FNM HPE 300 Owner's Manual
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FNM HPE 300 Owner's Manual

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OWNER'S
MANUAL
HPE 300

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Summary of Contents for FNM HPE 300

  • Page 1 OWNER’S MANUAL HPE 300...

  • Page 2: Table Of Contents

    Engine manufacturer’s indications _________________________________________________________________ 7 Safety rules & info ______________________________________________________________________________ 8 Residual risks __________________________________________________________________________________ 9 HPE 300 Engines general info and drawings: _______________________________________________________ 11 HPE 300 ANODES ______________________________________________________________________________ 12 HPE300 without cover top view ___________________________________________________________________ 12 Main engine components ________________________________________________________________________ 13...
  • Page 3 Lubricate or grease the joints, bearings and gears. __________________________________________________ 70 Every 200 hours or every 2 years _________________________________________________________________ 72 Engine winter maintenance ______________________________________________________________________ 72 Troubleshooting _______________________________________________________________________________ 73 Ordinary maintenance schedule __________________________________________________________________ 77 Winter Maintenance : ___________________________________________________________________________ 79 Engine maintenance operations summary table _____________________________________________________ 81 ENG rel. 1/11 www.fnm-marine.com...

  • Page 4: General Information

    The observance of the installation procedures THE FNM SERVICE NETWORK and routine maintenance contained in this manual The FNM® service points offer low costs and a high installation manual*, ensures degree of specialization. They make sure that your...
  • Page 5 CMD need to abide by new regulations or norms. The S.p.A (owner of the FNM® brand name and Engine Manufacturer declines any responsibility logo) from any responsibility.
  • Page 6 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Page in blank ENG rel. 1/11 www.fnm-marine.com...

  • Page 7: Engine Manufacturer's Indications

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Engine manufacturer’s indications The ID label is applied on the engine and on the ECU box as show in pictures below: ID LABEL ID label data are indicated in the picture below:...

  • Page 8: Safety Rules & Info

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Safety rules & info Read carefully the information contained in the manual and those applied to the engine in order to avoid unpleasant incidents. The manufacturer cannot be held responsible for any damage resulting from misuse of the engine ,from the failure to follow the indications contained in this manual and for every tampering with or change made without the manufacturer’...

  • Page 9: Residual Risks

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Do not start the engine without the air filter, the detachment of rotor parts of the compressor during operation could cause damage to persons, furthermore any aspirated particles could damage the blades. Avoid contact of hands with the rotor.
  • Page 10 Marine Diesel Engines ATTENTION! FNM ® is not responsible for damage caused by misuse of the engine and for non-compliance with the procedures issued and for damages caused by unauthorized personnel. Do not drive the boat if you consume alcohol or other substances that may alter your state of attention and reflexes.

  • Page 11: Hpe 300 Engines General Info And Drawings

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines HPE 300 Engines general info and drawings: EXHAUST RAISER TURBOCHARGER OIL FILLING CAP EXPANSION TANK STARTER ANODE 2 MAIN THERMOSTAT HOUSING SECONDARY AUXILIARY SERVCES THERMOSTAT HOUSING PULLEY OIL SUMP ALTERNATOR...

  • Page 12: Hpe 300 Anodes

    ’ WNER ANUAL HPE 300 Marine Diesel Engines HPE 300 Anodes On the engine there are n. 3 anodes positioned as follows: Water to water exchanger front cover. Exhaust manifold front cover (under the expansion tank) Intercooler rear cover The graphical identification of the elements on the engine can be found on the previous page.

  • Page 13: Main Engine Components

     Installation form Certificates HPE 300 engines are certified for CE directive 94/25/EC as amended by directive 2003/44/EC for exhaust emissions (SYSTEMS WITH AND WITHOUT INTEGRATED EXHAUST): Standard reference EN ISO 8178-1 Reciprocating internal combustion engines, EXHAUST EMISSION MEASUREMENT. HPE 300 engines are certified for noise emissions: Standard reference ISO 14509 Small Craft Measurement of airborne SOUND EMITTED by powered recreational craft.
  • Page 14 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Fuel introduction cap (on the tank, if Risk of burns, presence of parts at high present) temperature Lubricating oil introduction cap. Risk of fire, presence of fuel Risk of impact and hooking to moving...

  • Page 15: Hpe 300 Stern Drive Version Installation Drawings

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines HPE 300 stern drive version installation drawings  Raiser outer diameter 90 mm  Sea water inlet pipe to the engine outer diameter 32 mm  Fuel line: (inlet outlet) rubber hoses inner diameter 8 mm ENG rel.

  • Page 16: Engine Data

    Engine oil type Only with this oil the engine service intervals are guarantee. -Avoid mixing different types of oil. If you don’t find FNM lubricant oil, use oil with the same specifications Starts opening at 80°C ± 1.5°C, fully open at 85°C Thermostatic valves Starts opening at 65°C ±...

  • Page 17: Sea Water Circuit Crossing Order

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Sea water circuit crossing order Pump suction side. Intercooler crossing (1 passage) Water to water exchanger crossing (2 passages) Fuel exchanger or fuel/steering oil exchanger crossing (1 passage) Heat exchanger integrated into exhaust manifold crossing (2 passages) Overboard discharge through the riser.

  • Page 18: Engine Delivery

    The instrument panel and connection cable must be integral.  Check for any fluids leaks. ATTENTION! At the time of shipment engines are bench tested and packaged according to internal specifications. FNM® is not responsible for damages caused by the carrier/transport company. ENG rel. 1/11 www.fnm-marine.com...

  • Page 19: Engine Lifting

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Engine lifting The engine lifting hooks are engineered only to lift the engine without any additional weights! When you install the engine on your boat and open the engine package, lift it using all 3 lifting points as shown in the figure.

  • Page 20: Engine Maintenance Indications (When Installed On Board)

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Engine maintenance indications (when installed on board) Below you find some indications to guarantee engine long life and to prevent hazards: Take care to maintain the engine room dry and well aerated. Residual water in bilge could vaporize and condensate on the engine, vapor created in this process damages the protection varnish.

  • Page 21: Engine Maintenance Information (Out Of Board Before Installation)

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Discharge the sea water circuit by draining through the zinc anodes if the engine isn’t utilized for a long time and if exposed to high temperature. Take care, avoid short-circuits. The short circuit can cause damage to people and engine parts.

  • Page 22: Stop The Engine

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Check the belts and tighteners status. Check all the engine levels and verify that they are correct, verify the fuel level in the tank (use only clean tank). Turn ON the red button on ECU box and verify that all the LEDs are lighted.
  • Page 23 Check the fuel tank for dirt or deposits, if necessary clean it**. **INFO: During the end of season or before the engine storage ,if possible, add an injector cleaning additive to the fuel and take care to leave the tank empty after the treatment and cleaning. FNM advises Bardahl injector cleaner.
  • Page 24 Store the engine in a well aerated place avoiding humidity and steam to prevent rust forming. For long storage of fuel in tank, FNM® advises to use Bardahl® DAB additive or IOSSO® Diesel fuel antibacterial to prevent the proliferation of algae and deposits.
  • Page 25 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Check the integrity of the anodes. Verify and if is necessary grease: the starter pinion, (white grease for gears), and the turbocharger actuator leverages. Turn off the engine and check again the engine oil and coolant levels.

  • Page 26: Engine Treatment & Maintenance Products

    Engine treatment and maintenance products ATTENTION! For the engine maintenance products read and follow the instructions indicated by producers or turn to FNM service. Some products and use are linked to the operating temperatures. FNM advises BARDAHL oil and products Engine oil...

  • Page 27: Hpe / Hpel Engines Ecu Box

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines HPE / HPEL engines ECU BOX The ECU (Electronic Control Unit) BOX contains the electronic control unit of the engine, the electric connections and relays, the red stop button, the Amphenol® plugs for the engine wiring, the fuses pilot lamps.

  • Page 28: Fuses & Relays

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Fuses & Relays The ECU box is equipped with a LED indicators panel to indicate the fuses integrity status. The fuses are on the connectors of the circuit in order to make the replacement procedure easier. In...

  • Page 29: Tightening Torques

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Tightening torques Tightening torques for threaded junctions, which should be tightened with torques different than those indicated in the table are indicated near the related pictures. The tightening torque refers to lightly oiled or dry surfaces. For all the junctions where no tightening torque is indicated refer to the table below.

  • Page 30: Instrument Panel

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Instrument panel Oil pressure meter REV Counter Coolant temp. meter Fuse Instrument light Voltmeter Ignition block Coolant high Generator light Glow plugs light Oil pressure light temperature light Accessories pilot lamps Injection–general engine failure...
  • Page 31 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Indicators  Oil pressure meter: indicates the measure of the engine oil pressure (bar). The indication of the oil pressure works only when the engine is running and it indicates the current pressure. When the engine is on, the oil pressure is usually somewhere between 2 and 6 bar.

  • Page 32: Ignition Block Functioning

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Ignition block functioning STEP 1 Check the engine preheating lights: When turning the key in position (I) the generator light and the oil pressure light are ON the alarm buzzer is ON.

  • Page 33: Accessory Indicator Lights

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Accessory indicator lights LIGHT PROBABLE CAUSE POSSIBLE REMEDY  Problem on injection system  Diagnosis  General failure ECU malfunction  Delete the ECU errors  Engine over heating ...

  • Page 34: Instrument Panel Electrical Scheme

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Instrument panel electrical scheme ENG rel. 1/11 www.fnm-marine.com...
  • Page 35 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Engine cable pin out ENG rel. 1/11 www.fnm-marine.com...
  • Page 36 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Engine cable Synoptic scheme FUSES & OEBD Diagnosis plug RELAYS EMERGENCY STOP BUTTON SENSORS ENGINE HPE INJECTORS ECU BOX Fuse ALTERNATOR STARTER GLOW PLUG MODULE BATTERY PANEL ENG rel. 1/11...

  • Page 37: Diagnosis

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Diagnosis HPE engines are equipped with a plug for electronic diagnosis connection. Refer only to FNM service points to make engine diagnosis EOBD Diagnosis plug ENG rel. 1/11 www.fnm-marine.com...

  • Page 38: Electronic Throttle Station

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Electronic throttle station The station allows commanding the boat from different positions shown in the figure. Each control station is prearranged to control one or two engines. The single lever repeats the functionality of a mechanical single lever.
  • Page 39 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Here following is the table with the definition of LEDs and push buttons: Push-button Meaning (Command) (Signalling) If the LED is on, the corresponding propulsion engine is Engine idle. If it is OFF the Station does not command the system.
  • Page 40 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Synchro mode operation IMPORTANT: This function is available only for two-engine systems. It is possible to command both engines at the same speed and direction with only one lever. With both levers in neutral position, press the Engine buttons at the same time for 3 seconds. The command of both engines is now on the right lever.

  • Page 41: Mechanical Remote Control

    General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Mechanical remote control The safety system, where installed, does not allow starting the engine with the gear engaged. The purpose of this is to avoid inadvertently starting the engine with propeller spinning causing damage to people in the water.
  • Page 42 General Information ’ WNER ANUAL HPE 300 Marine Diesel Engines Console mounted type ENG rel. 1/11 www.fnm-marine.com...

  • Page 43: Gearboxes Data (Oil Type And Quantity)

    ATTENTION! Do not work on the gearbox if the boat is moored or anchored in a river because the propeller may rotate. Engine requirements ENGINE ROOM Flow of comburent air HPE 300 > 4.5 cubic m/min Static depression < 0.1 kPa Admitted increment of temperature in the engine room 15°C...

  • Page 44: Installation Form

    Marine Diesel Engines Installation form To ensure long life to the engine and transmission unit carry out the installation at a specialized FNM service center. The installation requires in occasion of the first boat and engine test in the sea, that the installation form is complied by the installer or the owner and sent to the engine manufacturer.

  • Page 45: Engine Maintenance

    -Avoid mixing different types of oil, because in these conditions, the maintenance intervals will not be truthful. -In case you are not able to find the FNM oil , make sure you use oil with the same characteristics and specifications (ACEA E3/API CF4/MIL L 2I04E/F), SAE 5W40 totally synthetic.
  • Page 46 C-If the oil is at level C or lower than that, then you must refill up to level A if possible, in any case the level must be equal to or greater than B. The oil level must never exceed level mark A. 4. Refill oil through the oil refill cap as shown in the figure. ENG rel. 1/11 www.fnm-marine.com...

  • Page 47: Check The Coolant Level

    To verify the coolant liquid level take care to the boat and/or engine inclination. -The correct level is between the minimum and maximum reference. -The refilling is done through the cap on expansion tank. -Fill-up to the maximum level indicated in the figure. Do not exceed this level. ENG rel. 1/11 www.fnm-marine.com...
  • Page 48 ATTENTION! Always read the coolant manufacturer instructions according to the temperature. Never refill the coolant circuit with sea water! ATTENTION! Be careful when you open the filler cap of the expansion tank, pressurized liquid may splash out CAUSING DAMAGE TO PERSONS OR PROPERTY. ENG rel. 1/11 www.fnm-marine.com...

  • Page 49: Clean The Sea Water Filter

    2) Clean or wash the filter with fresh water to remove the clogging elements. 3) Reclose the filter and check for any leaks. Verify oil level The following instruction is only explicative, in any case read the manufacturer’s instructions. ENG rel. 1/11 www.fnm-marine.com...

  • Page 50: Hpe Engine Gearbox Version, Verify The Transmission Oil Level

    Keep the oil level close to the FULL line on the tank during operation. If you see traces of water or the liquid is dirty or with different color contact the nearest service center. ENG rel. 1/11 www.fnm-marine.com...
  • Page 51 HPEP engine Stern drive version, verify steering oil level 1) Check the oil level by the marks on the tank. 2) Level should be maintained within the MIN. and MAX. levels. 3) Fill as necessary with the specified fluid. 4) Reposition the cap. ENG rel. 1/11 www.fnm-marine.com...

  • Page 52: Weekly Maintenance

    Dark color, charge level below 65%. Recharge immediately Yellow color: Replace the battery ATTENTION! The data are for information, always read the producer’s instructions. ATTENTION! Never try to refill with any type of fluid with this type of battery. Traditional lead-acid batteries ENG rel. 1/11 www.fnm-marine.com...
  • Page 53 ATTENTION ! Avoid discharging excessively the batteries. ATTENTION ! Battery state of charge could influence the engine performance. >Grease the battery poles with basic grease periodically. >The battery electrolyte status can be measured with a manual densimeter. ENG rel. 1/11 www.fnm-marine.com...

  • Page 54: Maintenance After First 50 Hours And Every 2 Months

    Unscrew the drain cap under the filter ad wait that fuel comes out. Close when you notice that the fuel is clean and free of impurities or contamination of water. The fuels such as waste oils are highly polluting. Respect the environment. ENG rel. 1/11 www.fnm-marine.com...

  • Page 55: Zinc Anodes

    3. Replace the anodes if the sacrificial part is consumed over the 50% and replace the copper washer when retightening the anodes using thread sealant type LOXEAL 1810. 4. Open the sea water circuit and verify for leaks. ENG rel. 1/11 www.fnm-marine.com...

  • Page 56: Verify The Belts Status

    For the timing belt NOTE: The engine is equipped with a timing chain; maintenance is not necessary during its ordinary life. GUARD Timing chain ATTENTION ! For the timing belt check and replacement refer to a specialized service center. ENG rel. 1/11 www.fnm-marine.com...

  • Page 57: Air Filter

    Take care when operating on belts Air filter The air filter integrity and cleaning is important for the engine life and performances. FNM® engine series air filters are developed for marine applications The filter has only the function to prevent the entrance of...
  • Page 58 Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines 7. Open the sea water intake valve. 8. Start the engine and check for any leaks . ATTENTION ! Use only original FNM spare parts. ENG rel. 1/11 www.fnm-marine.com...

  • Page 59: Every 200 Hours Or Once Every Year

    2. Let the engine cool down adequately for at least 20 minutes, to help oil flowing in the sump. 3. Prepare a tank of proper capacity to collect exhaust oil. 4. Connect a hose to the exhaust valve placed in position A. ENG rel. 1/11 www.fnm-marine.com...

  • Page 60: Oil Filter Replacement

    Refill the engine with new oil up to proper level. Turn the engine ON and leave it running at minimum RPM(idle) for few minutes till it reaches the working temperature. Increase the speed until reaching the maximum and check the oil pressure level. ENG rel. 1/11 www.fnm-marine.com...

  • Page 61: Fuel Filter Replacement

    In any case you should run the engine with fresh water for at least 5 minutes every 50 hours, in order to prevent the accumulation of salt deposits in the cooling circuits related to the sea water section. ENG rel. 1/11 www.fnm-marine.com...
  • Page 62 3. Drain the coolant circuit and remove the coolant pipes. 4. Remove the water/water heat exchanger from its support (there are 4 M8 screws at the bottom) 5. Remove the caps of the exchanger (one nut on threaded bolt M16) ENG rel. 1/11 www.fnm-marine.com...
  • Page 63 Pull off the tube bundle: Pay attention to the fins during the tube bundle dismounting operations, to not affect the exchanger performances. 6. Clean inside the tubes with a cleaning brush, remove any salt incrustations and wash with fresh water. ENG rel. 1/11 www.fnm-marine.com...

  • Page 64: Lubricate Or Grease The Joints, Bearings And Gears

    The pinion of the starter must be greased with grease for gears. During engine operation grease is expelled from the pinion, we suggest that you grease the pinion periodically. 1. Unscrew the mounting screws and disconnect the electrical connections of the starter. ENG rel. 1/11 www.fnm-marine.com...
  • Page 65 3. Clean the pinion with a clean cloth or paper and grease again. 4. Reassemble the starter and electrical connections. ATTENTION ! In any case we suggest referring always to a FNM service center to perform these operations. Joints and splines greasing.

  • Page 66: Every 200 Hours Or Every 2 Years

    Drain the fuel filter; bleed air from fuel supply line. Check the belts tension and status Connect and verify the electrical system. Verify the battery charge status. Inspect, grease, and check the alignment and turbocharger levers. Check the coolant level ENG rel. 1/11 www.fnm-marine.com...

  • Page 67: Troubleshooting

    Intake air filter clogged . Clean/replace Check fuel. Drain and flush fuel tank. Replace with new Wrong fuel quality or contaminated fuel. fuel. Faulty glow plugs. Check / replace. Incorrect lube oil SAE class or quality for ambient Replace. temperature. ENG rel. 1/11 www.fnm-marine.com...
  • Page 68 Motor becomes apparently overheated as a result of faulty temperature Check / replace. switch, sensor or meter. Faulty thermostat . Check / replace. Faulty coolant pump Check/clean. Faulty oil filter/dirty oil exchanger. Replace. Faulty turbo compressor. Check /replace ENG rel. 1/11 www.fnm-marine.com...
  • Page 69 Engine overloaded, max. rpm is not reached. Check sizes of propeller and/or boat weight. Engine overloaded, dirty propeller -boat hull, excessive Check and clean if required. load on-board. Turbocharger actuator blocked Unblock / replace. Faulty turbo compressor. Check / replace. ENG rel. 1/11 www.fnm-marine.com...
  • Page 70 Burnt oil trace in exhaust line . Possible fault Remedy Oil level too high . Check . Faulty turbocharger . Check, Repair / Replace . Excessive wear of cylinder / piston, piston rings. Check compression; refurbish engine. ENG rel. 1/11 www.fnm-marine.com...
  • Page 71 Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines RDINARY MAINTENANCE FORM Hours Date Stamp of assistance point Signature First 50 First 200 ENG rel. 1/11 www.fnm-marine.com...
  • Page 72 Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines RDINARY MAINTENANCE FORM Hours Date Stamp of assistance point Signature ENG rel. 1/11 www.fnm-marine.com...

  • Page 73: Winter Maintenance

    Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines INTER AINTENANCE Hours Date Stamp of assistance point Signature First winterizing ENG rel. 1/11 www.fnm-marine.com...
  • Page 74 NOTES ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………. PRODUCED & PRINTED by CMD IN ATELLA (PZ) ITALY DATE: March 2011 Revision Date Description 1/11 28-03-11 First issue ENG rel. 1/11 www.fnm-marine.com...

  • Page 75: Engine Maintenance Operations Summary Table

    By owner By Service Timing/auxiliary belts replacement. Replace the coolant liquid. Check the engine –propulsion alignment. Check for any leaks on the engine circuit. Check the flexible coupler status. Check the engine battery status (replace if necessary). ENG rel. 1/11 www.fnm-marine.com...
  • Page 76 Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines Wema Panel connection cable Wema panel pinout ENG rel. 1/11 www.fnm-marine.com...
  • Page 77 Engine maintenance ’ WNER ANUAL HPE300 Marine Diesel Engines ENG rel. 1/11 www.fnm-marine.com...
  • Page 78 www.fnm-marine.com...

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