Perkins M190C Installation Manual Download

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N40475

Title

Perkins M300C, M250C,

M216C & M190C

Installation Manual

6 cylinder, turbocharged, intercooled, diesel engine for

marine propulsion applications

Publication N40475, Issue 2

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:

[email protected]

www

.perkins-sabre.com

Summary of Contents for M190C

Page 1: ...Installation Manual Part No N40475 GB Marine Power M300C M250C M216C M190C ...

Page 2: ......

Page 3: ...cation N40475 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 ...

Page 4: ...nformation 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 ...

Page 5: ...e 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 the 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 operator...

Page 6: ......

Page 7: ... Part dry part wet systems 12 Water lift systems 12 Silencers 13 5 Engine room ventilation 15 6 Engine cooling systems 17 Auxiliary water systems 17 Keel cooling system 18 7 Fuel systems 19 Cleanliness of fuel system components 19 Cleanliness of the engine 19 Environment 19 New components 19 Refuelling 19 Fuel connections 19 Thread details of the connections on the engines for fuel pipes 20 Typica...

Page 8: ...t or starboard expansion connectors 40 Diagnostic lamp Pin 2 41 Warning lamp Pin 1 41 Battery Pin 11 41 Keyswitch Pin 12 41 Maintenance Clear switch Pin 16 41 Cold start system 42 Cold start data 12V and 24V 42 Battery performance 42 Battery to starter lead resistance 42 Battery isolator switches 43 Zinc Anode bonding system 43 Typical system in common use 44 Optional sensors 44 Engine wiring harn...

Page 9: ...nnections 61 Calorifier 61 Block heater connection points 61 12 Reference data 63 Basic data M300C M250C 63 Cooling 63 Fuel system 64 Air intake 64 Lubricating system 65 Electrical system 65 Cold start limits 65 Basic data M216C M190C 67 Cooling 67 Fuel system 68 Air intake 68 Lubricating system 69 Electrical system 69 Cold start limits 69 ...

Page 10: ...Contents N40475 ...

Page 11: ...points Exhaust Systems See chapter 4 Starter Cables See chapter 8 Fuel Feed See chapter 7 Bonding Stud See chapter 8 Ventilation See chapter 5 Mounting Brackets See chapter 2 Engine Mounting Point See chapter 2 Cooling Systems See chapter 6 Engine side views ...

Page 12: ...ee chapter 4 Engine Mounting Points See chapter 2 Mounting Brackets See chapter 2 Engine end views Warning Use spreader bar Front Lifting Eye Rear Lifting Eye Warning Use spreader bar Electrical Systems See chapter 8 Fuel Return See chapter 7 ...

Page 13: ... 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 Details are not available at time of print Figure 1 Figure 2 Figure 3 35O 35O 25O 25O 20O ...

Page 14: ... 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 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 Plea...

Page 15: ...n 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 A 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 utilised to obtain the optimum position Engines used with unusual drive arrangements suc...

Page 16: ... and racking forces being applied to the engine To enable minimum shaft centre distances to be achieved in a twin installation a common centre bearer supporting the inner mountings of both engines is sometimes used as shown in figure 6 By this method shaft centres down to 783mm 31 may be adopted but wider spacing is desirable The shaft centres could be theoretically reduced further but this would ...

Page 17: ...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 sha...

Page 18: ...Chapter 3 N40475 Page 8 ...

Page 19: ...ice 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 A general 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 5O 2 is required and that th...

Page 20: ...sideration 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...

Page 21: ...ong 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...

Page 22: ...ixture 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 2 Water injection elbow 3 To overboard outlet 4 1 2 bore siph...

Page 23: ...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 shows an engine sited well above the waterline 1 with a gradient steeper than 5O to the back of the boat The water will run naturally down the exhaust to the stern To reduce noise a straightforward in line silencer 2 should be use...

Page 24: ...Chapter 4 N40475 Page 14 ...

Page 25: ...s 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 must not be too small With an effective ventilation system the engine air intake temperature will be no more than 10O C higher than the outside air temperatur...

Page 26: ...Chapter 5 N40475 Page 16 ...

Page 27: ...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 su...

Page 28: ...ork to suit 45mm 1 75 bore hose connections TBA 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...

Page 29: ... 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 o...

Page 30: ...nter 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 should have a removable pa...

Page 31: ... 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...

Page 32: ...orage 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 t...

Page 33: ...lectric 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 directi...

Page 34: ...ccidental 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 35: ...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 Harness main or auxillary panel J1939 requires tee connector Harness keyswitch Harness MMPD digital panel Battery lead customer s...

Page 36: ...rated The Main Panel shown in Figure 4 is 250mm x 175mm and includes Tachometer Engine hours fault code display Warning light Oil pressure gauge Warning light Water temperature gauge Warning light Warning lamp Diagnostic lamp Engine crank Voltage gauge Warning light Keyswitch on off Engine stop switch Panel illumination The cutout dimensions are shown below the panel illustration 1 2 3 4 5 6 7 8 9...

Page 37: ...ges IP67 rated The Auxiliary panel shown in Figure 5 is 180mm x 140mm and includes Tachometer Engine hours fault code display Warning light Warning lamp Engine crank Keyswitch on off Diagnostic lamp Engine stop switch Panel illumination The cutout dimensions are shown below the panel illustration 1 2 3 4 5 6 7 8 9 Figure 5 ...

Page 38: ...eflecting 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 IP 67 rated The Digital panel shown in Figure 6 is 150mm x 103mm and includes Display Screen illumination Alarm mute Scroll forward button Scroll back button The cutout dimensions ...

Page 39: ... The Keyswitch panel used with the digital panel is shown in figure 7 and is 110mm x 90mm and includes Engine crank Warning lamp Diagnostic lamp Engine stop switch Keyswitch on off The cutout dimensions are shown below the panel illustration 1 2 3 4 5 ...

Page 40: ... A variety of panels may be run simultaneously in any of the combinations as shown in figure 8 Power supply Cable or electronic throttle and gearbox control options Main panel Auxiliary panel Mini Marine Power Dispaly MMPD digital panel Keyswitch panel 1 2 3 4 5 6 ...

Page 41: ...e 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 th...

Page 42: ...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 displ...

Page 43: ...r 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 indicator...

Page 44: ...r Status Display Text Slow Vessel Mode SVM SVM active SVM inactive SVM No text displayed Gear position Forward AHEAD Neutral NEUTRAL Reverse ASTERN Gear Lockout Active Gear L O Troll Mode Troll active Troll inactive TROLL No text displayed Engine sync mode Synchronized PORT SYNC P Synchronized STBD SYNC S PORT Master Sync cruise active CRUISE P STBD Master Sync cruise active CRUISE S Sync not acti...

Page 45: ...on 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 Maxim...

Page 46: ... Available for single figure 17 item 1 or twin figure 10 item 2 engine installations Inside the twin engine installation junction box there 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...

Page 47: ...s 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 processor not used Connection for battery battery Connection for battery battery 1 2 3 4 5 6 7 8 9 10 11 12 Figure 18 ...

Page 48: ... port side Throttle starboard side Expansion starboard side ECM starboard side J1939 starboard side Key alarm starboard side Custom starboard side Throtlle synchronization panel PDL connector to service tool Power for the power train control processor not used Connection for battery battery Connection for battery battery 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Figure 19 ...

Page 49: ... 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 p...

Page 50: ... 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 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 sta...

Page 51: ...Then the lamp will turn off unless the ECM detects a warning condition Diagnostic lamp 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 t...

Page 52: ...40 12V Iskra AZF 950 24V Iskra AZF 650 Commercial reference number Perkins code Battery minimum performance BS EN 50342 1 SAE J537 BCI 2 DIN 43539 3 643 A 440 640 400 647 B 510 700 465 069 D 340 540 300 655 E 570 760 490 621 F 860 900 505 1 Voltage no less that 7 5V after 10 seconds 6V after 90 seconds at 18O C 0O F across each 12V battery 2 Voltage no less than 7 2V after 30 seconds at 18O C 0O F...

Page 53: ...elines 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 ...

Page 54: ...y exceed 1 amp the cable sizes should be generous as shown in the table below Length of run to Zinc Anode Suggested cable size Up to 30 feet 30 40 feet 7 strand 0 85mm 4mm2 7 strand 1 04mm 6mm2 As many of the connections may be splashed with sea water they should be soldered wherever possible and clamped elsewhere with the joint protected from corrosion by neoprene paint or a similar material to e...

Page 55: ...N40475 Chapter 8 Page 45 Engine wiring harness overview ...

Page 56: ...Chapter 8 N40475 Page 46 Panel harness overview ...

Page 57: ...N40475 Chapter 8 Page 47 Wiring diagrams Engine wiring harness 1 ...

Page 58: ...Chapter 8 N40475 Page 48 Engine wiring harness 2 ...

Page 59: ...N40475 Chapter 8 Page 49 Engine panels 1 ...

Page 60: ...Chapter 8 N40475 Page 50 Interconnecting leads 1 ...

Page 61: ...N40475 Chapter 8 Page 51 Master slave option port ...

Page 62: ...Chapter 8 N40475 Page 52 Marine junction box ...

Page 63: ...N40475 Chapter 8 Page 53 Master slave option starboard ...

Page 64: ...Chapter 8 N40475 Page 54 Interconnecting leads 2 ...

Page 65: ...N40475 Chapter 8 Page 55 Engine panels 2 ...

Page 66: ...Chapter 8 N40475 Page 56 ...

Page 67: ... Engine controls It is recommended that a Morse single lever system is used to control engine speed and gearbox engagement Throttle lever Anchor for Morse 33C cable Morse 33C cable Idle position Run position 1 2 3 4 5 Figure 1 ...

Page 68: ...Chapter 9 N40475 Page 58 ...

Page 69: ...oupling 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 or 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 i...

Page 70: ...m 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 Figure 4 ...

Page 71: ...alled 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 th...

Page 72: ...Chapter 11 N40475 Page 62 ...

Page 73: ...ooling 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 37O C Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh Water Flow TBA at 2400 rpm Coolant pump speed and method of drive 1 1 Gear Driven System Capacity 26 litres 5 7 gallons Pres...

Page 74: ...t pump lift 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 full 56 6 l hr 12 4galls hr power Air intake Combustion airflow 14 8m3 min 524ft3 min Maximum engine compartment 60O C air temperature Maximum air temperature at 52O C engine inlet Ventilation maximum engine 125 mm WG 5 WG room depression Suggested ventilation airf...

Page 75: ...ngle 20O nose up Heel 25O constant 35O intermittent Oil pressure in operating 2 5 to 3 5 bar 36 to 50 psi speed range steady state Electrical system Alternator 55 amp 28 volt or 100 amp 14 volt Starter type 12V or 24V Number of teeth in flywheel 126 Number of teeth on starter 10 Cold start limits Minimum cold start temperature with aid 40O C 40O F ...

Page 76: ...Chapter 12 N40475 Page 66 ...

Page 77: ...oolant shown is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37O C Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh Water Flow TBA at 2400 rpm TBA at 2100 rpm Coolant pump speed and method of drive 1 1 Gear Driven System Capacity 26 litres 5 7 gallons Pressur...

Page 78: ...t pump lift 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 full 56 6 l hr 12 4galls hr power Air intake Combustion airflow 14 8m3 min 524ft3 min Maximum engine compartment 60O C air temperature Maximum air temperature at 52O C engine inlet Ventilation maximum engine 125 mm WG 5 WG room depression Suggested ventilation airf...

Page 79: ...ngle 20O nose up Heel 25O constant 35O intermittent Oil pressure in operating 2 5 to 3 5 bar 36 to 50 psi speed range steady state Electrical system Alternator 55 amp 28 volt or 100 amp 14 volt Starter type 12V or 24V Number of teeth in flywheel 126 Number of teeth on starter 10 Cold start limits Minimum cold start temperature with aid 40O C 40O F ...

Page 80: ...Chapter 12 N40475 Page 70 ...

Page 81: ...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 ...

Page 82: ...22 Cobham Road Ferndown Industrial Estate Wimborne Dorset BH21 7PW England Tel 44 0 1202 893720 Fax 44 0 1202 851700 E mail Web www Perkins Sabre com Marine Perkins com Wimborne Marine Power Centre ...

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