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2. Figure 19 N40475 Chapter 8 DO a Power connections amw ow ee 1 Marine junction box a Battery reverse isolator lt gt 2 3 Batteries 4 Minus battery bus bar Cable 4Stations 8Stations length 12 volt 24volt 12 24 volt 5ft 1 52m 10AWG 12AWG 6AWG 10 AWG 10ft 305m 10AWG 12AWG 6AWG 10AWG TAE 8AWG 10AWG 4AWG 8AWG 4 57m on 6AWG 8AWG 2AWG 6AWG 7 62m 30ft 4AWG 8AWG 1AWG 4AWG 9 14m Refer to ABYC rules E 11 for AC amp DC electrical systems on boats for more details Figure 20 Note Perkins recommends installing two battery and two battery cables from the reverse isolator to the MJB and from the reverse isolator to the batteries Current requirements 12 or 24 vdc system The typical current draw for the MSCS with a twin engine installation with 4 control stations is 30 amps The current draw for a twin engine installation with 8 control stations is 62 amps ECM port or starboard interface connectors The MJB provides two interface connectors one for the port engine and one for the starboard engine which connect to the J61 customer connector The connections are to interface with the ECM customer connector and pro
3. 8949 5 SLVOVN N40475 Chapter 8 ey Tanya 390149 We ivit IN d CERES Engine panels 2 Page 55 gg 8 49849 GLVOVN 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 Run position Figure 1 Page 57 Chapter 9 N40475 Page 58 N40475 Figure 2 Figure 3 Chapter 10 Provision for power tak
4. Mechanical Pipe size Supply outside diameter 10mm 0 394 Supply okini 8 4mm 0 331 outside diameter oiii ees 10mm 0 394 DOME m 8 4mm 0 331 Maximum lift pump 1 8 m 6ft to bottom of tank suction pipe Maximum fuel lift pump 127 mm 5 inches Hg depression at inlet Fuel consumption at 56 6 I hr 12 4galls hr power Air intake Combustion 14 8m min 524ft min Maximum engine compartment 60 C air temperature Maximum air temperature Al 52 engine inlet Ventilation maximum engine 125 mm WG 5 WG room depression Suggested ventilation 30m min 1050ft min including combustion air Minimum cross section 910cm 142sq ins for hot climates of air duct per engine 455 7164 ins for temperate climates Exhaust Exhaust Gas x icut cR Eua n 43 1m min 1520ft min Maximum restriction 15kPa within 305mm 12 of turbocharger outlet Recommended pipe bore wet exhaust 127mm 5 0 Recommended pipe bore
5. 101 6mm 4 0 Minimum rise from sea level 0 203mm 8 0 exhaust outlet centre line Page 68 N40475 Chapter 12 Lubricating system Recommended lubricating API CI 4 Sump capacity 15 litres 3 3 gallons Maximum operational angle 20 nose up Heel 25 constant 35 intermittent Oil pressure in operating 2 5 to 3 5 bar 36 to 50 psi speed range steady state Electrical system 28 100 14 55 4442 545 12 24 Number of teeth in 126 Number of teeth on 51 10 Cold start limits Minimum cold start temperature with aid 409C 409F Page 69 Chapter 12 N40475 Page 70 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 83 Perkins Wimborne Marine Power Centre 22 Cobham Road Ferndown Industrial Estate Wimborne Dorset BH21 7PW England Tel 44 0 1202 893720 Fax 44 0 1202 851700 E mail Marine Perkins com Web www Perkins Sabre com
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7. 125 mm WG 5 WG room depression Suggested ventilation 30m min 1050ft min including combustion air Minimum cross section 910cm 142sq ins for hot climates of air duct per engine 455 7164 ins for temperate climates Exhaust Exhaust Gas x icut cR Eua n 43 1m min 1520ft min Maximum restriction 15kPa within 305mm 12 of turbocharger outlet Recommended pipe bore wet exhaust 127mm 5 0 Recommended pipe bore 101 6mm 4 0 Minimum rise from sea level 0 203mm 8 0 exhaust outlet centre line Page 64 N40475 Chapter 12 Lubricating system Recommended lubricating API CI 4 Sump capacity 15 litres 3 3 gallons Maximum operational angle 20 nose up Heel 25 constant 35 intermittent Oil pressure in operating 2 5 to 3 5 bar 36 to 50 psi speed range steady state Electrical system 28 100 14 55 4442 545 12 24 Number of teeth in 126 Number of teeth on 51 10 Cold sta
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11. Figure 1 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 Wet systems 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 The exhaust bore is 125mm 5 Ageneral arrangement for such a system is shown on Figure 1 In many cases the exhaust outlet passes through the transom just above the waterline 1 It will be seen that a minimum fall of 5 2 is required and that the point of water injection must be at least 8 inches above the waterline 3 although the actual height necessary for a particular boat can only be decided in the light of the exhaust system design and the pitch and roll which may be encountered in service Caution It is essential that the exhaust system is designed so that water from the exhaust does not enter the engine under any conc
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16. 39 Grounding the battery negative 39 Port or starboard expansion connectors 40 Diagnostic lamp Plin 2 2 41 Warning lamp PIN 1 41 PMII 41 hic pbi 41 Maintenance Clear switch Pin 16 41 Cold start SY STOW ge 42 Cold start data 12V and 24V 42 Battery performance 42 Battery to starter lead resistance 22 2 42 Battery isolator 5 43 Zinc Anode bonding system 43 Typical system in common 1 2 44 Optional SOUS eR 44 Engine wiring harness 45 46 Wiring diagrams 47 Engine wiring harness 7 47 Engine wiring harness 2 48 Engine panels 1 49 Interconnecting leads 1 0 50 Master slave option 4 4 2 11 51 Marin junction Cc 52 Master slave option starboard 1 53 Interconn
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19. 5 5000 19 Cleanliness of fuel system 19 Cleanliness of the 19 Environment e 19 New 19 mre eer 19 Fuel 19 Thread details of the connections on the engines for fuel pipes 20 Typical fuel systems M 21 8 Engine electrical 5751076544 23 E gine wiring 00MS 23 0 24 Interconnecting cables e 25 deri rl fem 26 Main or Mer Tc 26 Auxiliary rm 27 Mini Marine Power Display MMPD digital 28 Keyswitch panel mc 29 Possible panel 5 30 Mini Marine Power Dispaly MMPD instructions 31 Data Link E 35 Marine Junction Box 36 Single engine MJB features and mounting details 37 Twin engine MJB features and mounting details 38 39 Current requirements 12 24 vdc system 39 ECM port or starboard interface connectors
20. GLOWPLUG_2 GLOWPLUG_3 GLOWPLUG 4 GLOWPLUG 5 GLOWPLUG_ 2929881 2929881 2929881 2929881 2929881 2929881 0 4 ine wiring 9 22 5 22070 88 16 CSS 0444 39 YL 18 GXL 48606872 BR 18 GXL 12 0824 382875 186 SELETS GN 18 GXL 391 888 PK G GXL 391 875 PK 18 GXxL 0204889 866 686 c214674 1 amp 2793 26 OR 18 6XL 90608290 E C7 EXHAUST GAS TEMP 2397349 3414827 A411 E42 BUAE GXL 47 YL 1S GXL en YL 18 GXL 4 NONE COOLANT LEVEL 1552257 _ 3193487 908577 8 18 Rpa anaoa sv 229 878 BK 18 GXL 462 45 wWH saxL dc 4 3E3382 101 658 RD 14 GXL BK 14 GXL TERMINATION KSS E2 BR 16 GXL RESISTOR NOTE J TWISTELE PAIR 4 EA pul NOTE Mj 87 18 34 1951 490 amp E32 BR 16 GXL P KEYSWITCH TWISTED PAIR 6 229 635 BK 18 GXL p NOTEM D 31939 SHIELD SERVICE TOOL 944 E36 OR IE GXL D CATDATALIMK CONNECTOR 945 037 BR 18 GAL D c CATDATALINK 080 K99 E38 GH T8 GXL B 41939 DATA LINK 900 556 YL 18 GXL D c 31937 DATA LINK TWISTED PAIR 3 NOTE EC2 NOTED
21. displayed in place of the active station location Page 34 n E ao hT F PROS 4 8 1549 173 21 8 MEH Figure 3 N40475 8 Perkins o Figure 14 Figure 16 Chapter 8 Cables required Where Used Connects the PCP and MMPD displays into the J1939 data link The J1939 data link item 1 figure 14 can not exceed 40 meters 131 ft Requires MMPD drop cable Tee to Tee cable 6 pin Tee Termination resistor Termination resistor figure 15 Used to terminate the ends of a data link run Two termination resistors required Tee connector figure 16 Used to connect tee to tee cables CAN Data Link SAE J1939 15 Unshielded twisted pair The CAN network operates at 250 Kb sec it follows J1939 15 protocol J1939 15 Maximum Drops nodes 10 Maximum Cable Stub Length 3M Maximum Cable Stub Length for service connector 2 66M Maximum Bus Length 40M Shielded Cable NO Page 35 Chapter 8 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 17 item 1 or twin figure 10 item 2 engine installations Inside the twin engine installation junction box t
22. Elbow Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement Page 11 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 2 Optional high rise extension not factory supplied B i Figure 5 3 Flexible hanger 4 Point of water injection to be 200mm 8 inches minimum height above water line 5 5 minimum average fall 6 Water line Water lift systems Figure 6 shows the main features of such a system which utilises pressure developed by the exhaust gases to force a mixture of gas and water to a height which may be considerably above the engine When the engine is stopped the exhaust tank contains the water which falls back from the exhaust riser If a proprietary unit is used the manufacturers instructions should be carefully followed but figure 5 identifies the key features 1 Exhaust tank water lock
23. 09F across each 12V battery 3 Voltage no less than 6 0V after 150 seconds at 18 C 0 F across each 12V battery Battery to starter lead resistance The resistance of the lead s used between the battery batteries and the starter motor must not be more than 0 0017 ohms for 12V systems and 0 0034 ohms for 24V systems More detailed information on types of battery is available from the Wimborne Marine Power Centre Page 42 N40475 Chapter 8 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 Electrolytic corrosion within the engine cooling system and transmission can be much reduced or eliminated by bonding the engine to a Zinc anode which is used to protect through the hull metal fittings and other metal components that are in contact with sea water The engine is fitted with a stud figure 26 item 1 that may be used for this purpose and is identified by a label as shown in figure 27 Figure 26 BOATBUILDER 0 Use this stud to connect the engine to the Zinc Anode system installed in the boat For further details see the Installation Manual Figure 27 Page 43 C
24. Battery bus bar Battery Pin 11 The minus battery input from the minus battery bus bar Keyswitch Pin 12 The switched battery input from the keyswitch used to supply battery to the components connected to the custom panel connector Maintenance Clear switch Pin 16 The mainitenance clear switch is required to reset the PM1 interval after manitenance has been performed on the engine Page 41 Chapter 8 N40475 Cold start system Cold start data 12V and 24V Battery type with oil viscosity used Min average Temperature Start aid type cranking speed rev min Total battery voltage nominal Glow plugs 130 Glow plugs 1 00 Glow plugs and mE PNE block heating m 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 mw cable resistance Starter information Temperature amp oil grade without glow plugs Voltage Starter type 5 C 15W40 12V Iskra AZF 950 24V Iskra AZF 650 Battery minimum performance Commercial reference number Perkins code BS EN 50342 SAE J537 9 DIN 43539 643 440 640 400 647 510 700 465 069 340 540 300 655 570 760 490 621 860 900 505 1 Voltage no less that 7 5V after 10 seconds 6V after 90 seconds at 189C 0 F across each 12V battery 2 Voltage no less than 7 2V after 30 seconds at 18 C
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26. Perkins Installation Manual M300C M250C M216C M190C 88 Perkins Marine Power Part No N40475 Perkins M300C M250C M216C amp M190C Installation Manual 6 cylinder turbocharged intercooled diesel engine for marine propulsion applications Publication 40475 Issue 2 Proprietary information of Wimborne Marine Power Centre all rights reserved The information is correct at the time of print Published in February 2011 by Wimborne Marine Power Centre Wimborne Marine Power Centre Wimborne Dorset England BH21 7PW Tel 44 0 1202 893720 Fax 44 0 1202 851700 E mail Marine Perkins com www perkins sabre com Thank you purchasing the Perkins M300C M250C M216C amp 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 Only use these engines in the type of application for which they have been designed Do not change the specification of the engine Do not smoke when you put fuel i
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28. 365 in Valves per Cylinder t oet e dares 2 Direction of Rotation Anti clockwise viewed from flywheel Order 1 5 3 6 2 4 Total Weight 738 kg 1627 Ibs engine only including alternator and starter 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 37 C Coolatit ite 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh Water FIOW TBA at 2400 rpm Coolant pump speed and method of 1 1 Gear Driven System 26 litres 5 7 gallons Pressure cap ecce doute a 50 kPa 7 psi Sea water pump Gear driven full cam Sea water suggested 32 mm Bore 1 25 hose diameter Full flow 32 1 25 Auxiliary water strainer must be included in suction side of the circuit Maximum sea water 39 C 102 F water A 141 l m
29. 4 1 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 Connections of the stainless steel bellows type are suitable but care must be taken to ensure that they are only required to accommodate movements that do not involve twisting the ends of the bellows relative to each other The remainder of the exhaust system should be well insulated to avoid fire risk If there is a long exhaust run which gains height as it leaves the engine it may be necessary to incorporate a trap to collect condensate and allow it to be drained Figures 4 shows a typical systems The minimum bore of the exhaust pipe should be 85mm 3 34 inches 1 Bracket with link to allow for movement due to expansion in the exhaust system horizontal exhaust systems should be suspended from the deck head using similar brackets rigid brackets should not be used 2 Insulating lagging 3 Rigid bracket to support the weight of the vertical exhaust system 4 Heat blanket 5 Twin stainless steel belows fitted to avoid torsional load on bellows unit 6 Heat blanket 7 Turbocharger adaptor 8 Heat blanket 9 90
30. C N C N C N C N C N C Figure 21 1 Figure 22 Figure 23 N40475 lt 2 9 n Figure 24 lt 1 9 lt n Figure 25 1 Chapter 8 Diagnostic lamp Pin 2 The diagnostic lamp figure 24 alerts the operator to the presence of an active diagnostic code Adiagnostic 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 Troubleshooting should be performed using diagnostic codes that are displayed by using an electronic service tool When the ECM is energized keyswitch turned ON the warning lamp will turn on for five seconds Then the lamp will turn off unless the ECM detects a warning condition 1 Diagnostic lamp 2 Battery bus bar Warning lamp Pin 1 The warning lamp figure 25 is used to alert the operator that an engine event has occurred A warning event code is active the warning lamp is on solid A derate event code is active the warning lamp will flash When the ECM is energized keyswitch turned ON the warning lamp will turn on for five seconds Then the lamp will turn off unless the ECM detects a warning condition 1 Warning lamp 2
31. Change Set Speed Change Sync Master and Change Station Location and cause the selected data to be displayed in reverse video Pressing the alarm button will cause the specified parameter to scroll through each available value Pressing the button labeled Exit will return the display to the Control System Information screen and transmit any changed data items to the PCP N40475 H 8 Change erkins Sereen CONTROL SYSTEM INFORMATION PCP Version 000 0000 00 Troll Mode Traditional Troll Set Engine Speed 750 amp Perkins CONTROL SYSTEM INFORMATION PCP Version Troll Mode 000 0000 00 TEE 750 Port Active Station Location Engine Room SA SVMSYC TR Station Button Status On Off Off On Off 4 Station Lamp Status On On Off On Off Engine Sync Master Port Active Station Location Engine Room SA SVMSYC TR Station Button Status On Off Off On Off Station Lamp Status On On Off On Off Figure 11 Page 32 N40475 CONTROL SYSTEM INFORMATION PCP Version 000 0000 00 Troll Mode Traditional Troll Set Engine Speed Engine Sync Master Port Active Station Location Engine Room Figure 12 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 I
32. FIOW TBA at 2400 TBA at 2100 rpm Coolant pump speed and method of 1 1 Gear Driven System 26 litres 5 7 gallons Pressure cap 50 50 kPa 7 psi Sea water pump Gear driven full cam Sea water suggested 32 mm Bore 1 25 hose diameter Full flow 32 mm 1 25 Auxiliary water strainer must be included in suction side of the circuit Maximum sea water 39 C 1029F Sea water flow 141 l min 31 galls min 2400rpm 141 l min 31 galls min 2100rpm Page 67 Chapter 12 N40475 Fuel system Recommended fuel DIN E 590 DERV class A F amp 0 4 BS2869 Class A2 Off highway gas oil red diesel ASTM D975 91 Class 1 1DA amp Class 2 2DA JIS K2204 1997 Grades 1 2 3 amp Special grade 3 JP7 F63 JP8 JP5 Jet A A1 Diesel fuel mix with 5 vol RME in accordance with proposal 51606 JIS K2203 Fuel injection pump in line with boost control and electric stop energised to stop plunger type Fuel feed pressure 2 2 222 414 20040 nia 0 3 to 0 6 5 to 8psi
33. allow compressed air to contact your skin If compressed air enters your skin obtain medical help immediately Glo I ecient ic EU UU Page 1 Location of engine installation points 1 2 Engine 3 Installation angles eL 3 Nose down 3 4 Flexible engine mioun fs eeruce ccu errore 5 Engine ANOS et 6 3 Propeller shafts and couplings 7 Propeller n EE DR 7 4 Exhaust Systems e 9 Wet 9 5 5 1 amp 11 Part dry part wet SystemS 12 Water lift eem 12 MM c 13 5 Engine room 0 0 15 6 Engine cooling systems ooo neon nee pneu REC 17 Auxiliary Water 17 Keel cooling System t 18 7
34. must not be too small With an effective ventilation system the engine air intake temperature will be no more than 10 C higher than the outside air temperature Note For the minimum cross section of air duct per engine see Reference data at the back of this manual The air entry vents should be situated where spray is not likely to enter them and some form of water trap is desirable see figure 1 Preferably the air ducts should reach the engine compartment at the sides of the hull so that water will fall into the bilge 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 Figure 1 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
35. to allow momentary angular misalignment in operation This system is only suitable for applications where the speed diameter and unsupported length of the propeller shaft will not induce whirling i e the centrifugal force generated by the speed of rotation is not sufficient to bend the shaft into a bow shape Figure 1 also shows a cutless bearing 3 flexibly mounted shaft seals 4 reinforced rubber hose 5 graphited asbestos string 6 stuffing box 7 and the drive shaft 8 Where the propeller shaft length is such that it cannot be simply supported by the gearbox coupling and P bracket without the risk of whirling the arrangement shown in figure 2 may be adopted Water supply 4 for bearings use hose from M14 x 1 5 tapping on heat exchanger end cap End cap with tapping is optional In this case one or more additional bearings 3 are included in the shaft log and flexible shaft couplings 2 which will accept thrust are used to permit the engine to move on the flexible mountings 1 Warning Use a syphon break 5 where a water lift exhaust system is specified A variation of this is to use a thrust block bearing at the point where the shaft emerges from the log into the engine room together with constant velocity joints at each end of the short shaft connected to the gearbox coupling Page 7 Chapter 3 N40475 Page 8 N40475 1 Chapter 4
36. 007 16 6 8 M 008 Ds E z 8 bs 101 RD 19 GXL ATT Qe IM SIT Loopere 00 BK 18 6XL kjo seem 88 uoc PORT CAN J183 INTERFACE gage TEZE 5 4 vassen 8 4 EHE EE 8 8820 4922 GN 18 6XxL 88 bz LL keseMPOS hje d mene HTHTTEHHES rome mesane E 9 INTERFACE 4 WE i Reset Rin CONNECTION weed SE EM 1 i PP ag 5 5 5 555555555592 5 g 3 5 542224222223 go 2 8 8 5 5 5 6 5 68 06 BLOCK_AS 55 5 8 8 583 908558 222 3222220 Bote cBLCO fies Fes Lud BATTERY EATTERY NOTE A REVERSE ISOLATOR TOGGLE_SWITCH 196052 M974 N16 1886 BRAE GXL BATTERYE Lu NOTE A EDI ON OFF SWITCH 1 1392118 2 1552267 1392118 ON OFF SWITCH H m 2 FA2ENI2 PU 19 GXL 229 18 2204
37. 13 Neca 1552268 GY 18 GXL 22915 THROTTLE SYNC HARNESS NOTE Morene 48 t Po marsm neas E 973 42 aie te ox T Bici 2E5179 YL 18 6XL M974 N3 YL 18 8XL BRAB GXL RZISN4 GY 18 GXL BR 18 6XL 86 88 66 229 45 amano BK 18 GXL PK 18 GXL PK 18 6XL BR 13 GXL GY 19 GXL 1 05020 8 F426 N12 08 66 1552252 M974 R3 229 55 MSTI RO 811 F425R12 BR 18 GXL YL 18 6XL GY 18 GXL BK 18 GXL BK 18 GXL PK 18 6XL BR 18 6XL BR 18 GXL BR 18 GXL PU 18 6XL box ion t ine Mar Page 52 5 uondo en oa 20 4 S HOLOSNNOO LYN MITYNOILONMS 3 15 3319 HO b pb 9866565 1291 2 W ONY O H SHOLOSNNOO ILYN z f ALITWNOILONN SAVIS MBLSYW YOA j SON b TKe 8i u8 3515681 682881 sow
38. 1930213 101 84 RD 18 GXL UNSWITCHED 229 5 BK 14 GXL BAT NOTE A 22986 BK 18 GKXL BAT NOTE A SECONDARY THROTTLE POSITION 191 511 RD 18 8xL UNSWITCHED 945 E12 BR 18 GXL CAT DATA LINK 944 064 OR 12 GXL CAT DATA LINK TWISTED PAIR 7 101 517 RD I2 GXL UNSWITCHED NOTE 229 819 BK 18 GXL BAT NOTE A 971 553 BR 18 GXL PRIMARY THROTTLE POSITION EHS 0212 3 BK 18 GXL MULIT STATION VE TWISTED PAIR 2 NOTE Mj 900 022 YL I GXL 41929 DATA NOTE 990 825 GN I GAL 11929 DATA NOTE L460 50 YL 18 GXL TRIP CLEAR SW 146364 GY 18 GXL LOW COOLANT LEVEL LAMP F401 E63 GY te GXL HIGH COOLANT TEMP LAMP 242451 YL A GXL MAINTENANCE IND LAMP F400 E62 GY 18 XL LOW OIL PRESSURE LAMP 2425 53 BUAe GXL DIAGNOSTIC LAMP F473 E60 YL 18 GXL WARNING LAMP 391 627 PK 16 GAL REMOTE START EHS 900 5280 BR G GXL KEYSWITCH M973E47 BR 18 GXL SYNC SWITCH INPUT 1 MeT amp E46 YL 18 GXL SYNC SWITCH INPUT 2 PU I GXL REMOTE SHUTDOWN SW F425 E49 PU IS GXL TROLLING MODE SW R819 E48 GY 18 GXL SLOW VESSEL MODE SW F426 E51 80 86 MAINTENANCE CLEAR SW BR I GXL STARTER INTERLOCK C214 E30 BK 14 GXL SMMS RETURN H452E18 6 18 WF WARNING LAMP BR1G GXL TROLL ENABLE MSCS
39. 2 Water injection elbow 3 To overboard outlet 4 1 2 bore siphon break 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 6 Exhaust riser Note that the system must meet the requirement for the maximum exhaust back pressure to be not greater than 15kPa measured within 305mm 12 inches of the turbocharger exhaust outlet Minimum volume of exhaust tank should be 3 times the volume of the water in the riser The tank should be installed near the centre line of sailing craft Page 12 N40475 Chapter 4 Silencers ee In some applications a reduction in noise levels from 0 Fa the exhaust would be desirable and to that extent a silencer be fitted qu S ME The exhaust system ejects the cooling water as wee Tul 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 Figure 7 Figure 7 shows an engine sited well above the waterline 1 with a gradient steeper than 5 to the back of the boat The water will run naturally down the exhaust to the stern To reduce noise a straightforward in line s
40. 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 amp 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 Engine MJB Marine Junction Box Throttle Battery customer supplied Instrument panel main or auxillary MMPD digital panel Keyswitch panel Harness engine to MJB Harness throttle 0 Harness main or auxillary panel J1939 requires tee connector 11 Harness keyswitch 12 Harness MMPD digital panel 13 Battery lead customer supply 14 Master slave lead 5 Perkins 4 M 23 Figure 3 Chapter 8 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 Engine hours fault code display Warning light Oil pressure gauge Warning light Water temperature gauge Warning light Warning lamp 9 gv M Diagnostic lamp e Engine crank Voltage gauge gt N Warning light Keyswitch on off 14 Engine stop switch 15 Panel illumination The cutout dim
41. 71010 209 622 8084 0214 5094 6874 504 9989 10 4 906 014 101 2019 6872 8014 0294 5014 8234 2014 1865 901479869 2014 18 1014 0067 927551 92761 1 Nid 8 TaNYd NIvW SOGIHSA 4 WYYTYHOLIMSAIN 1804 01 gece3t HOLO3NNOO 8 WY TW HOLIMSASY 1804 01 LOANNOD N40475 Chapter 8 1552273 starter INTERLOCK 179 STARTER NTERLOCK 8 B eben 2 o sentes pao 9 15 0 d a STARBOARD CAM GS INTERFACE 5 d omen 6 06 BATTERY EREAKER IGN 41839 DATA 990 4 8 118608 LOOP CIRCUITS 25 s 1552264 m Loo oRcure sosen 08 60
42. CTFON CONTROL MODU IMERFACE S 2 BW M GXL BY 0 SYNC SWITCH 2 940 YL 18 6XL 7 4 22 To ATTEN bo 22003 BK 14 GXL 4 BATTERY po p m nesmen bas od ba fs 4 po azos 96 04 56 J E smeta 44 D senos 4 4 DIAGNOSTIC LAMP 95 M r422 w24 18 220 04408 BK 14 GXL po BAT ECN BATTERY iz ps 990 0018 GN 18 GXL r9 DATA MAINTENANCE CLEAR SW 952 BU 18 8XL 301AMWOG REMOTE START 4 88 18 0 1 1 4292 6002 BU 18 GXL 5 DIAGNOSTIC Lame CAT DATALINC bu 94420607 51 HIGH COOLANT TEMP LAMP p razewwwan Bux 1 wanrenance cura sw 0 bs 975 0034 6 smc OR 18 BXL CAT DATALINK aaas DI vL 18 8XL 5 d SW tsa D 6866 0486 00 18 60 4 do Bar eom To Mo ranewos 57 4 BAT ECM TO BATTERY De vireo 6 REMOTE sw ens FATSAMW2S 1 18 5 1 7 8 q WARNING Lame b de owon Press icm b
43. aditional SA SVMSYC TR Station Button Status On Off Off On Off Station Lamp Status On On Off On Off Figure 9 8 Perkins 8 Perkins SYSTEM INFORMATION SYSTEM INFORMATION User Name USERO00001 61 Exit User Name Software Version 70 Software Version 204 0777 00 RBL Version 01 04 RBL Version 01 04 Serial Number 15396027 1 Serial Number 15396027 Unit Location Port Wing Station Unit Location Port Wing Station Engine Location Port Engine Location Port Display Units English Display Units English Vessel Spd Units Knots Vessel Spd Units Knots Figure 10 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 and Multi Station Control System MSCS information The MMPD software has been redesigned to include MSCS functions Information screens There are two information screens available the System Information screen and the Control System Information screen figure 9 Pressing the button labelled Menu will display the System Information screen or the control system Information screen The System Information screen is the first screen displayed by default however the MMPD will retain which information screen was displayed last until a power off reset System information screen The System Inf
44. be situated well clear of other components such as shafts logs rudders to prevent flow problems at high speeds The intake fittings and pipework should have a minimum bore of 32mm 1 25 be provided This should be of the full flow type giving unobstructed passage to the water in the open position with a minimum bore of 32mm 1 25 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 From the sea water strainer a pipe 2 should be run to the sea water pump inlet connection on the engine The pipe may either be mainly rigid of for example copper or cupro nickel or flexible but only flexible hose which is reinforced to prevent collapse should be used Rubber hose connections in the sea water system should be kept as short as possible The system must be sufficiently flexible to permit the engine to move on its flexible mountings The sea water pump connection is for hose with a 32mm 1 25 bore Care should be taken to use compatible materials in the sea water systems to prevent excessive electrolytic corrosion Systems incorporating copper cupro nickel stainless steel Type 316 gun metal silver solder and aluminium brass will generally be satisfactory Components made from lead iron steel aluminium or its alloys zinc or magnesium should be generally avoided Refer to section 8
45. e 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 Ib ft 115Nm Fit the key figure 1 item 3 to the power take off shaft For axial drives For axial drives it is recommended that a flexible drive coupling between the engine and any given load is used For belt drives Standard options are Either a 5 A section pulley with three grooves figure 2 item 1 and a taper lock figure 2 item 2 A 5 B section pulley with two grooves figure 3 In this case the maximum power which can be taken will be limited by the belts and it will be necessary to calculate for marginal applications Caution Additional inertia must not be added to the shaft without specialist advice Consult your distributor if you need advice about non standard drive arrangements Page 59 Chapter 10 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 Page 60 N40475 N40475 1 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
46. ecting leads 2 54 Engine 2 55 9 Engine Controls eee 57 10 Provision for power take off 59 F r LIE gu c HEN 59 ed nul 59 Polar 00 11 Calorifier and block heater connections 61 lt EO oS LEE 61 Block heater connection nna 61 12 Reference 63 Basic data M300C M25UC 63 Cooling 63 51 11 11 64 64 Lubricating 65 Electrical System eer 65 DE cgqd n Pe 65 Basic 216 190 22 67 94012 AMENE EEEE AEAEE SE Ee SENEN ERESSE nR 67 79 7 2 68 68 L bricating 5510 69 Electrical 550 69 Ead 69 N40475 Chapter 1 Location of engine installation points Exhaust Systems See chapter 4 Starter Cables See chapter 8 Bonding Stud See chapter 8 Fuel Feed See Ventilation See chapter 7 chapter 5 Cooling Systems See chapter 6 1 Mounting Brackets Engine Mo
47. ed to obtain the optimum position Engines used with unusual drive arrangements such as V drives when integral with the engine unit pose special mounting problems and recommendations as to the most suitable mounting arrangement can be made for specific applications Note For transmission ratios above 2 1 or use in extreme conditions please contact your local distributor for advice Installation drawings are available showing the preferred mounting arrangements when using a variety of gearboxes and applications Page 5 Chapter 2 40475 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 The bearers should be cross connected to give lateral rigidity in order to maintain the shaft alignment and to prevent twisting and racking forces being applied to the engine To enable minimum shaft centre distances to be achieved in a twin installation common centre bearer supporting the inner mountings of both engines is sometimes used as shown in figure 6 this method Figure 6 shaft centres down to 783mm 31 may be adopted but wider spacing is desirable The shaf
48. eivable operational condition Page 9 Chapter 4 Figure 2 shows the exhaust elbow 1 with water injection and insulating blanket The elbow can be rotated 3 to achieve the optimal position Note The exhaust elbow must have a fall of 10 downwards If a taller system is required then a dry 90 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 Due consideration must be given to providing flexibility in the exhaust hose particularly if the engine is flexibly mounted Where the exhaust hose must pass through a bulkhead immediately behind the engine it is preferable that the arrangement shown in figure 3 is adopted using rubber bellows 1 to provide flexibility Note that the bellows should be in an unstrained condition when fitted a minimum fall of 5 3 is required and that the point of water injection must be at least 8 inches above the waterline 2 Note A single double hump bellows can be used where space is restricted Caution Movement of the engine on the flexible mounts must not be restricted by the exhaust hose Page 10 N40475 Figure 2 Figure 3 N40475 lt lt Figure
49. ensions are shown below the panel illustration Page 26 N40475 20 15 25 ALA Figure 4 N40475 1 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 10 1 Tachometer W Engine hours fault code display oa Warning light Warning lamp 2 3 4 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 Figure 5 Page 27 Chapter 8 40475 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 BOOST PRES 0 50 e 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 P 67 rated The Digital panel shown in Figure 6 is 150mm x 103mm and includes 1 Display 110mm 2 Screen illumination 3 Alar
50. eze This mixture is necessary even in warm climates as the anti freeze contains corrosion inhibitors which protect the engine cooling system Page 18 N40475 m gt Engine Thermostat Fresh water pump Aftercooler Gearbox oil cooler Exhaust manifold Remote tank Figure 2 8 Cylinder cooler jacket grid 9 Aftercooler grid cooler 10 Auxiliary water pump 11 Integral oil cooler 12 Bleed 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 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 Perki
51. fittings may be ordered as part ofthe 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 Block heater connection points A mains powered cylinder block heater may be fitted to keep the engine warm when the boat is stored in low temperatures A suitable heater may be ordered as part of the engine assembly or may be fitted later Figure 2 shows the connection point The core plug in the position shown on the engine block is removed and the block heater fitted and secured with a bolt If the heater is ordered same time as the engine it can be attached to the engine Figure 1 Figure 2 Page 61 Chapter 11 N40475 Page 62 N40475 Chapter 12 Reference data Basic data M300C M250C Rated power 300 hp 225 250hp 186 kW Rated engine speed 2400 rpm Number of cylinders EEA 6 Cylinder In line 0 4 Stroke Induction Turbocharged aftercooling lm 105 mm 4 13 SITOKE 127 5 00 Compression 16 2 1 CUBIC Capacity zs dr 6 6 Litre
52. hapter 8 N40475 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 Although the current carried by the bonding system will not normally exceed 1 amp the cable sizes should be generous as shown in the table below Length of run to Suggested cable size Up to 30 feet 7 strand 0 85mm 4mm 30 40 feet 7 strand 1 04mm 6mm As many of the connections may be splashed with 7 5 9 3 69 sea water they should be soldered wherever possible and clamped elsewhere with the joint protected from Figure 28 corrosion by neoprene paint or a similar material to exclude water Figure 28 shows the main components 1 Engine 2 Propeller shaft 3 Sea cock 4 Zinc anode 5 Bonding stud 6 Common bonding wire 7 Through the hull metal fittings Optional sensors Throttle position Fuel level Transmission oil pressure Transmission oil temperature Exhaust gas temperature Coolant level Fuel temperature Fuel supply pressure Page 44
53. he battery terminals before a repair is made to the electrical system Only one person must control the engine Ensure that the engine is operated only from the control panel or from the operators position 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 Do not wear clothing which is contaminated by lubricating oil Do not put material which is contaminated with oil into the pockets of clothing Discard used lubricating oil in accordance with local regulations to prevent contamination Use extreme care if emergency repairs must be made at sea or in adverse conditions The combustible material of some components of the engine for example certain seals can become extremely dangerous if it is burned Never allow this burnt material to come into contact with the skin or with the eyes Always close the seacock before the removal of any component of the auxiliary water circuit Wear a face mask if the glass fibre cover of the turbocharger is to be removed or fitted Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested Do not
54. here are two separate wiring sections one for the port system and a second for the starboard system These sections provide the interconnection points for engine power and vessel control and monitoring The Marine Junction Box also provides circuit protection for the ECM keyswitch and the other components connected to the vessel control system Page 36 Figure 17 N40475 1 Chapter 8 Single engine MJB features and mounting details N40475 6 67 1 216 2 mm m 8 51 1 Y i i 2 amp Perkins 3 3 MARINE JUNCTION BOX 5 4 oQ IGNITION 3224 2 i268 6 PRIMARY SECONDARY m PCP 7 xO ECM 8 e 9 7 10 vo 1 508 mm 11 2 00 12 Ww J ala BATTERY 12V 24V Figure 18 Breakers Throttle Expansion ECM J1939 Key alarm Custom Throttle synchronization panel PDL connector to EMS engine vision or service tool Power for the power train control p
55. honing of the fuel when the engines are stopped The fuel lines may be of metal either copper or bundy steel tubing used either with compression fittings or preferably soldered nipples with a flexible armoured rubber hose to connect to the primary fuel filter This simple fuel system is satisfactory when one or more engines are run from a single fuel tank and it may also be used when there are two tanks each supplying one engine In the latter case the system may include a cross connection between the tanks by means of a balancing pipe with a valve at each end In some installations cross connecting pipes between the two engine feed pipes and the two engine return pipes have been used but valves are necessary in every line so that the appropriate system may be selected and the complexity of installation and operation is such that the advantages in operating flexibility are out weighed by the possibility of obscure problems due to component malfunctions incorrect operation or engine interaction Page 21 Chapter 7 40475 In some cases it is necessary to have number of fuel tanks in order to achieve the required operating range Insuch 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 Figure 3 shows a col
56. hould have a removable panel to simplify cleaning 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 Figure 1 Figure 2 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 Fuel return pipe Manual fuel feed 2 3 4 Stop cock 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 Fuel return pipe Manual fuel feed 2 3 4 Vent 5 Fuel feed tap 6 Drain tap The fuel tank may be steel aluminium or G R P or alternatively a rubber bag tank may be used The main fuel connection is taken from the rear of the tank so that all the fuel is available for use when under way when the hull will be at an angle The fuel return is extended within the tank to near the bottom in order to prevent air locks which can arise due to syp
57. ilencer 2 should be used Note The above is used in relation to 15kPa Page 13 Chapter 4 N40475 Page 14 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 52 C 126 F The air temperature entering the engine room should not exceed 60 C 140 In most applications in temperate climates the engine will draw air from the engine room If this is the case then as a rough guide it can be taken that every horsepower produced by the engines requires as a minimum 6 35 sq mm 0 25 sq ins of vent area If the boat is likely to be used in hot climates and if engine room ventilation fans are fitted then a vent area of 12 7 sq mm 0 5 sq ins per horsepower should be provided Wherever possible a Figure 1 flow of air through the engine room should be encouraged by using forward facing intake vents to take advantage of ram airflow together with other vents to allow hot air to escape Noise absorbing chambers 1 with deflector baffles and noise absorbent material 2 are positioned to direct ventilation air flow over a large surface area of absorbent material Cross sectional area of air flow path
58. in 31 galls min 2400rpm Page 63 Chapter 12 N40475 Fuel system Recommended DIN E 590 DERV class A F amp 0 4 BS2869 Class A2 Off highway gas oil red diesel ASTM D975 91 Class 1 1DA amp Class 2 2DA JIS K2204 1997 Grades 1 2 3 amp Special grade 3 JP7 F63 JP8 JP5 Jet A A1 Diesel fuel mix with 5 vol RME in accordance with proposal 51606 JIS K2203 Fuel injection pump in line with boost control and electric stop energised to stop plunger type Fuel feed pressure 2 2 222 414 20040 nia 0 3 to 0 6 5 to 8psi Mechanical Pipe size Supply outside diameter 10mm 0 394 Supply okini 8 4mm 0 331 outside diameter oiii ees 10mm 0 394 DOME m 8 4mm 0 331 Maximum lift pump 1 8 m 6ft to bottom of tank suction pipe Maximum fuel lift pump 127 mm 5 inches Hg depression at inlet Fuel consumption at 56 6 I hr 12 4galls hr power Air intake Combustion 14 8m min 524ft min Maximum engine compartment 60 C air temperature Maximum air temperature Al 52 engine inlet Ventilation maximum engine
59. jointed drive shaft is used the bolts on all four corners of the engine should be positioned at the end of the slot all either fully in or fully out This will provide additional security in the fixing arrangements Note Please refer to the GA General Arrangement drawings for specific engine mount positions For any non standard options please contact the Wimborne Marine Power Centre for advice Page 4 N40475 Figure 4 N40475 Figure 5 1 Chapter 2 Flexible engine mounts It is recommended that flexible engine mounts should be used for all applications The principal purpose of the mounts is to reduce the transmission of vibration from the engine to the hull but another valuable advantage is that the mountings reduce the shock transmitted from the hull to the engine under adverse weather conditions and also prevent the engine being inadvertently used as a structural part of the boat due to flexing in the hull a function the engine will not satisfactorily fulfil Figure 5 shows the flexible engine mount for most applications Note refer to the installation drawing for specific dimensions which are for the mount in the unloaded condition To adjust the height of the mount use the adjuster nut and bolt 2 against the pad 3 to introduce shims 4 maximum of thirteen shims per mount can be used eleven at 1mm thick and 2 at 0 5mm thick Radially slotted holes 5 can be utilis
60. lector tank 1 fed by all the storage tanks and connected to the engine feed 2 and return systems 3 but with a vent pipe 4 taken to any convenient tank There is no doubt however that a simple fuel system as illustrated in Figure 1 should be used wherever possible as having a completely separate tank and supply to each engine guarantees that if an engine stops due to running out of fuel or to water or foreign matter in the fuel the other engine will not be affected simultaneously This will give some time for appropriate manoeuvring action to be taken The simple system Figure 3 will also require the minimum number of valves and fittings which ensures maximum reliability in service Page 22 N40475 NS 8 17 os My 0 1 i 8 Chapter 8 Engine electrical systems A plug together electrical system is available with the engine providing the following choices from the engine connection e 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 Engine wiring looms The engine wiring loom connects the starter alternator breakers elect
61. m mute 4 Scroll forward button 5 Scroll back button Figure 6 The cutout dimensions are shown below the panel illustration Page 28 N40475 1 Chapter 8 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 29 Chapter 8 Possible panel configurations A variety of panels may be run simultaneously in any of the combinations as shown in figure 8 1 2 o nn Power supply Cable or electronic throttle and gearbox control options Main panel Auxiliary panel Mini Marine Power Dispaly MMPD digital panel Keyswitch panel Page 30 N40475 Figure 8 N40475 amp Perkins SYSTEM INFORMATION User Name USER000001 1 Software Version 204 0777 00 RBL Version 01 04 Serial Number 15396027 Unit Location Wing Station Engine Location Port Display Units English Vessel Spd Units Knots 8 Perkins CONTROL SYSTEM INFORMATION PCP Version Troll Mode Troll Set Engine Speed Engine Sync Master Active Station Location Engine Room 000 0000 00 Tr
62. n the tank Clean away fuel which has been spilt Material which has been contaminated by fuel must be moved to a safe place Do not put fuel in the tank while the engine runs unless it is absolutely necessary Do not clean add lubricating oil or adjust the engine while it runs unless you have had the correct training even then extreme care must be used to prevent injury Do not make adjustments that you do not understand Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions Other persons must be kept at a safe distance while the engine auxiliary equipment or boat is in operation Do not permit loose clothing or long hair near moving parts Keep away from moving parts during engine operation Warning Some moving parts cannot be seen clearly while the engine runs e Do not operate the engine if a safety guard has been removed Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure because dangerous hot coolant can be discharged Do not use salt water or any other coolant which 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 Disconnect t
63. na 1VNOLLdO 0 L oea 5 Tosa Toning 4 iring 47 3E5239 24 VOLT 8 4451616 12 11 9k 1084 harness 2 Eng 229 870 BK 1 amp GXL e 209 871 GY 12 GXL 2 4 906 072 ER I GXL 54 ALTERNATOR RELAY z CA44 E39 YL 13 GXL 4 6 1181618 24 GLOW PLUG RELAY diane d CBLFI 1552269 2095582 24V 382 675 PK 18 GXL 2096681 124 383 76 GN 18 GXL 24 CELGG OR4 GLOW PLUG RELAY f Ecs eomm HERE d 2095581 12 F793E26 ORAEGXL 24 iso EHS 204 887 RD 12 SMMS RELAY CJ 109 E86 RD 12 ECS psisusiS 2095582 24V 1552268 STARTER MOTOR 391 888 PK 1 GXL 2095881 12 2687388 12 21468 BK 14 GXL 2 6 2097269 24V 304 E87 PD 12 1712212 GLOW PLUG BREAKER CBL GG1 OR 1552269 321 573 PK 18 GXL T 6 4 109 880 RD 12 0914078 BKAS GEL 2 4 1882158 ALTERNATOR 2837658 12 VOLT 100 AMP 2937872 24 VOLT 58 i RD 209 71 CBLGi BK 4 i i H CBLH2 BK 4 GLOWPLUG BUSS BAR 2774407 SLOWFLUG_
64. ns 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 Operation and Maintenance Manual Fluid Recommendations Fuel Specifications 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 pres
65. ntelli Troll Change troll speed Selecting Change Troll Set Speed as figure 12 will display the following screen Pressing will increase the set speed by 1 rpm and pressing will decrease the set speed by 1 rpm Pressing Save will cause the MMPD to send the data to the PCP and exit the screen and pressing Cancel will cause the MMPD to exit the screen without sending any data to the PCP Change engine sync master Pressing the alarm button will cause the displayed Engine Sync Master to scroll through the available sync master selections PORT and STBD Active station location Displays the Active Station Location Bridge Port Wing Starboard Wing Tower Engine Room Aft Station Fly Bridge and Bow Station If the PCP reports that there is no active station then the MMPD will display NONE in the Active Station Location field Button status indicator The Station Button Status indicators display the button status as read by the active control station SA Activate Station Button Status e SVM Slow Vessel Mode Button Status SYC Engine Synchronization Button Status e N idle Neutral Lockout Button Status TR Trolling Mode Button Status Lamp status indicator The Station Lamp Status indicators display the commanded lamp status from the active control station e SA Activate Station Lamp Status SVM Slow Vessel Mode Lamp Status SYC Engine Synchronization Lamp Status e N idle Neutral Lock
66. on anodes Note Where possible mount the strainer 5 so that the top is just above the waterline 6 to facilitate cleaning Page 17 Chapter 6 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 Cylinder Jacket Circuit Heat rejection Design value for the water temperature at the exit from the keel cooler Design value for the water flow through the cooler Pipework to suit 45mm 1 75 bore hose connections Aftercooler Circuit Includes gearbox oil cooler Heat rejection Design value for the water temperature at the exit from the cooler Design value for the water flow through the cooler Pipework to suit 45mm 1 75 bore hose connections Note Under extreme conditions the water flow in the jacket circuit may increase to 40 gallons min The pipework between the engine and coolers should be as short and direct as is possible but should be sufficiently flexible to allow the engine to move on it s flexible mountings The layout should discourage the formation of air locks and venting points should be provided wherever an air lock is likely to occur The keel cooling system should normally be filled with a water antifreeze mixture containing 50 antifre
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68. ormation screen will display the current User Name Software Version ROM Bootloader Software Version Unit Serial Number Unit Location Engine Location Display Units and Vessel Speed Units Pressing the button labelled Menu will display the System Information menu screen On this screen the button function is re defined as shown on the right side of the screen see figure 10 If a diagnostic code is active and the diagnostic code window is on screen the button actions return to their normal definitions Pressing the up or down arrow button will cause the top menu item labeled Change Screen to scroll through the items to be changed Change Screen Change User Change Unit Location Change Display Units and Change Vessel Speed Units and cause the selected data to be displayed in reverse video Pressing the alarm button will cause the specified parameter to scroll through each available value i e Change Vessel Speed would scroll through Knots MPH and KPH Pressing the button labelled Exit will return the display to the System Information screen and save any changed data to non volatile memory Page 31 Chapter 8 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
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70. out Lamp Status TR Trolling Mode Lamp Status Page 33 N40475 Chapter 8 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 13 1 Active diagnostic status of active station location 1839 2 Slow Vessel Mode SVM status does EROTS 3 Gear position a UCM 2480 1848 2085 Troll mode status yr gps SH 5 Engine synchronization status The Diagnostic icon overrides the Active Station Location when condition Parameter Status Display Text f there is an active diagnostic the word DIAGNOSTIC will be Slow Vessel Mode SVM Gear position Troll Mode Engine sync mode Active station there SVM active SVM inactive Forward Neutral Reverse Gear Lockout Active Troll active Troll inactive Synchronized PORT Synchronized STBD PORT Master Sync cruise active STBD Master Sync cruise active Sync not active bridge PORT Wing STBD Wing Tower Engine room Aft station Fly bridge Bow station is an active diagnostic SVM No text displayed AHEAD NEUTRAL ASTERN Gear L O TROLL No text displayed SYNC P SYNC S CRUISE P CRUISE S No text displayed BRIDGE PORT WING STBD WING TOWER ENG ROOM AFT STATION FLY BRIDGE BOW STATION
71. rocessor not used Connection for battery battery Connection for battery battery Page 37 Chapter 8 Twin engine MJB features and mounting details 1 Breakers Custom port side Key alarm port side J1939 port side 2 3 4 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 Throtlle synchronization panel 15 PDL connector to service tool 16 Power for the power train control processor not used 17 Connection for battery battery 18 Connection for battery battery Page 38 O6x7 1mm 0 28 216 2mm N40475 8 51 9 6 T Gol To l 88 Perkins MARINE JUNCTION BOX PORT es STBD IGNITION 20 IGNITION e e e PORT STBD e e 9 PRIMARY SECONDARY Do PCP e e e 308 4 mm 12 14 322 1 mm 12 68 12V 24V
72. ronic engine controller ECM electric stop engine senders and injectors to a waterproof IP67 multiway connector situated on a flying lead attached to the engine The engine circuit diagram can be found at the back of this chapter When working on the harness always secure the harness in the original position with the correct clips and away from pinch points heat and sharp edges The connectors are keyed to fit in only one direction which ensures proper pin to socket alignment Never force connectors as they should fit together with minimal effort Connectors are designed to seal out dirt and moisture without the use of electrical grease When servicing the harness inspect the condition of the seals on the connectors When pins are unused be sure to use blanking plugs to protect the connector against dirt and moisture 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 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 Figure 1 Page 24 N40475 Figure 2 Chapter 8 Interconnecting cables Interconnecting cables figure 3 are used to join the engine 1 throttle
73. rt limits Minimum cold start temperature with aid 409C 409F Page 65 Chapter 12 N40475 Page 66 N40475 12 Reference data Basic data M216C M190C Rated 300 hp 225 KW 250hp 186 kW Rated engine speed 2100 Number of 6 3 0000 In line gt 4 Stroke Induction Turbocharged aftercooling 55 m 105 mm 4 13 127mm 5 00 Compression Ratio essem 16 2 1 Cubic Capacity esise 6 6 Litre 365 in Valves 2 Direction of Anti clockwise viewed from flywheel c 1 5 3 6 2 4 Total Weight wet 738 kg 1627 Ibs engine only including alternator and starter 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 379C Bais e M 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh Water
74. s FAM D t mantenancemn rame bs Hourmeree TROLLING MOLE SW ras we Hour merer be Wewa gR 18 GXL 85 lt TACHOMETER KEYSWITCH ps Pr 0906 4980 BR 18 GXL kd bn PU MS GXL q TROLLING wane sw FCAT DATALINK J905 WW30 BR 18 GXL 6 DIAGNOSTIC LAMP 2 73 4 1002 d uen PB 1952282 wanrenanceinouawe TR 2 d Trou mame wes b SYNC SWITCH LOOP 13 4 4 9 LOOP 20 d 5 suen woa 4 n arrear carters b d bo aces eq PORT THROTTLE RTESEADE 76222 g staaten STARTER INTERLOCK 4 pamawa 0 12 swwvese sw vaarrenveneaien D 1 vasrrenyeresier B a 1552264 Ebro VAROM d pcp aan Ds BU 18 0xL remore woemurs puit BRDIRGXL PORT sew L rasepeos 0010 18 60 Mk s sucnosnie tame PANEL INTERFACE SYNC PANEL CAT DATALINK STARBOARD EXPANSION eatery 18 5 lt WARNING LAMP INTERFACE INTERFACE INTERFACE LOOP CIRCUIT 7 229 0
75. sure 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 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 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 Fuel tanks should have the following features 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 Internal baffles may be required to prevent fuel surge The tank s
76. t centres could be theoretically reduced further but this would result in the engine accessibility becoming very restricted and it would be impossible to carry out service operations It should be noted that if minimum shaft centres are to be adopted space must be left in front of and behind the engine to provide access A minimum clearance on all sides will mean that the engine cannot be serviced Page 6 N40475 Figure 1 Figure 2 1 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 It is recommended that a Torsional Vibration Analysis TVA is carried out on the complete drive system Mass Elastic Data can be provided on request from Wimborne Marine Power Centre Figure 1 shows a simple arrangement where the propeller shaft is supported only by the gearbox coupling and an outboard rubber bearing at the propeller end Entry of water into the boat is prevented by a shaft seal which must be flexibly mounted to allow for engine movement A flexible shaft coupling 2 is fitted to the gearbox coupling
77. 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 The vessel locations that are available are Bridge Port Wing Starboard Wing Tower Engine Room Aft Station Fly Bridge and Bow Station Change display units Pressing the alarm button will cause the displayed Display Units text to scroll through the available units selections English and Metric Change vessel speed units Pressing the alarm button will cause the displayed Vessel Speed Units text to scroll through the available units selections Knots MPH and KPH Change system information screen The Control System Information screen will only be displayed if a Powertrain Control Processor PCP is detected on the data link This screen will display the PCP software part number Troll Mode Troll Set Engine Speed Engine Sync Master Active Station Location active Station Button Status and Active Station Lamp Status Pressing the button labelled Menu will display the screen shown in figure 11 On this screen the button functions are re defined as shown on the right side of the screen However in the presence of a diagnostic code window button actions return to their normal definitions Pressing the up or down arrows will cause the top menu item labeled Change Screen to scroll through the items to be modified Change Screen Change Troll Mode
78. unting Point See chapter 2 See chapter 2 Engine side views Page 1 Chapter 1 4 N40475 Rear Lifting Eye Use spreader bar Exhaust Systems See chapter 4 Electrical Front Lifting Eye Systems See Use spreader bar Fuel Return See chapter 7 Mounting Brackets Engine Mounting Points See chapter 2 See chapter 2 Engine end views Page 2 N40475 Figure 2 Figure 3 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 179 nose up adding 3 for planing craft with a heel angle of 25 continuous and 35 as shown in figures 2 and 3 Nose down capability Details are not available at time of print Page 3 Chapter 2 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 Where fine alignment is not necessary for example when a flexibly
79. vide battery power switched inputs and data link signals to and from the ECM The pin out is the same for both the port and starboard connectors Grounding the battery negative It is recommended that the battery negative busbar should be grounded as close as possible to the battery by a substantial connection to the bonding system within the boat This will reduce the likelihood of interference between items of electrical and electronic equipment fitted to the boat Page 39 Chapter 8 Port 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 amp 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 If no such device is installed a jumper wire should be installed between expansion connector pins 1 and 2 as in figure 22 Figure 23 shows a neutral safety switch figure 16 item 1 between the starter interlock pins 1 and 2 Page 40 N40475 Expansion Connector Starter Interlock Switch Starter Interlock Switch A N C N C Battery Ignition Breaker Battery Ignition Breaker Battery Battery N C N C N C Trip Clear N C Keyswitch Switch N

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