the

transmission

to

provide good ventilation and cooling.

TRANSMISSION

COOLER

Some UNIVERSAL model's transmissions are equipped

with

an

exlernally

attached

convection

type

transmission

cooler.

The

cooler

is a separate

part

of

the

transmission

which

prevents

any

possibilities

of

coolant

diluting

the

transmission

fluid. However, the continued

flow

of

coolant thru the cooler

will,

in

time,

erode

the

inside

of

the

cooler causing

external

leaks.

A

transmission

cooler

may

last

ten

years

or

more

but,

in

some circumstances, depending

on

operating

hours,

tropical

waters, maintenance, etc. it might only last half that time.

WESTERBEKE recommends having a spare cooler aboard.

TIIANSMISSION

-~It.!::!.;~-"

ef!.!/9.~(!q1\fX

INSPECT

FOR

EROSION

AND

LEAKAGE

MAINTENANCE

Transmission

maintenance

is

minimal.

Keep

the

exterior

housing clean, check the fluid level

as

part of your regular

routine, and change the fluid every

300 operating hours.

Periodically inspect

the

transmission

and

the

cooler

for

leaks

and

corrosion.

Lubricate

the

cable connections.

Lay-up/Winterize

Storage requires special care. Follow these procedures:

D Drain water from the transmission oil cooler and replace

with a proper

mixture

of

antifreeze coolant.

NOTE:

This operation will normally occur when the

engine raw water cooling system is properly winterized.

D Clean up the transmission and touch up unpainted areas

(use heat resistant paiot).

D Fill the transmission with Dextran 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 remov· ing the boat from the water. Separate the flanges and spray with lubricant.

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

Look

for

corrosion

of

the

end

fittings,

cracks

or

cuts

in

the conduit, and bending

of

the actuator rods. Lubricate

all moving parts.

NOTE:

If the transmission is to be stored

for

a long time

(twelve months

or

more), it should be topped

off

with

fluid to prevent internal corrosion. Reduce the fluid level

before putting the engine back into

selVice.

For

additional

infonnation

contact:

HURTH MARINE GEAR ZF Industries Marine

US Headquarters

3131

SW

42nd Street

Fort Lauderdale,

FL

33312

Tel.: (954)

581·4040

Fax: (954) 581-4077

+

;.,Unlvanal

MARINE

POWER

39

HURTH

HBWJZF

TRANSMISSION

TROUBLESHOOTING

CONTROL

CABLES

The

majority

of transmission difficulties arise

as

a result

of

improper clutch adjustments (manual transmissions)

or

. problems

with

control cables (hydraulic transmissions)

rather

than

from

problems with

the

transmission itself.

A

new

cable

and

perhaps a

new

linkage mechanism

may

be

needed. While the cable

is

loose, shift

the

transmission

in

and

out

of

gear using the lever on the side

of

the transmission

to

make sure there's no binding inside the case.

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 - while

you

observe the actuating lever on the transmission.

If

the remote

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.

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; if the shaft isn't turning,

the

transmission

needs professional attention.

If

it

does

turn

but there's

no

thrust, check

to

see

you

still have a propeller

on

the

end

of

the shaft

or,

if

you

have a folding or feathering propeller,

Problem

Transmission

gears

cannot

be

shifted.

1.

Fails

to

move

into

gear.

2.

3.

Transmission

shifts

into

gear,

1.

but

fails

to

propel

the

boat.

2.

3.

Delay

of

gear

engagement

or

engages

1.

only

after

an

increase

in

speed.

2.

3.

Transmission

noise

becomes

louder.

1,

2.

Chattering

transmission

noise,

1.

mainly

at

low

engine

speed.

80at

fails

to

attain

specified

max.

speed.

1.

2.

Oil

Leakage.

1.

2.

that it isn't stuck in the

"no

pitch" position.

NOTE:

If

you suspect a major problem

il1

your

tra11smissioll,

immediately

cOlltact

your WESTERBEKE dealer or ali

authorized marine trallsmissiolljacility.

Probable

Cause

Verlficalion/Remedy

Actuating

lever

is

loose.

1.

Tighten

damping

boll

on

shifting

lever.

Shifting

cable

is

broken,

bent

or

2.

Check

the

cable,

reattach

or

replace.

unattached.

Cable

radius

is

too

severe.

Shift

lever

is

binding

against

cover

plate.

3.

Detach

the

shift

cable

and

operate

the

tever

by

hand.

Clearance

should

be

0.02

in

(0.5mm).

Output

coupling

is

not

turning.

1.

Transmission

needs

professional

attention.

Propeller

shaft

is

not

turning.

2.

The

coupling

bolts

are

sheared

or

the

coupling

is

slipping

Output

coupling

is

turning.

on

the

propeller

shaft.

Tighten

or

replace

set

screws,

keys,

pins

and

coupling

bolts

as

necessary.

Output

coupling

and

3.

Inspect

the

propeller.

It

may

be

missing

or

damaged.

propeller

shaft

are

turning.

A

folding

propeller

may

be

jammed. A variable

pitch

propeller

may

be

in

"no

pitch"

position.

lever

travel N to B not

equal

to N to

A.

1.

Adjust

cover

plate

until

the

lever

is

exact

mid-position.

Refer

to

diagram,

Refer

to

SHIFT

LEVER

TEXT

AND

DIAGRAM.

Shift

level

travel

in

insufficient.

2.

Check

shift

lever

cable

length.

See

SHtFT

LEVER

DtAGRAM.

Shift

lever

is

binding

against

cover

plate.

3.

Check

clearance,

adjust

if

necessary.

Damage

starting

on

flexible

coupling

due

1.

Check

alignment,

inspect

flexible

coupling.

If

noise

persists,

to

wear

or

fatigue,

possibly

due

to

inspect

the

damper

plate

between

the

transmission

and

the

misalignment

between

engine

and

engine.

Replace

if

necessary.

driveshaft.

Beginning

damage

of

bearings

in

2.

Transmission

needs

professional

attention.

transmission

due

to

torsional

vibrations,

running

without

fluid,

overload,

wrong

alignment

of

transmission,

or

excessive

engine

output.

The

engine

or

propeller

generates

torsional

1.

Mount a flexible

coupling

with

another

stiffness

factor

vibrations

in

the

drive

unit

which

produces

between

the

transmission

coupling

with

and

the

driveshaft.

a

"chattering"

noise

in

the

transmission.

A

higher

stiffness

factor

might

be

sufficient.

2.

Inspect

the

damper

plate

between

the

engine

and

the

transmission.

Replace

if

necessary.

Operating

temperature

is

high,

1.

Wrong

type

of

fluid.

Use

ATf.

Check

fluid

level.

Operating

without

cooling.

2.

Check

cooler.

Inspect

coolant

hoses

and

coolant

flow.

Corrosion

at

radial

sealing

ring

and

shaft.

1.

Transmission

needs

professional

attention.

Damaged

sealing

ring._

Misalignment

of

output

flanges.

2.

Check

alignment.

Must

be

within

0.003

in

(O.OBmm).

NOTE:

If

)'01/ suspect a major problem

ill

your transmission,

'immediately contact your WESTERBEKE dealer or

an

O1lfhorized

marine trallsmissionjacility,

+

.Unlvarsa.

MARINE

POWER

40

HURTH

HBW/ZF

TRANSMISSION

TROUBLESHOOTING

Problem

High

fluid

Auid

on

Auid

and

Slow

engagement.

No

movement

NOTE:

If

marine

transmission

temperature.

transmission

water

you

housing.

miXed,

shiHs

of

the

boat.

suspect a major

hard.

facility.

problem

Probable

Fluid

level

1.

Fluid

level

2.

Plugged

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

1.

2.

3.

1.

2.

3.

4.

5.

6.

7.

in

or

No

water

Riter

clogged

loose

screws.

Loose

screw

Loose

dipslick.

Loose

fluid

Fluid

level

Damage

to

Selector

control

Selector

control.

Low

Iluid

Linkage.

Selector

control.

Improper

Low

fluid

Propeller

'Transmission

Engine

mallunclion.

your

transmission,

Cause

high

during

low.

restricted

in

cooling

system.

(if

applicable).

connections.

filter.

high

during

fluid

cooler

linkage.

level.

selector

pOSition.

level.

missing.

shaff

broken.

malfunction.

operation.

1.

2.

fluid

cooler.

3.

4.

5.

1.

2.

3.

operation.

..

4.

5.

1.

2.

1.

2.

3.

L

2.

3.

4.

5.

6.

7.

immediately contact your

Pump

out

Add

Replace Check

Replace

lighten

Tighten, Tighten. Tighten, Pump

Replace

Refer

Add Adjust

Consult

Adjust Add

Replace.

Contact

fluid

fluid.

cooler

cooling

element.

to

replace. replace. replace.

out

fluid

cooler

this

manual.

this

manual.

fluid.

(reler

service

(see

Iluid.

marine

manufacturer. marine

WESTERBEKE

Verificalion/Remedy

to

the

maximum

and

flush

system

and

water

repair.

and

mark

system.

specification.

to

the

and

this

maximum

flush

manual.

station.

manual).

repair.

and

mark

transmission

dealer or

on

and

hoses.

all

authorized

dipstick.

41

LAY-UP

AND

RECOMMISSIONING

LAY·UP

Many owners rely on their boatyards

to

prepare their craft, including engines and generators, for lay-up during the off-season or for long periods

of

inactivity. Others prefer

to

accomplish lay-up preparation themselves. The following procedures will allow you

to

perform your

own

lay-up

and

recommissioning.

or

you

may

use

them

as

a

check list for others. These procedures should afford your engine protection during a lay-up and also help familiarize

you

with

the

maintenance

needs

of

your

engine.

If you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than willing

to

provide

assistance.

PROPELLER

SHAFT

COUPLING

The transmission and propeller half couplings should always 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

of

the boat often puts a

severe strain on the propeller shaft

or

coupling, or both,

while the boat is taken out or put

in

the water.

In

some cases, the shaft has actually been bent by these strains. This does not apply to small boats that are hauled out

of

the water when not in use, unless they have been dry for a considerable period

of

time.

FRESH

WATER

COOLING

SYSTEM

A 50-50 solution

of

antifreeze and distilled water is recom-

mended

for

use

in

the

freshwater

cooling system

at

all

times.

This

solution

may

require a higher

concentration

of

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. Operate the engine to ensure a complete circulation

and

mixture

of

the

antifreeze

concentration

throughout

the

cooling system. Now recheck the antifreeze solution's strength.

LUBRICATION

SYSTEM

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter.

(Place some paper

towels and a plastic bag around the filter

to

catch the oil

during its removaL) When installing the new oil filter,

be

sure

to

apply a small

amount

of

oil on the rubber sealing gasket at the base

of

the

filter.

Fill the sump with the correct amount

of

oil for your

engine model. (Refer

to

the SPECIFICATIONS section

of

this

manuaL)

Use an oil with

an

API specification

of

CC or CD.

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.

A

CAUTION:

Do

not

leave

the

engine's

old

engine

oil

in

the

sump

over

the

lay-up

period_

Engine

oil

and

combustion

deposits

combine

to

produce

harmful

chemicals

which

can

reduce

the

life

of

the

engine's

internal

parts.

FUEL

SYSTEM

Top off your fuel tanks with No. 2-D (SAE 1313) that has a cetane rating

of

#45

or

higher grade

of

diesel according

to

ASTM 0975. Fuel additives should be added at this time

to

control bacterial growth and a fuel conditioner such as

Diesel Kleen

+ Cetane Boost (DO NOT use any alohol

based additives). Change the element in your primary fuel

filter/water

separator,

if

the

system

contains

one,

and

clean

the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the system as needed.

Start the engine and allow it to run for

5-10 minutes to make sure no air is left

in

the fuel system.

Check for any leaks that may have been created

in

the fuel

system

during

this

servicing,

correcting

them

as

needed.

RAW

WATER

CIRCUIT

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

Place the end

of

this hose into a

5-gallon bucket

of

clean fresh water. Before starting the

engine, check the zinc anode found in the heat exchanger on

the

engine

and

clean

or

replace

it

as

required.

Clean

the

raw

water

strainer,

if

one

is

installed

in

the

inside

of

the

hull.

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

of

this mixture

to

be

drawn through the raw water system. Once the bucket

is

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. Acquire replacement,

if

needed, and a

cover gasket. Do not replace the impeller (into the pump)

until

recommissioning,

but

replace

the

cover

and

gasket.

NOTE:

If

the engine storage is going

to

be a lengthy one,

12

months

and

beyond, it is wise to rotate the engine by hand

two complete turns every additional

4 month to allow the

injectill pump components to move. This will help prevent their sticking during extended storage periods.

,I,

,I,UnivGrsal

MARINE

POWER

42

LAY-UP

AND

RECOMMISSIONING

STARTER

MOTOR

Lubrication and cleaning

of

the starter drive pinion is

advisable,

if

access to the starter permits its removal. Make

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

LUBRICATION

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

of

normal lay-up. However,

if

you anticipate a longer lay-up period (12 months or more), we recommend that this procedure be performed. The light oil in the cylinders will prevent the pistons' rings from sticking to the cylinder walls. With oil in the cylinders, turn the engine over by

hand two revolutions.

TRANSMISSION

Check or change fluid in the transmission as required.

If

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.

SPARES

Lay-up time provides a good opportunity to inspect your UNIVERSAL engine

to

see

if

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

BATTERIES

If batteries are to be left on board during the lay-up period, make sure they are fully charged and will remain that way,

to

prevent them from freezing.

If

you have any doubt that the

batteries will not remain fully charged, or that they will be

subjected

to

severe

environmental

conditions,

remove

the

batteries

and

store

them

in a wanner,

more

compatible

envi-

ronment.

A

WARNING:

l.8ad

acid

batterlas

emit

hydrogen,

a

high"

tII/Ilosire

gas,

which

can

belgnltBd

by

electrical

l1li:1119

olllghtBd

tobacco

products.

Do

not

smolee

or

allow

en

opsn

flame

nBar

thB

batttlry

beIng

SBlVlced.

Shut

0«

all

BlBCtricalequlpment

In

the

rdcln/ty

to

prrmmt

BlBCtrfcal

arcing

during

serrdclng.

Wear

rubber

gJ_,

a

rubbBr

apron

and"",

protection

when

Slllrdclng

battarias.

43

RECOMMISSIONING

The recommissioning

of

your UNIVERSAL engine after a

seasonal lay-up generally follows the same procedures

as

those presented

in

the PREPARATIONS FOR STARTING section regarding preparation for starting and normal starts. However, some

of

the lay-up procedures will need to be

counteracted before starting the engine.

I. 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, if required). Install the

raw

water

pump

cover

with

a new cover

gasket.

3.

Reconnect the shaft coupling and check for proper align-

ment.

4.

Reinstall the batteries that were removed during the lay-

up, and reconnect the battery cables, making sure the ter-

minals

are

clean

and

that

the

connections

are

tight.

Check

to

make sure the batteries are fully charged.

5.

Check

the

condition

of

the

zinc

anode

in

the

raw

water

circuit

and

clean

or

replace

the

anode

as

needed.

Note

that

it is not necessary

to

flush the antifreeze/freshwater solu-

tion

from

the

raw

water

coolant system.

When

the

engine

is put into operation, the system will self-flush

in

a short

period

of

time with no adverse affects.

6.

Start

the

engine

in

accordance

with

procedures

in

the

PREPARATIONS FOR INITIAL START-UP section of

this

manual.

UNIVERSAL

MARINE

ENGINES

SPECIFICATIONS

Description

M·35B,

M-48B,

M·50B

Description

M3·2DB, M·25XPB

Displacement

M3·20B M·25XPB M·35B M-48B M·50B

Aspiration

Combustion

Chamber

Bore & Stroke

M3·208 M·25XPB M·35B M-48B M·50B

Compression

Ratio

Firing

Order

M3·20B,

M·25XPB

M·35B

,M-48B,

M·50B

Weight

M3·2DB M·25XPB M·35B M-48B M·50B

Direction

of

Rotation

GENERAL

Diesel,

four-cycle,

four-cylinder,

fresh

water-cooled,

Vertical,

in-line

overhead

valve

mechanism.

Diesel,

four-cycle,

three-cylinder,

fresh

water-cooled,

Vertical,

in-line

overhead

valve

mechanism.

Cubic

Inches

[Uters)

43.8

(7177)

61.2

[t

.000)

81.47

[1.335)

91.41

[1.498)

113.32

[1.857)

Naturally

aspirated

Spherical

type,

three

vortex

system

Inches

[mm)

2.64 x 2.68

[67 x 68.0)

2.99 x 2.90

[76 x 73.6)

2.99 x 2.90

[76 x 73.6)

2.09 x 3.09

[78 x 78.4)

3.15 x 3.64

[80 x 92.4)

23:1

1

·2·3

1·3·4·2

lbs

[Kg]

with

transmission

241

[110.0)

295

[134.0)

352

[159.0)

356

[161.5)

529

[240.0)

Clockwise

when

viewed

from

the

front

LUBRICATION

SYSTEM

Description

Lube

Oil

filter

Lubrication

Capacity

M3·2DB,

M·25XPB M·35B M-48B M·50B

Operating

Oil

Pressure

(engine

hot)

Oil

Grade

Forced

lubrication

by

gear

pump

Full

flow,spin

on

filter

element

Quarts

[Uters)

4.0

[3.8)

4.0

[3.8)

4.5

[4.3)

10.5

[9.9)

42·64

psi

(294 • 441

Kpa)

at

rated

speed

API

Specification

CF,

CG-4,

CH-4

or

CI·4

SAE

15W-40

all

season

oil.

Transmission

Specifications:

Refer

to

the

TRANSMISSION

SECTION

in

this

manual.

COOLING

SYSTEM

Description

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

Flow

Rate

Coolant

Capacity

M3·20B M-25XPB M-35B M-48B M-50B

Description-type

Fuel

Nozzl,

Type

Fuel

Injection

Pump

fuel

Lift

Pump

Fresh

water-cooled

block,

thermostatically-

controlled

with

heat

exchanger.

150'

-170'

f (66'

-77'

C)

Centrifugal

type,

metal

impeller,

belt-driven.

Positive

displacement,

rubber

impeller,

belt-driven.

8.0

GPM

(30.2

litres)

at

3000

rpm.

Quarts

[Liters]

3.75

[3.5)

4.0

[3.8)

6.0

[5.6)

4.5

[4.3)

12.0

[11.4)

FUEL

SYSTEM

Open

flow,

self

priming

[Bosch)

throftle

type

In-line

plunger

type

[Bosch)

No.2

diesel

oil

[centan,

rating

of

45

or

higher)

12

volt

5'

lift

capacity

solid

stat,

ELECTRICAL

SYSTEM

Starting

Baftery

Capacity

DC

Charging

Alternator

Starting

Aid

Starter Alternator

12

Volt, H negative

ground.

600 -800

Cold

Cranking

Amps

(CCA).

51

Amp

rated,

belt

driv'n

Glow

plugs,

sheathed

type

12

Volt.

reduction

gear

51

Amp

with

internal

regulation,

set

volts

at

14.7

max.

TUNE-UP

SPECIFICATIONS

Compression

Pressure

[at

250

RPM)

M3-208,

M·25XPB

M·35B,

M-48B M-50B Injection

Pressure

Engine

TIming

(spill)

Valve

Clearance

(,ngine

COLD)

M3·20B~

M·25XPB

]

M·35B

r-

M-48B.-.J

M·50B----

412 -469

PSI

[2.84 -3.23

MPal

512 -540

PSI

[35.3 -37.2

MPa)

1991

PSI

[13.73

MPa)

static

timed

18' -20'

BTDC

Inches

[mm)

0.0057 -0.0072

IN

[0.145 -0.185mm[

0.0071·

0.0087

IN

[0.18 -0,22mmJ

MARINE

POWER

••

Univorsal

44

SUGGESTED

UNIVERSAL

CONTACT YOUR UNIVERSAL DEALER FOR SUGGESTIONS AND ADDITIONAL

SPARE

MARINE

ENGINES

ZINC

PARTS

ANODES

INFORMATIO~

UNIVERSAL each Kit

"An

Kit

"B"

also

packaged

Includes Is

for

KIlA

Impeller Heal

Exchanger

Fuel

Filler

Fuel

Filler

011

Filler

Bell

Zinc

Anodes

offers

in a rugged

the

basic

more

extensive

Kit

with

two

Spare

hinged

spares.

off-shore

Gasket

UNIVERSAL

Parts

Kits,

toolbox.

cruising.

FUEL FILTERS

SPARE

PARTS

UNIVERSAL CARRYING ENGINE FOR

AND A GALLON

MIXED

OIL

AN

OIL

COOLANT.

KITB

Impeller

Oil

Water Zinc Heat Thermostat Complete Injector

Fuel

Fuel Bell

Glow

Kit

Filler

Pump

Anodes

Exchanger

Gasket

Filter

with

Plug

RECOMMENDS

ENOUGH

(YOUR CHANGE,

Repair

Kit

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

IkIdy

(In

...

SIze

)'

(llnad)

1/4·20 8

·28

5/16

·18

·24

3/8

-16

-24

7116-14

-20

112

-13

-20

9/16

-12

-18

518-11

-18

314-10

-16

7Ja-

9

-14

1 - 8

-14

Use

tire

torque

These

torques

Reduce

torques

BOLT & NUT

SAE

T

.....

R'Lb(Nm)

10 17

19

31 35(47)

49(66) 55

75 85

110 120

150 170

270 295

395 435

590 660

values

are

by

Gr.Jde

5

(11) (14)

(23) (26)

(42)

(75) (102)

(115)

(149) (163)

(203) (231)

(366) (400)

(536) (590)

(800) (895)

listed

below

based

on

clean,

30%

or

more,

TOROUE

SAEGradelH

Torque

Ft·Lb

10

19

34

55

85

120

167

280

440

660

when

specific

torque

dry

threads.

when

Reduce

threading

capscrews

SPECIFICATIONS

SAEGrado8

(Nm)

(14)

(26)

(46)

(75)

(115)

(163)

(226)

(380)

(597)

(895)

TOI1I111

A·Lb(Nm)

12(16)

14(19) 24

(33)

27

(37)

44(60) 49

(66)

70(95) 78(106)

105

(142)

120

(163)

155

(210)

170(231)

210

(285)

240

(325)

375

(508)

420

(569)

605

(820)

675

(915)

910

(1234)

990

(1342)

values

torque

into

M22

M24 M27 M30

M33 M36

are

not

by

10%

aluminum.

METRIC

80lt Dla.

M3

M4

M5

M8 M9

M10

M12 M14 M16

M18 M20

available.

when

Wrench

5.5mm 7mm 8mm

10mm 13mm 16mm

18mm 21

mm

24mm

27

mm

30mm

33mm

36mm

41

mm

46mm

51

mm

55

mm

engine

oil

is

BOLT & NUT

Grad.

S~.

4.6

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.

TOROUE

Grad.

Ft·Lb

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)

774

(1050)

992

(1345)

SPECIFICATIONS

4.8

Grad.

(Nm)

8.8 -9.8

Ft-Lb(Nm)

1

(1.3)

2(3)

4.5(6)

7.5

(10)

18

(25)

37

(50)

63(85)

103

(140)

159

(215)

225

(305)

32t

(435)

435

(590)

553

(750)

811

(1100)

1103

(1495)

1500

(2035)

1925

(2610)

1571

2139 2744

Grad.

10.9

FI-lb

(Nm)

1.5

(2)

3

(4.5)

6.5

(9)

11

(15)

35

(26)

55

(75)

97

(130)

151

(205)

232

(315)

321

(435)

4571620) 620

(840)

789

(1070)

1154

(1565)

(2130)

(2900)

(3720)

GASKETS/SEAlANT

Oil

based

purpose coolant,

A and

LOCTITE filter

Coat When

sides High-copper

ing Specialized

ing

copper

PERMATEX

sealers.

raw

light

coating

O-rings.

hydraulic

assembly. both

surfaces

instafling

with

WHITE

assembly.

gasket

non-hardening

cylinder-head

12

They

are

waler,

oil

or

of

OIL

or

red

sealant

of

tilt

gaskets

that

SILICONE

ADHESIVE

sealers

properties.

gaskets

and

it's

HIGH

effective

fuel.

LIQUID

TEFLON

should

oil

pan

gasket

seal

grease.

SPRAYS

such

as

HYLOMAR

as

it

TACK

in

just

about

can

be

used

with

around

water

are

useful

HYLOMAR

is

resists

fuel,

equivalent

be

on

high

(coolant)

for

holding

work

particlarly

oil

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

sealing

any

used

oil

temp

well

and

are

joint

in

on

rubber

adapter

RED

passages,

gaskets

in

effective

water.

excellent

all

contact

with

gaskets

hoses

and

SILICONE

coat

in

position

applications

on

the

oil

seal"

both

dUr-

requir-

passages.

BOLTS & FASTENERS/ASSEMBUES

Lightly plugs HIGH

When Anti-seize

threaded

LOCTITE LITHIUM

ing

Heavily

use

Do

oil

head

that

penetrate

TACK.

assembling

compounds

components

offers

based

boxes.

oil

aU

clean

engine

not

use

bolts

the

levels

grease

sliding

oil!

tape

and

other

the

water

flywheel,

and

yet

allows

of

locking

is

waterproof,

and

reciprocating

46

pipe

s.alantsl

fasteners

jacket

coat

thread

locking

them

according

plugs

and

as

you

should

be

the

bolt

threads

adhesives

to

came

to

the

ideal

lor

water

components

lillings

that

assemble

sealed

with

such

apart

when

job.

pump

when

connect

coolant

them.

Bolts

PERMATEX

LOCTITE

blue.

as

LOCTITE

necessary.

bearings

and

assembling.

and

#2

or

protect

stuft-

Always

STANDARD

AND

METRIC

CONVERSION

DATA

LENGTH-DISTANCE

Inches

(in) x 25.4 ~ Millimeters

(mm) x .0394 ~ Inches

Feet

(ft) x .305 ~ Meters

(m) x 3.281 ~ Feet

Miles x 1.609 ~ Kilometers

(km) x .0621 ~ Miles

VOLUME

Cubic

Inches

(in') x

16.387

~

Cubic

Centimeters x .061

~in'

Imperial

Pints

(IMP

pt) x .568 ~ Liters

(L) x 1.76 ~ IMP

pt

Imperial

Quarts

(IMP

qt) x 1.137 ~ Liters

(L)

x.B8 ~ IMP

qt

Imperial

Gallons

(IMP

gal) x 4.546 ~ Liters

(L) x .22 ~ IMP

gal

Imperial

Quarts

(IMP

qt) x 1.201 ~ US

Quarts

(US

qt) x .833 ~ IMP

qt

Imperial

Gallons

(IMP

gal) x 1.201 ~ US

Gallons

(US

gal) x .833 ~ IMP

gal

Fluid

Ounces x 29.573 ~ Milliliters x .034 ~ Ounces

US

Pints

(US

pt) x .473 ~ Liters(L) x 2.113 ~ Pints

US

Quarts

(US

qt) x .946 ~ Liters

(L) x 1.057 ~ Quarts

US

Gallons

(US

gal) x 3.

785 ~ Liters

(L) x .264 ~ Gallons

MASS-WEIGHT

Ounces

(oz) x 28.35 ~ Grams

(g) x .035 ~ Ounces

Pounds

(Ib) x .454 ~ Kilograms

(kg) x 2.205 ~ Pounds

PRESSURE

Pounds

Per

Sq

I n

(psi) x 6.895 ~ Kilopascals

(kPa) x .145 ~ psi

Inches

of

Mercury

(Hg) x .4912 ~ psi x 2.036 ~ Hg

Inches

of

Mercury

(Hg) x 3.377 ~ Kilopascals

(kPa) x .2961 ~ Hg

Inches

of

Water

(H,O) x .07355 ~ Inches

of

Mercury x 13.783 ~ H,O

Inches

of

Water

(H,O) x .03613 ~ psi x 27.684 ~ H,O

Inches

of

Water

(H,O) x .248 ~ Kilopascals

(kPa) x 4.026 ~ H,O

TORQUE

Pounds-Force

Inches

(in-Ib) x .113 ~ Newton

Meters

(Nm) x 8.85

~in-Ib

Pounds-Force

Feet

(ft-Ib) x 1.356 ~ Newton

Meters

(Nm)

x .

738 ~ ft-Ib

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 ~ Kilometers

Per

Hour

(KPH) x .621 ~ MPH

POWER

Horsepower

(Hp) x .745 ~ Kilowatts

(Kw) x 1.34 ~ MPH

FUEL

CONSUMPTION

Miles

Per

Hour

IMP

(MPG) x .354 ~ Kilometers

Per

Liter

(Km/L)

Kilometers

Per

Liter

(Km/L) x 2.352 ~ IMP

MPG

Miles

Per

Gallons

US

(MPG) x .425 ~ Kilometers

Per

Liter

(Km/L)

Kilometers

Per

Liter

(Km/L) x 2.352 ~ US

MPG

TEMPERATURE

Degree

Fahrenheit

(OF) ~ (OC X 1.8) + 32

Degree

Celsius

(OC) ~ (OF -32) x .56

47

METRIC

CONVERSIONS

INCHES TO MILLIMETERS

MILLIMETERS

TO INCHES

Inches

mm

Inches

mm mm

Inches

mm

Inches

1 25.40

15

381.00 1

0.0394 15 0.5906

2 50.80

20

508.00 2

0.0787 20

0.7874

3 76.20

25

635.00 3

0.1181 25 0.9843

4

101.60

30

762.00 4

0.1575 30

1.1811

5

127.00 35

889.00 5 0.1969

35 1.3780

10

254.00 40 1016.00

10 0.3937 40

1.5748

10

MILLIMETERS

= 1

CENTIMETER,

100

CENTIMETERS

= 1

METER

= 39.37

INCHES

(3.3

FEET)

INCHES TO METERS

METERS

TO INCHES

Inches

Meters

Inches

Meters Meters

Inches

Meters

Inches

1

0.0254 7 0.1778

0.1

3.937 0.7 27.559

2

0.0508 8

0.2032 0.2 7.874

0.8 31.496

3

0.0762 9 0.2286

0.3

11.811 0.9

35.433

4

0.1016

10

0.2540 0.4

15.748 1.0 39.370

5

0.1270

11

0.2794 0.5 19.685 1.1

43.307

6

0.1524 12 0.3048 0.6

23.622 1.2 47.244

m

CONVERT

METERS

TO

CENTIMETERS,

MOVE

DECIMAL

POINT

TWO

PLACES m THE

RIGHT

YARDS TO METERS

METERS

TO YARDS

Yards

Meters Yards Meters

Meters Yards Meters Yards

1

0.91440 6 5.48640

1 1.09361 6 6.56168

2

1.82880 7 6.40080 2

2.18723 7 7.65529

3

2.74320 8

7.31520 3 3.28084 8

8.74891

4

3.65760 9

8.22960 4

4.37445 9 9.84252

5

4.57200

10

9.14400 5 5.46807

10

10.93614

MOVE

DECIMAL

POINT

FOR

HIGHER

VALUES

- e.g.

6,000

METERS

= 6,561.68

YARDS

Ib

1 2 3 4 5

Gallons

1 2 3 4 5

Pints

1 2 3 4 5

32

I

0

POUNDS TO KILOGRAMS

KILOGRAMS TO POUNDS

kg

Ib

kg kg

0.454 6 2.722 1

0.907 7 3.175

2

1.361 8 3.629 3

1.814 9

4.082 4

2.268

10

4.536 5

GALLONS

TO LITERS

Liters

Ga"ons

LIters Liters

3.79

10

37.86 1

7.57

20

75.71

2

11.36

30

113.57 5

15.14

40

151.42

10

18.93

50

189.28

20

PINTS TO LITERS

Liters

Pints

0.47 6

0.95 7

1.42

8

1.89 9

2.37

10

40

50 60

I I I

5

10 15

Liters Liters

2.84 1

3.31 2

3.79 3

4.26 4

4.73 5

TEMPERATURE

70

75

85

95

I I I I

20 25 30

35

...

...unlvarsal

2 •

48

Ib

kg Ib

2.205

6

13.228

4.409 7 15.432

6.614

8

17.637

8.818 9 19.842

11.023

10

22.046

LITERS TO

GALLONS

Ga"ons

Liters

Ga"ons

0.26 60 15.66

0.53 90 23.77

1.32

120 31.32

2.64

150

39.62

5.28

180

47.54

LITERS

TO PINTS

Pints

Liters

Pints

2.11

6 12.68

4.23 7

14.79

6.34 8

16.91

8.45 9

19.02

10.57 10

21.13

105 140 175

212

OF

I I I I

40

60

80

100

°C

I

EUROPEAN

MARITIME

COUNCIL

CERTIFICATION

EUROPEAN

ECONOMIC

COUNCIL

Declaration of Conformity

Application

of

Council Directives

EMC

89/3361EEC

9

Slandard(s) to Which Conformity is declared

ENS0081-1 ENS0082-2 ENSS020

Manufacturer's

Name

and

Address

Type

of

Equipment

Product Name

Model(s) Product

Options

Supplementary

Information

Westerbeke

Corporation·

41 Ledin Drive

Avon Industrial

Park·

Avon, MA 02322, USA

Marine

Diesel Engine

Universal

Marine

Diesel Engine

M2S-XPB, M35B, M40B

All

1.)

The

equipment listed is only for use in

Marine

Applications

aboard

boats.

2.) The equipment listed

must

be located below decks on the vessel and permanently installed in

it's

location.

3.}

The

equipment listed

must

be wired to the grounding system of the vessel.

I the undersigned, hereby declare

that

the equipment specified above conforms to the above Directive(s)

and

Slandard(s)_ C

~

/r--L

Place

Avon

Massachusetts.

USA

~~

ignature)

Date January I 1996

Carleton E Bryant Chief Operating Officer

INTERNATIONAL

MARINE

CERTIFICATION

INSTITUTE

Rond

Point Schuman 6,

Box

6·

B - 1040 BRUXELLES' BELGIQUE'

tel:

+32

(OJ

2-238-7892 • fax: +32

(0)

:'-238-71'''!!._

CER'HlFKCATE

We hereby certify that the engines(s) stated below meet the EC Directive 94/25/EC.

1999 I.M.C.I. Power Rating Report

(kW)

No

Hi

hest Oul

ut

1

la,3

17,a

3.000

2

ii

49

3

Inboard

Diesel

Natural

4

EST

I 4

lars

E.

G nholm

Mana in Director

0609

27-Jun-99

lowest

Out

ut

5

ii

INTERNATIONAL

MARINE

CERTIFICATION

lana,rlTI

Rond Poinl Schuman 6, Box

6.8

- 1040 BRUXELlES. BELGIQUE o lei: +32 (0) 2-238-7892

-lax:

+3i'2~(0i·':;3-'.:;7(;o

CERTKlFlCATE

We

hereby certify that

the

englnes(s) stated below meet

the

EC

DirecUve

94/25/EC.

owe,

No

(kW) (kW)

19991.M.e.1. Power Rating Report

Hi

hast Oul

ul

1

25,1

24,3

3.000

2 3

Inboard

Diesel

Natural

4

STERI 4

Lars

E.

Gr m

Mana

in

Direclor

0609

'·Mar·99

INTERNATIONAL

MARINE

CERTIFICATION

I

Rond Poinl Schuman 6, Box

6.

B - 1040

BRUXELLES.

BELGIQUE o'el: +32 (0)

2-238-7892.

fax:

CERTKFK

CATE

lowest Out

ul

5

We

hereby certify that

the

engines(s) stated below meel

the

EC

Directive 94/25/EC.

19991.M.C.I.

Power

Rating Report

""'.,

Crankshaft

Power

ler

shaft

Power

No

(kW)

k

Hi

hesl Oul

ul

1

26,6

26,1

3.000

5D

2 3

Inboard

Diesel

Natural

WEST

I

4

lars

holm

Mana

in

Director

0609

16-Sap-99

lowest Out ul 5

1147-~010