Universal M-25XPB(C) User manual

OPERATORS MANUAL
4.Unlvarsal
-
· 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 Parle
150 John Hancock Road- Taunton, MA 02780-7319 U.S.A.
Website: www.westerbeke.com
JS!j Member National Marine Mamifacturen Association

A 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
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until
it has been inspected and repaired.
A WARNING DECAL Is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters ofyoui vessel.
They are inexpensive and easily
·WARN IN G· obtainable at your local marine store.
. Engfrles Produce CARBON MONOXIDE .
Regular Maintenance Required
f'W./'fP'S!BeiCl!
-·-
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline 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
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions existand
take the necessary precautions to protectyourself, your
peJ:sonne4 andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PRMNT ELECTRIC SHOCK
A WARNING: Do not touch AC electricaf connections
while engine Is running. Lethal voltage is present at
these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut off electrical power before accessing electrical
equipment. ·
•
Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment. ·
PREVENT BURNS - HOT ENGINE
A WARNING: 011 n11t flluch hot engine parts 11r
exhaust system c11mponents. A running engine gets
veryhotl
• Monitor engine ani:i.freezP/coolantieveht the plaStic
coolant recovet}l ·tartk andPeriodicaly at the filler cap
location on the water jacketed ~J.Ihaustmiinifold~ but t)nly
when the engine iS COLD; · · · .. ·.
AWARNINll: S~Hm:can,l:at~Se,:JnJiiry"or deSthi
,':' ... ... .-.·.,: .... _.,.;,. ··-··' ·......
• l1'1 case of an tmgine twerhe&.t, ·anow the engm¢ to cool
before touching the ~ngine or cbeeklrig the cobiant
i
PREVENT BURNS -FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or pennit flames or
sparks to occur near the fuel injector, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
. removing the fuel lines or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames orsparks to occur near.
the fuel sysfe~. J(eep t11e compartment 8lld the
.
et~.gine 'clean and free of debris to minimize the
chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
fnjury.or de;#/.1!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor refore running
the blciwer. Run the blower per four minutes before starting
your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out ofthe reach ofchildren.
• Do not fill the fuel tank(s) while the ,engine while it is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources offire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
·• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• Make sure a fire extinguisher is-installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for
all applications encountered in this environment.
I
I

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
w Thin OFF the DC breaker on the control panel or turn the
unit's battery selector switch to
OFF before servicing the
engine.
• Make certain.all personnel are clear of the engine before
starting. _
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lea~ acid batteries ~mi! hydrogen, ~
highly explosive gas, which can be 1gmted by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~tncal
equipment in the vicinity to prevent electncal arcmg
during servicing.
• Never connect the negative(-) battery cable to the
positive (
+) connection terminal of the starter solenoi~.
Do not test the battery condition by shorting the termmals
together. Sparks could ignite batt~ry gases o~ fuel vapors.
Ventilate any compartment contammg battenes to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion.
Remo~e
wristwatch, rings, and any otherjewelry before handlmg
the battery.
• Always tum the battery charger offbefore .disconnecting
the battery connections. Remove the negative lead first
and reconnect it lastwhen servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain
sulfuri~ acid whic~ is ·
destructive. If it comes in contact wtth your skin, wash
it offat once with water. Acid may splash on the skin
or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• 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 manifold/
water-injected elbow is securely attached.
11 Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set
or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder
or dealer for installation of approved
detectors.
• For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
·A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu·like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration
of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow
of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some
of the
symptoms
or signs of carbon monoxide inhalation or
poisoning are:
Vomiting·
Dizziness
Headache
Inability to think coherently
Throbbing in temples
Muscular twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: 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 operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
,..., ... Unlvanal
52 M·
1
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1
59:t;•
ii

SAFETY INSTRUCTI·ONS
• Do not wear loose clothing orjewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces orbracelets that could be caught in
.
moving parts.
• Make sure all attaching hardware is properly tightened.
Kf!ep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
. the engine is operating.
• Stay clear of the drive shaft and the transmission t:oupling
when the engine is running; hair and clothing can easily
be caught in tliese rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss/
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR 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.
Sections of the ABYC standards ofparticular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion ofExhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-11 AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
. INSTALLING MARINE ENGINES AND GENERATORS
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 Standartls for Small Craft" ·
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
- ( 41 0) 990-4460
·
www.abycinc.~rg
NFPA (National Frre Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CPR 33 AND CFR46"
Code of Federal Regulations
Order From:
U.S. Government Printing Office
Washington, D.C. 20404

.INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid
to the following information:
CODES AND REGULATIONS .
Strict federal regulations, ABYC 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
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of20" above the vessel's waterline. Failure to use a siphon-break'when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt aboutthe positi9n ofthe water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siplton-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can· result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaus·t system's hose MIJST:o~·celtified for marine use. Con11gated Marine
Exhaust Hose is recommended:. The use of this type ofhose a,llows for extreme bends
and turns withoutthe ne~d of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length ofcorrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of wat~r into the exhaust system
under any sea conditions and at any angle of vessels heal.
A detailed Marine Installation Manual covering g;~soline and diesel
engines and generators is supplied with every unit sold. This manual
.is also available in pdf format on our website to download
Website: www.westerbeke.com
~Univcarsal
2& M·l;l1~1JA•£t'13;W
.
IV
AVAILABLE FROM
YOUR. WESTERBEKE
DEALER
SIPHON-BREAK WITH STAINLESS
LOOP FOR 1" HOSE .
PART NO. 044010

TABLE OF CONTENTS
Parts Identification ................................................ 2 Wiring Schematic (Catalina) .............................. 26
lntroduction ............................................................. 3
Engine Adjustments ............................................. 27
Warranty Procedures.........................................3 Throttle and Stop Assembly...........................27
Serial Number Location .................................. .4
Valve Clearance .............................................27
Admiral Control Panel ............ ............................. 5 Testing Oil Pressure........................................28
Captain Control Panel .................. ....................... 6
Diesel Fuel, Engine Oil and Engine Coolant.. ..... ?
Preparations for Initial Start-Up ...................... ... 8
Starting/Stopping Procedure ............................... 9
Fuel Injectors..................................................28
Engine Troubleshooting (Chart) ........................ 29
Control Panel Troubleshooting (Chart) ............ .31
Troubleshooting Water Temperature.............
.31
Troubleshooting Oil Pressure Gauges............ 31
Break-In Procedure ........................................... 10
Tachometer Troubleshooting ............................ 32
The Daily Routine .............................................. 11
Water Heater ..................................................... 33
Alarms and Circuit Breakers ..........................
11
PRM Transmission ............................................ . 34
Maintenance Schedule ..................................... 12 Changing the Fluid.........................................34
Engine Cooling Circuit ...................................... 14 Gear Shifting ..................................................34
Raw Water Pump............................................
15
Changing the Raw Water Impeller................. 15
Raw Water Intake Strainer..............................16
Daily Operation ..............................................35
Control Cables................................................35
Maintenance....................................................35
Thermostat......................................................16
Transmission Troubleshooting (Chart) .............. 36
Heat Exchanger ..............................................16
HBW Transmission ........................ ..................... 37
Engine Oil Change ............................................. 17
Shaft Couplings ..............................................37
Remote Oil Filter ............................................... 18
Shift Lever......................................................37
Fuel System ....................................................... 19
Air Cleaner/Silencer.......................................19
Priming the Fuel Pump...................................19
Fuel Lift Pump................................................19
Fuel Filters......................................................
20
DC Electrical System ........................................ . 21
Drive BeltAdjustment.................................... 21
Battery Care.................................................... 21
Glow Plugs ..................................................... 21
Fluid Change ..................................................38
Specifications..................................................38
Operating Temperature...................................39
Transmission Cooler.......................................39
Maintenance....................................................39
Transmission Troubleshooting (Chart) ............. .40
Control Cables............................................... .40
Lay-up and Recommissioning .......................... .42
Specifications ................................................... 44
Alternator Troubleshooting ............................ 22
Spare Parts ........................................................ 45
Wiring Diagram ................................................ .. 23
Standard Hardware Torques .............................. 46
Wiring Schematic .............................................. 24
Metric Conversions Chart ................................ .4 7
Wiring Diagram (Catalina) .................................. 25

HEAT
EXCHANGER----'->~
TRANSMISSION
CONTROL
BRACKET
REAR
TRANSMISSION
FLUID DRAIN
PREHEAT
SOLENOID
REAR
MANIFOLD PRESSURE CAP
!COOLANT FILL]
PARTS IDENTIFICATION
OIL FILL
WATER
TEMPERATURE
SEND OR
INJECTION PUMP
ZINC
RIGHT SIDE
COOLANT PUMP SHEAVE
OIL FILL
RAW WATER
PUMP
~~~~~~~~~~£;::.~~~b.::-:__COOLANT
DRAIN
FUEL FILTER
ALTERNATOR
M-50BILLUSTRATED
OIL FILTER
FRONT
COOLANT
DRAIN
FLEXIBLE
MOUNT
,.,
4
Unlvarsal
56 M·1;1@!M•'W3;W
2
FLEXIBLE
MOUNT
M·40BILLUSTRATED
'AIR FILTER
SILENCER
MANIFOLD
PRESSURE CAP
OIL PAN
COOLANT
DRAIN
MANIFOLD PRESSURE CAP
!COOLANT FILL]
ALTERNATOR
MANIFOLD
I.D. NAME PLATE
LEFT SIDE
START
MOTOR
OIL DRAIN HOSE

INTRODUCTION
These new high performance UNIVERSAL marine diesel
engines are a product of UNIVERSALIWESTERBEKE'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.
In order to get the full use and benefit from your engine, it is
important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout.
An extensive network of UNIVERSAL
WESTERBEKE distributors, dealers and service centers are
available worldwide. Should your engine require servicing,
contact your nearest dealer for assistance.
This is
your Operators Manual. A Parts List is also
provided
and a Service Manual is available from your
Universal Dealer or in pdf form off our website. If you ts
are planning to install this equipment, reference the
Installation
Manual supplied with the unit.
WARRANTY PROCEDURES
Your UNIVERSALWarranty is included in a separate folder.
If you have not received a customer identification card regis-
tering your warranty 60 days after submitting the warranty
registration form, please contact the factory in writing with
model information, including the unit's serial number and
commission date.
Unlvarsal
Customer Identification
UNIVERSAL OWNER
MAIN STREET
HOMETOWN, USA
Model M-358
Expires.7/20/2000
Ser. #6C442E711
TYPICAL CUSTOMER IDENTIFICATION CARD
Your UNIVERSAL Warranty Statement is included in the
product documentation package. There is a Warranty
Registration Card you can fill out and mail to Westerbeke
Corporation
or go to our website: www.westerbeke.com and
register your products warranty on line. You should receive
a CustomerIdentification card in the mail within 60 days of
registering. If you do not, please contact the factory and have
your model number, serial number and in service date
available.
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures and
catalogs) provided from sources other than UNIVERSAL are not
within UNIVERSAL'S CONTROL.
UNIVERSAL CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH
OR ARISING OUT
OF THE FURNISHING OR USE OF SPCH SOFTWARE.
UNIVERSAL customers should also keep in mind the time
span between printings
of UNIVERSAL product software
and the unavoidable existence
of earlier UNIVERSAL
manuals. In summation, product software provided with
UNIVERSAL products, whether from UNIVERSAL or other
suppliers, must not and cannot be relied upon exclusively as
the definitive authority on the respective product. It not only
makes good sense but is imperative that appropriate repre-
sentatives of UNIVERSAL or the supplier in question be
consulted to determine the accuracy and currentness
of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
Nnlvarsal
* Ml;!IIIJ#•I119;W
3

INTRODUCTION
SERIAL NUMBER LOCATION
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. This will provide a quick
reference when seeking technical information and/or ordering
parts.
SEA. NO.
Fili in the. informationfor your rejer(mce. · /lJJ
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged
above a closed crankcase; the crankshaft is of
the same general type as that of a gasoline engine, and the
diesel engine has the same types ofvalves, camshaft, pistons,
connecting rods and lubricating system.
To a great extent, a diesel engine requires the same preven-
tive maintenance as a gasoline engine. Most important are
proper ventilation and proper maintenance
of the fuel, lubri-
cating and cooling systems. Replacement
of fuel and lubri-
cating filter elements at the time periods specified and
frequent checking for contamination (water, sediment, etc.) in
the fuel
~ystem are essential. Also important is the consistent
use of a brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine, how-
ever, in its method ofhandling and firing offuel. The carbu-
retor and ignition systems are done
away with and in their
place
is a single component (the fuel injection pump) which
performs the function ofboth.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model number and engine serial number
as 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
insist upon UNIVERSAIJWES1ERBEKE packaged parts
because will fit or generic parts are frequently not made
to
the same specifications as original equipment.
SPARES AND ACCESSORIES.
. Certain spares will be needed to support and maintain
your UNIVERSAL marine engine.
Your UNIVERSAl)
WES1ERBEKE dealer will assist
you in preparing an on
board inventory
of spare parts. See the UNIVERSAL SPARE
PARTS page in this manual for a suggested list.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a UNIVERSAL diesel engine capable
of
many thousands of hours of dependable service. However the
manufacturer cannot control how orwhere the engine is
installed in the vessel or the manner in which the unit
is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long engine life:
0 Proper engine installation and alignment.
0 An efficient well-designed exhaust system that includes
an anti-siphon break
to prevent water from entering the
engine.
0 Changing the engine oil and oil filters every 100 operating
hours.
0 Proper maintenance of all engine components according
to the maintenance schedule in this manual.
0 Use clean, filtered diesel fuel.
0 Winterize your engine according to the LAY-UPAND
RECOMMISSIONING section in this manual.

ADMIRAL CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch and RPM gauge with an ELAPSED TIME
meter which measures the engine's running time in hours and
in 1110 hours. The panel also includes a WATER TEMPER-
ATURE gauge which indicates water temperature in degrees
Fahrenheit, an OIL PRESSURE gauge which measures the
engine's
oil pressure in pounds per square inch, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem's voltage. All gauges are illuminated when the key
switch is turned on and remain illuminated while the engine
is in operation. The .panel also contains two rubber-booted
pushbuttons, gne for PREHEAT and one for START.
RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OFTHE PANEL.
HOURMETER:
REGISTERS ELAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
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(77"- 88"C).
PREHEAT BUTTON: DEPRESSED, IT CLOSES ·
When the engine is shut down with the key switch turned off,
the water temperature gauge will continue to register the last
temperature reading indicated by the gauge before electrical
power was turned off The oil pressure gauge will fall to zero
when the key switch is turned off The temperature gauge
will once again register the engine's true temperature when ·
electrical po"";"er is restored to the gauge.
A separate alarm buzzer with harness is supplied with every
Admiral Panel The installer is responsible for electrically con-
necti~g the buzzer to the four-pin connection on the engine's
.. electncal harness. The installer is also responsible for installing
the buzzer in a location where it will be dry and where it will
be audible to the operator should it sound while the engine is
running. The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engine's oil pressure rises above 15 psi (1.1 kg/cm
2
).
OIL PRESSURE GAUGE: THIS GAUGE IS GRADU-
ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
ILLUMINATED WHILE THE KEY SWITCH IS TURNED
ON. THE ENGINE'S NORMAL OPERATING OIL
PRESSURE RANGES BETWEEN 30- 60 psi
(2.1-4.2 kg/cm
2
).
SWITCH: THE KEY
SWITCH WHEN TURNED
ON SUPPLIES DC POWER
TO THE INSTRUMENT
PANEL CLUSTER, PREHEAT
SWITCH, EXCITATION
TERMINAL OF THE DC
CHARGING ALTERNATOR
AND TO THE ALARM
BUZZER ENERGIZING IT IN
A PULSING MODE.
I
• DC VOLTMETER:
INDICATES THE AMOUNT THE
.BAmFW IS BEING CHARGED.
SHOULD SHOW 13VTO 14V.
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON
THE PREHEAT SOLENOID ALSO RECEIVES POWER AND
THIS IS TRANSMITTED TO THE ELECTRIC FUEL PUMP. .
DC POWER IS ALSO TRANSMITTED TO THE START
BUTTON.
AUTOMATIC ALARM SYSTEM
'
,'/.
·. ·--~····' COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
"/~ SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
REACHES 210" F (99"C), THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.
THIS BUTTON WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD
AT THE SAME TIME.
5
OIL PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
FALL TO 10-5 psi (0.7- 0.4 kg/em'), THE SWITCH WLL(OPEIN: 'SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PIJl.SATJNG
SIGNAL.

CAPTAIN CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch, an RPM gauge, PREHEAT and START but-
tons, an INSTRUMENTTEST button and three indicator
lamps,
one for AL1ERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for highENGINE COOLANT
TEMPERATURE.
RPM GAUGE: REGISTERS REVOLUTIONS
PER MINUTE OFTHE ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OF THE PANEL.
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME
TIME.
The panel also includes an alarm buzzer for low on.
PRESSURE or high COOLANT TEMPERATURE. The
RPM gauge is illuminated when the KEY switch is turned on
and remains illmninated while the engine is in operation.
ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE FALLS
BELOW 10- 5 psi (0.7 - 0.4 kg/em"). IN THIS EVENT, THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER. COOLING CIRCUIT RISES TO
210"F (99"C). IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
PRESSURE REACHES 15 psi (1.1 kg/em"), THE ALARM WILL SILENCE.
TEST BunDN: WHEN
PRESSED, TESTS THE
ALTERNATOR, THE OIL
PRESSURE, AND THE
COOLANT TEMPERA-
TURE CONTROL CIR-
CUITS. WHEN PRESSED,
THE ALTERNATOR, THE
OIL PRESSURE, AND
THE WATER TEMPERA-
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND-
ING THE ALARM
BUZZER..
~-----~~swrr~:THEKEY
SWITCH WHEN TURNED ON
SUPPLIES DC POWER TO THE
INSTRUMENT PANEL
CWSTER, PREHEAT SWITCH,
EXCITATION TERMINAL OF THE
DC CHARGING ALTERNATOR
AND TO THE ALARM BUZZER
ENERGIZING IT IN A PULSING
MODE.
BUTTON: WHEN DEPRESSED, IT CLOSES
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON THE
PREHEAT SOLENOID ALSO RECEIVES POWER AND THIS IS
TRANSMITTED TO THE ELECTRIC FUEL PUMP. DC POWER
IS ALSO TRANSMITTED TO THE START BUTTON.
4 4
Unlvarsal
£6 mN;!I§Ij#•M!;M
6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use a diesel fuel that meets the requirements ofNo.2-D SAE
J 313 and has a Cetane rating of #45 or higher. Grade of
diesel fuel according to ASTM D975.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished parts. It
is important to buy clean f
fuel, and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling
or improper storage
facilities.
To assure that the fuel going into the tank for your
engine's daily use is clean and pure, the following practice
is
advisable:
Purchase a well-known brand
of fuel.
Install and regularly service a good, visual-type filter/water
separator between the fuel tank and the engine. Raycor 230
or 245 are good examples
of such a filter. Micron filter rating
of #10 is recommended.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF,
CG-4, CH-4 or CI-4. Change the engine oil and filter after
the initial 50 hours
of break-in operation. Then follow the oil
and filter change intervals as specified in the
MAINTENANCE SCHEDULE in this manual.
Westerbeke Corporation does not approve or disapprove
the use
of synthetic oils. If synthetic oils are used, engine
break-in must be performed using conventional oil. Oil
change intervals must be as listed in the MAINTENANCE
SCHEDULE section in this manual and not be extended
if
synthetic oils are used.
NOTE: The infomwtion above supersedes all statements
regarding synthetic oil.
For recommended oil viscosity, see the following chart:
Operating Temperature Oil Viscosity
Above 68°F (20°C)
SAE lOW-40 or 15W-40
41 °-68°F (5-20°C)
SAE lOW-40 or 15W-40
Below 41°F (5°C)
SAE lOW-40 or 15W-40
ENGINE COOLANT
UNIVERSAL recommends a mixture of 50% antifreeze and
50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty.
It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Look for the new environmentallyjriendly long lasting
antifreeze that is now available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial to the engine's cooling system. They
retard rust and add to the life
of the circulating pump seal.
ANTIFREEZE PROTECTION
Antifreeze concentration
Freezing Temperature
23%
14oF
(-5°C)
COOLANT RECOVERY TANK
30% 35% 50%
A coolant recovery tank kit is supplied with each
UNIVERSAL diesel engine. The purpose of this recovery
tank
is to allow for engine coolant expansion and contraction
during engine operation, without the loss
of coolant and
without introducing air into the cooling system.
COOLANT RECOVERY TANK
~ ,.,Unlvarsal
£6 &f.1;11S!JQ•i'tj3;M
7

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff- check the following items.
D Check the engine oil level; add oil to maintain the level at
the high mark on the dipstick.
D Check the DC electrical system. Inspect wire connections
and battery cable connections.
D Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections.
D Check the fuel supply and examine the fuel filter/separator D Check the coolant level in the plastic recovery
tank and at
the manifold.
bowls for contaminants.
D Check the transmission fluid level.
NOTE: Referto the specificationspages in this manual for
fuel, oi~ and transmission types and quantities.
COOLANT
RECOVERY
TANK
NOTE: If the engine has not yet beenfilled with coolant, refer
to the ENGINE COOLING CIRCUIT section
of this manual.
MANIFOLD
MANIFOLD
(M-358 SHOWN)
~
8

STARTING/STOPPING PROCEDURE
STARTING PROCEDURE
Place the transmission in neutral and advance the throttle
control to slightly open.
A CAUTION: Make certain the transmission is in
neutral. Starting in gear could result in serious damage
to your transmission, your boat, and vessels nearby.
Thrn the KEY SWITCH to the ON position (2 o'clock)
PREHEAT: Depress the PREHEAT switch. The voltmeter,
panel lights, gauges and meters, and fuel solenoid will be
activated. The PREHEAT switch should be depressed in
accordance with the following chart:
Temperature/Preheat
Atmospheric Temperature Preheating Time
¥WF(+5°C) or hig~er Approx. 10 seconds
+41°F(+5°C) to 23°F (-5°C)
Approx. 15 seconds
+23°F(-5°C) or lower
Approx. 20 seconds
Limit of continuous use 30 seconds before cranking
START: While still depressing the PREHEAT switch, depress
the START switch. This will engage the start solenoid. Upon
engine starting, release the START switch. Do not release the
PREHEAT switch until the oil pressure reaches
15 psi.
NOTE: When starting:
A voltage
drop will occur'
when the preheat switch
is depressed.
VOLTAGE
DROP
Should the engine not start when the START switch is
depressed for 10 to
20 seconds, release both switches and
wait 30 seconds; repeat the procedure above and
prehe~t
longer. Never run the starter for more than 30 seconds.
9
AcAUTION: Prolonged cranking intervals without the
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
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust sPfem 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 cranlcing.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind.
Once the engine starts, check instruments for proper oil
pressure and battery charging voltage.
NOTE: Never attempt to engage the starter while the engine is
running.
NOTE: Some unstable running may occur in a cold engine.
Depressing the Preheat switchfor 10-15 second intervals
will help stabilize the engine RPM until the operating
temperature reaches 150°- 170°F (60°- 77°C) and a
propeller load
is applied to the engine. When the engine is
running and the PREHEATswitch is depressed, a charging
load on the DCalternator will be discernible.
STARTING UNDER COLD CONDITIONS
Make certain the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table on the engine oil
~ction of this manual.
The battery should
be fully charged to minimize voltage
drep.
Use a sufficient amount
of preheat to aid in starting, see
Temperature/Preheat chart elsewhere in this section.
STOPPING PROCEDURE
To stop the engine, bring the throttle to an idle position and
place the transmission in neutral. Allow the engine to idle for
a few moments
to stabilize temperatures. Pull the STOP lever
to shut down the engine. Onee the engine stops, return the
l~ver to the runposition. Then turn OFF panel key switch.
Made certain the key switch is in the OFF position
(
12 o'clock). 1f the Key _Switch}!tkft-QN, the battery wfll
discharge. An engine alarm buzzer iso.providedro·wam the
operator of this condition (Key Switch ON). The best method
of preventing the batteryfrom discharge is to remOve the key
from the Key Switch after stopping the engine. (The extra key
should be stowed in a safe place).

BREAK-IN PROCEDURE
THE FIRST 50 HOURS
Although your engine has experienced a minimum of one
hour
of test operations to ensure accurate assembly and
proper operation
of all systems, break-in time is required.
The service life of your engine is dependent upon how the
engine is operated and serviced during its initial
50 hours of
use.
Your new engine requires approximately 50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life of the engine.
Perform this conditioning carefully, keeping in mind the
following:
1. Start the engine according to the Starting Procedure
section in this manual; run the engine at fast idle while
checking that all systems (raw water pump, oil pressure,
battery charging) are functioning.
2. Allow the engine to warm up (preferably by running at fast
idle) until the water temperature gauge moves into the
130°-140°F range.
3. While using the vessel, run the engine at varying engine
rpms for the first 25 hours.
4. Avoid rapid acceleration, especially with a cold engine.
5. Use caution not to overload the engine. The presence
of a
gray or black exhaust, and the inability
of the engine to
reach its full rated rpm, are 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.
10
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. This cannot be accomplished
by long periods
of running at idle, nor by early running at full
rpm. Idle running may glaze the cylinder 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. Operate the engine in moderation during the 50-hour
break-in period. (Don't baby the engine, but do not abuse it.)
RECOMMENDED RPM RANGES
MODEL
IDLE CRUISE
MAXIMUM
RPM
RPM RPM
M3-20B 1000-1200
2500-3000 3500- 3600
M25XPB
1000-1200 2000-2500 2900- 3000
M358 800-1000 2000-2500
2900-3000
M408 800-1000 2000-2500 2900-3000
M50B 800-1000
2000-2500 2700-2800
NOTE: Attempting to reduce idle speed below the minimum
shown
may produce unstable engine operation and stalling.
NOTE: The propeller should be either 2 or3 blade. It should
allow
the engine to reach its maximum rated rpm atfull open
throttle underway in forward gear to ensure the availability of
rated horsepower when needed.
NOTE: See the TRANSMISSION section ofthis manualfor
break-in information
on your transmission.

THE DAILY ROUTINE
CHECK LIST
Each day before starting your engine, take a few moments to
run this check list:
D Visually inspect the engine for fuel, oil, coolant and
exhaust leaks.
D Check the oil level.
D Check the transmission fluid level.
D Check for loose wires at the alternator.
D Check for loose wires and electrical connections at the
DC alternator and elsewhere on the engine's DC harness.
D Check the starting batteries level (weekly)
D Check drive belts for wear and proper tension (weekly).
D Log your engine running time. These hours relate to
scheduled_maintenance.
D Check fuel supply; always keep fuel tank(s) as full as
possible.
D Look for clean fuel in the fueVwater separator bowl.
.D Check the coolant level in the plastic recovery tank.
D Check for any obviously loose components or nuts or
bolts.
NOTE: Excessive loss of coolant indicates a cooling system
leak. Check the entire system. If necessary, use a cooling sys-
tem pressure tester to pressurize the cooling system to locate
the area of leakage. In cases of excessive coolant loss, refill
the system as outlined in the ENGINE COOLING CIRCUIT
section in this manual.
START YOUR ENGINE
NOTE: See STARTING STOPPING PROCEDURE in this
manualfor more detailed· instructions.
1. Put transmission in neutral, throttle advanced.
2.
Tum KEY to the ON position (2 0' clock)
3. Depress PREHEAT (10 to 15 seconds).
4. While pressing PREHEAT, push the START.
As engine fires -release START and PREHEAT.
5. Observe the panel gauges, check the oil pressure, DC
charges, etc. Check for water discharge with the exhaust.
NOTE: Should engine fail to start, wait 30 seconds, repeat the
above procedure, and PREHEAT longer.
6. Allow a few minutes for the engine to warm at a
comfortable high idle (1400- 1500 rpm), then reduce the
rpm to the normal idle position, shift into gear, and get
underway.
A CAUTION: When shifting the transmission,
always reduce the engine rpm to idle, then shift the
transmission firmly from one direction to another. A
slight pause in neutral will allow the propeller to slow.
Shifting at high rpm will damage the
transmission/damper plate.
ALARMS AND CIRCUIT BREAKER
ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive current draw
or electrical overload anywhere in
the instrument panel wiring
or engine wiring will cause the
breaker to trip. In this event most engines will shut down
because the open breaker disconnects the fuel supply.
If
this should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
engine.
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located offthe engine's
oil gallery. This switch's sensor monitors the eugine's oil
pressure. Should the engine's oil pressure fall to 5
-1.Q psi
(0.4 -0.7 kg/cm2 ), this switch will activate a pulsating alarm.
OIL PRESSURE ALARM SWITCH.
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thetmostat .
housing. This switch will activate a continuous
alarm if the
coolant's operating temperature reaches approximately
210"F (99°C).
THERMOSTAT ASSEMBLY
[M·50B SHOWN]
OIL GALLERY
[M-508 SHOWN]
+'
4
Univarsal
aa &f.1;'@1P·NI#i•
'11

MAINTENANCE SCHEDULE
ll 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. When servicing/rep/acing DC components, turn off the DC circuit breaker on the
control panel, or turn off the battery switch.
SCHEDULED MAINTENANCE
I DAILY CHECK BEFORE START-UP
Coolant Level
Engine Oil level
Fuel/Water Separator (owner Installed)
Fuel Supply
VIsual Inspection of Engine
Drive Belts
I INITIAL 50 HOURS OF OPERATION
Engine 011 and Filler
Exhaust System
Engine Throttle, Transmission
and Shutoff Lever Cables
Inlet Fuel Filler
· Fuel Filler
Engine Idle Speed
Transmission Fluid
Heat Exchanger
I EVERY 50 OPERATING HOURS OR MONTHLY
'Drive Belt
(Fresh Water/Raw Water Pumps)
Starling Batteries
··Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Air Intake Filter
Heat Exchanger
Key Switch (Instrument Panel)
Drive Belts
(Fresh Water/Raw Water Pumps as applicable)
Starling Batteries
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water.and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
there is adequate fuel for the vessel's needs.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Inspect for frayed edges. Belts must be properly tensioned
Initial engine oil and filter change at 50 hours then change both every 200 hours oryearly.
Initial check at 50 hours, then every 250 hours or once a year. Carefully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check the integrity/mounting security of the water injected exhaust elbow.
Check all connections are secure, proper travel and lubricate with WD-40.
Initial change, then every 250 hours or once a year.
Initial change, then every 250 hours or once a year.
Refer to Specifications.
Initial change, then at 300 hours or once a season.
Open end caps and clean out debris. Change zinc anode if necessary. Determine zinc service
interval for your. area.
Inspect for proper tension (3/8" to 1/2" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect, no leaks. Connections are clean and tight. Clean/replace filter element if applicable.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Inspect, clean and replace as needed.
Inspect and clean zinc anode. Note the condition, then determine your own schedule. If zinc
anode needs replacing, you should remove the end cap and clean out the debris.
Replace zinc if necessary.
Lubricate with "lockeze".
Inspect for proper tension (3/8" to 1/2" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Electric Fuel Pump Inspect, no leaks. Connections are clean and tight. Clean/replace filter element if applicable.
Raw Water Pump Inspect impeller, check drive shaft security. Inspect there is no shaft water or oil seal leaks.
• Unlvarscil recommends this service be performed by an knowledgeable mechanic .
• • unlvarsctl
MARINE POWER
12
i
.,

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or rec;"ro your eng~ne hours running time.
SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
· Transmission
Engine 011
Fuel Filter and D·Rings
Inlet Fuel Filter
DC Alternator
'Electric Fuel Pump
'Vibration Isolators/Engine Mounts
Heat Exchanger
· Exhaust Elbow/Exhaust System
I EVERY 500 OPERATING HOURS OR YEARLY
*Fuel Injectors
Coolant System
•valve Clearances
•starter Motor
Raw Water Pump
·Preheat Circuit
Engine/ShaH Alignment
Crank Case Vent
EXPLANATION OF SCHEDULED MAINTENANCE
Change fluid at 300 operating hours. Lubricate control cable and check attachment.
Change the engine oil and oil filter (always together) every 200 hours or yearly.
Remove and replace fuel filter and all sealing 0-rings:
Remove and replace inlet fuel filter.
Check mounting bracket, tighten electrical connections.
Inspect, no leaks. Connections are clean and tight. Clean/replace filter element if applicable.
Check vibration isolators, brackets and mounting hardware. Replace as needed.
Inspect zinc anode replace if necessary.
Check the structural integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust system attached to the elbow. All hose connections should be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Check and adjust injection opening pressure and spray conditions.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix.
Adjust valves. (Incorrect valve clearance will result In poor engine performance)
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
Remove from engine, remove cover and inspect cam and wear plate&. Replace any
components showing wear. If needed, replace impeller and gasket.
Lubricate when re-assembling.
Check operation of the pre-heat. Remove and clean the glow plugs. Re-Install with anti-seize
compounds on threads.
Check security of the shaft coupling and check shaft alignment.
Clean crank case vent components located inside the rocker cover.
Replace filter element as needed.
I EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
*Heat Exchanger
• Adjusting the Valve Clearances
*Positive Crankcase Ventilation Valve
*Fuel Injectors
*Transmission 011 Cooler (as applicable)
•starter Motor
*Transmission Damper Plate
Remove the heat exchanger for professional cleaning and pressure testing. Change the
antifreeze and flush the system.
Adjust the valves.
Disassemble and clean. Replace as needed.
Pressure test injectors/re-build at 1500 hours.
Remove and have professionally tested and cleaned.
Remove, clean and lubricate the drive.
Inspect the damper plate, replace if necessary (damper plate chatter at Idle speed Is an
indication of damper spring wear).
NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engine's ability to remain cool
•:lJnlvGnGl recommends this service be performed by an knowledgeable mechanic.

ENGINE COOLING CIRCUIT
DESCRIPTION
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 dis-
placement impeller pump. After
the raw water cools the
engine coolant in the heat exchanger, it mixes with the
engine's
eXhaust gases, cools the exhaust gases, and dis-
charges
overboard.
The engine's coolant is circulated by a belt-driven centrifu-
gal-type
metal impeller pump mounted on the front of the
engine. The engine's coolant temperature is thermostatically
controlled.
The engine's coolant
must be changed according to the main-
tenance schedule· in this manual. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
AcAUTION:· Proper cooling system maintenance is
crif!cal; a substantial-number of engine failures can be
traced back to cooling system corrosion.
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss ofcoolant
and without introducing airinto the cool-
ing system. This tank is best located at or above the engine
manifold
level, and should be easily accessibie.
. .
M-508 COOLANT DRAIN JUST ABOVE
THE RIGHT FRONT ENGINE MOUNT
~
MANIFOLD
MANIFOLD
PRESSURE CAP
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.
· NOTE: The petcock on the heat exchanger can also be used to
help drain engine coolant.
A wARNING: 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 the petcocks on the thennostat housing and heat
exchanger
to help remove airfrom the system. When a steady
flow of coolant appears at the drain plug opening, close the
water drain plug and continue to fill the system until the
manifold remains full. Close 'the petcock on the heat
exchanger
when antifreeze flows from it. ·
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the pressure
cap.The petcock
on the thermostat should also be opened
when refilling to allow trapped air to escape.
Remove the cap on
the coolant recovery tank, fill with
coolant mix
to halfway between LOW and MAX, and
replace the cap. Run
the engine, close all petcocks and
observe the coolant expansion flow into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant shouii draw back into the cooling system
as the
engine cools do·vn. Add coolant to the recovery tank if
needed. Clean
t1P .''lilY spilled coolant.
PRESSURE CAP
NOTE: Periodicq.lly check the condition of the pressure cap.
Ensure that the upper and lower rubber seals are in good
condition and check
that the vacuum valve opens and closes
tightly. Carry a spare cap.