WESTERBEKE Universal Marine Power M-30 M-40 M-50*Factory Service / Repair/ Workshop Manual !

SERVICE MANUAL M - 30 MODELS M - 40 PIN 200154 M - 50

CONTENTS NOTE: Refer to the beginning of the individual sections for a cqrnplete table of contents for that section. SECTION I - SPECIFICATIONS .................................................... 1-18 SECTION II - PREVENTIVE MAINTENANCE ........................................ 19-24 SECTION III - CONSTRUCTION AND FUNCTION .................................... 25-30 SECTION IV - LUBRICATION, COOLING, AND FUEL SySTEMS ....................... 31-49 SECTION V - ELECTRICAL SYSTEM .............................................. 51-82 SECTION VI - DISASSEMBLY AND REASSEMBLY ................................. 83-130 SECTION VII - DYNAMO AND REGULATOR ...................................... 132-147 TROUBLESHOOTING ......................................................... 148-157

NOTES ii I a I --- ---------

SECTION 1- SPECIFICATIONS Model M-30 ...................................................................... 2,3 Model M-40 ..................................................................... 4,5 Model .M-50 .................................................. , .................. , . 6,7 Parts Specifications . ............................................................. 8-15 Bolt Torques . ................................................................. . 16-18 1

UNIVERSAL MODEL M-30 SPECIFICATIONS Horsepower No. of Cylinders Bore x Stroke Cubic Inch Maximum R.P.M. Cruising Range (Approx.) Compression Ratio Electrical Equipment Lubrication (Eng. Approx. Qts) 24 @ 2800 3 3.00 x 3.23 68 2800 2000-2400 R.P.M. 21:1 12 Volt - 51 Amp W/Glow Plugs 5.0 to 5.5 (SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK Lubrication (Trans.) FILL TO FULL RING ON DIPSTICK (Type AFT. "/1\' or GM-DEXRON - II Do not mix different oils) Transmission Reduction Coolant FWC (50/50 Solution Approx.) Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng. Operating Temp. Degrees F. Propeller Rotation We.ight (Ibs.) Injection Nozzle 2:1 6 qts. 1 V4" N.P.T. #2 Diesel PIN 298854 PIN 300209 Right Hand 4251bs. PIN 298787 & 298788 Engine is governor controlled to prevent overspeed. It is recommended to carry the following extra parts should the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 Qt. of Trans. Oil, 2 Qts. Lub. Oil and 1 Gal. 50/50 Coolant. All pictorial views and specifications subject to change without notice. 2

GLOW ____ __ SEA WATER OVERBOARD HEAT EX. DRAIN & ZINC_ TRANS. DIP STICK OIL FILL HOLE --- SHIFT LEVER ENGINE COUPLIN UNIVERSAL MODEL M-30 FUEL LINES TIMING PORT AIR BREATHER FUEL AIR LEED VALVE c---_ STOP LEVER '----OIL FILTER BLOCK COOLANT DRAIN COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG. F.W. CIRCULATING PUMP ---, ALTERNATOR SEA WATER PUMP V·BELT DIP STICK OIL PAN "3 MANIFOLD AUST FLANGE MANIFOLD DRAIN HEAT EXCHANGER HEAT EX. CLEAN·OUT COVERS ----DRAIN AND ZINC TRANSMISSION DRAIN PLUG

UNIVERSAL MODEL M-40 SPECIFICATIONS Horsepower No. of Cylinders Bore x Stroke Cubic Inch Maximum R.P.M. Cruising Range (Approx.) Compression Ratio Electrical Equipment Lubrication (Eng. Approx. ats.) 32 @ 2800 4 3.00 x 3.23 91 2800 2000/2500 R. P.M. 21:1 12 Volt - 51 Amp WIGlow Plugs 8.0 to 8.5 (SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK . Lubrication (Trans.) FILL TO FULL RING ON DIPSTICK (Type AFT. "1\' or GM-DEXRON - II Do not mix different oils) Transmission Reduction Coolant FWC (50/50 Solution Approx.) Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng. Operating Temp. Degrees F. Propeller Rotation Weight (Ibs.) Injection Nozzle (Prior to Ser. #315023) (After Ser. #315023) 2:1 8 qts. 1 V4" N.P.T. #2 Diesel PIN 298854 PIN 299927 Right Hand 5451bs. PIN 299517 & 299518 PIN 299567 Engine is governor controlled to prevent overspeed. It is recommended to carry the following extra parts should the need arise: V-belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 at. of Trans. Oil, 2 Ots. Lub. Oil and 1 Gal. 50/50 Coolant. All pictorial views and specifications subject to change without notice. 4

FUEL RETURN GLOW PLUGS-____ _ SEA WATER OVERBOARD HEAT EX. DRAIN & ZIN TRANS. DIP STICK OIL FILL HOLE --- ENGINE COUPLING/ UNIVERSAL MODEL M-40 FUEL LINES TIMING PORT AIR BREATHER FUEL AIR BLEED VALVE ---THROTTLE -- STOP LEVER --OIL FILTER BLOCK COOLANT DRAIN EX MOUNTS COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG F.W. CIRCULATING PUMP ---' ALTERNATOR SEA WATER PUMP V·BELT DIP STICK OIL PAN 5 MANIFOLD MANIFOLD DRAIN HEAT EXCHANGER HEAT EX. CLEAN·OUT COVERS ---- DRAIN AND ZINC TRANSMISSION RANS. DRAIN PLUG

UNIVERSAL MODEL M-50 SPECIFICATIONS Horsepower 44 @ 3000 No. of Cylinders 4 Bore x Stroke 3.35 x 3.23 Cubic Inch 115 Maximum R.P.M. 3000 Cruising Range (Approx.) 2000/2500 R.P.M. Compression Ratio 21:1 Electrical Equipment 12 Volt - 51 Amp WIGlow Plugs Lubrication (Eng. Approx. Ots.) 8.5 (SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK Lubrication (Trans.) FILL TO FULL RING ON DIPSTICK Transmission Reduction 1.9:1 Coolant FWC (50/50 Solution Approx.) 8 qts. Exhaust Flange 1 1/4" N.P.T. Fuel Type #2 Diesel Fuel Filter PIN 298854 Oil Filter PIN 299927 Eng. Operating Temp. Degrees F. 165 0 to 195 0 Propeller Rotation Right Hand Weight (Ibs.) 545 Ibs. Injection Nozzle PIN 299567 Engine is governor controlled to prevent overspeed. It is recommended to carry the following extra parts should the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 at. of Trans. Oil, 2 Ots. Lub. Oil and 1 Gal. of 50/50 Coolant. All pictorial views and specifications subject to change without notice. 6

UNIVERSAL MODEL M-50 FUEL LINES FUEL RETURN GLOW PLUGS-____ _ SEA WATER OVERBOARD HEAT EX. DRAIN & ZINC_ TRANS. DIP STICK OIL FILL HOLE -- SHIFT LEVER ENGINE COUPLING/ TIMING PORT COOLANT AIR BLEED VALVE THERMOSTAT HSG. F.W. CIRCULATING PUMP --- ALTERNATOR SEA WATER PUMP V·BELT DIP STICK AIR BREATHER INJECTOR PUMP FUEL AIR --, ... , EED VALVE ------ TH ROTTLE ,..--- STOP LEVER FILTER BLOCK COOLANT DRAIN LEX MOUNTS COOLANT FILL CAP MANIFOLD EXHAUST FLANGE / LD DRAIN HEAT EX. CLEAN·OUT COVERS . DRAIN AND ZINC NS. DRAIN PLUG STARTER OIL PAN 7

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WESTERBEKE Universal Marine Power M-30 M-40 M-50*Factory Service / Repair/ Workshop Manual !

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