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Marine Diesel Engines

WNER

’

ANUAL

Engine

maintenance

HPE300

ENG rel. 1/11

www.fnm-marine.com

Weekly maintenance

WEEKLY

Activities

Achievable

by owner

Achievable

service

Inspection and possible draining of the filter and the fuel line (page).

Check the battery electrolyte level (page 58).

Check for any leaks.

Check the stern drive anodes/propeller consumption, replace if over 50%.

(MERCRUISER® STERNDRIVE) refer to producer indications.

Verify battery electrolyte level and status

Be careful when operating near the battery compartment. Disconnect the battery cables before
working on it.

Do not smoke near the battery. Flammable gases could be left by the battery.

Maintenance free batteries

This type of battery is equipped with an indicator of the state of battery charge (1).

Green color, charge level above 65%.
Dark color, charge level below 65%. Recharge immediately

Yellow color: Replace the battery

ATTENTION! The data are for information, always read the produce

r’s instructions.

ATTENTION! Never try to refill with any type of fluid with this type of battery.

Traditional lead-acid batteries

Содержание HPE 300

Страница 1: ...OWNER S MANUAL HPE 300...

Страница 2: ...______________________29 Instrument panel _______________________________________________________________________________30 Ignition block functioning _________________________________________________...

Страница 3: ...e winter maintenance ______________________________________________________________________72 Troubleshooting _______________________________________________________________________________73 Ordinary...

Страница 4: ...d according to demand and the needs of customers and builders of pleasure and work boats CMD S p A the company that produces and markets worldwide the marine diesel engines under the trade name FNM of...

Страница 5: ...inary maintenance the procedures and operations have been carried out by FNM Service Points ATTENTION The information featured in this manual only refer to the engine itself more specifically the illu...

Страница 6: ...Marine Diesel Engines OWNER S MANUAL General Information HPE 300 ENG rel 1 11 www fnm marine com 6 Page in blank...

Страница 7: ...de definition Type of engine code Year of construction Progressive numbering 6 1 1 1 0 0 1 Engine serial number is also printed on the engine block It position is shown in the picture below Engine man...

Страница 8: ...and follow the instructions of this manual During the engine lifting and transportation use means with appropriate load capacity During the installation the installer shall follow the manufacturer s i...

Страница 9: ...n the engine never point this to rubber pipes or electrical connections Use proper protection clothing gloves etc during maintenance and or work on the engine During maintenance operations provide cor...

Страница 10: ...m 10 ATTENTION FNM is not responsible for damage caused by misuse of the engine and for non compliance with the procedures issued and for damages caused by unauthorized personnel Do not drive the boat...

Страница 11: ...RE FUEL SUPPLY PUMP INTERCOOLER HOUSING WATER WATER EXCHANGER ACELERATOR POTENTIOMETER LOW PRESSURE FUEL SUPPLY PUMP SEA WATER PUMP ANODE 3 ANODE 1 FUEL OR STEERING OIL FUEL EXCAHNGER ENGINE OIL FILTE...

Страница 12: ...On the engine there are n 3 anodes positioned as follows 1 Water to water exchanger front cover 2 Exhaust manifold front cover under the expansion tank 3 Intercooler rear cover The graphical identific...

Страница 13: ...a water Low pressure electric fuel pump Sucks fuel from the low pressure line and sends it to the high pressure line Main thermostat housing Contains the thermostatic valve of the cooling circuit Seco...

Страница 14: ...m marine com 14 Fuel introduction cap on the tank if present Risk of burns presence of parts at high temperature Lubricating oil introduction cap Risk of fire presence of fuel Lubricating oil dipstick...

Страница 15: ...Information HPE 300 ENG rel 1 11 www fnm marine com 15 HPE 300 stern drive version installation drawings Raiser outer diameter 90 mm Sea water inlet pipe to the engine outer diameter 32 mm Fuel line i...

Страница 16: ...ngine oil type Advice Synthetic Multigrade SAE5W40 ACEA A3 B3 B4 API SL SM CF MB 229 3 VW 505 00 502 00 BMW Longlife 98 see the oil spec in function of utilization temperature ATTENTION FNM advises us...

Страница 17: ...ge 5 Heat exchanger integrated into exhaust manifold crossing 2 passages 6 Overboard discharge through the riser Take care of the sea water pump impeller and pay attention to the maintenance schedule...

Страница 18: ...to it The ECU box must be integral and with no obvious signs of breakage The engine wiring and any extensions must be integral with no cuts the Amphenol connector must be integral and all the pins of...

Страница 19: ...eights When you install the engine on your boat and open the engine package lift it using all 3 lifting points as shown in the figure Be sure to use a chain in good condition and able to carry the wei...

Страница 20: ...e seals of doors and hatches must prevent the entrance of water in the engine room Engine room ventilation in respect of what discussed above could be forced or natural Take care of the distance betwe...

Страница 21: ...a storage temperature of 20 C ATTENTION The sea water circuit could contain engine test room stand water Drain completely the sea water circuit if the storage temperature is lower than 0 C to prevent...

Страница 22: ...lation form 16 Verify for any leaks verify the sea water pump correct functioning verify the flow of water on exhaust system verify that all lights on instrument panel are OFF and no alarm buzzer is p...

Страница 23: ...hile for washing and storage it recommends Vanguard Storage 30 oil MIL L 2104B fill oil and let the engine run for 5 minutes at 800 RPM After filling with oil and any additive start the engine and run...

Страница 24: ...age to use diesel fuel antifreeze additive FNM advises use of Bardahl Diesel Antifreeze ATTENTION Take care of the engine storage room out of the boat or maintain the boat engine room dry and free fro...

Страница 25: ...el 1 11 www fnm marine com 25 Check the integrity of the anodes Verify and if is necessary grease the starter pinion white grease for gears and the turbocharger actuator leverages Turn off the engine...

Страница 26: ...L 2104B Fuel characteristics Use only DIN EN 590 diesel fuel Winter diesel fuel For winter use if used at temperatures lower than 0 C common diesel fuel may cause problems because it may become too d...

Страница 27: ...d cause damage to persons Take care to disconnect the ECU box by pushing the stop button during long inactivity period during the battery replacement and during all operations on electrical systems Be...

Страница 28: ...Fuse F10 Pin 5 ECU Fuse F4 Key on Fuse F3 EOBD diagnosis Fuse F5 Main relay Fuse F2 Fuse F1 Relay TYCO Code Characteristics Description J4 46520432 12V 30 Main relay J5 12V 30 Fuel pump J6 12V 30 Fuel...

Страница 29: ...roved hose for the passage of fuel 8mm Fuel return fuel hose rubber hose inner diameter Use approved hose for the passage of fuel 8mm Inlet sea water sea water hose inner diameter Use only hoses accor...

Страница 30: ...lter Transmission low oil level sea water leaks from the rubber gasket in sail drive applications AUX Auxiliaries NOTE Don t use aggressive substances to clean the instrument panel to prevent damaging...

Страница 31: ...ne and check the service belt status If the belt is in good conditions the malfunction most likely depends on the alternator or on too low voltage Glow plugs indicator light Glow plugs indicator light...

Страница 32: ...ompleted according to the temperature after few seconds the light turns OFF Is now possible to start the engine position II STEP 2 Engine start Turn the key in position II and release immediately when...

Страница 33: ...tion Check and drain the filter Diagnosis Delete the ECU errors Test the sensor Low transmission oil level or water intrusion in the bilge in sail drive applications Low oil level in the stern drive s...

Страница 34: ...Marine Diesel Engines OWNER S MANUAL General Information HPE 300 ENG rel 1 11 www fnm marine com 34 Instrument panel electrical scheme...

Страница 35: ...Marine Diesel Engines OWNER S MANUAL General Information HPE 300 ENG rel 1 11 www fnm marine com 35 Engine cable pin out...

Страница 36: ...al Information HPE 300 ENG rel 1 11 www fnm marine com 36 Engine cable Synoptic scheme STARTER ALTERNATOR INJECTORS SENSORS BATTERY ECU BOX Fuse PANEL FUSES RELAYS OEBD Diagnosis plug ENGINE HPE EMERG...

Страница 37: ...MANUAL General Information HPE 300 ENG rel 1 11 www fnm marine com 37 Diagnosis HPE engines are equipped with a plug for electronic diagnosis connection Refer only to FNM service points to make engine...

Страница 38: ...PVC cap A unscrew the lever fixing screw B and remove the lever Now just screw unscrew the adjusting dowel placed into the hole C to make the lever friction harder or softer When the adjustment will...

Страница 39: ...Command button pressed for at least 1 second 3 the Command LED is lighted and the Warm Sync LED is blinking 4 now you are in warm up mode i e the gearboxes are disabled It is only possible to acceler...

Страница 40: ...s switched off Trim control unit stern drive application Double station Single station The trim command can be activated by the Command Station by means of the and buttons The command signals are tran...

Страница 41: ...in the water Panel mounted type Neutral lock button Prevents accidental shift engagement Throttle only button It allows engine throttle advancement without shifting the engine Lanyard stop switch Turn...

Страница 42: ...Marine Diesel Engines OWNER S MANUAL General Information HPE 300 ENG rel 1 11 www fnm marine com 42 Console mounted type...

Страница 43: ...ox if the boat is moored or anchored in a river because the propeller may rotate Engine requirements ENGINE ROOM Flow of comburent air HPE 300 4 5 cubic m min Static depression 0 1 kPa Admitted increm...

Страница 44: ...lation module will activate if installation is in conformity the engine warranty service The form must be sent by e mail to giuseppe cafaro cmdengine com or mailed to the address enclosed ATTENTION Th...

Страница 45: ...the correct amount of oil therefore it is not necessary to refill the engine with oil Some engine installations could affect the oil level reading in the sump only in certain extreme circumstances it...

Страница 46: ...vel A If the oil is at level A on the dipstick you don t need to refill B If the oil is at level B fill up to level A C If the oil is at level C or lower than that then you must refill up to level A i...

Страница 47: ...tion both longitudinally and laterally Do not exceed 3 the horizontal inclination during the test do not make the measurement in the presence of excessive loads on the bow stern or starboard port side...

Страница 48: ...st be over the engine head to ensure a correct operation ATTENTION Always read the coolant manufacturer instructions according to the temperature Never refill the coolant circuit with sea water ATTENT...

Страница 49: ...e clean from elements that can block the passage Close the sea water intake valve when you dismount the filter Always verify for the good seal of the filter cap to avoid leakage after reassembly For t...

Страница 50: ...ick 2 Refill with oil SAE 20W 40 or 15W 40 refer to the manufacturer s manuals up to the MAX reference mark 3 Start the engine at idle speed of rotation without engaging the gear for other 2 minutes 4...

Страница 51: ...uld be a leakage in the system In the old MERCRUISER stern drive the dipstick is placed directly on the head HPEP Engine Stern drive version verify TRIM oil level MERCRUISER stern drive applications 1...

Страница 52: ...battery electrolyte level and status Be careful when operating near the battery compartment Disconnect the battery cables before working on it Do not smoke near the battery Flammable gases could be le...

Страница 53: ...ontained use appropriate protections 1 The electrolyte level should cover the plates 2 Refill if is necessary to MAX level mark with distilled water 3 Replace the caps after the charging cycle ATTENTI...

Страница 54: ...tus p 62 Verify the engine alignment and retorque the engine mounts Verify the bolts tightening torque Verify the electrical connection and plant Check the transmission fluids page 55 Clean the air fi...

Страница 55: ...oxidation of engine metal parts They are position in the sea water circuit Replace the anodes if the sacrificial zinc cartridge see the picture below is consumed over the 50 the length of the new par...

Страница 56: ...To verify for the service belts status Verify the belt status 1 Replace if the belt is worn For the timing belt NOTE The engine is equipped with a timing chain maintenance is not necessary during its...

Страница 57: ...crankshaft The function of the sea water pump is to draw water from the sea intake and to put it into circulation in the cooling systems heat exchangers exhaust manifold etc Water circulation is ensur...

Страница 58: ...esel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 64 7 Open the sea water intake valve 8 Start the engine and check for any leaks ATTENTION Use only original FNM sp...

Страница 59: ...erify the electrical connections Check the transmission fluids levels page 55 Clean the air filter page 63 Replace the sea water pump impeller page 63 Clean the heat exchangers tube bundles page 67 St...

Страница 60: ...engine and let it cool down adequately 2 Prepare a container to collect any leaks Take care to dismount the oil filter cartridge H after oil from the sump 3 Unscrew the oil filter element cover H with...

Страница 61: ...filter and tighten the lower cap 7 Fill the new filter with fuel 8 Assemble filter on the engine and open the fuel supply circuit 9 Bleed the fuel supply circuit Turn the key to I position and wait f...

Страница 62: ...ure The coolant fluid is polluting use appropriate precautions to avoid releasing it into rivers or the sea The sea water freezing in the cooling circuit causes damage to the circuit itself Winter use...

Страница 63: ...et 11 Reposition the pipes and seal collars 12 Fill the coolant circuit 13 Start the engine let it warm up to 80 C 14 Check for any leaks and if necessary drain the circuit from air Clean the intercoo...

Страница 64: ...d screw the clamps 12 Verify for any leaks after tightening Clean the fuel exchanger 1 Stop the engine and close the sea water circuit valve 2 Drain the sea water circuit by unscrewing the anodes see...

Страница 65: ...ctrical connections ATTENTION In any case we suggest referring always to a FNM service center to perform these operations Joints and splines greasing Mercruiser stern drives Lubricate the gimbal beari...

Страница 66: ...air filter page 54 Replace and grease the sea water pump impeller page 54 Clean the exchangers tube bundles and the sea water circuit page 60 Lubricating splines gears and joints page 63 Grease the en...

Страница 67: ...Seized components Repair Water in the cylinders Repair Engine cranks but will not start no smoke from exhaust Possible fault Remedy Fuel supply valve closed Open Almost empty fuel tank Fill the tank A...

Страница 68: ...heck or replace Fuel pre filter clogged Clean replace Leaking in the fuel supply line or fuel injection line Check replace Incorrect lube oil SAE class or quality for ambient temperature Replace Wrong...

Страница 69: ...Replace Engine overloaded Check size of propeller Leak in lubricating oil system Repair replace Oil steams condenser clogged Replace Turbocharger oil leaks Replace or repair Excessive fuel consumption...

Страница 70: ...in and flush fuel tank Replace with new fuel Water in fuel system Check water separator Faulty glow plugs Check replace Faulty injector injection pump Check replace if required Vapors condensing at th...

Страница 71: ...Marine Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 77 ORDINARY MAINTENANCE FORM Hours Date Stamp of assistance point Signature First 50 First 200...

Страница 72: ...Marine Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 78 ORDINARY MAINTENANCE FORM Hours Date Stamp of assistance point Signature...

Страница 73: ...Marine Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 79 WINTER MAINTENANCE Hours Date Stamp of assistance point Signature First winterizing...

Страница 74: ...Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 80 NOTES PRODUCED PRINTED by CMD IN ATELLA PZ ITALY DATE March 2011 Revision Date Description 1 11 28 03 11 Firs...

Страница 75: ...rs Check the belts and tighteners status Verify engine transmission alignment and screw the flex mounting nuts Verify screwing torque bolts nut clamps Verify clean the electrical connections Air filte...

Страница 76: ...Marine Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 82 Wema Panel connection cable Wema panel pinout...

Страница 77: ...Marine Diesel Engines OWNER S MANUAL Engine maintenance HPE300 ENG rel 1 11 www fnm marine com 83...

Страница 78: ...www fnm marine com...

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