Part No N40469 ® User’s Handbook 1106 Series Marine Propulsion Engines GB
N40469 Title Perkins M300C, M250C, M216C & M190C User’s handbook 6 cylinder, turbocharged, intercooled, diesel engines for marine propulsion applications Publication N40469, Issue 3 © Proprietary information of Wimborne Marine Power Centre, all rights reserved. The information is correct at the time of print. Published in July 2013 by Wimborne Marine Power Centre, Wimborne Marine Power Centre, Wimborne, Dorset, England BH21 7PW Tel:+44(0)1202 796000 Fax: +44(0)1202 796001 E-mail: Marine@Perkins.com www.
Title N40469 Foreword Thank you for purchasing the Perkins M300C, M250C, M216 & M190 marine diesel engine. This manual contains information for the correct operation and maintenance 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.
N40469 Title General safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications. can cause corrosion in the closed circuit of the cooling system. • Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes.
Title N40469
N40469 Table of Contents Chapter......................................................................................................................................... Page 1 Engine views................................................................................... 1 Introduction.............................................................................................................1 Location of engine parts.......................................................................................
Table of Contents When required.............................................................................................24 Daily............................................................................................................24 Every week..................................................................................................24 Initial 500 service hours..............................................................................24 Every 500 service hours or 1 year...................
N40469 Table of Contents On-board repair kit...............................................................................................49 General data..................................................................................... 51 Engine..................................................................................................................
N40469 Chapter 1 Engine views Introduction Perkins engines are built for specific applications and the views which follow may not necessarily match your engine specification.
Chapter 1 N40469 Location of engine parts Front and right side view 1. Coolant filler cap 8. Sump 2. Secondary fuel filter 9. Auxiliary water pump 3. Dipstick 10.Fuel return 4. Top cover 11. Belt guard 5. Aftercooler 12.Primary fuel filter 6. Gearbox oil cooler 13.Fuel feed 7. Heat exchanger 14.
Chapter 1 N40469 Rear and left side view 15.Rear lifting bracket 23.Air cleaner 16.Oil filler cap 24.Oil breather 17.Exhaust manifold / header tank 18.Front lifting bracket 19.Alternator 20.Oil filter 21.Starter 22.
N40469 Chapter 2 General information Introduction The Perkins range of marine engines are the latest developments from the Perkins Group of Companies together with Wimborne Marine Power Centre. These engines are designed for use in pleasure craft and for commercial craft. Over sixty years of diesel production experience, together with the latest technology, have been applied to the manufacture of your engine to give you reliable and economic power.
Chapter 2 How to care for your engine Warning! Read the “Safety precautions” and remember them. They are given for your protection and must be applied at all times. Caution: Do not clean an engine whilst it is running. If cold cleaning fluids are applied to a hot engine, certain components on the engine may be damaged. This handbook has been written to assist you to maintain and operate your engine correctly.
N40469 Chapter 2 Engine guarantee If a claim under guarantee is necessary, the boat owner should make a guarantee claim on the nearest Perkins marine distributor or an approved dealer. If it is difficult to find a Perkins distributor or an approved dealer, consult the Sales and Customer Support of Wimborne Marine Power Centre. Engine identification Identification of the engine model is by a label fitted on top of the rocker cover.
Chapter 2 Contact details Wimborne Marine Power Centre Ferndown Industrial Estate Wimborne Dorset BH21 7PW England Telephone: +44 (0)1202 796000 Fax: +44 (0)1202 796001 www.Perkins.
N40469 Chapter 3 Operation instructions Running-in A gradual running-in of a new engine is not necessary. Prolonged operation at light loads during the early life of the engine can cause lubricating oil to enter the exhaust system. Maximum load can be applied to a new engine as soon as the engine is put into service and the coolant temperature has reached a minimum of 60OC (140OF). Cautions: • The engine will benefit if the load is applied as soon as possible after the engine is put into service.
Chapter 3 N40469 Control panel overview The main control panel for single and twin engine installations is shown in figure 1. The switches are protected from the entry of water, but if the control panel is in an exposed location, it should be protected by a cover when not in use. Below is a description of the instruments and switches on the main panel. 1. Tachometer - indicates the engine speed. 2. Engine hours/fault code display - displays accumulated hours and fault codes. 3. Warning light 4.
N40469 Chapter 3 Auxiliary control panel overview The auxiliary control panel shown in figure 2 is used on craft which have an extra control point. The switches are protected from the entry of water, but if the control panel is in an exposed location, it should be protected by a cover when not in use. Below is a description of the instrument and switches on the auxiliary panel. Figure 2 1. Tachometer - indicates the engine speed. 2.
Chapter 3 N40469 Digital control panel overview The digital control panel shown in figure 3 is used with the keyswitch panel. The switches are protected from the entry of water, but if the control panel is in an exposed location, it should be protected by a cover when not in use. Below is a description of the instrument and switches on the digital panel. 1. 2. Display - this screen shows the following information.
N40469 Chapter 3 Keyswitch panel overview The keyswitch panel shown in figure 4 is used in conjunction with the digital panel. The switches are protected from the entry of water, but if the control panel is in an exposed location, it should be protected by a cover when not in use. Below is a description of the lamps and switches on the keyswitch panel. 1. Engine crank - turns the engine over. 2. Warning lamp - indicates a problem. 3. Diagnostic lamp - indicates active diagnostics codes. 4.
Chapter 3 Preparations for an engine start 1. Ensure that there is more than enough fuel in the tank for the voyage. 2. Ensure that the fuel supply control (if fitted) is in the open position. 3. Check that the seacock strainer is clean. 4. Open the seacock. 5. Check the amount of coolant in the header tank. 6. Check the amount of lubricating oil in the sump, and in the gearbox. 7. Ensure that the control lever for the gearbox is in the neutral position.
N40469 Chapter 3 How to start the engine 1. Switch on the electrical system (1). 2. Adjust the engine speed control to the minimum speed position. 3. Press and hold the start switch (2) to engage the starter motor, there may be a short delay if the cold start aid is required (this is an automatic process when the temperature is below 5OC. If the digital control panel is used, a message will flash up with ‘Wait to Start’).
Chapter 3 N40469 How to stop the engine 1. Adjust the engine speed control to the minimum speed position. Ensure that the control lever for the reverse gearbox is in the neutral position. If the engine has operated at high load for a long period of time, allow the engine to cool for one to two minutes. 2. Hold the stop switch in until the engine stops. Release the stop switch.
N40469 Chapter 3 Circuit breakers Cautions: • Always fit the correct breaker. Damage to the wiring loom may occur if a higher rated breaker is fitted. • Always find the cause of a breaker failure and correct the fault. If in doubt, consult an electrician at your nearest Perkins distributor. A wiring loom, which includes a breaker panel to protect the wiring from damage by a short circuit, has been fitted to your engine.
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N40469 Chapter 4 Engine fluids Fuel specification To get the correct power and performance from your engine, use good quality fuel. The recommended fuel specification for Perkins engines is indicated below: Cetane number..........................................45 minimum Viscosity............................2.0/4.5 centistokes at 40OC Density.......................................... 0,835/0,855 kg/litre Sulphur..................................0.2% of mass, maximum Distillation.........................
Chapter 4 N40469 Lubricating oil specification Use only good quality lubricating oil which is equivalent to or above the minimum specification shown in the table below. Target oil specifications are: Engine type Specification 1106D-E66TA API/CH4/CI4 Oil change period is 500 hrs. on CH4 oils and higher specifications Caution: The type of lubricating oil to be used may be affected by the quality of the fuel which is available.
N40469 Chapter 4 Coolant specification The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling system. The recommendations indicated below can help to maintain a good cooling system and to protect it against frost and/or corrosion. If the correct procedures are not used, Wimborne Marine Power Centre cannot be held responsible for damage caused by frost or corrosion, or for loss of cooling efficiency.
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N40469 Chapter 5 Regular maintenance Maintenance periods These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the boat in which the engine is installed. If necessary, use the shorter periods. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine.
Chapter 5 Schedules The schedules which follow must be applied at the interval (hours or months) which occur first.
N40469 Chapter 5 • Auxiliary water strainer (if fitted) - check • Heat exchanger seals - check • Heat exchanger tubestack - check Every 1000 service hours • Aftercooler condensate drain valve - inspect/clean • Engine valve lash - inspect/adjust • Water pump - inspect Every 2000 service hours • Engine mounts - inspect • Heat exchanger - inspect • Starting motor - inspect • Turbocharger - inspect • Coolant gravity - check Every 3000 service hours or 2 years • Cooling system water temperature regulator - rep
Chapter 5 N40469 How to fill the coolant circuit Warning! If coolant is to be added to the circuit during service, allow the engine to cool before the coolant is added. Remove the filler cap slowly as dangerous coolant could be discharged if the coolant is still hot and the system under pressure. Do not put too much coolant in the coolant circuit. There is a relief valve in the filler cap which will open and release hot coolant if too much coolant is added.
N40469 Chapter 5 How to drain the coolant circuit Warnings! • Discard the used coolant in a safe place and in accordance with local regulations. • Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. 1. Remove the coolant filler cap (figure 2 item 1). 2. Remove the drain plug (figure 3 item 1) from the heat exchanger. 3. After the system has been drained, fit the filler cap and the drain plug. 4.
Chapter 5 N40469 How to check the specific gravity of the coolant For mixtures which contain inhibited ethylene glycol: 1. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the coolant has circulated the cooling system. 2. Stop the engine. 3. Allow the engine to cool until the temperature of the coolant is below 60OC (140OF).
N40469 Chapter 5 How to drain the auxiliary water system Caution: The auxiliary water system cannot be drained completely. If the system is drained for engine preservation purposes or for protection from frost, the system must be filled again with an approved antifreeze mixture. 1. Ensure that the seacock is closed (figure 4 item 1). Figure 4 2. Remove the drain plug (figure 5 item 1), from the gearbox oil cooler. Ensure that the drain hole is not restricted. 3.
Chapter 5 N40469 How to check the impeller of the auxiliary water pump Caution: When the impeller is checked, the strainer in the outlet hose of the auxiliary water pump must also be checked. 1. Ensure that the seacock is closed. 2. Release the four bolts (items 1 figure 6) which fasten the end plate of the auxiliary water pump and remove the plate. When the end plate of the auxiliary water pump is removed, some auxiliary water will flow from the pump. 3.
N40469 Chapter 5 How to check the drive belt of the alternator Warning! The engines have a guard fitted to give protection from the alternator fan and the drive belt. Ensure that this guard is fitted before the engine is started. Note: The engine may have the ability to auto start. Ensure that the power supply is isolated before any service or repair is performed. To maximize the engine performance, inspect the belt for wear and for cracking. Replace a belt that is worn or damaged.
Chapter 5 N40469 How to adjust the belt tension 1. Loosen the nut and bolt (figure 11 item 1). Then loosen the nut and bolt (figure 11 item 2). 2. Loosen bolt (figure 12 item 1) and adjust the alternator in order to alter the belt tension. Tighten all bolts for the adjustment of the alternator to 22 Nm (16 lb ft). 3. Refit the belt guard.
N40469 Chapter 5 How to check the condition of the heat exchanger The interval for the maintenance of the tube type heat exchanger (figure 13 item 1) depends on the operating environment of the vessel and on the operating time.
Chapter 5 If tubestack is greasy 1. Degrease using solvent or by washing with warm alkaline detergent that is compatible with aluminium. 2. Rinse with water and air dry. Tubestack is not greasy. 1. Wash with warm alkaline detergent that is compatible with aluminium. Note: Do not use Acids on aluminium. 2. Rinse with water and air dry. 3. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests.
N40469 Chapter 5 How to renew the element on the primary fuel filter Warning! Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Note: Refer to, “Cleanliness of Fuel System Components” in the Installation Manual for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Chapter 5 6. Rotate the bowl counter clockwise in order to remove the bowl. Remove ‘O’ ring seal (3). Clean the bowl. 7. Use a chain wrench in order to remove old canister (2). 8. Lubricate the ‘O’ ring seal (1) with clean engine oil on the new canister. Install a new canister. Caution: Do not prefill. 9. Spin on the canister until the ‘O’ ring seal contacts the sealing surface. Then rotate the canister 3/4 of a full turn. Do not use a tool in order to install the canister. 9.
N40469 Chapter 5 How to renew the element on the secondary fuel filter Warning! Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Note: Refer to, “Cleanliness of Fuel System Components” in the Installation Manual for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Chapter 5 N40469 How to renew the lubricating oil of the engine Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations. 1. Attach a suitable length of hose on the sump pump (figure 18 item 1) and place a suitable container with a capacity of at least 16 litres (28 UK pints) at the other end. If possible, the lubricating oil should be drained while it is still hot. 2. Pump until all the oil is drained.
N40469 Chapter 5 How to renew the canister of the lubricating oil filter Warning! Discard the used canister and lubricating oil in a safe place and in accordance with local regulations. 1. Put a tray or plastic bag under or around the filter to retain spilt lubricating oil. 2. Remove the filter canister (figure 21 item 1) with a strap wrench or similar tool. Ensure that the adaptor (figure 22 item 1) is secure in the filter head. Then discard the canister. 3. Clean the filter head. 4.
Chapter 5 N40469 How to renew the engine breather Caution: Do not use excessive force to remove the hose (figure 23 item 1) from the breather outlet pipe. 1. Remove the hose (figure 23 item 1) from the engine breather body (figure 23 item 2). 2. Unscrew the breather cap (figure 24 item 1) and pull away from the main body 3. Remove the filter canister (figure 24 item 2) and discard. 4. Insert new filter canister. 4.
N40469 Chapter 5 How to clean the air filter 1. Remove nut (1) and washer (2 ). 2. Loosen setscrew (3) and rotate bracket (4) away from the cowl (7). 3. Relax the two hose clips (5) and remove the cleaner assembly. 4. Remove the support tube (9) and filter element (8). 5. Renew the foam element. 6. Refit the element (8) ensuring that the support tube (9) is expanded for correct location within (6) & (7) . 7. Refit mounting hardware.
Chapter 5 N40469 How to check the condition of the vibration damper Caution: A vibration damper (figure 27 items 1) should be renewed if there is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. Check the area around the holes for the damper bolts for cracks and general wear if the damper has become loose in service. Check that the six bolts (figure 27 item 2) for the viscous damper are tightened correctly: Tighten the six M12 bolts to 115 Nm (85 lb ft).
N40469 Chapter 5 How to check the valve tip clearances Check the valve lash while the engine is stopped. The temperature of the engine does not change the valve lash setting. Warning! Accidental engine starting can cause injury or death to personnel. To prevent accidental engine starting, turn the ignition switch to the OFF position and place a ‘DO NOT OPERATE’ tag at the ignition switch location. Note: Number one cylinder is at the front of the engine or where the vibration damper is.
Chapter 5 N40469 TC Exhaust Stroke 1. Measure the valve lash for the valves when the engine is at TC exhaust stroke according to the table below. If necessary, make an adjustment to the valves accordingly. TC Exhaust Stroke Inlet Valves Exhaust Valves Valve Lash 0.35 mm (0.0138 inch) 0.35 mm (0.0138 inch) Cylinders 3-5-6 2-4-6 2. Loosen the valve adjustment screw locknut (3) that is on the adjustment screw (2). 3. Place an angled feeler gauge (1) between the rocker arm and the valve.
N40469 Chapter 5 • Bent pushrods • Broken socket on the upper end of a pushrod • Loose adjustment screw for the valve lash If the camshaft and valve lifters show rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause. • Valve Lash Check Corrosion This can occur when two different metals are in contact near to, or in, sea water. For example, a brass or bronze pipe fitted into aluminium can cause rapid corrosion.
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N40469 Chapter 6 Engine preservation Introduction The recommendations indicated below are designed to prevent damage to the engine when it is withdrawn from service for a prolonged period. Use these procedures if the engine is to be withdrawn from service. The instructions for the use of POWERPART products are given on the outside of each container. Procedure 1. Completely clean the outside of the engine. 2.
Chapter 6 N40469 14. Remove the alternator drive belt and put it into storage. 15. In order to prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray the area inside the alternator cooling fan. 16. If the transmission is not to be used for at least a year, fill the gearbox completely with its normal lubricating oil. This will have to be drained and the normal amount of new lubricating oil added when the engine is returned to service.
N40469 Chapter 7 Parts and service Introduction If problems occur with your engine or with the components fitted onto it, your Perkins distributor can make the necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly. Service literature Workshop manuals, Installation drawings and other service publications are available from your Perkins distributor at a nominal cost.
Chapter 7 POWERPART recommended consumable products Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor or Wimborne Marine Power Centre. POWERPART Antifreeze Protects the cooling system against frost and corrosion.
N40469 Chapter 8 General data Engine Number of cylinders.........................................................................................................................................6 Cylinder arrangement...............................................................................................................................In line Cycle...............................................................................................................................................
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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 subsequently. Part No. N40469 issue 3 Produced in England ©2013 by Wimborne Marine Power Centre Wimborne Marine Power Centre 22 Cobham Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PW, England. Tel: +44 (0)1202 796000, Fax: +44 (0)1202 796001 E-mail: Marine@Perkins.com Web: www.perkins.
