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Summary of Contents for Perkins 4GM
- Page 1 Part No TPD 1327E ® User’s Handbook 4TGM 6TG2AM 6TWGM...
- Page 3 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: +44(0)1202 796000 Fax: +44(0)1202 796001 E -mail: Marine@Perkins.com www.perkins.com/marine...
- Page 4 Title TPD1327E...
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Page 5: Table Of Contents
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) .................... - Page 6 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...
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Page 7: General Information
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 8: How To Care For Your Engine
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. -
Page 9: General Safety Precautions
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... -
Page 10: Engine Guarantee
Perkins marine distributor or an approved dealer. If it is difficult to find 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. -
Page 11: Engine Identification
TPD1327E Chapter 1 Engine identification 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. -
Page 12: Perkins Main Dealers
Telephone: 0040 (0) 1202 796000 Telephone: [81] (3) 5157 0571 Fax: 0040 (0) 1202 796001 Fax: Fax: [81] (3) 5157 0572 www.perkins.com/marine. *This is just a small selection of Perkins dealers. For a more comprehensive list, please see www.perkins.com/marine. Page 6... -
Page 13: Engine Views
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. Location of engine parts - 4 cylinder turbocharged engines Front and left side (A) 1. Crankcase breather 10. -
Page 14: Rear And Right Side (B)
Chapter 2 TPD1327E 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-filter 25. Sump for the engine lubricating oil 26. Flywheel 27. -
Page 15: Front And Left Side (A)
TPD1327E Chapter 2 Location of engine parts - 6 cylinder turbocharged engines Front and left side (A) 1. Rear lift bracket 2. Fuel filter 3. Air filter 4. Drain pump for the engine lubricating oil 5. Cooler for the engine lubricating oil 6. -
Page 16: Front And Right Side (B)
Chapter 2 TPD1327E 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. -
Page 17: Front And Left Side View (A)
TPD1327E Chapter 2 Location of engine parts - 6 cylinder turbocharged, intercooled engines Front and left side view (A) 1. Rear lift bracket 2. Fuel filter 3. Air filter 4. Drain pump for the engine lubricating oil 5. Cooler for the engine lubricating oil 6. -
Page 18: Front And Right Side View (B)
Chapter 2 TPD1327E 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. -
Page 19: Operation Instructions
TPD1327E Chapitre 4 Operation instructions How to start the engine Several factors affect engine start, for example: heat switch down for 10 seconds and engage the starter motor again. When the engine has started, • The power of the battery release the heat switch. -
Page 20: Adjustment Of The Engine Speed Range
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. -
Page 21: Preventive Maintenance
TPD1327E Chapter 4 Preventive maintenance Preventive maintenance periods These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the boat in which the engine is installed. If necessary, use the shorter periods. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. -
Page 22: Schedules
Chapter 4 TPD1327E Schedules The schedules which follow must be applied at the interval (hours or months) which occur first. A First service at 20/40 hours D Every 250 hours or 6 months B Every day or every 8 hours E Every 400 hours or 12 months C Every week Every 2000 hours or 2 years... -
Page 23: How To Fill The Coolant Circuit
TPD1327E Chapter 4 How to fill the coolant circuit Warning! • If coolant is to be added to the circuit during service, allow the engine to cool before the coolant is added. Remove the filler cap slowly as dangerous coolant could be discharged if the coolant is still hot and the system under pressure. -
Page 24: How To Drain The Coolant Circuit
Chapter 4 TPD1327E How to drain the coolant circuit Warnings! • Discard the used coolant in a safe place and in accordance with local regulations. • Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. -
Page 25: Engines Fitted With Keel Coolers
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 26: How To Check The Specific Gravity Of The Coolant
Chapter 4 TPD1327E How to check the specific gravity of the coolant For mixtures which contain inhibited ethylene glycol: 1. Ensure that the machine is on level ground. 2. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the coolant has circulated the cooling system. -
Page 27: How To Drain The Raw Water Circuit
TPD1327E Chapter 4 How to drain the raw water circuit Caution: The raw water system cannot be drained completely. If the system is drained for engine preservation purposes or for protection from frost, the system must be filled again with an approved antifreeze mixture. -
Page 28: How To Check The Drive Belt Of The Alternator
Chapter 4 TPD1327E How to check the drive belt of the alternator Note: The guard shown in (A) is for the four cylinder engine. Warning! All engines have a guard (A3) fitted to give protection from the alternator fan and the drive belt. Ensure that this guard is fitted before the engine is started. -
Page 29: How To Clean The Strainer For The Raw Water Pump (6Twgm Model)
TPD1327E Chapter 4 How to clean the strainer for the raw water pump (6TWGM model) The strainer for the raw water pump is fitted in the outlet hose for the raw water pump. The purpose of the strainer is to protect the air charge cooler from debris. -
Page 30: How To Check The Impeller Of The Raw Water Pump
Chapter 4 TPD1327E How to check the impeller of the raw water pump 1. Ensure that the seacock is closed. 2. Release the six screws (B1) which fasten the end plate of the raw water pump and remove the plate. When the end plate of the raw water pump is removed, some raw water will flow from the pump. -
Page 31: How To Clean The Gauze Strainer Of The Fuel Lift Pump
TPD1327E Chapter 4 How to clean the gauze strainer of the fuel lift pump 1. Remove the cover complete with the joint (A3) from the top of the fuel lift pump (A1) and remove the gauze strainer (A2). 2. Wash carefully all of the sediment from the lift pump body. -
Page 32: How To Renew The Canister Of The Fuel Filter
Cautions: • It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump. • Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. -
Page 33: How To Renew The Element Of The Fuel Pre-Filter
Cautions: • It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump. • Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. -
Page 34: Atomiser Fault
Chapter 4 TPD1327E Atomiser fault Warning! • If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. • Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while the engine runs. An atomiser fault can cause an engine misfire. -
Page 35: How To Renew An Atomiser
TPD1327E Chapter 4 How to renew an atomiser Cautions: • Atomisers must be removed and fitted by a person with the correct training. • Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. -
Page 36: How To Eliminate Air From The Fuel System
Chapter 4 TPD1327E How to eliminate air from the fuel system If air enters the fuel system, it must be removed before the engine can be started. Air can enter the system if: • The fuel tank is drained during normal operation. •... - Page 37 TPD1327E Chapter 4 6. Loosen the union nuts (A1) of the high-pressure pipes at two of the atomisers. Caution: Do not tighten the union nuts of the high- pressure pipes more than the recommended torque tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.
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Page 38: How To Renew The Lubricating Oil Of The Engine
Chapter 4 TPD1327E How to renew the lubricating oil of the engine Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations. Warning! All these engines are fitted with a ‘closed’ crankcase breather system. Any necessary oil additions to the sump must be carried out with the engine stationary. -
Page 39: How To Renew The Canisters Of The Lubricating Oil Filter
Caution: The canister contains a valve and special tube to ensure that lubricating oil does not drain from the filter. Therefore, ensure that the correct Perkins POWERPART canister is used. Page 33... -
Page 40: How To Renew The Engine Breather
Chapter 4 TPD1327E How to renew the engine breather 6TWGM and 4 cylinder engines (closed breather) Caution: Do not use excessive force to remove the hose (A4) from the breather outlet pipe. 1. Release the hose clip and carefully remove the hose from the breather outlet. -
Page 41: Air Filter
TPD1327E Chapter 4 Air filter Environmental conditions have an important effect on the frequency at which the air filter needs service. The air filter has a dust bowl (A1) or (B1) which must be cleaned. Do not allow dust to fill the bowl, because this will reduce the life of the filter element (A3) or (B3). -
Page 42: How To Clean The Air Filter (6Twgm Model)
Chapter 4 TPD1327E How to clean the air filter (6TWGM model) 1. Release the clip (A4) at the turbocharger and the bracket which supports the air filter and remove the air filter. 2. Release the clip (A3) and remove the adaptor (A5). -
Page 43: Restriction Indicator
TPD1327E Chapter 4 Restriction indicator The restriction indicator is fitted on the air filter outlet or between the air filter and the induction manifold. When the red warning indicator (A1) is seen through the clear panel (A2) after the engine has stopped, the air filter element must be removed for service. -
Page 44: How To Check The Valve Tip Clearances
Chapter 4 TPD1327E How to check the valve tip clearances These are checked between the top of the valve stem and the rocker lever (A), with the engine hot or cold. The correct clearance for inlet valves is 0,20 mm (0.008 in) and 0,45 mm (0.018 in) for exhaust valves. -
Page 45: Six Cylinder Engines
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. -
Page 46: How To Check The Condition Of The Viscous Damper
Chapter 4 TPD1327E How to check the condition of the viscous damper 6 cylinder engines Caution: A viscous damper (A1) should be renewed if there is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. -
Page 47: Seacock Strainer
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: Wire, 20 SWG (1mm in diameter) - Page 48 Chapter 4 TPD1327E Page 42...
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Page 49: Engine Fluids Fuel Specification
TPD1327E Chapter 5 Engine fluids of the available fuel, consult your nearest Perkins distributor or one of the companies listed on page 6. Fuel specification To get the correct power and performance from your engine, use good quality fuel. The recommended... -
Page 50: Lubricating Oil Specification
Chapter 5 TPD1327E Lubricating oil specification Use only a good quality oil which is not less than the specification given below. Naturally aspirated engines should use ACEA E1 or API CD. They can also use ACEA E2 or API CF4, but not for the first 20 to 40 hours of operation or for light load applications. -
Page 51: Coolant Specification
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 52 Chapter 5 TPD1327E Page 46...
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Page 53: Fault Diagnosis
TPD1327E Chapter 6 Fault diagnosis Problems and possible causes Problem Possible causes Checks by the user Checks by the workshop personnel The starter motor turns the engine too 1, 2, 3, 4 slowly The engine does not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 32, 33, 34, 36, 37, 41, 42, 43 15, 17 The engine is difficult to start... -
Page 54: List Of Possible Causes
Chapter 6 TPD1327E List of possible causes 44. Valve stems and/or guides are worn. 45. Crankshaft bearings are worn or damaged. 1. Battery capacity low. 46. Lubricating oil pump is worn. 2. Bad electrical connections. 47. Relief valve does not close. 3. -
Page 55: Engine Preservation Introduction
TPD1327E Chapter 7 Engine preservation 8. Close the seacock and drain the raw water cooling system. Introduction Caution: The raw water system cannot be drained completely. If the system is drained for engine The recommendations indicated below are preservation purposes or for protection from frost, designed to prevent damage to the engine when it the system must be filled again with an approved is withdrawn from service for a prolonged period. - Page 56 If the engine protection is done correctly according to the above recommendations, no corrosion damage will normally occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.
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Page 57: Parts And Service Introduction
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. -
Page 58: Powerpart Recommended Consumable Products
To retain components which have an interference fit. given on the outside of each container. These Currently Loctite 638. Part number 21820638. products are available from your Perkins distributor. POWERPART Safety cleaner POWERPART Antifreeze General cleaner in an aerosol container. Part number Protects the cooling system against frost and 21820128. -
Page 59: General Data
Maximum capacity of lubricating oil sump: ........8,1 litres (14.25 UK pints) 8.5 US quarts Coolant capacity (closed circuit) ............18 litres (31.5 UK pints) 19 US quarts Weight (wet) - 4GM ............................448 Kg (988 lbs) - 4TGM ..........................455 Kg (1003 lbs) Battery ........................12V or 24V negative earth... -
Page 60: 6Tg2Am And 6Twgm Engines
Chapter 9 TPD1327E 6TG2AM and 6TWGM engines Number of cylinders............................6 Cylinder arrangement ......................... Vertical In line Cycle............................... Four stroke Induction system 6TG2AM ......................Turbocharged Induction system 6TWGM ................Turbocharged and Intercooled Combustion system ........................Direct injection Nominal bore ........................100 mm (3.937 in) Stroke .......................... -
Page 61: Electrical Diagrams
TPD1327E Chapter 10 Electrical diagrams Earth relay and resistors Page 55... - Page 62 Chapter 10 TPD1327E Page 56...
- Page 63 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 64 Wimborne Marine Power Centre subsequently. 22 Cobham Road, Part No. TPD 1327E issue 12 Ferndown Industrial Estate, Produced in England ©2013 by Wimborne Wimborne, Dorset, BH21 7PW, England. Marine Power Centre Tel: +44 (0)1202 796000, Fax: +44 (0)1202 796001 E-mail: Marine@Perkins.com Web: www.perkins.com/Marine...
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