Perkins Installation Manual
Perkins Installation Manual
® GB
Installation Manual
Foreword
Thank you purchasing the Perkins M300C, M250C, M216C & M190C marine diesel engine. This manual
contains information for the correct installation of your Perkins engine.
Information contained in this manual is correct at the time of printing. Wimborne Marine Power Centre
reserves the right to make changes at any time. If there are any differences between this manual and your
engine, please contact the Wimborne Marine Power Centre.
General safety precautions • If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
These safety precautions are important. You must refer
also to the local regulations in the country of use. Some • Diesel fuel and lubricating oil (especially used
items only refer to specific applications. lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special
• Only use these engines in the type of application for solution to protect the skin.
which they have been designed.
• Do not wear clothing which is contaminated
• Do not change the specification of the engine. by lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
• Do not smoke when you put fuel in the tank.
• Discard used lubricating oil in accordance with local
• Clean away fuel which has been spilt. Material which regulations to prevent contamination.
has been contaminated by fuel must be moved to a
safe place. • Use extreme care if emergency repairs must be
made at sea or in adverse conditions.
• Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary). • The combustible material of some components of
the engine (for example certain seals) can become
• Do not clean, add lubricating oil, or adjust the engine extremely dangerous if it is burned. Never allow this
while it runs (unless you have had the correct
burnt material to come into contact with the skin or
training; even then extreme care must be used to
with the eyes.
prevent injury).
• Always close the seacock before the removal of any
• Do not make adjustments that you do not understand. component of the auxiliary water circuit.
• Ensure that the engine does not run in a location • Wear a face mask if the glass fibre cover of the
where it can cause a concentration of toxic
turbocharger is to be removed or fitted.
emissions.
• Always use a safety cage to protect the operator
• Other persons must be kept at a safe distance when a component is to be pressure tested in
while the engine, auxiliary equipment or boat is in
a container of water. Fit safety wires to secure
operation.
the plugs which seal the hose connections of a
• Do not permit loose clothing or long hair near moving component which is to be pressure tested.
parts.
• Do not allow compressed air to contact your skin. If
• Keep away from moving parts during engine compressed air enters your skin, obtain medical help
operation. immediately.
2 Engine mounting............................................................................3
Installation angles............................................................................................ 3
Nose down capability............................................................................ 3
Engine mounting brackets.............................................................................. 4
Flexible engine mounts.................................................................................... 5
Engine bearers................................................................................................. 6
4 Exhaust systems............................................................................9
Wet systems...................................................................................................... 9
Dry systems..................................................................................................... 11
Part dry, part wet systems.............................................................................. 12
Water lift systems............................................................................................ 12
Silencers.......................................................................................................... 13
7 Fuel systems..................................................................................19
Cleanliness of fuel system components....................................................... 19
Cleanliness of the engine.................................................................... 19
Environment......................................................................................... 19
New components.................................................................................. 19
Refuelling.............................................................................................. 19
Fuel connections.................................................................................. 19
Thread details of the connections on the engines for fuel pipes.... 20
Typical fuel systems............................................................................ 21
Alarm tank............................................................................................. 22
Interconnecting cables................................................................................... 25
Instrument panels............................................................................................ 26
Main panel............................................................................................. 26
Auxiliary panel...................................................................................... 27
Mini Marine Power Display (MMPD) digital panel.............................. 28
Keyswitch panel................................................................................... 28
Throttle synchronization / slow vessel mode panel......................... 29
Possible panel configurations............................................................ 30
Mini Marine Power Display (MMPD) instructions.............................. 31
CAN Data Link...................................................................................... 35
For engines without an MJB (Marine Junction Box).................................... 36
For engines fitted with the Marine Junction Box (MJB).............................. 37
Single engine MJB features and mounting details........................... 38
Twin engine MJB features and mounting details.............................. 39
Power connections.............................................................................. 40
Current requirements 12 or 24 vdc system....................................... 40
ECM port or starboard interface connectors..................................... 40
Grounding the battery negative.......................................................... 40
Port or starboard expansion connectors........................................... 41
Diagnostic lamp (Pin 2)........................................................................ 42
Warning lamp (Pin 1)............................................................................ 42
- Battery (Pin 11)................................................................................... 42
Keyswitch (Pin 12)................................................................................ 42
Maintenance Clear switch (Pin 16)..................................................... 42
Cold start system ........................................................................................... 43
Cold start data 12V and 24V ............................................................... 43
Battery performance ........................................................................... 43
Battery to starter lead resistance ...................................................... 43
Battery isolator switches..................................................................... 44
Zinc Anode bonding system.......................................................................... 44
Typical system in common use.......................................................... 45
Optional sensors............................................................................................. 45
Wiring diagrams.............................................................................................. 47
*Engine wiring harness overview, without MJB................................ 47
*Engine wiring harness, wiring description, without MJB............... 48
*Engine wiring harness overview....................................................... 49
*Panel harness overview..................................................................... 50
*Engine wiring harness 1..................................................................... 51
*Engine wiring harness 2..................................................................... 52
*Engine panels 1................................................................................... 53
*Interconnecting leads 1...................................................................... 54
*Master/slave option, port................................................................... 55
*Marine junction box............................................................................ 56
*Master/slave option, starboard.......................................................... 57
*Interconnecting leads 2...................................................................... 58
*Engine panels 2................................................................................... 59
N40475 Contents
9 Engine controls.............................................................................61
12 Options.........................................................................................67
Gearbox oil temperature sensor.................................................................... 67
13 Reference data.............................................................................69
Basic data M300C, M250C, M216C, M190C................................................... 69
Cooling............................................................................................................. 69
Fuel system...................................................................................................... 70
Air intake.......................................................................................................... 70
Lubricating system......................................................................................... 71
Electrical system............................................................................................. 71
Cold start limits............................................................................................... 71
Contents N40475
N40475 Chapter 1
Exhaust Systems
(See chapter 4)
Bonding Stud
(See chapter 8)
Front Lifting Eye
Warning! Ventilation (See
Use spreader bar. chapter 5)
Cooling Systems
(See chapter 6)
Mounting Brackets
Engine Mounting Point
(See chapter 2)
(See chapter 2)
Engine side views
Page 1
Chapter 1 N40475
Exhaust Systems
(See chapter 4)
Electrical
Systems (See
chapter 8)
Fuel Return
(See chapter 7)
Mounting Brackets
Engine Mounting Points (See chapter 2)
(See chapter 2)
Page 2
N40475 Chapter 2
Engine mounting
Installation angles
These engines are intended to be mounted so that
the cylinders are vertical, when viewed from ahead or
astern as in figure 1. The operational angles that are
permissible in service are a static installation angle of
17O nose up, adding 3O for planing craft, with a heel
angle of 25O continuous and 35O as shown in figures
2 and 3.
25O 25O
35O 35O
Figure 2
20O
Figure 3.
Page 3
Chapter 2 N40475
Figure 4
Page 4
N40475 Chapter 2
Page 5
Chapter 2 N40475
Engine bearers
The materials and methods of construction of engine
bearers which have proved to be satisfactory in service
vary to such an extent that it is difficult to lay down
universal guide lines. However, as a rough guide it
can be said the engine bearers should be capable of
supporting a static load of about eight times the weight
of the engine, to cater for the effects of rough seas.
Page 6
N40475 Chapter 3
Propeller shafts
It is recommended that all engines are mounted on flexible
mountings (1), which will reduce noise and vibration,
and will prevent hull movements resulting in forces being
applied to the engine.
Water supply (4) for bearings (use hose from M14 x 1.5
tapping on heat exchanger end cap). End cap with tapping
is optional.
Figure 2
Page 7
Chapter 3 N40475
Page 8
N40475 Chapter 4
Exhaust systems
Wet systems
Figure 1
Wet exhaust systems, where the auxiliary water
used to circulate through the heat exchangers on the
engine is finally dumped into the exhaust pipe to cool
the exhaust gases, are the most common choice for
small craft. Their principal advantage is that a rubber
exhaust hose may be used, with a fairly low surface
temperature, which presents no risk of fire.
Page 9
Chapter 4 N40475
Figure 2 shows the exhaust elbow (1) with water
injection and insulating blanket (3) & (4). The elbow
can be rotated (2) to achieve the optimal position.
Figure 2
Figure 3
Page 10
N40475 Chapter 4
Dry systems
Dry exhaust systems for marine installations need
careful design to minimize the disadvantages of
enclosing components that are at a high temperature
in confined spaces.
Page 11
Chapter 4 N40475
(5) Top of exhaust riser and point at which the siphon break
is connected to the engine pipe work must be above the Figure 6
water line under the worst possible conditions (normally
a distance of 450mm (18”) under static conditions will be
sufficient)
Page 12
N40475 Chapter 4
Silencers
In some applications a reduction in noise levels from
the exhaust would be desirable and to that extent, a
silencer can be fitted.
Page 13
Chapter 4 N40475
Page 14
N40475 Chapter 5
Cross sectional area of air flow path must not be too small.
When the engines are shut down after a run at high output
in high ambient temperature conditions, it will be found
that very high air temperatures will build up in the engine
compartment. In boats with open cockpits this is usually of
no real consequence but if the engines are mounted below
a wheel house, then unpleasantly warm conditions may
result. In these circumstances engine room ventilation fans
are beneficial, preferably arranged to exhaust air from over
the engine.
Page 15
Chapter 5 N40475
Page 16
N40475 Chapter 6
Between the intake fitting and the sea water pump (1)
on the engine, there should be a strainer (5) which
should be easily accessible for routine examination,
and should be easily removable.
Figure 1
Page 17
Chapter 6 N40475
Figure 3
Page 18
N40475 Chapter 7
Fuel systems
NOTICE
It is important to maintain extreme cleanliness when working on the fuel system, since even tiny particles can
cause engine or fuel system problems.
Ensure the external surfaces of the engine are clean and dry before commencing work. Remove dirt and loose
debris before starting a repair on the fuel system. Ensure that no high pressure water is directed at the seals
for the injectors.
Environment
When possible, the service area should be positively pressurised with a clean air supply in order to ensure
that the components are not exposed to contamination from airborne dirt and debris. When a component is
removed from the system, the exposed fuel connections must be closed off immediately with suitable sealing
plugs. The sealing plugs should only be removed when the component is reconnected. The sealing plugs must
not be reused. Dispose of the sealing plugs immediately after use. Contact your nearest Perkins distributor in
order to obtain the correct sealing plugs.
New components
High pressure fuel lines are not reusable. New high pressure lines are manufactured for installation in one
position only. When a high pressure line is replaced, do not bend or distort the new line. Internal damage to the
pipe may cause metallic particles to be introduced to the fuel.
All new fuel filters, high pressure lines, tube assemblies and components are supplied with sealing plugs.
These sealing plugs should only be removed in order to install the new part. If the new component is not
supplied with sealing plugs then the component should not be used. The technician must wear suitable rubber
gloves. The rubber gloves should be disposed of immediately after completion of the repair in order to prevent
contamination of the system.
Refuelling
In order to refuel the diesel fuel tank, the refuelling pump and the fuel tank cap assembly must be clean and
free from dirt and debris. Only use fuel, free from contamination, that conforms to the specifications in the
Users Handbook.
Design and assembly faults in the fuel system are responsible for many problems with marine diesel engines.
A good system is not hard to achieve, being largely a matter of avoiding obvious pitfalls.
Fuel connections
A common reason for service problems with fuel systems is the use of poor or incompatible connectors, where
the pressure tightness depends upon the use of sealing compounds, hose clamps, fibre washers trapped
between inadequate and unmachined faces, or compression fittings which have been over-tightened to the
point where they no longer seal.
Cleanliness during initial assembly is also of vital importance, particularly when fuel tanks are installed, as
glass fibres and other rubbish may enter tanks through uncovered apertures.
Page 19
Chapter 7 N40475
It is strongly recommended that the flexible fuel pipes, available as an option with the engine are used, which
are as follows:
Fuel feed
The free end of the flexible pipe has a 11/16” ORFS ended fitting, and is supplied with an connector to 1/4”
NPT.
Fuel return
The free end of the flexible pipe has a 11/16” ORFS ended fitting, and is supplied with an connector to 1/4”
NPT.
• The filler neck should be raised so that water will not enter when filling.
• The filler cap should seal effectively to prevent water entering when under way.
• A vent pipe should be fitted, again in such a way as to avoid the entry of water.
• The tank should have a sump or angled bottom with a drain tap so that water and sediment can be removed.
(This is not always possible).
• The fuel pipe work should be as simple as possible with the minimum of valves and cross connections, so
that obscure fuel feed problems are minimised.
• The tank should have at least two connections; a fuel feed connection, and a fuel return connection.
Whenever possible a tank should only supply one engine, but in any case each engine should have its own
fuel pipes, from tank to engine.
Page 20
N40475 Chapter 7
1. Fuel tank.
4. Stop cock.
Figure 1 5. Vent.
6. Drain.
1. Fuel tank.
4. Vent.
6. Drain tap
Page 21
Chapter 7 N40475
In some cases it is necessary to have a number of
fuel tanks in order to achieve the required operating
range. In such cases, where possible, one tank
should be regarded as the main tank for each engine
and the other tanks should be arranged so that they
will drain into the main tank by gravity. If a gravity
system is not possible, then the system shown in
figure 3 should be used.
Alarm tank
If the engine is equipped with duplex fuel pipes the
sensor in the alarm tank detects if there is a leak in
the inner fuel pipe.
Page 22
N40475 Chapter 8
Page 23
Chapter 8 N40475
Breakers
Note: Breakers are provided to protect the electrical
system against accidental short circuits. The risk is
highest when the engine is being installed, or when
additional equipment is wired in, and is negligible
during normal operation.
Figure 1
Page 24
N40475 Chapter 8
Interconnecting cables
Interconnecting cables (figure 3) are used to join the
engine (1), throttle (3), battery (4), via the marine
junction box (2), to the instrument panel(s) (5). Cables
are made in a 12m length as standard, 3, 6 & 9 lengths
are optional. If a longer cable is required it should be
ordered as a special item, to be made in one piece.
Figure 2 shows:
1. Engine.
2. MJB (Marine Junction Box).
3. Throttle.
4. Battery (customer supplied).
5. Instrument panel - main or auxiliary.
6. MMPD, digital panel.
7. Keyswitch panel.
8. Harness, engine to MJB.
9. Harness, throttle.
10. Harness, main or auxiliary panel, J1939 requires
tee connector.
11. Harness, keyswitch.
12. Harness, MMPD (digital panel).
13. Battery lead (customer supply).
14. Master/slave lead.
Figure 2
Figure 3
Page 25
Chapter 8 N40475
Instrument panels
Three types of panel are available, providing different
levels of instrumentation.
Main panel
• 12 or 24 volt operation from same panel.
1. Tachometer
3. Warning light
5. Warning light
7. Warning light
8. Warning lamp
9. Diagnostic lamp
Page 26
N40475 Chapter 8
Auxiliary panel
• 12 or 24 volt operation from same panel.
1. Tachometer
3. Warning light
4. Warning lamp
5. Engine crank
6. Keyswitch on/off
7. Diagnostic lamp
9. Panel illumination
Figure 5
Page 27
Chapter 8 N40475
• 5 display screens.
• Operates on 12 or 24 V systems.
• IP 67 rated.
1. Display:
2. Screen illumination
Figure 6
3. Alarm mute
Keyswitch panel
The ‘Keyswitch panel’, used with the digital panel, is
shown in figure 7 and is 110mm x 90mm and includes:-
1. Engine crank
2. Warning lamp
3. Diagnostic lamp
4. Engine stop switch
5. Keyswitch on/off
The cutout dimensions are shown below the panel
illustration.
Figure 7
Page 28
N40475 Chapter 8
The slow vessel mode (2) reduces the low idle of the
engine to 600rpm. This feature allows the customer to
Figure 8 operate the vessel at slow speeds with all engines in
gear for manoeuvring. Slow Vessel Mode cannot be
engaged during the first 15 seconds after the engine
has started or while the engine is in cold mode. When
slow vessel mode is engaged, the desired engine
speed will ramp down to the appropriate speed at a
fixed rate. Slow vessel mode can be exited at any
time. When slow vessel mode is disengaged, the
desired engine speed will ramp up to the appropriate
speed at a fixed rate.
Page 29
Chapter 8 N40475
1. Power supply.
3. Main panel.
4. Auxiliary panel.
6. Keyswitch panel.
Figure 9
Page 30
N40475 Chapter 8
Information screens
There are two information screens available, the
System Information screen and the Control System
Information screen (figure 10). Pressing the button
labelled Menu will display the System Information
screen or the control system Information screen.
Page 31
Chapter 8 N40475
Change screen
Pressing the alarm button will cause the Control
System Information screen to be displayed. This
option is only available if the MMPD has detected a
Powertrain Control Processor (PCP) on the CAN data
link.
Page 32
N40475 Chapter 8
Change screen
Pressing the alarm button will cause the System
Information screen to be displayed.
Page 33
Chapter 8 N40475
Vessel status bar
The status indicators are shown across the top of
the screen in reverse video and are only available on
parameter screens, except for the diagnostic icon,
which is shown on all screens.
Page 34
N40475 Chapter 8
Cables required
Where Used: Connects the PCP and MMPD displays
into the J1939 data link.
The J1939 data link (item 1 figure 15) can not exceed
40 meters (131ft.).
Requires:
6-pin Tee
Termination resistor
J1939-15
Figure 16
Maximum Drops (nodes) 10
Shielded Cable NO
Figure 17
Page 35
Chapter 8 N40475
2. Twin engine.
Figure 18
3. Throttle synchronisation and slow vessel mode.
4. Key switch.
5. Throttle.
6. J1939.
7. Fuse (ignition).
Figure 19
Page 36
N40475 Chapter 8
Figure 20
Page 37
Chapter 8 N40475
2. Throttle.
3. Expansion.
4. ECM.
5. J1939.
6. Key/alarm.
7. Custom.
9. PDL connector.
Figure 21
Page 38
N40475 Chapter 8
Figure 22
Page 39
Chapter 8 N40475
Power connections
1. Marine junction box.
3. Batteries
Page 40
N40475 Chapter 8
Figure 24
Figure 25
Figure 26
Page 41
Chapter 8 N40475
1. Diagnostic lamp.
Figure 28
2. + Battery bus bar.
1. Warning lamp
2. + Battery bus bar.
Page 42
N40475 Chapter 8
Battery performance
Battery Selection Tables By Engine-Results For Bare Engines based on min required speed of 100 rpm
Engine tested with 75% state of charge batteries and 1.7 mω cable resistance
Starter information Temperature & oil grade without glow plugs
Voltage Starter type -5OC 15W40
12V Iskra AZF 950
24V Iskra AZF 650
(1) Voltage no less that 7,5V after 10 seconds, 6V after 90 seconds at -18OC (0OF) across each 12V battery.
(2) Voltage no less than 7,2V after 30 seconds at -18OC (0OF) across each 12V battery.
(3) Voltage no less than 6,0V after 150 seconds at -18OC (0OF) across each 12V battery.
Page 43
Chapter 8 N40475
Figure 30
Page 44
N40475 Chapter 8
Length of run to
Suggested cable size
Zinc Anode
Up to 30 feet 7 strand / 0.85mm (4mm2)
30 - 40 feet 7 strand / 1.04mm (6mm2)
(1) Engine.
Optional sensors
• Throttle position.
• Fuel level.
• Coolant level.
• Fuel temperature.
Page 45
Chapter 8 N40475
Page 46
N40475 Chapter 8
Wiring diagrams
*See the CD for PC compatible version of this diagram. *Engine wiring harness overview, without MJB
Page 47
Chapter 8 N40475
*See the CD for PC compatible version of this diagram. *Engine wiring harness, wiring description, without MJB
Page 48
N40475 Chapter 8
*See the CD for PC compatible version of this diagram. *Engine wiring harness overview
Page 49
Chapter 8 N40475
*See the CD for PC compatible version of this diagram. *Panel harness overview
Page 50
N40475 Chapter 8
*See the CD for PC compatible version of this diagram. *Engine wiring harness 1
Page 51
Chapter 8 N40475
*See the CD for PC compatible version of this diagram. *Engine wiring harness 2
Page 52
N40475 Chapter 8
Page 53
Chapter 8 N40475
Page 54
N40475 Chapter 8
*See the CD for PC compatible version of this diagram. *Master/slave option, port
Page 55
Chapter 8 N40475
*See the CD for PC compatible version of this diagram. *Marine junction box
Page 56
N40475 Chapter 8
*See the CD for PC compatible version of this diagram. *Master/slave option, starboard
Page 57
Chapter 8 N40475
Page 58
N40475 Chapter 8
Page 59
Chapter 8 N40475
Page 60
N40475 Chapter 9
Engine controls
1. Throttle lever.
4. Idle position.
5. Run position
Figure 1
Page 61
Chapter 9 N40475
Page 62
N40475 Chapter 10
or
Figure 3
Page 63
Chapter 10 N40475
Polar diagram
This diagram shows the loading capability of the front
of the crankshaft.
Figure 4
Page 64
N40475 Chapter 11
Calorifier
Fittings are available to allow a calorifier to be
connected to the engine, as shown in figure 1. The
fittings may be ordered as part of the engine assembly,
or as loose parts to be fitted later.
Figure 2
Page 65
Chapter 11 N40475
Page 66
N40475 Chapter 12
Options
Figure 1
Page 67
Chapter 12 N40475
Page 68
N40475 Chapter 13
Reference data
Cooling
Cooling System ....................................The coolant shown is mandatory for use in all climates to
ensure that adequate levels of corrosion inhibitor are present.
It will give frost protection to -37OC.
Coolant..................................................................... 50% inhibited ethylene glycol or
50% inhibited propylene glycol with 50% fresh clean water.
Fresh Water Flow........................220 l/min at 2400 rpm....220 l/min at 2400 rpm... 220 l/min at 2400 rpm... 193 l/min at 2100 rpm
Coolant pump speed and method of drive............................1:1 Gear Driven.
System Capacity............................................................. 26.3 litres (5.7 gallons).
Pressure cap setting................................................................ 50kPa (7psi).
Sea water pump type........................................................ Gear driven full cam.
Sea water suggested inlet...................................... 32mm Bore (1.25”) hose diameter.
Sea cock...........................................................................Full flow 32mm (1.25”)
Strainer........................................ Auxiliary water strainer must be included in suction side of the circuit
Maximum sea water temperature............................................ 38OC (100OF)
Sea water flow........................ 137 l/min at 2400rpm.... 137 l/min at 2400rpm.....137 l/min at 2400rpm.....128 l/min at 2100rpm
Page 69
Chapter 13 N40475
Fuel system
Recommended fuel ............................................... DIN E 590 DERV (class A-F & 0-4)
BS2869 Class A2 (Off highway, gas oil, red diesel)
ASTM D975-91 Class 1-1DA & Class 2-2DA
JIS K2204 (1997) Grades 1, 2, 3 & Special grade 3
Fuel injection pump...................................................................... CR200
Fuel lift pump................................................................................manual
Fuel feed pressure (static)...............................................0.3 to 0.6 bar (5 to 8psi)
Governor type................................................................................A4:E2
Pipe size:
• Supply - outside diameter.................................................... 10mm (0.394”)
• Supply - bore....................................................................... 8.4mm (0.331”)
• Return - outside diameter..................................................... 10mm (0.394”)
• Return - bore....................................................................... 8.4mm (0.331”)
Maximum lift pump lift.........................................1.8m (6ft) to bottom of tank suction pipe.
Maximum fuel lift pump .................................... 127mm (5 inches) Hg depression at inlet.
Fuel consumption at full .................62 l/hr...................51.9 l/hr................ 44.74 l/hr................ 37.03 l/hr
Air intake
Combustion airflow..................... 15.7m3 /min...........15.04m3 /min.......... 14.6m3 /min........... 12.33m3 /min
Maximum engine compartment .................................................... 60OC.
air temperature.
Maximum air temperature at......................................................... 52OC.
engine inlet
Ventilation - maximum engine...........................................125mm WG (5” WG).
room depression
Minimum cross section........... 968cm2 for hot climates...806cm2 for hot climates....697cm2 for hot climates... 613cm2 for hot climates
of air duct (per engine).......... 484cm2 for temp climates..403cm2 for temp climates.. 348cm2 for temp climates. 306cm2 for temp climates
Exhaust
Exhaust gas flow........................ 45.9m3 /min............36.8m3 /min.......... 27.13m3 /min.......... 22.97m3 /min
Maximum restriction measured.....................................................15kPa
within (305mm) 12” of turbocharger outlet .
Recommended pipe bore (wet exhaust) ................................ 127mm (5.0”)
Recommended pipe bore (dry)................................................. 69mm (2.7”)
Minimum rise from sea level to................................................ 203mm (8.0”)
exhaust outlet centre-line
Page 70
N40475 Chapter 13
Lubricating system
Recommended lubricating oil................................................API / CH4 / CI-4
Sump capacity maximum.................................................. 15 litres (3.3 gallons)
Maximum operational angle ........................20O nose up. Heel 25O constant, 35O intermittent
Oil pressure in operating.............................................................. 3.6 bar
speed range (steady state)
Electrical system
Alternator................................................... Insulated return 12 Volt-100 amp or 24 Volt-55 amp
Starter type....................................................................................4.0Kw
Number of teeth in flywheel.............................................................126
Number of teeth on starter...............................................................10
Page 71
Chapter 13 N40475
Page 72
Index
A
Absorbent material.........................15 Battery voltage...............................43 Common bonding wire...................45
Activate station button status.........33 Bellows...........................................10 Component failures........................42
Activate station lamp status............33 Belt drives.......................................63 Compression fittings.................19, 21
Active diagnostic code....................42 Bilge...............................................15 Condensate.................................... 11
Active diagnostic status..................34 Blanking plugs................................23 Configuration screen......................29
Active station lamp status...............32 Bleed..............................................18 Connections...................................65
Active station location.........32, 33, 34 Blockage.........................................17 Connectors.....................................23
Adjuster nut......................................5 Block heater...................................65 Constant velocity joints.....................7
Aftercooler......................................18 Block heating..................................43 Contamination................................19
Aftercooler circuit............................18 Boat builder......................................7 Control processor.....................38, 39
Aftercooler grid cooler....................18 Boat designer...................................7 Control stations..............................40
Aft station.................................32, 33 Bonding..........................................44 Control system...............................42
Air...................................................15 Bonding stud....................................1 Control system information.......31, 32
Airborne dirt....................................19 Bonding system........................40, 45 Control system information screen.32
Air duct...........................................15 Bore..........................................17, 18 Coolant level...................................45
Air entry vents................................15 Bow station...............................32, 33 Coolers...........................................18
Air flow............................................15 Breakers.......................23, 24, 38, 39 Cooling systems...............................1
Air intake........................................15 Bridge.......................................32, 33 Cooling water.................................13
Air locks....................................18, 21 Bulkhead........................................10 Copper......................................17, 21
Air temperature...............................15 ‘Bundy’ steel tubing........................21 Core plug........................................65
Alarm button.......................31, 32, 33 Busbar......................................40, 42 Corrosion inhibitors........................18
Alarm mute.....................................28 Button status indicator....................33 Cranking speed..............................43
Alarm tank......................................22 Crankshaft......................................64
Alignment.........................................4 C Cross connection......................20, 21
Alloys..............................................17 Cross section..................................15
Cable........................................30, 45
Alternator..................................15, 23 Cross sectional area.......................15
Cable length...................................40
Aluminium.................................17, 21 Cupro-nickel...................................17
Cables......................................25, 35
Ambient temperature......................15 Current draw...................................40
Calorifier.........................................65
Angular misalignment.......................7 Custom...........................................38
Cancel............................................33
Anodes...........................................17 Customer connect harness............36
Can data.........................................35
Armoured rubber hose...................21 Customer connector.......................40
Can data link..................................32
Assembly faults..............................19 Custom panel connector................42
Cap.................................................19
Audible alarm.................................28 Custom (port side)..........................39
Cavity.............................................22
Auxiliary..........................................23 Custom (starboard side).................39
Centrifugal force...............................7
Auxiliary panel................................30 Cutless bearing................................7
Change display units......................32
Auxiliary water..................................9 Cutout dimensions....................26, 28
Change display units......................31
Auxiliary water pump......................18 Cylinder jacket................................18
Change engine sync master...........33
Auxiliary water systems..................17 Cylinder jacket circuit.....................18
Change screen.........................32, 33
Auxiliary panel................................25 Cylinder jacket grid cooler..............18
Change screen.........................31, 32
Average fall.....................................12
Change set speed..........................32 D
Axial drives.....................................63
Change station location..................32
B Change sync master......................32 Data link.............................32, 35, 40
Change system information screen.32 Debris.............................................19
Back pressure..........................12, 13 Change troll mode.....................32,33 Deflector baffles.............................15
Baffles............................................20 Change troll speed.........................33 Derate event code..........................42
Balancing pipe................................21 Change unit location.................31, 32 Diagnostic code........................31, 32
Batteries.........................................40 Change user.............................31, 32 Diagnostic flash codes...................42
Battery..........................25, 38, 39, 44 Change vessel speed.....................31 Diagnostic icon...............................34
Battery......................................25, 42 Change vessel speed units......31, 32 Diagnostic lamp..................26, 28, 42
Battery bus bar...............................42 Clamps...........................................10 Diesel fuel tank...............................19
Battery cables.................................40 Cleaning...................................17, 20 Digital.............................................23
Battery isolator switches.................44 Cleanliness.....................................19 Digital panel..............................28, 30
Battery lead....................................25 Clips...............................................23 Dirt............................................19, 23
Battery negative.............................40 Cold mode......................................29 Disabled.........................................29
Battery power.................................40 Cold start system............................43 Display............................................28
Battery reverse isolator..................40 Collector tank.................................22 Display units.............................31, 32
Battery selection tables..................43 Combustion....................................15 Distributor.......................................19
Battery type....................................43 Combustion noise...........................13 Drain...............................................21
Drain tap...................................20, 21 Expansion.......................................38 G.R.P..............................................21
Dry riser..........................................12 Expansion connectors....................41 Gun-metal.......................................17
Dry systems.................................... 11 Expansion (port side).....................39
Dual engine installation..................29 Expansion (starboard side)............39 H
Duplex fuel pipes............................22 Harness..............................23, 25, 50
F
E Heat................................................23
Fault codes.....................................28 Heat blanket................................... 11
Ecm..............................22, 37, 38, 42 Fault condition................................42 Heater.............................................65
Ecm and battery.............................36 Feed pipes......................................21 Heat exchangers..............................9
Ecm port.........................................40 Fibre washers.................................19 Heat rejection.................................18
Ecm (port side)...............................39 Filler cap.........................................20 Heel angle........................................3
Ecm (starboard side)......................39 Filler neck.......................................20 High air temperatures.....................15
Electrical grease.............................23 Fire risk........................................... 11 High output.....................................15
Electrical systems.............................2 Flexibility.........................................10 High pressure fuel lines..................19
Electric stop....................................23 Flexible drive coupling....................63 High pressure water.......................19
Electrolytic corrosion................17, 44 Flexible engine mounts....................4 High rise extension.........................12
Electronic engine controller (ecm)..23 Flexible fuel pipes...........................20 High temperature............................ 11
Electronic service tool....................42 Flexible hanger...............................12 Holding down bolts...........................4
Electronic throttle............................30 Flexible hose..................................17 Horsepower....................................15
Enabled..........................................29 Flexible mountings...............7, 17, 18 Hose clamps...................................19
Engine............................................25 Flexible shaft couplings....................7 Hot air.............................................15
Engine bearers.............................4, 6 Flow of air.......................................15 Hot climates....................................15
Engine circuit diagram....................23 Flow problems................................17 Hull 15, 17, 44
Engine compartment......................15 Fly bridge..................................32, 33 Hull movements................................7
Engine controls...............................61 Flying lead......................................23
Engine cooling systems..................17 Foreign matter................................22 I
Engine crank............................26, 28 Fresh water pump..........................18 Idle (neutral) lockout button............33
Engine electrical systems...............23 Front facia......................................26 Idle (neutral) lockout lamp..............33
Engine feed....................................22 Front lifting eye.................................1 Idle position....................................61
Engine hours/fault code display.....26 Fuel....................................19, 21, 22 Ignition............................................36
Engine installer.................................7 Fuel connection........................19, 21 Incompatible connectors................19
Engine interaction...........................21 Fuel feed....................................1, 20 Information screens........................31
Engine interface (ecm)...................36 Fuel feed tap..................................21 Injectors....................................19, 23
Engine location...............................31 Fuel filters.......................................19 Inlet connection..............................17
Engine mounting..............................3 Fuel level........................................45 In-line silencer................................13
Engine mounting brackets................4 Fuel lines........................................21 Inner fuel pipe.................................22
Engine mounting point..................1, 2 Fuel pipes.......................................20 Installation angles.............................3
Engine panels...........................53, 59 Fuel return..................................2, 20 Instrument panel.................23, 25, 26
Engine room.......................15, 32, 33 Fuel return pipe..............................21 Insulating blanket...........................10
Engine room ventilation..................15 Fuel supply pressure......................45 Insulating lagging........................... 11
Engine senders..............................23 Fuel surge......................................20 Insulation........................................45
Engine speed...........................32, 61 Fuel system....................................19 Intake fitting....................................17
Engine stop switch...................26, 28 Fuel system problems....................19 Intake vents....................................15
Engine synchronization..................34 Fuel tank.......................19, 20, 21, 22 Integral oil cooler............................18
Engine synchronization button.......33 Fuel temperature............................45 Intelli-troll........................................33
Engine synchronization lamp.........33 Full flow..........................................17 Interconnecting cables.............23, 25
Engine sync master..................32, 33 Fuse...............................................36 Interconnecting leads...............54, 58
Engine wiring looms.......................23 Interference....................................40
Environment...................................19 G
Ip 65...............................................26
Est..................................................29 Gas.................................................12 Ip 67....................................23, 28,26
Excessive temperature...................15 Gearbox..........................................67 Iron.................................................17
Exhaust..........................................13 Gearbox control options.................30
Exhaust back pressure.....................9 Gearbox coupling.............................7 J
Exhaust bore....................................9 Gearbox engagement.....................61
Exhaust elbow................................10 J61..................................................40
Gearbox oil cooler..........................18 J1939............................25, 35, 36, 38
Exhaust gases......................9, 12, 13 Gearbox oil temperature sensor.....67
Exhaust gas temperature...............45 J1939 (port side)............................39
Gear position..................................34 J1939 (starboard side)...................39
Exhaust manifold............................18 General arrangement.......................4
Exhaust outlet.............................9, 12 Jumper wire....................................41
Glass fibres....................................19 Junction box...................................37
Exhaust pipe.....................................9 Glow plugs......................................43
Exhaust riser..................................12 Gradient..........................................13
Exhaust system......................1, 9, 13 K
Gravity............................................22
Exhaust tank...................................12 Grounding.......................................40 Keel cooling system.......................18
Exit...........................................31, 32
Key.................................................63 O Rubbish..........................................19
Key/alarm.......................................38 Rudders..........................................17
Key/alarm (port side)......................39 Oil...................................................43 Run position...................................61
Key/alarm (starboard side).............39 Oil filter...........................................24
Keyswitch...........................36, 37, 42 Oil pressure gauge.........................26 S
Keyswitch on/off.......................26, 28 Open cockpits.................................15
Operating range.............................22 Sae j1939-15..................................35
Keyswitch panel...........23, 25, 28, 30 Safety switch..................................41
Knots........................................31, 32 Operational angles...........................3
Optional harness............................23 Sailing craft.....................................12
L Overboard outlet.............................12 Save...............................................33
Overheat.........................................15 Screen illumination.........................28
Labelled change screen.................31 Overhung load................................64 Screens..........................................28
Lamp status indicator.....................33 Scroll back button...........................28
Legislation......................................21 P Scroll forward button......................28
Load angle......................................64 Sea cock.........................................45
Loading...........................................64 Paint...............................................63 Sea level.........................................45
Logs................................................17 Panel illumination...........................26 Sealing compounds........................19
Loose debris...................................19 Parameters.....................................28 Sealing plugs..................................19
Low idle..........................................29 Parameter screens.........................34 Seals........................................19, 23
Low temperatures...........................65 Part dry...........................................12 Sea water.................................44, 45
Part wet..........................................12 Sea water pump.............................17
M Pcp.....................................32, 33, 35 Sea water strainer..........................17
Pdl connector...........................38, 39 Sea water system...........................17
Magnesium.....................................17 Pin..................................................23
Main..........................................23, 25 Secondary throttle..........................29
Pinch points....................................23 Secondary throttle enable status....29
Main panel................................26, 30 Pipework...................................17, 18
Main tank........................................22 Sediment........................................20
Plug-together..................................23 Sensors..............................22, 45, 67
Maintenance clear switch...............42 Pm1................................................42
Manual fuel feed.............................21 Service area...................................19
Polar diagram.................................64 Service problems............................19
Marine junction box......25, 37, 40, 56 Port wing........................................32
Mass elastic data..............................7 Shaft...............................................63
Position sensor...............................29 Shaft alignment................................6
Master/slave lead...........................25 Positive glow plug...........................24
Master/slave option..................55, 57 Shaft log...........................................7
Positive lead...................................44 Shafts.............................................17
Master throttle................................29 Possible panel configurations.........30
Menu........................................31, 32 Shaft seal.........................................7
Power connections.........................40 Sharp edges...................................23
Metal...............................................21 Power supply..................................30
Metallic particles.............................19 Shims 5
Power take-off................................63 Short circuits...................................24
Mini marine power display (mmpd).... Powertrain control processor (pcp)...32
...............................30, 31, 32, 33, 35 Silencer..........................................13
Pressure.........................................12 Silver solder....................................17
Mini marine power display..............28 Pressure tightness..........................19
Minus battery..................................40 Simple fuel system.........................22
Primary fuel filter............................21 Single engine mjb...........................38
Mjb (marine junction box)...25, 36, 40 Propeller shaft............................7, 45
Mmpd.................................32, 33, 35 Single fuel tank...............................21
Propeller shafts and couplings.........7 Siphon break..................................12
Mmpd, digital panel........................25 P.T.O...............................................63
Modular exhaust.............................12 Slow speeds...................................29
Pulley..............................................63 Slow vessel mode....................34, 36
Moisture..........................................23
Slow vessel mode button status.....33
Monitoring.......................................37 R Slow vessel mode lamp status.......33
Morse 33c.......................................61
Mounting brackets........................1, 2 Racking............................................6 Slow vessel mode panel.................29
Mscs...............................................40 Radiator..........................................65 Socket alignment............................23
Multiple instrument panels..............23 Ram airflow....................................15 Software version.............................31
Multiway connector.........................23 Rear lifting eye.................................2 Soldered nipples.............................21
Refuelling.......................................19 Spray..............................................15
N Refuelling pump.............................19 Stainless steel bellows............. 11, 12
Remote kit......................................18 Stainless steel type 316.................17
Naval architect..................................7 Remote tank...................................18 Standard brackets............................4
Negative glow plug.........................24 Return pipes...................................21 Starboard interface connectors......40
New components............................19 Return systems..............................22 Starboard wing.........................32, 33
Noise..........................................7, 13 Reverse isolator.............................40 Start aid type..................................43
Noise absorbent material...............15 Reverse video....................31, 32, 34 Starter.................................23, 43, 44
Noise absorbing chambers.............15 Rigid bracket.................................. 11 Starter cables...................................1
Noise levels....................................13 Rom bootloader software version...31 Starter interlock..............................41
Non-volatile memory......................31 Routine examination.......................17 Starter lead resistance...................43
Nose down capability.......................3 Rubber bag.....................................21 Station button status.......................32
Number of synchronized engines Rubber exhaust hose.......................9 Status items....................................34
configuration.........................29 Rubber hose connections...............17 Steel.........................................17, 21
Stop cock........................................21 User name................................31, 32
Storage tanks.................................22 Users handbook.............................19
Strainer...........................................17
Stud................................................44 V
Sump..............................................20 Valves.................................20, 21, 22
Switched circuit..............................41 ‘V’ drives...........................................5
Synchronization switch...................29 Vent................................................21
Syphon break...................................7 Vent area........................................15
Siphoning.......................................21 Ventilation...................................1, 15
System information...................31, 33 Ventilation fans...............................15
T Ventilation system..........................15
Venting points.................................18
Tachometer.....................................26 Vent pipe..................................20, 22
Tank..........................................20, 21 Vessel control.................................37
Taper lock.......................................63 Vessel locations..............................32
Tee connector...........................25, 35 Vessel speed units...................31, 32
Tee to tee........................................35 Vessel status bar............................34
Temperate climates........................15 Vibration.......................................5, 7
Temperature.............................18, 43 Viscosity.........................................43
Termination resistor........................35 Voltage gauge................................26
Thermostat.....................................18 Volume...........................................12
Thread details.................................20
Throttle synchronization panel.......39 W
Throttle...........................................25 Warm climates................................18
Throttle...............................25, 36, 38 Warm conditions.............................15
Throttle lever..................................61 Warning event code........................42
Throttle (port side)..........................39 Warning lamp.....................26, 28, 42
Throttle position..............................45 Warning light...................................26
Throttles.........................................29 Water........................................12, 20
Throttle (starboard side).................39 Water/antifreeze.............................18
Throttle synchronization.................29 Water flow.......................................18
Throttle synchronization panel.......38 Water injection......................9, 10, 12
Throttle synchronisation.................36 Water injection elbow.....................12
Thrust block......................................7 Water lift...........................................7
Torsional load................................. 11 Water lift systems...........................12
Torsional vibration analysis (tva)......7 Water line.......................................12
Tower........................................32, 33 Waterline..............................9, 13, 17
Traditional.......................................33 Water lock.......................................12
Transmission oil pressure...............45 Water temperature..........................18
Transmission oil temperature.........45 Water temperature gauge...............26
Transmission operating data..........31 Water trap.......................................15
Transom...........................................9 Wet systems...............................9, 12
Trap................................................ 11 Wheel house..................................15
Troll.................................................34 Whirling............................................7
Trolling mode button status............33 Wing...............................................33
Trolling mode lamp status..............33 Wire................................................45
Troll mode.................................32, 33 Wiring harness.............48, 49, 51, 52
Troll set speed................................33
Troubleshooting..............................42 Z
Tube assemblies............................19
Turbocharger............................10, 12 Zinc.................................................17
Turbocharger adaptor..................... 11 Zinc anode......................................44
Twin engine mjb.............................39 Zinc sacrificial anode......................45
Twin installation................................6
Twisting............................................6
Two tanks.......................................21
Typical fuel systems.......................21
U
Uncovered apertures......................19
Unit location..............................31, 32
Unit serial number..........................31
Unmachined faces..........................19
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.
All information in this document is substantially
correct at time of printing and may be altered Wimborne Marine Power Centre
subsequently. 22 Cobham Road,
Part No. N40475 issue 3
Produced in England ©2013 by Wimborne
Ferndown Industrial Estate,
Marine Power Centre Wimborne, Dorset, BH21 7PW, England.
Tel: +44 (0)1202 796000,
Fax: +44 (0)1202 796001
E-mail: [email protected]
Web: www.perkins.com/Marine