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Universal M3-20B Operator's Manual

Marine diesel engines
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OPERATORS MANUAL
MARINE DIESEL ENGINES
M3-20B M-25XPB(C) M-35B(C)
M-408 M-508
PUBLICATION NO. 200550
REVISION 3 ' .
AUGUST 2015
Westerbeke Corporation - Myles Standish Industrial Park
150
MA 02780-7319
John Hancock Road-Taunton,
U.S.A.
Website: www.westerbeke.com
,,S!;/g'
Member NatUmal Marine Manufacturers Association

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  • Page 1 OPERATORS MANUAL MARINE DIESEL ENGINES M3-20B M-25XPB(C) M-35B(C) M-408 M-508 PUBLICATION NO. 200550 REVISION 3 ' . AUGUST 2015 Westerbeke Corporation - Myles Standish Industrial Park MA 02780-7319 John Hancock Road-Taunton, U.S.A. Website: www.westerbeke.com ,,S!;/g' Member NatUmal Marine Manufacturers Association...
  • Page 2 wARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can include: •Dizziness • Throbbing in Temples •Nausea •Muscular Twitching •Headache •Vomiting •Inability to Think Coherently •...
  • Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and WARNING: Fire can cause injury or death! when dangerow; conditiom; exist and precautions. Know Prevent flash fires. Do not smoke or permit flames or take the necessary precautions to protect yourself, your •...
  • Page 4 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING Accidental starting can cause injury WARNING: WARNING: Carbon monoxide (CO) is deadly gas! death! • Twli Ensure that the exhaust system is adequate to expel gases • b re on the tum the control panel or discharged from the engine.
  • Page 5 SAFETY INSTRUCTIONS • ABYC, NFPA AND USCG PUBLICATIONS FOR Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, .. INSTA LLING MARIN E ENGIN ES AND GENER ATORS rings, necklaces or bracelets that could be caught in Read the followin g ABYC, NFPA and USCG publicati ons moving parts.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS (Catalina) Parts Identification Wiring Schematic ..........lntroduction Engine Adjustments ....................Warranty Procedures Throttle and Stop Assembly ............27 Serial Number Location Valve Clearance ....

  • Page 8: Parts Identification

    PARTS IDENTIFICATION MANIFOLD PRESSURE CAP OIL FILL !COOLANT FILL] THERMOSTAT ASSEMBLY WATER M·40B ILLUSTRATED TEMPERATUR E SENOOR INJECTION PUMP H EAT EXCHANGER TRANSMISSION MANIFOLD CONTR OL PRESSURE CAP BRACKET ALTERNATOR MANIFOLD REAR RIGHT SIDE ZINC TRANSMISSION COOLANT PUMP SHEAVE FLUIO DRAIN PREHEAT SOLENOIO OIL PAN...

  • Page 9: Warranty Procedures

    OF THE FURNISHING OR USE OF SYCH SOFTWARE. available worldwide. Should your engine require servicing, contact your nearest dealer for assistance. UNIVERSAL customers should also keep in mind the time span between printings of UNIVERSAL product software This is your Operators Manual.

  • Page 10: Serial Number Location

    Care at the factory during assembly and thorough testing diesel engine has the same types of valves, camshaft, pistons, have resulted in a UNIVERSAL diesel engine capable of connecting rods and lubricating system. many thousands of hours of dependable service. However the manufacturer cannot control how or where the engine is To a great extent, a diesel engine requires the same preven­...

  • Page 11: Admiral Control Panel

    ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off, the water temperature gauge will continue to register the last This manually-operated control panel is equipped with a temperature reading indicated by the gauge before electrical TIME switch and RPM gauge with an ELAPSED power was turned...

  • Page 12: Captain Control Panel

    CAPTAIN CONTROL PANEL DESCRIPTION The panel also includes alarm buzzer for low OIL PRESSURE or high COOLANT IBMPERATURE. The 1bis manually-operated control panel equipped with a RPM gauge is illuminated when the switch is turned PREHEAT and switch, RPM gauge, START but­...

  • Page 13: Diesel Fuel, Engine Oil And Engine Coolant

    ENGINE COOLANT Use a diesel fuel that meets the requirements ofNo.2-D SAE UNIVERSAL recommends a mixture of 50% antifreeze and and has a Cetane rating of #45 or higher. Grade of 50% distilled water. Distilled water is free from the diesel fuel according to ASTM D975.

  • Page 14: Preparations For Initial Start-Up

    PREPARATIONS FOR INITIAL START-UP Check the DC electrical s ystem. Inspect wire connections PRESTART INSPECTION and battery cable connections. Before starting your engine for the first time or after a pro­ Visually examine the unit. Look for loose or missing longed layoff - check the following items.

  • Page 15: Starting/Stopping Procedure

    STARTING/STOP PING PROCEDURE STARTING PROCEDURE cAUTION: Prolonged cranking intervals without the Place the transmission in neutral and advance the throttle engine starting can result in the engine exhaust system control to slightly open. fill i ng with raw water. This may happen because the pump is pumping raw water through the raw water CAUTION: Make certain the transmission is in...

  • Page 16: Break-In Procedure

    MODEL IDLE CRUISE Perform this conditioning carefully, keeping in mind the MAXIMUM following: M3-20B 1000 - 1200 2500 - 3000 3500 - 3600 Start the engine according to the Starting Procedure M25XPB 1000 - 1200...

  • Page 17: The Daily Routine

    THE DAILY ROUTINE CHECK LIST START YOUR ENGINE Each day before staiting your engine, take a few moments to NOTE: STARTING STOPPING PROCEDURE in this run this check list: manual for more detailed· instructions. Visually inspect the engine for fuel, oil, coolant and 1.

  • Page 18: Maintenance Schedule

    MAINTENANCE SCHEDULE · Il WARNING: Never attempt to perform any service while the engine i s running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each Job. When servicing/rep/acing components, turn off the circuit breaker on the control panel, or turn off the battery switch.
  • Page 19 MAINTENANCE SCHEDULE NOTE: Use the engine hourmeter gauge to log your engine hours or rec rd your engune hours running time. SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE OPERATING HOURS OR YEARLY Transmission Change fluid at 300 operating hours. Lubricate control cable and check attachment. Engine Oil Change the engine oil and oil filter (always together) every...

  • Page 20: Engine Cooling Circuit

    ENGINE COOLING CIRCUIT DESCRIPTION Drain the engine coolant by loosening the drain plug on the engine block and opening the manifold pressure cap. Flush The engine is fresh water cooled (engine coolant) by an the system with fresh water, then start the refill process. See engine-mounted heat exchanger.

  • Page 21: Raw Water Pump

    ENGINE COOLING CIRCUIT RAW WATER COOLING CIRCUIT Check the cam and inner wear plate for wear. Replace as needed. 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 CAUTION: any of the vanes have broken off the hose to the water strainer.

  • Page 22: Raw Water Intake Strainer

    ENGINE COOLING CIRCUIT THERMOSTAT GASKET A thermostat, located near the manifold at the front of the engine, controls the coolant temperature as it continuously flows through the closed cooling circuit. When the engine is first started the closed thermostat prevents coolant from flow­ ing (some coolant is by-passed through a hole in the thermo­...

  • Page 23: Engine Oil Change

    See UNIVERSAL'S Installation Manual. NOTE: Use genuine UNNERSAL oil filters - generic filters are not recommended.

  • Page 24: Remote Oil Filter

    REMOTE OIL FILTER (OPTIONAL KIT PN #040078 INSTALLATION NOTE: Westerbeke is not responsible for engine f ailure due to incorrect installation the Remote Oil Filter. This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as CAUTION: an engine room bulkhead.

  • Page 25: Fuel System

    , injector seat washers, and a fuel fil­ FUEL SHUT·OFF VALVE ter be carried on board at all times. Purchase needed spares from your local UNIVERSAL dealer or distributor. If a leak Air Cleaner/Silencer should develop at a banjo washer that cannot be corrected by a simple tightening of the fitting, replace the sealing washer.

  • Page 26: Fuel Filters

    FUEL SYSTEM FUEL WATER SEPARATOR AwARNING: Shut off the fuel valve at the tank when A primary fuel filter of the water separating type must be servicing tbs fuel system. T ake care in catching any fuel installed between the fuel tank and the engine to remove that may spill.

  • Page 27: Dc Electrical System

    DC ELECTRICAL SYSTEM GLOW PLUGS ENGINE VOLT DC CONTROL CIRCUIT The engine has a 12 volt DC electrical control circuit that is The glow plugs are wired through the preheat solenoid. shown on the wiring diagrams that follow. Refer to these dia­ When PREHEAT is pressed at the control panel this solenoid grams when troubleshooting or when servicing the DC elec­...
  • Page 28 I f the isolator is charging the starting battery but not the house battery, the alternator is OK and the problem is in the battery charging circuit. TYPICAL UNIVERSAL 51 AMP WARNING: Shut off the engine battery switch...
  • Page 29 DC ELECTRICAL SYSTEM WIRING DIAGRAM #391 44 These diagrams illustrate the volt negative ground electrical circuit. The two optional instrument panels, the CAPTAIN PANEL and the ADMIRAL PANEL are diagramed below. 1 1 4 r'lfl When an ADMIRAL PANEL is installed, two additional instrument sendors are assembled to the engine to r�I •...

  • Page 33: Engine Adjustments

    - 4 - 2 CYLINDER MODELS Adjust the valves beginning with Cylinder # 1 . Rotate the MODEL M3-20B 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).
  • Page 35 ENGINE TROUBLESHOOTING NOTE: T he engine 's electrical system is protected b y a 20- The following trouble shooting chart describes certain prob­ lems, the probable causes of the problems, and the recom­ Ampere manual reset circuit breaker located on the bracket mendations to overcome the problems.

  • Page 36: Engine Troubleshooting (Chart)

    ENGINE TROUBLESHOOTING Probable Cause Verification/Remedy Problem 1 . Oil Pressure switch. 1 . Observe if gauges and panel lights are activated when engine is Battery runs down. not running. Test the oil pressure switch. 2. High resistance leak to ground. 2.

  • Page 37: Control Panel Troubleshooting (Chart)

    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 Verification/Remedy PREHEAT depressed, no panel indications Oil Pressure switch.
  • Page 38 MAXIMUM IDLE CRUISE MODEL Tachometer Inaccurate 3500 - 3600 2500 - 3000 M3-20B 1000 - 1 200 1. With a hand-held tach on the front of the crankshaft 2000 - 2500 2900 - 3000 1000 - 1 200 M25XPB pulley retaining nut or using a strobe type tach, read the...

  • Page 39: Water Heater

    WATER HEATER CONNECTIONS WATER HEATER INSTALLATIONS The pressure cap on the engine's manifold should be installed after the engine's cooling system is filled with This engine is equipped with connections for the plumbing of coolant. Finish filling the cooling system from the remote engine coolant to heat an on-board water heater.

  • Page 40: Changing The Fluid

    PRM NEWAGE TRANSMISSIONS MODELS BO AND 1 20 NOTE : When changing the fluid, take care not to. lose the drain plug sealing washer. The drain plug will leak without this sealing washer. HEX PLUG 112" WARNING: Never pull out the dipstick while the .
  • Page 42 PRM NEWAGE TRANSMISSIONS TROUBLESHOOTING Problem Probable Cause Verification/Remedy Excessive noise at low speeds. 1 . Engine idle speed too low. Increase.idling speed. Excessive noise at all speeds. 1 . Defective coupling. 1 . Inspect/replace coupling if necessary. 2. Shaft misalignment. 2.

  • Page 43: Control Cables

    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 SHIFT - ­...

  • Page 44: Fluid Change

    HURTH HBWn.F TRANSMISSIONS INITIAL OPERATION LOCKING THE PROPELLER All HBW/ZF marine transmissions are test-run on a test Locking of the propeller shaft by an additional brake is not stand with the engine at the factory prior to delivery. For required: use the gear shift lever position opposite your safety reasons the fluid is drained before shipment.

  • Page 45: Operating Temperature

    TRANSMISSION COOLER O Clean up the transmission and touch up unpainted areas Some UNIVERSAL model's transmissions are equipped (use heat resistant paint). with an externally attached convection type transmission 0 Fill the transmission with Dextron Ill ATF fluid to pre­...

  • Page 46: Control Cables

    HURTH HBW/ZF TRANSMISSION TROUBLESHOOTING CONTROL CABLES The majority of transmission difficulties arise as a result of new cable and perhaps a new linkage mechanism may be improper clutch adjustments (manual transmissions) or needed. \Yhile the cable is loose, shift the transmission in and .
  • Page 47 HURTH HBW/ZF TRANSMISSION TROUBLESHOOTING Probable Cause Problem Verification/Remedy High fluid temperature. 1 . Fluid level high during operation. 1 . Pump out fluid to the maximum and mark o n dipstick. Fluid level low. Add fluid. Plugged or restricted fluid cooler. Replace cooler and flush water system.

  • Page 48: Lay-Up And Recommissioning

    LAY-UP AND RECOMMISSIONING LAY-UP CAUTION: Many owners rely on their boatyards to prepare their craft, Do not leave the engine's aid engine ail including engines and generators, for lay-up during the in the sump aver the lay-up period. Engine ail and cam· off-season or for long periods of inactivity.
  • Page 49 Lay-up time provides a good opportunity to inspect your UNIVERSAL engine to see if external items such as drive 6. Start the engine in accordance with procedures in the belts or coolant hoses need replacement. Check your basic...

  • Page 50: Specifications

    UNIVERSAL MARINE ENGINES SPECIFICATIONS GENERAL COOLING SYSTEM Description Diesel, four-cycle, four-cylinder, Description Fresh water-cooled block, thermostatically­ M·358, M-411 8 , fresh water-cooled, Vertical, in-line controlled with heat exchanger. M-508 overhead valve mechanism. Operating Temperature 1 50° - 1 70° F (66° - 77° C)
  • Page 51 SUGGESTED SPARE PARTS UNIVERSAL MARINE ENGINES � CONT ACT YOUR UNIVERSAL DEALER FOR SUGGESTIONS AND ADDITION AL INFORMATIO - =--- -- UNIVERSAL RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE, AND A GALL ON OF PRE­...
  • Page 52 STANDARD HARDWARE BOLT HEAD MARKINGS Metric bolt class numbers identify bolts by their strength with 1 0.9 the strongest. NOTES: Use the torque values listed below when specific torque values are not available. 2. These torques are based on clean, dry threads. Reduce torque by when engine oil is used.
  • Page 53 STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE x 25.4 x .0394 Inches (in) = Millimeters (mm) = Inches x .305 x 3.281 Feet (ft) = Meters (m) = Feet x 1 .609 x .0621 Miles = Kilometers (km) = Miles VOLUME x 1 6.387 x .061 Cubic Inches (in3)
  • Page 54 1210 ( 200550 ) 8/2015 Downloaded from www.Manualslib.com manuals search engine...

This manual is also suitable for:

M-25xpbM-35bM-408M-508M-25xpbcM-35bc

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