User's Handbook: 4GM 4Tgm
User's Handbook: 4GM 4Tgm
® GB
User’s Handbook
4GM 4TGM
6TG2AM 6TWGM
TPD1327E Title
Perkins
Marine Gen Set Power
User’s handbook
1 General information
Introduction....................................................................................................................... 1
How to care for your engine............................................................................................. 2
General safety precautions.............................................................................................. 3
Engine guarantee............................................................................................................. 4
Engine identification......................................................................................................... 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 fill the coolant circuit........................................................................................... 17
Engines fitted with keel coolers............................................................................. 17
How to drain the coolant circuit...................................................................................... 18
Engines fitted with keel coolers............................................................................. 19
How to check the specific gravity of the coolant............................................................. 20
How to drain the raw water circuit.................................................................................. 21
Engines fitted 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 filter..................................................................... 26
How to renew the element of the fuel pre-filter............................................................... 27
Atomiser fault................................................................................................................. 28
How to renew an atomiser.............................................................................................. 29
How to eliminate air from the fuel system...................................................................... 30
Contents TPD1327E
9 General data
4GM and 4TGM engines................................................................................................ 53
6TG2AM and 6TWGM engines...................................................................................... 54
10 Electrical diagrams
Earth relay and resistors................................................................................................ 55
TPD1327E Chapter 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.
Page 1
Chapter 1 TPD1327E
Page 2
TPD1327E Chapter 1
General safety precautions • Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
These safety precautions are important. You must persons. Protect your hands with gloves or a
refer also to the local regulations in the country of special solution to protect the skin.
use. Some items only refer to specific applications.
• Do not wear clothing which is contaminated
• Only use these engines in the type of application by lubricating oil. Do not put material which
for which they have been designed. is contaminated with oil into the pockets of
• Do not change the specification of the engine. clothing.
• Do not smoke when you put fuel in the tank. • Discard used lubricating oil and coolant in
accordance with local regulations to prevent
• Clean away fuel which has been spilt. Material
contamination.
which has been contaminated by fuel must be
moved to a safe place. • Use extreme care if emergency repairs must be
made at sea or in adverse conditions.
• Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary). • The combustible material of some components
of the engine (for example certain seals) can
• Do not clean, add lubricating oil, or adjust the
become extremely dangerous if it is burned.
engine while it runs (unless you have had the
Never allow this burnt material to come into
correct training; even then extreme care must be
contact with the skin or with the eyes.
used to prevent injury).
• Always close the seacock before the removal of
• Do not make adjustments that you do not
any component of the raw water circuit.
understand.
• Wear a face mask if the glass fibre cover of the
• Ensure that the engine does not run in a location
turbocharger is to be removed or fitted.
where it can cause a concentration of toxic
emissions. • Always use a safety cage to protect the operator
when a component is to be pressure tested in
• Other persons must be kept at a safe distance
a container of water. Fit safety wires to secure
while the engine, auxiliary equipment or boat is
the plugs which seal the hose connections of a
in operation.
component which is to be pressure tested.
• Do not permit loose clothing or long hair near
• Do not allow compressed air to contact your
moving parts.
skin. If compressed air enters your skin, obtain
• Keep away from moving parts during engine medical help immediately.
operation. Warning! Some moving parts cannot
• Turbochargers operate at high speed and at
be seen clearly while the engine runs.
high temperatures. Keep fingers, tools and
• Do not operate the engine if a safety guard has other items away from the inlet and outlet ports
been removed. of the turbocharger and do not contact the hot
• Do not remove the filler cap or any component of surfaces.
the cooling system while the engine is hot and • The latest marine engines have a cover fitted
while the coolant is under pressure, because to give some protection from the alternator fan
dangerous hot coolant can be discharged. and the drive belt. Ensure that this cover is fitted
• Do not use salt water or any other coolant which before the engine is started.
can cause corrosion in the closed circuit of the • Fit only genuine Perkins parts..
cooling system.
• Do not allow sparks or fire near the battery
(especially when the battery is 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.
• If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
Page 3
Chapter 1 TPD1327E
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.
Page 4
TPD1327E Chapter 1
Engine identification
The 4GM engine consists of four different types:
Page 5
Chapter 1 TPD1327E
Page 6
TPD1327E Chapter 2
Engine views
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
Page 7
Chapter 2 TPD1327E
Page 8
TPD1327E Chapter 2
Page 9
Chapter 2 TPD1327E
Page 10
TPD1327E Chapter 2
Page 11
Chapter 2 TPD1327E
Page 12
TPD1327E Chapitre 4
Operation instructions
Page 13
Chapter 3 TPD1327E
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).
Cautions:
Page 14
TPD1327E Chapter 4
Preventive maintenance
It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which
conform to the specifications given in this handbook.
Schedules
The schedules which follow must be applied at the interval (hours or months) which occur first.
l l Check the tension of the drive belt for the alternator (3)
l Drain water from the fuel pre-filter (or earlier if your fuel supply is contaminated)
l Clean the sediment chamber and the strainer of the fuel lift pump
l Renew the elements of the fuel pre-filter and the fuel filter
Page 15
Chapter 4 TPD1327E
Schedules
The schedules which follow must be applied at the interval (hours or months) which occur first.
l l Ensure the valve tip clearances of the engine are checked and, if necessary,
adjusted (3)
l Ensure the turbocharger impeller and the turbocharger compressor casing are
cleaned (3)
l Ensure the alternator, the starter motor, and the turbocharger, etc. are checked (3)
l Check the condition of the crankshaft damper
(1) The oil change interval will change with the amount of sulphur in the the fuel (see the fuel specification in
section 5). The interval to change the canister of the lubricating oil filter is not affected.
(2) The valve for the breather system must be renewed every 4000 hours.
Note: To ensure that the engine runs at maximum efficiency the operations which follow must be done every
12 months or less. If the raw water is excessively contaminated, clean more frequently the tube stack of the
heat exchanger for the closed circuit coolant and the tube stack of the heat exchanger for the closed circuit
coolant. Refer to the workshop manual for instructions.
Page 16
TPD1327E Chapter 4
Page 17
Chapter 4 TPD1327E
Page 18
TPD1327E Chapter 4
8. If a cassette oil cooler (A) is fitted to the filter
head, then this must also be drained and
flushed. To do this, disconnect the hoses (A1 and
A2) at the top of the cooler and flush the cooler
through the outlet connection (A1) until clean
water runs from the inlet (A2).
Page 19
Chapter 4 TPD1327E
Antifreeze/water Protection
(% by volume) down to (°C)
50/50 -35
60/40 -40
Page 20
TPD1327E Chapter 4
Page 21
Chapter 4 TPD1327E
5. Fit the guard for the drive belt to the engine and
fasten the two setscrews..
Page 22
TPD1327E Chapter 4
Page 23
Chapter 4 TPD1327E
Page 24
TPD1327E Chapter 4
Page 25
Chapter 4 TPD1327E
Cautions:
Page 26
TPD1327E Chapter 4
Cautions:
Page 27
Chapter 4 TPD1327E
Atomiser fault
Warning!
Page 28
TPD1327E Chapter 4
Page 29
Chapter 4 TPD1327E
Page 30
TPD1327E Chapter 4
6. Loosen the union nuts (A1) of the high-pressure
pipes at two of the atomisers.
Page 31
Chapter 4 TPD1327E
Page 32
TPD1327E Chapter 4
Page 33
Chapter 4 TPD1327E
Warning! Do not allow compressed air to contact and valve assembly into position on the breather
your skin. If compressed air enters your skin, obtain body. Loosely fit the fasteners. Tighten the
medical help immediately. fasteners gradually and evenly to 3 Nm (2.2 lbf
ft) 0.3 kgf m.
6. Wash the body of the breather, the cover, the
baffle plates (A6) and the breather pipe, every Caution: Do not use excessive force to fit the hose
2000 hours of operation. Use an approved to the breather outlet pipe.
kerosene cleaning fluid and dry them with
5. Check that there is no restriction in the breather
compressed air at low pressure.
pipe or the breather hose. Fit the breather hose
7. Ensure that the holes at the bottom of the baffle to the cover and tighten the clip.
plates in the breather body are not restricted. If
necessary, clean the holes.
To assemble
1. Fit the baffle plates into the grooves in the
breather body.
Page 34
TPD1327E Chapter 4
Air filter
Environmental conditions have an important effect
on the frequency at which the air filter needs service.
Page 35
Chapter 4 TPD1327E
Page 36
TPD1327E Chapter 4
Restriction indicator
The restriction indicator is fitted on the air filter outlet
or between the air filter and the induction manifold.
Page 37
Chapter 4 TPD1327E
1 2 3 4
Cylinder and
valve number
1 2 3 4 5 6 7 8
Valve
I = Inlet I E E I I E E I
E = Exhaust
Page 38
TPD1327E Chapter 4
Six cylinder engines
1. Rotate the crankshaft in the normal direction
of rotation until the inlet valve (A12) of number
6 cylinder has just opened and the exhaust
valve (A11) of the same cylinder has not closed
completely. Check the clearances of the valves
(A1 and A2) of number 1 cylinder and adjust
them, if necessary.
Cylinder 1 2 3 4 5 6
and
valve 1 2 3 4 5 6 7 8 9 10 11 12
number
Valve
I = Inlet I E E I I E E I I E E I
E = Exhaust
Page 39
Chapter 4 TPD1327E
8,7 kgf m.
Page 40
TPD1327E Chapter 4
Seacock strainer
The seacock strainer must be cleaned regularly.
Corrosion
This can occur when two different metals are in
contact near to, or in, sea water. For example, a
brass or bronze pipe fitted into aluminium can cause
rapid corrosion. For this reason, special precautions
are necessary when an engine is installed. In this
situation, some components will be connected
to a sacrificial anode fitted to the hull. Specialist
manufacturers will advise on the maintenance of
these anodes.
Supplementary tools
A general tool kit and an on-board parts kit are
available from your Perkins Distributor. It is
recommended that the tools and other parts, listed
below, are also retained on-board:
Insulation tape
Jointing compound
Mechanical fingers
Self-gripping wrench
Page 41
Chapter 4 TPD1327E
Page 42
TPD1327E Chapter 5
Fuel specification
To get the correct power and performance from your
engine, use good quality fuel. The recommended
fuel specification for Perkins engines is indicated
below:
Page 43
Chapter 5 TPD1327E
Page 44
TPD1327E Chapter 5
Coolant specification
The quality of the coolant which is used can have a
great effect on the efficiency and life of the cooling
system. The recommendations indicated below
can help to maintain a good cooling system and to
protect it against frost and/or corrosion.
Page 45
Chapter 5 TPD1327E
Page 46
TPD1327E Chapter 6
Fault diagnosis
Page 47
Chapter 6 TPD1327E
List of possible causes 44. Valve stems and/or guides are worn.
1. Battery capacity low. 45. Crankshaft bearings are worn or damaged.
2. Bad electrical connections. 46. Lubricating oil pump is worn.
3. Fault in starter motor. 47. Relief valve does not close.
4. Wrong grade of lubricating oil. 48. Relief valve does not open.
5. Starter motor turns engine too slowly. 49. Relief valve spring is broken.
6. Fuel tank empty. 50. Fault in suction pipe of lubricating oil pump.
7. Fault in stop control. 51. Piston is damaged.
8. Restriction in a fuel pipe. 52. Piston height is incorrect.
9. Fault in fuel lift pump. 53. Flywheel housing or flywheel is not aligned
correctly.
10. Dirty fuel filter element.
54. Fault in thermostat or thermostat is of an
11. Restriction in air induction system. incorrect type.
12. Air in fuel system. 55. Restriction in coolant passages.
13. Fault in atomisers or atomisers of an incorrect 56. Fault in water pump.
type.
57. Valve stem seal is damaged.
14. Cold start system used incorrectly.
58. Restriction in sump strainer.
15. Fault in cold start system.
59. Valve spring is broken.
16. Restriction in fuel tank vent.
60. Turbocharger impeller is damaged or dirty.
17. Wrong type or grade of fuel used.
61. Lubricating oil seal of turbocharger leaks.
18. Restricted movement of engine speed control.
62. Induction system leaks (turbocharged engines).
19. Restriction in exhaust pipe.
63. Fault in raw water pump.
20. Engine temperature is too high.
21. Engine temperature is too low.
22. Not enough lubricating oil in sump.
23. Defective gauge.
24. Dirty lubricating oil filter element.
25. Fault in engine mounting or flywheel housing.
26. Too much lubricating oil in sump.
27. Restriction in breather system.
28. Restriction in seacock or raw water strainer.
29. Insufficient coolant in circuit.
30. Restriction in heat exchanger or oil coolers.
31. Drive belt for water pump is loose.
32. Fault in fuel injection pump.
33. Broken drive on fuel injection pump.
34. Timing of fuel injection pump is incorrect.
35. Valve tip clearances are incorrect.
36. Valve timing is incorrect.
37. Insufficient compression.
38. Cylinder head gasket leaks.
39. Valves are not free.
40. Wrong high-pressure pipes.
41. Worn cylinder bores.
42. Leakage between valves and seats.
43. Piston rings are not free or they are worn or
broken.
Page 48
TPD1327E Chapter 7
Engine preservation 8. Close the seacock and drain the raw water
cooling system.
3. Operate the engine until it is warm. Then correct 11. Spray POWERPART Lay-Up 2 into the induction
leakages of fuel, lubricating oil or air. Stop the manifold. Seal the manifold with waterproof tape.
engine and drain the lubricating oil from the
sump. 12. Remove the exhaust pipe. Spray POWERPART
Lay-Up 2 into the exhaust manifold. Seal the
4. Renew the canister of the lubricating oil filter. manifold with waterproof tape.
5. Fill the sump to the full mark with new and clean 13. If the lubricating oil filler is fitted onto the rocker
lubricating oil and add POWERPART Lay-up 2 cover, remove the filler cap. If the lubricating oil
to the oil to protect the engine against corrosion. filler is not fitted onto the rocker cover, remove
If POWERPART Lay-Up 2 is not available, use the rocker cover. Spray POWERPART Lay-Up
a proprietary preservative fluid instead of the 2 around the rocker shaft assembly. Fit the filler
lubricating oil. If a preservative fluid is used, this cap or rocker cover.
must be drained and the lubricating oil sump
must be filled to the correct level with normal 14. Disconnect the battery. Then put the battery
lubricating oil at the end of the storage period. into safe storage in a fully charged condition.
Before the battery is put into storage, protect its
6. Drain the coolant circuit, see page 18. In order to terminals against corrosion. POWERPART Lay-
protect the cooling system against corrosion, fill it Up 3 can be used on the terminals.
with an approved antifreeze mixture because this
gives protection against corrosion. 15. Seal the vent pipe of the fuel tank or the fuel filler
cap with waterproof tape.
Caution: If protection against frost is not
necessary and a corrosion inhibitor is to be used, 16. Remove the alternator drive belt and put it into
it is recommended that you consult the Service storage.
Department, Wimborne Marine Power Centre, refer 17. In order to prevent corrosion, spray the engine
to company address list on page 6. with POWERPART Lay-Up 3. Do not spray the
7. Operate the engine for a short period in order to area inside the alternator cooling fan.
circulate the lubricating oil and the coolant in the
engine.
Page 49
Chapter 7 TPD1327E
Caution: After a period in storage, but before the
engine is started, operate the starter motor with
the stop switch held in the “STOP” position until oil
pressure is indicated. Oil pressure is indicated when
the low pressure warning light is extinguished. If a
solenoid stop control is used on the fuel injection
pump, it must be disconnected for this operation.
Page 50
TPD1327E Chapter 8
Introduction
If problems occur with your engine or with the
components fitted onto it, your Perkins distributor
can make the necessary repairs and will ensure that
only the correct parts are fitted and that the work is
done correctly.
Service literature
Installation drawings and other service publications
are available from your Perkins distributor at a
nominal cost.
Training
Local training for the correct operation, service and
overhaul of engines is available at certain Perkins
distributors. If special training is necessary, your
Perkins distributor can advise you how to obtain
it at the Perkins Customer Training Department,
Peterborough, or other main centres.
Page 51
Chapter 8 TPD1327E
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion.
Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed
systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
Page 52
TPD1327E Chapter 9
General data
Page 53
Chapter 9 TPD1327E
Page 54
TPD1327E Chapter 10
Electrical diagrams
Page 55
Chapter 10 TPD1327E
Page 56
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.
All information in this document is substantially
correct at time of printing and may be altered Wimborne Marine Power Centre
subsequently. 22 Cobham Road,
Part No. TPD 1327E issue 12
Produced in England ©2013 by Wimborne
Ferndown Industrial Estate,
Marine Power Centre 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