Installation Manual: 415GM 422GM 422TGM 700GM
Installation Manual: 415GM 422GM 422TGM 700GM
Installation Manual: 415GM 422GM 422TGM 700GM
® GB
Installation Manual
415GM 422GM 422TGM 700GM
4.4TWGM &
4.4GM Radiator 4.4TW2GM Radiator
N38143 Title
415GM
422GM
422TGM
700GM
4GM
4TGM
4.4GM
4.4TGM
4.4TWGM
4.4TW2GM
6TG2AM
6TWGM
4.4GM Radiator
4.4TWGM Radiator
4.4TW2GM Radiator
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.
N38143 Contents
Introduction....................................................................................................... 4
Exhaust systems...............................................................................7
Wet Systems..................................................................................................... 7
Water lift systems............................................................................................. 8
Syphon break.................................................................................................... 9
Part wet/part dry systems............................................................................... 10
Water separator............................................................................................... 11
Dry systems..................................................................................................... 12
Fuel systems.....................................................................................15
Fuel connections............................................................................................. 15
Fuel connections - 415GM, 422GM, 422TGM & 700GM............................. 15
Fuel connections - 4GM, 4TGM 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM,
6TG2AM 6TWGM & Radiator Versions....................................................... 15
Fuel tank connections..................................................................................... 16
Typical fuel systems........................................................................................ 16
Electrical system..............................................................................45
Electrolytic corrosion..................................................................................... 45
Definition of galvanic and electrolytic corrosion........................................... 45
Avoiding electrolytic corrosion...................................................................... 45
Zinc Anode bonding system.......................................................................... 46
Battery and starter cables.............................................................................. 46
Other electrical features 415GM, 422GM & 422TGM.................................... 48
APECS calibration tool (ACT) part number 36204........................................ 50
Electronic governor overview........................................................................ 51
Electronic governor in detail.......................................................................... 52
Controller installation and wiring diagram.................................................... 52
Controller wiring table.................................................................................. 53
System wiring............................................................................................... 53
Other electrical features 700GM.................................................................... 54
APECS calibration tool (ACT) part number 36204........................................ 56
Electronic governor overview........................................................................ 57
Electronic governor in detail.......................................................................... 58
Controller installation and wiring diagram.................................................... 58
Controller wiring table.................................................................................. 59
System wiring............................................................................................... 59
Other electrical features 4GM & 4TGM.......................................................... 60
L Series electronic governor guidelines....................................................... 61
Other electrical features 4.4GM, 4.4TGM, 4.4TWGM & 4.4TW2GM............. 62
Standard control system (optional on 4.4 range)......................................... 64
Voltage Converter Fitting Instructions.......................................................... 64
For the 4.4 range of engines supplied without a loom................................ 65
Other electrical features 6TG2AM.................................................................. 66
Other electrical features 6TWGM................................................................... 67
Electronic governor........................................................................................ 68
6TWGM from March 2014............................................................................... 70
L Series electronic governor guidelines....................................................... 70
Data - 415GM.................................................................................................... 71
Data - 422GM.................................................................................................... 73
Data - 422TGM................................................................................................. 75
Data - 700GM.................................................................................................... 77
Data - 4GM........................................................................................................ 79
Data - 4TGM...................................................................................................... 81
Data - 4.4GM..................................................................................................... 83
Data - 4.4TGM................................................................................................... 85
Data - 4.4TWGM............................................................................................... 87
Data - 4.4TW2GM............................................................................................. 89
Data - 6TG2AM................................................................................................. 91
Data - 6TWGM.................................................................................................. 93
Data - 4.4GM Radiator..................................................................................... 95
Data - 4.4TGM Radiator................................................................................... 97
Data - 4.4TWGM Radiator................................................................................ 99
Data - 4.4TW2GM Radiator............................................................................. 101
N38143 Chapter 1
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.
Page 1
Chapter 1 N38143
Radiator Cooling:
Note: Only flexible ducts to be used on the front of the radiator.
Note: Ducting or duct-work should not be hard mounted to the genset or radiator. The genset is fitted with
flexible mounts and therefore is able to vibrate and slightly move in operation. A flexible compensation section
should be used in any duct which is fitted to the genset or radiator, in order to take up slight movements without
causing undue stress to either the duct-work or genset components.
The radiator cooling pack option uses air to cool the engine, rather than sea water. As such a good supply of
air is vital to achieving the correct cooling performance. Not only is the supply of air important but so is the
exhaust of air from the radiator. The complete air circuit must be given great consideration to achieve the
correct cooling performance.
Illustration A shows the cooling air circuit. Although the exact details of the layout will need to vary from
installation to installation, the basic air circuit will remain the same. The marine genset utilises a pusher fan,
which draws cooling air from the inlet (A2) over the generator and engine (A1), and then pushes through the
radiator and charge air cooler. Typically the exhaust from the radiator and charge air cooler then exit the engine
room via a vent to outside (A3). Cool air enters the engine room from outside through another set of vents.
The radiator cooling system is designed for a maximum air temperature behind the genset of 50OC. The design
accounts for the radiated heat from the engine and generator which will lead to air temperatures greater than
50OC at the inlet to of the radiator fan. The design does not account for any other heat sources in the engine
bay. If other sources of heat are present then additional ventilation will need to be considered. This is especially
important for gensets likely to operate in hotter climates.
The radiator cooling system is designed to operate with a maximum duct restriction pressure of 127Pa (0.5 in
H20). The pressure is measured from a location in-front of the fan (typically along the length of the engine) to
a location directly in-front of the radiator outlet, illustrations (B3) and (C). In this way the total pressure over the
cooling pack(B2) is measured, including both the restrictions encountered in drawing the air into the engine
and the restriction encountered in air exiting the engine room. When designing the engine room ventilation a
pressure restriction target of 63.5Pa should be aimed for, although lower is better.
In order to measure the duct restriction of an installation, static pressure tubes will be required. Use of any
other means is likely to give inaccurate results. A water manometer (B4) is normally sufficient for measuring the
pressure. The static tube should be aligned parallel with the air flow. A fine thread on a stick is a useful tool in
identifying the direction of air flow over the engine. (Care should be taken to keep it away from rotating parts,
including the fan) Illustrations B and C shows typical locations of the static tubes used for taking pressure
readings.
Page 2
N38143 Chapter 1
2 Height.
3 Air flow.
An alternative to taking pressure measurements is to measure the air flow through the radiator. This can be
done using an anemometer to measure the air velocity through an opening of known area, from which the
volumetric flow can be calculated. As air density decreases with temperature, to get an accurate reading air
flow measurements should be taken with the generator running, but at no load, such that there is minimum
heating of the air flow.
Anemometers are specifically available for ventilation and duct work, an instrument of this type should be used
where possible. Measurements should be made where air flow is uniform, ideally just after the radiator outlet,
but not after any louvers, bends or obstructions which could lead to non-uniform air velocities. An accurate
measurement of volumetric flow is best made by taking at least twelve air velocity readings across the opening.
Page 3
Chapter 1 N38143
It is best to draw up a grid with each cell being of equal area. Air velocity readings are then averaged, to give a
total average air velocity through the opening. This is then multiplied by the opening area to give the volumetric
air flow.
Illustration (E) shows the layout of the grid for calculating the volumetric flow
TMI contains air flow data for the fans fitted to CAT generator sets along with the restriction curves for radiator
cores. Overlaying the two curves will give the operating volumetric air flow at the curve intersection point. If
the air flow is measured then the total pressure across the fan can be measured of the fan curve. Given the
air flow reading, the pressure drop can also be read off the radiator restriction curve. The difference in the two
pressures is the total duct restriction present within the air system.
• Q = h x w x vm
• vm = (v1 + v2 + v3 + v4 + … + v12) / 12
Where:
• Exhaust pipes should be lagged, right from the turbine outlet. The lagging should be sufficient to
ensure that the external surface temperature does not exceed 220OC at full load. This helps to ensure
that no extra heat is carried into the radiator air.
• Exhaust routing should, where possible, be away from the radiator so that the air flow into the radiator
is not impeded.
• Ensure there is sufficient space in front and behind of any exhaust or inlet vent (see illustration (D),
this includes:
◦◦ Fire / heavy weather hatches should be able to fully open away from the vent.
◦◦ Placing the vent such that a bulkhead is not immediately in front or behind the opening.
◦◦ A suggested clearance between the vent and any bulkhead or otherwise is at least the longest of
the height or width of the vent itself.
• Inlet air vents should be placed such that they pick up cool ambient air, not air which has picked up any
additional heat, such as air exhausted from another engine room.
• The exhaust vent should have a frontal area equivalent to the total radiator exit area and ideally the
same dimensions. If this cannot be achieved then tapered ductwork should be used to adapt the
two together. A minimum length of 1m (3’ 3”) is recommended for any adapting ductwork, where a
significant dimension change needs to take place.
Illustration D shows the basic considerartions for allowing the genset to cool and breath.
1 Engine room.
Page 4
N38143 Chapter 1
2 Vents.
The graphs below show the variation on engine power output based on changes to air inlet temperature and
fuel density. The power output change with fuel is the same across all engines regardless of cooling system.
The power output change with inlet air temperature does however depend on the charge air cooling method.
Engines using an air to water cooler, Heat Exchanged and Keel Cooled, have less variation. This is due to the
water being a more stable heat-sink, with resulting inlet manifold air temperatures being stable also. Air to air
cooling methods, Radiators, are less stable with the ambient air being used to cool the charge air, leading to
high output variability.
CAT engines have their rated power defined at standardised conditions; typically these are 25OC air and 850
kg/m3 fuel. As such operating in conditions away from these will likely cause engine power output to drop. This
should be born in mind when designing engine room ventilation, so that ambient air temperatures are kept to
a minimum.
108
106
104
102
100
98
96
94
92
90
0 10 20 30 40 50 60
1 Power adjustment
Engine - %. By Fuel Density
Power Adjustment
SAE J1995 Rating Standard
102.0
2 Engine power adjustment by ambient temperature. SAE J1995 rating standard.
101.0
3 Ambient temperature.
Power Adjustment - %
100.0
99.0
4 Radiator.
96.0
0.8 0.81 0.82 0.83 0.84 0.85 0.86 0.87 0.88
Fuel Density - kg/m3
Page 5
Chapter 1 N38143
102.0
101.0
100.0
99.0
98.0
97.0
96.0
800 810 820 830 840 850 860 870 880
1 Power adjustment - %.
Page 6
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.
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 Engine mode Exhaust bore
415GM 4.4GM & Rad. 76mm (3.0 ins)
422GM 50mm (2.0ins) 4.4TGM & Rad.
422TGM 4.4TWGM & Rad.
700GM 63.5mm (2.5ins) 4.4TW2GM & Rad. 100mm (4.0ins)
4GM 6TG2AM
76mm (3ins)
4TGM 6TWGM 125mm (5ins)
Page 7
Chapter 2 N38143
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 (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.
Page 8
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 riser 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.
Page 9
Chapter 2 N38143
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 10o. The table below shows the recommended minimum sizes.
Model Minimum diameter of dry part of Minimum diameter of wet part of exhaust
exhaust system system
415GM 51mm (2ins)
422GM
40mm (1.6ins)
422TGM 63.5mm (2.5ins)
700GM
4GM
4TGM
60mm (2.36ins) 76mm (3ins)
4.4GM & Rad
4.4TGM & Rad
4.4TWGM & Rad.
4.4TW2GM & Rad. 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.
Page 10
N38143 Chapter 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 11
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 dry 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.
Bellows should be in an unstrained condition when installed, so that the full bellows movement is available to
absorb expansion and engine movement.
Page 12
N38143 Chapter 2
Page 13
Chapter 2 N38143
The weight of the exhaust system should be supported by brackets and not carried by the bellows, as shown
in (G).
1. 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
2. Insulating lagging
3. Rigid bracket to support the weight of the vertical exhaust system
4. Heat blanket
5. Twin stainless steel bellows fitted to avoid torsional load on bellows unit - it is strongly recommended that
twin bellows are used.
6. Turbocharger adaptor (except 415GM, 422GM, 700GM, 4GM, & 4.4GM)
7. 90o elbow
Page 14
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:
Page 15
Chapter 3 N38143
• 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 panel 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.
Page 16
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 locks 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.
Page 17
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 18
N38143 Chapter 4
A completely separate sea water system should be provided for each engine to prevent a blockage resulting
in the need to shut down more than one engine.
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 taken 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 19
Chapter 4 N38143
Note: Where possible mount the strainer so that the top is just above the waterline to facilitate cleaning.
Page 20
N38143 Chapter 4
Page 21
Chapter 4 N38143
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 25oC, then
when sizing the grid coolers the maximum coolant temperature returning to the intercooler of 43oC could be
used and 75oC coolant temperatures returning to the engine circuit.
Page 22
N38143 Chapter 4
1. Connections
2. Flow
3. Keel cooler
4. Engine
Page 23
Chapter 4 N38143
1. Connections
2. Flow
3. Keel cooler
4. Combined header tank and exhaust manifold
5. Thermostat
6. Engine
7. Fresh water pump
8. By pass
Page 24
N38143 Chapter 4
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 25
Chapter 4 N38143
1. Connections
2. Flow
3. Keel cooler
4. Remote tank
5. Fresh water pump
6. Thermostat
7. Engine
8. Integral engine oil cooler
9. Exhaust manifold
Page 26
N38143 Chapter 4
Page 27
Chapter 4 N38143
1. Connections
2. Flow
3. Keel cooler
4. Thermostat
5. Bleed pipe
6. Engine oil filter
7. Engine oil cooler
8. Fresh water pump
9. Engine
10. High water temperature switch
11. Header tank
12. Exhaust manifold
Page 28
N38143 Chapter 4
Page 29
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 around 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 50oC at both 1500 and 1800
rev/min, 50% ethylene glycol 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 1.8m3/s for the Na/
turbo and 2.5m3/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 5% 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:
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 to the
expansion tank without using tee’s or other fittings that would join the bleed pipes together in a common
vent.
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N38143 Chapter 4
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Chapter 4 N38143
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).
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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).
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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 the pressure cap. First
release the pressure in the system by loosening the pressure cap.
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N38143 Chapter 4
1. Remote expansion tank - 4GM, 4TGM and 6TG2AM
A remotely 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.
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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.
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N38143 Chapter 4
6. Fill the remote expansion tank with 50% antifreeze solution (Q1) to the maximum position on the sight glass
(Q2).
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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.
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N38143 Chapter 5
Note: Fitting the PTO should be undertaken by a qualified marine engineer.
Warning! For safety reasons, all moving parts should be shielded by a guard.
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Chapter 5 N38143
• 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.
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N38143 Chapter 5
Caution: Additional inertia must not be added to the P.T.O. without specialist advice. Consult your distributor
if you need advice about non-standard drive arrangements.
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Chapter 5 N38143
• 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.
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N38143 Chapter 5
• 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.
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Chapter 5 N38143
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N38143 Chapter 6
Electrical system
Electrolytic corrosion
Caution: The engine may be damaged by electrolytic corrosion (stray current corrosion) if the correct bonding
procedure is not adopted.
Electrolytic corrosion (stray current corrosion) is caused by a current from an external source such as the boats
battery or shore supply.
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 in (A).
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:
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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 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.
• 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 -18OC.
• SAE J537 is similar except that the current is only maintained for 30 seconds and the voltage is allowed to
fall to 7.2 volts.
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N38143 Chapter 6
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
Nominal resistance in
*Maximum total length Nominal C.S.A. Approx. equivalent size
Cable size ohms
metric English America
Metres Feet mm2 in2 Per metre Per foot
imperial B&S SAE
5.6 19.00 61/1,13 61 0.0948 0,000293 0.0000890 61/.044 00
9,0 28.30 19/2,52 95 0.1470 0,000189 0.0000600 513/.018 000
* The length of all cables in the starter circuit (whether positive or negative), should be added together to give the ‘Total
Length’
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.
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.
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Chapter 6 N38143
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N38143 Chapter 6
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Chapter 6 N38143
Note: The APECS unit must be powered up, but need not be mounted on the engine to carry out the calibration
procedure.
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N38143 Chapter 6
If the electronic governor fails, the mechanical governor will control the maximum engine speed to 2050 rev/
min.
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.
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Chapter 6 N38143
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N38143 Chapter 6
Model 3100
Battery Red +
Black -
Actuator White +
White/Black -
Speed signal input Magnetic pickup
Blue +
Green -
1500 (50Hz) Violet
1800 (60Hz) Gray
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.
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Chapter 6 N38143
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N38143 Chapter 6
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Chapter 6 N38143
Note: The APECS unit must be powered up, but need not be mounted on the engine to carry out the calibration
procedure.
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N38143 Chapter 6
If the electronic governor fails, the mechanical governor will control the maximum engine speed to 2050 rev/
min.
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.
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Chapter 6 N38143
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N38143 Chapter 6
Model 3100
Battery Red +
Black -
Actuator White +
White/Black -
Speed signal input Magnetic pickup
Blue +
Green -
1500 (50Hz) Violet
1800 (60Hz) Gray
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.
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Chapter 6 N38143
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N38143 Chapter 6
Note: If any features are not required in the application, the related wiring may be omitted.
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Chapter 6 N38143
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N38143 Chapter 6
1.
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Chapter 6 N38143
• 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 from the engine and the other in the rear of the control box.
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N38143 Chapter 6
A pinout of the L Series speed controller, as viewed into the control connector, is shown below. (H)
Note: Power supply must be connected directly from the associated battery to pin 1 via a 5A fast acting fuse.
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Chapter 6 N38143
Note: The engine speed controller is mechanical and contains the adjustment screws to set the engine speed
for the 6TG2AM.
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N38143 Chapter 6
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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 (I2) to position 30 on the dial.
Note: The settings on the dial are in increments of 10.
3. Turn the adjustment screw (I1) 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 (I2)
gradually in a clockwise direction, to a position just above 30 on the dial.
6. Apply a load to the engine and check that the speed and governing are correct. If necessary, repeat operation
5.
7. If the time taken is too quick and the engine is erratic, turn the adjustment screw (I2) gradually in a counter-
clockwise direction, to a position just below 30 on the dial.
8. Apply load to the engine and check that the speed and governing are correct. If necessary, repeat operation
7.
Note: It may be necessary to make further adjustments to the screws (I1) and (I2) until the correct speed and
governing are obtained.
Caution: Any adjustments to these screws must be made gradually.
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N38143 Chapter 6
Identification of component numbers in triangles
Number Description
1 Controller for engine speed
2 Actuator
3 Electro-magnetic sensor
4 Battery
5 Connector
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.
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Chapter 6 N38143
Note: If any features are not required in the application, the related wiring may be omitted.
Page 70
N38143 Data
Data - 415GM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power, (mechanical).................. 12.3kW (16.5 hp)..................... 14.7kW (19.7hp)
Number of cylinders.................................................................3
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.........................................................Naturally Aspirated
Bore................................................................................ 84mm (3.31”)
Stroke............................................................................. 90mm (3.54”)
Compression ratio................................................................22.5:1
Cubic capacity..................................................................... 1496cc
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order...........................................................................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 -37oC. (-34.6oF)
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 capacity....................................................... 8 litres (2.4 US galls)
Pressure cap setting.......................................................50 kPa (7 psi)
Protection switch setting..................................................96oC (205oF)
Sea water pump type..................................... Jabsco gear driven model size 40
Sea water suggested inlet hose diameter.................... 25.4mm (1.00”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
Strainer..............................A raw water strainer must be included in the suction side of the circuit.
Maximum sea water temperature....................................38oC (100oF)
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............................................................... 45 minimum.
Fuel injection pump.......................... Cassette type, inline pump with electronic governor
Fuel lift pump....................................................................Mechanical
Governor type....................................................................Electronic
Page 71
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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 l/hr (1.0 US galls/hr) ..........4.5 l/hr (1.2 US galls/hr)
Air Intake
Combustion airflow................................................ 1.07m3/min (37.9 ft3/min) 1.26m3/min (44.4 ft3/min)
Maximum engine compartment air temperature..............60oC (140oF)
Maximum air temperature at engine inlet........................52oC (126oF)
Ventilation - maximum engine
room depression...................................................... 125mm H2O (5in H2O)
Minimum cross section
of air duct (per engine)...................................65 cm2(10 sq ins) for hot climates.
................................................................ 32 cm2 (5 sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................. 2.75m3/min (97ft3/min)............ 3.37m3/min (119ft3/min)
Maximum restriction measured
within (305 mm) 12” outlet..........................................10.13kPa (3.0” Hg)
Recommended pipe bore (wet exhaust)......................... 50mm (2.0”)
Recommended pipe bore (dry)........................................ 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............................... 25o from horizontal in any direction
Oil pressure, in operating
speed range (steady state)............................................200kPa (29psi)
Low oil pressure switch setting.......................................80kPa (12psi)
Electrical System
Generator..........................................................................55A (12V)
Starter............................................................................ 12 volt 2.0 kW
Number of teeth in flywheel....................................................109
Number of teeth on starter.......................................................9
Cold Start Limits
Minimum cold start temperature (with aid)....................... -15oC(5oF)
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 72
N38143 Data
Data - 422GM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power, (mechanical).................. 18.4kW (24.7 hp).......................22kW (29.5hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.........................................................Naturally Aspirated
Bore................................................................................ 84mm (3.31”)
Stroke............................................................................ 100mm (3.94”)
Compression ratio................................................................23.3:1
Cubic capacity..................................................................... 2216cc
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................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 -37oC. (-34.6oF)
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........................................................50kPa (7psi)
Protection switch setting..................................................96oC (205oF)
Sea water pump type..................................... Jabsco gear driven model size 40
Sea water suggested inlet hose diameter.................... 25.4mm (1.00”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
Strainer..............................A raw water strainer must be included in the suction side of the circuit.
Maximum sea water temperature....................................38oC (100oF)
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............................................................... 45 minimum.
Fuel injection pump.......................... Cassette type, inline pump with electronic governor
Fuel lift pump....................................................................Mechanical
Governor type....................................................................Electronic
Page 73
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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....... 5.2 l/hr (1.4 US galls/hr) ..........6.2 l/hr (1.6 US galls/hr)
Air Intake
Combustion airflow.........................1.46m3/min (51.5ft3/min)............ 1.76m3/min (62ft3/min)
Maximum engine compartment air temperature..............60oC (140oF)
Maximum air temperature at engine inlet........................52oC (126oF)
Ventilation - maximum engine
room depression...................................................... 125mm H2O (5in H2O)
Minimum cross section
of air duct (per engine)...................................103cm2(16sq ins) for hot climates.
................................................................52cm2 (8sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................ 3.51m3/min (124ft3/min)........... 4.45m3/min (157ft3/min)
Maximum restriction measured
within (305 mm) 12” outlet......................................... 10.13 kPa (3.0” Hg)
Recommended pipe bore (wet exhaust)......................... 50mm (2.0”)
Recommended pipe bore (dry)........................................ 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................................... 10.6 litres (2.7 US galls/min)
Normal operating angles....................................25o continuously at all angles
Oil pressure, in operating
speed range (steady state)............................................200kPa (29psi)
Low oil pressure switch setting.......................................80kPa (12psi)
Electrical System
Generator..........................................................................55A (12V)
Starter............................................................................ 12 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)....................... -15oC(5oF)
Batteries for min cold start............................... 1 x 12 volt 540 amps to BS3911
..................................................................or 1 x 12 volt 740 amps to SAE J537
Page 74
N38143 Data
Data - 422TGM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power, (mechanical)...................25.2kW (33.8hp)...................... 30.3kW (40.6hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.............................................................Turbocharged
Bore................................................................................ 84mm (3.31”)
Stroke............................................................................ 100mm (3.94”)
Compression ratio................................................................23.3:1
Cubic capacity..................................................................... 2216cc
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet).......................267kg (589lbs) 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 -37oC. (-34.6oF)
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........................................................50kPa (7psi)
Protection switch setting..................................................96oC (205oF)
Sea water pump type..................................... Jabsco gear driven model size 40
Sea water suggested inlet hose diameter.................... 25.4mm (1.00”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
Strainer.............................. A raw water strainer must be included in the suction side of the circuit.
Maximum sea water temperature....................................38oC (100oF)
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............................................................... 45 minimum.
Fuel injection pump.......................... Cassette type, inline pump with electronic governor
Fuel lift pump....................................................................Mechanical
Governor type....................................................................Electronic
Page 75
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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....... 5.2 l/hr (1.4 US galls/hr) ..........6.2 l/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..............60oC (140oF)
Maximum air temperature at engine inlet........................52oC (126oF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Minimum cross section
of air duct (per engine).................................. 103cm2 (16sq ins) for hot climates.
................................................................52cm2 (8sq 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 (2.5”)
Recommended pipe bore (dry)........................................ 50mm (2.0”)
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................................... 10.6 litres (2.7 US galls/min)
Normal operating angles....................................25o continuously at all angles
Oil pressure, in operating
speed range (steady state)............................................200kPa (29psi)
Low oil pressure switch setting.......................................80kPa (12psi)
Electrical System
Generator..........................................................................55A (12V)
Starter............................................................................ 12 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)....................... -15oC(5oF)
Batteries for min cold start................................ 1 x 12 volt 540 Amp to BS3911
..................................................................or 1 x 12 volt 740 amps to SAE J537
Page 76
N38143 Data
Data - 700GM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power........................................ 27.2kW (36.5 hp).....................31.8kW (42.7 hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.........................................................Naturally Aspirated
Bore................................................................................ 97mm (3.82”)
Stroke............................................................................ 100mm (3.94”)
Compression ratio................................................................17.5:1
Cubic capacity............................................................. 3.0 litres (183in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................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 adequate levels of corrosion
inhibitor are present. It will give frost protection to -37OC. (-34.6OF)
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................................................. 96OC (205OF)
Sea water pump type........................ Jabsco gear driven model 19mm (0.75”) 3/4 cam.
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
Sea water flow.............................. 53 l/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............................................................... 45 minimum.
Fuel injection pump.............................Zexel PTR, inline pump with electronic governor
Fuel lift pump....................................... FCM type XY - lever operated diaphragm pump
Pressure............................................................ 42 - 70 kPa (6.1 - 10.2 Ibf/in2)
Governor type....................................................................Electronic
Page 77
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9 mm (0.315”)
• Supply - Bore............................................................ 6.53 mm (0.257”)
• Return - Outside diameter........................................... 6.3 mm (0.25”)
• Return - Bore............................................................. 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 l/hr (1.8 US galls/hr) ..........7.4 l/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............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Minimum cross section
of air duct (per engine)..................................135 cm2(21 sq ins) for hot climates.
..............................................................71 cm2 (11 sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................ 5.0 m3/min (175 ft3/min).......... 5.75 m3/min (203 ft3/min)
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 (dry)....................................... 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............................... 25O 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
Generator..........................................................................70A (12V)
Starter type..........................................................Magneti Marelli 12V 2.5 kW
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)....................... -15OC(5OF)
Batteries for min cold start.........................1 x 12 volt 540 Amp SAE (340 Amp IEC)
Page 78
N38143 Data
Data - 4GM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power..........................................39.5kW (53 hp).......................46.5kW (62.3 hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.........................................................Naturally Aspirated
Bore............................................................................. 100 mm (3.937”)
Stroke........................................................................... 127 mm (5.00”)
Compression ratio................................................................. 16:1
Cubic capacity.......................................................... 3.99 litres (243.0 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet)......................449 kg (990 lbs) 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 -37OC. (-34.6OF)
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 setting.......................................................50 kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type......................... Jabsco gear driven model 25.4 mm (1”) full cam.
Sea water suggested inlet hose diameter..................... 32 mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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............................................................... 45 minimum.
Fuel injection pump........................Stanadyne rotary and electric stop. (Energised to run).
Fuel lift pump.............................................................. AC Delco type LU
Delivery/hour........................................................ 89 l/hr (23.5 US galls/min) 98 l/hr (25.9 US galls/min)
Pressure.......................................................................30 kPa (4.4 PSI)
Governor type...................................................................Mechanical
Page 79
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9 mm (0.315”)
• Supply - Bore............................................................ 6.53 mm (0.257”)
• Return - Outside diameter........................................... 6.3 mm (0.25”)
• Return - Bore............................................................. 4.93 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 l/hr (2.5 US galls/hr) .........13.6 l/hr (3.6 US galls/hr)
Air Intake
Combustion airflow..........................2.64m3/min (93 ft3/min)............3.19m3/min (112 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Suggested ventilation airflow
including combustion air...........................................18.6m3/min (657ft3/in)
Minimum cross section
of air duct (per engine)..................................200 cm2(31 sq ins) for hot climates.
.............................................................103 cm2 (16 sq ins) for temperate climates.
Exhaust
Exhaust gas flow........................... 7.54 m3/min (266 ft3/min)......... 9.09 m3/min (321 ft3/min)
Maximum restriction measured
within (305 mm) 12” outlet............................................6 kPa (1.76” Hg)
Recommended pipe bore (wet exhaust)....................... 76.2mm (3.0”)
Recommended pipe bore (dry)....................................... 60mm (2.36”)
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/min)
Normal operating angles............................... 25O from horizontal in any direction
Oil pressure, in operating
speed range (steady state)..................................310 to 390kPa (45 to 57psi)
Low oil pressure switch setting...................................... 83kPa (12 psi)
Electrical System
Generator................................................. Prestolite AS128 90A (24V) or 55A (12V)
Starter type....................................................................Prestolite S115
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid).........................-15C(5F)
Batteries for min cold start.a qty of 2 12V 315 Amps to BS3911 or 2 off - 12V, 535 amps to SAE J537
Page 80
N38143 Data
Data - 4TGM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power.........................................68.5kW (91.9hp).......................80.5kW (108hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.............................................................Turbocharged
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................. 16:1
Cubic capacity............................................................3.99 litres (243 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet)......................456kg (1005lbs) 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 -37OC (-34.6OF).
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 capacity...................................................... 18 litres (4.8 US galls)
Pressure cap setting........................................................50kPa (7psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type......................... Jabsco gear driven model 25.4 mm (1”) full cam.
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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................................................................ 45 minimum
Fuel injection pump........................Stanadyne rotary and electric stop. (Energised to run).
Fuel lift pump.............................................................. AC Delco type LU
Delivery......................................... 89 l/hr (23.5 US galls/hr)........98 l/hr (25.9 US galls/min)
Pressure....................................................................... 30kPa (4.4 PSI)
Governor type...................................................................Mechanical
Page 81
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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 l/hr (5.3 US galls/hr)
Air Intake
Combustion airflow.........................4.52m3/min (159 ft3/min).......... 5.85m3/min (206 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine room depression.....125mm H2O (5 in H2O)
Suggested ventilation airflow
including combustion air......................................... 31m3/min (1095 ft3/min)
Minimum cross section of
air duct (per engine)...................................... 348cm2 (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............................................. 6kPa (1.76” Hg)
Recommended pipe bore (wet exhaust)....................... 76.2mm (3.0”)
Recommended pipe bore (dry)....................................... 60mm (2.36”)
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............................... 25O 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
Generator................................................. Prestolite AS128 90A (12V) or 55A (24V)
Starter type....................................................................Prestolite S115
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)...................... -15OC (5OF)
Batteries for min cold start.a qty of 2 off 12V 315 Amps to BS3911 or 2 off - 12V, 535 amps to SAE J537
Page 82
N38143 Data
Data - 4.4GM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power, (mechanical)...................427kW (57.3 hp)......................49.1kW (65.8 hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.........................................................Naturally Aspirated
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio...............................................................18.23:1
Cubic capacity.................................................................... 4.4 litres
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................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 corrosion
inhibitor are present. It will give frost protection to -37OC. (-34.6OF)
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....................................................... 50kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type............................. Jabsco gear driven model size 25.4mm (1”)
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Pressure.............................................................. 30 - 75kPa (4.4 - 10.9 PSI)
Delivery/hr....................................... 120 - 150 ltr/hr (31.7 US galls/hr to 39.6 US galls/hr)
Governor type..................................................... L Series, electronic governor
Page 83
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 l/hr (3.2 US galls/hr) ........14.5 l/hr (3.8 US galls/hr)
Air Intake
Combustion airflow......................... 3.19m3/min (113 ft3/min).......... 3.58m3/min (126 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Minimum cross section
of air duct (per engine)..................................232 cm2(36 sq ins) for hot climates.
.............................................................116 cm2 (18 sq ins) for temperate climates.
Exhaust
Exhaust gas flow.............................7.6m3/min (268 ft3/min).............8.8m3/min (311 ft3/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............................... 25O 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), 55A (24V)
Starter............................................................................ 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)....................... -15OC(5OF)
Batteries for min cold start.....................................1 x 12 volt 660 Amp SAE
Page 84
N38143 Data
Data - 4.4TGM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power (mechanical)...................56.4 kW (75.6 hp).................... 63.6 kW (85.3 hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.............................................................Turbocharged
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................19.3:1
Cubic capacity.................................................................... 4.4 litres
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet)......................505kg (1113 lbs) 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 -37OC. (-34.6OF)
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....................................................... 50kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type....................................Jabsco gear driven model 25.4 (1”)
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery/hr....................................... 120 - 150 ltr/hr (31.7 US galls/hr to 39.6 US galls/hr)
.........................................................................30 - 75 kPa (4.4 - 10.9 PSI)
Governor type......................................................L series electronic governor
Page 85
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 (5.00”) Hg
Fuel consumption at full power...... 14.8 l/hr (3.9 US galls/hr) ........16.9 l/hr (4.5 US galls/hr)
Air Intake
Combustion airflow......................... 5.0 m3/min (177 ft3/min).......... 5.97 m3/min (211 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Minimum cross section
of air duct (per engine).................................. 302cm2 (47sq ins) for hot climates.
............................................................ 159cm2 (24.7sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................10.1m3/min (357 ft3/min).......... 13.0m3/min (459 ft3/min)
Maximum restriction measured
within (305 mm) 12” outlet............................................ 15kPa (4.4” Hg)
Recommended pipe bore (wet exhaust)....................... 76.2mm (3.0”)
Recommended pipe bore (dry)....................................... 57mm (2.24”)
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............................... 25O 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), 55A (24V)
Starter type....................................................................... 12V 4.0kW
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)....................... -15OC(5OF)
Batteries for min cold start.....................................1 x 12 volt 660 Amp SAE
Page 86
N38143 Data
Data - 4.4TWGM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power (mechanical)..................... 75kW (101 hp)........................82.7kW (111 hp)
Number of cylinders.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system...................................................Turbocharged, aftercooled
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................19.3:1
Cubic capacity............................................................ 4.4 litres (19.3 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet)......................522kg (1151 lbs) 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 -37OC. (-34.6OF)
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 setting....................................................... 50kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type.................................... Jabsco gear driven model 25.4mm
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery/hour.................................... 120 - 150 l/hr (31.7 US galls/hr to 39.6 US galls/hr)
Pressure.............................................................. 30 - 75kPa (4.4 - 10.9 PSI)
Governor type......................................................L series electronic governor
Page 87
Data N38143
Pipe size:
• Supply - Outside diameter ......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 l/hr (5.8 US galls/hr)
Air Intake
Combustion airflow................................................. 7.3 m3/min (258 ft3/min) 9.4 m3/min (332 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine
room depression......................................................125mm H2O (5 in H2O)
Minimum cross section
of air duct (per engine).................................358cm2 (55.5sq ins) for hot climates.
...............................................................81cm2 (28sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................17.7m3/min (625 ft3/min).......... 21.2m3/min (749 ft3/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........................... AP1 CG4/CH4 or ACEA E3/E5
Sump capacity maximum...................................... 15 litres (4 US galls/min)
Normal operating angles............................... 25O 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), 55A (24V)
Starter type...................................................................... 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)....................... -15OC(5OF)
Batteries for min cold start..................................... 1 x 12 volt 660 amp SAE
Page 88
N38143 Data
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.................................................................4
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system................................................... Turbocharged/Aftercooled
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................19.3:1
Cubic capacity............................................................3.99 litres (243 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.........................................................................1, 3, 4, 2
Total weight (wet)......................522kg (1151 lbs) 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 -37OC (-34.6OF).
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 (4.8 US galls)
Pressure cap setting....................................................... 50kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type..........................Jabsco gear driven model 25.4mm (1”) full cam.
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery............................................. 120-150l/hr (31.7 US galls/hr to 39.6 US galls/hr)
Pressure................................................................ 30-75kPa (4.4-10.9 PSI)
Governor type......................................................L series electronic governor
Page 89
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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 l/hr (7.3 US galls/hr)
Air Intake
Combustion airflow..........................7.9m3/min (279 ft3/min)............ 9.9m3/min (350 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine room depression.....125mm H2O (5 in H2O)
Suggested ventilation airflow
including combustion air......................................... 31m3/min (1095 ft3/min)
Minimum cross section of
air duct (per engine)....................................461 cm2 (71.5 sq ins) for hot climates.
........................................................... 231 cm2 (35.8 sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................19.5m3/min (689 ft3/min).......... 24.3m3/min (858 ft3/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..................................AP1 CD/SE CCMC D4
Sump capacity maximum........................................15 litres (4 US gallons)
Normal operating angles............................... 25O 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), 55A (24V)
Starter type........................................................................12V, 4 kW
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)...................... -15OC (5OF)
Batteries for min cold start.......................................1 x 12V, 660 amp SAE
Page 90
N38143 Data
Data - 6TG2AM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power.........................................92.5kW (124 hp)........................99kW (133 hp)
Number of cylinders.................................................................6
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system.............................................................Turbocharged
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................. 16:1
Cubic capacity.......................................................... 5.99 litres (365.0 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.....................................................................1, 5, 3, 6, 2, 4
Total weight (wet).....................626 kg (1380 lbs) 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 -37OC (-34.6OF).
Coolant..............50% inhibited ethylene glycol or 50% inhibited propylene glycol with 50% fresh clean water
Fresh water flow ................................................123 l/min (32.5 US galls/min) 150 l/min (40 US galls/min)
Coolant pump speed and method of drive................... 1:1 Gear driven
System capacity...................................................... 24 litres (6.3 US galls)
Pressure cap setting.......................................................50 kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Sea water pump type..........................Jabsco gear driven model 25.4mm (1”) full cam.
Sea water suggested inlet hose diameter...................... 32mm (1.25”)
Sea cock........................................ Full flow 25.4mm (1.00”) max lift of seawater pump 2m
................................................... 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................................... 38OC (100OF)
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 number................................................................ 45 minimum
Fuel injection pump........................Stanadyne rotary and electric stop. (Energised to run).
Fuel lift pump.............................................................. AC Delco type LU
Delivery/hour ................................ 122 l/hr (32 US galls/min........ 134 l/hr (35 US galls/min)
Pressure ......................................................................30 kPa (4.4 PSI)
Page 91
Data N38143
Governor type...................................................................Mechanical
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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 l/hr (6.2 US galls/hr).........27.8 l/hr (7.3 US galls/hr)
Air Intake
Combustion airflow......................... 6.12m3min (216 ft3/min).......... 7.78m3/min (275 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine room depression.... 125mm H2O (5in H2O)
Suggested ventilation airflow
including combustion air......................................... 32m3/min (1130 ft3/min)
Minimum cross section
of air duct (per engine).................................. 477cm2 (74sq ins) for hot climates.
..............................................................240cm2 (37sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................ 16.6m3/min (586 ft3/min............ 20m3/min (706 ft3/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............................... 25O from horizontal in any direction
Oil pressure, in operating
speed range (steady state)................................ 300 to 340 kPa (44 to 49 PSI)
Low oil pressure switch setting...................................... 83kPa (12 psi)
Electrical System
Generator................................................. Prestolite AS128 90A (12V) or 55A (24V)
Starter type....................................................................Prestolite S115
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)...................... -15OC (5OF)
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 92
N38143 Data
Data - 6TWGM
1500 rev/min...........................1800 rev/min
Basic Technical Data
Prime power...................................... 125.5kW (168.2 hp).................. 146kW (195.7 hp)
Number of cylinders.................................................................6
Cylinder arrangement...........................................................In-line
Cycle.................................................................................. 4 stroke
lnduction system...................................... Turbocharged, water to air charged cooled
Bore.............................................................................. 100mm (3.937”)
Stroke............................................................................ 127mm (5.00”)
Compression ratio................................................................. 17:1
Cubic capacity..........................................................5.99 litres (365.0 in3)
Valves per cylinder...................................................................2
Direction of rotation........................................Anti-clockwise viewed on flywheel
Firing order.....................................................................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 -37OC (-34.6OF).
Page 93
Data N38143
Governor type......................................................... Mechanical / **Electrical
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 l/hr (6.93 US galls/hr)............................ 37.6 l/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............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine room depression..... 125mm H2O (5in H2O)
Minimum cross section
of air duct (per engine)................................. 626 cm2 (97 sq ins) for hot climates.
.............................................................316 cm2 (49 sq ins) for temperate climates.
Exhaust
Exhaust gas flow............................ 27.8m3/min (800 ft3/min............ 33m3/min (950 ft3/min)
Maximum restriction measured
within (305 mm) 12” of turbocharger outlet.................. 6kPa (1.26” Hg)
Recommended pipe bore (wet exhaust)........................ 127mm (5.0”)
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............................... 25O 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
Generator................................................. Prestolite AS128 90A (12V) or 55A (24V)
Starter type....................................................................Prestolite S115
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)...................... -15OC (5OF)
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 94
N38143 Data
Maximum Airon......................................................................55OC
Air Velocity............................................................................ 5 m/s
Volume Flow...................................................................... 1.53 m3/s
Air pressure Drop over Radiator......................................... 320 kPa
Maximum Duct Restriction.................................................. 200 Pa
Combustion air flow...........................3.92 m3/min @ 1500................ 3.58 m3/min @ 1800
Coolant..............50% inhibited ethylene glycol or 50% inhibited propylene glycol with 50% fresh clean water
Coolant 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....................................................100kPa (14.5 psi)
Protection switch setting................................................. 96OC (205OF)
Fuel System
Recommended fuel specifications..........BS2869 Class A2 ASTM D 975 Number 2D.
Cetane number............................................................... 45 minimum.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Pressure.............................................................. 30 - 75kPa (4.4 - 10.9 PSI)
Delivery/hr....................................... 120 - 150 ltr/hr (31.7 US galls/hr to 39.6 US galls/hr)
Governor type..................................................... L Series, electronic governor
Page 95
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 l/hr (3.2 US galls/hr) ........14.5 l/hr (3.8 US galls/hr)
Air Intake
Combustion airflow......................... 3.19m3/min (113 ft3/min).......... 3.58m3/min (126 ft3/min)
Maximum engine compartment air temperature............. 52OC (126OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Exhaust
Exhaust gas flow.............................7.6m3/min (268 ft3/min).............8.8m3/min (311 ft3/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............................... 25O 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), 55A (24V)
Starter............................................................................ 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)....................... -15OC(5OF)
Batteries for min cold start.....................................1 x 12 volt 660 Amp SAE
Page 96
N38143 Data
Maximum Airon......................................................................55OC
Air Velocity............................................................................ 5 m/s
Volume Flow...................................................................... 1.53 m3/s
Air pressure Drop over Radiator......................................... 320 kPa
Maximum Duct Restriction.................................................. 200 Pa
Combustion air flow............................5.2 m3/min @ 1500.................. 6.1 m3/min @ 1800
Coolant..............50% inhibited ethylene glycol or 50% inhibited propylene glycol with 50% fresh clean water
Coolant 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...................................................... 15.5 litres (4 US galls)
Pressure cap setting....................................................100kPa (14.5 psi)
Protection switch setting................................................. 96OC (205OF)
Fuel System
Recommended fuel specifications..........BS2869 Class A2 ASTM D 975 Number 2D.
Cetane number............................................................... 45 minimum.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery/hr....................................... 120 - 150 ltr/hr (31.7 US galls/hr to 39.6 US galls/hr)
.........................................................................30 - 75 kPa (4.4 - 10.9 PSI)
Governor type......................................................L series electronic governor
Page 97
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 (5.00”) Hg
Fuel consumption at full power...... 14.8 l/hr (3.9 US galls/hr) ........16.9 l/hr (4.5 US galls/hr)
Air Intake
Combustion airflow......................... 5.0 m3/min (177 ft3/min).......... 5.97 m3/min (211 ft3/min)
Maximum engine compartment air temperature............. 52OC (126OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Exhaust
Exhaust gas flow............................10.1m3/min (357 ft3/min).......... 13.0m3/min (459 ft3/min)
Maximum restriction measured
within (305 mm) 12” outlet............................................ 15kPa (4.4” Hg)
Recommended pipe bore (wet exhaust)....................... 76.2mm (3.0”)
Recommended pipe bore (dry)....................................... 57mm (2.24”)
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............................... 25O 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), 55A (24V)
Starter type....................................................................... 12V 4.0kW
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)....................... -15OC(5OF)
Batteries for min cold start.....................................1 x 12 volt 660 Amp SAE
Page 98
N38143 Data
Maximum Airon......................................................................55OC
Air Velocity............................................................................ 5 m/s
Volume Flow...................................................................... 1.53 m3/s
Air pressure Drop over Radiator......................................... 320 kPa
Maximum Duct Restriction.................................................. 200 Pa
Combustion air flow............................7.6 m3/min @ 1500................. 9.56 m3/min @ 1800
Coolant..............50% inhibited ethylene glycol or 50% inhibited propylene glycol with 50% fresh clean water
Coolant 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...................................................... 20 litres (4.4 US galls)
Pressure cap setting....................................................100kPa (14.5 psi)
Protection switch setting................................................. 96OC (205OF)
Fuel System
Recommended fuel specifications..........BS2869 Class A2 ASTM D 975 Number 2D.
Cetane number............................................................... 45 minimum.
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery/hour.................................... 120 - 150 l/hr (31.7 US galls/hr to 39.6 US galls/hr)
Pressure.............................................................. 30 - 75kPa (4.4 - 10.9 PSI)
Governor type......................................................L series electronic governor
Page 99
Data N38143
Pipe size:
• Supply - Outside diameter ......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 4.93mm (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 l/hr (5.8 US galls/hr)
Air Intake
Combustion airflow................................................. 7.3 m3/min (258 ft3/min) 9.4 m3/min (332 ft3/min)
Maximum engine compartment air temperature............. 52OC (126OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Exhaust
Exhaust gas flow............................17.7m3/min (625 ft3/min).......... 21.2m3/min (749 ft3/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........................... AP1 CG4/CH4 or ACEA E3/E5
Sump capacity maximum...................................... 15 litres (4 US galls/min)
Normal operating angles............................... 25O 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), 55A (24V)
Starter type...................................................................... 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)....................... -15OC(5OF)
Batteries for min cold start..................................... 1 x 12 volt 660 amp SAE
Page 100
N38143 Data
Maximum Airon......................................................................55OC
Air Velocity............................................................................ 5 m/s
Volume Flow...................................................................... 1.53 m3/s
Air pressure Drop over Radiator......................................... 320 kPa
Maximum Duct Restriction.................................................. 200 Pa
Combustion air flow...........................8.31 m3/min @ 1500................ 7.89 m3/min @ 1800
Coolant..............50% inhibited ethylene glycol or 50% inhibited propylene glycol with 50% fresh clean water
Coolant 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 (4.8 US galls)
Pressure cap setting....................................................... 50kPa (7 psi)
Protection switch setting................................................. 96OC (205OF)
Fuel System
Recommended fuel specifications..........BS2869 Class A2 ASTM D 975 Number 2D.
Cetane number................................................................ 45 minimum
Fuel injection pump.........................................................Delphi rotary
Fuel lift pump.......................................................................Electric
Delivery............................................. 120-150l/hr (31.7 US galls/hr to 39.6 US galls/hr)
Pressure................................................................ 30-75kPa (4.4-10.9 PSI)
Governor type......................................................L series electronic governor
Page 101
Data N38143
Pipe size:
• Supply - Outside diameter.......................................... 7.9mm (0.315”)
• Supply - Bore............................................................ 6.53mm (0.257”)
• Return - Outside diameter........................................... 6.3mm (0.25”)
• Return - Bore............................................................. 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 l/hr (7.3 US galls/hr)
Air Intake
Combustion airflow..........................7.9m3/min (279 ft3/min)............ 9.9m3/min (350 ft3/min)
Maximum engine compartment air temperature............. 60OC (140OF)
Maximum air temperature at engine inlet....................... 52OC (126OF)
Ventilation - maximum engine room depression.....125mm H2O (5 in H2O)
Exhaust
Exhaust gas flow............................19.5m3/min (689 ft3/min).......... 24.3m3/min (858 ft3/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..................................AP1 CD/SE CCMC D4
Sump capacity maximum........................................15 litres (4 US gallons)
Normal operating angles............................... 25O 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), 55A (24V)
Starter type........................................................................12V, 4 kW
Number of teeth in flywheel....................................................126
Number of teeth on starter......................................................10
Cold Start Limits
Minimum cold start temperature (with aid)...................... -15OC (5OF)
Batteries for min cold start.......................................1 x 12V, 660 amp SAE
Page 102
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
All information in this document is substantially
correct at time of printing and may be altered Wimborne Marine Power Centre
subsequently. 22 Cobham Road,
Part No. N38143 issue 9
Produced in England ©2014 by Wimborne
Ferndown Industrial Estate,
Marine Power Centre Wimborne, Dorset, BH21 7PW, England.
Tel: +44 (0)1202 796000,
Fax: +44 (0)1202 796001
E-mail: Marine@Perkins.com
Web: www.perkins.com/Marine