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Installation Manual

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1. 10 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold start a quantity of 2 off 12V 340 Amps to BS3911 or 2 off 12V 540 amps to SAE J537 Page 88 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 Perkins seem SABRE ENGINES LTD Wimborne Dorset England BH21 7PW Tel 44 0 1202 893720 Fax 44 0 1202 851700 E mail post sabre engines co uk www perkins sabre com
2. 25 from horizontal in any direction Oil pressure in operating speed range steady state 250kPa 36 psi Low oil pressure switch setting 83kPa 12 psi Electrical System Generatot 100A 12V 55A 24V S 12V 4 0kW Number of teeth in flywheel 126 Number of teeth on starter u a 10 Cold Start Limits Minimum cold start temperature with aid 150C 50F Batteries for min cold 1 x 12 volt 660 Amp SAE Page 80 Data 4 4TWGM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical TERN 101 hp is 82 7kW 111 hp Number of cyllnders coi 4 Cylinder arrangement u e In line er E 4 stroke Induction system see Turbocharged aftercooled lm aces 100mm 3 9377 igo ET 127mm 5 007 Compression ratio 19 3 1 Cubic capacity e 4 4 litres 19 3 in3 Valves per cylinder 2 Direction of rotation Anti clockwise viewed on flywheel
3. u uu Turbocharged BONG O 100mm 3 9377 igo ET 127mm 5 007 Compression ratio 16 1 Cubic capacity e 5 99 litres 365 0 in Valves per cylinder u 2 Direction of Anti clockwise viewed on flywheel Orde 1 5 3 6 2 4 Total weight wet 626 kg 1380 Ibs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 379C 34 6 F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow sss dee 123 I min 32 5 US galls min 150 I min 40 US galls min Coolant pump speed and method of drive 1 1 Gear driven System 24 litres 6 3 US galls Pressure cap Setting 50 kPa 7 psi Protection switch setting 96 2059F Sea water pump type Jabsco gear driven model 25 4mm 17 full cam Sea water suggested inlet hose diameter
4. 39 Definition of galvanic and electrolytic corrosion 39 Avoiding electrolytic COFTOSIOR inerenti ritenere ritenere 39 Zinc Anode bonding system 40 Battery and starter cables 40 Other electrical features 415GM 422GM amp 422TQGM 42 APECS calibration tool ACT part number 36204 44 Electronic governor OVEIVIGW 45 Electronic governor in detail u 46 Controller installation and wiring 46 Controller wiring table Me 47 eciam T 47 Other electrical features 700GM 48 APECS calibration tool ACT part number 36204 50 Electronic governor overview L 51 Electronic governor in detail U UL 52 Controller installation and wiring 52 Controller wiring table c 53 sus 53 Other electrical features 4GM 8 4 54 L Series e
5. uy 1 3 4 2 Total weight wet 522kg 1151 Ibs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 379C 34 69F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 145 l min 37 3 US galls min 171 l min 45 2 US galls min Coolant pump speed and method of drive 1 1 Gear driven System capacity 16 5 litres 4 4 US galls Pressure cap arii 50kPa 7 psi Protection switch setting 96 2059F Sea water pump type Jabsco gear driven model 25 4mm Sea water suggested inlet hose diameter 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 86 l min 22 7 US galls min 102 l min 26 9 US galls min
6. HOLIMS SM 1d MO 19 OL 313130 Y y uw VA B v 1A2 MO19 AVTIH ALNG P Q O MO19 142 MO19 P O O ly CEC Z142 MOTO Y CY Ne x 1A9 MO19 9 Yad 9 05 QvO1 MO19 aaridans OSIY 38V Q3 VIA SWALI TVNOLLIQOV AHL 9315193945 SI GALVINSNI 383HAM AHL HLIAA Q3r1adns 431 5 Page 43 Chapter 6 N38143 APECS calibration tool ACT part number 36204 Refer to the figure C for setting up the ACT for APECS calibration The ACT software can be run from the 3 5 floppy disk supplied with the kit You can also install the ACT software on your personal computer please refer to the APECS 3000 user s manual SE 3872 Note The APECS unit must be powered up but need not be mounted on the engine to carry out the calibration procedure Computer Controller Red 1 Black J o White WhUBIk Blue Green J MODEL 3100 Violet Speed Select 1 Programmable Engine Controller Gray Speed Select 2 For Magnetic Pickup Yellow Tx ques Orange RX Tool a Maris aoa Cate ym La Connector N38143 Chapter 6 Electronic governor overview The engines are fitted with both mechanical and electronic governors The electronic governor controls the engine speed w
7. 60 C 140 F Maximum air temperature at engine inlet 52 126 F Ventilation maximum engine room depression u 125mm H O 5 in H O Minimum cross section of air duct per engine 103 2 16sq ins for hot climates 52 2 859 ins for temperate climates Exhaust Exhaust gas flow 4 13m3 min 146ft3 min 5 01m3 min 177ft3 min Maximum restriction measured within 305 mm 12 outlet 10 21kPa 3 0 Hg Recommended pipe bore wet exhaust 63 5mm 2 57 Recommended pipe bore dry 50mm 2 0 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating AP1 CH4 ACEA E5 Sump capacity maximum 10 6 litres 2 7 US galls min Normal operating angles 25 continuously at all angles Oil pressure in operating speed range steady 200kPa 29psi Low oil pressure switch setting 80kPa 12psi Electrical System OGeneral f e 55A 12V cid E E E T 12
8. REMOTE CONTACTS E REMOTE CONTACTS p FOR GENERATOR FOR GENERATOR SPARE RUN SHUTDOWN m GREEN RUN LAMP TEST GENERATORRUN RED GVE in Wi O L SERIES GOVERNOR FAILURE ALARM ALARM GENERATOR NUT SHUTDOWN RUN RELAY RELAY WARNING LAMP RELAY f E 3 2 2o E Te 1 ro EE 12 134 Po e Qe gt ali aji 20 21 Eo e O6 L 42 8 al a T m ALARM LAMP 150R a PED AUDIBLE ALARM P MUTE TEST o AUDIBLE 8 3 ALARM D J E FIT LNK FOR 12 1 iE FIT LINK FOR 24V x x 8 8 m m 5 h YELLOW u Muro 43 i SENDER x COOLANT Tete SENDER 0 59 s A CRM MUTE ALARM MUTE z EESTI ALARM MUTE z BLACK sS 0 5 V 5A FAST g 5 ACTING FUSE z Oo z i 9 WE A I DC CIRCUIT FROM z BREAKER 10A BATTERY BATTERY z ISOLATOR SWITCH 8 9 5 amp amp a 4 START E im amp RELAY h 8 ii 2 GLOW PLUG HEAVY AMBIENT 5 DUTY RELAY L TEMPERATURE E swrcH I E GLOWPLUG MOMENTARY E EARTH RELAY z E 8 8 0 55 56555 5 ol olo g VE CIRCUIT o x x x x 54 57 5 3 5 5 2020202 BREAKER 804 vE COOLANT a STARTER ALTERNATOR F EBOM TEMP
9. 39 5kW 53 46 5kW 62 3 hp Number of Cylinders u ul 4 Cylinder arrangement u e In line e 4 stroke Induction system a Naturally Aspirated l c 100 mm 3 937 EE 127 mm 5 007 Compression ratio 16 1 Cubic capacity e ieri 3 99 litres 243 0 in3 Valves per cylinder uu 2 Direction of rotation Anti clockwise viewed on flywheel 1 3 4 2 Total weight wet 449 kg 990 Ibs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 379C 34 69F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 80 l min 21 US galls min 97 l min 25 6 US galls min Coolant pump speed and method of drive 1 25 1 ratio belt driven System capacity 18 litres 4 8 US galls Pressure cap 50 kPa 7 psi Protection switch
10. 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water tn 71 l min 18 8 US galls min 91 l min 24 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number u u u 45 minimum Fuel injection pump Stanadyne rotary and electric stop Energised to run Fuel lift AC Delco type LU Delivery hour sss 122 l hr 32 US galls min 134 I hr 35 US galls min 30 kPa 4 4 PSI Page 85 Governor Ypo e Mechanical Pipe size Supply Outside diameter 7 9mm 0 315 Supply Boe te dent Rt 6 53mm 0 257 Return Outside 6 3mm 0 257 BOG uu 4 93mm 0 194 Maximum lift pump lift 1 8m 6 ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 23 6 I hr 6 2 US galls
11. Chapter 3 N38143 In some cases it is necessary to have a number of fuel tanks in order to achieve the required operating range In such cases where possible one tank should be regarded as the main tank for each engine and the other tanks should be arranged so that they will drain into the main tank by gravity If a gravity system is not possible then the system shown in figure C should be used Figure C shows a collector tank C1 fed by all the storage tanks C2 and connected to the engine feed and return systems but with a vent pipe C3 taken to any convenient tank and connected to it at the highest point The fuel feeds C5 should be taken from the bottom of the collector tank and the fuel returns C6 at the top A water separator C4 should be installed which should suit the total flow for all the installed engines There is no doubt however that a simple fuel system as illustrated in Figure A or B should be used wherever possible as having a completely separate tank and supply to each engine guarantees that if an engine stops due to running out of fuel or to water or foreign matter in the fuel the other engine will not be affected simultaneously This will give some time for appropriate manoeuvring action to be taken The simple system will also require the minimum number of valves and fittings which ensures maximum reliability in service Page 14 N38143 Chapter 4 Raw water systems A completely separate sea
12. Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US galls min Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady 310 to 390kPa 45 to 57psi Low oil pressure switch setting 83kPa 12 psi Electrical System Generator Sauna ss Prestolite AS128 90A 24V or 55A 12V Starter type od pe Prestolite S115 Number of teeth in 126 Number of teeth on starter u 10 Cold Start Limits Minimum cold start temperature with aid 15C 5F Batteries for min cold starta qty of 2 12V 315 Amps to BS3911 or 2 off 12V 535 amps to SAE J537 Page 74 Data 4TGM 1500 rev min 1800 rev min Basic Technical Data Prime tena 68 5kW 91 9hp 80 5kW 108hp Number of cylinders ceno 4 Cylinder arrangement u In line er E 4 stroke Induction system u uu Turbocharged BONG O 100mm 3 9377 igo
13. Ul u u 2 Direction of rotation Anti clockwise viewed on flywheel P 1 5 3 6 2 4 Total weight wet 659kg 1450lbs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 34 6 F 5096 inhibited ethylene glycol or 50 inhibited propylene glycol with 5096 fresh clean water Fresh water flow 140 l min 37 US galls min 172 l min 45 US galls min Coolant pump speed and method of drive 1 1 Gear driven System capacity cie se dL Das 24 litres 6 3 US galls Pressure setting u 50 kPa 7 psi Protection switch setting sess 96 2059F Sea water pump type Jabsco gear driven model 25 4 mm 17 full cam Sea water suggested inlet hose diameter 32mm 1 25 DOA COCK iini tenu Full flow 25 4mm 1 00 max lift of seawater pump 2m Full flow 38 1mm 1 25 max lift of seawater pump 4m Siae ecceri A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature
14. Chapter 4 N38143 12 Check coolant level in the sight glass S1 Warning Hot coolant is under pressure and can cause severe burns when removing the pressure cap First release the pressure in the system by loosening the pressure cap 13 Top up with 5096 antifreeze to maximum level T1 Page 34 N38143 Chapter 5 Power take off not optional on the 415GM 422GM amp 422 Belt drives 4 4GM 4 4TGM 4 4TWGM and 4 4TW2GM only Standard options are Fenner 5 A section pulley with three grooves A1 and taper lock A2 or AFenner 5 B section pulley with two grooves and taper locks A4 In this case the maximum power which can be taken will be limited by the belts and it will be necessary to calculate for marginal applications Caution Additional inertia must not be added to the P T O shaft without specialist advice Consult your distributor if you need advice about non standard drive arrangements 2 36 ins 60mm 4 426 Page 35 Chapter 5 i N38143 Belt drives 700GM only Standard options are An A section pulley with three grooves B1 at 195mm 7 7ins diameter or An A section pulley with one groove B2 at 143mm 5 6ins diameter In this case the maximum power which can be taken will be limited by the belts and it will be necessary to calculate for marginal applications Caution Additional inertia must not be added to the P T O without speci
15. GALLI dJNISN3 JHL AO LNOYS 3H1 LV MNVL H3QOV3H OL 3HV NMOHS SHOLSIS3MH JHL AN3OVfQOV H3JAOO 3H1 GALNNOW SI AVT3H V aariddns e SI 3 3 58 98 9 Cc HINV3 JHL AV 138 3ALLVO3N d WILSAS 1OHLNOO lt s B 9 o 0 5 2 A 1YYLSONWYJHL gt G 9 2 Z 1901982 ON LYVd EE o sc HOLSIS3M E 3NION3 OL HLHV3 o Q u G Fem x Note The engine speed controller is mechanical and contains the adjustment screws to set the engine speed for the 6TG2AM Page 60 Chapter 6 N38143 Other electrical features 6TWGM 3 Wiring loom derived from document number 98 1178 LYVLS V ONINNG aarivsado SNI38 SI LYVLSOWYSAHL NAHM Ld3SX3 SAWIL 11 LV Q3NIV LNIVIN 38 OL 545 43 NV 10 ALISO3 LNI MOTIV OL SI SIHL HO ASOduYNd JHL HNION3 JHL HLIM 93119905 SI AV T38 V IN31SAS LYVLSOWYSHL OL eo ANCT38 SALLVO3N SV 91535 NI G33lAA 38 5 YOLSISSY JHL aaiao3ds SOIHLIO3I3 Ave S3NION3 JHL H LIM GaliddNs SI 5 53 JHL LYVLSOWYSHL ACL Lo x 3 3NISN3 OL H1V3
16. V6LEE ON LYVd 3H8vs YOLSISSY Page 61 Chapter 6 N38143 Electronic governor To set the engine speed 1 Ensure that the speed control lever I3 on the fuel injection pump is held in the fixed position and that adjustment screws are both locked 2 Set the screw 12 to position 30 on the dial Note The settings on the dial are in increments of 10 3 Turn the adjustment screw 11 for the engine speed in a counter clockwise direction 20 complete turns Then turn the screw in a clockwise direction 5 complete turns 4 Start the engine and allow it to reach its normal temperature of operation Initially the engine speed will be low To increase the speed of the engine gradually turn the speed adjustment screw I1 in a clockwise direction until the correct engine speed is obtained Note As load is applied to or removed from the engine the engine speed will be electronically governed to within 0 25 If this does not happen further adjustments will be necessary 5 If the time taken is too long for the engine to return to its correct speed turn the adjustment screw 12 gradually in a clockwise direction to a position just above 30 on the dial 6 Apply aload to the engine and check thatthe speed and governing are correct If necessary repeat operation 7 If the time taken is too quick and the engine is erratic turn the adjustment screw 12 gradually in a counter clockwise direction to a position just below 30 on th
17. s SUPPLY e ee ee 6 53mm 0 257 Return Outside 6 3mm 0 257 e En eee ede 4 93mm 0 194 Maximum lift pump lift 1 8m 6 ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 24 6 l hr 6 5 US galls hr 27 7 Vhr 7 3 US galls hr Air Intake Combustion airflow 7 9m min 279 ft min 9 9m min 350 ft min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression 125mm H O 5 in H O Suggested ventilation airflow including combustion air u uuu u uses 31m min 1095 ft min Minimum cross section of air duct per 461 cm 71 5 sq ins for hot climates 231 cm 35 8 sq ins for temperate climates Exhaust Exhaust gas flow 19 5m min 689 ft min 24 3m min 858 ft min Maximum restriction measured within 305 mm 12 outlets asas 15kPa 4 4 Hg Recommended pipe bore wet exhaust 100mm 4 0 Recommended pipe bore dry 76 2
18. 1 00mm 47 N38143 Chapter 6 Other electrical features 700GM Wiring loom derived from document number 5153 1 02 GASIOYANA SI LINN SIH L CN O m t 149 9frld MOTO 149 9N1d AO19 AV 133 ALNG AAV3H 1 AO19 HOLIMS LAVIS 3NION3 OL Z149 9N1d O C O 0 4 G O L 1A9 9d MOTO V00L GVO1 WLOL 9NId MO19 sawas M3TIOH1NOO 3NION3 XH 39NV3O 318VWIAVHOOMSHd TOOL 39IAN3S LMOTBA 001 SO3dV lHVIS OHHONAS NOILVH3dO 389 Wd 0081 ZH09 HOS TOI A389 MOW1E NIT Nd 0091 ZHOS 13701A MOVIE XNI1 N33H9 ama OILANOVW MOV1E ALIHM HOLIMS N3dO 3NISN3 015 OL YOLVNLOV ALIHM Waldv GALYVLS 38 AINO NVO 3NION3 HOLIAS LINDYIO 3NION3 OL 3ovi18 TN e 33 1HOF1 WHviv 38n1vsladWa 131 OL HOLIMS AONVS 3 TIO OL OIM HOLIANS 9 43aN3S JYNSSJYd G3NISNOO LHOM Ws3V TV 0553 110 MOT OL 3 IN 39nvo aunssasd 110 OL 9 OL HOLIMS AM HOLIMS H3QN3S AYNSSAYd Q3NISINOO HO NOLLVOIALLN3GI TVNIIA H3 L Page 48 Chapter 6 N38143 20 L SIS ON 90q 3NION3 dO SNILNVIS S9fYld MOTO 30 NOILVH3dO ONINNG 3NION3 dO
19. 25 4mm 1 007 Dea COCK Full flow 25 4mm 1 007 max lift of seawater pump 2m Strainer i cs A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 31 9 l min 8 4 US galls min 40 1 l min 10 6 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number uu terere 45 minimum Fuel injection pump Cassette type inline pump with electronic governor Fuel mt pump emite denen eene iua Mechanical Governor type ete u Electronic Page 69 Pipe size Supply Outside 7 9mm 0 315 s Supply ce 6 53mm 0 257 Return Outside diameter 6 3mm 0 257 BORG teer ede 4 93 0 194 Maximum lift pump lift clean filter 0 8m 2 6ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 5 2 Vhr 1 4 US galls hr 6 2 I hr 1 6 US galls hr Air Intake Combustion airflow 1 46 m3 min 51 5ft3 min 1 76m3 min 62 ft3 min Maximum engine compartment air temperature
20. Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number l 45 minimum F el injection PUMP uiii eic rore reed a Delphi rotary Fuel lift aaqa Electric Delivery hour 120 150 I hr 31 7 US galls hr to 39 6 US galls hr Micro cR 30 75kPa 4 4 10 9 PSI typo umu m adn Ere tus L series electronic governor Page 81 Pipe size Supply Outside diameter 7 9mm 0 315 s Supply rete e etra ecc cae 6 53mm 0 257 Return Outside 6 3mm 0 257 BORG u e EP de 4 93 0 194 Maximum lift pump lift clean filter 17kPa at 1 7m using 8mm dia bore pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 18 6 l hr 4 9 US galls hr 22 I hr 5 8 US galls hr Air Intake Combustion ett dt 7 3 m min 258 9 4 m min 332 ft min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression u 125mm H O 5 in H O Minimum cross section of air duct per engine 3
21. maximum engine room depression 125mm H O Sin H O Minimum cross section of air duct per engine 626 cm 97 sq ins for hot climates 316 49 sq ins for temperate climates Exhaust Exhaust gas flow 27 8m min 800 ft min 33m min 950 ft min Maximum restriction measured within 305 mm 12 of turbocharger outlet 6kPa 1 26 Hg Recommended pipe bore wet exhaust 127mm 5 07 Recommended pipe bore dry 76 2mm 3 0 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US galls Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady state 300 to 340kPa 44 to 49 PSI Low oil pressure switch setting 83kPa 12 psi Electrical System Getierator teet cipue tuts Prestolite AS128 90A 12V or 55A 24V LY C Prestolite 5115 Number of teeth in flywheel 126 Number of teeth on
22. 9 AYVLNAWOW MOTIV OL 934014 VIA HOLIMS LYVLS Q 102 ANY HOLIMS LYVLS ANION OL IVNINON MZ 2 LHOM SNINHVM 3 3NION3 ONINNSVAW HO WNIWYAL H3 L3INOHOV L Sud v3 LIQO3IO YO S3Sn4 GALOALOYd 38 GINOHS SLIDOSIO TIY HNISN3 JHL 43 5 SLYVd ONISN 3A3HOS 21579 JHL SMOHS SIH L JON 4 AV T3H H18V3 NOILdO AV1SY 3A O O O NII SA3 AV T38 H398V13HL NO V9 SMVQ 1109 3H1 SV AV 133 3 3H1 3AIHG OL Q3N9SIS3Q SI AV 133 IOHLNOO JHL 59 9 Q9 A TINO SWALSAS GALVINSNI X04 qasn SAV T3H HLYVA 1896 Hed Il330VH8 AV Tat VIA NOILOANNOO Q3SN3S 3NIHOVW HOLVNH3LTV GNNOND ASIMYSHLO SWALSAS GALVINSNI AINO SWALSAS Od J AMALLVE OL Q3193103NNOO 38 OL 3 HOLIMS LYVLS AV 133 L8VIS YALYVLS 3 3 OL e E ele ES aaauvoassia 38 GINOHS SIHL N3H1 481 113 SI HOLVNH3L IV HL8V3 GALVINSNI NV NAHM 5331108 OL Page 49 Chapter 6 N38143 APECS calibration tool ACT part number 36204 Refer to the figure E for setting up the ACT for APECS calibration The ACT software can be run from the 3 5 floppy disk supplied with the kit You can also install
23. min Maximum restriction measured within 305 mm 12 outlet 15kPa 4 4 Hg Recommended pipe bore wet exhaust 76mm 3 0 Recommended pipe bore dry 57mm 2 25 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CG4 CH4 ACEA E3 E5 Sump capacity maximum 8 5 litres 2 2 US galls min Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady 250kPa 36 psi Low oil pressure switch setting 83kPa 12 psi Electrical System Generator cita 100A 12V 55A 24V cd m 12 volt 4 0 kW Number of teeth in flywheel 126 Number of teeth on starter 9 Cold Start Limits Minimum cold start temperature with aid 159C 59F Batteries for min cold 1 x 12 volt 660 Amp SAE Page 78 Data 4 4TGM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical 56 4 k
24. 159C 59F Batteries for min cold 1 x 12 volt 660 amp SAE Page 82 Data 4 4TW2GM 1500 rev min 1800 rev min Basic Technical Data Prime power 93 4kW 125 3 hp 106 8kW 143 hp Number of cylinders oir eiie aeternae tk donee un 4 Cylinder arrangement seen In line er 4 stroke Induction system sese Turbocharged Aftercooled 100mm 3 9377 igo EET 127mm 5 007 Compression ratio 19 3 1 Cubic capacity e irent 3 99 litres 243 in3 Valves per cylinder a 2 Direction of rotation Anti clockwise viewed on flywheel uy 1 3 4 2 Total weight wet 522kg 1151 Ibs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 34 6 F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 145 l min 37 3 US galls min 171 l min 45 2 US galls min Coolant pump
25. 24 7 N38143 Chapter 6 Controller wiring table Battery Red Black Actuator White White Black Speed signal input Magnetic pickup Blue Green 1500 50Hz 1800 60Hz Service tool Yellow Tx Orange Rx System wiring Resistance in the wiring due to inadequate wire gauge or excessive wire length will result in insufficient force from the actuator The table shows the recommended gauges and maximum lengths of wires Wire length is the total length used to connect the actuator to the controller and controller to the system power System wiring table AWG14 AWG16 AWG18 2 50mm 1 50mm 1 00mm 66ft 20m 33ft 10m 22ft 6 7m Page 53 N38143 Chapter 6 Other electrical features 4GM amp 4TGM NNY OL Q3SIOMN3N3 HOLIMS 3 o fe did IHd 140 669 L3Vd 3H8VS did JNAQVOINVLS 200 986 LYVd SNDIH3d SHHLI3 YOLSISSY TOYULNODS dOLS 3NION3 OL masi fo NAAOHS SV 953335 NI Q38IM 38 Q InOHS YOLSISAY AHL 521419919 Arve AHL lt LYVLS v ONINNG 31 8340 SNI38 Galdlo3ds SI LYVLSOWYSHL JHL N3HM 1d39X3 SINIL 17 LY Q3NIV LNIVIN 38 OL WALSAS NYNLAY GALVINSNI NY JO ALIMDALNI 3HL MOTI SI SIHL 40 3SOdwNd IHL SI NMOHS MOLSISSY JHL ANIONA JHL Q3riadns SI AV133 V N
26. 422TGM Figure B shows the connections Connections are both 32mm 1 25 inches 1 Connections 2 Flow 3 Keel cooler 4 Engine Page 19 Chapter 4 N38143 Keel cooling connections 700GM Figure C shows the connections and flow Connections sizes are both 38mm 1 5 inches Connections Flow Keel cooler Combined header tank and exhaust manifold Thermostat Engine Fresh water pump By pass O WD gt Page 20 N38143 Chapter 4 Keel cooling connections 4GM and 4TGM Figure D shows the connections and flow Connections sizes are both 38mm 1 5 inches 1 Connections 2 Flow 3 Keel cooler 4 Engine oil cooler 5 Fresh water pump 6 By pass 7 Engine 8 Thermostat 9 Exhaust manifold 10 Header tank Page 21 Chapter 4 N38143 Keel cooling connections 4 4GM and 4 4TGM These engines do not have a header tank as part of the engine package but have a remotely mounted ex pansion tank Figure E shows the connections and flow Connections sizes are both 38mm 1 5 inches Connections Flow Keel cooler Remote tank Fresh water pump Thermostat Engine Integral engine oil cooler Exhaust manifold IM4 4GM Page 22 N38143 Chapter 4 Keel cooling connections 4 4TWGM and 4 4TW2GM These engines require two keel coolers and do not have a header tank as part
27. 93 mm 0 194 Maximum lift pump lift 1 8m 6 ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127 mm 5 Hg Fuel consumption at full power 9 4 Ihr 2 5 US galls hr 13 6 I hr 3 6 US galls hr Air Intake Combustion airflow 2 64m min 93 ft min 3 19m min 112 ft3 min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depres SiON e 125mm H O 5 in H O Suggested ventilation airflow including combustion air 18 6m min 657ft in Minimum cross section of air duct per 6 200 cm 31 sq ins for hot climates A 103 16 sq ins for temperate climates Exhaust Exhaust gas flow 7 54 m min 266 ft min 9 09 m min 321 ft min Maximum restriction measured within 305 mm 12 outlet u u uu uuu aaa hua saqaaai 6 kPa 1 76 Hg Recommended pipe bore wet exhaust 76 2mm 3 07 Recommended pipe bore dry 60mm 2 36 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0
28. CONTACTS AUTO SIGNAL Ho RED ele RED L8C1 Le LSERIES E RELAY 3 PIN ARRANGEMENT ON L SERIES SPEED CONTROL Pin Function Comment L SERIES 24v SYSTEMS ONLY SPEED 1 tama voc input power Supply power see nate below 6 CONTROL i 2 TPS signal output Direct postion feedback output indication 24v IN 5 u aux Signal ground Ground for AUX inputs 2 x 10 3 z g S awcinput sms292 transmit Aux 3 and service tool input Raise Speed m amp 5 4 3 BROWN 20 gt 5 F 8 T input power ground Ground for the 12 24 V input power 5 RUBLON i sO Aucinput 4 RS232 receive Combination Aux 4 and service tool input RELAY 8 svout Power for extemal sensors 10m A max d Os 4O g s dct input Aux bias input a z 50 Relay driver output Status fault detection output 3 3 0760 a a Aucinput2 Aux2 input Lower speed PINK M 2 at pus MPU speed signal input PINK 42 Ignition input Ignition speed signal input a PIN ARRANGEMENT AS SHOWN ON THE CIRCUIT IS VEIWED AS 8 M LOOKING INTO THE L SERIES CONTROL E 3 E a 2 3 35 x EE a FUEL PUMP FUEL STOP COMBINED OIL START ADVANGE SOLENOID PRESSURE COCDANT SWITCH AND TEMPERATURE TEMPERATURE SENDER SENDER SWITCH gt THE WIRING IS MADE UP OF INDIVIDUAL MAGNETIC MAGNETIC CAB
29. an earth connection from a shore line When a shore line is in use the boat system should be protected from earth leakage by an earth leakage switch on shore but as additional safety there should be a switch on board the boat Caution This section on bonding covers a typical system and has been included for guidance purposes only It may not be appropriate for your boat As installations vary it is advised that specific recommendations from a specialist in the subject of electrolytic corrosion are obtained Zinc Anode bonding system a Electrolytic corrosion within the engine cooling system and transmission can be much reduced or eliminated by bonding the engine to a Zinc anode which is used to protect through the hull metal fittings and other metal components that are in contact with sea water The engine is fitted with a stud that may be used for this purpose The stud is identified by a label B shown below BOATBUILDER Use this stud to connect the O engine to the Zinc Anode system installed in the boat For further details see Installation Manual 7089 1 95 Battery and starter cables a Batteries There are two standards by which battery performance is commonly stated BS3911 uses the current which can be maintained for 60 seconds without the voltage of a nominal 12V battery dropping below 8 4 volts whilst at a temperature of 180C SAE J537 is similar except that the current is only maintained for 30 seconds and
30. from the engine and the other in the rear of the control box Page 58 N38143 Chapter 6 For the 4 4 range of engines supplied without a loom For the 4 4 range of engines supplied without a loom a connector is provided for the L Series speed controller This information derived from drawing 05 1257 3 A pinout of the L Series speed controller as viewed into the control connector is shown below H 6 Auxinput 47 RS 232 receive Combination Aux 4 and service tool input Power for external sensors 10mA max e Nmxmui Aximpu _ S 9 driver output Staus fautdelecionoupu Note Power supply must be connected directly from the associated battery to pin 1 via a 5A fast acting fuse Page 59 e d al e z 5 s dOLS 3NISN3 OL O O SdINNd 13 o NOLLO3INI NO H LIM S3NION3 SZE9E ON LHVd SOLIS SdINNd 3NAGVGNV1S HLIM S3NION3 ZOOVL98Z ON LHVd HOLSISdH SV 91435 NI G33IAA LHVIS v ONINNG aarvsado ONIAg 38 GINOHS SYOLSISAY JHL SI LUVLSOWYAHL 3H L Ld32X3 SINIL 11 LY SOlMLO313 Ave 38 OL IN3 LSAS NYNLAY GALVINSNI NV dO ANIDNA S3NION3 NO AV T34 H LHV3 ALIHO3 LNI AHL MOTIV OL SI SIHL JO 0 AHL JHL OL JHL
31. setting 96 2059F Sea water pump type Jabsco gear driven model 25 4 mm 1 full cam Sea water suggested inlet hose diameter 32 mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 73 l min 19 US galls min 91 l min 24 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number u 45 minimum Fuel injection pump Stanadyne rotary and electric stop Energised to run Fuel lift PUM L RR AC Delco type LU Delivery NOUP uu itte ice 89 I hr 23 5 US galls min 98 I hr 25 9 US galls min Press UG c EE 30 kPa 4 4 PSI decederet ed ea dr nae Mechanical Page 73 Pipe size Supply Outside diameter 7 9 mm 0 315 Supply BOP u corri coe ae 6 53 mm 0 257 Return Outside 6 3 mm 0 257 Return Bore 4
32. the voltage is allowed to fall to 7 2 volts Page 40 N38143 Chapter 6 Batteries for temperatures down to 5 C 23 F 12 Volt 24 Volt One battery 520 Amps BS3911 or 800 Amps SAE J537 415GM 422GM 422TGM 415GM Two 12V batteries in series each 315 Amps m BS3911 or 535 Amps SAE J537 422TGM Two 12V batteries in parallel each 315 Amps 700GM BS3911 or 535 Amps SAE J537 4GM 4TGM 700GM 4GM 4TGM 4 4GM 4 4TGM 4 4TWGM 4 4TW2GM 6TG2AM 6TWGM Batteries for temperatures down to 15 55 700GM 4GM 4TGM 4 4GM 4 4TGM 4 4TWGM 4 4TW2GM 415GM 422GM 422TGM Two 12V batteries in parallel each 315 Amps Two 12V batteries in series each 315 Amps or 700GM BS3911 or 535 Amps SAE J537 535 Amps SAE J537 4GM 4TGM One battery 520 Amps BS3911 or 800 Amps Two 12V batteries in series each 440 Amps SAE J537 BS3911 Two 12V batteries in parallel each 520 Amps Two 12V batteries in series each 520 Amps BS3911 or 800 Amps SAE J537 BS3911 or 800 Amps SAE J537 Note Where starting at temperatures below freezing is an important requirement a 24 volt system is the preferred choice Starter cables for 12 or 24 volt systems Maximum total length Nominal C S A Nominali se anes in Approx equivalent size Cable size ohms English America 2 Per metre Per foot imperial B amp S SAE metric Metres Feet to om or oo suo oo o9 The length of all cables in
33. u uu Turbocharged iq aysa 84mm 93 317 WOK iino 100mm 3 94 Compression ratio 23 3 1 Cubic capacity ae ire er Lo e cR oo Da 2216cc Valves per cylinder U u 2 Direction of Anti clockwise viewed on flywheel Finng Orde 1 3 4 2 Total weight wet 267kg 589108 engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 34 6 F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 48 l min 12 7 US galls min 56 l min 14 8 US galls min Coolant pump speed and method of drive 1 25 1 ratio belt driven System capacity 10 5 litres 2 4 US galls Pressure cap setting 50 7psi Protection switch setting 96 205 F Sea water pump type Jabsco gear driven model size 40 Sea water suggested inlet hose diameter
34. volt 2 0 kW Number of teeth in flywheel 126 Number of teeth on starter 9 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold 1 x 12 volt 540 Amp to BS3911 ONE EE or 1 x 12 volt 740 amps to SAE J537 Data 700GM 1500 rev min 1800 rev min Basic Technical Data Prime 27 2KW 36 5 hp 31 8kW 42 7 hp Number of Cylinders oorr tie 4 Cylinder arrangement sse In line er 4 stroke Induction system a Naturally Aspirated BOM 97mm 3 82 OORE nete bec 100mm 3 943 Compression ratio 17 5 1 Cubic capacity 3 0 litres 183in3 Valves per cylinder ul u u 2 Direction of Anti clockwise viewed on flywheel Finno Orde 1 3 4 2 Total weight wet 282kg 622 lbs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adeq
35. water system should be provided for each engine to prevent a blockage resulting in the need to shut down more than one engine A typical system is shown in figure A The water intake fitting A6 situated below the water line A1 should not project appreciably below the bottom of the hull and it should be situated well clear of other components such as shafts logs rudders to prevent flow problems at high speeds The intake fittings and pipework should have a minimum bore of 25mm 1 A2 Inboard of the intake fitting a 1 inch BSP or NPT sea cock A3 must be provided This should be of the full flow type giving unobstructed passage to the water in the open position with a minimum bore of 25mm 1 Between the intake fitting and the sea water pump A4 on the engine there should be a strainer A5 which should be easily accessible for routine examination and should be easily removable Note Ensure a separate feed for each engine A shared supply is not recommended From the sea water strainer a pipe should be run to the sea water pump inlet connection on the engine see figure A The pipe may either be mainly rigid of for example copper or cupro nickel or flexible but only flexible hose which is reinforced to prevent collapse should be used The system must be sufficiently flexible to permit the engine to move on its flexible mountings The sea water pump connection is for hose with a 32mm 1 25 bore Care should be tak
36. 0 315 s Supply ce 6 53mm 0 257 Return Outside diameter 6 3mm 0 257 BORG teer ede 4 93 0 194 Maximum lift pump lift clean filter 0 8m 2 6ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full 5 2 Vhr 1 4 US galls hr 6 2 I hr 1 6 US galls hr Air Intake Combustion airflow 1 46m min 51 5ft min 1 76m min 62ft min Maximum engine compartment air temperature 60 C 140 F Maximum air temperature at engine inlet 52 126 F Ventilation maximum engine room reete thanh nnn 125mm H O Sin H O Minimum cross section of air duct per engine 103cm2 16sq ins for hot climates 52cm 8sq ins for temperate climates Exhaust Exhaust gas flow 3 51m min 124ft min 4 45m min 157ft min Maximum restriction measured within 305 mm 12 outlet u u u u u u uuu uuu 10 13 kPa 3 0 Hg Recommended pipe bore wet exhaust 50mm 2 07 Recommended pipe bore dry 40mm 1 6 Minimum rise from sea water level to exhaust outlet cen
37. 38 1009F Sea water flow 71 l min 18 8 US galls min 91 l min 24 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane n trrbD6er u 45 minimum Fuel injection pump Stanadyne rotary and electric stop Energised to run Fuel lift DUImp te e tne AC Delco type LU Delivery hour 122 l hr 32 US galls min 134 I hr 35 US galls min irc 30 kPa 4 4 PSI Page 87 Governor Mechanical Pipe size Supply Outside diameter 7 9mm 0 315 S pply raa 6 53mm 0 257 Return Outside diameter 6 3mm 0 257 IRet rn nece core ec 4 93 0 194 Maximum lift pump lift 1 8 m 6 ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 31 5 Ihr 6 93 US galls hr 37 6 I hr 8 3 US galls hr Air Intake Combustion airflow 8 07m3min 285 ft3 min 10 62m3 min 375 ft3 min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation
38. 4 4TWGM amp 4 4TW2GM Part No N38143 Perkins Sabre Marine Auxiliary Engines Installation Manual 415GM 422GM 422TGM 700GM 4GM 4TGM 4 4GM 4 4TGM 4 4TWGM 4 4TW2GM 6TG2AM 6TWGM Publication N38143 Issue 3 Published in May 2007 by Sabre Engines Ltd Wimborne Dorset England BH21 7PW Tel 44 0 1202 893720 Fax 44 0 1202 851700 Email post sabre engines co uk Website www Perkins Sabre com Introduction The aim of this publication is to provide information in the form of technical data and installation guidance enabling auxiliary engines to be installed in a manor which will ensure safety reliability and ease of servicing 1 Engine room ventilation 2 Exhaust systems Wet Systems Tt 3 Water 4 Syphon 5 Part wet part dry 6 Water separator cec e cure uu uuu 7 Diy SySteM uuu S 8 3 Fuel systems Fuel connectio nS uuu u u e eee rre cotes etre eu Pensieri e Ries erEs d 11 Fuel connections 415GM 422GM 422TGM amp 11 Fuel connections 4AGM 4TGM 4 4GM 4 4TGM 4 4TWGM 4 4TW2GM 6TCG2AM amp 6TWGM nutu a ba 11 Fuel tank CONS CUI ONS 12 Typical fuel SUSIOITIS 12 4 Raw water systems Kee
39. 58cm 55 5sq ins for hot climates 81cm 28sq ins for temperate climates Exhaust Exhaust gas flow 17 7 m min 625 ft min 21 2m min 749 ft min Maximum restriction measured within 305 mm 12 outlet 15kPa 4 4 Hg Recommended pipe bore wet exhaust 100mm 4 0 Recommended pipe bore dry 76 2mm 3 0 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil CG4 CH4 or ACEA E3 E5 Sump capacity maximum 15 litres 4 US galls min Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady 250kPa 36 psi Low oil pressure switch setting 83kPa 12 psi Electrical System Generator etn irr 100A 12V 55A 24V Starter type sete 12 V 4 0 kW Number of teeth in flywheel 126 Number of teeth on starter 10 Cold Start Limits Minimum cold start temperature with aid
40. B3 should be a minimum of 450mm 18 inches above the static water line B7 and the exhaust outlet B4 should either be well above the static water level or a siphon break should be fitted at B5 The exhaust system may also become flooded by water entering through the sea water system on the engine as the sea water pump impeller can not be relied upon to seal when stationary To prevent such flooding the above system should be implemented o 5 4 N38143 Chapter 2 Syphon break A syphon break admits air to the top of any inverted U bend and prevents unwanted syphonic action The syphon break should vent through a skin fitting well above the water level Some commercially available syphon break units contain a valve to prevent water loss through the vent pipe and vent within the vessel Note Syphon breaks with a valve requires periodic maintenance checks should be carried out every time the engine oil is changed Caution Do not overcrank your engine when it will not start or crank the engine to bleed the fuel system as there will not be the exhaust gas present to empty the exhaust riser Water fills the riser and can back up the exhaust and fill the engine The seacock must be closed and raw water pump impeller removed if the engine is to be cranked for more than one minute Remember to replace the impeller and open the seacock when finished Top of the exhaust ris
41. EET 127mm 5 007 Compression ratio sss 16 1 Cubic capacity e irent 3 99 litres 243 in3 Valves per cylinder u u 2 Direction of rotation Anti clockwise viewed on flywheel utere m 1 3 4 2 Total weight wet 456kg 1005108 engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 379C 34 6 F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 80 l min 21 US galls min 97 l min 25 6 US galls min Coolant pump speed and method of drive 1 1 Gear driven System u 18 litres 4 8 US galls Pressure cap setting 50kPa 7psi Protection switch setting 96 2059F Sea water pump type Jabsco gear driven model 25 4 mm 1 full cam Sea water suggested inlet hose diameter 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A ra
42. ERATURE PRESSURE 5 8 8 8 SENDER SENDER a al a BATTERY 4 4 56 N38143 1 Chapter 6 4 COOLANT AUTOMATIC ENGINE CONTROL MODULE DEEP SEA MODEL 520 HOUR PRESSURE TEMPERATURE VOLTMETER METER GAUGE GAUGE NOTE TO RESET UNIT SELECT OFF POSITION ON MODE SWITCH i ao O O on i 5 O O z i u 5 O O Os m a i z E 5 e amp x 2 5 z 2 2 5 E E E 8 z d I i m 5 9 8 u EMERGENGY x a S z 3 i u m STOP ON m CANOPY 18 6 7 5 4 3 17 9 10 m OTHERWISE Q O O O O s s cues TERMINALS 4 1 BROWN RED 134 BIBBE On PINK 135 z z i E 4 4 5 z 6 EMERGENCY u STOP n g z z a 4 a E g x x 8 x x 8 amp E 5 5 z 6 m E E 3 gt 13 p E 2 m Sr a CONTACTS BLUE DSM 21 START BLUE DSM 20 SIGNAL BLACK GREEN BLACK Q9 00 OQ c Q Q Q o Q BROWN REMOTE
43. GM 4 4TW2GM and 6TWGM Heat rejection data Heat rejection Jacket water Engine Btu min 1109 1302 2098 2250 3424 kW 19 5 22 9 36 9 TBA 39 5 60 2 Aftercooler Intercooler Btu min kW Engine US gals min Litres min Intercooler US gals min Litres min Max coolant temp from grid cooler Engine F Intercooler F eC Chapter 4 N38143 Heat rejection data cont Engine model 4 4GM 4 4TGM 4 4 4 4TW2GM 6TG2AM 6TWGM Heat rejection Jacket water Engine Btu min 2440 2838 5198 6541 kW 429 49 9 91 4 115 Aftercooler Intercooler Btu min 1570 kW 27 6 Engine US gals min 22 40 20 40 Litres min 150 150 150 71 150 77 150 Intercooler US gals min 20 Litres min 102 91 Max coolant temp from grid cooler Engine F C Intercooler F C As a general rule the pressure drop across the grid cooler should be between 14 28kPa 2 to 4 psi this can be acheived by keeping the water velocity below 0 46m s 5ft s The above table shows data that will satisfy all world wide operational conditions However if the applica tion is known to be only operating in areas where the sea water temperature is unlikely to exceed 25 C then when sizing the grid coolers the maximum coolant temperature returning to the intercooler of 43 could be used and 75 coolant temperatures returning to the engine circuit Page 18 N38143 Chapter 4 Keel cooling connections 415GM 422GM amp
44. L1 Y4 V dO LN3A3 3 NI NMOGLNHS 3NION3 3GIAOSd TTIAA WHYTY NMOHS SV SLOVLNOS IAV IV ONISIA OL HOLIMS HOLIMS S83QN3S HOLIMS 3811 VS3dlN3 L H3 LVM HOIH O lt 3 H3JLYM OL Nd NOILVOISILNAGI TVNIIASI3 L IH9IT IAHV TIV 330ss38d 10 MOI OL OIM HOLIMS 9 JANIS 33 sS33d 10 Q3NISINOO H2 LIMS M30N3S AYNSSAdd Q3NISWOO 3 39nvo aanssasd 10 OL Other electrical features 415GM 422GM amp 422TGM Wiring loom derived from drawing number 02 1188 3 Chapter 6 39nv9 AYNLVYAdNAL S3 vA OL 5 3s3n d vsadiNaL S3 VM Page 42 Chapter 6 N38143 CISNES 3NIHOVIA HOLVNH3 LTV 91 SHL H3 LHV LS JHL HOLSIS3H NOLLVLIOX3 MO NOE nasce JO NOIL V33dO ONINNG ATI V LNSINOIWN ANNOYS 38 OL 3NION3 IHL MOTIV A3HL a oc nm NOILdO NV Sv 3HV HLHV3 IHL TOHINO2 HLNV3 AV 1321 JHL SW31SAS q31VT1nSNI YALAWOHOVL OL H3IMVIS JA E D HOLIMS HOLV TOSI vas GION310S YSLYVLS OA A C ill AMALLVE OL T3NYd 1OH1NO2 Q3193193NNO9 3A Aviu Lavis 38 OL 3NION3 HOLIMS LYVLS 3NION3 OL
45. LE COLOURS AS SHOWN NOT FITTED ON TA PICKUP PICKUP WHERE DUPLICATION TAKES PLACE AN ADDITIONAL IDENTIFICATION IS PRINTED ON TO THE CABLE AS SHOWN IN Page 57 Chapter 6 N38143 Standard control system optional on 4 4 range A standard control system is available when used with a factory supplied engine wiring harness that allows for the control of the genset including start and stop functions which can be performed remotely with the appropriate panel The control module is able to display any fault condition that may occur with automatic shutdowns being available where programmed The main control also includes three analogue gauges indicating the operational status of the engine The automatic engine control module contains the following features The following relay outputs are provided Fuel solenoid output Start output Pre heat Common shutdown Not in auto The following inputs are provided Governor failure alarm Lamp test Two spare inputs Multiple alarm channels are provided to monitor the following Under overspeed DC alternator charge fail Emergency stop Low oil pressure High coolant temperature Fail to start Loss of speed sensing The standard control can be mounted remotely if required This is achieved by using a 4 57m 15ft extension lead which is inserted between the connectors at the rear of the control box This places the extension lead in series with the two connectors one
46. Maximum restriction measured within 305 mm 12 outlet 10 2 kPa 3 0 Hg Recommended pipe bore wet exhaust 63 5 mm 2 5 Recommended pipe bore 40 mm 1 6 Minimum rise from sea water level to exhaust outlet centreline 203 mm 8 0 Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US galls min Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady state 310 to 390 kPa 45 to 57 psi Low oil pressure switch setting 83kPa 12 psi Electrical System GEeneral r M 70A 12V Starter type aspere rentes Magneti Marelli 12V 2 5 kW Number of teeth in flywheel 126 Number of teeth on starter a 10 Cold Start Limits Minimum cold start temperature with aid 159C 59F Batteries for min cold start 1 x 12 volt 540 Amp SAE 340 Amp IEC Page 72 Data 4GM 1500 rev min 1800 rev min Basic Technical Data Prime
47. OILOAPNI NO GION3 OS dOLS AVT38 HLSV3 3ALLVO3N G G NALSAS IONLNOO NE LYVLSOWYSAHL OL lNVlSOWMSHL Wiring loom derived from document number 97 1084 3 J 3NION3 OL H18V3 Page 54 N38143 Chapter 6 L Series electronic governor guidelines A pinout of the L Series governor as viewed into the control connector is shown below G This information derived from document 5198 1 05 Comment Supply power Direct position feedback output indication Ground for AUX inputs Combination Aux 3 and service tool input Ground for the 12 24V input power Combination Aux 4 and service tool input Power for external sensors 10mA max Aux 1 input Status fault detection output Aux 2 input MPU speed signal input 12 Ignition speed signal input Note If any features are not required in the application the related wiring may be omitted Page 55 Chapter 6 N38143 Other electrical features 4 4GM 4 4TGM 4 4TWGM amp 4 4TW2GM Wiring loom derived from document number 04 1006 1 f COMMON ALARM 29
48. W 75 6 hp 63 6 kW 85 3 hp Number of cylinders u tae 4 Cylinder arrangement sse In line er E 4 stroke Induction system 1 Turbocharged BONG O 100mm 3 9377 igo EET 127mm 5 007 Compression ratio 19 3 1 Cubic capacity e ire er 4 4 litres Valves per cylinder l u 2 Direction of rotation Anti clockwise viewed on flywheel Finno Orde a ET 1 3 4 2 Total weight wet 505kg 1113 Ibs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 379C 34 69F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 145 l min 37 3 US galls min 171 l min 45 2 US galls min Coolant pump speed and method of drive Gear driven System capacity 16 5 litres 4 4 US galls Pressure cap Setting aeri acere rocas cera 50kPa 7 psi Protection switch setting 96 2059F Sea water pum
49. alist advice Consult your distributor if you need advice about non standard drive arrangements 5 5 N38143 Chapter 5 Belt drives 4GM and 4TGM only Standard options are Fenner 5 A section pulley with three grooves A1 and taper lock A2 or A Fenner 5 B section pulley with two grooves A3 and taper locks A4 In this case the maximum power which can be taken will be limited by the belts and it will be necessary to calculate for marginal applications Caution Additional inertia must not be added to the P T O shaft without specialist advice Consult your distributor if you need advice about non standard drive arrangements 88mm 3 5ins Page 37 Chapter 5 N38143 Belt drives 6TG2AM and 6TWGM only Standard options are Fenner 5 A section pulley with three grooves A1 and taper lock A2 or AFenner 5 B section pulley with two grooves and taper locks A4 In this case the maximum power which can be taken will be limited by the belts and it will be necessary to calculate for marginal applications Caution Additional inertia must not be added to the P T O shaft without specialist advice Consult your distributor if you need advice about non standard drive arrangements IM022 N38143 6 Electrical system Electrolytic corrosion Caution The engine may be damaged by electrolytic corrosion stray current corrosion
50. back flooding into the engine exhaust The general arrangement D shows that the dry part of the system extends to a safe height above the water line using an elbow D1 a stainless steel bellows D2 a riser pipe to give the required height D3 and a further elbow D4 which is supported from the deck head by a flexible hanger D5 which supports the weight of the system but permits movement side to side and fore and aft At this point water is injected into the exhaust through the injection elbow D6 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 D7 and the wet exhaust should have an average fall of at least 105 The table below shows the recommended minimum sizes Minimum diameter of dry part of Minimum diameter of wet part of exhaust exhaust system system 63 5mm 2 5ins 60mm 2 36ins 76mm 3ins E eM om 4 4TWGM 4 4TW2GM 102mm 4ins 76mm 3ins 6TG2AM 6TWGM 127mm 5ins The dry part of the system should be insulated to avoid excessive heat loss to the engine compartment Note The bellows should be in an unstrained condition when installed so that the full bellows movement is available to absorb expansion and engine movement The weight of the exhaust system should be supported by brackets and not carried by the bellows 4 410 Pag
51. col and 200Pa duct allowance The air velocity over the radiator is 5m s for both the NA turbo and turbo aftercooled engines A pusher fan is used that has an airflow of 1 8m s for the Na turbo and 2 5m s for the aftercooled engines at 1800 rpm Expansion Tank The expansion volume in the tank must be large enough for the entire cooling system Since the engine cool ant expands about 596 between cold and hot engine operating temperatures the expansion tank must have a volume equal to 5 of the entire cooling system volume When designing the larger expansion tank the following allowance should be made A 50 kPa pressure cap should be fitted to pressurise the system 396 to 5 of total system capacity for expansion losses 10 of total system capacity for volume loss on hot shut down 5 of total system capacity for working volume The illustration 1 shows the allowances required when designing a larger expansion tank Engine bleed Vents Warning Joining the bleed pipes into a common vent will reduce the total water flow and may result in aerated water flowing back into the engine resulting in the engine overheating and possible failure The engine bleed system provides a continuous flow of water through the expansion tank as a method of removing air from the engine coolant Depending on the model of the engine there can be up to three bleed pipes which need to be connected to the top of the expansion tank Each bleed must be connected
52. d resistance and shorts Use of convoluted tubing or other wire shielding is recommended to minimize mechanical damage to the wires Avoid sharp edges and pinching when routing wires Mount the controller in a location where the effects of vibration and temperature are minimal KI Speed sensor Twisted pair Pro i portional lt shielded cable actuator F 1 ano Speed select Dimensions in L X P lt 4 Switch optional inches mm H E L To ground or vbatt Power 9 depending 0 475 APECS controller v configuration 120 E MODEL 3100 Violet Speed Select 1 Programmable Engine Controller Gray Speed Select 2 For Magnetic Pickup in SAL Si i Controller Part No 36204 IMO 0 97 24 7 N38143 Chapter 6 Controller wiring table x Model3100 Battery Red Black Actuator White White Black Speed signal input Magnetic pickup Blue Green 1500 50Hz 1800 60Hz Service tool Yellow Tx Orange Rx System wiring Resistance in the wiring due to inadequate wire gauge or excessive wire length will result in insufficient force from the actuator The table shows the recommended gauges and maximum lengths of wires Wire length is the total length used to connect the actuator to the controller and controller to the system power System wiring table AWG14 AWG16 AWG18 2 50mm 1 50mm
53. e Maximum fuel lift pump depression at inlet 127mm 5 00 Hg Fuel consumption at full power 14 8 I hr 3 9 US galls hr 16 9 I hr 4 5 US galls hr Air Intake Combustion airflow 5 0 m min 177 ft min 5 97 m min 211 Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression u 125mm H O 5 in H O Minimum cross section of air duct per 6 302cm 47sq ins for hot climates 159cm 24 7sq ins for temperate climates Exhaust Exhaust gas flow 10 1m min 357 ft min 13 0m min 459 ft min Maximum restriction measured within 305 mm 12 outlet u L 15kPa 4 4 Hg Recommended pipe bore wet exhaust 76 2mm 3 07 Recommended pipe bore 57mm 2 247 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CG4 CH4 or ACEA E3 E5 Sump capacity maximum 8 5 litres 2 2 US galls min Normal operating angles
54. e 6 N38143 2 Water separator The benefit of a water separator E1 in addition to a water lift silencer is that it separates the water from the water gas mix and discharges below the waterline E3 thus avoiding the often irritating spluttering noise associated with water cooled generators especially in a quiet marina A water separator also reduces exhaust back pressure in long exhaust runs Warning Sailing yachts can present special problems when considering the amount of heel and therefore care must be taken when designing the system When designing the exhaust system for sailing yachts the predicted heel and any engine installation offset from the centreline must be taken into account The designer may include in the system a gate valve or sea cock E2 if there is any likelihood of the engine being at risk in extreme heel conditions as a precaution Page 7 Chapter 2 N38143 Dry systems Dry exhaust systems are most commonly used with engines which are keel cooled and are used for environmental reasons in some areas This arrangement is particularly useful for commercial or pleasure craft operating in heavily silted water with debris and with radiator cooled engines Dry exhaust systems for marine installations need careful design to minimise the disadvantages of enclosing components that are at a high temperature in confined spaces A typical system is shown in F The first part of a d
55. e dial 8 Apply load to the engine and check that the speed and governing are correct If necessary repeat operation Note It may be necessary to make further adjustments to the screws 11 and I2 until the correct speed and governing are obtained Caution Any adjustments to these screws must be made gradually Red pm Black T urple Ber Purple Speed White i MPUBI Wn WI 0 37mm 0 127mm 0 015 inches 0 005 inches Page 62 N38143 Chapter 6 Identification of component numbers in triangles Number Description 5 Connector Details for cables identified in circles Controller to actuator Controller to battery Purple Red Red Black Red Black white White Earth Shield Controller to sensor Caution The plastic connector that is supplied loose for the circuit controller to actuator should be fitted with a crimping tool of the correct size If it is not the connector may be damaged Page 63 6 N38143 This page is intentionally blank Page 64 Data 415GM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical 12 3kW 16 5 14 7kW 19 7hp Number of cyll ders l eri Su RR En Ue 3 Cylinder arrangement rcnt enitn In line GY CIOS ceteri 4 stroke Inducti
56. ectric 30 75kPa 4 4 10 9 PSI Delivery hr iiit 120 150 Itr hr 31 7 US galls hr to 39 6 US galls hr Governor type oce dee a ebd ete donee L Series electronic governor Page 77 Pipe size Supply Outside 7 9mm 0 315 s Supply ce 6 53mm 0 257 Return Outside 6 3mm 0 257 BORG u e EP de 4 93 0 194 Maximum lift pump lift clean filter 17kPa at 1 7m using 8mm dia bore pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 12 2 I hr 3 2 US galls hr 14 5 I hr 3 8 US galls hr Air Intake Combustion 3 19m3 min 113 ft3 min 3 58m3 min 126 ft3 min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression uu 125mm H O 5 in H O Minimum cross section of air duct per 232 cm 36 sq ins for hot climates M M 116 cm 18 sq ins for temperate climates Exhaust Exhaust gas flow 7 6m min 268 ft min 8 8m min 311 ft
57. en to use compatible materials in the sea water systems to prevent excessive galvanic corrosion Systems incorporating copper cupro nickel stainless steel Type 316 gun metal silver solder and aluminium brass will generally be satisfactory Components made from lead iron steel aluminium or its alloys zinc or magnesium should be generally avoided Page 15 Chapter 4 N38143 415GM 422GM 422TGM Note Where possible mount the strainer so that the top is just above the waterline to facilitate cleaning Page 16 N38143 Chapter 4 Keel cooling skin cooling Keel cooling or skin cooling is a closed circuit method of cooling that uses only coolant with 50 50 antifreeze mix A properly designed and installed cooling system is essential for satisfactory engine life and performance This system uses a group of tubes pipes or channels attached to the outside of the hull below the waterline as a heat exchanger Keel coolers are used in preference to the standard raw water cooled engine mounted heat exchanger when operating in areas that have heavy silt and debris in the water that would erode the heat exchanger tubes or block them Keel cooling is used in Arctic conditions to avoid the problems of freezing that is experienced with the raw water circuit on the heat exchanger cooling system Keel coolers are available in standard designs from several manufacturers These units are simple to install and are sized by the manufactur
58. er and the point at which the syphon break C1 is connected to the engine pipework must be above the water line C6 under the worst possible conditions normally a distance of 450mm 18 inches C2 under static conditions will be sufficient There should be a minimum distance of 300mm 12 inches C3 between the exhaust tank inlet C4 and the water injection elbow C5 Note Minimum volume of exhaust muffler water lift should be three times the volume of the water in the riser The tank should be installed near the centre line of sailing craft Warning Sea water inlet fittings with a scoop must not be used The pressure generated when the vessel is under way can force the water past the raw water pump when the generator is not in operation thus allowing water to fill up the water lift With no exhaust pressure to force the water out of the system water can enter the engine via the exhaust manifold 1 fu Tp P 039 aoe gt 050109 0 a raw ARTU ra Page 5 Chapter 2 i N38143 Part wet part dry systems In some installations this arrangement may be chosen in place of a water lift The part wet part dry system allows the engine exhaust manifold outlet to be near or below the waterline and provides protection against sea water
59. er for the engine model and boat application Commercial coolers are made of erosion resistant materials and have a relatively high heat transfer efficiency The disadvantage of external keel coolers is that they are vulnerable to damage and must be guarded An alternative to the commercially available coolers are fabricated keel coolers manufactured by the boat builder as part of the hull construction These coolers are not as efficient and must be designed oversize to allow for a decrease in performance that follows the formation of rust scale and marine growth on the keel cooler If the genset is a replacement package and the original cooling system keel cooler and expansion tank is to be reused then it is essential that the system thoroughly flushed to remove sludge that may be in the system Failure to remove sludge could block air bleeds leading to the engine overheating Sizing the coolers Commercial keel coolers are manufactured in a variety of sizes and shapes The keel cooler manufacturer will recommend a keel cooler when provided with the following data Engine model and rating Engine data sheet see section 7 Heat Rejection see table below Engine coolant flow rates are at a system resistance of 28kPa 4 Ibf in2 Max coolant temperatures from grid cooler Maximum raw water temperature Pipe connections see illustrations on following pages Coolant 50 50 antifreeze mix Warning Twin grid coolers are required for the 4 4TW
60. he pressure cap First release the pressure in the system by loosening the pressure cap 11 Top up with 50 antifreeze to maximum level N1 Page 30 N38143 Chapter 4 1 Remote expansion tank 4GM 4TGM and 6TG2AM Aremotely mounted expansion tank is recommended where longer pipe runs are required and where fabricated coolers are used A remote cooler expansion tank kit can be fitted using the following procedure 1 Figure O shows draining the engine coolant O1 cutting removing and discarding the bleed pipes O2 and removing the existing expansion tank O3 and disposing of the rubber elbow O4 at the base Page 31 Chapter 4 N38143 2 Mount the remote expansion tank in a position where the bottom of the unit is no lower than where the filler cap was P1 on the original expansion tank as shown in figure P 3 Connect the new bleed hoses P2 to the tank and the original fittings on the engine 4 Connect the main inlet hose to the engine P3 5 Secure the inlet hose P3 the front of the engine in the position shown in P4 with the hose clip N38143 Chapter 4 6 Fill the remote expansion tank with 50 antifreeze solution Q1 to the maximum position on the sight glass Q2 50 Antifreeze 7 Switch on engine panel R1 8 Start engine R2 9 Run engine until normal working temperature is reached between 82 to 88oC R3 10 Stop engine R4 11 Switch off panel R5 Page 33
61. hr 27 8 l hr 7 3 US galls hr Air Intake Combustion airflow 6 12m min 216 ft3 min 7 78m min 275 Maximum engine compartment air temperature 60 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression 125mm H2O 5in H20 Suggested ventilation airflow including combustion air 32m min 1130 ft min Minimum cross section of air duct per engine 477cm 74sq ins for hot climates Vd e 240cm 37sq ins for temperate climates Exhaust Exhaust gas flow 16 6m min 586 ft min 20m min 706 ft min Maximum restriction measured within 305 mm 12 of turbocharger outlet 6kPa 1 26 Hg Recommended pipe bore wet exhaust 100mm 4 0 Recommended pipe bore dry 76 2mm 3 0 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US galls Normal operating angles 25 from horizontal in any directi
62. if the correct bonding procedure is not adopted Definition of galvanic and electrolytic corrosion Galvanic corrosion is caused when two different metals are immersed in a conductive fluid such as seawater called electrolyte with a connection between them an electric current is generated in the same way as a battery Electrolytic corrosion stray current corrosion is caused by a current from an external source such as the boats battery or shore supply Avoiding electrolytic corrosion The current that causes electrolytic action is called stray current which can emanate from two sources The first is the batteries on board the vessel where the negative terminal is earthed to the hull at a central earth terminal If other negative connections are made elsewhere on the vessel then the resulting small differences in voltage between the earth terminals can cause the same chemical action as in galvanic corrosion but it must be stressed that this is not GALVANIC CORROSION but stray current known as electrolysis caused by an external electrical current The way to prevent electrolytic corrosion is to ensure a good electrical installation and to bond the genset to the bonding system in the boat which is providing a low resistance connection between all the metals in contact with the sea water The bonding system should be connected to a zinc sacrificial anode that is fixed to the outside of the hull below sea level A typical layout is shown i
63. in detail The Synchro Start APECS Advanced Proportional Engine Control System series 3000 is an isochronous engine governor that provides a means of controlling and limiting engine speed The controller is set up using an APECS Calibration Tool ACT part number 36204 The ACT is computer based software that can be used for monitoring and is available separately Controller installation and wiring diagram Use the drawing F and table to install and wire the controller Connect power leads directly to the switched power source Use of a 10 amp slow blow fuse is recommended in the battery positive wire Use proper terminations and crimping techniques to avoid elevated resistance and shorts Use of convoluted tubing or other wire shielding is recommended to minimize mechanical damage to the wires Avoid sharp edges and pinching when routing wires Mount the controller in a location where the effects of vibration and temperature are minimal KI Speed sensor Twisted pair Pro i portional lt shielded cable actuator F 1 ano Speed select Dimensions in L X P lt 4 Switch optional inches mm H E L To ground or vbatt Power 9 depending 0 475 APECS controller v configuration 120 E MODEL 3100 Violet Speed Select 1 Programmable Engine Controller Gray Speed Select 2 For Magnetic Pickup in SAL Si i Controller Part No 36204 IMO 0 97
64. ithin 0 25 If the electronic governor fails the mechanical governor will control the maximum engine speed to 2050 rev min The electronic governor is made up of three parts 1 The engine speed controller is set at the factory or can be adjusted using a laptop computer and data link 2 The actuator This is fitted to the fuel injection pump and controls the engine speed 3 The electro magnetic sensor This is fitted to the flywheel housing and measures the engine speed Caution Ensure that the electro magnetic sensor is set correctly and the cables are connected in accordance with the wiring diagram Ensure that there is electrical continuity between the frame for the engine and the frame for the control panel Page 45 Chapter 6 N38143 Electronic governor in detail The Synchro Start APECS Advanced Proportional Engine Control System series 3000 is an isochronous engine governor that provides a means of controlling and limiting engine speed The controller is set up using an APECS Calibration Tool ACT part number 36204 The ACT is computer based software that can be used for monitoring and is available separately Controller installation and wiring diagram Use the drawing D and table to install and wire the controller Connect power leads directly to the switched power source Use of a 10 amp slow blow fuse is recommended in the battery positive wire Use proper terminations and crimping techniques to avoid elevate
65. l cooling or skin cooling U 17 SIZIN the amp 17 Keel cooling connections 415GM 422GM amp 422TQGM 19 Keel cooling connections 7 20 Keel cooling connections 4GM and 4 21 Keel cooling connections 4 4GM and 4 4 22 Keel cooling connections 4 4TWGM and 4 4TW2QGM 23 Keel cooling connections 24 Keel cooling connections 6TGWM 25 DE aera D 26 Radiator 2 26 Expansi n Tank m E 26 Engine pl eed eesin 26 Remote expansion tank 4 4GM 4 4 amp 4 4TW2GM 28 5 Power take off not optional on the 415GM 422GM amp 422TGM Belt drives 4 4GM 4 4TGM 4 4TWGM and 4 4TW2GM only 35 Belt drives 00GM only 36 Belt drives 4GM and 4 37 Belt drives 6 2 and 6TWGM 38 6 Electrical system Electrolyti6 COrTOSIOn u
66. lectronic governor guidelines 1 55 Other electrical features 4 4GM 4 4TGM 4 4TWGM amp 4 4TW2GM 56 Standard control system optional on 4 4 58 For the 4 4 range of engines supplied without loom 59 Other electrical features 6 2 60 Other electrical features 6 61 Electronic governor 62 7 Data 65 Data 422 67 Data 69 Data 700GM ere eee eee 71 4 w saa 73 u 75 Brom 77 e S 79 Data 4 4 81 cupo eec 83 Data 6 2 Mee 85 87 N38143 Chapter 1 Engine room ventilation The engine room must be ventilated for two reasons To supply the engine with air for combustion To provide a flow of air through the engine room to prevent an excessive temperature build up which may cause components such as the generato
67. lycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 48 l min 12 7 US galls min 56 l min 14 8 US galls min Coolant pump speed and method of drive 1 25 1 ratio belt driven System capacity 10 5 litres 2 4 US galls Pressure SeN 50 7psi Protection switch setting 96 205 F Sea water pump type Jabsco gear driven model size 40 Sea water suggested inlet hose diameter 25 4mm 1 007 Sea cock a Full flow 25 4mm 1 00 max lift of seawater pump 2m Olraltier A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 100 Sea water flow 31 9 l min 8 4 US galls min 40 1 l min 10 6 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane mber ERE ERE 45 minimum Fuel injection pump Cassette type inline pump with electronic governor Fuel litt p trip Mechanical Governor typ6 i Electronic Page 67 Pipe size Supply Outside 7 9mm
68. m Slrallner utes A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 100 Sea water flow 31 9 l min 8 4 US galls min 40 1 l min 10 6 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number iere inta 45 minimum Fuel injection pump Cassette type inline pump with electronic governor F el lift Mechanical Governor type Electronic Page 65 Pipe size Supply Outside 7 9mm 0 315 s Supply ce 6 53mm 0 257 Return Outside diameter 6 3mm 0 257 Roum BORG b e te 4 93mm 0 194 Maximum lift pump lift clean filter 0 8m 2 6ft To bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 3 7 Vhr 1 0 US galls hr 4 5 1 2 US galls hr Air Intake Combustion airflow 1 07 m min 37 9 ft min 1 26m min 44 4 ft min Maximum engine compartment air temperature 60 C 140 F Maximum air temperature at engine inlet 52 126 F Ventilation
69. maximum engine room depression u 125mm H O Sin H O Minimum cross section of air duct per 65 cm 10 sq ins for hot climates use d 32 cm2 5 sq ins for temperate climates Exhaust Exhaust gas flow 2 75m min 97ft min 3 37 m min 119ft min Maximum restriction measured within 305 mm 12 outlet 10 13kPa 3 0 Hg Recommended pipe bore wet exhaust 50mm 2 07 Recommended pipe bore 40mm 1 6 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CH4 ACEA E5 Sump capacity maximum 6 litres 1 5 US galls min Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady 200kPa 29psi Low oil pressure switch setting 80kPa 12psi Electrical System OGeneral f e 55A 12V cid E E E T 12 volt 2 0 kW Number of teeth in flywheel 109 Number of teeth
70. mm 3 0 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US gallons Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady state 250kPa 36 psi Low oil pressure switch setting 83kPa 12 psi Electrical System Generator 100A 12V 55 24V Starter Lype uuu 12V 4 kW Number of teeth in flywheel 126 Number of teeth on starter 10 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold start 1 x 12V 660 amp SAE Page 84 Data 6TG2AM 1500 rev min 1800 rev min Basic Technical Data Prime tenen 92 5kW 124 hp 99kW 133 hp Number of Cylinders oir u R REX RUD ER 6 Cylinder arrangement sss In line er E 4 stroke Induction system
71. n A Common bonding system wire in a ring Sea cock circuit as shown Through hull metal fittings G t Propulsion engines Zinc anode The bonding should consist of heavy stranded wire not braiding or wire with fine strands It is an advantage if the wire is tinned Insulation is also an advantage and should preferably be green in colour Although the current carried by the bonding system will not normally exceed 1 amp the cable sizes should be generous as shown in the table below Length of run to zinc anode Suggested cable size Up to 30 feet 7 strand 0 185mm 4mm2 30 40 feet 7 strand 1 04mm 6mm2 Page 39 Chapter 6 N38143 As many of the connections may be splashed with sea water they should be soldered wherever possible and clamped elsewhere with the joint protected from corrosion by neoprene paint or a similar material to exclude water Bonding of aluminium boats is a special case as the various appliances on board should be earth free and therefore to avoid stray currents all appliances must be earthed to a single terminal Grounding is required for safety if voltages are high i e when there is a 240 volt generator on board or when a shore line is connected Grounding or earthing must not be confused with the term earth return Earth return carries current whereas grounding earthing does not Another source of unplanned current giving raise to a form of stray current corrosion is
72. nd the coolers The keel coolers should be installed so that air pockets are not present during the initial fill Vents at all high points along the connecting pipes will be necessary Keel coolers should not be fitted where they would be exposed to pounding seas or hull flexing The bow of the vessel is not considered to be a good location whereas adjacent to the keel where it is the strongest area of the vessel is the preferred location De aeration Warning Air in the engine coolant can cause the following problems 1 Air accelerates the corrosion within the engine water passages that can lead to high water temperatures as silt deposits on the surface of the cooler reducing the heat transfer Premature failure of the engine can occur 2 Air expands more than coolant when heated and may cause loss of coolant from the engine system through the expansion tank overflow 3 In an extreme case air will collect in one area and cause a loss of coolant flow around the cylinder block resulting in piston seizure and major engine damage Radiator cooled Radiator cooled engines are typically used for emergency units or if the engine is located more than 4m above the sea water such as on the deck of barges The radiator cores are fully tinned to give the best corrosion protection and are therefore capable of operat ing in worldwide environments The design allows for air on temperatures of 50 C at both 1500 and 1800 rev min 50 ethylene gly
73. nel to simplify cleaning The fuel pipework should be as simple as possible with the minimum of valves and cross connections so that obscure fuel feed problems are minimised A fuel sedimenter water separator A2 is required in the fuel system between the fuel tank and the engine mounted lift pump To avoid problems when venting air after draining the sedimenter it should preferably be installed below the normal minimum level of fuel in the fuel tank This is not always possible The tank should have at least two connections a fuel feed connection A3 and a fuel return connection A4 Whenever possible a tank should only supply one engine but in any case each engine should have its own fuel pipes from tank to engine Typical fuel systems The more simple the fuel system the better it will perform in service Figure A shows an ideal system Page 12 N38143 Chapter 3 In some applications there may be legislation that requires that fuel lines draw from and return to the top of the tank Figure B shows an acceptable arrangement The fuel tank may be steel aluminium or G R P Glass Reinforced Plastic or alternatively a rubber bag tank may be used The main fuel connection is taken from the rear of the tank B1 so that all the fuel is available for use when under way when the hull will be at an angle The fuel return B4 is extended within the tank to near the bottom in order to prevent air lock
74. of the engine package but have a remotely mounted expansion tank Figure F shows the connections and flow Connections sizes are 38mm 1 5 ins for the water jacket circuit and 32mm 1 25 ins for the aftercooler circuit 1 Connections 5 Fresh water pump 9 Exhaust manifold 2 Flow 6 Thermostat 10 Aftercooler 3 Keel cooler 7 Engine 11 Bleed 4 Remote tank 8 Integral engine oil cooler 12 Raw water pump IM4 4TWGM Page 23 Chapter 4 i N38143 Keel cooling connections 6TG2AM Figure G shows the connections and flow Connections sizes are both 45mm 1 75 inches Connections Flow Keel cooler Thermostat Bleed pipe Engine oil filter Engine oil cooler Fresh water pump 9 Engine 10 High water temperature switch 11 Header tank 12 Exhaust manifold mm IM6TG2AM_01 N38143 I Chapter 4 Keel cooling connections 6TGWM Figure H shows the connections and flow Connections sizes are 44 5mm 1 75 ins for the water jacket circuit and 32mm 1 25 ins for the aftercooler circuit 1 Connections 5 Thermostat 9 Header tank 2 Flow 6 Bleed 10 Exhaust manifold 3 Keel cooler 7 Raw water pump 11 Intercooler 4 Engine 8 Fresh water pump IMeTWGM Page 25 Chapter 4 N38143 Keel coolers should be installed below the waterline far enough to avoid the aerated water close to the sur face Recessed and shielded coolers must allow for unobstructed flow arou
75. on Oil pressure in operating speed range steady 300 to 340 kPa 44 to 49 PSI Low oil pressure switch setting 83kPa 12 psi Electrical System Generator tea Prestolite AS128 90A 12V or 55A 24V Starter typo stu lateres ineunt Usted Prestolite 5115 Number of teeth in 126 Number of teeth on starter 10 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold start a quantity of 2 off 12V 315 Amps to BS3911 or 2 off 12V 535 amps to SAE J537 Page 86 Data 6TWGM 1500 rev min 1800 rev min Basic Technical Data u Qa 154 125 5kW 168 2 hp 146kW 195 7 hp Number of Cylinders LL u Ere xau nk ER den Rx dun 6 Cylinder arrangement 1 u en In line er 4 stroke Induction system Turbocharged water to air charged cooled BONG O 100mm 3 937 igo ER 127mm 5 007 Compression ratio 17 1 Cubic Capacity noe 5 99 litres 365 0 in3 Valves per cylinder
76. on starter 9 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold start 1 x 12 volt 540 amp SAE to BS3911 or 1 x 12 volt 740 amps to SAE J537 Page 66 Data 422GM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical 18 4kW 24 7 22kW 29 5hp Number of cylinders uu A 4 Cylinder arrangement sssssseeem resene In line CY CIS M 4 stroke Induction system a Naturally Aspirated n S 84mm 93 317 WOK G iiir ret Ried 100mm 3 94 Compression ratio 23 3 1 Cubic capacity ae ire er Lo e cR oo Da 2216cc Valves per cylinder U u 2 Direction of rotation Anti clockwise viewed on flywheel 1 3 4 2 Total weight wet 258kg 568lbs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 34 6 F Coolant 50 inhibited ethylene g
77. on system a Naturally Aspirated ll T 84mm 93 317 Ee EE DEEP 90mm 3 54 Compression Fallo erc eb 22 5 1 1496cc Valves per cylinder u 2 Direction of rotation Anti clockwise viewed on flywheel FIRING T 1 2 3 Total weight wet 213kg 470lbs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 34 6 F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 41 l min 10 8 US galls min 49 l min 12 9 US galls min Coolant pump speed and method of drive 1 25 1 ratio belt driven System capall uu et edt t d 8 litres 2 4 US galls Pressure cap setting ence 50 kPa 7 psi Protection switch setting 96 205 F Sea water pump Jabsco gear driven model size 40 Sea water suggested inlet hose diameter 25 4mm 1 007 OA COCK cnet Full flow 25 4mm 1 00 max lift of seawater pump 2
78. orrosion inhibitor are present It will give frost protection to 379C 34 69F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 100 l min 26 4 US galls min 116 l min 30 6 US galls min Coolant pump speed and method of drive Gear driven System capacity 16 5 litres 4 4 US galls Pressure cap Setting acetic cera 50kPa 7 psi Protection switch setting 96 2059F Sea water pump type Jabsco gear driven model size 25 4mm 1 Sea water suggested inlet hose diameter 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 50 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 86 l min 22 7 US galls min 102 l min 26 9 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number u u 45 minimum F el injection pump ci Delphi rotary Fuel lift DUMP ada El
79. p type Jabsco gear driven model 25 4 1 Sea water suggested inlet hose diameter 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 86 l min 22 7 US galls min 102 l min 26 9 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane 45 minimum Fuel injection PUMP Delphi rotary Fuel lift Electric 120 150 Itr hr 31 7 US galls hr to 39 6 US galls hr ipu 30 75 kPa 4 4 10 9 PSI L series electronic governor Page 79 Pipe size Supply Outside 7 9mm 0 315 Supply itera tne 6 53mm 0 257 Return Outside 6 3mm 0 257 Returii BOO ioci teet ent sta Lect i ade 4 93mm 0 194 Maximum lift pump lift clean filter 17kPa at 1 7m using 8mm dia bore pip
80. r to overheat In most applications in temperate climates the engine will draw air from the engine room If this is the case then as a rough guide it can be taken that every horsepower produced by the engines requires as a minimum 0 25 sq ins of vent area If the boat is likely to be used in hot climates and if engine room ventilation fans are fitted then a vent area of 0 5 sq ins per horsepower should be provided see the table below Wherever possible a flow of air through the engine room should be encouraged by using forward facing intake vents to take advantage of ram airflow together with other vents to allow hot air to escape With an effective ventilation system the engine air intake temperature will be no more than 10 Centigrade degrees higher than the outside air temperature Minimum cross section of air duct per engine For hot climates For temperate climates 415GM 103sq cm 16sq ins 52sq cm 8sq ins 422GM 422TGM Note This is in addition to the ventilation needs of the main propulsion engines Page 1 Chapter 1 N38143 This page is intentionally blank Page 2 N38143 Chapter 2 Exhaust systems The exhaust system should conduct exhaust gases from the engine to the atmosphere with acceptable back pressure at the same time reducing exhaust noise to the minimum avoiding gas leaks and excessive surface temperatures while accommodating engine movement on flexible mounts There are two types of systems used
81. read Caution Ensure that flexible fuel hose routing avoids coming into contact with parts of the engine which can lead to abrasion of the hose Fuel connections 4GM 4TGM 4 4GM 4 4TGM 4 4TWGM 4 4TW2GM 6TG2AM amp 6TWGM Standard Fuel Feed 5 16 OD nut and olive to suit 5 16 OD steel or copper tube Standard Fuel Return a 1 4 OD nut and olive to suit 1 4 OD steel or copper tube Optional Fuel Feed 5 16 BSP male thread nut and olive to suit 5 16 OD steel or copper tube Optional Fuel Return a 1 4 BSP male thread nut and olive to suit 1 4 OD steel or copper tube Caution Ensure that flexible fuel hose routing avoids coming into contact with parts of the engine which can lead to abrasion of the hose Page 11 Chapter 3 N38143 Fuel tank connections The more simple the fuel system the better it will perform in service Fuel tanks should have the following features as shown in A The filler neck should be raised so that water will not enter when filling The filler cap should seal effectively to prevent water entering when under way A vent pipe should be fitted again in such a way as to avoid the entry of water The tank A1 should have a sump or angled bottom with a drain tap A5 so that water and sediment can be removed This is not always possible Stop cocks can be fitted where necessary A6 Internal baffles may be required to prevent fuel surge The tank should have a removable pa
82. ry system should include flexible connections F2 to permit movement between the engine and the fixed part of the exhaust except the 415GM and 422GM which have a simple flange F1 for the customer to connect to Connections of the stainless steel 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 Fitting a second bellows F4 90 degrees to the first will achieve this The bellows and elbows should be covered with fire blankets F3 The remainder of the exhaust system should be well insulated 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 collect condensate and allow it to be drained Minimum bore of the exhaust pipe Md E 60mm 2 4ins 76mm 3ins Bellows should be in an unstrained condition when installed so that the full bellows movement is available to absorb expansion and engine movement Page 8 N38143 Chapter 2 422TGM Page 9 Chapter 2 N38143 The weight of the exhaust system should be supported by brackets and not carried by the bellows as shown in G Bracket with link to allow movement due to expansion in the exhaust system horizontal exhaust systems should be suspended from the deck head using similar brackets Note Rigid brackets should not be used In
83. s 6TWGM 125mm Sins 4TGM Page 3 Chapter 2 N38143 Water lift systems For applications where the engine is installed below the water line and in any installations where it is possible for water from the exhaust pipe to run back into the engine there are a number of solutions which can be considered In sailing yachts and deep draught displacement boats it may be found that the engine exhaust outlet is near or below the waterline a water lift exhaust system is then an option that may be considered The main features of such a system are shown in B Pressure developed by the exhaust gases force a mixture of gas and water to a height which may be considerably above the engine When the engine is stopped the exhaust tank B1 contains the water which falls back from the exhaust riser B2 If a commercially available unit is used the manufacturers instructions should be carefully followed but the key features are shown in B The exhaust muffler water lift B1 should have a minimum volume equal to 3 times the volume of the water that could be contained in the exhaust riser B2 On sailing craft the muffler water lift should be installed near the centre line of the vessel Particular care should 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
84. s which can arise due to syphoning of the fuel when the engines are stopped The fuel returned to the tank should be kept away from the main fuel feed to avoid recirculation A drain tube B5 should be fitted to aid servicing and cleaning From the tank the main engine feed line B2 goes first to a water separator B3 preferably one fitted with a thick clear plastic bottom and a drain cock use only if allowed by local regulations The fuel lines may be of metal either copper or seamless steel tubing used either with compression fittings or preferably soldered nipples with a flexible armoured rubber hose to connect to the fuel lift pump Stop cocks B6 may also be fitted where necessary This simple fuel system is satisfactory when one or more engines are run from a single fuel tank and it may also be used when there are two tanks each supplying one engine In the latter case the system may include a cross connection between the tanks by means of a balancing pipe with a valve at each end In some installations cross connecting pipes between the two engine feed pipes and the two engine return pipes have been used but valves are necessary in every line so that the appropriate system may be selected and the complexity of installation and operation is such that the advantages in operating flexibility are out weighed by the possibility of obscure problems due to component malfunctions incorrect operation or engine interaction
85. speed and method of drive 1 1 Gear driven System capacity 16 5 litres 4 8 US galls Pressure cap Setting i aeri acere roca cora 50kPa 7 psi Protection switch setting 96 2059F Sea water pump type Jabsco gear driven model 25 4mm 17 full cam Sea water suggested inlet hose diameter 32mm 1 25 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 86 l min 22 7 US galls min 102 l min 26 9 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number 45 minimum F el injection PUMP coii Delphi rotary Fuel lift Electric Delivery eate 120 150I hr 31 7 US galls hr to 39 6 US galls hr Press UE EE 30 75kPa 4 4 10 9 PSI m Mechanical Page 83 Pipe size Supply Outside 7 9mm 0 315
86. stolite AS128 90A 12V or 55A 24V cinque Prestolite S115 Number of teeth in flywheel 126 Number of teeth on starter essc 10 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold starta qty of 2 off 12V 315 Amps to BS3911 or 2 off 12V 535 amps to SAE J537 Page 76 Data 4 4GM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical 42TKkW 57 3 hp 49 1kW 65 8 hp eoi ad 4 Cylinder In line CY CIS 4 stroke Induction system a Naturally Aspirated BORG 100mm 3 9377 igo EET 127mm 5 007 Compression ratio 18 23 1 Cubic e ire er 4 4 litres Valves per cylinder u 2 Direction of Anti clockwise viewed on flywheel mueren LS 1 3 4 2 Total weight dry 489kg 1078lbs engine only including starter and generator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of c
87. sulating lagging Rigid bracket to support the weight of the vertical exhaust system Heat blanket Twin stainless steel bellows fitted to avoid torsional load on bellows unit it is strongly recommended that twin bellows are used Turbocharger adaptor except 415GM 422GM 700GM 4GM amp 4 4GM 90 elbow N38143 Chapter 3 Fuel systems Fuel connections A common reason for service problems with fuel systems is the use of poor or incompatible connectors where the pressure tightness depends upon the use of sealing compounds hose clamps fibre washers trapped between inadequate and unmachined faces or compression fittings which have been over tightened to the point where they no longer seal Cleanliness during initial assembly is also of vital importance particularly when fuel tanks are installed as glass fibres and other rubbish may enter tanks through uncovered apertures It is strongly recommended that the flexible fuel pipes available as an option with the engine are used which are as follows Fuel connections 415GM 422GM 422TGM amp 700GM Standard Fuel Feed The free end of the flexible fuel pipe has either 1 4 BSP male thread Standard Fuel Return The free end of the flexible pipe has either a 1 4 BSP male thread Optional Fuel Feed The free end of the flexible fuel pipe has either 1 4 BSP male thread Optional Fuel Return The free end of the flexible pipe has either a 1 4 BSP male th
88. the ACT software on your personal computer please refer to the APECS 3000 user s manual SE 3872 Note The APECS unit must be powered up but need not be mounted on the engine to carry out the calibration procedure Computer Controller Red 1 Black J o White WhUBIk Blue Green J MODEL 3100 Violet Speed Select 1 Programmable Engine Controller Gray Speed Select 2 For Magnetic Pickup Yellow Tx ques Orange RX Tool a Maris aoa Cate ym La Connector N38143 Chapter 6 Electronic governor overview The engines are fitted with both mechanical and electronic governors The electronic governor controls the engine speed within 0 25 If the electronic governor fails the mechanical governor will control the maximum engine speed to 2050 rev min The electronic governor is made up of three parts 1 The engine speed controller is set at the factory or can be adjusted using a laptop computer and data link 2 The actuator This is fitted to the fuel injection pump and controls the engine speed 3 The electro magnetic sensor This is fitted to the flywheel housing and measures the engine speed Caution Ensure that the electro magnetic sensor is set correctly and the cables are connected in accordance with the wiring diagram Ensure that there is electrical continuity between the frame for the engine and the frame for the control panel Page 51 Chapter 6 N38143 Electronic governor
89. the starter circuit whether positive or negative should be added together to give the Total Length b Grounding the battery negative It is recommended that the battery negative busbar is grounded as close as possible to the battery by a substantial connection to the bonding system in the boat This will reduce the likelihood of interference between items of electrical and electronic equipment fitted to the boat c Battery isolator switches A switch should be fitted in the positive lead to the starter as close to the battery as is convenient The switch should be suitable for a momentary current of at least 1000 Amps Page 41 N38143 TANVd OL 3A TOOL 32IAM3S S3TIOS LNOO ANION d1l8vi NI NVHOOHd XM JONVYO O 000 SO3dV XL MOTISA LYVLS ONHONAS 3 5 NOLLVil3dO L310IA 5 INd 0091 09 N33HO ASMO MOVIE MNII ama INd 0091 ZHOS MOVIES L31OIA OL 3OV18 e JIM x9v18 8 Alddns HOLIMS LINOUIO QAHOLIMS WOds AlddNs 3A N3dO 3NION3 dOLS OL Q3SIS33N3 SI LINN SIHL 431 5 3g A INO NV2 ANIDNA 5 0 LNIOd HOLIMS 3AOSV 3510 OL 3H S33d TIO AHL 3 5 AV T3G V SAIS OL JA N G3NWNAV39SOtd SI S3TIOSW LNOO JHL
90. to the expansion tank without using tee s or other fittings that would join the bleed pipes together in a common vent mr r 55000000000 Page 26 N38143 Chapter 4 3 to 5 of total Expansion volume system capacity 10 of total Volume loss on shutdown system capacity 5 of total Working volume system capacity Page 27 Chapter 4 N38143 Remote expansion tank 4 4GM 4 4TGM amp 4 4TW2GM A remotely mounted expansion tank is supplied as standard with a capacity of 19 litres A remote cooler expansion tank kit can be fitted using the following procedure 1 Mount the remote expansion tank in a position where the bottom of the unit is as shown in figure J 2 Connect the new bleed hoses J2 to the tank and the fittings on the engine 3 Connect the main inlet hose to the engine J3 4 4GM amp 4 4TGM 4 4TGM amp 4 4TW2GM N38143 Chapter 4 4 Secure the inlet hose J3 the front of the engine in the position shown in J4 with the hose clip 5 Fill the remote expansion tank with 50 antifreeze solution K1 to the maximum position on the sight glass K2 6 Start engine L1 7 Run engine until normal working temperature is reached between 82 to 880C L2 8 Stop engine L3 9 Switch off panel L4 Page 29 Chapter 4 N38143 10 Check coolant level in the sight glass M1 Warning Hot coolant is under pressure and can cause severe burns when removing t
91. treline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CH4 ACEA E5 Sump capacity maximum 10 6 litres 2 7 US galls min Normal operating angles 25 continuously at all angles Oil pressure in operating speed range steady 200kPa 29psi Low oil pressure switch setting 80kPa 12psi Electrical System Generator buo ket 55A 12V HAM iecit uuu 12 volt 2 0 kW Number of teeth in 126 Number of teeth 9 Cold Start Limits Minimum cold start temperature with aid 15 C 5 F Batteries for min cold 1 x 12 volt 540 amps to BS3911 or 1 x 12 volt 740 amps to SAE J537 Data 422TGM 1500 rev min 1800 rev min Basic Technical Data Prime power mechanical 25 2kW 33 8 30 3kW 40 6hp oiii 4 Cylinder arrangement sse In line CY CIS 4 stroke Induction system 1
92. uate levels of corrosion inhibitor are present It will give frost protection to 370C 34 60F Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 80 l min 21 US galls min 97 l min 25 6 US galls min Coolant pump speed and method of drive 1 25 1 ratio belt driven System capacity 8 75 litres 2 31 US galls Pressure cap Setting 50kPa 7 psi Protection switch setting 96 2059F Sea water pump Jabsco gear driven model 19mm 0 75 3 4 cam Sea water suggested inlet hose diameter 32mm 1 257 Sea COCK si cte tti dede Full flow 25 4mm 1 00 max lift of seawater pump 2m m Full flow 38 1mm 1 25 max lift of seawater pump 4m Strainer A raw water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea Water NOW u sasa s 53 I min 14 US galls min 69 l min 18 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number a emnes 45 minimum Fuel injection pump Zexel PTR inline pump with electronic go
93. ure 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression 125mm H O 5 in H O Suggested ventilation airflow including combustion alr luu asas 31m min 1095 ft min Minimum cross section of air duct per engine uuu massa 348cm 54sq ins for hot climates 174cm2 27sq ins for temperate climates Exhaust Exhaust gas flow 13 1m3 min 462 ft3 min 15 9m3 min 561 ft3 min Maximum restriction measured within 305 mm 12 outlet u 6 1 76 Hg Recommended pipe bore wet exhaust 76 2mm 83 07 Recommended pipe bore dry 60mm 2 367 Minimum rise from sea water level to exhaust outlet centreline 203mm 8 0 Lubricating System Recommended lubricating oil AP1 CD SE CCMC D4 Sump capacity maximum 15 litres 4 US gallons Normal operating angles 25 from horizontal in any direction Oil pressure in operating speed range steady state 310 to 390 kPa 45 to 57 psi Low oil pressure switch setting 83kPa 12 psi Electrical System Gene Pre
94. vernor Fuel lift DUMP sisan FCM type XY lever operated diaphragm pump 42 0 kPa 6 1 10 2 Ibf in Govertlor type ici Electronic Page 71 Pipe size Supply Outside 7 9 mm 0 315 s Supply io ere eram e ee nte 6 53 mm 0 2577 Return Outside 6 3 mm 0 257 IReturm eget bee 4 93 mm 0 194 Maximum lift pump lift 1 53 m 5 ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 120 mm 4 72 Hg Fuel consumption at full power 6 7 Ihr 1 8 US galls hr 7 4 hr 2 0 US galls hr Air Intake Combustion airflow 1 8 m3 min 65 ft3 min 2 2 m3 min 77 ft3 min Maximum engine compartment air temperature 609C 1409F Maximum air temperature at engine inlet 52 1269F Ventilation maximum engine room depression u u 125mm H O 5 in H O Minimum cross section of air duct per engine 135 cm 21 sq ins for hot climates OT 71 cm 11 sq ins for temperate climates Exhaust Exhaust gas flow 5 0 m3 min 175 ft3 min 5 75 m3 min 203 ft3 min
95. w water strainer must be included in the suction side of the circuit Maximum sea water temperature 38 C 100 F Sea water flow 73 l min 19 galls min 91 l min 24 US galls min Fuel System Recommended fuel specifications BS2869 Class A2 ASTM D 975 Number 2D Cetane number u uuu 45 minimum Fuel injection pump Stanadyne rotary and electric stop Energised to run Fuel lift PUM RL AC Delco type LU DeliVery u aia 89 I hr 23 5 US galls hr 98 I hr 25 9 US galls min rito idi 30kPa 4 4 PSI GOVERNON TYPO ait decida ad Mechanical Page 75 Pipe size Supply Outside diameter 7 9mm 0 315 Supply Bore 6 53mm 0 257 Return Outside 6 3mm 0 257 BO os enero t etate 4 93mm 0 194 Maximum lift pump lift 1 8m 6ft to bottom of tank suction pipe Maximum fuel lift pump depression at inlet 127mm 5 Hg Fuel consumption at full power 17 1 l hr 4 5 US galls hr 19 9 5 3 US galls hr Air Intake Combustion airflow 4 52m min 159 ft min 5 85m min 206 ft min Maximum engine compartment air temperat
96. wet and dry Caution In all types of exhaust system when measured within 305mm 12 inches of the exhaust outlet from the engine the exhaust back pressure must not exceed the amount stated in the relevant data section at the back of this manual Wet Systems Wet exhaust systems where the raw water used to circulate through the heat exchangers on the engine is finally injected 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 A general arrangement for such a system is shown on A In many cases the exhaust outlet passes through the transom just above the waterline A1 It will be seen that a minimum fall of 10 degrees is required A2 and that the point of water injection must be at least 200mm 8 inches above the waterline A3 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 Exhaust pipes Engine model Exhaust bore Exhaust bore 415GM 4 4GM 76mm 3 0 ins 422GM 50mm 2 0ins 4 4TGM 422TGM 4 4TWGM 700GM 63 5mm 2 5ins 4 4TW2GM 100mm 4 0ins 6TG2AM 76mm 3in

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