Universal M3-20A User manual

• •
OPERATORS MANUAL
Unlvarsal
MARINE DIESEL ENGINES
M3·20A M3·20B M·25XPA M·25XPB
M·35A M·35B
PUBUCATION 200494
1
ST EDITION I APRIL 1997
I~
WESTERBEKE CORPORATION·AV ON INDUSTRIAL PARK
AVON, MA 02322 • TEL: (508) 588 -n oo • FAX: [phone]
"'~~~
N MMA M ~ mMr N aJ; olllll Marin ~ Manuf octurrrsAssociation
---

OPERATORS MANUAL
Univarsal
MARINE DIESEL ENGINES
M3-20A M3-20B M-25XPA M-25XPB
M-35A M-35B
PUBLICATION 200494
1 ST EDITION I APRIL 1997
I~
WESTERBEKE CORPORATION· AVON INOUSTRIAL PARK
AVON, MA 02322 • TEL: [phone] • FAX: [phone]
.... 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 followjuruiJlmenJal rules and precautions.
Know when dangerous conditions erist and take the
necessary precautionsto protectyourself,
yo ur personnel,
and your machinery.
ThefoUuwing safety instructions are in compliance with
the American Boat and Yacht Council ( ABYC) staruiJlrtis.
PREVENT ELECTRIC SHOCK
A WARNING: Do nat touch AC electrical CI1IIIIIiCtions
nile engine is running, IX nen connected to shore
power. Lethal roltage ispresent at these connections!
• Do not operate this machinery without electrical
enclos ur es 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.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC ge nerator may
result ifthis procedure 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
exhaust system components. A running 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 the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - ARE
IA WARNING: Steam can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor , fuel line, filter, fuel
pump , or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line , carburetor , or fuel filters.
• Do not operate with the Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do n ot operate with the air cieaner / siJencer removed.
Backfire can cause severe injury or death .
• Do not smoke or perm it flames or sparks to occur near the
fuel system. Keep the compartment and the engine/gener-
ator clean and free of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fu el will bum.
PREVENT BURNS - EXPlOSION
A WARNING: Explosions from fuel raptllS can cause
injury Dr death!

SAFETY INSTRUCTIONS
PREVENT BURNS - EXPLOSION (continued)
• 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 start-
ing your engine.
• All fuel vapor.; 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 of the
reach
of children.
• Do not fill the fuel tank(s) while the engine 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 of fire 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 firtings are adequately tightened and
free
of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained.
Be familiar with its proper use.
Extinguisher.; rated ABC by the NFPA are appropriate
for all applications encountered in this environmenL
ACCIDENTAL STARTING
I
A WARNING: Accidetrtal slaTting can cause iajuty
· ar death!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last.
• 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.
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 off all electrical
equipment in the vicinity to prevent electrical arcing during
seJVicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal
of the starter solenoid. Do not
test the battery condition by shorting the terminals
together. Sparks could ignite battery
gases or fuel vapor.;.
Ventilate any compartment containing baneries to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery is
being cbarged.
• Avoid contacting the terminals with tools, etc ., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery cbarger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulphuric acid in batteries can cause
sereTe iajury /If death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron , and eye protec-
tion. Batteries contain sulfuric acid which is destructive. If
it comes in contact with your skin, wash it off at once
with water. Acid may splash on tbe skin or into the eyes
inadvertently when removing electrolyte caps.

SAFETY INSTRUCTIONS
TOXIC EXHAUST GASES
IA WARNING: Cal'llon 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 manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector . Consult your boat
builder or dealer for installation of approved detectors.
• For additional informati on refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odOfless gas_ Inhalation produces flu-like symptDms,
nausea Of death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy coppertubing in exhaust sys-
tems. 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 tbe 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 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
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 operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system compone~ts.
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings , neckJaces or bracelets that could be caught in
moving parts.
• Make sure all attaching hardware is properly tightened.
Keep 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 coupling
when the engine is running ; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
I
A WARNING: High noise /ere/s can cause hearing
· loss!
• Never operate an engine without its muffler installed .
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
OpeD.
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.

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.
Sections
of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations 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 (Na ti onal Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Banerymarch Park
P.O. Box 9101
Quincy. MA 02269-9101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
Washington, D.
C. 20404

TABLE OF CONTENTS
Introduction ....................................................................... 2 Description ............ .......................................20
Warranty Procedures .. __ ............................................ __ .. 2 Alternator Troubleshooting.................................
20
Typical Customer Identification Card..........................2
Checking for Propcr Voltage.............................. .20
Product Software .........._..........._..........._.......................2
Engine 12 Volt DC Control Circuit............................ 21
Notes, Cautions and Warnings .....................................2 Drivc Belt Adjustmcnt ..............................................
.21
Serial Number Location ...............................................3 Battery Care ...............................................................
21
Understanding the Diesel Engine.................................3
Glow Plugs................................................................ 21
Ordering Parts ..............................................................3 Wiring Diagram .............................................................. .22
Spares and Accessories ................................................3
Wiring Schematic ........................................................... 23
Protecting Your Investment..........................................3
Engine Adjustments ...................................................... .24
Admiral Control Panel .................................................... .4 Throttle and Stop Assembly.......................................24
Captain Control Panel .................................................... .5
Diesel Fuel, Engine Dil and Engine Coolant ............... 6
Diesel Fuel ...................................................................6
Valve
Clearance ..........................................................24
Water Heater Connections ............................................ 25
Water Heater Installations ..........................................25
Care
of the Fuel Supply ........................................6
Engine Troubleshooting ................................................ .26
Engine Oil .............................................................6
Control Panel Troubleshooting .................................... 28
Engine Coolant.............................................................6 Manual Starter Disconnect (Toggle Switches) ..........28
Coolant and Recovery Tank.........................................6
Troubleshooting Water Temperature and
Preparations for Initial Start-Up ................................... 7
Prestart Inspection ........................................................7
Oil Pressure Gauges ...................................................28
Tachometer Troubleshooting ........................................ 29
StartingJStopping Procedure .......................................... 8
Starting Procedure ........................................................8
Preheat..........................................................................8
Tachometer/Hourmeter ...............................................29
Hourmeter Inoperative ........................................29
Tachometer Inoperative.......................................29
Start ..............................................................................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 Circuit... ................................................ 13
Description .................................................................13
To Refill With Coolan!........................................
13
Capacity .............................................................. 31
Fluid Change ...................................................... .31
Checking the Bowdin Cable or Rod Linkage..... 31
Thermostat..................................................................14
Propeller Shaft Alignment ................................ .31
To Replace the Thermostat .................................14 Lay-Up/Winterize...............................................
.31
Raw Water Cooling Circuit........................................14
Raw Water
Pump ................................................14
Changing the Raw Water Impeller......................15
Heat Exchanger...................................................
15
Zinc Anode..........................................................15
Engine Oil Change .......................................................... 16
Lay-Up and Recommissioning ...................................... 32
Lay-Up ....................................................................... 32
Propeller Shaft Coupling ............................................32
Fresh Water
Cooling System...................................... 32
Lubrication System ....................................................32
Fuel
System ................................................................ 32
Drain the Sump ..........................................................16 Raw Water Circuit......................................................32
Replacing the Oil Filter.......................................16 Intake Manifold ..........................................................32
Refill the Oil Sump .............................................16 Starter Motor ..............................................................33
Remote Oil Filter ............................................................ 17
Cylinder Lubrication .................................................33
Installation ..................................................................17
Transmission ..............................................................33
Fuel System .................................................................... 18
Fuel Filters ................................................................18
Fuel Water Separator..................................................18
Fuel Additivcs ............................................................19
Spares .........................................................................33
Batteries ......................................................................33
Recommissioning .......................................................33
Specifications ................................................................. 34
Spares .........................................................................19
Parts Identification ....................................................... .36
Primary (Blecding/The Fuel System) ........................19 Metric
Conversions...................................... . ......... 37
Air Cleaner/Silencer............................................19
Standard Hardware Torques ....................... . ......... 3R
DC Electrical System ................................................. 20
Spare Parts ................................................................... .39
1

INTRODUCTION
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.
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!
\VESTERBEKE 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 Catalog is also
provided and a Technical Manual
is available from your
UNIVERSAL dealer. Also, if you are planning to instal! this
equipment, contact your
UNIVERSAL dealer for
UNIVERSAL'S installation manual.
WARRANTY PROCEDURES
Your UNIVERSAL Warranty 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
fonn, please contact the factory in writing with
model information, including the unit's serial number and
commission date.
Customer Identification
UNIVERSAL OWNER
MAIN STREET
HOMETOWN, USA
Model M-35B Sec #XXXX-D704
Expires 7/20/97
TYPICAL CUSTOMER IDENTIFICATION CARD
The UNIVERSAL serial number is an alphanumeric
number that
can assist in determining the date of manufacture
of your
UNIVERSAL 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 CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WlTH 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 SUCH 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
UNNERSAL 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 represen-
tatives
of UNNERSAL or the supplier in question be con-
sulted to
detennine 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,
AWARNING: Procedures, which if not properly fol-
lowed, can result in personal injury or loss of life,

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.
• MODE'- SPEC SER.NO. •
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
of valves, 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 system are essentiaL Also important is the consistent
usc of a brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from
the gasoline engine, how-
ever,
in its method of handling and firing of fuel. The carbu-
retor and ignition systems are done away with and
in their
place
is a single component (the fuel injection pump) which
pcrfonns the function
of both.
3
ORDERING PARTS
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
insist upon UNIVERSAUWESTERBEKE 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 UNIVERSAU
WESTERBEKE 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
or where 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 sleps to ensure long engine bfe:
o Proper engine installation and alignment.
o An efficient well-designed exhaust system that includes
an anti-siphon break
to prevent water from entering the
engine.
o Changing the engine oil and oil filters every JOO operating
hours.
o Proper maintenance of all engine components according
to the maintenance schedule
in this manual.
o Use clean. tiltered diesel fucl.
o Winterize your engine according to the LAY-UP AND
RECOMMISSIONING section in this manual.

ADMIRAL CONTROL PANEL
UNIVERSAL offers two optional panels. Refer to the
instruction page that applies to the panel you purchased.
ADMIRAL PANEL
This manually-operated control panel is equipped with a Key
Switch and
RPM gauge with an ELAPSED TIME metcr
which measures the engine's running time in hours and in
1110 hours. The panel also includes a WATER TEMPERA·
TURE gauge which indicates water temperature in degrees
Fahrenheit, an OIL PRESSURE gauge which measures the
engine'5 oil pressure in
pounds per square inCh, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem'5 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, one for PREHEAT and one for START.
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 elec-
tncal power was turned off. The oil pressure gauge will fall
to zero when the Key Switch is turned oft·.
The temperature
gauge will
once again register the engine's true temperature
when electrical power is restored to the gauge.
A se~aratc alarm buzzer with harness is supplied with every
Admiral Panel.
The installer is responsible for electrically
connecting the
buzzer to the four~pin connection on the
engine's electrical harness.
The installer is also responsible
~or installing the buzzer in a location where it will be dry and
where
it will be audible 10 the operator should it sound while
t~eengin.e is running. The buzzer 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 INCH (PSI) AND IS
ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
OIL PRESSURE RANGES BETWEEN 30·60 PSI
RPM GAUGE: REGIS·
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATEO FOR
ACCURACY FROM THE
REAR Of THE PANEL
HOURMETER:
REGISTERS ElAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
PREHEAT BUTTON: WHEN PRESSED. ENERGIZES THE
ALTERNATOR'S REGUlATOR, THE FUEL LIFT PUMP, THE
fUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS, AND BYPASSES THE I
OIL PRESSURE AlARM SWITCH. IN ADDITION, I
BUDON ENERGIZES THE START BUDON.
START BUTTON: WHEN
STARTER'S SOLENOID I
THIS BUDDN WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUDON IS PRESSED AND HELD
ATTHE SAME TIME.
4
AUTOMATIC ALARM SYSTIM
KEY SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER.
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED
SHOULD SHOW 13V TO 14V.
HIGH WATER TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
SUPPLIED WITH THE INSTRUMENT PANEL If THE ENGINE'S FRESH
WATER COOLANT REACHES 210° f 19BOC), THIS SWITCH WILL CLOSE
SOUNDING THE AlARM WHICH WILL EMIT A
CONTINUOUS SIGNAL.
LOW OtL PRESSURE AlARM: A LOW OIL PRESSURE AlARM SWITCH
IS LOCATED OfF THE ENGINE'S OIL GALLERY THIS SWITCH MONITORS
THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINEiS OIL PRESSURE
FALL TO 5·10 PSI, THE SWITCH WILL CLOSE SOUNDING THE ALARM.
IN THIS EVENT, THE AlARM WILL EMIT A PULSATING SIGNAL

CAPTAIN CONTROL PANEL
CAPTAIN PANEL
This manually~operated control panel is equipped with a Key
Switch, an RPM gauge, PREHEAT and START buttons, an
fNSTRUMENT TEST button and three indicator lamps, one
for ALTERNATOR DISCHARGE, one for low
OlL PRES·
SURE,
RPM GAUGE:
REGISTERS REVOLUTIONS PER
MINUTE Of THE ENGINE AND CAN BE
RECALIBRATED fOR ACCURACY fROM
THE REAR Of THE PANEl.
Oil PRESSURE ALTERNATOR ALARM
ALARM LIGHT LIGHT
WATER TEMPERATURE ALARM
LIGHT
START BUTTON: WHEN PRESSED. ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE THIS
BUTTDN WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME
TIME.
5
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 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 A PULSATING 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 NORMAl. ONCE THE ENGINE STARTS AND THE ENGINE'S
OIL PRESSURE REACHES 15 PSI, THE ALARM WILL SILENCE.
TEST BUTTON: WHEN
PRESSED, TESTS THE
ALTERNATOR. THE OIL
PRESSURE. AND THE
WATER TEMPERATURE
CONTROL CIRCUITS
WHEN PRESSED. THE
ALTERNATOR. THE OIL
PRESSURE, AND THE
WATER TEMPERATURE
INDICATOR LIGHTS
ILLUMINATE IN ADDI·
TION TD SOUNDING
THE ALARM BUZZER
KEY SWITCH:
PROVIDES POWER TO
THE INSTRUMENT
PANEL CLUSTER AND
THE DC ALTERNATOR
REGULATOR TERMINAL.
PREHEAT BUTTON: WHEN PRESSED. ENERGIZES THE fUEL
LIfT PUMP AND THE ENGINE'S GLOW PLUGS. ANa BYPASSES
THE ENGINE'S OIL PRESSURE ALARM SWITCH. IN ADDITION.
THIS BUTTON ENERGIZES THE START BUTTON

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (ASTM), and has a cetane rating of #45 or better.
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 par~
tides which might pass through the filter can damage these
finely finished parts.
It is important to buy clean 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 500
FG or 900 FG is a good example of such a filter.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG4 or better, Change the engine oil after an initial 50
hours of break-in operation, and every 200 hours of operation
thereafter. For recommended oil viscosity, see the following
chart:
Operating Temperature
Oil Viscosity
Above 68"F (2D"C)
SAE 30 or 1 OW-3D
41 "-68"F (5-2D"C) SAE 20 or 1DW-3D
Below 41"F (5"C) SAE 1DW-3D
A CAUTION: 00 not allow two or more brands of
engine oil to mix, Each brand contains its own additives;
additives ofdifferent brands could react 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 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 flew environmenwl(v-jriendiy IOllR la.l'finf!,
antifreeze that is nol1.'· 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 concen1ration
Freezing Temperature
23%
WF
(-5"C)
COOLANT RECOVERY TANK
30%
8"F
(-13"C)
35%
-4"F
(-20"C)
50%
-40"F
(-40"C)
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. This
kit is
provided and must be installed before running the engine.
COOLANT RECOVERY TANK

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.
o Check the engine oil1evel; add oil to maintain the level at
the high mark on the dipstick.
oCheck the fuel supply and examine the fuel filter/separator
bowls for contaminants.
o Check the transmission fluid 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 at
the manifold.
NOTE: If the engine has not yet been filled with coolanT. refer
to the ENGINE COOLING CIRCUIT section of this manual.
_DIPSTICK
MANIFOLD
(M-35B SHOWN)
7

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 neu-
tral. starting in gear could result in serious damage to
your transmission, your boat, and vessels nearby.
Turn the KEY SWlTCH to the ON position (2 o'clock)
PREHEAT: Depress the PREHEAT switch. The voltmeter and
panel lights, gauges and meters will be aClivated. The PRE-
HEAT switch should be depressed in accordance with the
following chart:
TemperatureJPreheat
Abnospheric Temperalure Preheating lime
+41°F(+5°C) or higher Approx. 10 seconds
+4n(+5°C) to 2n (-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 starter solenoid.
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches
15 psi. Then as long as the high water temperature and low
oil pressure protective circuits do not activate, the engine will
remain energized and continue to run.
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 secol!ds, release both switches and
wait 30 seconds; repeat the procedure above and preheat
longer.
Never run the starter lor more than 30 seconds.
8
ACAUTloN: 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 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. 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 starts, check instruments for proper oil pres-
sure 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
switch/or /0-/5 second intervals 'will
help stabilize the engine RPM until the operating tempera-
ture reaches J70o-190°F
(77°_88°C) and a propeller load is
applied to the engine. When the engine i~' running and the
preheat switch is depressed, a charging load on the
DC alter-
nator will
be discernible.
STARTING UNDER COLD CONDITIONS
Make certain the lubricating oil confonns with the ratings for
the prevailing temperature. Check the table on the engine oil
section
of this manual.
The battery should
be fully charged to minimize voltage
drop.
Use a sufficient amount of preheat to aid in starting, see
Temperature/Preheat chart On this page.
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. Then turn OFF the key 10 close
down the electric fuel pump and accessories.
Made certain the key switch
is in the OFF position (12
o'clock). If the Key
Switch is left ON. the battery will diS-
charge. An engine alarm buzzer is provided to warn the oper-
ator
of this condition (Key Switch ON). The best method of
preventing the battery from discharge is to remove the key
from the Key Switch after stopping the engine.

BREAK-IN PROCEDURE
THE FIRST 50 HOURS
Although your engine has experienced a minimum of one
hour of test operations to ensure accurate assemhly and
proper operation
of all systems. hrcak~in lime is required.
The service life of your engine is dependent upon how the
engine is
operated and serviced during its initial 50 hours of
usc.
Your new engine requires approximately 50 hours of initial
conditioning operation to hreak in cach moving part in order
to maximize the performance and service life of the engine.
Perform this conditioning carefully. keeping in mind the fol-
lowing:
1. Start the engine according to the Starting Procedure sec-
tion in this manual; run the engine at fast idle while
checking that all systems (raw water pump, oil pressure,
battery charging) arc functioning.
2. Allow the engine to warm up (preferably by running at fast
idle) until the
water temperature gauge moves into the
130o-J40°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.
S. Usc caulion nol 10 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 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. produc-
ing similar results. Operate the engine in moderation during
the
50-hour break-in period. (Don', baby the engine_ bu! do
not abuse it.)
NOTE: Allemptillg to reduce idle speed helow the minimum
shown may product' wisiahle ellgine operatioll and stalling.
NOTE: The propeller should he eithc!r 2 or 3 Node. It should
allow the enRine to
rf!ach iiS maximum rated rpm at full open
throttle undenvay ill forward gear to ensure the ami/ahility
of rated horsepower whell Ilet'ded.
NOTE: See the TRANSMISSION section of this manual jor
hreak-ill illformation Oil your transmissio!l.

THE DAILY ROUTINE
CHECK LIST
Each day before starting your engine, take a few moments to
run this check list:
o Visually inspect the engine for fuel, oil, or water leaks.
o Check the oil level.
o Check the transmission fluid level.
o Check for loose wires at the alternator.
o 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.
oCheck fuel supply; always keep fuel tank(s) as full as pos-
sible.
o Look for clean fuel in the fueVwater separator bowl.
o Check the coolant level in the plastic recovery tank.
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
[he area of leakage. In cases of excessive 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.
When engine starts -release START.
5. Hold
PREHEAT until oil pressure reaches 15 psi andlor
alarm shuts Qff.
NOTE: Should engine fail to stan, wait 30 seconds, repeaT the
above procedure, and PREHEAT longer
6. Allow a few minutes for the engine to warm at a comfort-
able rpm (approx. 1200 rpm), then reduce the rpm, shift
into gear, and get underway.
A CAUTION: When shifting the transmission, always
reduce the engine rpm to idle, then shift the transmis-
sion firmly from one direction to another_ Aslight pause
in neutral will allow the propeller to slow. Shifting at
high rpm will damage the transmission/damper plate.