Universal M-25XPA, Operator'S Manual

Page 1: ...L 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 N MMA M mMr NaJ olllll Marin Manufocturrrs Association ...

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Page 3: ...GINES 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 ...

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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: ...cedure 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 much hat engine parts or exhaustsystem components Arunning engine gets vert hat Always check the engine coolant level at the coolant recovery tank IA WARNING Steam can cause injury or death In case of an engine overheat allow...

Page 7: ... clear of the engine before starting Make certain all covers guards and hatches are re installed before starting the engine ii BATTERY EXPLOSION I A WARNING Battery explasian can cause injury ardeath Do not smoke or allow an open flame near the battery being serviced Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or by lit tobacco products Shut o...

Page 8: ... diesel exhaust fumes Some of the symp toms or signs of carbon monoxide inhalation or poisoning are Vomiting Dizziness Throbbing in temples Muscular twitching Intense headache Weakness and sleepiness iii AVOID MOVING PARTS I AWARNING Rotating parts can cause injury or death Do not service the engine while it is running If a situation arises in which it is absolutely necessary to make operat ing ad...

Page 9: ...lations must comply with the Federal Code of Regulations FCR ABYC NFPA AND USCG PUBUCATIONS FOR INSTAWNG DIESEL ENGINES Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their recommenda tions when installing your UNIVERSAL engine ABYC American Boat and Yacht Council Safety Standards for Small Craft Order From ABYC 15 East 26th Street New York NY 10010 NFPA N...

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Page 11: ...8 Tachometer Sticking 29 Starting Under Cold Conditions 8 Stopping Procedure 8 Break In Procedure 9 Calibration 29 HBW Transmission 30 Initial Operation 30 The First 50 Hours 9 Gearbox Operation 30 The Daily Routine 10 Check List 10 Start Your Engine I0 Maintenance Schedule 11 When Under Sailor Being Towed 30 Locking the Prop 30 Control Cables 30 Maintenance 31 Transmission Fluid 31 Engine Cooling...

Page 12: ...engine The first character after the dash indicates the decade A 1960s B 1970s C 1980s D 990s etc the second character represents the year in the decade and the fourth and fifth numbers represent the month of manufacture 2 PRODUCT SOFTWARE Product software tech data parts lists manuals hrochurcs and catalogs provided from sources other than liNTVERSAL arc not within UNIVERSAL S CONTROL UNIVERSAL C...

Page 13: ...Whenever replacement parts are needed always provide the engine model number and engine serial number a 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 insi...

Page 14: ...zzer will sound when the igni hon key IS turned on and should silence when the engine has started and the engine s oil pressure rises above 15 psi WATER TEMPERATURE GAUGE THIS GAUGE IS GRADUATED IN DEGREES fAHRENHEIT AND IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED ON THE ENGINE S NORMAL OPERATING TEMPERATURE IS 170 190 f 177 BBOC OtL PRESSURE GAUGE THIS GAUGE IS GRADU ATED IN POUNDS PER SQUARE I...

Page 15: ...remains illumi nated while the engine is in operation ALARM THE ALARM WILL SOUND If THE ENGINES OIL PRESSURE fALLS BELOW 15 PSI IN THIS EVENT THE ALARM WILL EMIT APULSATING SIG NAl THE ALARM WILL ALSO SOUND If THE WATER TEMPERATURE IN THE fRESHWATER COOLING CIRCUIT RISES TO 20S f IN THIS EVENT THE ALARM WILL EMIT A SIGNAl NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS ...

Page 16: ...s own additives additives of different brands couldreact in the mixture to produce properties harmful to your engine 6 ENGINE COOLANT UNNERSAL recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemi cals that can corrode internal engine surfaces The antifreeze performs double duty It allows the engine to run at proper temperatures by transferring heat aw...

Page 17: ...d level NOTE Refer to the specifications pages in this manual for fuel oil and transmission types and quantities RECOVERY TANK o Check the DC electrical system Inspect wire connections and battery cable connections o Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check threaded connections o Check the coolant level in the plastic recovery tank and...

Page 18: ... can enter the engine s cylinders by way of the exhaust manifold once the exhaust system fills Prevent this from happening by closing the raw water supply through hull Shut off draining the exhaust muffler and correcting the cause of the excessive engine cranking Engine damage result ing from raw water entry is not a warrantable issue the owner operator should keep this in mind Once the engine sta...

Page 19: ...0 overload the engine The presence of a gray or black exhaust and the inahility of the engine 10 reach its full rated rpm arc signs of an overload 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 9 Breaking in a new engine hasically involves seating the pis ton rings 10 the cylinder wal...

Page 20: ... area of leakage In cases ofexcessive coolant loss refill Ihe S1 Slem as oUllined ill Ihe ENGINE COOLING CIRCUIT section ill this manuaL 10 START YOUR ENGINE NOTE See STARTING STOPPING PROCEDURE in Ihis 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 IOta IS seconds 4 While pressing PREHEAT push START W...

Page 21: ...ct wiring Dir and oil will inhibillhe engine s ability and electncal connections Keep bolts nuts tight 10 remain cool Check for loose belt tension Engine Throttle and 0 0 0 0 0 0 Check tor loose tiltings colter pins etc Transmission Control Lubricate with WO 40 or equivalent Cables and Shutoff Levers Adjust Engine Idle Speed 0 Adjust to 750 1200 rpm Fuel Filter 0 0 0 0 0 0 Initial change at 50 hrs...

Page 22: ...plate wear and cam wear Coolant System 0 0 Drain flush and refill cooling system With appro priate antiireeze mix Fuel Injectors 0 Check and adjust Injection opening pressure and spray condition see Engine Adjustments Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the Starter motor pinion drive Preheat Circuit 0 0 Check operatIOn of preheat soleno...

Page 23: ... Flush the system with fresh water then start the refill process See the Parts Identification photos in this manual for locations NOTE The petcack on the heat exchanger can also be used fo help drain engine coolant AWARNING Beware of the hot engine coolant Wear protective gloves To Refill With Coolant With the engine running in idle slowly pour clean premixed coolant into the manifold NOTE Open th...

Page 24: ...sitive 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 m...

Page 25: ...this will allow the pump to align itself with its drive shaft 15 Stop the engine and tighten the pump assembly mount ing screws 16 Start and run the engine check for leaks and check for a norrnal operating temperature NOTE Should a failure occur with the pumps internal parts seals and bearings it may be more cost efficient to purchase a new pump The price ofindividual parts would almost match the ...

Page 26: ...ake certain it will come off 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 tilter as it is removed to make sure that the ruhber scaling gasket comes off with the old oil filter If this rubber sealing gasket remains sealed against the ...

Page 27: ...own APPLY ATHIN COAT OF CLEAN OIL TO THE O RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN TIGHTEN BY HAND A314 TURN AFTER THE O RING CONTACTS THE BASE 17 Always install this kit with the oil filter facing down as illus trated Contact your UNIVERSALIWESTERBEKE dealer for more infonnation NOTE Westerbeke is not responsible for engine failure due to incorrect installation a the Remote Oil Filre...

Page 28: ...Tum on the fuel and start the engine The nonnal preheat function should quickly prime the system and the engine should start NOTE The cartridge contains fuel Take care not 10 spill it during disassembl Peiform the PRIMING TIlE FUEL SYSTEM after replacing the spin on Jilt FUEL FILTER TO INJECTORS SPIN ON FUEL FILTER 18 FUEL WATER SEPARATOR A primary fuel filter of the water separating type must be ...

Page 29: ...oper ventilation TO FUEL FILTER FROM FUEL TANK 1L_ CHECK AND CLEAN filTER AT OIL CHANGE TO FUEl FILTER FUEL LIFT PUMPS FROM FUEL TANK 19 If it becomes necessary to bleed air from the system use the following procedure Loosen all the high pressure injector lines not injectors and crank the engine starter motor as fue I spurts from between the nut and the line tighten the injector Jines in sequence ...

Page 30: ...m Checking for Proper Voltage If you suspect the alternator has failed perform the following tests with the engine off 1 Using a voltmeter connect the voltmeter red wire clip to the output terminal B 2 Connect the voltmeter negative wire to any ground on the engine 3 Check the battery voltage It should read 12 to 12 volts 4 Check the voltage between the alternator positive ter minai B and any engi...

Page 31: ...roper lcvel o Make certain that battery cable connections are clean and tight to the battery posts and to your engine o Keep your batteries clean and free of corrosion 21 A WARNING Sulfuric acid in lead batteries can cause severe burns on skin and damage clothing Wear protective gear A CAUTION When quick charging the battery with an external charger be sure to disconnect the battery cables from th...

Page 32: ...l and the Admiral Panel NOTE AN ON OFF SWITCH SHOULD BE INSTALLED BE1WEEN THE BATIERY AND STARTER TO DISCON NECT THE BATIERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH WITH ACONTINUOUS RAT ING OF 175 AMPS AT 12 vae WILL SERVE THIS FUNCTION THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT 9 rlHi iIlH I 1 11 ADMIRAL PANEL CAPTAIN PANEL I 1 ____ 1 ___ g ll 22 ...

Page 33: ...T Qf CAPTAIN PANEL till Rw 51 AMP AI JEBNATOR oPRESTO ITF Af P AI T SHWPARD ALTERNA10 ON TN 3 a 3C 0 liB l l _ 315 Ii _________________ loeB i _ t He n r M T o IN I VERSAI ON 0 0 PRESTO I TF o i AMP AI OPT I aNAl AI HENAIORS A to A Too r v J xu g n u rIARo 23 ...

Page 34: ...ession stroke Each cylinder is adjusted following the engine s firing order 24 Firing Orders 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 Watch for the intake valve to open indicating the piston is on its intake stroke the piston is moving down in the cylinder Contin...

Page 35: ...engine s return Instal the remote expansion lank in a con venient location so the fresh water coolant level can easily be checked The remote expansion lank will now serve as a check and system fill point The plastic coolant recovery lank is not used when the remote expansion lank kit is installed since this tank serves the same function y HEATER ABOVE THE ENGINE REMOTE EXPANSION l TANK j 1 I t WAT...

Page 36: ...enoid and connection to engine ground stud Check battery cable connections 5 Check solenoid 1 Check connection at solenoid 2 Check switch with ohmmeter J Check that 12 volts are present at starter solenoid activation connection 4 Check connection to starter solenoid and connectIOn to engine ground stud Check battery cable connections 5 Check battery charge state 1 Check that fuel valves are open 2...

Page 37: ...ery 1 Broken or loose belt at raw water pump 2 Raw water pump failure Check impeller replace 2a Obstruction at raw water intake or raw water filter 2b Thermostat remove and test in hot water Replace thermostat 2c Loss of coolant check hoses hose clamps drain plug etc for leaks 2d Broken or loose belts tighten replace 2e Air leak in system run engine and open cooling system petcocks heat exchanger ...

Page 38: ... ground 2 Check the wiring Insert sensitive 0 25 amp meter in battery 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 riuse to locate the fault 4 Faulty alternator 4 After a good battery charging disconnect alternator at output If leakage stops Remove alternator and benck test Repair or replace TROUBL...

Page 39: ...ration access hole No results repair or replace meter h AC voltage not present check for proper alternator DC output voltage c Check for AC voltage at tach terminal on alternator to ground d Check electrical connections from tach inp terminal to alternator connection Tachometer Sticking a Check for proper AC voltage between tach inp tenninal and terminal h Check for good ground connection between ...

Page 40: ... neutral pOSition the propeller flOW at idle can free wheel without causing any problem 30 Locking the Prop 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 A WARNING 00 not start the engine with the transmission in ...

Page 41: ...ry 250 operating hours or at least once a year or when you change engine oiL When changing the fluid also check the gearbox cooling device and clean or replace it as necessary NOTE When changing the fluid take care flot to lose the drain plug sealing H Qsher The drain plug will leak without rhis sealing washel 31 Checking the Bowden Cable or Rod Linkage The Bowden cable or rod linkage should be ch...

Page 42: ...ect amount of oil for your engine model Refer to the SPECIFICATIONS section of this manual Usc an oil with an API specification of CF or CG4 or better 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 32 A CAUTION 00 not leave the engine s old engine oil in the sump over the ...

Page 43: ...ions remove the batteries and store them in a warmer more compatible envi ronment A WARNING Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or lighted tobacco products Do not smoke or allow an open flame near the battery being serviced Shut offall electrical equipment in the vicinity to pre vent electrical arcing during servicing Wear rubber glove...

Page 44: ...m 76 x 70 mm spherical type three vortex combustion system 38 9 C 1 57 C I 75 5 C I 23 1 21 1 21 1 1 2 3 1 2 3 1 3 4 2 SAE 30 lOW 30 or lOW 40 Above CF or CG 4 Grade 0057 to 007 0 14 to 0 18 mm 3 20ts 3L 4 3 Ots 4L 5 Ots 4 7L HBW 50 HBW 50 HBW l00 Dexron II or Dexron III 2351bs l06kg 285 Ibs 129kg 335 Ibs 152kg No 2 Diesel Oil cetane rating of 45 or higher 30ts 2 8L 5Ots 4 7L 5 Ots 4 7L Freshwater...

Page 45: ...3 6 mm Spherical type three vortex combustion system 43 89 C 1 61 08 C 1 81 45 C 1 23 1 23 1 23 1 1 2 3 1 2 3 1 3 4 2 005 to 007 10 14 to 0 18 mm SAE 30 1OW 30 or 1OW 40 Above CF Or CG 4 Grade 4 0 Ots 3 8L 4 0 Ots 3 8L 5 44 Qts 5 1L HBW 50 HBW 50 HBW 100 Dexron II or Dexron III 2411bs 110kg 295 Ibsl134kg 352 Ibs 159kg No 2 Diesel Oil cetane rating of 45 or higher 3 75 Qts 3 5L 4 Ots 3 8L 6 Ots 5 6...

Page 46: ...HANGER ZINC TRANSMISSION SHIFT LEVER OIL PRESSURE SENDER MANIFOLD CONNECTION LEFT SIDE TIMING MARK THROTTLE CONTROL LOCATION BRACKET FUEL FILTER REAR LEFT SIDE 36 1 0 NAME PLATE REAR FRONT HEAT EXCHANGER TRANSMISSION CONTROL BRACKET TRANSMISSION SHAFT COUPLING FILL THERMOSTAT HOUSING FUEL INJECTION PUMP FRESHWATER PUMP RAW WATER PUMP STOP AND THROTTLE CONTROLS COOLANT DRAIN OIL DRAIN HOUSE FLEXIBL...

Page 47: ...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 POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0 454 6 2 722 1 2 205 6 13 228 2 0 907 7 i 3 175 2 4 409 7 15 432 3 1 361 8 3 629 3 I 6 614 ...

Page 48: ...lt head nut Grade 5 Cap Screw 1 4 UNC 1 4 UNF 5116 UNC 5116 UNF 3 8 UNC 3 8 UNF 7 16 UNC 7116 UNF 1 2 UNC 1 2 UNF 1 25 1 25 1 5 1 25 ISO 1 5 1 75 1 5 1 5 2 1 5 2 1 25 1 25 1 5 1 25 ISO 1 5 1 75 1 25 1 25 1 5 1 25 ISO 1 5 1 75 1 5 1 5 2 1 5 2 38 Ib ft kg m 2 9 5 1 0 4 0 7 7 2 11 6 1 0 1 6 13 7 22 4 1 9 3 1 130 21 7 1 8 3 0 25 3 39 8 3 5 5 5 25 3 39 8 3 5 5 5 21 7 36 2 3 0 5 0 32 5 50 6 4 5 7 0 36 2...

Page 49: ...S KITS UNIVERSAL also offers two Spare Parts Kits cach packaged in a rugged hinged tool box Kit A includes the basic spares Kit B is more extensive for off shore cruising 39 THERMOSTAT and GASKET Carry a spare for extended cruising RAW WATER IMPELLER Check once a year ZINC ANODES O d DRIVE BELTS Cheek weekly f Mg Pil itlii and proper tension BKit Impeller Kit Oil Filter Water Pump Repair Kit Zinc ...

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Page 52: ...WESTERBEKE CORPORATION AVON INOUSTRIAL PARK AVON MA 02322 TEL 508 588 7700 FAX 508 559 9323 ...