Perkins M65, Installation Manual

Page 1: ... Installation Manual GB Part No TPD 1399E M65 M85T ...

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Page 3: ...tions Publication TPD 1399E Issue 7 Proprietary information of Wimborne Marine Power Centre all rights reserved The information is correct at the time of print Published in December 2013 by Wimborne Marine Power Centre Wimborne Dorset England BH21 7PW Tel 44 0 1202 796000 Fax 44 0 1202 796001 E mail Marine Perkins com www perkins com marine ...

Page 4: ...TPD1399E ...

Page 5: ...tems 9 Water Lift Systems 10 Part wet part dry systems 11 Systems for operation at high angles of heel 12 Engine Room Ventilation 13 Engine Cooling Systems 15 Sea Water Systems 15 Keel cooling system 16 Fuel systems 17 Fuel connections 17 Fuel tanks 18 Multiple tanks 19 Engine electrical systems 21 Engine wiring loom 21 Insulated return 21 Fuseboard 23 Interconnecting cables and Y harness 24 Instr...

Page 6: ...E Zinc Anode Bonding System 30 Typical System in Common Use 30 Engine controls 33 Provision for Power Take Off 35 PTO Fitting Instructions 36 Electro Mechanical Bilge Pump 37 Calorifier Connections 37 Reference data 39 ...

Page 7: ...In service however the sump fitted as standard on the M65 and as an option on the M85T B may operate continuously at a heel angle of 20O and intermittently i e for up to 15 seconds at a time at an angle of 25O Ahigh inclination sump fitted as standard on the M85T and as an option on the M65 allows an operating heel angle of 25O continuously and intermittently up to 35O C ...

Page 8: ... or starting to plane Engine mounting brackets The standard brackets provide mounting points which are 35mm below and parallel with the crankshaft centre line B1 The brackets may be used to mount the engine directly on to engine bearers but for all applications it is recommended that flexible engine mounts are used B2 Engine mounting brackets are available for transverse mounting centres of either...

Page 9: ... the bearers but do not fully tighten if the mount has a cross slot and a longitudinal slot bolt through the longitudinal slot Carry out any fine side to side adjustments necessary by allowing the mount to rotate slightly about the bolts just fitted C Then drill the remaining 4 holes for the engine mounts through the centres of the slots Fit bolts and tighten all around The mounts are provided wit...

Page 10: ...tions should be arranged to give lateral rigidity in order to maintain shaft alignment and to prevent twisting and racking forces being applied to the engine If the bearers are flexible unwanted vibrations may be set up in the hull so the assembly should be made as stiff as possible Close spacing To enable minimum shaft centre distances to be achieved in a twin installation a common centre bearer ...

Page 11: ...ill a hole 1 4 diameter so that it extends at full diameter for not more than 2mm into the shaft measured on the shaft diameter B2 5 Remove shaft then open up the hole in the coupling to 5 16 or 8mm and tap 3 8 UNC Clean up the bore of the coupling as necessary 6 Reassemble the shaft to the coupling Fit the half dog 3 8 UNC grubscrew C1 supplied with the coupling The grubscrew locks the coupling t...

Page 12: ...to provide a safeguard against loss of the shaft when going astern Flexible couplings Elasticity may be incorporated in the connection between the gearbox output flange and the propeller shaft by means of a flexible coupling B1 This type of coupling is not intended for use with continuous misalignment but will cater for momentary deflections due for example to the effect of shock loadings on the a...

Page 13: ...e 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 elbow incorporates a water feed connection A1 which may be used to cool a shaft stuffing box and a sampling point A2 for temperature or pressure measurements Warning Use a siphon break where a water lift exhaust sy...

Page 14: ...om the exhaust does not enter the engine under any conceivable operational condition It is important that there is sufficient flexibility in the exhaust hose to allow the engine to move on its flexible mounts The internal diameter of the hose for the wet exhaust B3 should be at least 63 5mm 2 1 2 inches ...

Page 15: ...bellows type are suitable but care must be taken to ensure that they are only required to accommodate movements that do not involve twisting the ends of the bellows relative to each other The remainder of the exhaust system should be well insulated A2 to avoid fire risk If there is a long exhaust run which gains height as it leaves the exhaust manifold it may be necessary to incorporate a trap to ...

Page 16: ... be taken to prevent water from siphoning into the system and then flooding the engine There are two routes by which this could happen from the exhaust outlet or by the sea water feed to the engine The top of the exhaust riser A3 should be 450mm 18 inches above the static water line and the exhaust outlet A4 should either be well above the static water level or a siphon break should be fitted at A...

Page 17: ...n elbow A6 and the remainder of the system follows usual wet exhaust practice with a rubber hose falling to a transom fitting The point of water injection should be at least 200mm 8 above the water line and the wet exhaust should have an average fall of at least 5O The minimum diameter of the dry part of the system should be 40mm 1 6 for the M65 and 63 5 2 5 for the M85T and the wet part of the sy...

Page 18: ...injection elbow A2 then cools the exhaust gas and the mixture of gas and water exits the hull either by a hose through the transom or by a cross pipe A3 running between skin fittings on both sides of the hull so that the exhaust gases can escape from whichever outlet is uncovered and the raw water can escape through the submerged outlet The minimum diameter of the dry part of the system should be ...

Page 19: ...encouraged by using forward facing intake vents to take advantage of ram airflow With an effective ventilation system the engine air intake temperature will be no more than 10 Celsius degrees higher than the outside air temperature 1 Minimum cross section of air duct per engine Model For hot climates For temperate climates M65 210 sq cm 32 sq ins 110 sq cm 16 sq ins M85T 260 sq cm 40 3 sq ins 130 ...

Page 20: ...Chapter 4 TPD 1399E Page 14 ...

Page 21: ...ble for routine examination and the lid should be easily removable Where possible mount the strainer so that the top is just above the waterline this will allow the strainer to be cleaned without closing the sea cock From the sea water strainer a pipe should be run to the sea water pump inlet connection on the engine B1 The pipe may either be mainly rigid of for example copper or cupro nickel or f...

Page 22: ...esign value for the water flow through the keel cooler 90 litres min 20 imp galls min 90 litres min 20 imp galls min The pipework between the engine and the cooler should be as short and direct as is possible but should be sufficiently flexible to allow the engine to move on its anti vibration mounts The pipe layout should discourage the formation of air locks and venting points should be provided...

Page 23: ...ad A1 Fuel connections on the engine Fuel feed 1 2 UNS female for 5 16 OD pipe Fuel return 7 16 UNS male for 1 4 OD pipe It is recommended that the flexible fuel pipes available as an option with the engine are specified These provide connections as shown below Optional flexible fuel pipes Fuel feed The free end has a 1 4 BSP nut and olive to suit 5 16 OD pipe to be supplied by installer Fuel retu...

Page 24: ...uel feed problems are minimised In a multiple engine installation care should be taken to ensure that the pipework for each engine is kept separate A fuel sedimenter i e water trap A8 is required in the fuel system between the fuel tank and the engine mounted lift pump A9 To avoid problems when venting air after draining the sedimenter it should be preferably installed below the normal minimum lev...

Page 25: ...tional balancing pipe between the tanks with a valve at each end A collector tank as shown on A1 with flow and return connections for the engine s and a vent pipe A11 The storage tanks A2 A3 A4 can be connected to the collector tank by valves A5 A6 A7 the flow passing through a sedimenter A8 Note The fuel feeds to the engine A9 should be taken from the bottom of the collector tank and the return f...

Page 26: ...Chapter 6 TPD 1399E Page 20 ...

Page 27: ...c stop engine senders and warning switches to a waterproof IP67 multiway connector situated on a flying lead attached to the engine in position A1 The circuit diagram is shown on page 22 where it will be seen that the system is earth return Insulated return To convert to an insulated return a kit incorporating a power relay can be specified The relay momentarily connects the battery negative to th...

Page 28: ...Chapter 7 TPD 1399E Page 22 ...

Page 29: ...quipment is wired in and is negligible during normal operation The location of the Fuseboard on the engine is shown on A1 and the fuse layout is shown on B where B1 is a 40A fuse protecting the starter relay circuit B2 is a 15A fuse protecting the stop solenoid circuit B3 is a 10A fuse protecting the supply to the instrument panel s B4 is a 30A fuse protecting the negative wires in the loom ...

Page 30: ...bles have a male plug A1 at one end and a female A2 at the other Cables may be plugged together to give up to 12m length but in general if a longer cable is required it should be ordered as a special item to be made in one piece A Y harness B is available with a male plug at B1 and two female plugs B2 If necessary more than one Y harness may be used to connect several instrument panels together ...

Page 31: ...instrumentation The Instrument Panel shown on A includes Tachourmeter Low oil pressure warning lamp High water temperature warning lamp Charge warning lamp Heat start switch On off switch Stop switch Oil pressure gauge Water temperature gauge Voltmeter Water in fuel warning lamp Panel illumination level switch ...

Page 32: ...rmeter Low oil pressure warning lamp High coolant temperature lamp Charge warning lamp Heat start switch On off switch Stop switch Up to three panels may be run simultaneously in any combination C Circuit diagrams for both types of panel are shown on page 27 and on page 28 ...

Page 33: ...TPD 1399E Chapter 7 Page 27 ...

Page 34: ...Chapter 7 TPD 1399E Page 28 ...

Page 35: ...a good state of charge at all times Starter cables The total resistance of the two leads from the battery to the engine should not exceed 0 0017 ohms In practice this means that the total length of the starter cables positive and negative should not exceed 6 metres if the commonly available 61 044 cable is used Longer cable runs which should be avoided if possible will require either double cables...

Page 36: ...ter together with a connection to a Zinc sacrificial anode which is fixed to the outside of the hull C1 below sea level The bonding should consist of heavy stranded wire C2 not braiding or wire with fine strands connecting the Zinc anode C3 propeller shaft C4 sea cock C5 through hull metal fittings C6 and the engine bonding stud C7 It is an advantage if the wire is tinned Insulation is also an adv...

Page 37: ...t earthing system should be connected to the bonding system A3 to which the engine and the shaft log if metal are also connected Before the boat enters service the effectiveness of the bonding and sacrificial Zinc anode system should be tested both when at rest and with all systems including engines in operation by a specialist in this field Note This section on bonding covers a typical system and...

Page 38: ...Chapter 7 TPD 1399E Page 32 ...

Page 39: ...e speed selector lever A3 which is shown in the idle speed position may be operated by a Morse 33C cable using the anchor point A2 The stop solenoid A1 which is energised to stop is normally controlled from the instrument panel but the engine may be stopped manually by pushing in the plunger A4 The illustration shows the plunger in the run position ...

Page 40: ...Chapter 8 TPD 1399E Page 34 ...

Page 41: ...priate characteristics in the drive line Seek advice from Wimborne Marine Power Centre if you are considering axially driven equipment Belt Driven Loads Loads of up to 8kw may be driven by belts providing that the side force is applied at a point not more than113mm from the cylinder block front face Pulleys are available to meet this requirement Part 34131 has a single A section groove of 143mm O ...

Page 42: ...36 PTO Fitting Instructions Key Size Torque 1 M12 100 Nm 2 7 16 70 Nm 3 M10 55Nm Note Fitting the PTO should be undertaken by a qualified marine engineer Warning For safety reasons all moving parts should be shielded by a guard ...

Page 43: ...ectro Mechanical Bilge Pump RTV 732 sealant Note Fitting the electro mechanical bilge pump should be undertaken by a qualified marine engineer Warning For safety reasons all moving parts should be shielded by a guard 10mm 1 5 55Nm 1 ...

Page 44: ...Chapter 9 TPD 1399E Page 38 ...

Page 45: ...ater The position of the connection for the flow to the calorifier is shown on A1 and the return on B1 Both are for 1 2 inch bore hose which should be of radiator or heater hose quality and must be installed so that chafing will not occur A shut off valve is part of each fitting Caution The hoses connecting the engine to a calorifier are part of the closed engine system Failure of a hose will lead...

Page 46: ...Chapter 10 TPD 1399E Page 38 ...

Page 47: ...olant inhibitor Perkins Powerpart anti freeze Perkins Powerpart anti freeze Fresh water flow 130 litre min 28 5 UK gal min 130 litre min 28 5 UK gal min 34 2 US gal min at 2600 rev min 34 2 US gal min at 2600 rev min Coolant pump speed and method of drive 1 25 1 ratio belt drive 1 25 1 ratio belt drive System capacity 8 75 litres 1 92 UK gal 2 31 US gal 9 5 litres 2 07 UK gal 2 48 US gal Pressure ...

Page 48: ...d pipe outside diameter 7 9 mm 0 315 in 7 9 mm 0 315 in Fuel feed pipe bore 6 53 mm 0 257 in 6 53 mm 0 257 in Return fuelpipe outside diameter 6 3 mm 0 25 in 6 3 mm 0 25 in Return fuel pipe bore 4 93 mm 0 194 in 4 93 mm 0 194 in Maximum lift pump lift 1 53 m 5 ft to bottom of fuel tank 1 53 m 5 ft to bottom of fuel tank suction pipe through a pipe 3 06 m suction pipe through a pipe 3 06 m 10 ft in...

Page 49: ...t3 min 10 4m3 min 360ft3 min Minimum cross section of air duct per engine 206 cm2 31 9 in2 Hot 260 cm2 40 3 in2 103 cm2 16 in2 Temperate 130 cm2 20 1 in2 Exhaust system Exhaust gas flow 4 1 kg min 120 8 ft3 min 16 4 kg min 471 ft3 min Maximum restriction measured within 305 mm 12 in of outlet at maximum rated speed 10 2 kPa 3 0 in Hg 10 2 kPa 3 0 in Hg Recommended exhaust pipe bore wet exhaust sys...

Page 50: ...rd sump 20O continuous 25O intermittent 20O continuous 25O intermittent optional Heel angle to port or starboard high inclination sump 25O continuous 35O intermittent 25O continuous 35O intermittent standard Oil pressure in operating speed range 280 kN in2 40 Ib in2 280 kN in2 40 Ib in2 Low oil pressure switch setting 83 kN in2 12 Ib in2 83 kN in2 12 Ib in2 Electrical system Alternator type earth ...

Page 51: ...40 amp SAE 340 amp IEC 340 amp IEC Power Take Off Axial power take off from front of crankshaft pulley Full load throughout the Full load throughout the engine speed range engine speed range Belt driven auxiliaries from crankshaft power take off pulley See section 9 or for technical See section 9 or for technical assistance contact assistance contact Wimborne Marine Power Centre Wimborne Marine Po...

Page 52: ...Chapter 11 TPD 1399E Page 44 ...

Page 53: ...California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 54: ...d subsequently Part No TPD 1399E issue 7 Produced in England 2013 by Wimborne Marine Power Centre Wimborne Marine Power Centre 22 Cobham Road Ferndown Industrial Estate Wimborne Dorset BH21 7PW England Tel 44 0 1202 796000 Fax 44 0 1202 796001 E mail Marine Perkins com Web www perkins com Marine ...