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Perkins Sabre Marine Engines Installation Manual

Contents

1. 5 i i EE 6 2 Propeller Shafts and Couplings 7 2 1 Propeller Shafts E 7 2 2 Gearbox Output Couplings 8 3 Exhaust SySIONTIS seccecccceestsspecerecensvecittisusnceeweseccedecereessranssawansdceoeusnes 11 aM dlc ciu mcm 11 34 Dry Systems Md DAI 13 3 3 Part Dry Part Wet Systems 20 3 4 Water Lift SV SCG e 20 4 Engine Room Ventilation 23 5 Engine Cooling Systems 25 5 1 eee 25 5 2 Keel Cooling Statement M300Ti and M265Ti Engines keel cooling is not offered with these models 27 5 3 Keel Cooling System M225Ti 215 and M185C Engines 27 5 4 Keel Cooling System M135 and M130C Engine 28 5 5 Keel Cooling System M115T M92 M92B engine 29 6 Fuel Systems REEE 33 Fuel uacua Fase Foe ean 33 7 Engine Electrical Systems 1 37 TA Engin Wiring LOOMS o ence 37 QI Mec 43 7 3 Circuit Protection M92B only 1
2. asas 79 We Location of Engine Installation Points Electrical Systems See section 7 Exhaust Systems See section 3 Starter Cables See section 7 5 Bonding Stud Fuel Feed See See section 7 6 section 6 1 Warning Use spreader bar when lifting 6 cylinder engines Engine Controls Fuel Return See section 8 See section Ventilation See section 4 Mounting Brackets See section 1 2 Cooling Systems See section 5 Flexible Mounts See section 1 3 Engine side views Page 1 TPD1317e Ventilation See Exhaust Systems section 4 See section 3 FX 79 a 4 o Cooling Systems Electrical Systems See section 5 See section 7 Flexible Mounts Mounting Brackets See section 1 3 See section 1 2 Engine end views Page 2 TPD 1317e Chapter 1 Engine Mounting 1 1 Installation Angles a The engine is intended to be mounted so that the cylinders are vertical when viewed from ahead or astern figure 1 The heel angles that are permissible in service are shown in figure 2a for 6 cylinder models and 2b for 4 cylinder models 30 30 25 35 Maximum Maximum Continuous Intermittent Figure 1 Vertical Figure 2a Acceptable Figure 2b Acceptable heel installation heel angle for 6 cyclinder angle for 4 cyliinder models models b In standard form all engine models a
3. Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement Page 17 Chapter 3 TPD1317e gt Bracket with link to allow for movement due to expansion in the exhaust system horizontal exhaust systems should be suspended from the pee deck head using similar brackets rigid brackets should not be used 7 Insulating lagging Rigid bracket to support the weight of the vertical exhaust system Flanges shown without bolts for clarity Heat blanket 90 Elbow Stainless steel belows UE Figure 8 Dry Exhaust System Features M92 Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement Cw Page 18 TPD1317e Chapter 3 Bracket with link to allow for movement due to expansion in the exhaust system horizontal EE exhaust systems should be suspended from the KX deck head using similar brackets rigid brackets should not be used Insulating lagging Rigid bracket to support the weight of the vertical exhaust system Flanges shown without bolts for clarity Heat blanket 90 Elbow DE EZB il ei E Stainless steel L Heat blanket Connection 6 5 Figure 9 Dry Exhaust System Features M92B Note When fitted the bel
4. 125 mm WG 5 WG 30m min 1050ft min 28m3 min 1000 TPD1317e Minimum cross section of air duct per engine Exhaust Chapter 11 910cm 142sq ins for hot climates 806cm 126sq ins for hot climates 455 2 7 1sq ins for temperate 406cm 63sq ins for temperate climates climates Exhaust gas flow 43 1m min 1520ft min 36 4m min 1290ft min Maximum restriction measured within 305mm 12 of turbocharger outlet Recommended pipe bore wet exhaust Recommended pipe bore dry Minimum rise from sea level to exhaust outlet centre line Lubricating System Recommended lubricating oil Sump capacity maximum Maximum installation angle plus planing angle for continuous operation Oil pressure in operating speed range steady state Low oil pressure switch setting Electrical System Alternator Starter type Number of teeth in flywheel Number of teeth on starter Cold Start Limits Minimum cold start temperature with aid Batteries for minimum cold start 10 2kPa 3 0 Hg 127mm 5 0 76 2mm 3 0 203mm 8 0 API CF 4 SE or CCMC D5 15 litres 3 3 gallons 17 engine front up plus 3 rise 5 nose down plus 3 rise with special kit of parts 30 heel when motor sailing 2 5 to 3 5 bar 36 to 50 psi 0 8 bar 12 psi Lucas A127 40 amp 24 volt or 70 amp 12 volt Lucas 115 126 10 15 C 5 F 2 off 12 volt each 520 amps to BS 3911 or 2 off
5. Radlus 25mm d A number will now be visible and individual digits will start to flash The flashing digit can be adjusted by depressing the operating set up switch to index the number to the required value Repeat this for all digits as required e When complete await for the display to revert back to engine hours f Switch panel to OFF Note to establish the correct setting for the tachourmeter the following formula should be applied Panel cut out dimensions 157 Diameter of Alternator Driven Pulley X 6 Number of Pulses Diameter of Alternator Drive Pulley Figure 13 Instrument panel Page 47 Chapter 7 TPD1317e THERE IS A FACILITY TO WIRE IN A WATER IN FUEL SENSOR THIS IS AN OPTIONAL EXTRA 2 VERSIONS ARE SHOWN BLACK 1 RED EN BROWN i ie WIRING FOR YELLOW GREEN GREY watenscan REEDS euren DEVICE GREY DEVICE BLUE 1 BROWN BOWL PROBES 1 L2 L d 7 1 ae WATER SCAN ONLY BLACK YELLOW RED GREEN BROWN NOTE NO ADDITIONAL LOADS ARE TO BE CONNECTED TO WATER IN FUEL WARNING LAMP THIS PANEL RED LENS OIL PRESSURE ALARM MUTE RELAY YELLOW OPERATES DURING MOM MOMENTARY ACTION MAIN MAINTAINED ACTION 9 HEAT AND START OPERATION LOW OIL PRESSURE PANEL BLACK ORANGE GREY HIGH WATER PANEL LIGHTS TEMPERATURE ORANGE AUDIBLE ALARM TURQUOISE BLAC
6. bore hose 1 00 B S P valve giving straight through M flow 722 1 00 B S P skin fitting Water line 32mm 1 25 bore reinforced flexible suction hose Figure 1 Sea water intake system Note Where possible mount the strainer so that the top is just above the waterline to facilitate cleaning Page 26 TPD1317e Chapter 5 5 2 Keel Cooling Statement M300Ti and M265Ti Engines keel cooling is not offered with these models 53 Keel Cooling System M225Ti M215C and M185C Engines All engine models may be purchased in a form suitable for keel cooling using two separate coolers one for the cylinder jacket circuit and one for the intercooler circuit Figure 2 shows the connections provided for the coolers The requirements for each section are as follows M21 M2ISCIMZ2STi M1 wes Cylinder Jacket Circuit 132kW 7500 em Heat rejection Design value for the water temperature at the exit from the keel cooler 60 C 140 F 60 C 140 F Design value for the water flow through the cooler Pipework to suit 45mm 1 75 bore hose connections 77 Vmin 17galls min 66 I min 14 5galls min Intercooler Circuit Includes gearbox oil cooler 25kW 1400 Btu min 19kW 1100 Btu min Heat rejection Design value for the water temperature 38 C 100 F 38 C 100 F at the exit from the cooler Design value for the water flow through the co
7. 5 minimum average fall 0 A Maler line Exhaust hose bore Engine model 125mm 5 6 cylinder turbocharged 90mm 3 5 4 cylinder turbocharged 76mm 3 4 amp 6 cyclinider naturally aspirated Figure 1 General exhaust arrangement Page 11 Chapter 3 TPD1317e In order to achieve sufficient height above the waterline it may be necessary to use the system shown in Figure 2 This also enables the two elbows to be rotated relative to each other to allow the exhaust hose to run towards the side of the boat The arrangement shown raises the exhaust height above the turbocharger outlet by about 230mm 9 inches greater heights can be achieved if necessary by using the arrangement described in Section 3 3 Elbow with facility for water injection Insulating blanket Possible rotation Dry elbow Figure 2 High rise exhaust elbow Page 12 TPD1317e Chapter 3 Due consideration must be given to providing flexibility in the exhaust hose particularly if the engine is flexibly mounted Where the exhaust hose must pass through a bulkhead immediately behind the engine it is preferable that the arrangement shown in Figure 3 is adopted using rubber bellows to provide flexibility Note that the bellows should be in an unstrained condition when fitted For turbocharged 6 Point of water cylinder engines use injection to be For turbocharged 6 cylinder a single double
8. TPD1317e BROWN LOW OIL PRESSURE SWITCH E 2 O BREAK ON RISE ORANGE 5 MAKE ON RISE HIGH WATER TEMPERATURE SWITCH C TURQUOISE o 4 OIL PRESSURE SENDER YELLOW O CH 5 GREY O 3 WATER TEMPERATURE SENDER LED GREEN INDICATING POWER RETARD UNIT IS AVAILABLE a gt THERMOSTAT ON INJECTION PUMP RETARDS TIMING WHEN CURRENT LIMIT NG CLOSES WHEN ER ENGINE IS WARM RESISTOR 1K5 ENGINE IS lt 559 BROWN RED BLACK SPLIT CHARGE RELAY CONNECTION BINK o VIOLET STOP SOLENOID THERMOSTART HEAT OPTION HEAT FUSE E WHITE o9 o START RELAY DROPPING RESISTOR FITTED TO 24V ELECTRICS ONLY WHERE REQUIRED GREEN o F4 VE FUSE et d 1 START FUSE FOR TWIN ENGINE INSTALLATIONS POEH SHOULD AN ALTERNATOR BE REQUIRED TO CHARGE A SET OF BATTERIES FOR DOMESTIC USE THEN THIS WIRE SHOULD BE DISCONNECTED AT THE STARTER AND CONNECTED TO THE VE ON THE F3 DOMESTIC SET OF BATTERIES THE VE PANEL FUSE RED CONNECTION IS COMMON TO BOTH SETS C 11 OF BATTERIES TACHOMETER TERMINAL FOR MEASURING ENGINE STARTER REVS MIN BLUE oi FAST FUSE T VIOLET 013 A Se CHARGE WARNING LIGHT TERMINAL I EARTH ALTERNATOR EINE I MACHINE SENSED I I TO CHARGE TWO SETS TO VE ON DOMESTIC BATTERIES OF BATTERIES THEN A SPLIT CHARGE 7 RELAY SHOULD BE FUSE RATINGS WIRED AS SHOWN 5 VE F1 STARTE
9. at the point where the shaft emerges from the log into the engine room together with constant velocity joints at each end of the short shaft connected to the gearbox coupling Water supply for bearings use hose from 1 4 BSP tapping on heat exchanger end cap End cap with tapping is optional Warning Use syphon break where a water lift exhaust system is specified See section 3 4 Flexible mountings Flexible shaft couplings Shaft bearings Figure 2 Alternative shaft arrangement 2 2 Gearbox Output Couplings Flanged propeller shaft couplings to suit the gearbox output couplings offered by the many gearbox manufacturers come in a number of different shapes and sizes and a variety of methods can be employed to grip the propeller shaft A traditional and sound method is to provide the same taper at both ends of the propeller shaft so that the gearbox coupling can be machined at the same time as the propeller This system is still commonly employed particularly where high thrusts and heavy boats are involved If the shaft becomes worn it can be turned end for end and re used at minimum cost As an alternative to the above procedure the method shown in figure 3 may be adopted Flanged couplings supplied with Twin Disc gearboxes are intended for this system The shaft is gripped by means of a split coupling with a key to provide positive drive and a dowel pin to eliminate the possibility of the shaft being drawn
10. lt OX MEI TO VE ON DOMESTIC BANTERIES ALTERNATOR MACHINE SENSED TACHOMETER TERMINAL FOR MEASURING ENGINE REVS MIN STARTER TO BATTERIES CHARGE WARNING LIGHT TERMINAL TO VE ON DOMESTIC BATTERIES PE Eau RELAY COIL FUSE RATINGS VE SPLIT ON F1 STARTER 40A CHARGE OY F2 HEAT 25 RELAY COIL ON PCB SPLIT CHARGE RELAY FOU STOP SOLENOID 25 WHERE ONE ENGINE IS REQUIRED TO CHARGE TWO SETS F4 ENGINE CIRCUITS 10A OF BATTERIES A SPLIT CHARGE RELAY SHOULD BE WIRED F5 VE FUSE 25A IN AS SHOWN VE EARTH RELAY MUST BE IN APPLICATIONS WHERE A RETARD IS FITTED A LINK CHANGED FOLLOWING A VE WIRE WILL BE LOCATED AS SHOWN TO ALLOW THE SPLIT FUSE FAILURE CHARGE CONNECTIONS TO BE UTILIZED IT IS RECOMMENDED THAT THE NEGATIVE LINE 15 GROUNDED AT THE BATTERY POST OR THE STARTER IN ORDER TO REDUCE INTERFERENCE BETWEEN ELECTRONIC DEVICES Figure 6 All 6 cylinder models insulated and earth return circuit diagram Information derived from drawing number 00 1020 3 eee Page 41 Chapter 7 TPD1317e TERMINAL IDENTIFICATION FOR COMBINED PRESSURE SENDER AND SWITCH WK SWITCH TO COMBINED OIL PRESSURE ORANGE ALARM LAMP SENDER G AND SWITCH WK G SENDER TO OIL PRESSURE YELLOW GAUGE
11. option of making the control functions on the flybridge panel Water in fuel warning lamp slave only operational when the wheelhouse panel master is switched on i The illustration below shows the removable link on the rear of Charge warning lamp the panel To convert a panel to slave remove the link from the master M terminal and refit to the slave S terminal Voltmeter On off switch Stop switch 2 3 4 5 Heat start switch 6 7 8 Oil pressure gauge 9 Low oil pressure warning lamp Note that one panel must always be a master and that no more 10 Tachourmeter than two panels should be connected to one engine without reference to Sabre Engines Ltd 11 Water tempe rature gauge Tachometer Set up Procedure All panels are supplied set to match their associated engine 12 High water temperature warning lamp In the event that the tachometer needs re calibrating the following procedure should be followed The circuit diagram of this panel is shown in Figure 14 a Ensure that the panel is connected to it s interconnecting lead leading back to the engine b Insert a probe into the rear of the tachometer as shown in the drawing below Lightly press the set up switch within the hole and at the same time switch ON the panel c Keeping the set up switch held down observe the LCD display on the front of the tachometer When the word PULSE is displayed release the set up switch
12. 12 volt each 800 amps to SAE J537 Page 69 Chapter 11 TPD1317e 11 2 225 215 and M185C Engines Rated power 213 PS 156 6 kW 190 PS 140 kW Basic Technical Data Rated engine speed 2500 rev min 2100 rev min Number of cylinders 6 Cylinder arrangement In line Cycle 4 stroke Induction system Wastegated turbocharger with charge air cooler Bore 100 mm 3 937 Stroke 127 mm 5 007 Compression ratio 16 1 Cubic capacity 6 00 litres 365 0 in Valves per cylinder 2 Direction of rotation Anti clockwise viewed on flywheel Firing order 1 5 3 6 2 4 Total weight wet 609 kg 1342 Ib engine only including starter and alternator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 50 fresh clean water Fresh water flow 205 l min 45 galls min at 2500 min 159 l min 35 galls min at 2100rev min Coolant pump speed and method of drive 1 1 Gear driven System capacity 25 3 litres 5 6 gallons Pressure cap setting 50 kPa 7 psi Protection switch setting 96 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 Page 70 TPD1317e Chapter 11 Model M225Ti M215C Model M185C
13. 5 Typical engine mounting brackets refer to installation drawings for specific applications The holes for the holding down bolts are slotted to allow for some movement during the final stages of alignment Where fine alignment is not necessary for example when a flexibly jointed drive shaft is used the bolts on all four corners of the engine should be positioned at the end of the slot all either fully in or fully out This will provide additional security in the fixing arrangements Page 4 1317e Chapter 1 13 Flexible Engine Mounts It is recommended that flexible engine mounts should be used for all applications The principal purpose of the mounts is to reduce the transmission of vibration from the engine to the hull but another valuable advantage is that the mountings reduce the shock transmitted from the hull to the engine under adverse weather conditions and also prevent the engine being inadvertently used as a structural part of the boat due to hull flexure a function the engine will not satisfactorily fulfil Figure 6 shows the leading dimensions of the flexible engine mount which is satisfactory for most applications Engines used with unusual drive arrangements such as V drives when integral with the engine unit pose special mounting problems and recommendations as to the most suitable mounting arrangement can be made for specific applications Where transmission ratios in excess of 2 5 1 are employed or
14. BUT NOT F2 HEAT 25A USED FOR THIS F3 STOP SOLENOID 25 APPLICATION F4 ENGINE CIRCUITS 10 F5 VEFUSE 25 VE EARTH RELAY MUST BE CHANGED FOLLOWING A YE FUSE FAILURE IT 18 RECOMMENDED THAT THE NEGATIVE LINE IE GROUNDED AT THE BATTERY POST OR THE STARTER IN ORDER TO REDUCE INTERFERENCE BETWEEN ELECTRONIC DEVICES Figure 7 6 cylinder models insulated and earth return circuit diagram fitted with Motorpal PP6M 10Pi fuel injection pump Information derived from drawing number 01 1064 3 Page 42 TPD1317e Chapter 7 7 2 Fuseboard Note Fuses are provided to protect the electrical system against accidental short circuits The risk is highest when the engine is being installed or when additional equipment is wired in and is negligible during normal operation On all models the fuseboard may be found behind a plastic cover adjacent to the starter motor For identification of fuses See Figure 8 4 cylinder models 6 cylinder models Start 40A Start 40A Not fitted Heat 25A Negative 25A Panel 10A Fast fuse 80A nom Check value of fuse Figure 8 Fuses Panel 10A Stop 25A Negative fuse 6 cylinder models only An additional fuse is located at the front of the engine behind the plastic belt cover see Figure 9 This fuse is to protect the engine wiring from damage due to the cylinder block being inadvertently connected to the battery positive and then
15. Lucas rotary Cold start advance and Cold start advance and electric stop energise to stop with electric stop energise to stop with manual override stop manual override stop Superpar mechanical Mechanical 8 mm 0 313 6 5 mm 0 26 6 35 mm 0 25 4 93 mm 0 194 1 5 m 60 in to bottom of tank suction pipe 127 mm 5 Hg 22 7 Whr 5 galls hr 17 94 I hr 3 95 galls hr 6 64 m min 235 4 6 m min 162 60 140 F 52 125 125mm WG 5 WG 13 5 m min 480 ft min 9 20 m min 324 ft min Page 77 Chapter 11 TPD1317e Minimum cross section of air duct per engine 174 cm 27 sq ins 139 cm 21 5 sq ins temperate climates temperate climates 348 cm 54 sq ins 277 cm 42 9 sq ins Exhaust Exhaust gas flow Maximum restriction measured within 305 mm 12 of turbocharger outlet Recommended pipe bore wet exhaust Minimum rise from sea water level to exhaust outlet centreline Lubricating System Recommended lubricating oil Sump capacity maximum Maximum installation angle plus planing angle for continuous operation Oil pressure in operating speed range steady state Low oil pressure switch setting Electrical System Alternator insulated Starter type earth return Starter type insulated Number of teeth in flywheel Number of teeth on starter Cold Start Limits Minimum cold start temperature without aid Batter
16. VE ON DOMESTIC BATTERIES WHERE ONE ENGINE IS REQUIRED TO CHARGE TWO SETS OF BATTERIES A SLIT CHARGE RELAY SHOULD BE WIRED IN AS SHOWN SPLIT CHARGE RELAY x i FIT Figure 5 M92B 12 and 24 volt insulated earth circuit diagram Information derived from drawing number 04 1270 3 www LLL Page 40 TPD1317e Chapter 7 TERMINAL IDENTIFICATION FOR COMBINED PRESSURE SENDER AND SWITCH GERNE WK SWITCH TO COMBINED OIL PRESSURE 02 ALARM LAMP SENDER 48 AND SWITCH WK O Q G SENDER TO OIL PRESSURE YELLOW GAUGE M VE MAKE ON RISE TURQUOISE HIGH WATER TEMPERATURE SWITCH WATER TEMPERATURE SENDER GREY LINK WIRE SEE SPLIT CHARGE RETARD UNIT THERMOSTAT CLOSES WHEN RELAY NOTE BELOW ON INJECTION PUMP ENGINE IS lt 559 r RETARDS TIMING WHEN ENGINE IS WARM REDIBERGK 27 GREEN Ce ED Gi mm ENGINE RETARD RELAY NNW AR BO Al CONNECTIONS U 7 AND INSULATED VE PINK N OHN STOP SOLENOID WHITE EARTH CONNECTION TO ENGINE VE EARTH RELAY DROPPING RESISTOR FITTED TO 24V ELECTRICS ONLY WHERE REQUIRED FOR TWIN ENGINE INSTALLATIONS SHOULD AN ALTERNATOR BE REQUIRED TO CHARGE A SET OF BATTERIES FOR DOMESTIC USE THEN THIS WIRE SHOULD BE DISCONNECTED AT THE STARTER AND CONNECTED TO THE VE ON THE DOMESTIC SET OF BATTERIES THE VE CONNECTION IS COMMON TO BOTH SETS OF BATTERIES gt
17. a sea cock 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 on the engine there should be a strainer which should be easily accessible for routine examination and should be easily removable From the sea water strainer a pipe should be run to the sea water pump inlet connection on the engine see figure 1 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 Rubber hose connections in the sea water system should be kept as short as possible and should be reinforced with a minimum of three layers of canvas 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 electrolytic 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 A typical system is shown in figure 1 Page 25 Chapter 5 TPD1317e Sea water b pump Ve Connection for 32mm 1 25
18. all types of exhaust system The components are designed to connect together allowing complex systems to be built from stock items to suit most installations Caution In all types of exhaust system the exhaust back pressure must not exceed 10 kPa of mercury except the M92B which is 15 kPa when measured within 305mm 12 inches of the exhaust outlet from the engine 31 Wet Systems Wet exhaust systems where the raw water used to circulate through the heat exchangers on the engine is finally dumped 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 Figure 1 In many cases the exhaust outlet passes through the transom just above the waterline It will be seen that a minimum fall of 5 is required and that the point of water injection must be at least 8 inches above the waterline 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 Point of water injection to be 200mm 8 minimum height above water line m SCH 7
19. and method of drive Gear driven System capacity 19 litres 4 18 gallons Pressure cap setting 50 kPa 7 psi Protection switch setting 96 C Sea water pump type Jabsco gear driven model 25 4 mm 1 full cam Page 79 Chapter 11 TPD1317e Model M92B Sea water strainer Maximum sea water temperature Sea water flow Fuel System Recommended fuel specifications Fuel injection pump Governor type Pipe size Supply Outside diameter Supply Bore Return Outside diameter Return Bore Maximum lift pump lift Maximum fuel lift pump depression at inlet Fuel consumption at full power Air Intake Combustion airflow Maximum engine compartment air temperature Maximum air temperature at engine inlet Ventilation maximum engine room depression Suggested ventilation airflow including combustion air Minimum cross section of air duct per engine A strainer must be included in the suction side of the circuit 38 100 98 I min 21 5 UK galls min BS2869 Class A2 ASTM D 975 Number 2D Bosch EPVE Mechanical 8 mm 0 313 6 5 0 26 6 35 0 25 4 93 0 194 2m 78in to bottom of tank suction pipe 127 mm 5 Hg 17 62 I hr 3 88 galls hr 6 64 m min 235 ft min 4 6 m min 162 ft min 60 C 140 F 52 C 125 F 125mm WG 5 WG 8 4 m min 296 ft min 139 cm 21 5 sq ins temperate climates 277 cm 42 9
20. and M130C Engine Both engine models may be purchased in a form suitable for keel cooling using a cooler for the engine circuit Figure 3 shows the connections provided for the cooler M130 Engine biker 123kW 7000Btu min gt 123kW 7000Btu min Heat rejection Design value for the water temperature at the exit from 60 140 60 C 140 F the keel cooler Design value for the water flow through the cooler Pipework to suit 45mm 1 75 bore hose connections TE nin tn Note Under extreme conditions the water flow in the system may increase to 180 l min 40 gallons min Pipework should have a clear bore of 38mm 1 5 The pipework between the engine and the cooler should be as short and direct as is possible but should be sufficiently flexible to allow the engine to move on it s flexible mountings The layout should discourage the formation of air locks and venting points should be provided wherever an air lock is likely to occur The keel cooling system should normally be filled with a water antifreeze mixture containing 50 antifreeze This mixture is necessary even in warm climates as the anti freeze contains corrosion inhibitors which protect the engine cooling system Page 28 TPD1317e Chapter 5 p E e L 1 Optional Gearbox Engine cir
21. coloured black Both the inverter and converter are supplied with an extension lead so that they can be mounted away from the engine Inverter Converter Fitting Instructions Note The inverter converter must not be engine mounted 1 Select a cool dry and ventilated position Use the bracket to mark the position of the holes Drill 3 5mm holes 2 3 4 Fix the clip using screws provided 5 Click the unit onto the clip 6 First connect both input wires Second connect the output wires T Max temp 55 Mount unit remote from engine in a cool dry and ventilated position Page 44 TPD1317e Chapter 7 7 4 Interconnecting Cable Interconnecting cables Figure 10 are used to join the engine loom to the instrument panel s Cables are made in 4 6 8 10 and 12m lengths and all cables have a male plug 1 at one end and a female 2 at the other Cables may be plugged together to give up to 12m length but in general if a longer cable is required it should be ordered as a special item to be made in one piece A Y harness Figure 11 is available with male plug at 1 and two female plugs 2 If necessary more than one Y harness may be used to connect several instrument panels together in any of the combinations shown on Figure 15 Details of the plugs and sockets and the wiring of the Y harness are shown on Figure 11 Figure 10 Interconnecting cable Figure 11 Y harness Page 45 Cha
22. depression at inlet Fuel consumption at full power Fuel consumption at full power Air Intake Combustion airflow Maximum engine compartment air temperature Maximum air temperature at engine inlet Ventilation maximum engine room depression Suggested ventilation airflow including combustion air Minimum cross section of air duct per engine Page 74 Model M135 Model M130C 38 C 100 F 127 28galls min BS2869 Class A2 ASTM D 975 Number 2D Stanadyne with electric stop AC Delco type LU 33 55 kPa 5 8 psi Mechanical 7 9 mm 0 315 6 53 mm 0 257 6 3 mm 0 25 4 93 mm 0 194 1 8 m 6 ft to bottom of tank suction pipe 127 mm 5 Hg 14 37 ml sec 28 I hr 6 2 galls hr 6 5 m min 230 ft min 60 140 52 125 F 125mm WG 5 WG 13m min 520ft3 min 320 cm 50 sq ins TPD1317e Exhaust Exhaust gas flow Maximum restriction measured within 305 mm 12 of turbocharger outlet Recommended pipe bore wet exhaust Recommended pipe bore dry Minimum rise from sea water level to exhaust outlet centreline Lubricating System Recommended lubricating oil Sump capacity maximum Maximum installation angle plus planing angle for continuous operation Oil pressure in operating speed range steady state Low oil pressure switch setting Electrical System Alternator Starter type Number of teeth in flywheel
23. exceed 1 amp the cable sizes should be generous as shown in the table below Length of run to Zinc Anode Suggested cable size Up to 30 feet 7 strand 0 85mm 4mm 30 40 feet 7 strand 1 04mm 6mm 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 Common bonding system wired in a ring circuit as Propeller shaft shown Zinc anode Through hull Sea cock metal flttings Engine Page 53 Chapter 7 TPD1317e c It is important to include the propeller shaft in the bonding system as the electrical path through the gearbox is not effective due to the gearbox oil acting as an insulator The electrical connection to the shaft may be made by means of graphite brushes riding on the shaft or a braided battery strap may be used as illustrated below In either case the shaft earthing system should be connected to the bonding system to which the engine and the shaft log if metal are also connected Note Strap should make contact with 90 of shaft circumference One way to earth the propeller shaft Connection to common bonding system Battery earthing strap Ahead d Before the boat enters service the effectiveness of the bonding and sacrificial Zinc anode system should be tested both when at rest and with all systems incl
24. grounded through the earth relay Note When replacing the ve fuse the earth relay must also be replaced Figure 9 Negative fuse Page 43 Chapter 7 TPD1317e 73 Circuit Protection M92B only There are two circuit breakers mounted within a steel enclosure that is mounted on the right hand side of the engine behind the alternator The 10A circuit breaker is to protect the instrument and control panel panels mounted away from the engine The 80A circuit breaker is to protect the negative line during momentarily grounding the engine whilst of the glow plugs are operating This protects the engine harness in the event of a stray positive supply accidentally finding its way to the block This is most likely to happen during installation Voltage Sensitive Equipment The M92B contains two components that are voltage sensitive and therefore require an additional piece of equipment when the voltage is outside of their operating range They are The stop solenoid fitted to all engines is for 24v operation The fuel lift pump fitted to all engines is for 12v operation M92B 12v models are supplied with a voltage inverter that inputs 12v and outputs 24v This allows the stop solenoid to function when required The inverter is coloured red M92B 24v models are supplied with a voltage converter that inputs 24v and outputs 12v This allows for the continuous operation of the fuel lift pump when the engine is running The converter is
25. hump 200mm 8 inches engines use silicone rubber bellows where space is minimum height bellows restricted u above water line I 5 average fall i I Figure 3 Movement of the engine on the flexible mounts must not be restricted by the exhaust hose Use rubber bellows as shown where space is restricted 32 Dry Systems Dry exhaust systems for marine installations need careful design to minimize the disadvantages of enclosing components that are at a high temperature in confined spaces The first part of a dry system should include a flexible connection so that excessive weight is not carried by the connection to the engine 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 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 engine it may be necessary to incorporate a trap to collect condensate and allow it to be drained Figures 4 5 6 7 amp 8 show typical systems The minimum bore of the exhaust pipe should be 76mm 3 inches for turbocharged engines 63mm 2 5 inches for naturally aspirated engines Page 13 Chapter 3 TPD1317e gt Bracket with link to allow for movement due to expansion in the exhaust system h
26. out of the coupling when going astern For lighter duty applications the system shown on figure 4 may be employed utilising the flanged couplings supplied with Hurth gearboxes In this case ahead thrust is taken directly by the gearbox output shaft as the propeller shaft is butted against it The shaft is secured by means of two half dog setscrews which also prevent loss of the shaft when going astern Positive drive is provided by a key Page 8 TPD1317e Chapter 2 Drill 15 32 Ream 0 5005 0 Machining Procedure Proppeller shaft Bore to size dimension Broach keyway 4 0 long dimension Split 0 135 Max width dimension J Clamp the coupling to the propeller shaft in the position shown Drill 15 32 Diameter hole through the propeller shaft and far side of the coupling using the starter hole dimension D 0 5005 0 4990 Diameter ream Gearbox through both the coupling and shaft output flange Dismantle and clean then assemble Figure 3 Twin Disc gearbox couplings Page 9 Chapter 2 TPD1317e Dimensions in inches A B B r i Key Propeller shaft Half dog set screws CRI Gearbox output Butt propeller shaft shaft against gearbox output shaft Figure 4 Hurth gearbox couplings Page 10 TPD1317e Chapter 3 Exhaust Systems A wide range of exhaust components are available for use with
27. then unpleasantly warm conditions may result In these circumstances engine room ventilation fans are beneficial preferably arranged to exhaust air from over the engine Page 23 Chapter 4 Noise absorbing chambers with deflector baffles positioned to direct ventilation air flow over a large surface area of absorbent material Cross sectional area of air flow path must not be too small Figure 1 Example of an engine room ventilation layout Note The air temperature entering the engine should not exceed 52 C 125 F Page 24 TPD1317e Noise absorbent material on panels surrounding the engine TPD1317e Chapter 5 Engine Cooling Systems 5 1 Raw Water Systems 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 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 If desired the rear edge of the water intake may be allowed to project more than the front by no more than 6mm 0 25 to give a slight scoop effect but if this is done it is necessary to locate the fitting so that it cannot be inadvertently partially rotated The intake fittings and pipework should have a minimum bore of 25mm 1 see figure 1 Inboard of the intake fitting
28. used which are as follows Fuel Feed M300Ti amp M265Ti Pt No 34051 The free end of the flexible pipe has a 3 8 BSP cone ended fitting and is supplied with an adaptor nut and olive to suit 10mm OD steel or copper tube M225Ti 215 M185C M135 M130 M115T M92B amp M92 Pt No 34055 The free end of the flexible pipe has a 1 2 UNS male thread and is supplied with a nut and olive to suit 5 16 OD steel or copper tube Fuel Return M300Ti amp M265Ti Pt No 34052 The free end of the flexible pipe has a 3 8 BSP cone ended fitting and is supplied with an adaptor nut and olive to suit 10mm OD steel or copper tube M225Ti M215C M185C M135 M130 M115T M92B amp M92 Pt No 34054 The free end of the flexible pipe has a 7 16 UNS male thread and is supplied with a nut and olive to suit 1 4 OD steel or copper tube Page 33 Chapter 6 TPD1317e Fuel tanks should have the following features 6 2 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 Avent pipe should be fitted again in such a way as to avoid the entry of water The tank should have a sump or angled bottom with a drain tap so that water and sediment can be removed This is not always possible Internal baffles may be required to prevent fuel surge The tank should have a removable panel
29. 1 44 Inverter Converter Fitting Instructions 44 7 4 Interconnecting Cable ernie 45 725 Instrument P elS 47 7 6 Battery and Starter Cables icici ee ati 51 7 7 Zinc Anode bonding system 1 52 8 Engine Controls UU 55 8 1 M300Ti and M265Ti nenna 55 8 2 M225Ti M215C and 185 Engines 56 8 3 M135 and M130C lk TE 57 8 4 M115T and M92 58 8 9 M92B ENINES 59 9 Provision for Power 44 2 1 61 10 Calorifier and Block Heater Connections 63 jupe aeter us 63 10 2 Block Heater for 6 cylinder engine models 65 11 67 11 1 300 and M265Ti 22 2 1 67 11 2 M225Ti 215 and M185C 70 11 3 M135 M130C Engines ie 73 114 M115T and M92 Engines tuto 76 11 5 M92B Ei nS
30. 800 Two 12V batteries in series each 440 M92B Amps SAE J537 Amps BS3911 o Batteries for temperatures down to 15 C 5 F Two 12V batteries in parallel each 520 Amps Two 12V batteries in series each 520 BS3911 or 800 Amps SAE J537 Amps BS3911 or 800 Amps SAE J537 M225Ti M215C M185C M135 M130C Two 12V batteries in parallel each 315 Two 12V batteries in series each 315 Amps BS3911 or 535 Amps SAE J537 Amps or 535 Amps SAE J537 Note Where starting at temperatures below freezing is an important requirement a 24 volt system is the preferred choice b Starter Cables Starter cables for 12 or 24 volt systems Maximum total Nominal C S A Nominal resistance in Approx equivalent size length Cable size ohms i English America 2 SS The length of all cables in the starter circuit whether positive or negative should be added together to give the Total Length Page 51 Chapter 7 TPD1317e c Grounding the battery negative It is recommended that the battery negative busbar should be grounded as close as possible to the battery by a substantial connection to the bonding system within the boat This will reduce the likelinood of interference between items of electrical and electronic equipment fitted to the boat d Battery isolator switches A switch should be fitted in the positive lead to the starter as close to the battery as is convenient The switch should be suitable for a momentar
31. ATOR WHERE ONE ENGINE MACHINE SENSED IS REQUIRED TO CHARGE TWO SETS VIOLET SPLIT CHARGE TO VE ON DOMESTIC BATTERIES OF BATTERIES THEN RELAY CONNECTION A SPLIT CHARGE w ON FUSE 4 lt RELAY SHOULD E WIRED AS SHOWN C Y FUSE RATINGS SPLIT CHARGE SPLIT CHARGE RELAY RELAY CONNECTION Fil ON FUSE PCB IT IS RECOMMENDED THAT THE NEGATIVE LINE IS GROUNDED AT THE BATTERY POST OR THE STARTER IN ORDER TO REDUCE INTERFERENCE BETWEEN ELECTRONIC DEVICES F2 STOP 25A F3 PANEL 10A F4 VE FUSE 25A Figure 4 M92 insulated return circuit diagram Information derived from drawing number 99 1151 3 Page 39 Chapter 7 TPD1317e ORANGE COMBINED OIL PRESSURE 8 SENDER G AND SWITCH WK 2 8 mE ESSUREI SENDER AND SWITCH HIGH WATER TEMPERATURE SWITCH G TURQUOISE WK SWITCH TO 1 4 ALARM LAMP OL PRESSURE GAUGE M WATER TEMPERATURE SENDER GREY i OQ FUEL LIFT PUMP 12V TO 24V VOLTAGE INVERTER STOP RELAY AMBIENT TEMPERATURE SWITCH OPENS AT 40 C 50 C GLOW PLUG TOTAL LOAD 48A012V GLOW PLUG CYL 1 WIRING FOR 12 TO 24 CONVERTER WIRING FOR 12v TO 24V INVERTER WHTE 9 all all l BLACK 12 ul L RED 11 6 m EARTH RELAY 10 TO BATTERIES HO Ap lt ALTERNATOR ACHOMETER TERMINAL MACHINE SENSED dere ENGINE 13 CHARGE WARNING LIGHT TERMINAL TO
32. Chapter 7 Engine Electrical Systems A plug together electrical system is available with the engine providing the following choices 7 1 The eng Earth return or insulated return except M115T which is earth return only Interconnecting cables of 4 6 8 10 or 12m length A Y harness to allow multiple instrument panels to be fitted 12V or 24V operation Instrument panels basic or comprehensive which may be used individually or in combination Connection to Control panel engine loom Interconnecting Y harness pu Instrument panel Figure 1 Elements of the plug together system 4 cylinder 6 cylinder Figure 2 Position of the multi way connector for the engine wiring loom Engine Wiring Looms ine wiring loom connects the starter alternator fuse board electric stop engine senders and warning switches to a waterproof IP67 multiway connector situated on a flying lead attached to the engine at the positions shown on Figure 2 The circuit diagrams for the various models are listed below Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 All 4 cylinder models earth return M92 insulated return M92B 12 and 24 volt insulated earth All 6 cylinder insulated and earth return 6 cylinder insulated and earth return fitted with Motorpal PP6M 10Pi fuel injection pump Page 37 Chapter 7
33. K RESISTOR 12V 8R2 25W EX X 24V 22R 25W WHITE 10 GREEN 11 D G Dp RED BLACK g 5 7 PINK LINK THE PANEL CAN BE SET TO OPERATE AS AN INDEPENDENT PANEL IN PANEL VE MASTER MODE OR AS A RED PANEL DEPENDENT ON THE OPERATION OF ANOTHER PANEL IN SLAVE MODE CHARGE WARNING LAMP SET C M FOR MASTER AND C S FOR SLAVE RESISTOR 12V 6W 24V 330R 6W 18 VIOLET 12 BLACK 5 E RED BLACK 1 BLUE INSTRUMENT PANEL WIRING DIAGRAM 98 1043 3 Figure 14 Page 48 TPD1317e Chapter 7 The Control Panel shown in Figure 15 includes 2 1 Low oil pressure warning lamp 1 80mm High coolant temperature lamp Charge warning lamp 2 3 4 On off switch 5 Heat start switch 6 Stop switch 7 Tachourmeter The circuit diagram for the Control panel is shown in Figure 17 Panel depth is 110mm Panel cut out dimenslons 124mm 15mm 15mm Figure 15 Control panel Figure 16 Possible panel configurations Up to three panels may be run simultaneously in any of the combinations as shown Page 49 Chapter 7 TPD1317e D1 3 ORANGE LOW OIL PRESSURE HIGH WATER TEMPERATURE PANEL VE RED ALARM MUTE RELAY OPERATES DURING PANEL VE HEAT AND STA
34. M VE HIGH WATER TEMPERATURE SWITCH fo RECON NIE TURQUOISE 4 WATER TEMPERATURE SENDER GREY OB A ITEMS MARKED ARE NOTA ESAME FUNCTION OF THIS HARNESS ON INJECTION PUMP THERMOSTAT ALTHOUGH THE WIRING 18 gt REDIBLACK INCLUDED Su e L GREEN I dm I BLACK RED WHITE I I I 1211 EXCESS FUEL SOLENOID I I I I E 1 1 1 PINK 1 il OO e I B I I IVIOUET I I I Noi 5 6 ITHERMOSTART I STOP SOLENOID I 1 I STOP RELAY l I I THERMOSTART 1 WHITE os GREEN O 10 d EARTH CONNECTION m TO ENGINE EARTH RELAY BLACK O 12 4 DROPPING RESISTOR FITTED TO 24V START RELAY ELECTRICS ONLY WHERE REQUIRED VIOLET 913 FOR TWIN ENGINE INSTALLATIONS SHOULD AN ALTERNATOR BE REQUIRED TO CHARGE A SET OF BATTERIES FOR F3 STOP FUSE DOMESTIC USE THEN THIS WIRE SHOULD Leger DISCONNECTED AT THE STARTER AND CONNECTED TO THE VE ON THE Fi START FUSE DOMESTIC SET OF BATTERIES THE VE CONNECTION IS COMMON TO BOTH SETS CE OF BATTERIES Po HEAT FURE TO ON DOMESTIC BATTI ALTERNATOR MACHINE SENSED TACHOMETER TERMINAL STARTER FOR MEASURING ENGINE E REVSIM LN BLUE Q1 e u P 227771 E VE AE CHARGE WARMING LIGHT TERMINAL 1 I 1 I I VE SPLIT CHARGE I DASHED LINES RELAY COIL FUSE RATINGS REPRESENT CABLES ON PCE A MT 4 WITHIN WIRING E HARNESS
35. Maximum restriction measured within 305 mm 12 of turbocharger outlet Recommended pipe bore wet exhaust Recommended pipe bore dry Minimum rise from sea water level to exhaust outlet centreline Lubricating System Recommended lubricating oil Sump capacity maximum Maximum installation angle plus planing angle for continuous operation Oil pressure in operating speed range steady state Low oil pressure switch setting Electrical System Alternator Starter type Number of teeth in flywheel Number of teeth on starter Cold Start Limits Minimum cold start temperature with aid Batteries for minimum cold start Page 72 Model M225Ti M215C Model M185C 35 08 m min 1240 ft min 10 2 kPa 3 0 Hg 127 mm 5 0 100 mm 4 0 76 2 mm 3 0 203 mm 8 0 AP1 CD SE CCMC D4 15 litres 3 3 gallons 17 engine front up 3 rise 5 nose down 3 rise with special kit of parts 30 heel when motor sailing 2 8 to 3 8 bar 40 to 55 psi 0 8 bar 12 psi Lucas A127 40A 24V or 70A 12V Lucas 115 126 10 15 C 5 F 2 off 12V 315 Amps to BS3911 2 off 12V 535 amps to SAE J537 TPD1317e Chapter 11 11 3 M135 and M130C Engines Basic Technical Data Rated power Rated engine speed Number of cylinders Cylinder arrangement Cycle Induction system Bore Stroke Compression ratio Cubic capacity Valves per cylinder Direction of r
36. Number of teeth on starter Cold Start Limits Minimum cold start temperature with aid Batteries for minimum cold start Chapter 11 20 m min 706 ft min 10 2 kPa 3 0 Hg 76 mm 3 07 63 5 mm 2 5 203 mm 8 0 AP1 CC SE API CD SE or CCMC D4 can also be used but are not recommended for first 20 40 hours 15 litres 3 3 gallons 17 engine front up 3 rise 5 nose down 3 rise with special kit of parts 30 heel 280 kN m 40 psi 83 kN m 12 psi Lucas A127 40A 24V or 70A 12V CAV CA45H 126 10 15 C b F 2 off 315 Amps to BS3911 or 2 off 535 Amps to SAE J537 Page 75 Chapter 11 TPD1317e 11 4 M115T and M92 Engines Model M115T Model M92 Basic Technical Data Rated power Rated engine speed Number of cylinders Cylinder arrangement Cycle Induction system Combustion system Bore Stroke Compression ratio Cubic capacity Valves per cylinder Direction of rotation Firing order Total weight wet Cooling System Coolant Fresh water flow Coolant pump speed and method of drive System capacity Pressure cap setting Protection switch setting Sea water pump type Page 76 80 kW 107 bhp 63 5 kW 85 bhp 2400 rev min 4 Vertical in line 4 stroke Turbocharged Naturally aspirated Fastram direct injection 100 mm 3 937 103 0 mm 4 055 in 127 mm 5 00 127 mm 5 00 17 25 1 18 5 1 3 99 litres 243 in 4 23 litres 258 in 2 Anti
37. Perkins Sabre Marine Engines Installation Manual M300Ti 6 Cylinder turbocharged intercooled diesel engine for pleasure boat applications M265Ti 6 Cylinder turbocharged intercooled diesel engine for pleasure boat applications M225Ti 6 Cylinder turbocharged intercooled diesel engine for pleasure boat applications M215C 6 Cylinder turbocharged intercooled diesel engine for commercial applications M185C 6 Cylinder turbocharged intercooled diesel engine for commercial applications M135 6 Cylinder naturally aspirated diesel engine for pleasure boat applications M130C 6 Cylinder naturally aspirated diesel engine for commercial applications M115T 4 Cylinder turbocharged diesel engine for all applications M92 4 Cylinder naturally aspirated diesel engine for all applications M92B 4 Cylinder naturally aspirated diesel engine for all applications Publication TPD 1317e Issue 10 Published in May 2007 by Sabre Engines Ltd Wimborne Dorset England BH21 7PW Tel 44 0 1202 893720 Fax 44 0 1202 851700 Email post sabre engines co uk Website www Perkins Sabre com This page is intentionally blank Location of Engine Installation Points 1 1 Engine Mounting e 3 SU E TEE UE A 1 2 Engine Mounting Brackets U 4 1 3 Flexible Engine
38. R 40A SBUTCHARGE F2 HEAT 25A OPTION SPLIT CHARGE RELAY RELAY CONNECTION IT IS RECOMMENDED THAT THE NEGATIVE LINE IS GROUNDED AT THE BATTERY POST OR THE STARTER IN ORDER TO REDUCE INTERFERENCE BETWEEN ELECTRONIC DEVICES F3 PANEL 10A F4 VE FUSE 25A Figure 3 All 4 cylinder models earth return circuit diagram Information derived from drawing number 99 1069 3 Page 38 TPD1317e VE o c ui E E 8 o Chapter 7 MAKE ON RISE LOW OIL PRESSURE SWITCH WES BREAK ON RISE MAKE ON RISE OO WATER TEMPERATURE SENDER HIGH WATER TEMPERATURE SWITCH OIL PRESSURE SENDER STOP SOLENOID NOTE THIS IS SHOWN WITH BOTH THE EARTH RETURN AND THE INSULATED EARTH SOLENOID THERMOSTART HEAT OPTION DROPPING RESISTOR FITTED TO 24V ELECTRICS ONLY WHERE REQUIRED FOR TWIN ENGINE INSTALLATIONS SHOULD AN ALTERNATOR BE REQUIRED TO CHARGE A SET OF BATTERIES FOR DOMESTIC USE THEN THIS WIRE SHOULD BE DISCONNECTED AT THE STARTER AND CONNECTED TO THE VE ON THE DOMESTIC SET OF BATTERIES THE VE CONNECTION IS COMMON TO BOTH SETS OF BATTERIES STARTER FAST FUSE HEAT FUSE BROWN 2 ORANGE TURQUOISE 4 YELLOW 5 GREY o6 O BLACK O START RELAY GREEN RED 11 TACHOMETER TERMINAL FOR MEASURING ENGINE REVS MIN BLUE o VIOLET 6 CHARGE WARNING LIGHT TERMINAL ALTERN
39. RT BLACK OPERATION AUDIBLE ALARM 9 WHITE MOMENTARY ACTION 05 10 GREEN MOMENTARY ACTION STOP MOMENTARY ACTION 7 PINK OFF D ON MAINTAINED O 11 np M S n O LINK 8 RED BLACK SEE NOTE 8 s 12 BLACK LINK The panel can be set to operate as an independent panel master mode as a panel dependent on the operation of another panel in slave mode lt gt Set C M for mast GE et C M for master RED BLACK and C S for slave 1 BLUE RESISTOR 12V 30R 6W TACHOMETER 24V 330R 6W 13 VIOLET Pp CHARGE WARNING LAMP CONTROL PANEL WIRING DIAGRAM 98 1055 3 Figure 17 Control panel circuit diagram Page 50 TPD1317e Chapter 7 7 6 Battery and Starter Cables a Batteries There are two methods by which battery performance is commonly stated BS3911 uses the current which can be maintained for 60 seconds without the voltage of a nominal 12V battery dropping below 8 4 volts whilst at a temperature of 18 C 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 Batteries for temperatures down to 5 C 23 F LIN 12 Volt 24 Volt One battery 520 Amps BS3911 or 800 Amps SAE J537 Two 12V batteries in series each 315 Amps BS3911 or 535 Amps SAE J537 M135 Two 12V batteries in parallel each 315 M130C Amps BS3911 or 535 Amps SAE J537 M115T One battery 520 Amps BS3911 or
40. StrainerA raw water strainer must be included in the suction side of the circuit Maximum sea water temperature Sea water flow Fuel System Recommended fuel specifications Fuel injection pump Fuel lift pump Fuel feed pressure static Governor type Pipe size Supply Outside diameter Supply Bore Return Outside diameter Return Bore Maximum lift pump lift Maximum fuel lift pump depression at inlet Fuel consumption at full power Air Intake Combustion airflow Maximum engine compartment air temperature Maximum air temperature at engine inlet Ventilation maximum engine room depression Suggested ventilation airflow including combustion air Minimum cross section of air duct per engine 38 C 100 F 123 I min 27galls min 109 I min 24galls min BS2869 Class A2 ASTM D 975 Number 2D Bosch rotary with boost control and electric stop energised to stop AC Delco type LU 0 3 to 0 6 bar 5 to 8 psi Mechanical 7 9 mm 0 315 6 53 mm 0 257 6 3 mm 0 25 4 93 mm 0 194 1 8 m 6 ft to bottom of tank suction pipe 127 mm 5 Hg 43 I hr 9 4galls hr 35 I hr 7 7galls hr 13 0 m min 460 10 76 m min 380 ft min 60 52 125mm WG 5 WG 25 3 1000ft min 640 cm 100 sq ins for hot climates 320 cm 50 sq ins for temperate climates Page 71 Chapter 11 TPD1317e Exhaust Exhaust gas flow
41. ble arranged so that it can be operated without opening the engine box in case of fire Gearboxes supplied at the time that the engine is purchased will be fitted with connections to suit Morse 33C cables Speed selector lever 92 115 Figure 2 Speed selector lever and stop lever Page 58 TPD1317e Chapter 8 8 5 M92B Engines Figure 3 shows the position of the speed selector lever on the injection pump fitted to the M92B engine An electric stop solenoid is provided as standard equipment Gearboxes supplied at the time that the engine is purchased will be fitted with connections to suit Morse 33C cables Speed selector lever Figure 3 Speed selector lever Page 59 Chapter 8 TPD1317e Page 60 TPD1317e Chapter 9 Provision for Power Take off The ability to drive additional equipment from the crankshaft nose varies according to the engine model as shown in the table below Engine Models Maximum FTO capability Maximum belt drive power axial and belt drives M92 M115T Full engine power M130C M135 e M185 M215C M225Ti rev min 8 kW at up to 2000 rev min 5 kW above 2000 rev min M300Ti 8 kW at up to 1800 rev min 8 kW atup to 1800 rev min Note Above 1800 rev min no additional equipment should be driven by a M300Ti Note Maximum recommended offtake 2 kW per belt ii Multiple belt driven accessories should as far as possible be dist
42. clockwise viewed on flywheel 1 3 4 2 422 6 kg 933 Ibs 417 8 kg 921 105 engine only including starter and alternator The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 5096 inhibited ethylene glycol or 50 inhibited propylene glycol with 5096 fresh clean water 202 litre min 44 4 gall min at 2400 rev min Gear driven 19 litres 4 18 gallons 50 kPa 7 psi 96 Jabsco gear driven model 25 4 mm 1 full cam Jabsco gear driven models 25 4 mm 1 2 3 cam TPD1317e Sea water strainer Maximum sea water temperature Sea water flow Fuel System Recommended fuel specifications Fuel injection pump Fuel lift pump Governor type Pipe size Supply Outside diameter Supply Bore Return Outside diameter Return Bore Maximum lift pump lift Maximum fuel lift pump depression at inlet Fuel consumption at full power Air Intake Combustion airflow Maximum engine compartment air temperature Maximum air temperature at engine inlet Ventilation maximum engine room depression Suggested ventilation airflow including combustion air Chapter 11 A strainer must be included in the suction side of the circuit 38 100 109 l min 24 galls min 98 l min 21 5 galls min BS2869 Class A2 ASTM D 975 Number 2D Lucas rotary with boost control
43. common centre bearer supporting the inner mountings of both engines is sometimes used as shown in figure 7 By this method shaft centres down to 690mm 27 may be adopted but wider spacing is desirable The shaft centres could be theoretically reduced further but this would result in the engine accessibility becoming very restricted and it would be impossible to carry out service operations It should be noted that if minimum shaft centres are to be adopted space must be left in front of and behind the engine to provide access A minimum clearance on all sides will mean that the engine cannot be serviced Figure 7 Illustration of the closest practicable engine spacing With this arrangement access space must be provided ahead and behind the engines for servicing Page 6 TPD1317e Chapter 2 Propeller Shafts and Couplings 24 Propeller Shafts It is recommended that all engines are mounted on flexible mountings which will reduce the transmission of noise and vibration and will prevent hull movements resulting in forces being applied to the engine The responsibility for the design and installation of the transmission system connected to the marine gearbox lies with the boat designer the boat builder the naval architect or the engine installer It is recommended that a Torsional Vibration Analysis TVA is carried out on the complete drive system Mass Elastic Data on the engine can be provided on request from Sabre Engines Ltd The
44. cuit inlet for 45mm 1 75 diameter hose Oil Cooler Q Engine circuit outlet for 45mm 1 75 diameter hose Figure 3 Connections for keel coolers M130C M135 5 5 Keel Cooling System M115T M92 and M92B engine Both engine models may be purchased in a form suitable for keel cooling Figure 4 shows the connections provided for the keel cooler 115 M92 N92B Engine circuit 74kW 4200Btu min 60kW 3400Btu min Heat rejection Design value for the water tem perature at the exit from the keel cooler Design value for the water flow through the cooler 60 C 140 F 60 C 140 45 70 l min 45 70 l min 10 15 galls min 10 15 galls min Pipework to suit 45mm 1 75 bore hose connections The pipework between the engine and the cooler should be as short and direct as possible but should be sufficiently flexible to allow the engine to move on it s flexible mountings The layout should discourage the formation of air locks and venting points should be provided wherever an air lock is likely to occur The keel cooling system should normally be filled with a water antifreeze mixture containing 5096 antifreeze This mixture is necessary even in warm climates as the antifreeze contains corrosion inhibitors which protect the engine cooling system Page 29 Chapter 5 From keel4 cooler From cylinder block Engine circuit inlet for 45mm 1 75 diameter hose Engine circ
45. d by the exhaust gases to 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 contains the water which falls back from the exhaust riser If a proprietary unit is used the manufacturers instructions should be carefully followed but figure 10 identifies the key features Note that the system must meet the requirement for the maximum exhaust back pressure to be not greater than 10 kPa except the M92B which is 15kPa of mercury measured within 305mm 12 inches of the turbocharger exhaust outlet Page 20 Chapter 3 TPD1317e 1 2 bore siphon To overboard outlet break Water injection elbow 450mm 18 Exhaust riser Top of exhaust riser and point at which the siphon break is connected to the engine pipe work must be above the water line under the worst possible conditions normally a distance of 450mm 18 under static conditions will be sufficient Figure 10 Water lift system Exhaust tank water lock a Minimum volume of exhaust tank should be 3 times the volume of the water in the riser b The tank should be installed near the centre line of sailing craft 21 Chapter 3 TPD1317e Page 22 TPD1317e Chapter 4 Engine Room Ventilation The engine room must be ventilated for two reasons To supply the engine with air for combustion To provide a flow of air through the engine r
46. following observations are offered to show some of the systems currently in use Figure 1 shows a simple arrangement where the propeller shaft is supported only by the gearbox coupling and an outboard rubber bearing at the propeller end Entry of water into the boat is prevented by a shaft seal which must be flexibly mounted to allow for engine movement A flexible shaft coupling is fitted to the gearbox coupling to allow momentary angular misalignment in operation This system is only suitable for applications where the speed diameter and unsupported length of the propeller shaft will not induce whirling i e the centrifugal force generated by the speed of rotation is not sufficient to bend the shaft into a bow shape Reinforced rubber hose Graphited asbestos string Stuffing box 4 o d 3 WC SE Gees Flexibly mounted shaft seals s Cutless Flexible shaft Flexible bearing coupling mountings Page 7 Chapter 2 TPD1317e Where the propeller shaft length is such that it cannot be simply supported by the gearbox coupling and P bracket without the risk of whirling the arrangement shown in figure 2 may be adopted In this case one or more additional bearings are included in the shaft log and flexible shaft couplings which will accept thrust are used to permit the engine to move on the flexible mountings A variation of this system is to use a thrust block bearing
47. ge 35 Chapter 6 TPD1317e 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 3 should be used Figure 3 shows a collector tank fed by all the storage tanks and connected to the engine feed and return systems but with a vent pipe taken to any convenient tank Supply tank below storage tanks for gravity feed Vent to be run to top of highest tank Fuel returns top of tank Water separator Size to suit total flow for all Fuel feeds to be taken from installed engines the bottom of the collector tank Figure 3 Fuel System for multiple tanks supplying multiple engines There is no doubt however that a simple fuel system as illustrated in Figure 1 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 36 TPD1317e
48. ies for minimum cold start Page 78 16 4 m min 579 ft min for hot climates for hot climates 15 1 m min 533 ft min 10 2 kPa 3 0 Hg 76 mm 88 9 mm 3 5 76 mm 3 203 mm 8 0 AP1 4 ACEA 7 litres 12 3 pints 20 nose up 3 0 to 3 7 bar 43 5 to 54 Ibf in 0 8 bar 12 Ibf in Prestolite A127 40A 24V or 70A 12V Prestolite M127 12 volt only Prestolite 115 12 volt and 24 volt 126 10 10 12 volt system 1 off 12 volt 520 amp to 53911 24 volt system 2 off 12 volt 440 amp to BS3911 TPD1317e Chapter 11 11 5 M92B Engines Rated power 64 kW 85 6 bhp Basic Technical Data Rated engine speed 2400 rev min Number of cylinders 4 Cylinder arrangement Vertical in line Cycle 4 stroke Induction system Naturally aspirated Combustion system Direct injection Bore 105 0 mm 4 13 in Stroke 127 mm 5 00 Compression ratio 18 23 1 Cubic capacity 4 4 litres 269 in Valves per cylinder 2 Direction of rotation Anti clockwise viewed on flywheel Firing order 1 3 4 2 Total weight wet 423 kg 933 Ibs engine only including starter and alternator Cooling System The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C Coolant Sabre extended life coolant 50 50 mix Fresh water flow 193 litre min 42 5 UK gall min at 2400 rev min Coolant pump speed
49. lows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement a 19 Chapter 3 TPD1317e 3 3 Part Dry Part Wet Systems Even where the engine is mounted well below the waterline the advantages of a wet system can still be gained providing that water injection takes place at a point sufficiently above the waterline In these circumstances the part dry part wet system shown in Figure 9 can be utilised The modular exhaust components allow a system to be readily constructed utilising a tall dry riser followed by a water injection elbow Point of water injection to be u 200mm 8 inches minimum height ISS i above water line 1 Flexible hanger Water line Stainless E steel bellows UE N Figure 9 Wet Part Dry Exhaust System The illustration shows a turbocharged engine but the principle also applies to naturally aspirated engines 3 4 Water Lift Systems Whenever an engine is mounted with the exhaust outlet at or below the waterline the exhaust systems shown in 3 2 and 3 3 should first be considered If the layout of the boat is such that neither are suitable then a water lift system may be appropriate but note that these systems make engine starting more difficult This should only be noticeable at low temperatures Figure 10 shows the main features of such a system which utilises pressure develope
50. must be installed so that chafing will not occur K Front lifting eye Return from calorifier Connections are to suit 1 2 bore hose Return from calorifier Supply to calorifier Figure 1b Calorifier fittings for M92 and M115T Page 63 Chapter 10 TPD1317e Supply to a calorifier Return from calorifier Figure 1b Calorifier fittings for M92B Caution The hoses connecting the calorifier to the engine are part of the closed engine cooling system Failure of a hose will lead to the engine overheating Page 64 TPD1317e Chapter 10 10 2 Block Heater for 6 cylinder engine models Return from block heater Connections are to suit 5 8 bore hose Supply to block heater Block heater Figure 2 Block heater connection points A mains powered cylinder block heater may be fitted to keep the engine warm when the boat is stored in low temperatures A suitable heater may be ordered as part of the engine assembly or may be fitted later Figure 2 shows the connection points the supply being taken from a hole in the cylinder block tapped 1 4 18 NPSI and the return from a hole in the cylinder head tapped 1 2 14 NPSI For most purposes a 500W heater will be satisfactory If the heater is ordered at the same time as the engine it will be attached to the engine If fitted later it may be more convenien
51. nsion and engine movement 15 Chapter 3 TPD1317e Bracket with link to allow for movement due to expansion in the exhaust system horizontal exhaust systems should be suspended from the deck head using similar brackets rigid brackets should not be used Rigid bracket to support the weight of the vertical exhaust system Heat blanket Twin stainless steel belows fitted to avoid torsional load on bellows unit Flanges shown without bolts for clarity Manifold adaptor SE Li D Heatblanket Heat blanket Figure 6 Dry Exhaust System Features M130C M1385 Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement www Page 16 TPD1317e Chapter 3 gt Bracket with link to allow for movement due to expansion in the exhaust system horizontal T exhaust systems should be suspended from the deck head using similar brackets rigid brackets KX 4 should not be used Insulating lagging Rigid bracket to support the weight of the vertical exhaust system Flanges shown without H bolts for clarity Heat blanket 90 Elbow Heat blanket 90 Elbow LMI d ire ion D SI Stainless steel belows k Figure 7 Dry Exhaust System Features M115T
52. oler Pipework to suit 32mm 1 25 bore hose 123 I min 27galls min 109 l min 24 galls min connections Note Under extreme conditions the water flow in the jacket circuit may increase to 40 gallons min Pipework should have a clear bore of 38mm 1 5 The pipework between the engine and coolers should be as short and direct as is possible but should be sufficiently flexible to allow the engine to move on it s flexible mountings The layout should discourage the formation of air locks and venting points should be provided wherever an air lock is likely to occur The keel cooling system should normally be filled with a water antifreeze mixture containing 50 antifreeze This mixture is necessary even in warm climates as the anti freeze contains corrosion inhibitors which protect the engine cooling system Page 27 Chapter 5 TPD1317e SC Cylinder jacket cooler 7 Pipework to suit 32mm 1 25 ID Cooler for hose intercooler system Pipework to suit D Intercooler circuit inlet for 32mm 1 25 diameter hose 45mm 1 75 ID Intercooler circuit outlet for 33mm 1 25 diameter hose hose Engine circuit inlet for 45mm 1 75 diameter hose Engine circuit outlet for 45mm 1 75 diameter hose Figure 2 Connections for keel coolers M185C M215C M225Ti 5 4 Keel Cooling System M135
53. oom to prevent an excessive temperature build up which may cause components such as the alternator to overheat In most applications in temperate climates the engine will draw air from the engine room If this is the case then as a rough guide it can be taken that every horsepower produced by the engines requires as a minimum 0 25 sq ins of vent area If the boat is likely to be used in hot climates and if engine room ventilation fans are fitted then a vent area of 0 5 sq ins per horsepower should be provided see the table below Wherever possible a flow of air through the engine room should be encouraged by using forward facing intake vents to take advantage of ram airflow together with other vents to allow hot air to escape With an effective ventilation system the engine air intake temperature will be no more than 10 Centigrade degrees higher than the outside air temperature The air entry vents should be situated where spray is not likely to enter them and some form of water trap is desirable see figure 1 Preferably the air ducts should reach the engine compartment at the sides of the hull so that water will fall into the bilge When the engines are shut down after a run at high output in high ambient temperature conditions it will be found that very high air temperatures will build up in the engine compartment In boats with open cockpits this is usually of no real consequence but if the engines are mounted below a wheel house
54. operated remotely if required using a piano wire type cable assembly Gearboxes supplied at the time that the engine is purchased will be fitted with connections to suit the Morse 33C cables Page 56 TPD1317e Chapter 8 83 M135 and M130C Engines Figure 4 shows the position of the speed selector lever on the injection pump An electric stop is fitted as standard equipment but a mechanical stop is also supplied The injection pump is fitted with a stop lever identified in figure 2 which may be connected by a piano wire type cable assembly to a position near the boat operator Gearboxes supplied at the time that the engine is purchased will be fitted with connections to suit Morse 33C cables Stop lever iL 7 E Speed selector lever Figure 4 Speed selector lever and stop lever Page 57 Chapter 8 TPD1317e 8 4 115 and M92 Engines Figure 2 shows the position of both the speed selector and manual stop lever on the injection pumps fitted to the M115T and M92 engines An electric stop solenoid is provided as standard equipment but the mechanical stop lever which is intended for remote operation by a piano wire type cable assembly is an alternative means of stopping the engine and it is independent of electrical supply The manual stop lever is therefore a back up control to be used in the rather remote eventuality of the failure of the electric stop to work It is recommended that it is connected with the ca
55. orizontal exhaust systems should be suspended from the deck head using similar brackets rigid brackets should not be used Insulating lagging Rigid bracket to support the weight of the vertical exhaust system Heat blanket Twin stainless steel belows fitted to avoid torsional load on bellows unit Flanges shown without clips for clarity Heat blanket Turbocharger adaptor 90 Elbow ON 1717 WK WF Heat blanket E Figure 4 Dry Exhaust System Features M265Ti Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expansion and engine movement ww Page 14 TPD1317e Chapter 3 Bracket with link to allow for movement due to expansion in the exhaust system horizontal exhaust systems should be suspended from the deck head using similar brackets rigid brackets should not be used Insulating lagging Rigid bracket to support the weight of the vertical exhaust system Twin stainless steel belows fitted to avoid torsional load on bellows unit Flanges shown without bolts for clarity SSS ZZ d 27 AS 90 Elbow Heat blanket Figure 5 Dry Exhaust System Features M185C M215C M225Ti M265Ti 8 M300Ti Note When fitted the bellows units should be in an unstrained condition so that the full bellows movement is available to absorb expa
56. otation Firing order Total weight wet Cooling System Coolant Fresh water flow Coolant pump speed and method of drive System capacity Pressure cap setting Protection switch setting Sea water pump type Sea water suggested inlet hose diameter Sea cock Strainer 130 PS 96 kW 2600 rev min 6 In line 4 stroke Naturally aspirated 100 mm 3 937 127 mm 5 007 16 5 1 6 00 litres 365 in 2 Anti clockwise viewed on flywheel 1 5 3 6 2 4 595 kg 1312 Ib engine only including starter and alternator The coolant shown below is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 5096 fresh clean water 213 litre min 47 gall min at 2600 rev min 1 1 Gear driven 25 3 litres 5 6 gallons 48 kPa 7 psi 96 Jabsco gear driven model 25 4 mm 1 full cam 32 mm 1 25 Full flow 25 4mm 1 00 A raw water strainer must be included in the suction side of the circuit Page 73 Chapter 11 TPD1317e Maximum sea water temperature Sea water flow Fuel System Recommended fuel specifications Fuel injection pump Fuel lift pump Fuel feed pressure static Governor type Pipe size Supply Outside diameter Supply Bore Return Outside diameter Return Bore Maximum lift pump lift Maximum fuel lift pump
57. pter 7 TPD1317e MALE FEMALE MULTIWAY MULTIWAY CONNECTOR CONNECTOR Vester VIEWED ON THE CABLE ENTRY CABLE ENTRY E BLUE 1 2 BROWN 2 E ORANGE 3 4 ae TURQUOISE 4 E YELLOW 5 MALE GREY MULTIWAY 5 CONNECTOR PINK MULTIWAY TO ENGINE 8 LLL LLL LA RED BLACK 8 TO MAIN STATION LOOM WHITE 9 PANEL of TT TTT TTT w 7 1 sx e s I ll ue BLUE 1 lll l l ls gt lll EE LE LE LL usage DL b sos 5 l FEMALE L TT I PINK 7 MULTIWAY 2 TO SECOND WHITE S STATION PANEL GREEN Lm oe RED Hn BLACK 12 VIOLET 13 Figure 12 Schematic of Y harness part number 34621 Information derived from drawing number 98 1044 1 Page 46 TPD1317e Chapter 7 7 5 Instrument Panels Panel Set up Information Two types of panel are available providing different levels of Master Slave Configuration instrumentation The Instrument Panel shown in Figure 13 panels are supplied configured as master panels includes In the event that more than one panel is being used to control one engine then there is the choice of making one of them a N 3 slave to the other master panel Where there is one panel in 1 Panel illumination level switch the wheelhouse and another on the flybridge then there is the
58. re suitable for installation so that in side view the crankshaft is flywheel down from a minimum of 3 to a maximum of 17 An allowance has been made for an additional 3 rise to occur in service when climbing waves or on to the plane 3 Minimum SWL SWL 17 Maximum Figure 3 When in standard form all engine models may be installed flywheel down from a minimum of 3 to a maximum of 17 Page 3 Chapter 1 TPD 1317 A kit of parts is available to modify 6 cylinder models only so that they are suitable for installation with the flywheel end of the crankshaft above the pulley end by up to 5 An allowance has been made for an additional 3 rise to occur in service when climbing waves or on to the plane Header tank 5 Maximum M raised using a flywheel up Br c E eat of j parts SWLy meld A fom Mf SWL 9 3 flywheel down Figure 4 Six cylinder models may be installed in a horizontal or nose down attitude if a special kit of parts is fitted to raise the header 1 2 Engine Mounting Brackets The standard brackets provide mounting points which are 76mm 3 in below and parallel with the crankshaft centre line The brackets may be used to mount the engine directly on the engine bearers but for all applications it is recommended that flexible engine mounts are used Slotted hole 36 x 17 1 7 16 x 21 32 Figure
59. ributed evenly on either side of the engine to minimise side loads iii Customers wanting to fit a non standard drive pulley or coupling should ensure the inertia of the added components does not exceed 0 0313 kg m iv If you are in any doubt please contact your distributor Page 61 Chapter 9 TPD1317e a For Axial Drives A Fenner F80 tyre type coupling should be used and can be supplied with the engine PTO shaft Taper lock Figure 1 The Fenner F80 coupling b For Belt Drives Standard options are Either a Fenner 5 A section pulley with three grooves or A Fenner 5 B section pulley with two grooves 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 Figure 2 The Fenner 5 A section with Figure 3 The Fenner 5 B section three grooves with two grooves 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 Page 62 Chapter 10 TPD1317e Calorifier and Block Heater Connections 10 1 Calorifier Fittings are available to allow a calorifier to be connected to the engine as shown in figure 1 The fittings may be ordered as part of the engine assembly or as loose parts to be fitted later The hose connections to the calorifier must be of a radiator or heater hose quality and
60. sq ins for hot climates TPD1317e Chapter 11 Exhaust gas flow 12 3 m min 434 ft min Exhaust Maximum restriction measured within 305 mm 12 of turbocharger outlet 15 kPa 4 43 Hg 112 mm Recommended pipe bore wet exhaust 76 mm 3 Minimum rise from sea water level to exhaust outlet centreline 203 mm 8 0 Lubricating System Recommended lubricating oil AP1 CG4 CH4 ACEA E3 E5 Sump capacity maximum 7 litres 12 3 pints Maximum installation angle plus planing angle for continuous operation 20 nose up Oil pressure in operating speed range steady state 3 0 to 3 7 bar 43 5 to 54 Ibf in Low oil pressure Switch setting 0 8 bar 12 Ibf in Electrical System Alternator insulated Prestolite A128E 55A 24V or 90A 12V Starter type insulated Prestolite 5115 12 volt and 24 volt Number of teeth in flywheel 126 Number of teeth on starter 10 Cold Start Limits Minimum cold start temperature without aid 10 C Batteries for minimum 12 volt system 1 off 12 volt 520 amp to BS3911 cold start 24 volt system 2 off 12 volt 440 amp to BS3911 Page 81 Chapter 11 TPD1317e Page 82
61. t to mount the heater on the engine bearer The hose connections to the block heater must be of a radiator or heater hose quality and must be installed so that chafing will not occur Caution The hoses connecting the block heater to the engine are part of the closed engine cooling system Failure of a hose will lead to the engine overheating Page 65 Chapter 10 TPD1317e Page 66 TPD1317e Chapter 11 Reference Data 11 1 M300Ti and M265Ti Engines Rated power 286 ps 210 4 kW 253 4 ps 186 2 kW Basic Technical Data Rated engine speed 2500 rpm Number of cylinders 6 Cylinder arrangement In line Cycle 4 Stroke Induction System Wastegated turbocharger with charge air cooling Bore 100 mm 3 937 Stroke 127mm 5 007 Compression Ratio 17 5 1 Cubic Capacity 5 995 Litre 365 in Valves per cylinder 2 Direction of Rotation Anti clockwise viewed from flywheel Firing Order 1 5 3 6 2 4 Total Weight wet 635 kg 1400 Ibs engine only including alternator and starter 718 kg 1583 Ibs engine with ZF IRM 220A gearbox Cooling System The coolant shown is mandatory for use in all climates to ensure that adequate levels of corrosion inhibitor are present It will give frost protection to 37 C Coolant 50 inhibited ethylene glycol or 50 inhibited propylene glycol with 5096 fresh clean water Fresh Water Flow 205 litre min at 2500 rpm Coolant pump speed and method of drive 1 1 Gear Driven System Capacity 26 3 li
62. tively a rubber bag tank may be used The main fuel connection is taken from the rear of the tank so that all the fuel is available for use when under way when the hull will be at an angle The fuel return 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 From the tank the main engine feed line goes first to a water separator preferably one fitted with a thick clear plastic bottom and a drain cock The fuel lines may be of metal either copper or bundy steel tubing used either with compression fittings or preferably soldered nipples with a flexible armoured rubber hose to connect to the fuel lift pump 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 Pa
63. 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 i e water trap 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 and a fuel return connection Whenever possible a tank should only supply one engine but in any case each engine should have its own fuel pipes from tank to engine Typical Fuel Systems The more simple the fuel system the better it will perform in service Figure 1 shows an ideal system Fuel return pipe Fueltank _ _ Main fuel feed Water separator Figure 1 A Simple Fuel System Page 34 TPD1317e Chapter 6 In some applications there may be legislation that requires that fuel lines draw from and return to the top of the tank Figure 2 shows an acceptable arrangement The fuel returned to the tank should be kept away from the main fuel feed to avoid recirculation Main fuel feed Water separator Figure 2 A simple fuel system with connections through the top of the tank The fuel tank may be steel aluminium or G R P or alterna
64. tres 5 6 gallons Pressure cap setting 50 kPa 7 psi Protection switch setting 96 Sea water pump type Jabsco gear driven model 080 full cam Sea water suggested inlet 32 mm Bore 1 25 hose diameter Page 67 TPD1317e Chapter 11 Sea cock Full flow 25 4 mm 1 inch Strainer Raw water strainer must be included in suction side of the circuit Maximum sea water temperature Sea water flow Fuel System Recommended fuel specifications Fuel injection pump Fuel lift pump Fuel feed pressure static Governor type Pipe size Supply outside diameter Supply bore Return outside diameter Return bore Maximum lift pump lift Maximum fuel lift pump Fuel consumption at full power Air Intake Combustion airflow Maximum engine compartment air temperature Maximum air temperature at engine inlet Ventilation maximum engine room depression Suggested ventilation airflow including combustion air Page 68 38 100 F 123 l min 27 galls min BS2569 Class A ASTM D975 Number 2D Bosch MW in line with boost control and electric stop energised to stop Bosch plunger type 0 3 to 0 6 bar 5 to 8 psi Mechanical 10mm 0 394 8 4mm 0 331 10mm 0 394 8 4mm 0 331 1 8 m 6ft to bottom of tank suction pipe 127 mm 5 inches Hg depression at inlet 56 4 12 4galls hr 50 I hr 11galls hr 14 8m min 524ft min 13 8m3 min 488 60 52
65. uding engines in operation by a specialist in this field Note 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 Page 54 TPD1317e Chapter 8 Engine Controls It is recommended that a Morse single lever system is used to control engine speed and gearbox engagement 8 1 M300Ti and M265Ti Engines These engines are equipped with an electric stop solenoid as standard but a piano wire stop cable may also be fitted as shown below Clamp for Morse A410 Anchor for Morse A410 stop cable inner stop cable assembly Anchor for Morse 33C cable to operate speed selector lever selector lever Page 55 Chapter 8 TPD1317e 8 2 M225Ti 215 and M185C Engines The engine is supplied with connections to suit a Morse 33C cable Figure 1 shows the position of the speed selector lever on the injection pump and the anchor for the cable outer sleeve Speed selector lever Anchor point Morse 33C cable not supplied f Figure 1 Speed selector lever and stop lever Although an electric stop is fitted as standard equipment in some cases a mechanical stop mechanism may be required The injection pump is fitted with a stop lever identified in figure 1 which may be
66. uit outlet for 45mm 1 75 diameter hose Figure 4 Connections for keel coolers M115T M92 Page 30 TPD1317e TPD1317e Chapter 5 To keel cooler From keel cooler Engine circuit inlet for 45mm 1 75 diameter hose Engine circuit outlet for 45mm 1 75 diameter hose Figure 5 Connections for keel coolers M92B Page 31 Chapter 5 TPD1317e Page 32 TPD1317e Chapter 6 Fuel Systems Design and assembly faults in the fuel system are responsible for many problems with marine diesel engines A good system is not hard to achieve being largely a matter of avoiding obvious pitfalls 6 1 Fuel Connections Acommon 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 Thread details of the connections on the engines for fuel pipes M225Ti 215 185 M135 Mang 1 M130C 115 M92B M92 Fuel feed 3 8 BSP 4 2 UNS It is strongly recommended that the flexible fuel pipes available as an option with the engine are
67. where extreme service conditions can be expected e g fast rescue boats the standard mount should not be used and a recommendation should be obtained for the specific application Installation drawings are available showing the preferred mounting arrangements when using a variety of gearboxes Height adjuster bolt and nut Minimum 125 4 9 Maximum 137 5 4 Bottom of mount to crankshaft centre line Height adjuster pad maximum of 13 shims be used per mount 11 at 1mm thick and 2 at 0 5mm thick Radially slotted hole Dimensions mm inches Dimensions given are for the mount in the unloaded condition Figure 6 Typical flexible engine mount refer to installation drawing for specific applications 5 Chapter 1 TPD 1317e 1 4 Engine Bearers The materials and methods of construction of engine bearers which have proved to be satisfactory in service vary to such an extent that it is difficult to lay down universal guide lines However as a rough guide it can be said the engine bearers should be capable of supporting a static load of about eight times the weight of the engine to cater for the effects of rough seas The bearers should be cross connected to give lateral rigidity in order to maintain the shaft alignment and to prevent twisting and racking forces being applied to the engine To enable minimum shaft centre distances to be achieved in a twin installation a
68. y current of at least 1000 Amps 7 7 Zinc Anode bonding system Caution The engine may be damaged by electrolytic corrosion if the correct bonding procedure is not adopted Please read the guidelines below carefully a Electrolytic corrosion within the engine cooling system and transmission can be much reduced or eliminated by bonding the engine to a Zinc anode which is used to protect through the hull metal fittings and other metal components that are in contact with sea water The engine is fitted with a stud that may be used for this purpose see Location of engine installation points at the beginning of this manual for location of the stud The stud is identified by a label shown below BOATBUILDER Use this stud to connect the engine to the Zinc Anode system installed in the boat For further details see the Installation Manual 7089 1 95 Page 52 TPD1317e Chapter 7 b Typical system in common use The bonding system in the boat should provide a low resistance connection between all metals in contact with sea water together with a connection to a Zinc sacrificial anode which is fixed to the outside of the hull below sea level 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

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