Westerbeke M3-20B User manual

OPERATORS MANUAL
U rsal
MARINE DIESEL ENGINES
M3-20B M-25XPB M-35B
-.
- ... B -50B
PUBLICATION 200550
REVISION 2
FEBRUARY 2010
WE5TERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
150JOHN HANCOCK ROAD, TAUNTON, MA 02780·7319 U.S.A. .
TEl..: [phone] FAX: (508}B84·9688· weBSITE: WWW.WESTERBEIfE.COM
..4JJs!J Member NaluJlla[ Marille Manu/acturers Associalioll

A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide Is poisonous and can cause
uncIIIISClousness and death. Symptoms of Carbon Monoxide
expDS1118 can include:
-Dizziness
- Throbbing In Temp/es
-/Iaus8a -
Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
- Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET BUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut dllwn 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
/ ~!-!~~lII!Ii!i!IlI!"~~\ Ilving/sleeping quarters of you; vessel.
(, They are inexpensive and easily
. WA RNING obtainabie at your locai marine store.
Engi!Is -.. CARBON MONOXlDE
AI9'ar""""""" Req.ired
"'.1.-
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some 01 Its constituents
are known to the State 01 Calilornia
to cause cancer, birth delects,
and other reproductive harm.

SAFETY INSTRUCTIONS
Readthis safety manual carefully. Most accidents are
causedbyfailure tofollow
fundamental rules and precau·
tions. Know when dangerous conditions exist
and take the
necessary precautions to protectyourself, your personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT B.ECmIC SHOCK
A WARNING: Do not touch AC electrical connsetlollS
wfr/IB tlllfl/ilfl Is fUnning, or when connocted to shoro
p __ LBlhBI roltage Is prtlSBnt at thBSIJ connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical 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 generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot onglne parts or
emaust 5JStIIm compollllllts. A running engine gois
reryhot!
• Always check the engine coolant level at the coolant
recovery tank.
A 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 - FIRE
A WARNING: Flro can cause injury or death!
• Prevent flash fires. Do not smoke or pennit 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
al1 fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and
free of debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
Injury or death!
• 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 run-
ning the blower. Run the blower for 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-ven-
tilated 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 offthe 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 servic-
ing. 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 of leaks.
• 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.

SAFETY INSTRUCTIONS
ACCIDENTAl STARTING
A WARNING: Accldtmtal stalflng can cause In/ury
III tItNIth!
• 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.
BAnERY EXPLOSION
A WARNING: Battery explosIon can cauulnlury
III tItNIth!
• 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 offall electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• 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 vapors.
Ventilate any compartment containing batteries 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. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: SUlfuric acid In banerles can cauu
_In/lIlT III dtlath!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain suJfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
ii
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 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 information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxIde (CO) Is an Invisible
odorless gas. Inhalation produces "u-Ilke symptoms,
nausea Dr death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing 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 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 symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can causs Inlury
Dr dllath!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces 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
!hi: engine is operating.
• Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High nl1lse lewis can cause hearing
II1tIsI
• 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
open.
A WARNING: 011 nl1t Wl1t1c I1n machinery when Yl1u are
mentally I1r 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 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-I Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
iii
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTAlLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY lOOlO
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
II Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
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 of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifoldbyeclion port is at or below the load waterline will result in
raw water damage to the engine
and possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, ins/all a
siphon-break.
NOTE: A siphon~break requires periodic inspection and cleaning to ensure proper
operation.
Failure fa pmperly maintain a siphon-break can result in catastrophic
engine damage. Consult
the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed Marine Installation Manual covering gasoline and diesel
engine and generators is suppied with each unit. Additional copies
can be obtained from our website in pdf form. www.westerbeke.com.
,/, .Univorsal
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ......................................................... .2
Wiring Schematic (Catalina) ......................................... 26
Introduction ...................................................................... .3
Engine Adjustments ....................................................... 27
Warranty Procedures ....................................................3 Throttle and Stop Assembly.......................................27
Serial Number Location .............................................. .3
Valve Clearance..........................................................27
Admiral Control Panel ............. ........................................ 5 Testing Engine Compression......................................28
Captain Control Panel ..................................................... 6
DIesel Fuel, Engine Oil and Engine Coolant ............... 7
Preparations for Initial Start-Up ................................... 8
StartlngJStopplng Procedure .......................................... 9
Testing Oil Pressure ...................................................28
Fuel Injectors.............................................................
.28
Engine Troubleshooting (Chart) ................................... 29
Control Panel Troubleshooting (Chart) ...................... .31
Troubleshooting Water Temperature ..........................
31
Break-In Procedure ........................................................ 10 Troubleshooting Oil Pressure Gauges........................
31
The Dall, Routine ........................................................... 11
Alarms and Circuit Breakers..................................... .11
Tachometer Troubleshooting ........................................ 32
PRM Transmissions ....................................................... .34
Maintenance Schedule .................................................. 12 Changing the Fluid.....................................................
34
EngIne Cooling Clrcuil... ................................................ 14
Raw Water Pump ........................................................ 15
Changing the Raw Water Impeller............................. IS
Raw Water Intake Strainer.........................................16
Therrnostat..................................................................16
Heat Exchanger ..........................................................16
EngIne 011 Change .... ...................................................... 17
Remote 011 Filter ............................................................ 18
Fuel s,stem ..................................................................... 19
Gear Shifting ..............................................................34
Daily Operation..........................................................35
Control Cables............................................................35
Maintenance ...............................................................35
Transmission Troubleshooting (Chart) ........................ 36
HBW Transmission .......................................................... 37
Shaft Couplings..........................................................37
Shift Lever ..................................................................37
Fluid
Change ..............................................................38
Specifications .............................................................38
Air Cleaner/Silencer................................................... 19
Operating Temperature............................................... 39
Priming the Fuel System ............................................19
Transmission Cooler........"............,............................39
Fuel Lift Pump ...........................................................19 Maintenance ...............................................................39
Fuel Filters .................................................................20
DC ElectrIcal Srstem ..................................................... 2I
Transmission Troubleshooting (Chart) ....................... .40
Control Cables............................................................40
Drive Belt Adjustment ............................................... 21
Lay-Up and Recommissioning ...................................... 42
Battery
Care ............................................................... 21
Glow Plugs................................................................21
Alternator Troubleshooting ........................................22
WIrIng DIagram ............................................................... 23
WirIng Schematic ...... ..................................................... 24
WirIng DIagram (Catalina) ............................................. 25
SpeCifications ................................................................ .44
Spare Parts ..................................................................... .45
Standard Hardware Torques ........................................ .46
Metric Conversions ....................................................... .47
European Maritime Council Certificate .................... .49
1

PARTS IDENTIFICATION
MANIFOLO'p'R.E.SSUI~E C,~P
ICOOLANT
FILL
THERMOSTAT
ASSEMBLY
REAR
PREHEAT
SOLENOID
REAR
OIL
FUEL
M-50BILLUSTRATED
=::;>F\-\---j\lR FIlTER SILENCER
~~~~:d "\l!i-of-----OIL DRAIN HOSE
RIGHT SIDE
FUEL
PUMP
COOLANT PUMP .u«"'r-~
COOLANT PUMP-~--->j1U1i
SHEAVE ~m---.T,
RAW WATER PUHIP---'''>',L
OIL
FRONT
OIL
2
M-40BILLUSTRATED
OIL PAN
COOLANT
DRAIN
/ MA."ULU PRESSURE CAP
FILL]
CAP
ALTERNATOR
1.0. NAME PLATE
LEFT SIDE
START
MOTOR
OIL DRAIN HOSE

INTRODUCTION
These new high performance UNIVERSAL marine diesel
engines are a product
of UNIVERSAUWESTERBEKE'S
design technology and their combined years ofexperience
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 Catalog is also
provided and a Thchnical Manual
is available from your
UNIVERSAL dealer. Also,
if you are planning to install 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 form, please contact the factory
in writing with
model information, including the unit's serial number
and
commission date.
Unlvarsal
Customer Identification
UNIVERSALOWNER
MAIN STREET
HOMETOWN, USA
Model M-35B
Expires 712012000
Ser. #D704XXXX
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 indicates
the decade
[A=1960s, B=1970s, C=1980s, 0=1990, etc.],
the second
character represents the year in the decade,
and the fourth
and fifth numbers represent the month of manufacture.
3
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuais, 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
OFTHE FURNISHING OR USE OF SUCH SOFTWARE.
UNIVERSAL customers should also keep in mind the time
span between printings ofUNIVERSAL product software
and the unavoidable existence ofearlier 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 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.
A WARNING: Procedures, which if not properly
followed, 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.
IllJERSTANDING 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 greatextent, 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-
eating 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
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.
4
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 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 UNlVERSAU
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 steps to ensure long engine life:
oProper engine installation and alignment.
o An efficient well-designed exhaust system that includes
an anti-siphon break to prevent water from entering the
engine.
oChanging the engine oil and oil filters every 100 operating
hours.
D Proper maintenance of all engine components according
to the maintenance schedule in this manual.
o Use clean, filtered diesel fuel.
oWinterize 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 PANn
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 hoUIS. The panel also includes a WJ'JER TEMPERA·
TURE gauge which indicates water temperature in degrees
Fahrenheit, an OILPRESSURE 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-hooted
pushbuttons, one for
PREHEPJ 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
last temperature reading indicated by the gauge before elec-
trical 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 power is restored
to the gauge.
A separate 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
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 igni-
tion key is turned on and should silence when the engine has
started and the en~ine's oil pressure rises above 15 psi.
Nole: Refer to the WIRING DIAGRAM in this manual for the
installation of two engine sendors.
WATER TEMPERATURE GAUGE: TliIS GAUGE IS
GRADUATED IN DEGREES FAHRENHEIT AND IS
IllUMINATED WHILE TliE KEY SWITCH IS
TURNED ON. TliE ENGINE'S NORMAl OPERATING
TEMPERATURE IS 170'-190' F(77'-aa'C).
OIL PRESSURE GAUGE: THIS GAUGE IS GRADU-
ATED IN POUNDS PER SQUARE INGH (PSI) AND IS
ILLUMINATEO WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
OIL PRESSURE RANGES BETWEEN 30·60 PSI.
RECAUBRATEO FOR
ACCURACY FROM THE
REAR OF THE PANEl.
I
THIS BUTTON
PRBtfAT BUTTON: WHEN PRESSED. ENERGIZES
AlTERNATOR'S REGULATOR, THE FUEL LIFT PUMP AND
THE ENGINE'S GLOW PLUGS, AND BYPASSES THE'
ENGINI"S OIL PRESSURE ALARM SWITCH. IN ADDI-
TlDN,1HIS BUTTON ENERGIZES THE START BUTTON.
5
KEY SWtTCH: PROVIDES
CLUSTER.
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED.
SHOULD SHOW 13VTO 14V.
HAS BEEN
~~l!~INji~~!~CJIF.:~~~E~ FRESH
WATER 2tO' F (9S'C), THIS SWITCH WILL CLOSE
SOUNDING THE ALARM WHICH WILL EMIT A
CONTINUOUS SIGNAl.
LOW OIL '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 ENGINE:S OIL PRESSURE
FALL TO 5-10 PSI, THE SWITCH WILL OPEN 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
INSTRUMENT TEST button and three indicator lamps, one
for AL1ERNATOR DISCHARGE, one for low On.. PRES-
SURE,
RPM GAUGE:
REGISTERS REVOLUTIONS PER
MINUTE OF THE ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OF THE PANEl.
WATER TEMPERATURE ALARM
LIGHT
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.
6
and one for high ENGINE COOLANTTEMPERATURE. It
also includes an alarm buzzer for low on.. PRESSURE or
high WA1ER 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 ENGINE'S OIL PRESSURE FALLS
BELOW 5-10 PSI. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
SIGNAl. THE ALARM WILL ALSO SOUND IF THE WATER TEMPERATURE IN
THE FRESHWATER COOLING CIRCUIT RISES TO 210°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 TO 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, AND 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 a diesel fuel that meets the requirements of No.2-D SAE
J 313 and has a Cetane rating of #45 or higher. Grade of
diesel fuel according to ASTM 0975.
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#
IO 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 ofbreak-in operation., Then follow the oil
and filter change intervals as specified in the
MAINTENANCESCHEDULE in this manual.
Westerbeke Corporation does not approve or disapprove
the use ofsynthetic oils. Ifsynthetic 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 in/ormation above supersedes all statements
regarding synthetic oil.
For recommended oil viscosity, see the following chart:
Opendlng Temperatu.e
011 Viscosity
Above 6soF (20°C) SAE 30 0.1 OW-30
41°-6soF (5-20°C)
SAE 20 or 10W-30
Below 41°F (5°C)
SAE 10W-30
A CAUTION: Do not allow two or more brands of
II1I/Ilne 011 to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
til prtJdllce prtJperties harmful to your engine.
7
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 tenn protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Laokfor the new environmentally-friendly 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 concentralion
Freezing Temperature
23%
14°F
WC)
COOLANT RECOVERY TANK
30% 35%
-4°F
(-20°C)
50%
-40°F
(-40"C)
Acoolant 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

PREPARATIONS FOR INITIAL START-UP
PREST ART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff-check the following items.
o Check the engine oil level; add oil to maintain the level at
the high mark on the dipstick.
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 fuel supply and examine the fuel filter/separator o
Check the coolant level in the plastic recovery tank and at
the manifold.
bowls for contaminants.
o Check the transntission fluid level.
NOTE: Refer to the specifications pages in this manual for
fuel, oil, and transmission types andquantities.
COOLANT
RECOVERY
TANK
NOTE: Ifthe engine has not yet beenfilled with coo/ant, refer
to the ENGINE COOLING CIRCUIT section of this manual.
MANtFOLD
MANIFOLD
IM-35B SHOWN)
(&J
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
1IIIIIIrBI. StartIng In gear could resun in serious damage
'" JOIIf transmission, your boat, and vessels nearby.
Thrn the KEY SWITCH to the ON position (2 o'clock).
PREHEAT:Depress the PREHEAT switch. The voltmeter and
panel lights, gauges and meters will be activated. The
PREHEAT switch should be depressed in accordance with
the following chart:
TemperatureJPreheat
... "' .... Ie Tompondun
Preheallng TIme
41"f(S'C) or higher
Approx. 10 seconds
41 "f(S'C) to 23'F (-5'C) Approx. 15 seconds
23'F(-5'C) or lower Approx. 20 seconds
UmH of conll.uou. use 30 seconds before cranking
START:While still depressing the PREHEAT switch, depress
the STAKr button. 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.
lUTE: When starting:
A voltage drop will occur
when the preheat button
is depressed.
VOLTAGE
DROP
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wail 30 seconds; repeat the procedure above and preheat
longer. Never run the starler for more than 30seconds.
9
A CAUTION: 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 system fills. Prevent this
from happening by closing the raw water supply
through·hull shutoff, draining the exhaust muffler, and
conecting the cause of the excessive engine cranking,
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
Once the engine starts, check the 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 PREHEATswitch for 10·15 second intervals
will help stabilize the engine rpm until the operating
temperature
of the engine reaches 150·170 F. (60-77 C) and
a propeller load is applied
10 the engine. When the engine is
running and the PREHEATswitch is depressed, a charging
load on the DC alternator 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
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 the
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. Then tum OFF the key to
close down the electric fuel pump and accessories.
Make certain this key switch is in the OFFposition
(12 o'clock).1fthe key switch is left ON, the battery will
discharge. An engine alarm buzzer is provided to warn the
operator
of this condition (Key Switch ON). The best method
of preventing the batteryfrom discharging 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°-1400P 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. Use caution not to overload the engine. The presence ofa
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
M35B
800 - 1000 2000 - 2500 2900 - 3000
M40B 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 or 3 blade. It should
allow the engine to reach its maximum rated rpm at full open
throttle underway in forward gear to ensure the availability of
rated horsepower when needed.
NOTE: See the 1RANSMISSION section of this manual for
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:
o Visually inspect the engine for fuel, oil, coolant and
exhaust leaks.
o Check the oil level.
o Check the transmission fluid level.
o Check for loose wires at the alternator.
o Check for loose wires and electrical connections at the
DC altemator and elsewhere on the engine's
DC harness.
oCheck the staJiing batteries level (weekly)
o Check drive belts for wear and proper tension (weekly).
o Log your engine running time. These hours relate to
scheduled_maintenance.
o Check fuel supply; always keep fuel tank(s) as full as
possible.
o Look for clean fuel in the fueVwater separator bowl.
.0 Check the coolant level in the plastic recovery tank.
o Check for any obviously loose components or nuts or
bolts.
NOTE: Excessive loss of coolant indicates a cooling system
leak. Check the entire system. Ifnecessary, use a cooling sys-
tem presslire lester to pressurize the cooling system to locate
the area of leakage. In cases of excessive coolant loss, refill
tlte system as outlined in tlte ENGINE COOLING CIRCUIT
section il1 this manual.
START YOUR ENGINE
NOTE: See STARTING STOPPING PROCEDURE in this
manual for more detailedinstructions.
I. Put transmission in neutral, throttle advanced.
2. Turn KEY
to the ON position (2 O'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 enginefail fa start, wait 30 secollds, repeat tlte
above procedure, alld PREHEAT longe!:
6. Allow afew 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, anci 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 hamess on the engine is protected by an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive CUiTent 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 restrui the
engine.
LOW OIL PRESSURE ALARM SWITCH
Allow oil pressure alarm switch is located offthe engine's
oil gallery. This switch's sensor monitors the engine's oil
pressure. Should the engine's oil pressure fan to5 -to psi
(0.4 -0.7 kg/cm'), this switch will activate a pulsating alarm.
OIL GALLERY
IM-50B SHOWN]
PRESSURE ALARM SWITCH
11
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
hOllsing. This switch will activate a continuous alarm if the
coolant's operating temperature reaches approximately
21O'F (99'C).
AIR BLEED PETCOCK
COOLANT rEMI'ERI,TURE,
SEND OR
THERMOSTAT ASSEMBLY
IM-50B SHOWN]

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Waler Separator
Engine 011 Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to pertonn any service whIle the engine is
runnIng. Wear the proper safety equIpment such as goggles and gloves, and
use the correct tools tor each Job. DIsconnect the battery tennlnals when
servIcIng any of the engIne's DC electrical equIpment.
NOTE: Many of thefollowing maintenance jobs are simple butothers are more
difficult
and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100
250
500
750 1000 1250 MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessal)').
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovel)' tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8" to 1/2" depression)
and adjust if needed. Check belt edges for wear.
Vlsuallnspectlon of Engine
0
NOTE: Please keep engine suiface clean.
Check for fuel, oil and water leaks. Inspect wiring
DirI and oil will inhibit the engine's ability
and electrical connections. Keep bolts & nuts tight.
to remain cool.
Check for loose belt tension.
Engine Throttle and
0 0 0 0 0 0
Check for loose fittings, cotter pins, etc.
Transmission Control Lubricate with WD-40 or equivalent.
Cables and Shutoff Levers
Adjust engine Idle Speed
0 Refer to page
10.
Fuel Filter
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
0
EveI)' 50 operating hours check electrolyte levels
(and House Batteries) and make sure connections are vel)' tight. Clean off
excessive corrosion.
engine 011 and Filter
0 0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both evel)' 100 hours.
'Torque Cylinder Head At engine overhaul or cylinder head overhaul.
Hold Down Bolts
Lubricate Panel Key
0
At first 100 hrs., then each year at winterizing.
Switch wllh "Lockeze"
Transmission Fluid
0 0 0 0 0
Initial fluid change at 50 hrs., then every 250 hrs.
or once a year.
Air Cleaner
0 0 0 0 0
Clean the filter and element.
Exhaust System
0 0 0
Initial check at 50 hrs .. then evel)' 500 hrs. Inspect
for leaks. Check siphon break operation. Check the
exhaust elbow for carbon and/or corrosion buildup
on inside passages; clean and replace as neces-
sal)'. Check that all connections are tight.
12

SCHEDULED
MAINTENANCE
Engine Hoses
Heat Exchanger
Zinc Anode
Electric Fuel Lift
MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY 50 100 250 500 750 1000 1250
MAINTENANCE
0 0 0 0 0 0 0
Hose should be hard & tight Replace if soft or
spongy. Check & tighten all hose clamps.
0 0 0 0 0 0 0
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
0 0 0 0 0 0
Clean at 50 hours, then clean every 250 hours.
Pump Filter (if applicable)
Raw Water Pump
0 0 0
Remove pump cover and inspect impeller for wear;
replace if needed. Also replace gasket Lubricate
both when reassembled. Inspect pump for internal
wear, cover plate wear and cam wear.
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
'Fuel Injectors
0
Check and adjust injection opening pressure and
spray condition (see Engine Adjustments).
'Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
'Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (0.7-0.8 ohms).
'Engine Cylinder
0 0
Incorrect valve clearance will result in poor engine
Compression and
performance; check compression pressure and timing,
Valve Clearance
and adjust valve clearances.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Heat Exchanger
0
Remove, have professionally cleaned and pressure
tested.
'Engine Transmission
0
Chattering at idle and low rpms is an indication of
Damper Plate
damper plate wear. Remove and replace.
'UNIVERSAL recommends this service be performed by an authorized mechanic.
13

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 schedulO'in this manual. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
ACAUTlON: Propllr cooling systBm mainfBnanclI is
critical; a substantia/numbllr of IInglnll failures can bll
traced back to cooling systllm corrosion.
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss of coolant and without introducing air into the cool-
ing system. This tank is best located at or above the engine
manifold . should
be easily accessible.
COOLANT
RECOVERY
TANK
MHOB. M·!lJB COOLANT DRAIN JUST
ABOVE TH~E MOUNT
M·40B
M·25XPB
M·35B
COOLAln
DRAIN
MANIFOLD
M·50B COOLANT
DRAtN
CAP
HEAT EXCHANGER
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.
AWARNING: Beware of the hot engine coolant. Wear
protectiVII 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 thermostat housing and heat
exchanger to help remove air from 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'lhe 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 shoui:! draw back into the cooling system as the
engine cools do·vn. Add coolant to the recovery tank if
needed. Clean up 'ny spilled coolant.
PRESSURE CAP
PRESSURE CAP
NOTE: Periodically 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.