FNM HPE 300 User manual

OWNER’S
MANUAL
HPE 300

Marine Diesel Engines
OWNER’S MANUAL
Index
ENG rel. 1/11
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i
General Information _____________________________________________________________________________1
Engine manufacturer’s indications _________________________________________________________________7
Safety rules & info ______________________________________________________________________________8
Residual risks __________________________________________________________________________________9
HPE 300 Engines general info and drawings: _______________________________________________________11
HPE 300 ANODES ______________________________________________________________________________12
HPE300 without cover top view___________________________________________________________________12
Main engine components________________________________________________________________________13
Documentation and info plates ___________________________________________________________________13
HPE 300 stern drive version installation drawings ___________________________________________________15
Engine data ___________________________________________________________________________________16
Engine cylinder numbering ______________________________________________________________________16
Sea water circuit crossing order__________________________________________________________________17
Engine delivery ________________________________________________________________________________18
Engine lifting __________________________________________________________________________________19
Engine maintenance indications (when installed on board) ___________________________________________20
Engine maintenance information (out of board before installation) _____________________________________21
First engine start on board. ______________________________________________________________________21
Stop the engine________________________________________________________________________________22
Long engine inactivity (prediction of extended storage) ______________________________________________22
Engine treatment & maintenance products _________________________________________________________26
Fuel characteristics ____________________________________________________________________________26
Paint _________________________________________________________________________________________26
HPE / HPEL engines ECU BOX ___________________________________________________________________27
Fuses & Relays ________________________________________________________________________________28
Tightening torques _____________________________________________________________________________29
Engine-boat interface (connections and optional kit ) ________________________________________________29
Battery cable section chart ______________________________________________________________________29
Instrument panel_______________________________________________________________________________30
Ignition block functioning _______________________________________________________________________32
Accessory indicator lights_______________________________________________________________________33
Instrument panel electrical scheme _______________________________________________________________34
Diagnosis_____________________________________________________________________________________37
Electronic throttle station _______________________________________________________________________38
Mechanical remote control ______________________________________________________________________41
Gearboxes data (oil type and quantity) ____________________________________________________________43
Engine requirements ___________________________________________________________________________43
Installation form _______________________________________________________________________________44
Engine maintenance____________________________________________________________________________51
Every 10 hours or before every engine start ________________________________________________________51
Check the engine oil level _______________________________________________________________________51
Check the coolant level _________________________________________________________________________53
Clean the sea water filter ________________________________________________________________________55
Verify oil level _________________________________________________________________________________55
HPE engine gearbox version, verify the transmission oil level_________________________________________56
Weekly maintenance____________________________________________________________________________58
Verify battery electrolyte level and status __________________________________________________________58
Maintenance after first 50 hours and every 2 months ________________________________________________60
Drain the fuel filter _____________________________________________________________________________60
Zinc anodes___________________________________________________________________________________61
Verify the belts status___________________________________________________________________________62
Air filter ______________________________________________________________________________________63
Sea water pump impeller ________________________________________________________________________63
Every 200 hours or once every year _______________________________________________________________65
Engine oil change ______________________________________________________________________________65
Oil filter replacement ___________________________________________________________________________66
Fuel filter replacement __________________________________________________________________________67
Clean the sea water circuits and exchangers _______________________________________________________67

Marine Diesel Engines
OWNER’S MANUAL
Index
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Lubricate or grease the joints, bearings and gears. __________________________________________________70
Every 200 hours or every 2 years _________________________________________________________________72
Engine winter maintenance ______________________________________________________________________72
Troubleshooting _______________________________________________________________________________73
Ordinary maintenance schedule __________________________________________________________________77
Winter Maintenance : ___________________________________________________________________________79
Engine maintenance operations summary table_____________________________________________________81

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE300
ENG rel. 1/11
www.fnm-marine.com
1
General Information
This manual is integral part of the engine; it
is made by the manufacturer to give all the
useful information to whoever will interact
with the engine during its life: installers,
carriers and end-users.
Please keep this manual for the entire life of
the product to obtain rapid information about
the engine during use.
The manufacturer reserves the right to
modify this document without prior
notice.
Danger and warning symbols
Indicates dangerous situations that can
compromise personal safety and functionality of
the engine.
Indicates the need to follow the instructions.
Indicates important technical information.
ATTENTION!
If the engine is serviced by unauthorized
technicians or if non-original spare parts are
used, you will lose immediately any rights in
terms of warranty of the purchased product.
ATTENTION
The observance of the installation procedures
and routine maintenance contained in this manual
and in the installation manual*, ensures
compliance for 10 years at the declared
performance and at the gas exhaust emission and
noise parameters for which your engine is
approved in accordance with Directive
2003/44/EC.
Dear Client, we wish to thank you for
purchasing an engine of HPE range.
FNM ® engines are designed and developed
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®offers
a wide range of products and models
according to each customer's request.
The FNM®marine diesel engines are known
worldwide for their performances.
- for their compact structure and
outstanding power-to-weight ratio;
- for their long life and low fuel
consumption.
This means that, when buying an FNM®
engine, you have chosen not only a
technologically advanced engine, but also
an engine designed to satisfy the anti-
pollution standards and regulations. For the
engine service and maintenance always
refer to an authorized service points and to
FNM®service network. Only by using
original spare parts and relying on our
specialized staff you can get the best
performances from your engine and ensure
a long life.
THE FNM SERVICE NETWORK
The FNM® service points offer low costs and a high
degree of specialization. They make sure that your
FNM® engine works and operates in accordance
with your expectations. Visit our website to know
the nearest service point.
This manual provides important
information on maintenance, operations
to be carried out periodically and
handling of your engine.
Before starting your engine, we advise
you to read this manual in order to get the
information necessary to operate your
engine.
The proper use of the FNM ® marine
engine as well as proper maintenance
plan during the lifetime of the engine
ensures durability and performance.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE300
ENG rel. 1/11
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2
ATTENTION!
The reliability of the total propulsion unit is
dependent on the quality of the installation. Nearly
all the problems are caused by faults or
inaccuracies which occur during the installation.
FNM®is not responsible for damages (engine
and/or persons) caused by wrong installation.
Spare Parts
The exclusive use of FNM® original spare
parts is an essential condition for a good
maintenance of the engine. The use of non-
original spare parts may cause the warranty to
expire and it also exempts the company CMD
S.p.A (owner of the FNM® brand name and
logo) from any responsibility.
Responsibility
The responsibility of the Manufacturer is
subject to the correct execution of the
“Maintenance Procedures” operations that are
described in this manual. For this purpose, it
will be necessary to demonstrate that all the
maintenance procedures and operations have
been carried out according to the manual and
that, in case of extraordinary 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
illustrations serve as a pure indication and the
instructions are described in a purely functional
way with the purpose of providing help and
guidance in carrying out the ordinary maintenance.
The execution of such operations may vary based
on the configuration of the controls and/or
accessories of the boat where the engine has been
installed. The information featured in this manual is
correct at the time of printing. The Engine
Manufacturer reserves the right to make
modifications without notice at any time for
technical or commercial reasons as well as for the
need to abide by new regulations or norms. The
Engine Manufacturer declines any responsibility
that may arise from possible mistakes and/or
omissions during the installation.
It is forbidden to alter the characteristics of the
engine and in particular the configuration of the
ECU box because such modifications and/or
alterations will invalid the warranty and safety
terms.
ATTENTION!
Never use the engine at the maximum
power for a period longer than 5 minutes.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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Page in blank

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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7
Engine manufacturer’s indications
The ID label is applied on the engine and on the ECU box as show in pictures below:
ID label data are indicated in the picture below:
Made in
Italy
Eng. type:
Eng. family:
Serial Num:
RPM kW HP
Serial number code 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 manufacturer data:
C. M. D. S. p. A.
Direzione Generale (Head Office)
S. S. 87 Km 23, 300 –81020 S. Nicola La Strada (CE) -ITALY
Tel.: [phone] –Fax: [phone]
E-mail: [e-mail]
Production plant
Nucleo Industriale –Valle di Vitalba –85020 Atella (PZ)-ITALY
Tel.: [phone] –Fax: [phone]
E-mail: [e-mail]
SERIAL NUMBER
ID LABEL

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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8
Safety rules & info
- Read carefully the information contained in the manual and those applied to the engine in order to
avoid unpleasant incidents.
- The manufacturer cannot be held responsible for any damage resulting from misuse of the
engine ,from the failure to follow the indications contained in this manual and for every
tampering with or change made without the manufacturer’ s authorization.
- Use the engine only for the tasks authorized by the manufacturer, do not tamper any
device to obtain different performances.
- Consult their own technical staff, with specific experience and technical skills. The lack of these
requirements could result in damage to people’s safety as well as damage to the engine.
- Pay attention to the meaning of the symbols and to the applied plates. Keep them visible and
follow the stated information
- Carry out the engine handling in accordance with the information provided directly on the
engine and on the packaging 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 instructions. Do not make
changes to the engine components for any reason!
- Before using the engine for the first time simulate a few trial maneuvers to identify the controls
and their main functions, especially those related to start -stop operations.
- Do not keep using the engine if anomalies are detected.
- In case of anomaly, stop immediately the engine or reduce the speed as far as possible. Start
again only when the normal operating conditions are restored.
- Keep the engine and related components in conditions of maximum efficiency and carry out the
maintenance operations established by the manufacturer.
- -Replace only original spare parts. Use oil. lubricants and grease recommended by the
manufacturer in accordance with the specifications of this manual.
- Pay attention to the disposal of polluting residues (used oil, diesel fuel, etc.)... Follow
the local legislation and disposal procedures.
- Do not open the expansion tank cap of the cooling circuit when the engine is hot! Slowly turn
until any steam under pressure comes out, and then remove the cap.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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- Do not start the engine without the air filter, the detachment of rotor parts of the compressor
during operation could cause damage to persons, furthermore any aspirated particles could
damage the blades. Avoid contact of hands with the rotor.
- Do not touch the turbogroup and the turbine cover with hands immediately after
using the engine, risk of burns. Let engine cool before interacting with the hot parts.
- Do not smoke near the battery compartment! The battery can release flammable gases.
Wrong battery connection could provoke sparks and explosion.
- Don’t provoke short circuits, electrical risk.
- If you use pressure water jet to clean 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 correct ventilation. Avoid stagnation of toxic and/or
flammable vapors.
- The replacement of fuel filter is to be made with cold engine to avoid the risk of fire and burn.
- Always close the sea water inlet tap when you dismount the coolant system!
- Danger of fire due to fuel splashing on hot parts, do not remove the guards.
Residual risks
- Potential/additional risks to persons:
- Risk of injury: do not put hands in any moving parts (pulleys, flywheel, belts, etc.).
- Risk of burns: attention to hot surfaces (exhaust manifold, turbocharger, raiser, etc.)
- Danger from splashes of hot oil-fuel, battery acids of accumulators or fuel: use gloves and
safety glasses.
- Risk of shock: use safety shoes when lifting the engine and/or working in the engine
compartment.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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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 if you consume alcohol or other substances that may alter your
state of attention and reflexes.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
www.fnm-marine.com
11
HPE 300 Engines general info and drawings:
\
OIL VAPOUR
CONDENSER
HIGH PRESSURE 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 FILTER
EXPANSION TANK
OIL FILLING CAP
ANODE 2
ALTERNATOR
SECONDARY
THERMOSTAT HOUSING
STARTER
TURBOCHARGER
AUXILIARY SERVCES
PULLEY
MAIN THERMOSTAT
HOUSING
OIL SUMP
EXHAUST RAISER

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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12
HPE 300 Anodes
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 identification of the elements on the engine can be found on the previous page.
HPE300 without cover top view
RAIL
INJECTORS

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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Main engine components
Intercooler :
Reduces the temperature of compressed air from the
compressor of the turbogroup that flows to the engine intake
duct using a bundle of finned tubes crossed by sea water.
Expansion tank:
Contains the engine coolant.
Oil sump:
Contains engine lubrication oil
Zinc anode (3):
Prevents the galvanic oxidation of metal parts.
Oil exchanger:
Reduces the temperature of the engine lubrication oil.
Fuel exchanger (single):
Reduces the diesel fuel temperature in the return line to the
heat exchanger.
Air filter:
Retains the impurities in the air intake.
Double exchanger (power steering oil-diesel fuel):
Reduces the temperature of steering oil and diesel fuel.
Turbocharger:
Compresses the intake air exploiting the energy of exhaust
gases through the use of a turbine-compressor group.
Fuel filter (mounted in the engine compartment)
Filters diesel fuel in inlet to the supply line of the engine
Raiser:
Reduces the temperature of the exhaust gases coming out of
the turbine, conveys fumes towards the exhaust and prevents
the return of sea water into the turbine.
Starter:
Starts the engine.
Water to water exchanger:
Reduces the temperature of engine coolant through heat
exchange with sea 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.
Secondary thermostat housing:
Contains the thermostatic valve of the auxiliary cooling
circuit.
Sea water pump:
Sucks water from the sea water intake and pushes it in the
cooling circuit.
Alternator:
Generates electric power, the output voltage is 12 Volt.
Oil filler cap:
Useful in filling the engine oil.
Lifting eyes
Documentation and info plates
The engine is shipped with this technical documentation:
Owner’s Manual
Installation Manual
Transmission producer installation manual
Installation form
Certificates
HPE 300 engines are certified for CE directive 94/25/EC as amended by directive 2003/44/EC for exhaust
emissions (SYSTEMS WITH AND WITHOUT INTEGRATED EXHAUST):
- Standard reference EN ISO 8178-1 Reciprocating internal combustion engines, EXHAUST EMISSION MEASUREMENT.
HPE 300 engines are certified for noise emissions:
- Standard reference ISO 14509 Small Craft Measurement of airborne SOUND EMITTED by powered recreational craft.
IMPORTANT!
At moment of delivery you can find on the engine some yellow plates indicating important information, take
care to read the info.
In addition the engine has warning labels whose the meaning is indicated below. Note: labels bearing the
exclamation mark highlight a potential danger.
Lifting point (of the motor only)
Risk of burns, ejection of hot water
under pressure.

Marine Diesel Engines
OWNER’S MANUAL
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HPE 300
ENG rel. 1/11
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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
Risk of impact and hooking to moving
parts, presence of fans, pulleys, belts or
other.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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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: (inlet outlet) rubber hoses inner diameter 8 mm

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OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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16
Engine data
Displacement
2988 cc
Bore
95.8 mm
Stroke
104 mm
Type
Four stroke diesel engine -
4 cylinder inline
Compression ratio
18 : 1
Injection
Electronically controlled Common Rail
Boosting
Water-cooled turbocharger
Timing system
16-Valve DOHC
Firing order
1-3-4-2
No-load revolution speed
750-850 RPM
Max revolution speed (with load)
4000-4200 RPM
Max power
300 HP at 4000-RPM
Max torque
560 N m at 2600 RPM
Alternator
110 A 12V
Engine oil capacity including filter
7.5 l
Engine 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 use of FNM special BARDAHL OIL
Only with this oil the engine service intervals are guarantee.
-Avoid mixing different types of oil.
If you don’t find FNM lubricant oil, use oil with the same
specifications
Thermostatic valves
1) Starts opening at 80°C ± 1.5°C, fully open at 85°C
2) Starts opening at 65°C ± 1.5°C, fully open at 70°C
Coolant
approx. 14 l
**mixing ratio according to the specifications of the
supplier of the fluid and operating temperatures.
Sea water flow (at max RPM )
approx. 100 l/min
Starter
12V -2.6 kW
Weight
(without transmission and ECU)
350 kg
Engine cylinder numbering

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HPE 300
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17
Sea water circuit crossing order
1) Pump suction side.
2) Intercooler crossing (1 passage)
3) Water to water exchanger crossing (2 passages)
4) Fuel exchanger or fuel/steering oil exchanger crossing (1 passage)
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. It is
important to keep the sea water circuit free from dirt and salt deposits to avoid engine
overheating!
Take care of the anodic protections to prevent oxidation of engine metal parts, follow the
maintenance schedule.
Take care of the hoses clamps; they must be correctly screwed to avoid any leaks!

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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18
Engine delivery
At moment of receiving an HPE/HPEL engine (if you’re the receiver) please verify:
The integrity of the packaging (the wood box must be integral; the engine must be fixed on the wood
support and secured 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 the connector must be correctly positioned.
The instrument panel and connection cable must be integral.
Check for any fluids leaks.
ATTENTION!
At the time of shipment engines are bench tested and packaged according to internal specifications. FNM®
is not responsible for damages caused by the carrier/transport company.

Marine Diesel Engines
OWNER’S MANUAL
General Information
HPE 300
ENG rel. 1/11
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19
Engine lifting
The engine lifting hooks are engineered only to lift the engine without any additional weights!
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 weight of the engine
and of the gearbox, if present.
Engine lifting hooks are positioned as shown in the following figures.
Gearbox weight shifts the engine centre of gravity, take care when lifting the engine.

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HPE 300
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20
Engine maintenance indications (when installed on board)
Below you find some indications to guarantee engine long life and to prevent hazards:
-Take care to maintain the engine room dry and well aerated. Residual water in bilge could
vaporize and condensate on the engine, vapor created in this process damages the protection
varnish. Humidity and corrosive vapor damage the electrical connections. Bilge water may wet
engine parts during the boat navigation.
-Maintain the engine room fresh and well aerated. During engine use, the engine room shall be
well aerated and the aeration holes must guarantee a good air flush. To guarantee a good air
supply during the engine use, follow the guideline instructions. Fresh, well aerated and dry engine
room guarantees long life to the engine protection varnish, to the plastic and rubber parts,
increases the engine performances and prevents excessive overheating of hot parts (exhaust,
turbine, etc.).
Maintain the engine room dry and well aerated.
--The ventilation holes must ensure a good flow of air, but should prevent the entrance of salt,
water and dirt in the engine room. The 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 between the turbocharger and the plastic part. The turbocharger
heats up during use and may damage the plastic and fiberglass parts (follow the installation
manual instructions). Insulate with a coating that ensures good thermal protection to
structures and bulkheads of the boat next to the hot parts of the engine to reduce the risk
of fire.
-Take care to oil or fuel leaks. The oil or fuel may come into contact with the turbocharger
during operation resulting in fire.
-Take care to the turbocharger protection varnish. The housing of the turbocharger is painted with
heat resistant varnish. Excessive use and high temperatures could remove this protection.
Periodically check the housing of the turbocharger and, if necessary, spray with new paint
resistant to high temperatures.
The turbocharger becomes hot during use. Take care, risk of fire.
-Electrical and electronic parts are affected by moisture and the attack of corrosive agents.
Never rapidly increase the speed of the engine if the engine does not reach the correct
temperature.
-Pay attention to the state of battery charge, recharge during the engine inactivity, if required
periodically. Maintain the battery compartment aerated and dry to avoid risk of fire.