Perkins M300C User manual

Installation Manual
Part No N40475
GB
®
Marine Power
!
M300C M250C M216C M190C
! !

N40475 Title
Perkins M300C, M250C,
M216C & M190C
Installation Manual
6 cylinder, turbocharged, intercooled, diesel engine for
marine propulsion applications
Publication 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:[phone] Fax: [phone] E-mail: [email protected]
www.perkins-sabre.com

Title N40475
Foreword
Thank you purchasing the Perkins M300C, M250C, M216C & M190C marine diesel engine. This manual
contains information for the correct installation of your Perkins engine.
Information contained in this manual is correct at the time of printing. Wimborne Marine Power Centre
reserves the right to make changes at any time. If there are any differences between this manual and your
engine, please contact the Wimborne Marine Power Centre.

General safety precautions
These safety precautions are important. You must refer
also to the local regulations in the country of use. Some
items only refer to specific applications.
Only use these engines in the type of application for
which they have been designed.
Do not change the specification of the engine.
Do not smoke when you put fuel 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 filler cap or any component of the
cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot
coolant can be discharged.
Do not use salt water or any other coolant which can
cause corrosion in the closed circuit of the cooling
system.
Do not allow sparks or fire near the batteries
(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the skin
and especially to the eyes.
Disconnect 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.
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If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special
solution to protect the skin.
Do not wear clothing which is contaminated
by lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
Discard used lubricating oil in accordance with local
regulations to prevent contamination.
Use extreme care if emergency repairs must be
made at sea or in adverse conditions.
The combustible material of some components of
the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this
burnt material to come into contact with the skin or
with the eyes.
Always close the seacock before the removal of any
component of the auxiliary water circuit.
Wear a face mask if the glass fibre cover of the
turbocharger is to be removed or fitted.
Always use a safety cage to protect the operator
when a component is to be pressure tested in
a container of water. Fit safety wires to secure
the plugs which seal the hose connections of a
component which is to be pressure tested.
Do not allow compressed air to contact your skin. If
compressed air enters your skin, obtain medical help
immediately.
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N40475 Contents
Chapter .......................................................................................................................................Page
1 Location of engine installation points.........................................1
2 Engine mounting ...........................................................................3
Installation angles ........................................................................................... 3
Nose down capability........................................................................... 3
Engine mounting brackets ............................................................................. 4
Flexible engine mounts................................................................................... 5
Engine bearers................................................................................................. 6
3 Propeller shafts and couplings....................................................7
Propeller shafts ............................................................................................... 7
4 Exhaust systems ...........................................................................9
Wet systems..................................................................................................... 9
Dry systems .................................................................................................... 11
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
Typical fuel systems ........................................................................... 21
8 Engine electrical systems............................................................23
Engine wiring looms ...................................................................................... 23
Breakers .......................................................................................................... 24
Interconnecting cables .................................................................................. 25

Contents N40475
Instrument panels........................................................................................... 26
Main panel............................................................................................ 26
Auxiliary panel..................................................................................... 27
Mini Marine Power Display (MMPD) digital panel............................. 28
Keyswitch panel .................................................................................. 29
Possible panel configurations. .......................................................... 30
Mini Marine Power Dispaly (MMPD) instructions ............................. 31
CAN Data Link ..................................................................................... 35
Marine Junction Box (MJB) ........................................................................... 36
Single engine MJB features and mounting details .......................... 37
Twin engine MJB features and mounting details ............................. 38
Power connections ............................................................................. 39
Current requirements 12 or 24 vdc system ...................................... 39
ECM port or starboard interface connectors.................................... 39
Grounding the battery negative ......................................................... 39
Port 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 harness overview........................................................ 45
Panel harness overview...................................................................... 46
Wiring diagrams ............................................................................................. 47
Engine wiring harness 1 ..................................................................... 47
Engine wiring harness 2 ..................................................................... 48
Engine panels 1 ................................................................................... 49
Interconnecting leads 1 ...................................................................... 50
Master/slave option, port.................................................................... 51
Marine junction box ............................................................................ 52
Master/slave option, starboard .......................................................... 53
Interconnecting leads 2 ...................................................................... 54
Engine panels 2 ................................................................................... 55
9 Engine controls ............................................................................57

N40475 Contents
10 Provision for power take-off......................................................59
For axial drives ............................................................................................... 59
For belt drives................................................................................................. 59
Polar diagram.................................................................................................. 60
11 Calorifier and block heater connections ..................................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

Contents N40475

N40475 Chapter 1
Page 1
Location of engine installation 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

Chapter 1 N40475
Page 2
Exhaust Systems
(See 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)

N40475 Chapter 2
Page 3
Engine mounting
Installation angles
These engines are intended to be mounted so that
the cylinders are vertical, when viewed from ahead or
astern as in figure 1. The operational angles that are
permissible in service are a static installation angle of
17Onose up, adding 3Ofor planing craft, with a heel
angle of 25O continuous and 35Oas shown in figures
2 and 3.
Nose down capability
Details are not available at time of print.
Figure 1
Figure 2
Figure 3.
35O35O
25O25O
20O

Chapter 2 N40475
Page 4
Figure 4
Engine mounting brackets
The standard brackets, provide mounting points which
are 76mm (3”) below, and parallel with, the crankshaft
centre line. The brackets may be used to mount the
engine directly on the engine bearers, but for all
applications it is recommended that flexible engine
mounts are used.
Figure 4 shows the holes (1) for the holding down
bolts are slotted, 36 x 17 (1.7/16 x 21/32”) to allow for
some movement during the final stages of alignment.
Where fine alignment is not necessary, for example
when a flexibly jointed drive shaft is used, the bolts
on all four corners of the engine should be positioned
at the end of the slot - all either fully in or fully out.
This will provide additional security in the fixing
arrangements.
Note: Please refer to the GA (General Arrangement)
drawings for specific engine mount positions.
For any non standard options, please contact the
Wimborne Marine Power Centre for advice.

N40475 Chapter 2
Page 5
Flexible engine mounts
It is recommended that flexible engine mounts should
be used for all applications. The principal purpose of
the mounts is to reduce the transmission of vibration
from the engine to the hull, but another valuable
advantage is that the mountings reduce the shock
transmitted from the hull to the engine under adverse
weather conditions and also prevent the engine being
inadvertently used as a structural part of the boat,
due to flexing in the hull, a function the engine will not
satisfactorily fulfil.
Figure 5 shows the flexible engine mount for most
applications.
Note: refer to the installation drawing for specific
dimensions, which are for the mount in the unloaded
condition.
To adjust the height of the mount, use the adjuster nut
and bolt (2) against the pad (3) to introduce shims (4).
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, such
as ‘V’ drives when integral with the engine unit, pose
special mounting problems and recommendations as
to the most suitable mounting arrangement can be
made for specific applications.
Note: For transmission ratios above 2:1 or use
in extreme conditions, please contact your local
distributor for advice.
Installation drawings are available showing the
preferred mounting arrangements when using a
variety of gearboxes and applications.
Figure 5

Chapter 2 N40475
Page 6
Engine bearers
The materials and methods of construction of engine
bearers which have proved to be satisfactory in service
vary to such an extent that it is difficult to lay down
universal guide lines. However, as a rough guide it
can be said the engine bearers should be capable of
supporting a static load of about eight times the weight
of the engine, to cater for the effects of rough seas.
The bearers should be cross connected to give lateral
rigidity, in order to maintain the shaft alignment and
to prevent twisting and racking forces being applied
to the engine.
To enable minimum shaft centre distances to be
achieved in a twin installation, 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 result in the engine accessibility
becoming very restricted, and it would be impossible
to carry out service operations. It should be noted that
if minimum shaft centres are to be adopted, space
must be left in front of and behind the engine to
provide access. A minimum clearance on all sides will
mean that the engine cannot be serviced!
Figure 6

N40475 Chapter 3
Page 7
Propeller shafts and couplings
Propeller shafts
It is recommended that all engines are mounted on flexible
mountings (1), which will reduce noise and vibration,
and will prevent hull movements resulting in forces being
applied to the engine.
The responsibility for the design and installation of the
transmission system connected to the gearbox lies with
the boat designer, the boat builder, the naval architect or
the engine installer. It is recommended that a Torsional
Vibration Analysis (TVA) is carried out on the complete
drive system. Mass Elastic Data can be provided on request
from Wimborne Marine Power Centre.
Figure 1 shows a simple arrangement, where the propeller
shaft is supported only by the gearbox coupling and an
outboard rubber bearing at the propeller end. Entry of water
into the boat is prevented by a shaft seal, which must be
flexibly mounted to allow for engine movement. A flexible
shaft coupling (2) is fitted to the gearbox coupling, to allow
momentary angular misalignment in operation.
This system is only suitable for applications where the
speed, diameter, and unsupported length of the propeller
shaft will not induce ‘whirling’ (i.e. the centrifugal force
generated by the speed of rotation is not sufficient to bend
the shaft into a bow shape).
Figure 1 also shows a cutless bearing (3), flexibly mounted
shaft seals (4), reinforced rubber hose (5), graphited
asbestos string (6), stuffing box (7) and the drive shaft (8).
Where the propeller shaft length is such that it cannot be
simply supported by the gearbox coupling and ‘P’ bracket,
without the risk of whirling, the arrangement shown in figure
2 may be adopted.
Water supply (4) for bearings (use hose from M14 x 1.5
tapping on heat exchanger end cap). End cap with tapping
is optional.
In this case one or more additional bearings (3) are included
in the shaft log, and flexible shaft couplings (2) (which will
accept thrust) are used to permit the engine to move on the
flexible mountings (1) .
Warning! Use a syphon break (5) where a water lift exhaust
system is specified.
A variation of this is to use a thrust block (bearing) at the
point where the shaft emerges from the log into the engine
room, together with constant velocity joints at each end of
the short shaft connected to the gearbox coupling.
Figure 1
Figure 2

Chapter 3 N40475
Page 8

N40475 Chapter 4
Page 9
Exhaust systems
A range of exhaust components are available for use
with all types of exhaust system. The components
are designed to connect together, allowing complex
systems to be built from stock items, to suit most
installations.
Caution: In all types of exhaust system the exhaust
back pressure must not exceed 15kPa, when
measured within 305mm (12 inches) of the exhaust
outlet from the engine.
Wet systems
Wet exhaust systems, where the auxiliary water
used to circulate through the heat exchangers on the
engine is finally dumped into the exhaust pipe to cool
the exhaust gases, are the most common choice for
small craft. Their principal advantage is that a rubber
exhaust hose may be used, with a fairly low surface
temperature, which presents no risk of fire.
The exhaust bore is 125mm (5”).
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 the point of water injection must be at least
8 inches above the waterline (3), although the actual
height necessary for a particular boat can only be
decided in the light of the exhaust system design,
and the pitch and roll which may be encountered in
service.
Caution: It is essential that the exhaust system is
designed so that water from the exhaust does not
enter the engine under any conceivable operational
condition.
Figure 1

Chapter 4 N40475
Page 10
Figure 2 shows the exhaust elbow (1) with water
injection and insulating blanket. The elbow can be
rotated (3) to achieve the optimal position.
Note: The exhaust elbow must have a fall of 10O
downwards.
If a taller system is required then a dry 90Oelbow
(not shown) can be used on the turbocharger outlet
with the water injected elbow (1). As both elbows use
a clamp, full articulation can be utilised to suit most
applications
Note: The clamps are to be torqued to 9Nm.
Due consideration must be given to providing flexibility
in the exhaust hose, particularly if the engine is
flexibly mounted. Where the exhaust hose must pass
through a bulkhead immediately behind the engine
it is preferable that the arrangement shown in figure
3 is adopted, using rubber bellows (1) to provide
flexibility.
Note: that the bellows should be in an unstrained
condition when fitted, a minimum fall of 5o(3) is
required, and that the point of water injection must be
at least 8 inches above the waterline (2).
Note: A single double hump bellows can be used
where space is restricted.
Caution: Movement of the engine on the flexible
mounts must not be restricted by the exhaust hose.
Figure 2
Figure 3