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- Page 1 • • OPERATORS MANUAL Unlvarsal MARINE DIESEL ENGINES M3·20A M3·20B M·25XPA M·25XPB M·35A M·35B PUBUCATION 200494 1 ST EDITION APRIL 1997 WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK 588-noo • AVON, 02322 • TEL: (508) FAX: (508) 559-9323 "'~~~ M~mMr Marin~ NaJ;olllll...
- Page 3 OPERATORS MANUAL Univarsal MARINE DIESEL ENGINES M3-20A M3-20B M-25XPA M-25XPB M-35A M-35B PUBLICATION 200494 1 ST EDITION APRIL 1997 WESTERBEKE CORPORATION· AVON INOUSTRIAL PARK AVON, 02322 • TEL: (508) 588-7700 • FAX: (508) 559-9323 iIIr~~ ..NMMA ...,.".,.., Member Nalional Marine Maflujacluren;Assocullion...
- Page 5 CALIFORNIA PROPOSmON 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
- Page 6 SAFETY INSTRUCTIONS UNIVERSAL DIESEL ENGINES INTRODUCTION PREVENT BURNS - HOT ENGINE Rem! this safety manlllll carefully. Most accidents are caused WARNING: Do not much engine parts failure to follow juruiJlmenJal rules and precautions. exhaust system components. A running engine gets Know when dangerous conditions erist...
- Page 7 SAFETY INSTRUCTIONS PREVENT BURNS - EXPLOSION (continued) BATTERY EXPLOSION • Follow re-fueling safety instructions. Keep the vessel 's WARNING: explasian can cause Battery injury hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before running ·...
- Page 8 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES AVOID MOVING PARTS WARNING: WARNING: Cal'llon monoxide (CO) is deadly gas! Rotating parts can cause injury · or death! • Ensure that the exhaust system is adequate expel gases discharged from engine. Check the exhaust system •...
- Page 9 SAFETY INSTRUCTIONS RECOMMENDED INSTALlATION CODES AND SAfETY STANDARDS ENGINE INSTALlATIONS ABYC, NFPA AND USCG PUBUCATIONS FOR INSTAWNG DIESEL ENGINES Preparations install an engine should begin with a thor- ough examination of the American Boat Yacht Council 's Read following ABYC. NFPA and USCG publications...
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Page 11: Table Of Contents
TABLE OF CONTENTS Introduction ............... 2 Description ........... 20 Alternator Troubleshooting ......... 20 Warranty Procedures .. __ ..........__ .. 2 Checking for Propcr Voltage .......20 Typical Customer Identification Card ......2 Engine 12 Volt DC Control Circuit ......21 Product Software .. -
Page 12: Introduction
INTRODUCTION PRODUCT SOFTWARE These new high perfonnance UNIVERSAL marine diesel engines are a product of UNIVERSAL/WESTERBEKE's Product software (tech data, parts lists, manuals, hrochurcs and design technology and their combined years of experience catalogs) provided from sources other than liNTVERSAL arc not manufacturing quality marine engines. -
Page 13: Serial Number Location
SER.NO. • Certain spares will be needed to support and maintain your UNIVERSAL marine engine. Your UNIVERSAU WESTERBEKE dealer will assist you in preparing an on UNDERSTANDING THE DIESEL ENGINE board inventory of spare parts. See the UNIVERSAL SPARE PARTS page in this manual for a suggested list. -
Page 14: Admiral Control Panel
ADMIRAL CONTROL PANEL UNIVERSAL offers two optional panels. Refer to the When the engine is shut down with the Key Switch turned instruction page that applies to the panel you purchased. off, the water temperature gauge will continue to register the Ja~t temperature rcading indicated the gauge bctllfC elec-... -
Page 15: Captain Control Panel
CAPTAIN CONTROL PANEL and one for high ENGINE COOLANT TEMPERATURE. CAPTAIN PANEL also includes an alarm buzzer for low OfL PRESSURE or manually~operated This control panel is equipped with a Key high WATER TEMPERATURE. The RPM gauge is illumi· Switch, an RPM gauge, PREHEAT and START buttons, an nated when the Key Switch is turned and remains illumi- fNSTRUMENT TEST button and three indicator lamps, one... -
Page 16: Diesel Fuel, Engine Dil And Engine Coolant
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT UNNERSAL recommends a mixture of 50% antifreeze and Use fuel that meets the requirements or specification of Class 2-D (ASTM), and has a cetane rating of #45 or better. 50% distilled water. -
Page 17: Preparations For Initial Start-Up
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Check the DC electrical system. Inspect wire connections 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. parts, disconnected wires, unattached hoses, and check Check the engine oil1evel;... -
Page 18: Startingjstopping Procedure
STARTING/STOPPING PROCEDURE STARTING PROCEDURE ACAUTloN: 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. filling with raw water. This may happen because the pump is pumping raw water through the raw water cool·... -
Page 19: Break-In Procedure
BREAK-IN PROCEDURE THE FIRST 50 HOURS Breaking-in a new engine hasically involves seating the pis- ton rings the cylinder walls. This cannot be accomplished Although your engine has experienced a minimum of one hy long periods of running at iulc, nor hy early running at hour of test operations to ensure accurate assemhly and full rpm. -
Page 20: The Daily Routine
THE DAILY ROUTINE CHECK LIST START YOUR ENGINE Each day before starting your engine, take a few moments to NOTE: See STARTING STOPPING PROCEDURE in Ihis run this check list: manual for more detailed instructions. Visually inspect the engine for fuel, oil, or water leaks. I. -
Page 21: Maintenance Schedule
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. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Man)' a/the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic. - Page 22 MAINTENANCE SCHEDULE NOTE: Use the engine hour meter gauge to log your engine hours or record your engine hours by running time. CHECK HOURS OF OPERATION SCHEDULED EACH EXPLANATION OF SCHEDULED 750 1000 1250 MAINTENANCE MAINTENANCE Hose should be hard & tight. Replace if soft or Engine Hoses spongy.
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Page 23: 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) the system with fresh water, then start the refill process. See engine-mounted heat exchanger. -
Page 24: Thermostat
ENGINE COOLING CIRCUIT THERMOSTAT RAW WATER COOLING CIRCUIT A thermostat, located ncar the manifold at the front of the The raw water flow is created a positive displacement engine, controls the coolant temperature as it continuously impeller pump. This pump draws water directly from the flows through the closed cooling circuit. -
Page 25: Changing The Raw Water Impeller
ENGINE COOLING CIRCUIT Changing the Raw Water Impeller Mount the pump to the engine taking care thai the end seal and gasket are in place. Do not tighten the pump 1. Close the raw water intake, mounting screws, just finger tight. rx>rt 2. -
Page 26: Engine Oil Change
ENGINE OIL CHANGE DRAIN THE SUMP Replacing the Oil Filter The engine oil should be warm. Remove the oil drain hose When removing the used oil filter, you may find helpful from its attachment bracket and lower into a container and and cleaner to punch a hole in the upper and lower portion of allow the oil to drain, or attach a pump to the end of the drain the old filter to drain the oil from it into a container before... -
Page 27: Remote Oil Filter
NOTE: Westerbeke is not responsible for engine failure due to NOTE: Refer to the ENGINE OIL CHANGE page in this incorrect installation a/the Remote Oil Filrer... -
Page 28: Fuel System
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 the fuel system. Take care in catching any fuel installed between the fuel tank and the engine to remove that may spill. -
Page 29: Fuel Additivcs
FUEL SYSTEM FUEL ADDITIVES If it becomes necessary to bleed air from the system, use the following procedure: fungus or bacteria is causing fuel problems, you should Loosen all the high pressure injector lines (not injectors) have an authorized dealer correct these problems. Then use a crank the engine starter motor;... -
Page 30: Dc Electrical System
DC ELECTRICAL SYSTEM DESCRIPTION WARNING: Before starting the engine make certain The charging system consists of an alternator with a mounted that everyone is clear Df mDving parts! Keep away frDm voltage regulator, an engine DC wiring harness, a mounted test sheaves and belts during prDcedures. -
Page 31: Engine 12 Volt Dc Control Circuit
DC ELECTRICAL SYSTEM ENGINE 12 VOLT DC CONTROL CIRCUIT WARNING: Sulfuric acid in lead batteries can The engine has a 12 volt DC electrical control circuit that is cause severe burns on skin and damage clothing. Wear shown on the wiring diagrams that follow. Refer these dia- protective gear. -
Page 32: Wiring Diagram
DC ELECTRICAL SYSTEM WIRING DIAGRAM #31944 This diagram illustrates the 12 VDC negative ground electrical circuit. Two optional instrument panels are also shown: the Captain Panel and the Admiral Panel. 9'! rlHi:iIlH NOTE; AN ON-OFF SWITCH SHOULD BE INSTALLED BE1WEEN THE BATIERY AND STARTER TO DISCON- NECT THE BATIERY IN... -
Page 33: Wiring Schematic
DC ELECTRICAL SYSTEM WIRING SCHEMATIC #31944 . . . " " .. "yo< ---""'@ t------:~:..~-;'~, ,------------ ------, " " ' ' ' , ' , , ' ,~'''T'''' CAPTAIN ,:::,~ PANEL ~ .~Qf~--~--~~~ "till ""., . ' . AI JEBNATOR PRESTO! ITF Af'.'P AI T... -
Page 34: Engine Adjustments
ENGINE ADJUSTMENTS THROTTLE AND STOP ASSEMBLY Firing Orders 3 Cylinder Models 1 - 3 - 2 The throttle and engine stop levers arc located on the out- board side of the engine just below the fuel injection pump. 1-3-4-2 4 Cylinder Models Brackets are provided for owner-installed push-pull cables that run to the steering station. -
Page 35: Water Heater Connections
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 36: Engine Troubleshooting
ENGINE TROUBLESHOOTING The following trouble shooting chart describes certain prob- NOTE: The engine electrical system is protected by a 20- 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 [he left side of [he engine. - Page 37 ENGINE TROUBLESHOOTING Problem Probable Cause VerificalionJRemedy Battery runs down. 1. Oil Pressure switch. 1. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. High resistance leak to ground. Check wiring. Insert sensitive (0 •. 25 amp) mete in battery lines. (Do not start engine.) Remove connections and replace after short is located.
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Page 38: Control Panel Troubleshooting
CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine control system is protected by a 20 amop manual breaker resel circuil located on the engine as close as possible the power source. Problem Probable Cause VerilicalionJRemedy PREHEAT depressed, no panel indications 1. -
Page 39: Tachometer Troubleshooting
TACHOMETER TROUBLESHOOTING Calibration TACHOMETER/HOURMETER instru~ The tachometerlhounneter used in propulsion engine a. With a hand-held tach on the front of the crankshaft pul- ment panels contains two separate electrical circuits with a ley retaining nut or using a strohe type lach, read the front common ground. -
Page 40: Hbw Transmission
HBW TRANSMISSION INITIAL OPERATION Locking the Prop All HBW marine transmissions are test-run on dynamometer If you prefer to lock the propeller when sailing. simply shift with the engine at the factory prior to delivery. into reverse. Do not shift into forward gear. (Locking the For safety reasons the fluid is drained before shipment. -
Page 41: Maintenance
HBW TRANSMISSION Checking the Bowden Cable or Rod Linkage WARNING: The position of the cover plate under- The Bowden cable or rod linkage should be checked at regu- neath the actuating lever is factory-adjusted to ensure lar intervals. Check the neutral position of the operating lever equal shift lever travel from neutral position to A and B. -
Page 42: Lay-Up And Recommissioning
LAY-UP AND RECOMMISSIONING LAY-UP CAUTION: 00 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- bustion deposits combine to produce hannful chemicals season or for long periods of inactivity. -
Page 43: Intake Manifold
LAY-UP AND RECOMMISSIONING STARTER MOTOR RECOMMISSIONING Lubrication and cleaning of the starter drive pinion is advis- The recommissioning of your UNIVERSAL engine after a able, if access to the starter permits its removal. Make slIre seasonal lay-up generally foHows the same procedures as the battery connections arc shut off before attempting to those presented in the PREPARATIONS FOR STARTING remove the starter. -
Page 44: Specifications
UNIVERSAL MARINE ENGINES SPECIFICATIONS Four cycle, fresh-water cooled, vertical in-line marine diesel engines. M3-20A M-25XPA M-35A HORSEPOWER 18 @3600 rpm 23 @3200 rpm 30 @3200rpm CYlINOERS BORE ANO STROKE 2.95 x 2.76 in 2.60 x 2.45 in 2.95 x 2.76 in... - Page 45 UNIVERSAL MARINE ENGINES SPECIFICATIONS Four cycle, fresh-water cooled, vertical in-line marine diesel engines. M3-20B M-25XPB M-35B HORSEPOWER 26 @3000 rpm 35@3000rpm 20 @3500 rpm CYLINDERS BORE AND STROKE 2.64 x 2.68 in 2.99 x 2.90 in 2.99 x 2.90 in (67 x 58 mm) (76 x 73.6 mm) (76 x 73.6 mm)
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Page 46: Parts Identification
UNIVERSAL ENGINES PARTS IDENTIFICATION TYPICAL ENGINE (MODEL 358 SHOWN) MAINFOLD MANIFOLD PRESSURE 51 AMP D.C. ALTERNATOR 1.0. NAME PLATE HEAT EXCHANGER TRANSMISSION CONTROL BRACKET SHAFT COUPLING STARTER/SOLENOID FLEXIBLE MnI'MT·""'- TRANSMISSION OIL PRESSURE CONNECTION OIL PAN SENDER REAR FRONT LEFT SIDE FILL AIR FILTER THERMOSTAT... -
Page 47: Metric Conversions
METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches Inches 25.40 381.00 0.0394 0.5906 50.80 508.00 0.0787 0.7874 76.20 635.00 0.1181 0.9843 762.00 0.1575 101.60 1.1811 889.00 127.00 0.1969 1.3780 1016.00 254.00 03937 1.5748 10 MILLIMETERS 1CENTIMETER, 100 CENTIMETERS 1 METER 39.37 INCHES (3.3 FEET) INCHES TO METERS... -
Page 48: Standard Hardware Torques
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly. use the following torque values when tightening standard hardware. Ib-ft kg-m Pitch Grade 4 2.9-5.1 0.4-0.7 6mm bolt head/nut 1.0-1.6 7.2·11.6 8rnm boll head/nut 1.25 1.9-3.1 13.7-22.4 10mm bolt head/nut 1.25 1.8-3.0 130-21.7... -
Page 49: Spare Parts
UNIVERSAL SPARE PARTS OIL FILTER THERMOSTAT and GASKET Change every 100 Hours. Carry a spare for extended cruising. RAW WATER IMPELLER FUEL FILTER 2~~~~ Check once a year . Change every .;,~ ~ ~, ,- : 1;,--:;'1," '>--.---~ AIR CLEANER ELEMENT __ Clean every 250 hours. - Page 52 • WESTERBEKE CORPORATION' AVON INOUSTRIAL PARK AVON, MA 02322. TEL (508) 588-7700· FAX: (508) 559-9323...
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