WESTERBEKE Universal Marine Diesel EngineS M-25XPB M-35B M-40B Service Repair Manual !

-( £ It IJ " .& f -I- 1ft -t '" q SERVICE MANUAL Univarsal MARINE DIESEL ENGINES M·25XPB M·35B M·40B PUBLICATION NO. 200554 1st Edition/January 2001 WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A. TEL: (508)823-7677' FAX: (508)884-9688· WEBSITE: WWW.WESTERBEKE.COM IIIMMA Member National Marine Manufacturers Association .,.,.,.,

CALIFORNIA PROPOSITION 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. A WARNING: Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can Include: - Dizziness -Nausea -Headache - Throbbing in Temples - Muscular Twitching - Vomiting - Weakness and Sleepiness - Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until it has been inspected and repaired. WARNING Engines Pn:xIJce CARBON MONOXIDE Regular Maintenance Required This WARNING DECAL is provided by UNIVERSAL and should be fixed to a bulkhead near your engine or generator. UNIVERSAL also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel. They are inexpensive and easily obtainable at your local marine store.

SAFETY INSTRUCTIONS INTRODUCTION Read these safety instructions carefully before servicing your engine. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK A WARNING: Do not touch AC electrical connections while engine is running, or when connected to shore power. Lethallloltage is present at these connections! • Do not operate this m.achinery without electrical enclosures and covers in place. • Shut off electrical power before accessing electrical equipment. • Use insulated mats whenever working on electrical equipment. • Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment. • Remove wristwatch and all jewelry when working on electrical equipment. • 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 capacitor. Discharge capacitor by shorting terminals together with an insulated tool. PREVENT BURNS - HOT ENGINE A WARNING: Do not touch hot engine parts or exhaust system components. A running engine gets lIery hot! • 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: Fire 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 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 clean and free of debris to minimize the chance of fire. Wipe up all spilled fuel and engine oil. • Be aware - diesel fuel will burn. PREVENT BURNS - EXPLOSION A WARNING: Explosions from fuelllapors 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 running 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-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 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: Accidental starting can cause injury or death! • Disconnect the battery cables before servicing the engine. 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. BATTERY EXPLOSION A WARNING: Battery explosion can cause injury or death! • 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 dur- ing servicing. • Never connect the negative (-) battery cable to the positive (+) 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 other jewelry before handling the battery. • Always tum the battery charger off before disconnecting the battery connections. To avoid sparks from an accidental short circuit, always remove the negative lead first and reconnect it last when servicing the battery. BATTERY ACID A WARNING: Sulfuric acid In batteries can cause severe injury or death! • When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric 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. 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 flu-like symptoms, nausea or death! • Do not use copper tubing in diesel exhaust systems. Diesel fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust/water leakage. • Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If .the engine exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Avoid overloading the craft. • Although diesel engine exhaust gases are not as 10xic as exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some of the symptoms or signs of carbon monoxide inhalation or poisoning are: Dizziness Headache Nausea Vomiting Throbbing in temples Muscular twitching Weakness and sleepiness Inability to think coherently AVOID MOVING PARTS A WARNING: Rotating parts can cause Injury or death! • 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 touching moving parts and hot exhaust system components.

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry 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 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 A WARNING: High noise levels can cause hearing loss! • Never operate an engine without its muffler installed. • Do not run an engine with the air intake (silencer) removed. • Do not run engines for long periods with their enclosures open. A WARNING: Do not work on machinery when you are mentally or physically incapacitated by fatigue! OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures. ENGINE 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). 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 3069 Solomons Island Rd. Edgewater, MD 21037 NFPA (National Fire Protection Association) Fire Protection Standardfor Motor Craft Order from: NFPA 11 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 UNIVERSAL engines, it is important that strict attention be paid to the following information: CODES AND REGULATIONS 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 in (51 em) above the vessel's waterline. Failure to use a siphon-break when the exhaust manifold injection pori is at or below the load waterline will result in raw water damage to the engine and possible flood- ing of the boat. If you have any doubt about the position of the water-injected exhaust elbow rela- tive to the vessel's waterline under any of the vessel's various operating conditions or when the vessel is not underway, install a siphon-break. This precaution is necessary to protect your engine. NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper operation. Failure to properly maintain a siphon-break can result in catastrophic engine damage. Consult the siphon-break manufacturer for a proper maintenance schedule. 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 vessel's hull. A detailed 40-page Marine Installation Manual covering gasoline and diesel, engines and generators, is available from your UNIVERSAL dealer. iv

TABLE OF CONTENTS Introduction .......................................................................................................... 2 Parts Identification...................... :........................................................................ 3 Specifications ....................................................................................................... 4 Testing for OverhauL ........................................................................................... 6 Engine Troubleshooting ....................................................................................... 7 Service Standards ............................................................................................... 15 Engine Description............................................................................................. 18 Engine Disassembly & Reassembly................................................................... 21 Engine Service................................................................................................... 32 Engine Adjustments ........................................................................................... .43 Exhaust Manifold Service .................................................................................. 47 Lubrication System Description......................................................................... 48 Lubrication System Service............................................................................... 50 Cooling System Description.............................................................................. 52 Cooling System Service..................................................................................... 54 Fuel System Description.................................................................................... 56 Fuel System Disassembly & Reassembly.......................................................... 60 Fuel System Service........................................................................................... 61 Admiral Control PaneL ...................................................................................... 63 Captain Control PaneL ....................................................................................... 64 Control Panel Troubleshooting .......................................................................... 65 Glow Plug Service............................................................................................. 67 Starter Service.................................................................................................... 68 Mando Alternator Service.................................................................................. 72 Prestolite Alternator Service.............................................................................. 82 Wiring Diagram #39144 .................................................................................... 94 Wiring Schematic #39144 .................................................................................. 95 Wiring Diagram #200360 - Catalina yachts ..................................................... 96 Wiring Schematic #200360 - Catalina Yachts ................................................... 97 Hurth HBW Transmissions. ............. ........... .......... ........ .......... .............. ........... 98 Transmission Troubleshooting ......................................................................... 101 Special Tools .................................................................................................... 102 Torques ............................................................................................................. 104 Standard Hardware; Sealants & Lubricants ..................................................... 105 Metric Conversions .......................................................................................... 106 Standard and Metric Conversion Data............................................................. 107 Index ................................................................................................................. 108 it itUnlvarsal 32 1'&'i J @jijeiW3i- 1

INTRODUCTION ENGINE OVERHAUL This service manual contains detailed information relating to the servicing and overhaul of the Universal M-25XPB, M-35B and M-40B marine diesel engines. Information about the construction and function of the various systems and components can be found in the Description sections. For the major engine overhaul procedure, refer to the ENGINE DISASSEMBLY & REASSEMBLY and ENGINE SERVICE sections. Additional service information for spe- cific components and systems may be found by referring to the TABLE OF CONTENTS and the INDEX. Refer also to your UNIVERSAL parts Catalog. These service procedures are intended for the guidance of suitably equipped and staffed marine engine service and rebuilding facilities, and should only be undertaken by such facilities and their personnel. The service information in this manual generally applies to all three models covered by this manual. The individual models will only be noted where information does not apply to all three models. PRODUCT SOFTWARE Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than UNIVER- SAL are not within UNIVERSAL'S CONTROL. UNIVERSAL CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE, MAKES NO WAR- RANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OF 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. 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 representatives of UNIVER- SAL or the supplier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer. NOTES, CAUTIONS AND WARNINGS As this manual takes you through the service procedures and troubleshooting of your marine engine, critical information will be highlighted by NOTES, CAUTIONS, and WARN- INGS. 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. 2 A WARNING: Procedures, which if not properly followed, can result in personal injury or loss of life. CUSTOMER IDENTIFICATION CARD Customer Identification UNIVERSAL OWNER MAIN STREET HOMETOWN, USA Model M-358 Ser. #XXXX-D704 Expires 4/24/01 The UNIVERSAL engine serial number is an alphanumeric number that can assist in determining the date of manufacture of your UNIVERSAL engine. The manufacturer's date code is placed at the end of the engine serial number and consists of a character followed by three numbers. The character indicates the decade (D=1990s, E=2000s), the first number represents the year in the decade, and the second and third numbers represent the month of manufacture. ORDERING PARTS/SERIAL NUMBER LOCATION 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 side of the engine's exhaust manifold. The engine serial number can also be found stamped into the engine block on the left side of the engine below the cylinder head cover. You must provide us with this information so we may properly identify your engine. In addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). Also insist upon UNIVERSAL packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment. NOTE: Component locations in this manual are referenced from the front of the engine which is the pulley/drive belt end. Left and right sides are determined as follows: imag- ine straddling the engine, facing in the same direction as the front of the engine: the left side is at your left, the right side is at your right. The cylinder number sequence starts with the No.1 cylinder located at the front of the engine.

TRANSMISSION CONTROL BRACKET TRANSMISSION CONTROL BRACKET PARTS IDENTIFICATION MANIFOLD PRESSURE CAP (COOLANT FILL) TRANSMISSION FLUID DRAIN MODEL M-25XPB MANIFOLD PRESSURE CAP (COOLANT FILL) TRANSMISSION FLUID DRAIN MODELS M-35B & M-40B OIL FILL THERMOSTAT ASSEMBLY INJECTION PUMP AIR INTAKE SILENCER RAW PUMP INJECTION PUMP OIL DRAIN RAW WATER PUMP AIR INTAKE SILENCER AIR INTAKE SILENCER OIL PAN MANIFOLD PRESSURE CAP MODEL M-25XPB AIR INTAKE SILENCER MANIFOLD PRESSURE CAP ALTERNATOR I.D. NAMEPLATE MANIFOLD I.D. NAMEPLATE OIL FILTER OIL PAN MODELS M-35B & M-40B 3

SPECIFICATIONS UNIVERSAL MODEL M-25XPB M·35B M-40B ENGINE Engine Type Diesel, four-cycle, fresh water cooled, vertical, in-line overhead valve mechanism Horsepower 26 @ 3000 rpm 35 @ 3000 rpm 37.5 @ 3000 rpm Cylinders 3 I 4 Aspiration Naturally aspirated Bore & Stoke 2.99 x 2.90 in. (76.0 x 73.6 mm) 3.07 x 3.09 in. (78.0 x 78.4 mm) Combustion Chamber Spherical type; three vortex combustion system Displacement 61.2 cu. in. (1.0 liters) 81.47 cu. in. (1.335 liters) 91.41 cu. in. (1.498 liters) Compression Ratio 23:1 Firing Order 1 - 2 - 3 1-3-4-2 Crankshaft Direction of Rotation Counterclockwise as viewed from flywheel end Maximum Torque 47 ft-Ibs (6.5 kg-m) @ 2440 rpm 62 ft-Ibs (8.6 kg-m) @ 2460 rpm 73 ft-Ibs (10.1 kg-m) @ 2180 rpm Dry Weight, with Transmission 295 Ibs (133.8 kg) 352 Ibs (159.0 kg) 356 Ibs (161.5 kg) Dimensions Length 28.4 in. 1721.4 mml Length 32.7 in. t 30 .6 mml Length 33.2 in. (843.3 mml Width 18.9 in. 4BO.1 mm Width 1B.9 in. 480.1 mm Width 18.9 in. 14BO.1 mm Height 22.1 in. 561.3 mm Height 22.0 in. 55B.9 mm Height 22.1 in. 561.3 mm Maximum Angle of Installation Not to exceed 14° (24 rad.) Maximum Angle of Rotation Not to exceed 25° (44 rad.) Engine Speed Idle speed M-25XPB: 1,000 - 1,200 rpm; M-35B, M-40B: BOO - 1,000 rpm Cruise Speed M-25XPB, M-35B, M-40B: 2,000 - 2,500 rpm Engine Timing 18° (0.314 rad.) before lD.C. Engine Stop Manual LUBRICATION SYSTEM Type of System Forced lubrication by gear pump Oil Grade API Specification CF or CG-4, SAE 30, 10W-30, 15W-40 Oil Filter Full-flow, spin-on filter element Lubricant Capacity 4.0 qts/3.8 liters 4.5 qts (4.3 liters) Operating Oil Pressure (Engine Hot) 40-60 psi (276-414 kPa) at rated speed FUEL SYSTEM Type of System Open flow, self priming Fuel No.2 Diesel Oil, cetane rating of 45 or higher Fuel Injection Pump Bosch in-line plunger type Fuel Injectors Bosch throttle type Governor Centrifugal mechanical type Fuel Lift Pump 12 volt 5 ft. lift capacity, solid state Fuel Filter Full flow, spin-on element Fuel Supply & Return Piping 1/8 in. 1.0. (3.18 mm) minimum; 3/8 in. 1.0. (9.52 mm) maximum Typical Fuel Consumption @2500 rpm 1.0 gal.lhr (3.8 liters/hr) 1.3 gal.lhr (4.9 liters/hr) 1.4 gal.lhr (5.3 liters/hr) Air Intake Silencer Cleanable, replaceable filter element Air Flow @ 3000 rpm 53.1 cfm (1503.5 Ipm) 70.7 cfm (2001.8 Ipm) 79.3 cfm (2245.3 Ipm) (Engine Combustion) (continued) 4

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WESTERBEKE Universal Marine Diesel EngineS M-25XPB M-35B M-40B Service Repair Manual !

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