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Westerbeke M2-12 Owner's Manual
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Westerbeke M2-12 Owner's Manual

Westerbeke M2-12 Owner's Manual

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MARINE DIESEL
OWNER'S MANUAL
MODELS
M2-12
M3-20
M4-30
M-25XP
M-35
M-30
M-40
M-50
M-12
M-15
M-18
M-20
M-25
PART NUMBER
200157
WESTERBEKE CORPORATION

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Summary of Contents for Westerbeke M2-12

  • Page 1 MARINE DIESEL OWNER'S MANUAL MODELS M2-12 M3-20 M4-30 M-25XP M-35 M-30 M-40 M-50 M-12 M-15 M-18 M-20 M-25 PART NUMBER 200157 WESTERBEKE CORPORATION...
  • Page 2 MARINE DIESEL OWNER'S MANUAL MODELS M2-12 M3-20 M4-30 M-25XP M-35 M-30 M-40 M-50 M-12 M-15 M-18 M-20 M-25 PART NUMBER 200157 WESTERBEKE CORPORATION...
  • Page 4 5421 M-30 5424 M-30 M-35 M-40 5432 M-40 M-50 5444 M-50 * Discontinued ** Replaced With New Model *** Improved # New Mini Series In 1 986 - M-25XP In 1987 - M-35 In 1 988 - M2-12, M3-20, M4-30...

  • Page 6: Table Of Contents

    PAGE CONTEN TS Table of Contents ............. Caution 4 - 5 General Information ..
  • Page 7 CAUTION Your Universal Diesel engine is supplied with top quality, factory tested components. These will not, however, replace safe practices in the handling of fuel and the use of your engine. The following pro­ cedures, if observed, will help insure safe operation and prevent damage to your engine and its components.

  • Page 8: Caution

    -CAUTION- FRESH WATER COOLING SYSTEM: ALL MODELS EXCEPT M-1 5. TH IS SYSTEM MUST BE FILLED SLOWLY W ITH A 50/50 BLEND OF WATER AND A GOOD GRADE OF PREMI U M ANTIFREEZE. H E COOLANT BLEND MAY CHANGE, BASED ON CLIMATIC CONDITION IN YOUR AREA.

  • Page 9: General Information

    G ENERAL I N FORMATION ENG I N E: U niversal Diesel engines are four stroke engines. They are designed with special swirl combustion cham bers, balanced crankshaft system for minimum vibration and noise levels. COOLING SYSTEM: All Models Except M-1 5 Engines are fresh water cooled, employing a rubber impeller sea water pump moving sea water through a heat exchanger thereby lowering the temperature of the fresh water coolant.

  • Page 10: General Care

    GENERAL CARE: If the boat is left afloat for periods of a month or more, the engine should be started at least every 14 days to prevent internal corrosion. Regularly spray external unpainted surfaces and exposed, unpainted electrical equipment with a corrosion and moisture protective coating.

  • Page 11: Before Starting

    Transmission shifting controls must allow the clutch to engage in the full forward and reverse positions. Restricted or partial engagement will cause undue wear. The transmission should always in the neutral position before starting the engine. Also, the transmission shifter arm must be at a 90° angle to the transmission bracket cable when in neutral.

  • Page 12: Starting Engine

    STARTING THE ENGINE Have safety equipment on board. and know how to use it. Ventilate engine compartment by opening hatches. Be sure engine compartment is thoroughly ventilated. (Run blowers for 4 minutes before starting engine, if installed.) 4. Turn blowers off after starting or before starting to eliminate excessive battery drain, if preferred. 5.

  • Page 13: Engine Break-In And General Running

    Repeat if engine does not stop the first time. Models M-35, M-12, M-25, M2-12, M3-20, M4-30, M-25XP, M-40, M-50 have a separate stop lever for shut­ ting the engine down. All newer models have a shut down lever on panel, pull lever 5.

  • Page 14: Decompression Lever

    DECOMPRESSION LEVER A decompression lever fitted to the engine enables the user to start the engine easier when it is ex­ tremely cold, when the battery is low or when bleeding the fuel system . There is no decompression lever on Models 1 2, M2-1 2, M3-20, M4-30 and M-35. -CAUTION- THE DECOM PRESSION LEVER MUST NOT BE USED TO STOP THE ENG INE EXCEPT I N EMERGENCY SITUATIONS SUCH AS R U N AWAY ENGINE OR...
  • Page 15 Operating temperature is approximately 1 65°F to 1 95°F on all models except M-1 5. Operating temperature is approximately 1 35°F to 155°F on Model 15. The ammeter should indicate the charge re­ quired based on equipment and battery condition . There are three (3) New style "...

  • Page 16: Wiring Diagram

    WIRING DI AGR AM Pluga cyl.) Temp Oii Pntaunt � � " � � " FIGU RE...

  • Page 17: Preparing Engine For Storage

    PREPARING THE ENGINE FOR WINTER STORAGE OR LAYUPS Proper preparation of your engine for storage will avoid damage and minimize expense when agai . n placing you r engine in service. NOTE: It is recommended that your engine be winterized by an authorized Universal mechanic or at least, a trained mechanic familiar with the engine and its options.
  • Page 18 You should now have antifreeze in sea water pump, hoses, heat exchanger and exhaust system. If aqua-lift or pot type m uffler is used, it is recommended to drain prior to pumping anti­ freeze thru system and afterwards to prevent coolant from backing up into the engine. SEA WATER COOLI NG SYSTEM : Model M-1 5 OPTION #1 Open the cylinder block drain cock on the side of the block where hose from water pump...

  • Page 19: Exhaust System

    EXHAUST SYSTEM: Exhaust pipes and muffler should be drained of sea water. Allow the exhaust pipes to d ry out. Seal exhaust pipe end to prevent entrance o f moisture into the engine through exhaust valves that are open. See Option -2 under Sea Water Cooling System appropriate for your model. All can type mufflers should be drained after any long periods of cranking, as Sea Water pump will fill the muffler causing water to backup and enter the engine.

  • Page 20: Preparing Engine For Spring Service

    PREPARING ENG INE FOR SPRI NG SERVICE Preparation of the engine should i nclude all those items of maintenance necessary to permit satisfac­ tory operation of the engine. A properly serviced engine will give a full season of carefree pleasure. The amount of service needed will be determined by the storage procedure of the previous fal l .
  • Page 21 EXHAUST SYSTEM : Check all hoses and hose clamps for serviceability and security. Any worn or damaged hoses or clamps must be replaced before operation . Check all valves and remove all plugs before operation. Check complete system monthly for leaks, make repairs as needed . ELECTRI CAL SYSTEM: Inspect all wiring, terminals, controls and switches for damage or corrosion.

  • Page 22: Maintenance Of Engine

    MAINTENANCE OF YOUR ENGINE Unless major repair work is done on the engine, timing should not be required. FUEL INJECTION TI MING: Basic tools required: (A) - 10 MM Socket wrench (B) - 1 3 MM Socket wrench (C) - 1 7 MM Open end wrench - 1 2 MM Box end wrench (E) - 27 MM Socket (1 -1 /1 6") Engine firing order - Two cylinder...

  • Page 23: Diesel Valve Timing

    DIESEL VALVE ADJUSTMENT *Valve clearance .Of17 M-12-M2-12, 15-18 ....006 - M-25XP-35, M3-20, M4-30 (0.145 - 0.1 85 mm) **Valve Clearance ....
  • Page 24 4. The injector pump internal unit can now be loosened and removed. It may be necess a ry to remove fuel lines from injector nozzles to aid in pump removal There are several shims located just below the pump top plate which will be used to adjust the timing.

  • Page 25: Decompression Device Adjustment

    Working through the access hole, loosen the lock nut with a wrench (tool A) and back the adjusting screw off until no contact is made on the rocker (Using screw driver). Now tum adjusting screw in until first contact is made, continue to tum screw in (1 ) turn . Lock the screw in this position with the lock nut.

  • Page 27: Bleeding The Fuel System

    BLEEDING THE FUEL SYSTEM : It will be necessary to bleed the fuel system to achieve a steady air free flow of fuel if any of the follow­ ing have occured: Models M-1 2, M2-1 2, M3-20, and M4-30 have self bleeding fuel systems. Running out of fuel.

  • Page 28: Removing I Njectors

    REMOVING I NJECTORS: Clean the area around the injectors before removing. Loosen n uts holding fuel lines to injector pump and injector nozzle and remove fuel lines (Tool C). Loosen · nuts on return line adapters · and remove adapters (Tool C.) Loosen i njectors (using Tool E) and remove i njectors.

  • Page 29: Sea Water Pump

    WBE OIL FILTER FIGURE 8 UNIVERSAL RECOMM ENDS THAT YOU USE FACTORY REPLACEMENT FILTERS. THE USE OF OTHERS MAY VOI D THE ENG I N E WARRANTY. SEA WATER PUMP: Your engine is equ ipped with a rubber impeller type sea water pump. CAUTION: DO NOT RUN PUMP DRY AT ANY TI ME OR YOU WILL DAMAG E TH E IMPELLER, CAUSING ENGI N E TO OVERHEAT.

  • Page 30: Pump Impeller And Parts Diagram

    · , NOTE: IF DURING IM PELLER REPLACEMENT THE PUMP SHAFT CAME FORWARD, IT COU LD HAVE COM E OUT OF THE G ROOVE AND DRIVE ADAPTOR. IF SO, YOU M UST COM­ PLETE TH E FOLLOWING. NOTE - ON NEWER U NITS WITHOUT A MOU NTING SPACER BET­ WEEN TH E PUMP AND ENG INE BLOCK YOU DO NOT HAVE A DRIVE ADAPTOR TO BE CON­...
  • Page 31 Cover Screws (6) Pump Cover Cover Gasket Impeller Snap Ring Impeller Pump Shaft 8. Water Seal 1 0. Pump Body 1 1 . Cam Locking Screw 1 2. Oil Seal 1 3. Drive Adaptor - Not used on Newer Models 1 4.
  • Page 32 Cover Screws (4) Pump Cover Cover Gasket Impeller Snap Ring Impeller Pump Shaft Water Seal 1 0. Pump Body 1 1 . Cam Locking Screw 1 2. Oil Seal 1 3 . Drive Adaptor - Not used on Newer Models 1 4.

  • Page 33: Sherwood Water Pu Mp

    Impeller Housing 0-Ring Cam Screw Impel ler Cir-Clip Flat Washer Seal Seat Not Available Order #1 3 Cir-Clip I nternal Cir-Clip External Ball Bearing Seal & Seat Assembly Cir-Clip External Shaft End Plate Gasket Pump Body SHERWOOD WATER PU MP Lock Washer Bolt 302648...

  • Page 34: Model 15 Sea Water Circulation Diagram

    MODEL 1 5 SEA WATER CIRCULATION Normal Range 1 350 to 1440 F "', - - - - - - - - - - - - - - - - "' _.. - - -- - � _ ./ L - - - - - - - - - - - - - - - - - - �...
  • Page 35 Enters thermostat which remains closed duri ng warm up, permitting a small amount of water to enter exhaust system for cooling and overboards. As engine temperature rises the thermostat starts to open, permitting hot water to enter ex­ haust line. At the same time the same amount of cool sea water is drawn in by the pump to replace the discharge hot water.
  • Page 36 FRESH WATER CIRCULATION DIAGRAM ALL MODELS EXCEPT M-15 Normal Range 1650F to 1950F FIGURE 13 SEA WATER Sea water enters through sea water inlet, Through sea water valve when open, Through sea water pump into heat exchanger to cool fresh water system, From heat exchanger to sea water overboard through exhaust port.

  • Page 38: Fresh Water

    FRESH WATER Coolant (fresh water with antifreeze) is introduced into the system from the coolant section of exhaust manifold by removing pressure cap and filling manifold tank to within one inch of lower rim of fill port. Fresh water engine driven circulating pump moves coolant from heat exchanger through engine block circulating pump and thermostat back through exhaust manifold into heat ex­...
  • Page 39 U N IVERSAL D I ESEL WITH H U RTH TRANSM ISSION Model HBW-50 ( 2:1 ) Used on Models 12, M2-12, M-18, M3-20, M4-30, M25 and M-25XP Model HBW-1 00 ( 1 .8:1 ) Used on Models 30, 35, and 40 Model H BW-150 ( 1 .9:1 )

  • Page 40: Description

    DESCRIPTION: The Hurth transmission housing is made of a high strength aluminum alloy that is resistant to sea water. The transmission is equipped with shaved and case hardened helical gears and with shafts mounted in heavy-duty roller bearings. Forward and reverse is accomplished by a mechanical fric­ tion clutch.

  • Page 41: General I Nformation

    GENERAL I N FORMATION: General If the transmission is being painted , care should be taken to protect the oil seals at the out­ put shaft in back of the coupling. Make sure the venting hole on the oil filter screw is not covered with paint.
  • Page 42 CAUTIO N : THE CABLE MUST B E MOUNTED TO TH E SHIFT LEVER AT A 90° ANGLE TO INSURE EQUAL TRAVEL FROM NEUTRAL TO FORWARD AN D NEUTRAL TO REVERSE (See Fig. 13-B CAUTIO N : TRANSMISSION MUST BE LEFT IN NEUTRAL WHEN SAI LI N G , DO NOT LEAVE IN FORWARD G EAR WHEN SAI LI NG WITHOUT POWER AS IT WILL DAMAGE G EAR.
  • Page 43 1 /64" FIGURE 1 3-B...
  • Page 44 COU PLINGS Rigid Coupling Specify Bore Size Drivesaver Flex Coupling 1 " Thick Require (1 ) rigid coupling (2A) & (2B) mounting screws and bolts. Flex Coupling (Deluxe) 2" Thick Specify Bore Size (3A) Mounting capscrews, locks, and n uts. Set Screws To Lock Coupling To Shaft.
  • Page 45 PERIODIC SERVICE CHART Always be sure engine is stopped and cool and that your personal safety is considered before making checks or doing any repair work. PERIOD OF OPERATION THINGS REMARKS Break-in period (Approx. 25 Change engine oil, filter and hours at 75% cruise speed).

  • Page 46: Product Warranty

    MAR I N E ENG I N E WAR RANTY - LI M ITED P RODUCT WAR RANTY Seller warrants all products and parts of its own manufacture against defects in material or workmanship for a period of o ne ( 1 ) year from date of shipment when given normal and proper usage as determined by seller upon examinations, and when owned by the origi nal purchaser.
  • Page 47 Moisture i n engine from exhaust systems which pe rmit condensation or back flow of moisture into the engi ne. Damage or loss of pe rsonal property, loss of revenue, towing charges, storage fees, fuel and telephone calls. Damages or losses related to handling and shipping. Expenses related to replacement of lubricants, anti-freeze or special additives.
  • Page 48 UNIVER SA L M-12 SPECIFICA TIONS Model 1 2 Horsepower 3600 No. of Cylinders Bore x Stroke 2.52 x 2.45 in. Cubic I nch Maximum R.P.M. 3600 Cruising Range (Approx.) 2600 - 3300 R . P. M . Compression Ratio 23:1 Electrical Equipment 12 Volt - 51 Amp W/Glow Plugs...
  • Page 49 UNIVERSAL MODEL M -12 GLOW PWGS FUEL RETURN FUEL FILTER ( AIR BLEED ON TOP ) FUEL AIR BLEED VALVE SEA WATER EXHAUST & ---�: :: :: :; ; TRANS. D I P STICK TH ROTTLE OIL FILL H OLE D I P STICK ENGINE COUPLING BLOCK COOLANT DRAIN...
  • Page 50 U N IVERSAL M2-1 2 SPECI FI CA TIONS M2-1 2 Horsepower 3600 No. of Cyli nders Bore x Stroke 2.6 x 2.45 i n Cubic Inch Maximum R . P. M . 3600 2600 - 3300 R . P. M . Cruising Range (Approx.) 23:1 Compression Ratio...
  • Page 51 U N IVERSAL MODEL M2-12 GLOW PWGS FUEL LINES FUEL RETURN FUEL FIL TER ( AIR BLEED ON TOP ) FUEL AIR BLEE D VALVE SEA WA TER TO EXHAUST & TRANS. DIP STICK TH ROTTLE OIL FILL HOLE DIP STICK...
  • Page 52 UN IVERSAL MODEL M -1 5 SPECI FI CATIONS orsepower 3000 No. of Cylinders Bore x Stroke 2.68 x 2.76 Cubic Inch Maximum R . P. M . 3000 Cruising Range (Approx.) 21 00/2600 R.P.M . Compression Ratio 22:1 Electrical Equipment 12 Volt - 51 Amp W/G low Plugs Lubrication (Eng.
  • Page 53 U N IVERSAL MODEL M-1 5 OIL FILL CAP GLOW PLUGS THERMOSTAT HSG. FUEL FILTER ( B LEED ON TOP) FUEL AIR B LEED VALVE SEA WATER TO EXHAUST TH ROTILE TRANSMISSION .._ B LOCK COOLANT DRAIN SHIFT LEVER FLEX MOUNTS TIMING PORT...
  • Page 54 U NIVERSAL MODEL M-1 8 SPECI FICATIONS Horsepower 3200 No. of Cylinders Bore x Stroke 2.60 x 2.45 Cubic I nch Maximum R.P.M. 3200 Cruising Range (Approx.) 2100/2600 R . P. M . 21 :1 Compression Ratio Electrical Equipment 1 2 Volt - 51 Amp W/Glow Plugs Lubrication (Eng.
  • Page 55 U N I V E RSA L M O D E L M · 1 8 OIL FILL CAP THERMOSTAT HSG. FUEL FILTER B LEED ON TOP FUEL AIR B LEED VALVE SEA WATER TO EXHAUST STOP LEVER THROTTLE TRANSMISSION ..._ B LOCK COOLANT DRAIN SHIFT LEVER FLEX MOUNTS...
  • Page 56 UNIVERSAL MODEL M-20 SPECIFICATIONS Horsepower 2800 No. of Cylinders Bore x Stroke 2.68 x 2.76 Cubic Inch Maximum R . P. M . 2800 Cruising Range (Approx.) 2000/2400 R . P. M . Compression Ratio 21 :1 Electrical Equipment 1 2 Volt - 51 Amp W/Glow Pl ugs Lubrication (Eng.
  • Page 57 UN IVERSAL MODEL M-20 FUEL LIN ES INJECTORS AIR B REATHER FUEL RETURN FUEL AIR GLOW PLUGS ---- --l B LEED VALVE SEA WATER OVER B OARD HEAT EX. DRAIN ZINC & STOP LEVER TRANS. DIP STICK & OIL FILL HOLE --- SHIFT LEVER B LOCK COOLANT DRAIN ENGIN E COUPLING/...
  • Page 58 UN IVERSAL MODEL M3-20 SPECIFICATIONS Horsepower 3600 No. of Cylinders Bore x Stroke 2.60 x 2.45 Cubic I nch 38.9 Maximum R . P. M . 3600 Cruising Range (Approx.) 2600 - 3300 Compression Ratio 23:1 12 Volt - 51 Amp W/Glow Pl ugs Electrical Equip.
  • Page 59 U N IVERSAL MODEL M3-20 OIL FILL CAP GLOW PWGS INJECTORS FUEL RET U R N FUEL FIL TER (A I R BLEED O N TOP ) FUEL AIR BLEED VALVE SEA WA TER TO EXHAUST & TRANS. DIP STICK OIL FILL HOLE DIP STICK ENGINE C O U P L I N G...
  • Page 60 U N IVERSAL MODEL M-25 SPECIFICA TIONS Horsepower 3200 No. of Cylinders Bore x Stroke 2.83 x 2.76 Cubic I nch Maximum R. P. M . 3000 Cruising Range (Approx.) 2100/2600 R . P. M . Compression Ratio 21 :1 Electrical Equipment 12 Volt 51 Amp W/G low Pl ugs...
  • Page 61 UN IVERSAL MODEL M-25 FUEL LINES AIR BREATHER FUEL RETURN INJ. PUMP BLEED EXHAUST FLANGE -­ G LOW PLUGS THROTTL E CLEAN OUT COVERS TRANS. DIP STICK STOP LEVER & OIL FILL HOLE DIP STICK ENGIN E COUPLING SHIFT LEVER FLEX MOUNTS TIMING PORT B ELL HOUSING...
  • Page 62 UN IVERSAL MODEL M-25XP SPECIFICA TIONS (UPDA TE OF M-25) Horsepower 3200 No. of Cylinders 2.95 x 2.76 Bore x Stroke Cubic I nch 56.6 Maximum R . P. M . 3200 Cruising Range (Approx.) 21 00/2600 R . P. M . Compression Ratio 21 :1 Electrical Equipment...
  • Page 63 U N IVERSAL MODEL M-25XP OIL FILL CAP THERMOSTA T HSG. AIR BREATHER FUEL FILTER AIR B LEED O N TOP FUEL AIR BLEED VALVE SEA WATER TO EXHAUS T DIP STICK ENG I N E COUPL I N G - BLOCK COOLANT DRAIN BELL HSG.
  • Page 64 U N IVERSAL MODEL M4-30 SPECIFICATIONS Horsepower 3600 No. of Cylinders Bore x Stroke 2.60 x 2.45 Cubic Inch 51 .9 Maximum R.P.M. 3600 Cruising Range (Approx.) 2600 - 3300 Compression Ratio 23:1 Electrical Equip. 12 Volt 51 Amp W/Glow Plugs Ots.) Lubrication (Eng.
  • Page 65 U NIVERSAL MODEL M4-30 OIL FILL CAP GLOW PWGS THERMOSTAT HSG. FUEL FILTER (AI R BLEED ON TOP ) FUEL AIR BLEED VAL VE SEA WA TER TO EXHAUST CLEAN OUT COVER & TRANS. D I P STICK --­ O I L FILL HOLE DIP STICK �...
  • Page 66 U N IVERSAL MODEL M-30 SPECI FI CATIONS Horsepower 2800 No. of Cylinders Bore x Stroke 3.00 x 3.23 Cubic I nch Maximum R . P. M . 2800 Cruising Range (Approx.) 2000-2400 R. P. M . Compression Ratio 21 :1 Electrical Equipment 1 2 Volt - 51 Amp W/Glow Plugs Lubrication (Eng.
  • Page 67 UNIVERSAL MODEL M-30 FUEL LINES AIR BREATHER FUEL RETURN FUEL AIR GLOW PLUGS ---- -- -' BLEED VALVE SEA WATER OVERBOARD H EAT EX. DRAIN ZINC & STOP LEVER ­ TRANS. DIP STICK & OIL FILL HOLE --- SHIFT LEVER BLOCK COOLANT DRAIN ENGINE COUPLING TIMING PORT...
  • Page 68 U N IVERSAL MODEL M-35 SPECI FI CATIONS Horsepower 3200 No. of Cyl inders Bore x Stroke 2.96 x 2.76 Cubic Inch 75.5 Maximum R . P. M . 3200 Cruising Range (Approx.) 21 00-2600 R . P. M . Compression Ratio 21 :1 Electrical Equipment...
  • Page 70 UNIVERSAL MODEL M-40 SPECIFICATIONS Horsepower 2800 No. of Cyli nders Bore x Stroke 3.00 x 3.23 Cubic Inch Maximu m R.P.M. 2800 Cruising Range (Approx.) 2000/2500 R . P. M . 21 :1 Compression Ratio Electrical Equipment 1 2 Volt - 51 Amp W/Glow Plugs Qts.) Lubrication (Eng.
  • Page 72 UNIVERSAL MODEL M-50 SPECIFICATIONS Horsepower 44 @ 3000 No. of Cylinders Bore x Stroke 3.35 x 3.23 Cubic I nch 1 1 5 Maximum R . P. M . 3000 Cruising Range (Approx.) 2000/2500 R . P. M . Compression Ratio 21 :1 Electrical Equipment 12 Volt - 51 Amp W/Glow Plugs...
  • Page 73 U NIVERSAL MODEL M-50 FUEL LINES AIR BREATHER FUEL RETU RN FUEL AIR G LOW PLUGS ---- -_ _; ; BLEED VALVE SEA WATER OVERBOARD H EAT EX. DRAIN ZINC & STOP LEVER ­ TRANS . DIP STICK & OIL FILL HOLE SHIFT LEVER BLOCK COOLANT DRAIN ENGINE COUPLING...
  • Page 74 PROGRAMMABLE TACHOMETER W/ HOURMETER On the back of the tachometer there i s a n over/shaped black p l u g . U po n removal o f the p l u g , fou rteen switches wi l l be visible. The switches are divided i nto two sections. The p rog ram m ust be e ntered from left to right, i .e.
  • Page 75 MODELS - M- 1 5 M- 1 8 � o . l BACK O F TACH SEND MODELS - M- 2 0 M- 3 0 BACK OF TACH SEND MODEL - M- 2 5 BACK O F TACH SEND...

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