• • OPERATORS MANUAL Unlvarsal MARINE DIESEL ENGINES M3·20A M3·20B M·25XPA M·25XPB M·35A M·35B PUBUCATION 200494 1ST EDITION I APRIL 1997 I~ WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK AVON, MA 02322 • TEL: (508) 588-noo • FAX: (508) 559-9323 "'~~~ M~mMr NaJ;olllll Marin~ Manufocturrrs Association --- N MMA
OPERATORS MANUAL Univarsal MARINE DIESEL ENGINES M3-20A M3-20B M-25XPA M-25XPB M-35A M-35B PUBLICATION 200494 1ST EDITION I APRIL 1997 I~ WESTERBEKE CORPORATION· AVON INOUSTRIAL PARK AVON, MA 02322 • TEL: (508) 588-7700 • FAX: (508) 559-9323 ....iIIr~~ NMMA Member Nalional Marine Maflujacluren;Assocullion ...,.".,..
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.
SAFETY INSTRUCTIONS UNIVERSAL DIESEL ENGINES INTRODUCTION Rem! this safety manlllll carefully. Most accidents are caused IJy failure to follow juruiJlmenJal rules and precautions. Know when dangerous conditions erist and take the necessary precautions to protect yourself, your personnel, and your machinery. The foUuwing safety instructions are in compliance with the American Boat and Yacht Council (ABYC) staruiJlrtis.
SAFETY INSTRUCTIONS PREVENT BURNS - EXPLOSION (continued) BATTERY EXPLOSION A WARNING: Battery explasian can cause injury • 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 running the blower. Run the blower for four minutes before starting your engine. I · ardeath! • Do not smoke or allow an open flame near the battery being serviced.
SAFETY INSTRUCTIONS TOXIC EXHAUST GASES AVOID MOVING PARTS IA WARNING: AWARNING: I· or Cal'llon monoxide (CO) is a deadly gas! Rotating parts can cause injury death! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close • Do not service the engine while it is running.
SAFETY INSTRUCTIONS RECOMMENDED INSTALlATION CODES AND SAfETY STANDARDS ENGINE INSTALlATIONS Preparations to install an engine should begin with a thor- ough examination of the American Boat and Yacht Council 's (ABYC) standards. These standards are a combination of sources including the USCG and the NFPA.
TABLE OF CONTENTS Introduction .......................................................................2 Warranty Procedures .. __ ............................................ __ .. 2 Typical Customer Identification Card .......................... 2 Product Software .......... _........... _........... _....................... 2 Notes, Cautions and Warnings ..................................... 2 Serial Number Location ............................................... 3 Understanding the Diesel Engine ........
INTRODUCTION PRODUCT SOFTWARE These new high perfonnance UNIVERSAL marine diesel engines are a product of UNIVERSAL/WESTERBEKE's design technology and their combined years of experience manufacturing quality marine engines. We take great pride in the superior durability and dependable performance of our marine engines. Thank you for selecting UNIVERSAL.
INTRODUCTION SERIAL NUMBER LOCATION ORDERING PARTS 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.
ADMIRAL CONTROL PANEL UNIVERSAL offers two optional panels. Refer to the instruction page that applies to the panel you purchased. When the engine is shut down with the Key Switch turned off, the water temperature gauge will continue to register the Ja~t temperature rcading indicated hy the gauge bctllfC electncal power was turned off. The oil pressure gauge will fall to zero when the Key Switch is turned oft·.
CAPTAIN CONTROL PANEL and one for high ENGINE COOLANT TEMPERATURE. ft also includes an alarm buzzer for low OfL PRESSURE or high WATER TEMPERATURE. The RPM gauge is illumi· nated when the Key Switch is turned on and remains illuminated while the engine is in operation.
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Use fuel that meets the requirements or specification of Class 2-D (ASTM), and has a cetane rating of #45 or better. UNNERSAL recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces. Care Of The Fuel Supply The antifreeze performs double duty.
PREPARATIONS FOR INITIAL START-UP o Check the DC electrical system. Inspect wire connections PRESTART INSPECTION and battery cable connections. Before starting your engine for the first time or after a prolonged layoff - check the following items. o Visually examine the unit. Look for loose or missing parts, disconnected wires, unattached hoses, and check threaded connections. o Check the engine oil1evel; add oil to maintain the level at the high mark on the dipstick.
STARTING/STOPPING PROCEDURE STARTING PROCEDURE ACAUTloN: Prolonged cranking intervals without the Place the transmission in neutral and advance the throttle control to slightly open. engine starting can result in the engine exhaust system filling with raw water. This may happen because the pump is pumping raw water through the raw water cool· ing system during cranking. This raw water can enter the engine's cylinders by way of the exhaust manifold once the exhaust system fills.
BREAK-IN PROCEDURE THE FIRST 50 HOURS Breaking-in a new engine hasically involves seating the piston rings 10 the cylinder walls. This cannot be accomplished hy long periods of running at iulc, nor hy early running at full rpm. Idle running may glaze the eylinuer walls. resulting in excessive oil consumption and smoky operation. Excessive speed or heavy over-loading. especially with a cold engine. may cause scoring of the cylinder walls. producing similar results.
THE DAILY ROUTINE CHECK LIST START YOUR ENGINE Each day before starting your engine, take a few moments to run this check list: NOTE: See STARTING STOPPING PROCEDURE in Ihis manual for more detailed instructions. o Visually inspect the engine for fuel, oil, or water leaks. o Check the oil level. o Check the transmission fluid level. I. Put transmission in neutral, throttle advanced. 2. Turn KEY to the ON position (2 o'clock) 3. Depress PREHEAT (IOta IS seconds).
MAINTENANCE SCHEDULE A 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.
MAINTENANCE SCHEDULE NOTE: Use the engine hour meter gauge to log your engine hours or record your ' engine hours by running time. SCHEDULED MAINTENANCE CHECK EACH DAY HOURS OF OPERATION 750 1000 1250 EXPLANATION OF SCHEDULED MAINTENANCE 50 100 250 500 Engine Hoses 0 0 0 0 0 0 0 Hose should be hard & tight. Replace if soft or spongy. Check & tighten all hose clamps. Heat Exchanger Zinc Anode 0 0 0 0 0 0 0 Clean or replace anode. Open heat exchanger end cap and clean out debris.
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 system with fresh water, then start the refill process. See the Parts Identification photos in this manual for locations. 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 displacement impeller pump.
ENGINE COOLING CIRCUIT THERMOSTAT RAW WATER COOLING CIRCUIT A thermostat, located ncar 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 flowing (some coolant is by-passed through a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up the thermostat gradually opens.
ENGINE COOLING CIRCUIT Changing the Raw Water Impeller 12. 1. Close the raw water intake, Mount the pump to the engine taking care thai the end seal and gasket are in place. Do not tighten the pump mounting screws, just finger tight. 2. Remove the inlet and outlet rx>rt hoses from the pump, noting the port location and positioning. 13. Rca<;semhlc the hose connections and open the raw water intake. 3. Remove the pump assembly and its gasket from the engine. 14.
ENGINE OIL CHANGE DRAIN THE SUMP Replacing the Oil Filter 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, or attach a pump to the end of the 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.
REMOTE OIL FILTER INSTALLATION Always install this kit with the oil filter facing down as illustrated. This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as an Contact your UNIVERSALIWESTERBEKE dealer for more engine room bulkhead. infonnation.
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 installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine. servicing the fuel system. Take care in catching any fuel that may spill. 00 NOT aI/ow any smoking, open flames or other sources of fire near the fuel system when servicing.
FUEL SYSTEM FUEL ADDITIVES If it becomes necessary to bleed air from the system, use the following procedure: If fungus or bacteria is causing fuel problems, you should have an authorized dealer correct these problems. Then use a diesel fuel biocide to sterilize the fuel (follow the manufacturer's instructions).
DC ELECTRICAL SYSTEM DESCRIPTION A WARNING: Before starting the engine make certain that everyone is clear Df mDving parts! Keep away frDm sheaves and belts during test prDcedures. The charging system consists of an alternator with a mounted voltage regulator, an engine DC wiring harness, a mounted DC circuil breaker, and a battery and connection wires.
DC ELECTRICAL SYSTEM ENGINE 12 VOLT DC CONTROL CIRCUIT A WARNING: Sulfuric acid in lead batteries can 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. cause severe burns on skin and damage clothing. Wear protective gear.
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 ADMIRAL AN EMERGENCY AND PANEL WHEN LEAVING THE BOAT A SWITCH WITH A CONTINUOUS RATING OF 175 AMPS AT 12 vae WILL SERVE THIS FUNCTION.
DC ELECTRICAL SYSTEM WIRING SCHEMATIC #31944 ... "yo< . ."---""'@ ,0, t------:~:..~-;'~, " i " ..n. - ,------------ ------, "' ,' ,' ,:::,~ 1 ,~'''T'''' CAPTAIN PANEL ~ ~ .~Qf~--~--~~~ "till ""., .'. 51 Rw o AMP AI JEBNATOR PRESTO! ITF ]? Af'.'P AI T '3C 0:. liB l:l!:_ 315 Ii. , _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ SHWPARD ALTERNA10~ ON TN£ '3~ a: loeB i::_ t 'He n r M"'-""T;;- ~ ,0<0"." OPT I aNAl AI HENAIORS ® ,.,. "'A to •• '''''A ,<,,, .. Too, ... · ... ,""r.
ENGINE ADJUSTMENTS THROTTLE AND STOP ASSEMBLY Firing Orders The throttle and engine stop levers arc 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. 3 Cylinder Models 1- 3- 2 4 Cylinder Models 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.
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 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. During engine operation, checking the engine's coolant should be done at the remote tank and not at the engine manifold cap.
ENGINE TROUBLESHOOTING The following trouble shooting chart describes certain problems, the probable causes of the problems, and the recommendations to overcome the problems. Problem Key switch on, PREHEAT switch depressed: no panel indications: fuel solenoid or electrical fuel pump NOTE: The engine s electrical system is protected by a 20Ampere manual reset circuit breaker located on the bracket on [he left side of [he engine. The preheat solenoid is moullled on lhe same bracket.
ENGINE TROUBLESHOOTING Problem Battery runs down. Probable Cause VerificalionJRemedy 1. Oil Pressure switch. 1. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. 2. High resistance leak to ground. 2. Check wiring. Insert sensitive (0 •. 25 amp) mete in battery lines. (Do not start engine.) Remove connections and replace after short is located. 3. Low resistance leak. 3. Check all wires for temperature fise to locate the fault. 4. Alternator.
CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine control system is protected by a 20 amop manual resel circuil breaker located on the engine as close as possible to the power source. Problem Probable Cause VerilicalionJRemedy PREHEAT depressed, no panel indications fuel solenoid, electric fuel pump and preheat solenoid not energized. 1. Oil Pressure switch, 1. Check switches and/or battery connections. 2. 20 amp circuit breaker tripped. 2. Reset breaker.
TACHOMETER TROUBLESHOOTING TACHOMETER/HOURMETER Calibration The tachometerlhounneter used in propulsion engine instru~ ment panels contains two separate electrical circuits with a common ground. One circuit operates the hounneter and the other the tachometer. The hounneter circuit operates on 12 volts alternator charging voltage supplied to the (+) terminal on the back of the instrument. a.
HBW TRANSMISSION INITIAL OPERATION Locking the Prop All HBW marine transmissions are test-run on dynamometer with the engine at the factory prior to delivery. For safety reasons the fluid is drained before shipment. If you prefer to lock the propeller when sailing. simply shift into reverse. Do not shift into forward gear. (Locking the propeller shaft by an additional hrakc is unnecessary). Return the shift lever to neutral before starting the engine.
HBW TRANSMISSION Checking the Bowden Cable or Rod Linkage A WARNING: The position of the cover plate underneath the actuating lever is factory-adjusted to ensure equal shift lever travel from neutral position to A and B. If this side shift cover is removed or in any way tampered with, the transmission warranty will be void. Authorized Hurth personnel only may adjust or remove this cover. The Bowden cable or rod linkage should be checked at regular intervals.
LAY-UP AND RECOMMISSIONING LAY-UP A.. CAUTION: 00 not leave the engine's old engine oil Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the offseason or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. in the sump over the lay-up period. Engine oil and combustion deposits combine to produce hannful chemicals which can reduce the life of the engine's internal parts.
LAY-UP AND RECOMMISSIONING STARTER MOTOR RECOMMISSIONING Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its removal. Make slIre the battery connections arc shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.
UNIVERSAL MARINE ENGINES SPECIFICATIONS Four cycle, fresh-water cooled, vertical in-line marine diesel engines. HORSEPOWER CYlINOERS BORE ANO STROKE M3-20A M-25XPA M-35A 18 @3600 rpm 23 @3200 rpm 30 @3200rpm 3 3 4 2.60 x 2.45 in (64 x 70 mm) 2.95 x 2.76 in (76 x 70 mm) 2.95 x 2.76 in (76 x 70 mm) COMBUSTION CHAMBER OISPLACEMENT (cubic inches) spherical type; three vortex combustion system 38.9 C.1. 57 C.I. 75.5 C.I. COMPRESSION RATIO 23:1 21 :1 21 :1 FIRING ORDER 1.2.3 1.2.3 1.3.4.
UNIVERSAL MARINE ENGINES SPECIFICATIONS Four cycle, fresh-water cooled, vertical in-line marine diesel engines. HORSEPOWER CYLINDERS BORE AND STROKE M3-20B M-25XPB M-35B 20 @3500 rpm 26 @3000 rpm 35@3000rpm 3 3 4 2.64 x 2.68 in (67 x 58 mm) 2.99 x 2.90 in (76 x 73.6 mm) 2.99 x 2.90 in (76 x 73.6 mm) COMBUSTION CHAMBER DISPLACEMENT (cubic inches) Spherical type; three vortex combustion system 43.89 C.1. 61.08 C.1. 81.45 C.1. COMPRESSION RATIO 23:1 23:1 23:1 FIRING ORDER 1.2.3 1.2.
UNIVERSAL ENGINES PARTS IDENTIFICATION TYPICAL ENGINE (MODEL 358 SHOWN) MAINFOLD PRESSURE MANIFOLD 51 AMP D.C. ALTERNATOR 1.0.
METRIC CONVERSIONS INCHES TO MILLIMETERS Inches mm 1 2 3 4 5 10 25.40 50.80 76.20 101.60 127.00 254.00 MILLIMETERS TO INCHES mm Inches 381.00 508.00 635.00 762.00 889.00 1016.00 15 20 25 30 35 40 mm Inches mm Inches 1 2 3 4 5 10 0.0394 0.0787 0.1181 0.1575 0.1969 03937 15 20 25 30 35 40 0.5906 0.7874 0.9843 1.1811 1.3780 1.5748 10 MILLIMETERS = 1CENTIMETER, 100 CENTIMETERS = 1 METER = 39.37 INCHES (3.3 FEET) INCHES TO METERS Inches Meters 1 2 3 4 5 6 0.0254 0.0508 0.0762 0.1016 0.
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly. use the following torque values when tightening standard hardware. Ib-ft kg-m 1.5 2 2.9-5.1 7.2·11.6 13.7-22.4 130-21.7 25.3-39.8 25.3-39.8 21.7-36.2 32.5-50.6 36.2·57.9 34.0-55.7 54.2-79.6 51.4-76.7 0.4-0.7 1.0-1.6 1.9-3.1 1.8-3.0 3.5-5.5 3.5-5.5 3.0-5.0 4.5-7.0 5.0-8.0 4.7-7.7 7.5-11.0 7.1-10.
UNIVERSAL SPARE PARTS OIL FILTER THERMOSTAT and GASKET Change every 100 Hours. Carry a spare for extended cruising. RAW WATER IMPELLER FUEL FILTER Change every 2~~~~ Check once a year. .;,~ ~ ~, ,- : L- 1;,--:;'1," '>--.---~ AIR CLEANER ELEMENT __ Clean every 250 hours. HEAT EXCHANGER END GASKET .., Check once a year. ZINC ANODES O'd ' ~"'"". ~~ DRIVE BELTS f~ Mg£Pil::\!itlii;;~/ Always carry a spare. Cheek weekly and proper tension.
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• WESTERBEKE CORPORATION' AVON INOUSTRIAL PARK AVON, MA 02322.
