Perkins 4GM Instruction Manual

®
User’s Handbook
GB
Part No TPD 1327E
4GM 4TGM
6TG2AM 6TWGM

TPD1327E Title
Perkins
Marine Gen Set Power
User’s handbook
4GM 4 cylinder, naturally aspirated, diesel engine for
marine on-board generating set
4TGM 4 cylinder, turbocharged, diesel engine for
marine on-board generating set
6TG2AM 6 cylinder, turbocharged, diesel engine for
marine on-board generating set
6TWGM 6 cylinder, turbocharged, intercooled, diesel
engine for marine on-board generating set
Publication TPD 1327E Edition 12
© Wimborne Marine Power Centre, all rights reserved.
The information is correct at the time of going to press.
Published in December 2013 by Wimborne Marine Power Centre, Dorset, England BH21 7PW
Wimborne Marine Power Centre, Wimborne, Dorset, England BH21 7PW
Tel: [phone] Fax: [phone] E -mail: [email protected]
www.perkins.com/marine

Title TPD1327E

TPD1327E Contents
1 General information
Introduction......................................................................................................................1
How to care for your engine ............................................................................................2
General safety precautions..............................................................................................3
Engine guarantee ............................................................................................................4
Engine identication ........................................................................................................5
Perkins main dealers....................................................................................................... 6
2 Engine views
Introduction......................................................................................................................7
Location of engine parts - 4 cylinder turbocharged engines ........................................... 7
Front and left side (A) ............................................................................................7
Rear and right side (B) .......................................................................................8
Front and left side (A) ............................................................................................9
Location of engine parts - 6 cylinder turbocharged engines............................................ 9
Front and right side (B) .......................................................................................10
Front and left side view (A) .................................................................................. 11
Location of engine parts - 6 cylinder turbocharged, intercooled engines ..................... 11
Front and right side view (B) ................................................................................12
3 Operation instructions
How to start the engine..................................................................................................13
How to start a cold engine with the fuelled starting aid ........................................ 13
How to start a warm engine .................................................................................13
How to stop the engine..................................................................................................13
Adjustment of the engine speed range.......................................................................... 14
Running-in .....................................................................................................................14
4 Preventive maintenance
Preventive maintenance periods ...................................................................................15
Schedules ............................................................................................................15
Schedules......................................................................................................................16
How to ll the coolant circuit.......................................................................................... 17
Engines tted with keel coolers............................................................................ 17
How to drain the coolant circuit .....................................................................................18
Engines tted with keel coolers............................................................................ 19
How to check the specic gravity of the coolant............................................................ 20
How to drain the raw water circuit ................................................................................. 21
Engines tted with heat exchangers .................................................................... 21
How to check the drive belt of the alternator ................................................................. 22
How to adjust the belt tension .............................................................................. 22
How to clean the strainer for the raw water pump (6TWGM model) ............................. 23
How to check the impeller of the raw water pump......................................................... 24
How to clean the gauze strainer of the fuel lift pump.....................................................25
How to renew the canister of the fuel lter .................................................................... 26
How to renew the element of the fuel pre-lter.............................................................. 27
Atomiser fault.................................................................................................................28
How to renew an atomiser.............................................................................................29
How to eliminate air from the fuel system......................................................................30

Contents TPD1327E
How to renew the lubricating oil of the engine............................................................... 32
How to renew the canisters of the lubricating oil lter ................................................... 33
How to renew the engine breather ................................................................................34
6TWGM and 4 cylinder engines (closed breather)............................................... 34
To assemble ......................................................................................................... 34
Air lter ..........................................................................................................................35
How to renew the element of the air lter...................................................................... 35
How to clean the air lter (6TWGM model) ................................................................... 36
Restriction indicator....................................................................................................... 37
How to check the valve tip clearances .......................................................................... 38
Four cylinder engines...........................................................................................38
Six cylinder engines .............................................................................................39
How to check the condition of the viscous damper ....................................................... 40
6 cylinder engines ................................................................................................40
Seacock strainer............................................................................................................41
Corrosion....................................................................................................................... 41
Supplementary tools......................................................................................................41
5 Engine uids
Fuel specication...........................................................................................................43
Lubricating oil specication............................................................................................44
Coolant specication .....................................................................................................45
6 Fault diagnosis
Problems and possible causes......................................................................................47
List of possible causes ..................................................................................................48
7 Engine preservation
Introduction....................................................................................................................49
Procedure...................................................................................................................... 49
8 Parts and service
Introduction....................................................................................................................51
Service literature............................................................................................................51
Training.......................................................................................................................... 51
On-board parts kit..........................................................................................................51
POWERPART recommended consumable products.....................................................52
9 General data
4GM and 4TGM engines ...............................................................................................53
6TG2AM and 6TWGM engines ..................................................................................... 54
10 Electrical diagrams
Earth relay and resistors................................................................................................55

TPD1327E Chapter 1
Page 1
General information
Introduction
The 4GM, 4TGM, 6TG2AM and 6TWGM marine
engines for on-board generating sets and other
auxiliary power units are the latest developments
from the business arrangement between Perkins
Engines Ltd and Wimborne Marine Power Centre.
Wimborne Marine Power Centre are the managers
of the Perkins marine business and all enquires
should be made to Wimborne Marine Power Centre;
refer to the company address list on page 6.
Over sixty years of diesel production experience,
together with the latest technology, have been
applied to the manufacture of your engine to give
you reliable and economic power.
To ensure that you use the relevant information
for your specic engine type, refer to “Engine
identication” on page 5.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible
danger to the person.
Caution: This indicates that there is a possible
danger to the engine.
Note: Is used where the information is important, but
there is not a danger.

Chapter 1 TPD1327E
Page 2
How to care for your engine
Warning! Read the “Safety precautions” and
remember them. They are given for your protection
and must be applied at all times.
Caution: Do not clean an engine while it runs. If cold
cleaning uids are applied to a hot engine, certain
components on the engine may be damaged.
This handbook has been written to assist you to
maintain and operate your engine correctly.
To obtain the best performance and the longest
life from your engine, you must ensure that the
maintenance operations are done at the intervals
indicated in “Preventive maintenance”. If the engine
works in a very dusty environment or other adverse
conditions, certain maintenance intervals will have
to be reduced. Renew the lter canisters and
lubricating oil regularly in order to ensure that the
inside of your engine remains clean.
Ensure that all adjustments and repairs are done by
personnel who have had the correct training. Perkins
distributors have this type of personnel available.
You can also obtain parts and service from your
Perkins distributor. If you do not know the address
of your nearest distributor, enquire at one of the
Perkins companies listed on page 6.
When reference is made to the “left side” and “right
side” of the engine, this is as seen from the ywheel
end.

TPD1327E Chapter 1
Page 3
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 specic applications.
• Only use these engines in the type of application
for which they have been designed.
• Do not change the specication of the engine.
• Do not smoke when you put fuel in 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.
• Do not operate the engine if a safety guard has
been removed.
• Do not remove the ller 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 re near the battery
(especially when the battery is on charge)
because the gases from the electrolyte are
highly ammable. The battery uid 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 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 and coolant 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 raw water circuit.
• Wear a face mask if the glass bre cover of the
turbocharger is to be removed or tted.
• 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 allow compressed air to contact your
skin. If compressed air enters your skin, obtain
medical help immediately.
• Turbochargers operate at high speed and at
high temperatures. Keep ngers, tools and
other items away from the inlet and outlet ports
of the turbocharger and do not contact the hot
surfaces.
• The latest marine engines have a cover tted
to give some protection from the alternator fan
and the drive belt. Ensure that this cover is tted
before the engine is started.
• Fit only genuine Perkins parts..

Chapter 1 TPD1327E
Page 4
Engine guarantee
If a claim under guarantee is necessary, the owner
should make a guarantee claim on the nearest
Perkins marine distributor or an approved dealer.
If it is difcult to nd a Perkins distributor or an
approved dealer, consult the Service Department
of Wimborne Marine Power Centre, refer to the
company address list on page 6.

TPD1327E Chapter 1
Page 5
Engine identication
The 4GM engine consists of four different types:
• Naturally aspirated, heat exchanger cooled, rated
at 1500 rev/min.
• Naturally aspirated, heat exchanger cooled, rated
at 1800 rev/min.
• Naturally aspirated, keel cooled, rated at
1500 rev/min.
• Naturally aspirated, keel cooled, rated at
1800 rev/min.
The 4TGM and 6TG2AM engine consists of four
different types:
• Turbocharged, heat exchanger cooled, rated at
1500 rev/min.
• Turbocharged, heat exchanger cooled, rated at
1800 rev/min.
• Turbocharged, keel cooled, rated at 1500 rev/
min.
• Turbocharged, keel cooled, rated at 1800 rev/
min.
The 6TWGM engine consists of four different types:
• Turbocharged, intercooled, heat exchanger
cooled, rated at 1500 rev/min.
• Turbocharged, intercooled, heat exchanger
cooled, rated at 1800 rev/min.
• Turbocharged, intercooled, keel cooled, rated at
1500 rev/min.
• Turbocharged, intercooled, keel cooled, rated at
1800 rev/min.
The engine number is stamped on a label tted
to the left side of cylinder block, (A2) for 6 cylinder
engines and (B2) for 4 cylinder engines.
An example of the engine number is:
YB30196U123456A
If you need parts, service or information for your
engine, you must give the complete engine number
to your Perkins distributor. If there is a number
in the area of the label marked TPL No (A1) or
(B1), then this number must also be given to your
Perkins distributor. This number refers to the build
specication tted to the engine before it leaves the
factory. Examples of this number are SGS027 and
SGS028.

Chapter 1 TPD1327E
Page 6
Perkins main dealers
Australia
Allight Pty Ltd (Sydney Ofce),
41 York Road,
Ingleburn, NSW 2565, Australia.
Telephone: [61](2) 9765 6800
Fax: [61](2) 9765 6899
Email: [email protected]
www.alight.com
France
Secodi,
Rue de la Scierie
17000 LA ROCHELLE,
France.
Telephone: [33] (5) 4645 1313
Fax: [33](5) 46 41 83 26
Email: [email protected]
www.secodi.fr
Germany
BU Power Systems GmbH & Co. KG,
Perkinsstraße 1,
49479 Ibbenbüren,
Germany.
Telephone: [49] 5451 5040-0
Fax: [49] 5451 5040-100
Email: [email protected]
www.bu-power-systems.de
Italy
Scan Diesel s.r.l.,
Via Coloredo,14,
28069 TRECATE (NO)
Italy.
Telephone: [39] [phone]
Fax: [39] [phone]
Email: [email protected]
www.scandiesel.it
Japan
Perkins Engines, Inc.,
Sanno Grand Bldg, 8th Floor,
2-14-2 Nagatacho, Chiyoda-ku,
TOKYO 100-0014, Japan.
Telephone: [81] (3) 5157 0571
Fax: Fax: [81] (3) 5157 0572
Singapore
Multico Power Drive Pte Ltd
11 Tuas View Crescent
Multico Building
Singapore 637643
Telephone: [65] 6 863 2863
Fax: [65] 6 863 6819
Email: [email protected]
www.multicorporation.net
United Kingdom
Perkins Engines Company Ltd,
Easteld, Peterborough PE1 5NA,
England.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]
www.perkins.com
United States of America
Perkins Pacic Inc.,
7215 South 228th Street,
Kent, Washington
WA 98032
USA
Telephone: [1][phone]
Fax: [1][phone]
www.pacicdda.com
Perkins Power Corp,
55 Industrial Loop North,
Orange Park,
Florida 32073
U.S.A.
Telephone: [1][phone]
Fax: [1][phone]
www.perkinspower.com
The managers of the marine business for
Perkins are:
Wimborne Marine Power Centre
Ferndown Industrial Estate
Wimborne
Dorset
BH21 7PW
England
Telephone: [phone]
Fax: [phone]
www.perkins.com/marine.
*This is just a small selection of Perkins dealers. For
a more comprehensive list, please see
www.perkins.com/marine.

TPD1327E Chapter 2
Page 7
Engine views
Introduction
Perkins engines are built for specic applications and the views which follow do not necessarily match your
engine specication.
Location of engine parts - 4 cylinder turbocharged engines
Front and left side (A)
1. Crankcase breather
2. Atomiser
3. Fuel lter
4. Fuel injection pump
5. Drain pump for the engine lubricating oil
6. Heat exchanger for the closed circuit coolant
7. Dipstick for the engine lubricating oil
8. Cooler for the engine lubricating oil
9. Lubricating oil lter
10.Engine crankshaft rotation adaptor
11.Raw water pump
12.Cover for the drive belt
13.Closed circuit water pump
14.Front lift bracket
15.Thermostat housing
16.Coolant header tank
17.Filler cap for coolant header tank

Chapter 2 TPD1327E
Page 8
Rear and right side (B)
18.Cooled exhaust manifold assembly
19.Exhaust outlet
20.Drive belt for alternator
21.Alternator
22.Turbocharger
23.Starter motor
24.Fuel pre-lter
25.Sump for the engine lubricating oil
26.Flywheel
27.Flywheel housing
28.Fuel lift pump
29.Restriction indicator for the air lter (tted to the
rear of lter body)
30.Air lter
31.Fuelled starting aid
32.Rear lift bracket
33.Filler cap for the engine lubricating oil

TPD1327E Chapter 2
Page 9
Front and left side (A)
1. Rear lift bracket
2. Fuel lter
3. Air lter
4. Drain pump for the engine lubricating oil
5. Cooler for the engine lubricating oil
6. Thermostat housing
7. Heat exchanger for the closed circuit coolant
8. Dipstick for the engine lubricating oil
9. Sump for the engine lubricating oil
10.Lubricating oil lter
11.Crankshaft pulley
12.Crankshaft damper
13.Raw water pump
14.Drive belt for alternator
15.Cover for the drive belt
16.Fuel injection pump
17.Atomiser
18.Front lift bracket
19.Exhaust outlet
Location of engine parts - 6 cylinder turbocharged engines

Chapter 2 TPD1327E
Page 10
Front and right side (B)
20.Filler cap for the engine lubricating oil
21.Filler cap for coolant header tank
22.Coolant header tank
23.Electrical housing
24.Oil separator for the crankcase breather
25.Closed circuit water pump
26.Alternator
27.Crankcase breather
28.Device to rotate the crankshaft
29.Fuel pre-lter
30.Starter motor
31.Fuel lift pump
32.Turbocharger
33.Cooled exhaust manifold assembly
34.Fuelled starting aid
35.Restriction indicator for the air lter

TPD1327E Chapter 2
Page 11
Front and left side view (A)
1. Rear lift bracket
2. Fuel lter
3. Air lter
4. Drain pump for the engine lubricating oil
5. Cooler for the engine lubricating oil
6. Thermostat housing
7. Heat exchanger for the closed circuit coolant
8. Sump for the engine lubricating oil
9. Strainer for the raw water pump
10.Lubricating oil lter
11.Device to rotate the crankshaft
12.Crankshaft damper
13.Drive belt for alternator
14.Raw water pump
15.Coolant pump for the closed circuit
16.Fuel injection
17.Front lift bracket
18.Atomiser
19.Crankcase breather
Location of engine parts - 6 cylinder turbocharged, intercooled engines

Chapter 2 TPD1327E
Page 12
Front and right side view (B)
20.Filler cap for the engine lubricating oil
21.Filler cap for the coolant header tank
22.Cooled manifold assembly
23.Electrical housing
24.Coolant header tank
25.Cover for drive belt
26.Alternator
27.Crankshaft pulley
28.Starter motor
29.Dipstick for the engine lubricating oil
30.Air charge cooler assembly
31.Exhaust outlet
32.Fuelled starting aid
33.Turbocharger

TPD1327E Chapitre 4
Page 13
Operation instructions
How to start the engine
Several factors affect engine start, for example:
• The power of the battery
• The performance of the starter motor
• The viscosity of the lubricating oil
• The installation of a cold start system
• Size of the starter cables.
Diesel engines need a cold starting aid if they are
to start in very cold conditions. The cold start aid
tted to these engines is a fuelled starting aid. This
electrically operated device ignites a specic amount
of diesel fuel in the induction manifold in order to
heat the induction air.
Preparations for an engine start
1.Ensure that there is more than enough fuel
available for the voyage.
2.Ensure that the fuel supply control (if tted) is in
the open position.
3.Check that the seacock strainer is clean.
4.Open the seacock.
5.Check the amount of coolant in the header tank.
6.Check the amount of lubricating oil in the sump.
Caution: If the engine has not run for a long period
(four weeks or more), ensure that there is lubricating
oil at the turbocharger. To do this, hold the engine
stop switch in the “STOP” position; operate the
starter motor until the oil warning light goes out or a
pressure is indicated on the oil pressure gauge.
How to start a cold engine with the fuelled
starting aid
Note: Use this method when the cylinder head
temperatures are approximately 0°C (32°F).
1.Switch on the electrical system.
2.Hold the heat switch in the down position for 15
seconds. Press the start button to engage the
starter motor. When the engine starts, release
the heat switch. The engine will run up to the set
speed, 1500 or 1800 rev/min.
3.If the engine does not start in 15 seconds, hold the
heat switch down for 10 seconds and engage the
starter motor again. When the engine has started,
release the heat switch. Check that water comes
out of the end of the exhaust pipe or out of the
separate discharge outlet. Always ensure that the
engine and starter motor are stationary before the
starter motor is engaged again.
Caution: Ether type starting aids must not be used
at the same time as the fuelled starting aid.
How to start a warm engine
1.Switch on the electrical system.
2.Press the start button to engage the starter motor.
When the engine starts it will run up to the set
speed, 1500 or 1800 rev/min. Check that water
comes out of the end of the exhaust pipe or out of
the separate discharge outlet.
Always ensure that the engine and starter motor are
stationary before the starter motor is engaged again.
How to stop the engine
Caution: It is recommended that a turbocharged
engine is run at a reduced load for 2-3 minutes
before it is shut down. This will allow the
turbocharger to cool.
1.Remove the load from the engine and allow the
engine to cool for 2-3 minutes.
2.Switch the engine stop switch to the stop position,
refer to the users’ handbook of the application
manufacturer..

Chapter 3 TPD1327E
Page 14
Adjustment of the engine speed range
The idle or the maximum speed settings must not
be changed by the engine operator, because this
can damage the engine or generator. The warranty
of the engine can be affected if the seals on the fuel
injection pump are broken during the warranty period
by a person who is not approved by Perkins.
Running-in
A gradual running-in of a new engine is not
necessary. Prolonged operation at light loads during
the early life of the engine can cause lubricating oil
to enter the exhaust system. Maximum load can
be applied to a new engine as soon as the engine
is put into service and the coolant temperature has
reached a minimum of 60OC (140OF).
The engine will benet if the load is applied as soon
as possible after the engine is put into service.
Cautions:
• Do not operate the engine at high speeds without
a load.
• Do not overload the engine.