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Summary of Contents for Universal M2-12A
- Page 2 CALIFORNIA PROPOSITION WARNING Marine diesel and gasoline engine exhaust and some of Its constituents are known to the State of Gallfomla to cause cancer, birth defects, and other reproductive harm. AwARNING Exhaust gass es contain t:arbon Monoxide, an odorless and colorless gas.
- Page 3 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents WARNING: Fire can cause Injury or death! mies and caused by failure to follow fundamental precautions. Know when dangerous conditions exist and take the necessary precautions protect yourself, your Prevent flash fires.
- Page 4 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury Carbon monoxide (CO} is a deadly gas! W AR NI N G or death! Ensure that the exhaust system is adequate to expel gases • Turn OFF the DC breaker on the control panel or •...
- Page 5 SAFETY INSTRUCTIONS Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR • equipment; avoid wearing loose jackets, shirts, sleeves, INSTALLING MARINE ENGINES AND GENERATORS rings , necklaces or bracelets that could be caught in Read the following ABY C, NFPA and USCG publications moving parts.
- Page 6 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS ABYC Strict federal regulations, 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 provisions must be made to install a siphon...
- Page 7 TABLE OF CONTENTS Parts ldentlfication DC Electrical System ......................Description Introduction ............................ Alternator Troubleshooting t y Procedures arran ................Checking fo r Proper Voltage Serial Number Location .............
- Page 8 PARTS IDENTIFICATION OIL FILL CAP GLOW PWGS FUEL LINES THERMOSTAT HSG. FUEL RETURN FUEL FILTER (AIR BLEED ON TOP) FUEL AIR BLEED VALVE SEA WATE R TO EXHAU ST CLEAN OU T COVER & TRANS. DIP STICK OIL FILL HOLE DIP STICK ENGINE COUPLING OIL PAN...
- Page 9 UNNERSAL or the supplier in question be consulted to determine the accuracy and currentness of the Your UNIVERSAL Warranty is included in a separate folder. product software being consulted by the customer. If you have not received a customer identification card regis...
- Page 10 UNN E RSAUWESIBRBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment. SPARES AND ACCESSORIES C ertain spares will be needed to support and maintain UNIVERSAL UNIVERSAl) your marine engine. Your WESTERBEKE...
- Page 11 ADMIRAL CONTROL PANEL UN I VERSAL offers two optional panels. Refer to the When the engine is shut down with the Key Switch turned otf, the water temperature gauge will continue to register the instruction page that applies to the panel you purchased. l �...
- Page 12 CA PTAIN CONTROL PANEL CAPTAIN PANEL and one for high ENGINE COOLANT TEMPERATURE. It also includes an alarm buzzer for low OIL PRESSURE or This manually-operated control panel is equipped with a Key high WAIBR lEMPERATURE. The gauge is illumi Switch, an gauge, PREHEAT and START buttons, an nated when the Key Switch is turned...
- Page 13 COOLANT DIESEL FUEL, ENGINE OIL AND ENGINE DIESEL FUEL ENGINE COOLANT UNIVERSAL of No. 2-D Use a diesel fuel that meets the requirements recommends a mixture antifreeze SAE J #45 or and has a Cetane rating higher grade of distilled water. Distilled...
- Page 14 P REPARATIONS FOR INIT IAL START-UP PRESTART INSPECTION D Check the DC electrical system. Inspect wire connections and battery cable connections. Before starting your engine for the first time or after a pro D Visually examine the unit. Look for loose missing longed layoff - check the following items.
- Page 15 STARTING/STO P PING PRO CEDURE STARTING PROCEDURE C AUTION: Prolonged cranking intervals without Place the transmission in neutral and advance the throttle control to slightly open. the engine starting can result in the engine exhaust system filling with raw water. This may happen because CAUTION: the pump is pumping raw water through the raw water Make certain the transmission is in...
- Page 16 BREAK-IN PROCEDUR E THE FIRST HOURS Breaking-in a new engine basically involves seating the pis ton rings to the cylinder walls. This cannot be accomplished Although your engine has experienced a minimum of one by long periods of running at idle, nor by early running at hour of test operations to ensure accurate assembly and full rpm.
- Page 17 THE DAILY ROUTINE CHECK LIST START YOUR ENGINE NOTE: STARTING STOPPING PROCEDURE in this Each day before starting your engine, take a few moments to manual f or more detailed instructions. run this check list: D Visually inspect the engine for fuel, oil, or water leaks. 1 .
- Page 18 MAINTENANCE SCHEDULE WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. W hen servicing/ replacing components, ensure the key switch in the instrument panel is in the position or turn starting battery.
- Page 19 DC electrical components. NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engine 's ability to remain cool. recommends this service be performed by an authorized mechanic. *UNIVERSAL 1 3 . .
- Page 20 ENGINE COOLING CIRCUIT Drain the engine coolant by loosening the drain plug on the DESCRIPTION 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 COOLING CIRCUIT ENGINE THERMOSTAT 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 22 ENGINE COOLING CIRCUIT 7. Check cam and RAW WATER COOLING CIRCUIT inner wear plate wear. Replace needed. · 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: If any of the vanes have broken off the hose to the...
- Page 23 This problem is often caused by the poor location or the lack of an anti siphon valve. See UNIVERSAL'S Installation Manual. OIL FILTER APPLY· OIL TO GASKET: WHEN ASSEMBLING : NEW FILTER.
- Page 24 Remote Oil Filter. manual f or instructions on removing the oil filter. To install, simply remove the engine oil filter and thread on UNIVERSAL's remote oil filter kit shown. FASTEN SECURELY TO A BULKHEAD (SCREWS ARE OWNER SU PPLIED) APPLY A.THIN COAT OF CLEAN OIL TO THE 0-RING WHEN...
- Page 25 FUEL SYSTEM FUEL WATER SEPARATOR WARNING: Shut o" the fuel valve the tank when A primary fuel filter of the water separating type must be system. servicing the fuel Take In catching any fuel t:aftl installed between the fuel tank and the engine to remove that spill.
- Page 26 Purchase needed spares from your local UNIVERSAL dealer or distributor. If a leak should develop a banjo washer that cannot be corrected by...
- Page 27 If the isolator is charging the starting battery but not the house battery, the alternator is OK and the problem is the battery charging circuit. bitte, , TYPICAL UNIVERSAL .WARNING: Shut a" the engine switch ALTERNATOR CONNECTIONS...
- Page 28 DC ELECTRICAL SYSTEM ENGINE VOLT DC CONTROL CIRCUIT WARNING: Sulfuric acid In lead batteries can The engine has a 12 volt electrical control circuit that is cause severe bums on skin and damage clothing. Wear shown on the wiring diagrams that follow. Refer to these dia protective gear.
- Page 29 #391 44 DC ELECTRICAL SYSTEM WIRING DIAGRAM These diagrams i l l ustrate the volt n egative ground e lectrical circuit. The two optional i nstrument panels, the CAPTAIN PAN EL a n d the ADMI RAL PANEL a re d i a g r a m e d b e l ow.
- Page 30 DC ELECTRICAL SYSTEM WIRING SCHEMATIC #391 44 + 1 2 VDC r - - - -i - - - - - - 1 L I FT PUMP �I F U E L ·I� �klM. f' U £ l lWHEN U.![� O .
- Page 32 WIRING SCHEMATIC CATALINA YACHTS #200360 S T A R T E R V D C S O L E N O I D S T A R T E R r - - - 1 _ _ _ P R E H E A T S O L E N O I D r - - - 1 G L O W P L U G S...
- Page 33 STARTER MOTOR SOLEN O I D SOLENOID M OTOR I G N ITION TERMINAL TYPICAL STARTER MOTOR REFER TO THE WIRING DIAGRAM IN THIS MANUAL TROUBLESHOOTING TESTI NG WITH SCREWDRIVER Prior to testing, make certain the ships batteries are at full charge To test the ignition circuit, locate the ignition(s) tenninal (it is one and that the starting system wiring connections (tenninals) are of the small terminal studs and is wired to the ignition circuit).
- Page 34 ..not meet USCG certified for marine use. Automotive starters standards. If in doubt, contact y our UNIVERSAL dealer. TO REMOVE FOR SERVICE I GNITION 1. Tum off the DC battery switch. TER M I NAL g ain 2.
- Page 35 STARTER M. O TOR DESCRIPTION No-load Test The starter can be roughly divided into the following sections: 1. Connect the e ter, voltmeter, and battery to the starter motor section which generates a drive power. as illustrated. • overrunning clutch section which transmits an arma •...
- Page 36 STARTER MOTOR Return test: . With a battery connected to the solenoid ter minal (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position ATTRACTION TEST when released from holding by hand. BATTERY Holding test.
- Page 38 ADJUSTMENTS ENGINE NOTE: UNIVERSAL recommends that the following engine The in f omiation below is provided to assist the meclfilnic. THROmE AND STOP CONTROLS Adjust the valves beginning with Cylinder #1. Rotate the crankshaft slowly and observe the operation of the valves for Cylinder #1.
- Page 39 ENGINE ADJUSTMENTS NOTE: UNIVERSAL recommends that the f ollowing engine ad justments be perf ormed by a competent engine mechanic. The in formation beluw is provided to assist the mechanic. OIL PRESSURE FUEL INJECTORS engine's oil pressure, dUrlng operation, is indicated...
- Page 40 TACHOMETER TACHOMETER/HOUR METER _LIQ.l!T EARLY MODEL TACHOMETERS The tachometer/hour meter used in propulsion engine instru ment panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and other the tachometer. The hour meter circuit operates on ( +) volts alternator charging voltage supplied to the terminal...
- Page 41 ENGINE TROUBLESHOOTING The following trouble shooting chart describes certain prob NOTE: The engine 's electrical system is protected by a lems, the probable causes of the problems, and the recom Ampere manual reset circuit breaker located on the bracket mendations to overcome the problems on the left side of the engine.
- Page 42 ENGINE TRO UBLESHOOTING Problem Probable Cause Verification/Remedy Battery runs down. Oil Pressure switch. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. H i g h resistance leak t o ground. Check wiring.
- Page 44 HURTH HBWn.F TRANSMISSIONS LOCKING THE PROP. E LLER INITIAL HBW/ZF marine transmissions are test-run on a test Locking o f the propeller shaft b y a n additional brake i s 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 46 HURTH TRANSMISSION TROUBLESHOOTING HBW/ZF CONTROL CABLES majority of trarismission difficulties arise as a result of ge mechanism cable and perhaps a n improper clutch adjustments (manual transmissions) or needed. While the cable is loose, shift the transmission in and . problems with control cables (hydraulic transmissions) out of gear using the lever on the side of the transmission to rather than from problems with the transmission itself.
- Page 47 HURTH HBW/ZF TRANSMISSION TROUBLESHOOTING l>roblem Probable Cause Verification/Remedy Fluid level high during operation. High fluid temperature. Pump out fluid to the maximum and mark on dipstick. Fluid level low. Add fluid. Plugged or re str ic t ed fluid cooler. Replace cooler and flush water system.
- Page 48 UNIVERSAL MARINE ENGINES SPECIFICATIONS Four cyc l e , fresh-water cooled , vertical i n - l i n e marine d iesel e n g ines. M35A(C) M4·30A HORSEPOWER 30 @3200 rpm @ 3 600 CYLINDERS BORE AND STROKE 2.95 x 2 .
- Page 49 UNIVERSA L MARINE ENGINES SP ECIF ICAT IONS Four cyc l e , fresh-water cooled , vertical in-li n e marine d iese l eng ines . M2·1 2A M3·20A M25XPA(C} HORSEPOWER 1 1 @3600 rpm 1 8 @3600 rpm 23 @3200rpm CYLINDERS BORE AND STRO KE...
- Page 50 LAY·UP AND RECOMMISSIONING LAY·UP CAUTION: Do not leave the engine's old engine oil Many owners rely on their boatyards to prepare their craft, in the sump over the lay-up period. Engine oil and com· including engines and generators, for lay-up during the off-season or for long periods of inactivity.
- Page 51 Lay-up time provides a good opportunity to inspect your Start the engine in accordance with procedures in the UNIVERSAL engine to see if external items such as drive PREPARATIONS FOR INITIAL START-UP section of belts or coolant hoses need replacement. Check your basic this manual.
- Page 52 STANDARD AND METRIC CONVERSION DATA LENGT H-DISTANCE x 25.4 x .0394 I n ches ( i n ) = M i l l i m eters ( m m ) = I nches (ft) x .305 x 3.281 Feet = M eters ( m ) = Feet x 1 .609 x .0621...
- Page 53 STANDARD HARDWARE BOLT HEAD MARKINGS Metric bolt class num bers 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. These torques are based on clean, dry threads. Reduce torque by when engine oil is used.
- Page 54 EXTERNAL Fua AND A GALLON OF PRE FILTER MIXED COOLANT. UNIVERSAL SPARE PARTS KITS UNIVERSAL also offers two Spare Parts Kits, KIT B each packaged in a rugged hinged toolbox. Impeller Kil Kil "A" includes the basic spares. Kit "B" Is for more extensive off-shore cruising.
- Page 56 6-2015 1 200 4 94 1208...
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