Part No N40475 ® Installation Manual 1106 Series Marine Propulsion Engines GB
N40475 Title Perkins M300C, M250C, M216C & M190C Installation Manual 6 cylinder, turbocharged, intercooled, diesel engine for marine propulsion applications Publication N40475, Issue 3 © Proprietary information of Wimborne Marine Power Centre, all rights reserved. The information is correct at the time of print. Published in December 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.
Title N40475 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 • 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. If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. • Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.
N40475 Contents Chapter........................................................................................................................................ Page 1 Location of engine installation points..........................................1 2 Engine mounting............................................................................3 Installation angles............................................................................................ 3 Nose down capability...............................
Contents Interconnecting cables................................................................................... 25 Instrument panels............................................................................................ 26 Main panel............................................................................................. 26 Auxiliary panel...................................................................................... 27 Mini Marine Power Display (MMPD) digital panel.......................
N40475 Contents 9 Engine controls.............................................................................61 10 Provision for power take-off.......................................................63 For axial drives................................................................................................ 63 For belt drives.................................................................................................. 63 Polar diagram..............................................................
Contents N40475
N40475 Chapter 1 Location of engine installation points Exhaust Systems (See chapter 4) Starter Cables (See chapter 8) Bonding Stud (See chapter 8) Front Lifting Eye Warning! Use spreader bar.
Chapter 1 N40475 Rear Lifting Eye Warning! Use spreader bar.
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. Nose down capability These engines are capable of an 8O nose down capability as standard.
Chapter 2 N40475 Engine mounting brackets The standard brackets, provide mounting points which are 76mm (3”) below, and parallel with, the crankshaft centre line. The brackets may be used to mount the engine directly on the engine bearers, but for all applications it is recommended that flexible engine mounts are used. Figure 4 shows the holes (1) for the holding down bolts are slotted, 36 x 17 (1.7/16 x 21/32”) to allow for some movement during the final stages of alignment.
N40475 Chapter 2 Flexible engine mounts It is recommended that flexible engine mounts should be used for all applications.
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.
N40475 Chapter 3 Propeller shafts and couplings 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. The responsibility for the design and installation of the transmission system connected to the gearbox lies with the boat designer, the boat builder, the naval architect or the engine installer.
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N40475 Chapter 4 Exhaust systems A range of exhaust components are available for use with all types of exhaust system. The components are designed to connect together, allowing complex systems to be built from stock items, to suit most installations. Caution: In all types of exhaust system the exhaust back pressure must not exceed 15kPa, when measured within 305mm (12 inches) of the exhaust outlet from the engine.
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. Note: The exhaust elbow must have a fall of 10O downwards. If a taller system is required then a dry 90O elbow (not shown) can be used on the turbocharger outlet with the water injected elbow (1). As both elbows use a clamp, full articulation can be utilised to suit most applications Note: The clamps are to be torqued to 9Nm.
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. The first part of a dry system should include a flexible connection so that excessive weight is not carried by the connection to the engine.
Chapter 4 N40475 Part dry, part wet systems Even where the engine is mounted well below the waterline the advantages of a wet system can still be gained, providing that water injection takes place at a point sufficiently above the waterline. In these circumstances the part dry, part wet system shown in figure 5 can be utilised. The modular exhaust components allow a system to be readily constructed, utilising a tall dry riser, followed by a water injection elbow. (1) Stainless steel bellows.
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. Figure 7 The exhaust system ejects the cooling water as well as silencing the engine’s combustion noise and removing the exhaust gases. The system must create minimal restriction to the flow of exhaust gases, known as back pressure, or the engine may be damaged.
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N40475 Chapter 5 Engine room ventilation The engine room must be ventilated for two reasons: 1. To supply the engine with air for combustion. 2. To provide a flow of air through the engine room to prevent an excessive temperature build up, which may cause components such as the alternator to overheat. Note: The air temperature entering the engine should not exceed 52OC (126OF). The air temperature entering the engine room should not exceed 60OC (140OF).
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N40475 Chapter 6 Engine cooling systems Auxiliary water systems A completely separate sea water system should be provided for each engine to prevent a blockage resulting in the need to shut down more than one engine and a typical system is shown in figure 1. The water intake fitting (4) should not project appreciably below the bottom of the hull and it should be situated well clear of other components such as shafts, logs, rudders to prevent flow problems at high speeds.
Chapter 6 N40475 Keel cooling system This engine may be purchased in a form suitable for keel cooling, using two separate coolers, one for the cylinder jacket circuit and one for the aftercooler circuit. Figure 2 shows the connections provided for the coolers. The requirements for each section are as follows: Models M190C M216C M250C M300C Cylinder Jacket Circuit Heat rejection /kW. 102 134 146 173 Design value for the water temperature at the exit from the keel cooler /OC.
N40475 Chapter 7 Fuel systems Cleanliness of fuel system components Cleanliness of the engine 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.
Chapter 7 N40475 Thread details of the connections on the engines for fuel pipes • Fuel feed - 11/16” ORFS • Fuel return - 11/16” ORFS 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.
N40475 Chapter 7 Typical fuel systems The more simple the fuel system, the better it will perform in service. Figure 1 shows an ideal system. 1. Fuel tank. 2. Fuel return pipe. 3. Manual fuel feed. 4. Stop cock. Figure 1 5. Vent. 6. Drain. In some applications there may be legislation that requires that fuel lines draw from, and return to , the top of the tank. Figure 2 shows an acceptable arrangement. 1. Fuel tank. 2. Fuel return pipe. 3. Manual fuel feed. 4. Vent. 5. Fuel feed tap. 6.
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.
N40475 Chapter 8 Engine electrical systems A plug-together electrical system is available with the engine, providing the following choices from the engine connection:• Interconnecting cables of 12m lengths are standard. 3, 6, and 9m lengths are available as options. • Optional harness to allow multiple instrument panels to be fitted. • 12V or 24V operation. • Instrument panels - main, auxiliary or digital, which may be used individually or in combination with a keyswitch panel.
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. The breakers may be found on the right hand side above the oil filter, see figure 1. • 10Amp - negative glow plug. • 105Amp - positive glow plug.
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.
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. • IP 65 rated from front facia, switches/gauges IP67 rated. The ‘Main Panel’ shown in Figure 4 is 250mm x 175mm and includes:1. Tachometer 2. Engine hours/fault code display 3. Warning light 4. Oil pressure gauge 5. Warning light 6. Water temperature gauge 7. Warning light 8. Warning lamp 9. Diagnostic lamp 10. Engine crank 11.
N40475 Chapter 8 Auxiliary panel • 12 or 24 volt operation from same panel. • IP 65 rated from front facia, switches/gauges IP67 rated. The ‘Auxiliary panel’ shown in figure 5 is 180mm x 140mm and includes:1. Tachometer 2. Engine hours/fault code display 3. Warning light 4. Warning lamp 5. Engine crank 6. Keyswitch on/off 7. Diagnostic lamp 8. Engine stop switch 9. Panel illumination The cutout dimensions are shown below the panel illustration.
Chapter 8 N40475 Mini Marine Power Display (MMPD) digital panel • Single engine support. • Displays engine parameters and fault codes with audible alarm. • 5 display screens. • High resolution display 320 X 240 DPI. • Transflective screen improves readability by reflecting more or less light conditions as ambient light changes. • Display brightness fully adjustable. • Operates on 12 or 24 V systems. • Supports several languages - English, German, French, Dutch, Portuguese, Norwegian and Italian.
N40475 Chapter 8 Throttle synchronization / slow vessel mode panel The function of the synchronization switch, figure 8, designates one of the throttles in a dual engine installation as the master throttle. When the switch (1) is activated each engine will respond to this master throttle. One parameter must be configured in EST prior to using a secondary throttle position sensor. In the configuration screen, Secondary Throttle Enable Status defaults to “Disabled” and must be set to “Enabled”.
Chapter 8 N40475 Possible panel configurations. A variety of panels may be run simultaneously, in any of the combinations as shown in figure 9. 1. Power supply. 2. Cable or electronic throttle and gearbox control options. 3. Main panel. 4. Auxiliary panel. 5. Mini Marine Power Dispaly (MMPD) digital panel. 6. Keyswitch panel.
N40475 Chapter 8 Mini Marine Power Dispaly (MMPD) instructions The Mini Marine Power Display (MMPD) provides current engine and transmission operating data. The screen can be customized to display various engine parameters. 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.
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. Change user Pressing the alarm button will cause the displayed User Name text to scroll through the available user names. Change unit location Pressing the alarm button will cause the displayed Unit Location text to scroll through the available location selections.
N40475 Chapter 8 Change screen Pressing the alarm button will cause the System Information screen to be displayed. Change troll mode Pressing the alarm button will cause the displayed Troll Mode to scroll through the available troll modes (Traditional and Intelli-Troll). Figure 13 Change troll speed Selecting Change Troll Set Speed (as figure 13) will display the following screen. Pressing + will increase the set speed by 1 rpm and pressing – will decrease the set speed by 1 rpm.
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. Status items (figure 14) 1. Active diagnostic status of active station location. 2. Slow Vessel Mode (SVM) status. 3. Gear position 4. Troll mode status. 5. Engine synchronization status.
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: MMPD drop cable Tee to Tee cable 6-pin Tee Termination resistor Figure 15 Termination resistor (figure 16) Used to terminate the ends of a data link run. Two termination resistors required Tee connector (figure 17) Used to connect tee to tee cables. CAN Data Link SAE J1939-15: Unshielded twisted pair.
Chapter 8 N40475 For engines without an MJB (Marine Junction Box) The customer connect harness (figure 18) can be used as a connection point for the various control panel options for both single engine applications and twin engine applications and is intended as a direct replacement for the MJB whilst maintaining the same functionality. Figure 19 shows the main components. 1. Engine interface (ECM). 2. Twin engine. 3. Throttle synchronisation and slow vessel mode. Figure 18 4. Key switch. 5. Throttle.
N40475 Chapter 8 For engines fitted with the Marine Junction Box (MJB) • Provides circuit protection for the ECM and other components connected to the on board monitoring and control systems. • Stand alone junction box for any marine application. • Used with various lengths of wiring harness for easier installation. • Available for single (figure 20 item 1) or twin (figure 20 item 2) engine installations.
Chapter 8 N40475 Single engine MJB features and mounting details 1. Breakers. 2. Throttle. 3. Expansion. 4. ECM. 5. J1939. 6. Key/alarm. 7. Custom. 8. Throttle synchronization panel. 9. PDL connector. 10. Power for the power train control processor (not used). 11. Connection for battery + battery. 12. Connection for battery - battery.
N40475 Chapter 8 Twin engine MJB features and mounting details 1. Breakers. 2. Custom (port side). 3. Key/alarm (port side). 4. J1939 (port side). 5. ECM (port side). 6. Expansion (port side). 7. Throttle (port side). 8. Throttle (starboard side). 9. Expansion (starboard side). 10. ECM (starboard side). 11. J1939 (starboard side). 12. Key/alarm (starboard side). 13. Custom (starboard side). 14. Throttle synchronization panel 15. PDL connector. 16. Power for the power train control processor (not used).
Chapter 8 N40475 Power connections 1. Marine junction box. 2. Battery reverse isolator. 3. Batteries 4. Minus battery bus bar. 4 Stations 8 Stations Cable length* 12 volt 24 volt 12 volt 24 volt 5ft.(1.52m) 10 AWG 12AWG 6AWG 10 AWG 10ft (3.05m) 10 AWG 12 AWG 6 AWG 10 AWG 15ft (4.57m) 8 AWG 10 AWG 4 AWG 8 AWG 25ft (7.62m) 6 AWG 8 AWG 2 AWG 6 AWG 30ft (9.14m) 4 AWG 8 AWG 1 AWG 4 AWG *Refer to ABYC rules E-11 for AC & DC electrical systems on boats for more details.
N40475 Chapter 8 Port or starboard expansion connectors The MJB provides two connectors, one for port and one for starboard, which will be used for future expansion. The pin out is the same for both the port and starboard connectors. Starter Interlock (Pins 1 & 2) The starter interlock provides a means of preventing the engine from starting through a switched circuit. The starter interlock may be wired through a neutral safety switch or other similar device.
Chapter 8 N40475 Diagnostic lamp (Pin 2) The diagnostic lamp, figure 27 alerts the operator to the presence of an active diagnostic code. A diagnostic code indicates a fault condition in the electronic control system. The operator uses this indication to help diagnose component failures in the electronic control system. The diagnostic flash codes should only be used to indicate the nature of the occurrence of a diagnostic condition. The flash codes should not be used to perform detailed troubleshooting.
N40475 Chapter 8 Cold start system Cold start data 12V and 24V Temperature Battery type with oil viscosity used 20W 5°C 15W 10W 5W 2XB -40°C Min average cranking speed rev/min Total battery voltage nominal Glow plugs 130 12V Glow plugs 100 12V Glow plugs and block heating 100 12V 0W F -25°C Start aid type 2XE 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.
Chapter 8 N40475 Battery isolator switches A switch should be fitted in the positive lead to the starter, as close to the battery as is convenient. The switch should be suitable for a momentary current of at least 950 Amps. Zinc Anode bonding system Caution: The engine may be damaged by electrolytic corrosion if the correct bonding procedure is not adopted. Please read the guidelines below carefully.
N40475 Chapter 8 Typical system in common use The bonding system in the boat should provide a low resistance connection between all metals in contact with sea water, together with a connection to a Zinc sacrificial anode which is fixed to the outside of the hull below sea level. The bonding should consist of heavy stranded wire (not braiding or wire with fine strands). It is an advantage if the wire is tinned. Insulation is also an advantage and should preferably be green in colour.
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N40475 Chapter 8 Wiring diagrams *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
Chapter 8 *See the CD for PC compatible version of this diagram.
N40475 *See the CD for PC compatible version of this diagram.
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N40475 Chapter 9 Engine controls It is recommended that a Morse single lever system is used to control engine speed and gearbox engagement. 1. Throttle lever. 2. Anchor for Morse 33C cable. 3. Morse 33C cable. 4. Idle position. 5.
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N40475 Chapter 10 Provision for power take-off Warning! Remove all paint traces from the mating faces before assembly. Fit the power take-off shaft, (figure 1 item 1) using bolts (figure 1 item 2) and tighten to a final torque of 84 lb.ft. (115Nm) Fit the key (figure 1 item 3) to the power take-off shaft . For axial drives Figure 1 For axial drives it is recommended that a flexible drive coupling between the engine and any given load is used.
Chapter 10 N40475 Polar diagram This diagram shows the loading capability of the front of the crankshaft. The load angle, when viewed from the front of the engine, is measured clockwise, with 0° aligned to TDC. Overhung load (Newtons) is directed radially outwards from the centre of the diagram.
N40475 Chapter 11 Calorifier and block heater connections 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. The hose connections to the calorifier must be of a radiator or heater hose quality and 1/2” bore, and must be installed so that chafing will not occur. (1) Supply to calorifier. (2) Return from calorifier.
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N40475 Chapter 12 Options Gearbox oil temperature sensor Gearbox sensors are available as an option. Please refer to the gearbox manufacturers handbook for installation requirements. Use the M12 tapping as shown in figure 1 for the transmission temperature sensor or refer to the gearbox manufactures handbook.
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N40475 Chapter 13 Reference data Basic data M300C M250C M216C M190C Rated power............................ 300hp (225kW)...... 250hp (186kW)......216hp (161kW)...... 190hp (142kW) Rated engine speed......................2400rpm................ 2400rpm.................2400rpm................ 2100rpm Number of cylinders......................................................................... 6. Cylinder arrangement................................................................... In-line. Cycle.....
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)..................
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..................................
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Index A Absorbent material.........................15 Activate station button status.........33 Activate station lamp status............33 Active diagnostic code....................42 Active diagnostic status..................34 Active station lamp status...............32 Active station location.........32, 33, 34 Adjuster nut......................................5 Aftercooler......................................18 Aftercooler circuit............................18 Aftercooler grid cooler...................
Drain tap...................................20, 21 Dry riser..........................................12 Dry systems.................................... 11 Dual engine installation..................29 Duplex fuel pipes............................22 E Ecm..............................22, 37, 38, 42 Ecm and battery.............................36 Ecm port.........................................40 Ecm (port side)...............................39 Ecm (starboard side)......................39 Electrical grease..
Key.................................................63 Key/alarm.......................................38 Key/alarm (port side)......................39 Key/alarm (starboard side).............39 Keyswitch...........................36, 37, 42 Keyswitch on/off.......................26, 28 Keyswitch panel...........23, 25, 28, 30 Knots........................................31, 32 L Labelled change screen.................31 Lamp status indicator.....................33 Legislation...............................
Stop cock........................................21 Storage tanks.................................22 Strainer...........................................17 Stud................................................44 Sump..............................................20 Switched circuit..............................41 Synchronization switch...................29 Syphon break...................................7 Siphoning.......................................21 System information...................
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. N40475 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.
