DBR Gensets DPL120UK Installation, Operation and Maintenance Manual For YN 513510 (MANUAL-I - 2958658 - 1 - A) - 1

Installation, Operation
& Maintenance Manual
&
Drawings, Reports & Certificates
DBR Auxiliary
Generator sets
Type: DPL120UK
Damen YN. 513510

ASD Tug 2810
DBR Generatorsets Tel. +31 (0)184 – 61 32 00

Lelystraat 53 – 3364 AH Fax. +31 (0)184 – 61 26 54
P.O. Box 1039 – 3360 BA E-mail: info@dbr-bv.nl
Sliedrecht – The Netherlands Internet: www.dbr-bv.nl
Index
1. ID-DCU Operator Guide LCP
2. User Guide Engine
3. Parts Manual Engine
4. Installation and Maintenance LSA Alternator
5. Instruction Manual Voltage Regulator R438
6. Wiring Diagram
7. Type Approvals
8. Statements Engine & Generator LR
9. Test Certificates & Reports
DBR Generatorsets Tel. +31 (0)184 – 61 32 00

Lelystraat 53 – 3364 AH Fax. +31 (0)184 – 61 26 54
P.O. Box 1039 – 3360 BA E-mail: info@dbr-bv.nl
Sliedrecht – The Netherlands Internet: www.dbr-bv.nl
Compact Controller for Industrial and Marine Applications
InteliDrive DCU
Expandable engine controller
with electronic engines support
Industrial Applications: SS and AS

Marine Applications: AUX, EME, CMB and PRP
January 2013 version r2
Operator guide
Copyright © 2004-2013 ComAp a.s. ComAp a.s.

Written by Ladislav Kadanik, Vladimir Sebian and Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Pavel Doubek Tel: +420 246 012 111, Fax: +420 266 316 647
Prague, Czech Republic E-mail: info@comap.cz, www.comap.cz
Table of Contents
Table of Contents............................................................................................................................................. 2
Abbreviations ................................................................................................................................................... 3
Conformity declaration...................................................................................................................................... 5
General description........................................................................................................................................... 6
Manuals............................................................................................................................................................ 7
Operator Interface ............................................................................................................................................ 8
Pushbuttons and LEDs................................................................................................................................. 8
How to select engine mode?........................................................................................................................ 9
Display menus.............................................................................................................................................. 9
How to view measured data?....................................................................................................................... 9
How to view and edit set points?.................................................................................................................. 9
How to view the HISTORY menu?............................................................................................................... 9
How to change the display contrast?............................................................................................................ 9
How to check the serial number and software revision?.............................................................................10
How to change the display backlight intensity?.......................................................................................... 10
How to change controller language?.......................................................................................................... 10
How to find active alarms ?........................................................................................................................ 10
Controller screens...................................................................................................................................... 11
Functions available from ID-DCU front panel keys.....................................................................................14
Alarm management........................................................................................................................................ 15
Warning...................................................................................................................................................... 15
Shut down.................................................................................................................................................. 15
Cool down.................................................................................................................................................. 15
Sensor fail.................................................................................................................................................. 15
Controller monitoring...................................................................................................................................... 17
Direct connection to the PC........................................................................................................................ 17
DriveMonitor............................................................................................................................................... 17
DriveMonitor screen example (ID-DCU-Industrial, SS)...............................................................................19
Password protection................................................................................................................................... 20
Modbus protocol......................................................................................................................................... 20
Technical data................................................................................................................................................ 21
ID-DCU....................................................................................................................................................... 21
InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -2-

ID-Operator_guide_r2.pdf
Abbreviations
aid Archive file extension for InteliDrive controller

AIN Controller or extension module Analog input
Alarm General term for any active engine protection Warning, Shutdown, … etc.
Alarm list Controller or PC DriveMonitor screen with list of active and unaccepted alarms
detected from ID controller.
AS Controller All Speed mode
ECU Alarm list Controller or PC DriveMonitor screen with list of active and unaccepted alarms
detected from engine ECU.
AOUT Controller Analog OUTput or outputs group.
Archive Usually aid file that contains all controller data: configuration, setpoints setting and
history records.
AUX Controller application (archive, operational mode) for Auxiliary engines.
BI Controller binary input.
BIN Controller binary inputs group.
BO Controller binary output.
BOUT Controller binary outputs group.
CAN Control Area Network – serial data link.
Cd Cool down protection, cooling period is included before engine stops.
CMB Controller Combined mode.
D+ Controller function for battery charging function check and/or engine running
indication.
DC DriveConfig, PC software for InteliDrive configuration.
DM DriveMonitor, PC software for InteliDrive monitoring.
DriveConfig PC software for InteliDrive configuration.
DriveMonitor PC software for InteliDrive monitoring.
ECU Engine Electronic (injection) Control Unit.
ECU alarm Alarm detected in engine electronic control unit that is received via J1939.
EME InteliDrive Emergency operational mode.
EMS I. Electronic Management System – version I.
EMS II. Electronic Management System – version II.
Fls Controller sensor fail alarm.
FMI Failure Mode Identifier.
GSM modem Modem for Global System of Mobile communication
History List of alarms and operational states with Reason, Date and Time and adjustable
values set that is stored in controller, can be listed from the screen or DriveMonitor.
HRB Controller Harbor mode.
I-CB Inteli - Communication bridge = controller interface for other electronic engines like
MTU, CAT etc.. that are not supported yet.
ID InteliDrive controller.
ID-COM InteliDrive communication module with interface to J1939, J1587 and to other
controllers.
ID-DCU InteliDrive – DieselControlUnit.
ID-MCU InteliDrive – Industrial Controller Unit with Volvo Penta front panel modification.
ID-RPU InteliDrive – Redundancy Protection Unit = ID backup unit for Over speed and
Emergency stop protection in Marine applications.
ID-SCM InteliDrive - Speed Control Module = interface unit for InteliDrive Industrial.
IG-IB InteliGen – Internet Bridge = controller interface for internet communication.
IGL-RA15 Remote Anunciator = external 15 LED indication panel (three colors, configurable).
IG-MU InteliGen – Modem Unit = controller interface for multiple engines application – one
point communication with group or one point modem connection.
IGS-PTM Controller extension module with 8 binary inputs and outputs and 4 analog inputs.
I-RB Inteli Relay board = interface board with 16 free contact relays.
I-RB16 Inteli Relay board = interface board with 16 free contact relays.
I-RD Inteli Remote Display (Remote Panel) = the same panel like on controller, all data
received via CAN2 bus.
I-RD-CAN Inteli Remote Display (Remote Panel) = the same panel like on controller, all data
I-RP Inteli Remote Display (Remote Panel) = the same panel like on controller, all data
IS-AIN8 InteliSys – Analog input module = extension module with 8 analog inputs.
IS-BIN16/8 InteliSys – Binary input/output module = extension module with 16 binary inputs and
8 binary outputs.
J1587 The J1587 bus is mainly used for redundant signals; system diagnosis and software
download on after market tools.
J1587/J1708 See J1587
J1939 The J1939 bus in mainly used for engine controls and engine monitoring.
KWP2000 Scania Communication protocol.
LOC Controller Local mode
mhx Extension for controller firmware (Motorola HeX file).
MID Message Identification Assignments.
OFF Controller mode when power supply is switched on, but all binary outputs and start
commands are disabled = engine start is blocked.
PID Parameter Identification Assignments.
PPID Proprietary Parameter Identification Assignments.
PRP Controller application (archive, operational mode) for Propeller engines.
RPM Engine Revolution Per Minute – engine speed.
PCB Printed Circuit Board
PSID Proprietary Parameter Identification Assignments.
RS232 Standard serial data line for PC or Modem connection (controller programming or
monitoring).
Sd Shut down protection.
SID Subsystem Identification Assignments.
SPN Suspect Parameter Number
SS Controller Single Speed mode
Wrn Warning protection.

Conformity declaration
Following described machine complies with the appropriate basic safety and health
requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC
Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type,
as brought into circulation by us.
!!! CAUTION !!!

Always properly connect grounding terminals!
Adjust set points

All parameters are preadjusted to their typical values. But the set points in the “Basic settings” settings
group !!must!! be adjusted before the first startup of the gen-set.
!!! WRONG ADJUSTMENT OF BASIC PARAMETERS
CAN DESTROY THE ENGINE !!!
The following instructions are for qualified personnel only.

To avoid personal injury do not perform any action not specified in the User guides for ID-
DCU Marine or ID-DCU Industrial !!!
WARNING – VERY IMPORTANT !!!

Be aware that the binary outputs can change state during and after software reprogramming.
Before the controller is used again ensure that the proper configuration and setpoint settings
are set in the controller.
Disconnect the Binary outputs Starter and Fuel or press EMERGENCY STOP button to avoid
unexpected automatic start of genset during any work or maintenance on the engine or switchboard.
Note:
ComAp believes that all information provided herein is correct and reliable and reserves the right to
update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly
undertaken.

General description
This guide provides general information on how to operate the InteliDrive controller. More detailed
information is available in the User guides for ID-DCU Marine or ID-DCU Industrial.
InteliDrive ID-DCU Industrial and ID-DCU Marine engine controllers controls, monitors and protects the
engine in single or variable speed operational modes (ID-DCU-Industrial) and propeller, emergency, auxiliary
and harbor modes (ID-DCU-Marine). The controllers can communicate with Engine Management System via
the CAN serial line using standard J1939 or another (KWP2000) communication protocol.
InteliDrive controllers are equipped with a powerful graphic display with icons, symbols and bar-graphs and
panel buttons for intuitive operation.
InteliDrive ID-DCU-Marine central unit together with ID-RPU provides redundant engine control. Switches
itself to the backup mode in the case of controller failure, protects engine using its own Shut down and
Emergency stop inputs and Fuel, Stop outputs. Monitors power supply, switches to the secondary power and
measures also the secondary RPM.
Engine functions
 Engine sequencing and control (start/stop, warm-up and cool-down, pre-lubrication etc.)
 Different operational modes – single or variable speed (ID-DCU-Industrial) and emergency, auxiliary,
harbor or propulsion (ID-DCU-Marine)
 Engine monitoring and protections (2 or more level analog inputs protection, adjustable delays)
 Speed measurement from magnetic pick-up or from ECU (+ redundant channel – ID-DCU-Marine
only)
 Running hours meter, number of starts counter
 Configurable 14 Binary inputs and Outputs and 8 Analog inputs
 Setpoints are adjustable via InteliDrive panel or via PC software
 3 level password protection
 On screen Alarm and ECU Alarm indication
 Event and time driven engine history for back tracing
 Two or more languages selectable in controller
Communication
 RS232 / Modbus RTU
 Analog or GSM modem
 Engines with Engine Electronic Control Unit: J1939, J1587, KWP2000
 Extension units for more I/O and Remote Display panel
Physical
 180x120 mm front panel mounted case
 Graphic back-lit LCD display 128x64 pixel resolution with icons and bar graphs
 LED status indicators / Lamp test
Available modules
 ID–RPU Redundant Protection Unit (at ID-DCU-Marine only)
 ID-SCM Speed control module (at ID-DCU-Industrial only)
 IS-AIN8 Extension module with 8 analog inputs
 IS-BIN16/8 Extension module with 16 binary inputs and 8 binary outputs
 IGS-PTM Extension module with 4 analog inputs and 8/8 binary in/outputs
 IGL-RA15 Extension module with 15 indicating LED

Manuals
To download manuals according to the specific controller:
1. Open http://www.comap.cz/ in your browser. To access manuals on ComAp website, please, register
in ComAp club
2. Where to find documentation on web
Products / Engine controllers / InteliDrive-DCU (Marine) / Downloads / Manuals
Types of Documents on Web page

All the documents are intended for everybody who is concerned with the installation, operation and
maintenance of an engine application.
o Data Sheets describe basic technical specification and purpose of various types of controllers.
o Getting Started Guide will help you to answer some basic questions that typically occur during the
first contact with engine controller.
o User guide is Installation, Application and Reference guide in one book.
o Communication Guides describe communication interface among controller(s) and superior
system. From this manual you can get information on all available types of communication.
o ComAp Electronic Engines Support describes all supported ECU, wiring and functionality.

Operator Interface
Pushbuttons and LEDs
3 2 1 4
5
7
11
12
8
13 9
10
14
Pushbuttons and LED’s:

1. MODE ► Cycle forward through engine operation modes OFF -> RUN (AUX, EME, HRB
and PRP in case of Marine version).
2. MODE ◄ Cycle backward through engine operation modes OFF <- RUN (AUX, EME,
HRB and PRP in case of Marine version).
3. HORN RESET Deactivates the HORN.
4. FAULT RESET Acknowledges faults and alarms.
5. START Starts the engine in SS or AS mode.
6. STOP Stops the engine in SS or AS mode (hold time =1 sec).
7. GREEN = Engine running.
8. Flashing RED = Not acknowledged (new) alarm present in Alarm List.
Stable RED = Acknowledged alarm present in Alarm List.
9. GREEN = On/Off output is active.
10. On/Off Button for Close load or Clutch Binary output control.
11. PAGE Cycles through the display screens MEASUREMENT -> ADJUSTEMENT
->HISTORY.
12. ▲ Select the set point, select the screen or increase set point value.
13. ▼ Select the set point, select the screen or decrease set point value.
14. ENTER Confirm set point value.

How to select engine mode?
Use MODE ► or MODE ◄ to select requested engine operation mode.
Hint:
Switching to OFF mode is blocked on running engine.
Display menus
There are 4 display menus available: MEASUREMENT, External measurement, ADJUSTMENT and
HISTORY.
Each menu consists of several screens. Pressing the PAGE button repeatedly will scroll the user through the
menu screens.
How to view measured data?

Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the
MEASUREMENT screen. Use ▲ or ▼ to select the screen with requested data.
How to view and edit set points?

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the
ADJUSTMENT screen.
2. Use ▲ or ▼ to select requested set points group.
3. Press ENTER to confirm.
4. Use ▲ or ▼ to select requested set point.
5. Set points marked “*” are password protected, necessary to input corresponding password first to
enable setpoint edit.
6. Press ENTER to edit.
7. Use ▲ or ▼ to modify the set point. When ▲ or ▼ is pressed for 2 sec, auto repeat function is
activated.
8. Press ENTER to confirm or PAGE to leave without change.
Press PAGE to leave selected set points group.
Hint:
Depending on the configuration of ID-DCU controller there can occur some PLC logic modules in
configuration. Then the user can adjust them from “PLC” set point group.
How to view the HISTORY menu?

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the
HISTORY screen.
2. Use ▲ or ▼ to select a requested record.
3. Use ENTER to select requested screen (record items) within displayed records.
How to change the display contrast?

Press ENTER and ▲ or ▼ at the same time to adjust the best display contrast.
Hint:
Only in MEASUREMENT menu.

How to check the serial number and software revision?
Hold down the ENTER and the press PAGE. On the display you can see Controller INFO screen for 10
seconds:
Controller name (see Basic setting group)

Controller serial number (8 character number)
SW version: The firmware version number.
Application: ID
Branch: InteliDrive
Hint:
Only in MEASUREMENT screen.
How to change the display backlight intensity?

Press ENTER and ▲ or ▼ at the same time to adjust the best display backlight.
Hint:
Only in INFO screen.
How to change controller language?

Press PAGE on controller INFO screen to go to Language screen. Select language ▲ or ▼ and press
ENTER to confirm selection and exit window.
How to find active alarms ?

Active alarm list and J1939 alarm list are the last two screens in the MEASUREMENT menu.
Select MEASUREMENT menu. Press ▲ ( ▲ ). You will see the list of all active alarms with the number of
alarms at the top-right corner. Inverted alarms are still active. Non-inverted alarms are not active, but not yet
confirmed.
Press FAULT RESET accepts all alarms in case if Industrial version and accepts just displayed alarms in
case of Marine version. Non-active alarms immediately disappear from the list.
Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is
active.
Hint:
Alarm list does not activate when you are reviewing the values, parameters or history.
InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 10 -

Main screen indication
1 2 3 4 5
6
OFF AUX LOC R L !
Running 7
Oil press
3,5 Bar
Cool temp 8
9 1500 75 C
1. Active controller mode (inverse)

2. Available mode
3. Controller Local mode indication
4. R = Remote connection indication (connection to DriveMonitor is opened)
L = Access lock indication
5. Record in Alarm list
6. State machine indication
7. Oil press indication
8. Coolant temperature indication
9. RPM indication
Controller screens
There are three screen groups available on ID-DCU controller: Measuring – Setpoints – History.
Measuring screen will be divided to more groups – ID-DCU, BIN/BOUT, AIN
Measuring (instrument) screens

Screen Content
Hidden, but available by Key combination – see Function available from ID-DCU front panel keys
Info screen: Fw and App. version, s.n., … Language list and switch.
Language screen
Fast edit screen
Available using Up or Down front panel keys
ECU diagnostics code list
Alarm list
1 =Main ID Mode, RPM1, Vbatt, Engine state,
screen Indication: Local, Alarm (in AL or ECU list), Remote data connection active, Access Lock
2 Analog 1 to Analog 4 , 4x single bargraph
3 Analog 5 to Analog 8 , 4x single bargraph
4 Battery ID-DCU, bargraph
5 ID-DCU BI 1 to 7
6 ID-DCU BI 8 to 14
7 ID-DCU BO 1 to 7
8 ID-DCU BO 8 to 14
9 Statistics: Run hours, Number of starts, Service time
Following screens appears depending on configuration
Opt Analog 1 to Analog 8, Name- value dimension, active alarm is negative (1x IS-AIN8)
Opt IS-BIN BI indication 1 to 8
Opt IS-BIN BI indication 9 to 16
Opt IS-BIN BO indication 1 to 8
Opt ECU values I.
Opt ECU values II.
Setpoints screens correspond with Setpoint table above.

Alarm, ECU Alarm list screen
See the Alarm management chapter
Info screen
Info Comment
CBH InteliDrive Product type
ComAp 2003 – 2013 Company name
ID-DCU-Industrial Controller name
Serial: 0200FFFF Controller serial number
Sw ver: 3.0 Software version
Appl: SS Application
Branch: DCU Industrial Customer branch
Statistic values
It is calculated:
1 Number of starts Each successful start (starter is switched off due to
RPM> Starting RPM) is calculated.
External (manual) engine start
2 Running hours Each finished 60 minutes when engine is running.
3 Number of unsuccessful starts Each finished cranking due to MaxCrank time is over
Statistic values can be adjusted from DriveMonitor, password 3 level protected.
History records
Following table does not contain Wrn, Sd and Fls messages from external units.
Events specification Protection Information available on

type binary output
Alarms
Wrn Analog input 1 to 8 WRN YES
Sd Analog input 1 to 8 SD YES
ID-DCU Binary input 1 to 14 Configurable YES
ID-DCU Battery voltage <, > WRN YES
Battery flat WRN

Start fail WRN YES
ParamFail NONE
Overspeed SD YES
Underspeed WRN YES
EmergencyStop SD
Pickup fail WRN
Stop fail WRN YES
WrnServiceTime WRN
ChrgAlternFail WRN YES
Fault reset
Local mode ON YES
Local mode OFF
Harbour mode ON YES
Harbour mode OFF
SecBattery YES
Emergency stop

Engine events Note
Starts
Button start Start from ID panel
CAN control + Button start Start from ID RD
RS232 control + Button start Start from DriveMonitor
Remote start Start from BI
Stops
Engine stop Stop from ID panel or BI
CAN control + Engine stop Stop from ID RD
RS232 control + Engine stop Stop from DriveMonitor
Remote start ID-DCU binary input
Blackout start ID-DCU binary input
Button start ID-DCU panel button

Fault reset ID-DCU panel button
Local mode ON ID-DCU panel button
Local mode OFF ID-DCU panel button
HRB mode ON ID-DCU panel button
HRB mode OFF ID-DCU panel button
RS232 control Start, Stop, Fault reset, On/Off button

from DriveMonitor or I-RD
Modem control Start, Stop, Fault reset, On/Off from
Modem
SMS control Received command from GSM modem
CAN control Received command via CAN bus e.g.
from I-RD or IG-MU
ActCallCH1-OK Successful active call on channel 1
Extern start Manual engine starter handling.
Engine stop Engine changed state from
Emerg.man ON Emergency manual mode ON
Emerg.man OFF Emergency manual mode OFF
Clutch ON Binary output clutch was closed
Clutch OFF Binary output clutch was opened
Stop button ID-DCU panel button
Switched on Controller was switched on

Cfg loaded Configuration archive was changed
FwLoaded Firmware upgrade
Time stamp Depends on setpoint setting period
Password set Any level from any terminal
Password changed Any level from any terminal
Access set Access code was set
Access changed Access code was changed
Watchdog Controller internal watchdog protection
Param fail Setpoints checksum fail
RTC battery RTC battery fail
Hint:
Value name can’t exceed 11 characters to be recorded to History file with prefix (Wrn, Fls etc..). Longer
names characters are canceled.

Corresponding Sd BINx, Sd BOUTx or Sd AINx is indicated in Alarm list and history record when
communication with any extension units (IS-BIN, IS-AIN, IGS-PTM) interrupted.
Example:
When IS-BIN16/8 is configured for addresses: Binary inputs = BIN1, BIN2 and Binary outputs = BOUT1, then
three messages Sd BIN1, Sd BIN2, Sd BOUT1 are indicated after communication is interrupted.
Hint:
Any “State” information can be configured to any binary output by DriveConfig software.
Functions available from ID-DCU front panel keys

Function Key combination From where
Contrast increase Enter - Up
Contrast decrease Enter - Down
Info screen Enter - Page
Local mode ON Enter - Mode > (Right) Main screen
Local mode OFF Enter - Mode < (Left)
Fast edit Enter hold for 4 sec.
Fault code reset Fault reset Alarm list

ECU fault code reset Fault reset ECU Alarm list
Requested speed increase Up
Requested speed decrease Down
Enter Fast edit screen
active when Engine params:
Request confirmation and exit EnLocalSpeed = ENABLED
Exit without confirmation Page
Backlight increase Enter – Up
Backlight decrease Enter - Down
Go to Language screen Page Info screen
Automatic after 10 sec to Main
Info screen exit screen
Language selection Up or Down key Language screen
Language screen exit Enter

Alarm management
Following alarms are available in InteliDrive-DCU:
Binary alarms Analog alarms

No protection None
Warning Warning
Shutdown Sensor fail
Cool down Wrn+shut down
Sensor fail Wrn+cool down
Warning + BW Alarm only
Shutdown + BW HisRecOnly
Warning + Fls
A new record containing selected values is written to the history file in the moment of any alarm comes up.
Detection of each binary input alarm is fix 1 sec time delayed.
Use DriveConfig to modify binary or analog inputs.
Warning
When warning comes up, only alarm outputs are closed.
Possible warnings:
Binary inputs configured as Warning (alarms are displayed and stored under configured name)
Analog inputs configured as Warning (alarms are displayed and stored under configured name)
Battery voltage alarm level
Shut down
When a shutdown occurs, InteliDrive-DCU opens outputs FUEL SOLENOID, STARTER.
Possible shut-down alarms:
Over speed
Under speed
Start fail
Binary inputs configured as Shut down (alarms are displayed and stored under configured name)
Analog inputs configured as Shut down (alarms are displayed and stored under configured name)
Cool down
When the cool down alarm comes up InteliDrive unloads engine, waits for Cooling time and opens FUEL
SOLENOID output.
Binary inputs configured as Cooldown (alarms are displayed and stored under configured name)
Sensor fail
Sensor fail Fls is detected when measured value is 6,2 percent out of range. The controller screen will
display #### instead of the measured value.

Alarms indication
There can be following actions when Alarm is active (depends on Alarm type and configuration):
 Alarm list record
 History list record
 Active call (when is enabled and modem is installed)
 Controller front panel LED indication
 Binary output ALARM is closed when Alarm is active or when was deactivated and FAULT RESET
button was not pressed to confirm.
Binary output ALARM opens when Alarm was deactivated (no other Alarm is active) and FAULT RESET
button was pressed to confirm.
 Binary output HORN is closed for adjustable time when any new Alarm occurs.
 Corresponding value reading (binary input state, analog input value, generator voltage, .. ) is inverse
(e.g. 100 ) on InteliDrive screen when value is out of limits (binary input protection is active).
Broken wire
Broken wire (BW) alarm is indicated on ID-RPU module only.
Alarm indication
Alarm list and History record prefixes
Prefix Meaning
Wrn Warning
Sd Shutdown
Cd Cooldown
Bw Broken wire
Fls Sensor fail
Three state Alarm list indication

* Wrn Water temp Active not accepted alarm
Wrn Water temp Active accepted alarm
* Wrn Water temp Inactive not accepted alarm
Inactive accepted alarm
ECU Alarm list - SPN/FMI codes screen

ECU Alarm list displays alarms from ECU unit of the engine. In the case there is no SPN translation
available, the SPN number is displayed only.
E n g O i l P r e s s W R N
B o o s t P r e s s F L S
E n g O i l T e m p F L S
6 2 9 F L S
> C o n t r o l l e r # 1
E n g C o o l T e m p W R N
F C : 1 1 0 O C : 7 F M I : 3

Controller monitoring
InteliDrive sw pack contains separate PC software tools: DriveConfig (DC) and DriveMonitor (DM). Drive
Monitor is meant to be monitoring tool for remote controller connection.
DriveMonitor is based on Windows 95/98/NT/ME/2000/XP or higher platform and requires 50 MB of hard
disc free space.
Direct connection to the PC

InteliDrive can be connected directly with PC via RS232 interface. Use the standard cable RS232 cable to
connect PC with InteliDrive controller.
Hint:
Make sure the grounding system on controller and PC – COM port (negative of the PC DC supply) are
identical – before the first direct connection. There must not be any voltage between these two points
otherwise the internal PTC protection activates and interrupts RS232 communication. In such case
disconnect RS232 line wait a minute for PTC recovery and try again. The simple solution is to assure, that
the PC supply 240/20V is ground free (GND terminal is not connected).
PC CONTROLLER
2 - RxD 2 - RxD
RS232
RS 232
RS232
3 - TxD 3 - TxD
230 VAC 5 - GND 5 - GND
Required the same

voltage potential
between GND‘s
0 VDC
- +
Battery
DriveMonitor
Functions
 On-line direct, Modem or Internet connection to one engine
 Active Modem or Internet call from engine to PC (activated by selected Alarm)
 Continuous one engine monitoring in on-line connection
 On-line or Off-line History record listing
 Setpoints listing and adjusting (password protected)
 Statistics value (e.g. Running hours) Set/Reset
 Password and Access code change

Connection type
Direct connection via RS232 (up to 10m). For longer distance use RS232/RS485 converters
(e.g. ADVANTECH – ADAM 4520).
Modem connection via Analog, ISDN or GSM modem.
Internet via IG-IB (InteliGen internet interface unit). IG-IB Internet - Ethernet or Dial-up
connection is available.
Active call (via modem). Controller calls to the preselected telephone number and sends the
AID file when active call is activated. To receive AID file the DriveMonitor must be in Active
call waiting window.
Off line connection enables open and list Application AID file stored in PC.
Hint:
More detail regarding different types of connection see in IG-IS Communication guide.
Control window: displays all ID-DCU and I/O states, enables engine
control.
ID-RPU window … not available in Industrial version
Setpoints: listing and adjusting
Values: reading of all I/O include external modules
History list: complete history list.

DriveMonitor screen example (ID-DCU-Industrial, SS)
1 2 3 4 5
7
11
8
12
9
13 10
14
15
16
17
18 19 20
Description:
1. Buttons to deactivate Fault and Horn reset.
2. Buttons to switch-over the engine operation modes OFF and RUN (in ID-DCU-Industrial).
3. Buttons for Start or Stop of the engine.
4. Engine operation state indication.
5. Engine timer indication.
6. LED indication for load or clutch – GREEN = On/Off load is Closed / Opened, see point 8.
7. LED indication of engine state: GREEN = Engine running, RED = event in Alarm List.
8. Button for Close / Open load or clutch (Binary output control).
9. Binary inputs list
10. Binary outputs list.
11. Alarm list
12. ECU Alarm list
13. Defined analog input bar graph – Oil press.
14. Undefined analog input.
15. ECU Alarm fault reset button.
16. Engine speed measurement.
17. Bar graph of battery voltage.
18. Connection indication.
19. Archive type indication.
20. DDE Server indication.
Hint:
More details of DriveMonitor software can be found in DriveMonitor User guide.

Password protection
Password is a four-digit number. Only setpoints associated with the entered password level can be modified.
There are three levels of password protection:

0. User level allows change of non-protected setpoints only
1. Operator level allows change of setpoints protected by Operator level 1.
2. Master level allows change of setpoints protected by Operator 1. and Master level 2.
3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade.
There can be password protected:

 Setpoints (depends on configuration)
 Statistics values (Level 3 only)
 Engine commands (depends on configuration)
Even though one level may have been set from the front panel, the affected setpoints are not
accessible from DriveMonitor (direct or Modem) until this level is set in DriveMonitor (direct or Modem).
Setpoints opened from front panel are automatically closed 15 minutes after the last key has been
depressed or when wrong value of password is set.
Password is a four-digit number. Only setpoints associated with the entered password level can be
modified.
Any password can be changed once that level password or higher has been entered.
Modbus protocol
 Direct connection: RS232, RS422, RS485
 Modem connection
 9600, 19200 or 38400 bps, 8 data bits, 1 stop bit, no parity
 Transfer mode RTU
 Function 3 (Read Multiply Registers)
 Function 6 (Write Single Register)
 Function 16 (Write Multiply Registers)
 The response to an incoming message is sent with minimum 4.096 ms delay after message reception
The complete description of Modbus communication protocol can be found in Modbus Protocol Reference
Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web
site at http://www.modicon.com/openmbus/ .
Modbus Multipack message

It is special communication object that contains all values that are used for History record (configurable) and
can be read by one command.
Hint:
Detail Modbus command description see in ComAp Communication guide.
Communication object vs. Register

All the data intended for communication has its representation as communication objects in the controller.
The communication object is represented by the n-byte array in the controller memory and identified by the
unique 16-bit communication object number. The register, according to Modbus communication protocol,
represents a two-byte data and in communication functions is referenced by 16-bit register address. Further
in the description of communication functions the communication object number will always be used as
a register address and length of the communication object will be expressed by number of registers. Just
one communication object can be read or written by one communication function.
Hint:
It is possible to download the Actual InteliDrive controller object description corresponding to actual
configuration from on-line controller or from aid archive using DriveConfig software.

Technical data
ID-DCU
Power supply
Voltage range 8-36V DC
Current consumption (depends on supply voltage) 0,34A at 8VDC
0,12A at 24VDC
0,09A at 36VDC
Battery voltage measurement tolerance 2 % at 24V
RTC battery life-cycle 10 year
Hint:
RTC battery flat causes wrong Date&Time information only.
Operating conditions
Operating temperature ID-DCU -20 to +70 °C
Operating temperature ID-DCU-LT -40 to +70 °C
Storage temperature -30 to +80 °C
Humidity 95% without condensation
Flash memory data retention time 10 years
Protection front panel IP65
Standard conformity
Low Voltage Directive EN 61010-1:95 +A1:97
Electromagnetic Compatibility EN 61000-6-2, October 2001
EN 61000-6-4, October 2001
IEC 60533, Ed. 2; 1999-11
Vibration 5 - 25 Hz, ±1,6mm
25 - 100 Hz, a = 4 g
Shocks a = 200 m/s2
Dimensions and weight

Dimensions (183x123x47mm)
See chapter terminals and dimensions
Weight 800g

Part No N39453
® GB
User’s Handbook
415GM 422GM
422TGM
4.4GM 4.4TGM
4.4TWGM &
4.4TW2GM
4.4GM & 4.4TGM 4.4TWGM & 4.4TW2GM

Radiator Radiator
N39453 Title
Perkins
415GM
422GM
422TGM
4.4GM
4.4TGM
4.4TWGM
4.4TW2GM
4.4GM Radiator
4.4TGM Radiator
4.4TWGM Radiator
4.4TW2GM Radiator
User’s Handbook
Publication N39453, Issue 7.

© Proprietary information of Wimborne Marine Power Centre, all rights reserved.
The information is correct at the time of print.
Published in December 2013 by Wimborne Marine Power Centre, Wimborne, Dorset, England BH21 7PW
Tel: +44(0)1202 796000 Fax: +44(0)1202 796001 E -mail: Marine@Perkins.com www.perkins.com/marine
Title N39453
N39453 Contents
1 General information..................................................................................1
Introduction....................................................................................................................1
How to care for your engine.........................................................................................2
General safety precautions......................................................................................... 11
Engine guarantee.........................................................................................................12
Engine identification....................................................................................................12
Perkins companies.......................................................................................................14
2 Engine views.............................................................................................15
Introduction...................................................................................................................15
Location of engine parts - 415GM...............................................................................16
Front and right side view (A)............................................................................16
Rear and left side view (B) - 415GM.................................................................17
Location of engine parts for the - 422GM...................................................................18
Front and left side view (C)..............................................................................18
Rear and right side view (D) - 422GM..............................................................19
Location of engine parts for the - 422TGM................................................................20
Front and right side view (E)............................................................................20
Rear and right side view (F) - 422TGM............................................................21
Location of engine parts - 4.4GM................................................................................22
Front and left side view (G) of the engine.......................................................22
Rear and right side view (H) of the engine......................................................23
Location of engine parts - 4.4TGM..............................................................................24
Front and right side view (I) of the engine......................................................24
Rear and left side view (J) of the engine.........................................................25
Location of engine parts - 4.4TWGM and 4.4TW2GM...............................................26
Front and left side view (K) of the engine.......................................................26
Rear and right side view (L) of the engine......................................................27
Location of engine parts - 4.4GM & 4.4TGM Radiator...............................................28
Front and left side view (M) of the engine.......................................................28
Rear and right side view (N) of the engine......................................................29
Location of engine parts - 4.4TWGM and 4.4TW2GM Radiator................................30
Front and left side view (O) of the engine.......................................................30
Rear and right side view (P) of the engine......................................................31
3 Operation instructions.............................................................................33
Models - 415GM, 422GM & 422TGM, how to start the engine..................................33
How to start a cold engine with the fuelled starting aid...........................................33
How to start a warm engine.........................................................................................33
How to stop the engine................................................................................................34
Adjustment of the engine speed range......................................................................34
Contents N39453
Running-in.....................................................................................................................34
Angle of operation........................................................................................................34
Models - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM, 4.4GM rad, 4.4TGM rad,
4.4TWGM rad & 4.4TW2GM rad, control panel (optional).........................................35
Control module (optional)............................................................................................37
Engine wiring harness (optional equipment).............................................................38
How to start the engine................................................................................................41
How to stop the engine................................................................................................42
Emergency procedures...............................................................................................43
4 Preventive maintenance, Models............................................................45

Preventive maintenance periods - 415GM, 422TGM & 422TGM...............................45
Schedules, models - 415GM, 422GM & 422TGM............................................46
How to drain the coolant circuit.......................................................................47
Engines fitted with keel coolers.......................................................................47
How to check the specific gravity of the coolant...........................................48
How to drain the raw water system.................................................................49
How to check the impeller of the raw water pump.........................................50
How to check the drive belt..............................................................................51
How to adjust the belt tension.........................................................................51
How to renew the element of the fuel filter.....................................................52
Fuel pre-filter.....................................................................................................52
Atomiser fault....................................................................................................52
How to renew an atomiser................................................................................53
How to eliminate air from the fuel system......................................................54
How to renew the lubricating oil......................................................................55
How to renew the canister of the lubricating oil filter ...................................56
How to renew the engine breather assembly.................................................57
How to renew the element of the air filter - 415GM and 422GM....................58
How to renew the element of the air filter - 422TGM......................................59
How to set the valve tip clearances - 415GM..................................................60
How to set the valve tip clearances - 422GM and 422TGM...........................61
Seacock strainer................................................................................................62
Corrosion...........................................................................................................62
Supplementary tools.........................................................................................62
Preventive maintenance periods - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM,
4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad. ........................................63
Schedules - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM.......................................64
Schedules - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad..........65
How to fill the coolant circuit - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM...................66
How to fill the coolant circuit - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad &
4.4TW2GM rad...............................................................................................................67
How to drain the coolant circuit - 4.4GM....................................................................68
How to drain the coolant circuit - 4.4TGM..................................................................69
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM.......................................70
How to drain the coolant circuit - 4.4GM & 4.4TGM rad............................................71
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM rad.................................72
N39453 Contents
Engines fitted with keel coolers..................................................................................73

How to check the specific gravity of the coolant......................................................73
How to drain the raw water system - 4.4GM & 4.4TGM.............................................74
How to drain the raw water system - 4.4TWGM & 4.4TW2GM..................................75
How to check the impeller of the raw water pump - 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM.....................................................................................................................76
How to check the drive belt - 4.4GM, 4.4TGM, 4.4TWGM & 4.4TW2GM................... 77
How to adjust the belt tension....................................................................................77
How to check the drive belt - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad &
4.4TW2GM rad...............................................................................................................78
How to adjust the belt tension.........................................................................78
How to renew the element of the fuel filter - 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM.....................................................................................................................79
Fuel pre-filter.................................................................................................................79
How to renew the element of the fuel filter - 4.4GM rad, 4.4TGM rad,
4.4TWGM rad & 4.4TW2GM rad...................................................................................80
Fuel pre-filter (optional)....................................................................................80
Atomiser maintenance.................................................................................................81
Atomiser faults..................................................................................................81
How to remove and to fit an atomiser........................................................................82
How to fit.......................................................................................................................83
How to eliminate air from the fuel system.................................................................84
How to renew the lubricating oil.................................................................................85
How to renew the canister of the lubricating oil filter...............................................86
Air filter..........................................................................................................................87
Restriction indicator.........................................................................................88
How to check the valve tip clearances............................................................89
Supplementary tools.........................................................................................90
Power take-off....................................................................................................90
5 Engine fluids.............................................................................................91
Fuel specification.........................................................................................................91
Lubricating oil specification........................................................................................92
Coolant specification...................................................................................................93
6 Fault diagnosis.........................................................................................95
Problems and possible causes...................................................................................95
List of possible causes................................................................................................96
7 Engine preservation.................................................................................97
Introduction...................................................................................................................97
Procedure models - 415GM, 422GM, 422TGM, 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM.....................................................................................................................97
How to add coolant to the raw water system for engine preservation purposes.. 98
Procedure models - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad....... 99
Contents N39453
8 Parts and service.....................................................................................101

Introduction..................................................................................................................101
Service literature.........................................................................................................101
Training.........................................................................................................................101
On-board spares kit....................................................................................................101
POWERPART recommended consumable products...............................................101
9 General data.............................................................................................103
415GM...........................................................................................................................103
422GM...........................................................................................................................104
422TGM........................................................................................................................105
4.4GM............................................................................................................................106
4.4TGM..........................................................................................................................107
4.4TWGM......................................................................................................................108
4.4TW2GM....................................................................................................................109
4.4GM Radiator............................................................................................................ 110
4.4TGM Radiator.......................................................................................................... 111
4.4TWGM Radiator....................................................................................................... 112
4.4TW2GM Radiator..................................................................................................... 113
N39453 Chapter 1
General information
Introduction
These on-board generating sets and other auxiliary power units are the latest developments from the business
arrangement between Perkins Engines Ltd and Wimborne Marine Power Centre.
Wimborne Marine Power Centre are the managers of the Perkins marine business and all enquires should be
made to Wimborne Marine Power Centre; refer to the company address list.
Over sixty years of diesel production experience, together with the latest technology, have been applied to the
manufacture of your engine to give you reliable and economic power.
To ensure that you use the relevant information for your specific engine type, refer to “Engine identification”.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
Page 1
Chapter 1 N39453
How to care for your engine

Warning! Read the “Safety precautions” and remember them. They are given for your protection and must be
applied at all times.
Caution: Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
This handbook has been written to assist you to maintain and operate your engine correctly.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the intervals indicated in “Preventive maintenance”. If the engine works in a very dusty
environment or other adverse conditions, certain maintenance intervals will have to be reduced. Renew the
filter canister and lubricating oil regularly in order to ensure that the inside of your engine remains clean.
Ensure that all adjustments and repairs are done by personnel who have had the correct training. Perkins
distributors have this type of personnel available. You can also obtain parts and service from your Perkins
distributor. If you do not know the address of your nearest distributor, enquire at Wimborne Marine Power
Centre,.
The “left side” and “right side” of the engine apply when the engine is seen from the flywheel end.
Page 2
N39453 Chapter 1
Page 3
Chapter 1 N39453
Page 4
N39453 Chapter 1
Page 5
Chapter 1 N39453
Page 6
N39453 Chapter 1
Page 7
Chapter 1 N39453
Page 8
N39453 Chapter 1
Page 9
Chapter 1 N39453
Page 10
N39453 Chapter 1
General safety precautions

These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications.
• Only use these engines in the type of application for which they have been designed.
• Do not change the specification of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
• Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
• Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct
training; even then extreme care must be used to prevent injury).
• Do not make adjustments that you do not understand.
• Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
• Other persons must be kept at a safe distance while the engine, auxiliary equipment or boat is in
operation.
• Do not permit loose clothing or long hair near moving parts.
Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly
while the engine runs.
• Do not operate the engine if a safety guard has been removed.

• Do not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
• Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
• Do not allow sparks or fire near the battery (especially when the battery is on charge) because the gases
from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the
eyes.
• Disconnect the battery terminals before a repair is made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the control panel or from the operators position.
• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
• Discard used lubricating oil and coolant in accordance with local regulations to prevent contamination.
• Use extreme care if emergency repairs must be made at sea or in adverse conditions.
• The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or
with the eyes.
• Always close the seacock before the removal of any component of the raw water circuit.
• Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
• The latest marine engines have a cover fitted to give some protection from the alternator fan and the drive
belt. Ensure that this cover is fitted before the engine is started.
• Fit only genuine Perkins parts.
Page 11
Chapter 1 N39453
Engine guarantee
If a claim under guarantee is necessary, the boat owner should make a guarantee claim on the nearest Perkins
marine distributor or an approved dealer.
If it is difficult to find a Perkins distributor or an approved dealer, consult the Service Department of Wimborne
Marine Power Centre, Wimborne.
Engine identification
• 415GM - identification letters HL • 4.4TW2GM - identification letters RJ
• 422GM - identification letters HP • 4.4GM Radiator - identification letters RE
• 422TGM - identification letters HR • 4.4TGM Radiator - identification letters RG
• 4.4GM - identification letters RE • 4.4TWGM Radiator - identification letters RJ
• 4.4TGM - identification letters RG • 4.4TW2GM Radiator - identification letters RJ
• 4.4TWGM - identification letters RJ
The engine identification number is shown at two locations on the engine:
Models 415GM, 422GM and 422TGM: stamped on a plate (I1) at the front right side of the cylinder block
under the fuel injection pipes. The other is shown on a label (I2) fitted to the top of the timing case.
Models 4.4GM, 4.4TGM, 4.4TWGM and 4.4TW2GM: stamped on a plate at the right side of the cylinder block
(J1) and shown on a label (K1) fitted to the front of the timing case.
Models 4.4GM rad, 4.4TGM rad, 4.4TWGM rad and 4.4TW2GM rad: stamped on a plate at the right side of
the cylinder block (L1) and shown on a label (M1) fitted to the front of the timing case.
An example of a 4.4TGM Radiator engine number is: RG30879U123456L.
The components of the engine number are as follows:
RG30879U123456L
RG Type code letters
30879 Build list number
U Built in the UK
123456 Engine serial number
L Year of manufacture
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor.
Page 12
N39453 Chapter 1
Page 13
Chapter 1 N39453
Perkins main dealers Singapore
Multico Power Drive Pte Ltd

Australia 11 Tuas View Crescent
Multico Building
Allight Pty Ltd (Sydney Office), Singapore 637643
41 York Road, Telephone: [65] 6 863 2863
Ingleburn, NSW 2565, Australia. Fax: [65] 6 863 6819
Telephone: [61](2) 9765 6800 Email: mpd@multicorporation.net
Fax: [61](2) 9765 6899 www.multicorporation.net
Email: valcenteno@allight.com
www.alight.com United Kingdom
France Perkins Engines Company Ltd,

Eastfield, Peterborough PE1 5NA,
Secodi, England.
Rue de la Scierie Telephone: 0044 (0) 1733 58 3000
17000 LA ROCHELLE, Telex: 32501 Perken G
France. Fax: 0044 (0) 1733 582240
Telephone: [33] (5) 4645 1313 www.perkins.com
Fax: [33](5) 46 41 83 26
Email: secodilr@secodi.fr United States of America
www.secodi.fr
Perkins Pacific Inc.,
Germany 7215 South 228th Street,
Kent, Washington
BU Power Systems GmbH & Co. KG, WA 98032
Perkinsstraße 1, USA
49479 Ibbenbüren, Telephone: [1](253) 854 0505
Germany. Fax: [1](253) 850 2631
Telephone: [49] 5451 5040-0 www.pacificdda.com
Fax: [49] 5451 5040-100
Email: service@bu-perkinssabre.de Perkins Power Corp,
www.bu-power-systems.de 55 Industrial Loop North,
Orange Park,
Italy Florida 32073
U.S.A.
Scan Diesel s.r.l., Telephone: [1](904) 278 9919
Via Coloredo,14, Fax: [1](904) 278 8088
28069 TRECATE (NO) www.perkinspower.com
Italy.
Telephone: [39] (0321) 777880 *This is just a small selection of Perkins dealers. For a
Fax: [39] (0321) 777959 more comprehensive list, please see
Email: info@scandiesel.it www.Perkins.com/Marine.
www.scandiesel.it
The managers of the marine business for Perkins
Japan are:
Perkins Engines, Inc., Wimborne Marine Power Centre,
Sanno Grand Bldg, 8th Floor, Ferndown Industrial Estate,
2-14-2 Nagatacho, Chiyoda-ku, Wimborne,
TOKYO 100-0014, Japan. Dorset BH21 7PW,
Telephone: [81] (3) 5157 0571 England
Fax: Fax: [81] (3) 5157 0572 Telephone: 0044 (0) 1202 796000
Fax: 0044 (0) 1202 796001
Email: Marine@Perkins.com
Page 14
N39453 Chapter 2
Engine views
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
Page 15
Chapter 2 N39453
Location of engine parts - 415GM

Front and right side view (A)
1. Coolant filler cap

2. Front lifting bracket
3. Belt cover
4. Oil filler cap
5. Raw water pump
6. Fuel inlet
7. Excess fuel return
8. Sump drain take-off point
9. Oil pressure switch/sender
10. Oil filter
11. Fuel lift pump
12. Fuel filter
13. Dipstick
14. Rear lifting bracket
Page 16
N39453 Chapter 2
Rear and left side view (B) - 415GM
15. Air filter

16. Exhaust
17. Starter Motor
18. Raw water cooler
19. Alternator
20. Coolant header tank / cooled exhaust manifold
Page 17
Chapter 2 N39453
Location of engine parts for the - 422GM

Front and left side view (C)

2. Exhaust
3. Starter motor
4. Alternator
5. Raw water cooler
6. Raw water pump
7. Belt cover
8. Coolant filler cap
Page 18
N39453 Chapter 2
Rear and right side view (D) - 422GM
9. Oil filler cap

11. Dipstick
12. Oil filler cap
14. Oil filter
15. Fuel inlet
18. Fuel lift pump
19. Fuel filter
20. Air filter
Page 19
Chapter 2 N39453
Location of engine parts for the - 422TGM

Front and right side view (E)
1. Coolant filler
3. Belt cover
4. Oil filler cap
5. Air filter kit (supplied loose)
6. Raw water pump
7. Solenoid, negative earth
8. Fuel inlet
12. Oil filter
13. Dipstick
14. Fuel filter
Page 20
N39453 Chapter 2
Rear and right side view (F) - 422TGM

17. Exhaust elbow
18. Starter motor
19. Raw water cooler
20. Alternator
Page 21
Chapter 2 N39453
Location of engine parts - 4.4GM

Front and left side view (G) of the engine
1. Fresh water filler cap 9. Air filter
2. Oil filler cap 10. Electric fuel pump
3. Header tank 11. Fuel filter canister
4. Fresh water pump 12. Heat exchanger
5. Oil filler cap 13. Fuel return hose
6. Raw water pump 14. Dipstick
7. Belt cover 15. Fuel inlet hose
8. Oil filter
Page 22
N39453 Chapter 2
Rear and right side view (H) of the engine
16. Rear lifting eye

17. Air filter
18. Exhaust manifold
19. Starter
20. Lubricating oil sump
21. Front lifting eye
22. Alternator
23. Exhaust elbow
Page 23
Chapter 2 N39453
Location of engine parts - 4.4TGM

Front and right side view (I) of the engine
1. Air cleaner
2. Oil filler cap
3. Alternator
4. Turbocharger
5. Exhaust elbow
6. Starter
8. Fresh water filler cap
11. Header tank
12. Belt cover
Page 24
N39453 Chapter 2
Rear and left side view (J) of the engine
13. Electric fuel pump

14. Fuel filter canister
15. Fresh water pump
16. Oil filler cap
17. Heat exchanger
18. Raw water pump
19. Dipstick
20. Oil filter
21. Fuel return hose
23. Air filter
24. Breather canister
25. Fuel inlet hose
Page 25
Chapter 2 N39453
Location of engine parts - 4.4TWGM and 4.4TW2GM

Front and left side view (K) of the engine
1. Rear lifting eye

3. Header tank
4. Fresh water pump
5. Oil filler cap
6. Belt cover
7. Fuel return hose
8. Air cleaner
10. Breather canister
12. Heat exchanger
13. Raw water pump
14. Dipstick
15. Fuel inlet hose
16. Oil filter
Page 26
N39453 Chapter 2
Rear and right side view (L) of the engine
17. Aftercooler
18. Turbocharger
20. Air filter
22. Alternator
23. Exhaust elbow
24. Starter
Page 27
Chapter 2 N39453
Location of engine parts - 4.4GM & 4.4TGM Radiator

Front and left side view (M) of the engine

2. Oil filler cap
3. Radiator
4. Fresh water pump
5. Oil filler cap
6. Fan guard
7. Oil filter
8. Air filter
10. Thermostat (manifold circuit)
12. Dipstick
Page 28
N39453 Chapter 2
Rear and right side view (N) of the engine

14. Air filter
16. Starter
19. Thermostat (cylinder head)
20. Alternator
21. Exhaust elbow
22. Turbocharger (4.4TGM Radiator only - not shown)
Page 29
Chapter 2 N39453
Location of engine parts - 4.4TWGM and 4.4TW2GM Radiator

Front and left side view (O) of the engine

2. Oil filler cap
3. Radiator
4. Oil filler cap
5. Fan guard
6. Oil filter
7. Air filter
8. Electric fuel lift pump
10. Thermostat (manifold circuit)
11. Dipstick
Page 30
N39453 Chapter 2
Rear and right side view (P) of the engine

13. Air filter
15. Starter
18. Thermostat (cylinder head)
19. Exhaust elbow
20. Alternator
21. Turbocharger
Page 31
Chapter 2 N39453
Page 32
N39453 Chapter 3
Operation instructions
Models - 415GM, 422GM & 422TGM, how to start the engine

Several factors affect engine start, for example:
• The power of the battery

• The performance of the starter motor
• The viscosity of the lubricating oil
• The installation of a cold start system
• Size of the starter cables.
Diesel engines need a cold starting aid if they are to start in very cold conditions. The cold start aid fitted to
these engines are glow plugs, which are fitted into the combustion chamber of each cylinder and are connected
electrically.
Preparations for an engine start
1. Ensure that there is more than enough fuel available for the voyage.
2. Ensure that the fuel supply control (if fitted) is in the open position.
3. Check that the seacock strainer is clean.
4. Open the seacock.
5. Check the amount of coolant in the header tank.
6. Check the amount of lubricating oil in the sump.
How to start a cold engine with the fuelled starting aid

1. Switch on the electrical system.
2. Hold the heat switch in the down position for 10 seconds. Press the start button to engage the starter
motor. When the engine starts, release the heat switch. The engine will run up to the set speed, 1500 or 1800
rev/min.
3. If the engine does not start in 10 seconds, hold the heat switch down for a further 10 seconds and engage
the starter motor again. When the engine has started, release the heat switch. Check that water comes out
of the end of the exhaust pipe or out of the separate discharge outlet.
Always ensure that the engine and starter motor are stationary before the starter motor is engaged again.
Caution: Ether type starting aids must not be used.
How to start a warm engine

1. Switch on the electrical system.
2. Press the start button to engage the starter motor. When the engine starts it will run up to the set speed,
1500 or 1800 rev/min. Check that water comes out of the end of the exhaust pipe or out of the separate
discharge outlet.
Always ensure that the engine and starter motor are stationary before the starter motor is engaged again.
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Chapter 3 N39453
How to stop the engine

1. Remove the load from the engine and allow the engine to cool for 2-3 minutes.
2. Switch the engine stop switch to the stop position, refer to the users’ handbook of the application
manufacturer.
Adjustment of the engine speed range

The idle or the maximum speed settings must not be changed by the engine operator, because this can
damage the engine or generator. The warranty of the engine can be affected if the seals on the fuel injection
pump are broken during the warranty period by a person who is not approved by Perkins.
Running-in
A gradual running-in of a new engine is not necessary. Prolonged operation at light loads during the early life
of the engine can cause lubricating oil to enter the exhaust system. Maximum load can be applied to a new
engine as soon as the engine is put into service and the coolant temperature has reached a minimum of 60OC
(140OF).
The engine will benefit if the load is applied as soon as possible after the engine is put into service.
Cautions:
• Do not operate the engine without a load.

• Do not overload the engine.
Angle of operation
The 415GM, 422GM and 422TGM can operate at 25O continuous or 35O intermittent in all directions.
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N39453 Chapter 3
Models - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM, 4.4GM rad, 4.4TGM rad, 4.4TWGM
rad & 4.4TW2GM rad, control panel (optional)
Oil pressure gauge (A1)
Shows engine oil pressure. The oil pressure will be greatest after a cold engine is started. If the gauge reading
is fluctuating and the load has become stable, perform the following steps:
• Remove the load.

• Check and maintain oil level.
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Chapter 3 N39453
Temperature gauge (A2)
Shows the engine water temperature. The engine should operate within the range of 78OC (172OF) to 90OC
(194OF). The temperature may vary according to load. However it should never exceed the boiling point for the
pressurised system that is being used. The temperature is regulated by the engine thermostats in the system.
Do not operate the engine if there are no thermostats fitted in the engine. If the engine is operating and a high
water temperature reading is observed, perform the following steps:
• Reduce the load
• Inspect the engine for coolant leaks.
• Determine if the engine should be shutdown.
Note: If the water temperature sensor is not fully submerged because of low water level, the temperature
reading will be false.
DC voltmeter (A3)
Shows the voltage of the starting system.
Hourmeter (A4)
Shows the total operating hours of the engine. The meter is powered whenever the engine is running.
Audible alarm (A5)
This activates when one of the fault indicators is illuminated. The alarm can be silenced by pressing the alarm
mute switch (A7).
Emergency stop button (A6)
This is used to shut down the engine during an emergency situation.
Alarm mute switch (A7)
This switch is used to silence the alarm.
Control module (A8)
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N39453 Chapter 3
Control module (optional)

The control panel (B) has six indicators (B3 to B8) that correspond to certain fault conditions. An indicator
illuminates when the corresponding problem exists. Each indicator has a label that identifies the problem. The
Engine Control Switch (B12) must be turned to the OFF/RESET position (B9) in order to turn off the indicators
and to reset the control panel. The panel also incorporates two spare indicators.
Programmable indicators (B1)
The control panel is programmed in order to alert the operator to various conditions, ie - Engine Running, Not
in Auto and Emergency Stop
Note: See separate manual supplied with the unit.
Indicators (B2)
These are not used.
Indicator for the oil pressure (B3)
This indicates when the engine oil pressure has fallen below the low limit of the oil pressure switch.
Indicator for the coolant temperature (B4)
This lights when the engine water temperature has risen above the upper limit of the water temperature
switch.
Indicator for engine overspeed (B5)
This lights when the control board detects that the engine speed has exceeded the overspeed set point.
Indicator for the alarm (B6)
This indicator lights as a warning when the control module has received any signals that have been programmed
to light with the alarm. When the indicator flashes, there is a shut down fault.
Indicator for engine overcrank (B7)
This lights when the engine fails to start due to the limit for cranking being exceeded.
Indicator for emergency stop (B8)
This lights when the stop push button has been pressed.
Stop/Reset position (B9)
When the Engine Control Switch (B12) is in this position, the fault indicators are reset and the engine shuts
down immediately.
Automatic start position (B10)
When the Engine Control Switch (B12) is in this position, the engine will start automatically when the remote
initiate contact is closed or will shutdown when opened.
Manual start position (B11)
When the Engine Control Switch (B12) is in this position, the engine will start and will continue to run until the
position is changed.
Engine control switch (B12)
This selects Automatic or Manual starting and off and reset options.
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Chapter 3 N39453
Engine wiring harness (optional equipment)

The engine wiring harness is designed to convey information to and from the engine control panel. Within the
harness is a circuit breaker and a negative earth fuse to protect the wiring in the event of a short circuit as well
as control relays.
Access to the circuit breaker is from the outside of the control box. This can be used to isolate the control
system during servicing. The 10A breaker protects the control system to the panel(s). Interuption of this will
inhibit the control panel and thus the starting of the engine.
The momentary connection of the negative line to earth is protected by an 80A breaker located within the
enclosure adjacent to the 10A breaker.
Within the control box are four relays. Three are high current relays designed to control the operation of
the starter and the glowplugs. During the operation of the glowplugs a negative earth relay momentarilly
grounds the engine to negative. The fourth relay controls the fuel lift pump stop solenoid and cold start advance
solenoid.
The fuel is delivered to the fuel injection pump via an electric fuel lift pump. This commences operation in
tandem with the stop solenoid when the engine circuit switch is operated on the control panel.
Engine circuit variations due to system damage

24V engines - Engines with 24V systems will have fitted a 24V to 12V converter (unit coloured black) to
operate the 12V fuel lift pump.
Care should be taken to ensure that there is adequate ventilation around the voltage converter to ensure that
it does not overheat.
Caution: On no account may any load be placed on either the inverter or converter as this may cause the unit
to fail.
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N39453 Chapter 3
Circuit diagram, engine wiring harness
Information derived from 05-1013-1
Page 39
Chapter 3 N39453
Standard DC circuits
Information derived from 04-1006-1
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N39453 Chapter 3
How to start the engine

Use only this procedure to start the engine; it has been designed to protect the engine and the environment.
Several factors can affect engine startup, for example:
• The power of the batteries

• The performance of the starter motor
• The viscosity of the lubricating oil
• The installation of a cold start system.
Diesel engines need a cold starting aid if they are to start in extremely cold conditions. These engines are fitted
with glow plugs as standard and are only necessary in ambient temperatures colder than -5OC
Before the engine is started the operator should understand fully the controls and their use.
Preparations for an engine start.
1. Ensure that there is more than enough fuel in the tank for the voyage.
2. Ensure that the fuel supply control (if fitted) is in the open position.
3. Check the amount of coolant in the radiator.
4. Check the amount of lubricating oil in the sump.
Caution: Ether type fuels must not be used.
Engine starting with the optional control panel - local operation

Use the following procedure in order to start the engine.
1. Turn the engine control switch (C4) to the manual start position (C3)
2. If the preheat timer is configured, it will be initiated. After the timer has expired, the engine will begin to
crank.
Note: When the engine starts, the starter motor is disengaged and is locked out.
3. If the engine did not start, then the control module (C1) will permit the starter motor to cool down for a
predetermined amount of time. Once this time has elapsed, the engine will crank.
Note: The ‘’Failed to Start’’ fault will be displayed after three unsuccessful attempts to start the engine and
an LED indicator will flash. In this situation, the engine control switch (C4) must be moved to the Stop/Reset
position (C2). Determine the reason that the engine failed to start before making further attempts.
4. After the engine has started, the fault protection timer is activated, which allows the engine to stabalise
before the fault protection system is activated. When the timer has expired, the fault protection is available.
The generator load may now be applied to the engine.
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Chapter 3 N39453
How to stop the engine

Stopping the engine
Cautions:
• Stopping the engine immediately after it has been working under load can result in overheating and
accelerated wear of the engine components.
• If the engine has been running at high loads, run at low load for at least three minutes to reduce and
stabalise the internal engine temperature before stopping the engine.
• Avoiding hot engine shutdowns will maximise turbocharger shaft and bearing life where fitted.
Standard control panel - manual operation
1. Turn the engine control (D3) to the AUTO position (D2). When the remote stop delay timer expires, the
engine will stop.
Note: If the remote start signal is removed with the control in manual start mode, the engine will continue to
run until the engine control switch (D3) is turned to the AUTO position (D2) and the remote stop delay timer
expires.
2. Turn the engine control switch (D3) to Stop/Reset (D1).

Standard control panel - automatic operation
1. Remove the remote start signal. When the remote stop delay timer expires, the engine will stop.
2. Turn the engine control switch (D3) to Stop/Reset (D1).
Note: The engine will stop immediately if the engine control switch (D3) is turned to the Stop/Reset position
(D1).
Adjustment of engine speed range

Note: Any adjustment to the engine speed is not permitted. Any interference with the fuel pump will invalidate
emission complience of the engine and warranty.
Running-in
A gradual running-in of a new engine is not necessary. Prolonged operation at light loads during the early life
of the engine can cause lubricating oil to enter the exhaust system. Maximum load can be applied to a new
engine as soon as the engine is put into service and the coolant temperature has reached a minimum of 60OC
(140OC).
Cautions:
• The engine will benefit if the load is applied as soon as possible after the engine is put into service.
• Do not overload the engine.
Angle of tilt
For yachts with auxillary engines, it may be necessary to use the engine during operation against the wind.
In these conditions, an angle of tilt (port or starboard) of up to 25O continuous operation or 35O intermittent
operation is permissible.
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N39453 Chapter 3
Emergency procedures
If the engine stops
1. Check that the fuel supply valve (if fitted) is in the open position.
2. Check the fuel pre-filter (if fitted) and the fuel filters for water. If a warning light for water in the fuel is fitted,
and it is illuminated, water has entered the pre-filter. Water must be removed before the engine is operated.
Drain any water found and fit new filters.
3. Check the amount of fuel in the tank. If the engine has run until the tank is empty, there may be dirt or air
in the fuel pipes. Change the fuel filter. Fill the tank. Eliminate air from the system.
4. Start the engine again. If the engine still will not start, check that the cables and contacts of the stop
solenoid are in good condition.
If there is a reduction in engine speed or a loss of power
1. Check that the induction system is not restricted and that the engine compartment has a good supply of
air.
2. Check that the fuel pre-filter or the fuel filter elements are not restricted or contaminated by water. If a
warning light for water in the fuel is fitted, and it is illuminated, water has entered the pre-filter. Water must be
removed before the engine is operated. Drain any water found and fit new filters.
If the warning lamp / audible warning for high coolant temperature operates
Warning! Do not remove the filler cap while the engine is still hot and the system is under pressure, because
dangerous hot coolant can be discharged.
1. Reduce the load on the engine. Stop the engine if there is a leakage of steam or coolant from the
engine.
2. Check that the coolant level is correct after the engine has cooled.
Note: Coolant leakage can be stopped temporarily with adhesive tape, hose and hose clips.
If a high-pressure fuel pipe is broken or has a crack

Ensure that fuel does not spray onto the skin. Stop the engine if there is a leakage of high-pressure fuel.
1. Stop the engine.

2. Remove the broken pipe from the engine.
3. Connect the end of the pipe that is not broken to the fuel injection pump. Put the broken end of the pipe
into a suitable container.
If leakage occurs from a low pressure fuel pipe
Temporarily stop the leak with a hose and hose clips.
If leakage of lubricating oil occurs:

1. Stop the engine immediately and try to find the cause.
2. If the main flow can be reduced, put a suitable container under the leakage point.
3. Fill the engine with new lubricating oil at the same rate as the loss of oil and frequently check the
lubricating oil pressure.
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Chapter 3 N39453
Page 44
N39453 Chapter 4
Preventive maintenance, Models
Preventive maintenance periods - 415GM, 422TGM & 422TGM

These preventive maintenance periods apply to average conditions of operation. Check the periods given by
the manufacturer of the boat in which the engine is installed. If necessary, use the shorter periods. When the
operation of the engine must conform to the local regulations these periods and procedures may need to be
adapted to ensure correct operation of the engine.
It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform
to the specifications given in this handbook.
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Chapter 4 N39453
Schedules, models - 415GM, 422GM & 422TGM
The schedules which follow must be applied at the interval (hours or months) which occur first.
A Every day or every 8 hours D Every 2000 hours

B Every 500 hours or 12 months E Every 3000 hours
C Every 1000 hours
A B C D E Operation
● ● ● ● ● Check the amount of coolant in the header tank
● Check the engine for leakage of oil and coolant
● Check the specific gravity of the coolant (2) (3)
● Check the tension and the condition of the drive belt
● Renew alternator drive belt
● Check the impeller of the raw water pump

● Check the sea water strainer
● Check heat exchanger end caps for signs of corrosion
● Drain water from the fuel pre-filter (1)

● Renew the element / canister of the fuel filter
● Check the atomisers(2)
● Ensure the turbocharger impeller and turbocharger impeller casing are cleaned(2)
● Check the amount of lubricating oil in the sump

● Renew the engine lubricating oil (4)
● Renew the canister of the lubricating oil filter
● Remove and clean the pipe(s) for the engine breather

● Renew the engine breather (2)
● Clean or renew the element of the air filter
● Check all hoses and connections
● Check the valve tip clearances of the engine, and adjust if necessary (2)
● Check the audible warning system which protects the engine
● Check the alternator, the starter motor etc.(2)
● Check the glow plugs (2)
(1) If one is fitted.

(2) By a person who has had the correct training.
(3) Renew the coolant every 6 years. If a coolant inhibitor is used instead of coolant, it should be renewed every 6 months.
(4) The oil change interval will change with the amount of sulphur in the fuel (see the table and the Fuel Specification in section 5). The
interval to change the canister of the lubricating oil filter is not affected.
Note: To ensure that the engine runs at maximum efficiency, the operations that follow must be done every
12 months or less. If the raw water is excessively contaminated, these operations should be done more
frequently.
• Clean the tube stack of the heat exchanger for the closed circuit coolant
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N39453 Chapter 4
How to drain the coolant circuit
Warnings!
• Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous
hot coolant can be discharged.
• Discard used coolant in a safe place and in accordance with local regulations.
1. Remove the filler cap of the coolant circuit.
2. Remove the drain plug (A1) from the cylinder block which is situated in the same place on all the engines
and the drain plug from the heat exchanger, (B1) on the 415GM and (C1) on the 422GM/422TGM. Ensure
that the drain holes are not restricted. Also, on the 422TGM, remove the drainplug on the raw water cooler
(D1).
3. After the system has been drained, fit the filler cap and the drain plugs.
4. Fasten a label in a suitable place to indicate that the coolant system has been drained.
Caution: The closed circuit system cannot be drained completely. If the coolant is drained for engine
preservation purposes or for protection from frost, the coolant system must be filled again with an approved
coolant mixture prior to the storage period. See “Coolant specification” for details of the correct coolant to be
used in the circuit.
Engines fitted with keel coolers
The coolant capacity and the method used to drain the coolant circuit of an engine connected to a keel cooler
will vary in different applications.
Use the instructions given by the keel cooler manufacturer to drain and renew the engine coolant when a keel
cooler is fitted.
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Chapter 4 N39453
How to check the specific gravity of the coolant
For mixtures which contain inhibited ethylene glycol:
1. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the
coolant has circulated through the cooling system.
2. Stop the engine.
3. Allow the engine to cool until the temperature of the coolant is below 140OF (60OC).
Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because
4. Remove the filler cap of the cooling system.

5. Drain some coolant from the cooling system into a suitable container.
6. Use a special coolant hydrometer that will check the temperature and the specific gravity of the coolant,
follow the manufacturer’s instructions.
Note: If a special coolant hydrometer is not available, put a hydrometer and a separate thermometer into the
coolant mixture and check the readings on both instruments. Compare the readings with the chart (E).
7. Adjust the strength of the mixture as necessary.

If it is necessary to fill or replenish the coolant system in service, mix the coolant to the correct strength before
it is added to the coolant system.
Note: A coolant to water ratio of 50:50 should be used even in warm ambient temperatures, in order to maintain
the concentration of the corrosion inhibitor in the coolant.
Specific gravity chart
A = Percentage coolant by volume
B = Mixture temperature in Fahrenheit
C = Specific gravity
D = Mixture temperature in Celsius.
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N39453 Chapter 4
How to drain the raw water system
Caution: The raw water system cannot be drained completely. If the system is drained for engine preservation
purposes or for protection from frost, the system must be filled again with an approved coolant mixture. See
“Coolant specification” for details of the correct coolant to be used.
1. Ensure that the seacock is closed.

2. Remove the drain plug on the 415GM and 422GM (F1) or 422TGM (G1) from the raw water cooler.
3. After the system has been drained, refit the drain plug.
Caution: When the raw water system is to be used again, ensure that the seacock is open.
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Chapter 4 N39453
How to check the impeller of the raw water pump

2. Release the four setscrews (H1) which fasten the end plate (H2) of the raw water pump and remove the
plate and ‘O’ ring (H3). When the end plate of the raw water pump is removed, some raw water will flow from
the pump.
3. Remove the rubber end cap (H4) and then pull the impeller from the shaft (I).
4. Clean the contact surfaces of the pump body and the end plate.
5. Inspect the rubber impeller for excessive wear or for damage and renew it, if necessary. Apply Spheerol
SX2 grease or liquid soap to the blades of the impeller and fit the impeller into the housing with the blades
bent counter-clockwise (H). Fit the rubber end cap.
6. Gease a new ‘O’ ring (H3), insert into the pump body groove.
7. Fit the end plate (H2) and tighten the end plate screws.
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N39453 Chapter 4
How to check the drive belt
Press down the belt with the thumb at the centre of the longest free length and check the deflection (J). With
moderate thumb pressure - 45N (10 lbf) 4,5 kgf - the correct deflection of the belt is 10 mm (3/8 in).
How to adjust the belt tension
Cautions:
• The alternator is driven by a drive belt of a specific design. Use only a Perkins POWERPART drive belt. If
this is not done, an early failure of the belt may occur.
1. Loosen the adjusting strap pivot setscrew (J1) and the pivot fasteners (J2) of the alternator and loosen
the setscrew (J3) of the adjusting strap.
2. Change the position of the alternator to give the correct tension. Tighten the pivot fasteners of the
alternator, and the setscrews of the adjusting strap.
3. Check the belt tension again to ensure that it is still correct. If a new belt is fitted, the belt tension must be
checked again after the first 25 hours of operation.
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Chapter 4 N39453
How to renew the element of the fuel filter
Warning! Discard the used element and fuel in a safe place and in accordance with local regulations.
Caution: It is important that only the genuine Perkins parts are used. The use of wrong parts could damage
the fuel injection equipment.
1. Thoroughly clean the outside surfaces of the fuel filter assembly.

2. Put the filter assembly within a plastic bag; the bag should fit loosely over the filter to retain spilt fuel.
Hold the bottom cover of the filter element and release the setscrew (K1) which is fitted through the filter head
above the centre of the element.
3. Lower the bottom cover (K6) and the filter element (K4).
4. Remove the element from the bag and discard it in accordance with local regulations. Remove the
bottom cover from the bag and discard safely the bag and any spilt fuel.
5. Clean the inside surfaces of the filter head and the cover.
6. Renew the seals (K2) and (K5) and the ‘O’ ring (K3) and lightly lubricate them with clean fuel.
7. Put the bottom cover under the new element and hold the element squarely to the filter head. Ensure
that the element is fitted in the centre against the ‘O’ ring in the filter head. With the assembly in this position,
engage and tighten the setscrew.
8. Eliminate the air from the fuel filter.
Fuel pre-filter
This will normally be fitted between the fuel tank and the engine. Check the filter bowl for water at regular
intervals and drain as necessary.
Atomiser fault
Warnings!
• Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while
the engine runs.
An atomiser fault can cause an engine misfire.
In order to find which atomiser is defective, operate the engine. Loosen and tighten the union nut of the high-
pressure fuel pipe at each atomiser. When the union nut of the defective atomiser is loosened, it has little or
no effect on the engine speed.
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N39453 Chapter 4
How to renew an atomiser
Cautions
• Use only deep sockets for this operation.

• Connections should be blanked off until assembly.
• Washer (L1) has two small holes 180O apart.
• Discard old washer (L2), on assembly fit new nozzle washer.
Note: If the atomisers or injection pipes are replaced it is essential that the fuel adjustment screw is not altered
from the original settings. The maximum no load speed must be checked after assembly.
1. Clean thoroughly the area around the atomiser to be removed.

2. Remove the union nuts of the high-pressure pipe (L3) from the atomiser and from the fuel injection pump.
Do not bend the pipe. If necessary, remove the pipe clamps.
3. Remove the fuel leak-off pipe (L4).
4. Remove the atomiser (L5) and the washer.
5. Before fitting the atomiser, clean and dry the male and female threads of the atomiser and the cylinder
head.
6. Apply a 2 mm (0.08 in) bead of sealant POWERPART universal jointing compound, part number 1861117,
to extend 6 mm (0.24 in) along the first two threads of the atomiser (L6).
7. Fit the atomiser into the cylinder head with a new washer (L2). Tighten to 64 Nm (47 lbf ft) 6,5 kgf m.
Cautions:
• If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.
• Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as
this can cause a restriction at the end of the pipe. This can affect the supply of fuel to the atomiser.
8. Fit the high-pressure fuel pipe and tighten the union nuts to 23 Nm (16.9 lbf ft) 2,3 kgf m. If necessary, fit
the pipe clamps.
9. Renew the sealing washers (L1) and fit the leak-off pipe. Tighten the banjo bolts to 27 Nm (19.9 lbf ft)
2,7 kgf m.
10. Eliminate air from the fuel system.
11. Operate the engine and check for leakage of fuel and air.
Illustration shows 422GM and 422TGM, 415GM is similar
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Chapter 4 N39453
How to eliminate air from the fuel system
Caution: When air is to be eliminated from the fuel system, only use the starter motor to start the engine after
air has been eliminated from the low-pressure side of the fuel system.
If air enters the fuel system, it must be eliminated before the engine can be started.
Air can enter the system if:
• The fuel tank is drained during normal operation.

• The low-pressure fuel pipes are disconnected.
• A part of the low-pressure fuel system leaks during engine operation.
In order to eliminate air from the fuel system, proceed as follows:
Caution: Do not allow fuel from the engine to contaminate the engine compartment. Put a drip tray under the
engine and discard old fuel in accordance with local instructions. When using the starter motor, do not exceed
continuous rotation of more than 15 seconds periods. If the engine does not run, on initial rotation, wait for 30
seconds and try again. Connections should be blanked off until assembly.
1. Loosen the vent screw on the fuel filter (M1).
2. Operate the hand primer (M2) until fuel, free of air, flows from the vent screw. Tighten the vent screw (A1).
If the hand primer does not work, rotate the engine half to one revolution and try again.
3. Loosen the vent screw on the fuel injection pump (M3). Operate the hand primer (M2) until fuel, free of
air, flows. Tighten the vent screw (M3).
4. Attempt to start the engine using the starter motor for a maximum of 15 seconds, wait for 30 seconds
before trying again. If the hand primer does not work, turn the engine half to one revolution to ensure correct
operation.
Illustration shows 422GM and 422TGM, 415GM is similar.
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N39453 Chapter 4
How to renew the lubricating oil
Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations.
Warning! Do not adjust the oil level while running.
Note: Renew the filter canister when the lubricating oil is renewed.
1. Use a spanner (N1) to release the union nut on the bracket for the fuel connection and sump drain.
2. Connect the pipe to a sump drain pump (O1). Pump the lubricating oil into a suitable container with a
capacity of approximately 11 litres (19 pints), the lubricating oil should be drained while it is still hot.
3. Disconnect the pipe from the pump and reconnect the pipe to the bracket. Tighten the connection.
Remove the container of used lubricating oil.
4. Clean the area around the filler cap on top of the rocker cover and remove the cap.
Caution: These engines are fitted with a ‘closed’ crankcase breather system. Any necessary oil additions to
the sump must be carried out with the engine stationary. Under no circumstances must oil additions be carried
out with an engine running as oil could enter the ‘closed’ crankcase breather system causing the engine speed
to increase rapidly without control.
It is important to ensure the correct level of lubricating oil is not exceeded in the sump. If there is too much oil
in the sump the excess must be drained to the correct level. An excess of engine oil in the sump can enter the
‘closed’ crankcase breather system, which could cause the engine speed to increase rapidly without control.
5. Add slowly, new and clean lubricating oil of an approved specification to the engine. Allow the oil enough
time to pass to the sump, remove the dipstick (P2) and ensure that the lubricating oil is to the full mark (P1).
The oil level must not be above the full mark. If it is, the engine could be damaged.
6. Fit the filler cap and ensure that the dipstick is
fitted correctly in the dipstick tube.
7. Start the engine and check for lubricating oil
leakage. Stop the engine. After 15 minutes check the
oil level on the dipstick and, if necessary, put more
lubricating oil into the sump.
Warning! Discard the used lubricating oil in a safe
place and in accordance with local regulations.
Illustration shows 422GM and 422TGM, 415GM is similar.
Page 55
Chapter 4 N39453
How to renew the canister of the lubricating oil filter
Warning! Discard the used canister and lubricating oil in a safe place and in accordance with local
regulations.
1. Clean thoroughly the outside surfaces of the oil filter.

2. Use a strap wrench or similar tool to just loosen the filter canister. Put a plastic bag (Q2) over the filter
canister; the bag should fit loosely over the filter to retain spilt oil. Remove and discard safely the canister and
the plastic bag that will contain the spilt oil.
3. Lubricate the seal (Q1) on top of the canister with clean engine lubricating oil.
4. Fit the new canister and tighten by hand until the seal contacts the cylinder block. Tighten the canister a
further 1/2 to 3/4 of a turn by hand only. Do not use a strap wrench.
5. Ensure that there is lubricating oil in the sump. Start the engine and run until oil pressure is obtained.
Check for leakage from the filter. Stop the engine. After 15 minutes check the oil level on the dipstick and, if
necessary, put more lubricating oil into the sump.
Cautions:
• Do not fill the sump past the notch on the dipstick.
• The canister contains a valve and special tube to ensure that lubricating oil does not drain from the filter.
Therefore, ensure that the correct Perkins POWERPART canister is used.
Page 56
N39453 Chapter 4
How to renew the engine breather assembly
The breather assembly should be renewed every 2000 hours.
Caution: Ensure that the components of the breather assembly are fitted in their correct position (R1 - R6). If
they are incorrectly fitted, the engine may be damaged.
1. 422TGM only - Undo the clip (R1) and detach the hose (R2).
2. Release the four setscrews (R4) and remove the breather cover (R3), the spring (R8) and the diaphragm
assembly (R6).
Caution: It is important that the area around the vent hole (R3) is clean.
3. Clean the breather cavity (R7) in the rocker cover.

4. Clean the breather in clean diesel fuel.
5. Fit the breather assembly into the cavity in the rocker cover, ensuring that the breather cover, diaphragm
and spring are assembled correctly and that the vent hole (R5) faces towards the flywheel.
6. Tighten the four setscrews.
Page 57
Chapter 4 N39453
How to renew the element of the air filter - 415GM and 422GM
1. Release the hose clip (S1) and remove the air filter assembly (S2).
2. Fit a new filter element.
3. Tighten the hose clip.
Page 58
N39453 Chapter 4
How to renew the element of the air filter - 422TGM
1. Release the three clips (T1) and remove the end cover (T2).
2. Remove the filter element (T3).
3. Fit a new filter element.
The illustration shows the air filter fitted to customers alternator
Page 59
Chapter 4 N39453
How to set the valve tip clearances - 415GM
Notes:
• The valve tip clearance is checked with a feeler gauge between the top of the valve stem and the rocker
lever (U), with the engine cold. The correct clearance for both the inlet and the exhaust valves is 0,20 mm
(0.0078 in). Tighten the valve adjustment nuts to 14Nm (10.3 Ibft ft) 1,4 kgf m.
• The arrangement of the valves is shown in (V). Valve numbers (V1) and (V2) are for number 1 cylinder
which is at the front of the engine.
• Clockwise rotation is when seen from the front of the engine.
1. Disconnect the breather pipe from the rocker cover and remove the three cap nuts, steel washers and
rubber seals. Lift off the rocker cover.
2. Rotate the crankshaft in a clockwise direction until the valve (V1) has just opened and the valve (V2) has
not closed completely. Check the clearances of the valves (V3) and (V6) and adjust them, if necessary.
not closed completely. Check the clearances of the valves (V2) and (B5) and adjust them, if necessary.
not closed completely. Check the clearances of the valves (V1) and (V4) and adjust them, if necessary.
Caution: If the outer cap nuts for the rocker cover are overtightened, the stud and plate assembly for the
rocker pedestal may be damaged.
5. Fit the rocker cover. Ensure that the cap nuts, washers and the rubber seals are fitted correctly. Tighten
the cap nuts to 11 Nm (8 lbf ft) 1,1 kgf m. Fit the breather pipe.
Page 60
N39453 Chapter 4
How to set the valve tip clearances - 422GM and 422TGM
Notes:
• The valve tip clearance is checked with a feeler gauge between the top of the valve stem and the rocker
lever (W), with the engine cold. The correct clearance for both the inlet and the exhaust valves is 0,20 mm
(0.0078 in). Tighten the valve adjustment nuts to 14Nm (10.3 Ibft ft) 1,4 kgf m.
• The arrangement of the valves is shown in (X). Valve numbers (X1) and (X2) are for number 1 cylinder
which is at the front of the engine.
• Clockwise rotation is when seen from the front of the engine.
1. Disconnect the breather pipe from the rocker cover and remove the three cap nuts, steel washers and
rubber seals. Lift off the rocker cover.
2. Rotate the crankshaft in a clockwise direction until the valve (X7) has just opened and the valve (X8) has
not closed completely. Check the clearances of the valves (X1) and (X2) and adjust them, if necessary.
Caution: If the outer cap nuts for the rocker cover are overtightened, the stud and plate assembly for the
rocker pedestal may be damaged.
6. Fit the rocker cover. Ensure that the cap nuts, washers and the rubber seals are fitted correctly. Tighten
the cap nuts to 11 Nm (8 lbf ft) 1,1 kgf m. Fit the breather pipe.
Page 61
Chapter 4 N39453
Seacock strainer
The seacock strainer must be cleaned regularly, especially if there is a large amount of small debris in the
water.
Corrosion
This can occur when two different metals are in contact near to, or in, sea water. For example, a brass or bronze
pipe fitted into aluminium can cause rapid corrosion. For this reason, special precautions are necessary when
an engine is installed. In this situation, some components will be connected to a sacrificial anode fitted to the
hull. Specialist manufacturers will advise on the maintenance of these anodes.
Supplementary tools
A general tool kit and an on-board spares kit are available from your Perkins Distributor. It is recommended that
the tools and other parts, listed below, are also retained on-board:
Wire, 20 SWG (1 mm in diameter)
Insulation tape
Jointing compound
Magnet (keep this away from the compass)
Mechanical fingers
Self-gripping wrench
Suitable lagging material
Rubber olives for the low-pressure fuel system 1
A small hacksaw, with extra blades
Start circuit fuse, rated at 40 amperes 1
Heat circuit fuse, rated at 40 amperes 1
Panel circuit fuse, rated at 10 amperes 1
Negative line protection fuse, rated at 10 amperes 1

(1) Also available in the On-board spares kit.
Page 62
N39453 Chapter 4
Preventive maintenance periods - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM, 4.4GM rad,

4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad.
These preventive maintenance periods apply to average conditions of operation. Check the periods given by
the manufacturer of the boat in which the engine is installed. If necessary, use the shorter periods. When the
operation of the engine must conform to the local regulations these periods and procedures may need to be
adapted to ensure correct operation of the engine.
It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform
to the specifications given in this handbook.
Use the procedures in this section to maintain your engine in accordance with the preventive maintenance
schedule.
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Chapter 4 N39453
Schedules - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM.
A First service at 25/50 hours D Every 500 hours or 12 months G Non-scheduled maintenance
B Every day or every 8 hours E Every 1000 hours
C Every 250 hours or 12 months F Every 2000 hours
A B C D E F G Operation
● Check the amount of coolant in the header tank
● Check the specific gravity of the coolant (2)
● ● Check the tension and the condition of the drive belt
● ● Check hose and clips

● Check the impeller of the raw water pump
● Check the sea water strainer, where applicable
● ● Drain water from the fuel pre-filter (1)

● Renew the element of the fuel filter
● Atomiser maintenance (2) (5)

● Check the lubricating oil pressure at the gauge
● Renew the engine breather elements

● Renew the engine breather (2) (6)
● Renew the element of the air filter

● Ensure that the alternator, the starter motor, etc. are checked (2)
● Check the engine mounts
● Inspect the electrical system for signs of damage (2)
(3) Renew the antifreeze every 6 years.
(5) Regular maintenance of the atomisers is not necessary, see page 39.
(6) Renew the complete engine breather assembly at major engine service or 8000 hours.
Page 64
N39453 Chapter 4
Schedules - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad.
A First service at 25/50 hours D Every 500 hours or 12 months G Non-scheduled maintenance
B Every day or every 8 hours E Every 1000 hours
C Every 250 hours or 12 months F Every 2000 hours
A B C D E F G Operation
● Check the amount of coolant in the radiator
● Check the specific gravity of the coolant (2) (3)
● ● Check the tension and the condition of the drive belt
● ● Check hose and clips
● ● Drain water from the fuel pre-filter (1)

● Renew the element of the fuel filter
● Atomiser maintenance (2) (5)

● Check the lubricating oil pressure at the gauge
● Renew the engine breather elements

● Renew the engine breather (2) (6)
● Renew the element of the air filter

● Ensure that the alternator, the starter motor, etc. are checked (2)
● Check the engine mounts
● Inspect the electrical system for signs of damage (2)
(3) Renew the antifreeze every 6 years.
(5) Regular maintenance of the atomisers is not necessary.
(6) Renew the complete engine breather assembly at major engine service or 8000 hours.
Page 65
Chapter 4 N39453
How to fill the coolant circuit - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM.

Warning! If coolant is to be added to the circuit during service, allow the engine to cool before the coolant is
added. Remove the filler cap slowly as dangerous coolant could be discharged if the coolant is still hot and the
system is under pressure.
Do not put too much coolant in the coolant circuit. There is a relief valve in the filler cap which will open and
release hot coolant if too much coolant is added.
Caution: If coolant is added to the circuit during service, it must consist of the same original mixture as used
to fill the system. See “Coolant specification” in section 5 for details of the correct coolant to be used in the
circuit.
1. Remove the filler cap (Y1) of the header tank and slowly fill the coolant system until the coolant level is
just below the level of the baffle (Y2).
Note: It is necessary to vent air from the system during initial fill, or if he system has been completely drained.
To vent air, remove the plug (Z1)
2. Fit the filler cap.

3. Start the engine. When it has reached its normal temperature of operation, stop it.
4. Carefully remove the filler cap of the header tank and add coolant until the level of the coolant is
correct.
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N39453 Chapter 4
How to fill the coolant circuit - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM
rad.
Warning! If coolant is to be added to the circuit during service, allow the engine to cool before the coolant is
added. Remove the filler cap slowly as dangerous coolant could be discharged if the coolant is still hot and the
system is under pressure. Do not put too much coolant in the coolant circuit. There is a relief valve in the filler
cap which will open and release hot coolant if too much coolant is added.
Caution: If coolant is added to the circuit during service, it must consist of the same original mixture as used
to fill the system. See “Coolant specification” for details of the correct coolant to be used in the circuit.
1. Remove the filler cap (AA1) of the radiator and slowly fill the coolant system until the coolant level is just
below the level of the filler neck (AA2).
3. Start the engine. When it has reached its normal temperature of operation, stop it.
4. Carefully remove the filler cap of the radiator and add coolant until the level of the coolant is correct.
Page 67
Chapter 4 N39453
How to drain the coolant circuit - 4.4GM

Warnings!
1. Remove the filler cap of the coolant circuit (BB1).
2. Remove the drain plugs (CC1) from the side of the cylinder block and the heat exchanger (DD1). Ensure
that the drain holes are not restricted.
antifreeze mixture. See “Coolant specification” in section 5 for details of the correct coolant to be used in the
circuit.
Page 68
N39453 Chapter 4
How to drain the coolant circuit - 4.4TGM

Warnings!
1. Remove the filler cap of the coolant circuit (EE1).
2. Remove the drain plugs (FF1) from the side of the cylinder block and the heat exchanger (GG1). Ensure
that the drain holes are not restricted.
circuit.
Page 69
Chapter 4 N39453
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM

Warnings!
1. Remove the filler cap of the coolant circuit (HH1).
2. Remove the drain plugs (II1) from the side of the cylinder block and the heat exchanger (JJ1). Ensure that
the drain holes are not restricted.
circuit.
Page 70
N39453 Chapter 4
How to drain the coolant circuit - 4.4GM & 4.4TGM rad.

Warnings!
1. Remove the filler cap on top of the radiator (KK1).
2. Remove the drain plugs (LL1) from the side of the cylinder block and the manifold.
3. Remove the drain plug (MM1) from the bottom of the radiator.
5. Fasten a label in a suitable place to indicate that the cooling system has been drained.
preservation purposes or for protection from frost, the cooling system must be filled again with an approved
antifreeze mixture. See “Coolant specification” for details of the correct coolant to be used in the circuit.
Page 71
Chapter 4 N39453
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM rad.

Warnings!
1. Remove the filler cap on top of the radiator (NN1).
2. Remove the drain plugs (OO1) from the side of the cylinder block and the manifold.
3. Remove the drain plug (PP1) from the bottom of the radiator.
5. Fasten a label in a suitable place to indicate that the cooling system has been drained.
preservation purposes or for protection from frost, the cooling system must be filled again with an approved
antifreeze mixture. See “Coolant specification” for details of the correct coolant to be used in the circuit.
Page 72
N39453 Chapter 4
Engines fitted with keel coolers

The coolant capacity and the method used to drain the coolant circuit of an engine connected to a keel cooler
will vary in different applications.
Use the instructions given by the keel cooler manufacturer to drain and renew the engine coolant when a keel
cooler is fitted.
How to check the specific gravity of the coolant

For mixtures which contain inhibited ethylene glycol:
1. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the
coolant has circulated the cooling system.
2. Stop the engine.
3. Allow the engine to cool until the temperature of the coolant is below 140OF (60OC).
Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because
4. Remove the filler cap of the cooling system.

5. Drain some coolant from the cooling system into a suitable container.
6. Use a special coolant hydrometer that will check the temperature and the specific gravity of the coolant,
follow the manufacturer’s instructions.
Note: If a special coolant hydrometer is not available, put a hydrometer and a separate thermometer into the
antifreeze mixture and check the readings on both instruments. Compare the readings with the chart (H).
Specific gravity chart
A = Percentage antifreeze by volume

B = Mixture temperature in Fahrenheit
C = Specific gravity
D = Mixture temperature in Celsius
7. Adjust the strength of the mixture as necessary.

Note: If it is necessary to fill or replenish the cooling system in service, mix the coolant to the correct strength
before it is added to the cooling system.
Caution: An antifreeze to water ratio of 50:50 should be used even in warm ambient temperatures, in order to
maintain the concentration of the corrosion inhibitor in the antifreeze.
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Chapter 4 N39453
How to drain the raw water system - 4.4GM & 4.4TGM

purposes or for protection from frost, the system must be filled again with an approved antifreeze mixture. See
“Coolant specification” in section 5 for details of the correct coolant to be used. See section 7 for details of how
to add antifreeze to the raw water system for engine preservation purposes.

2. Loosen the four setscrews (RR1) of the cover for the raw water pump and withdraw the cover slightly.
3. Rotate the crankshaft to ensure that the raw water pump is empty.
4. Tighten the four setscrews of the cover for the raw water pump (If necessary replace joints).
5. Remove the drain plug (SS1) and drain the heat exchanger. Refit the drain plug.
Page 74
N39453 Chapter 4
How to drain the raw water system - 4.4TWGM & 4.4TW2GM

purposes or for protection from frost, the system must be filled again with an approved antifreeze mixture. See
“Coolant specification” in section 5 for details of the correct coolant to be used. See section 7 for details of how
to add antifreeze to the raw water system for engine preservation purposes.

2. Loosen the four setscrews (TT1) of the cover for the raw water pump and withdraw the cover slightly.
3. Rotate the crankshaft to ensure that the raw water pump is empty.
4. Tighten the four setscrews of the cover for the raw water pump (If necessary replace the ‘O’ ring).
5. Remove the drain plug (UU1) and drain the heat exchanger. Refit the drain plug.
Page 75
Chapter 4 N39453
How to check the impeller of the raw water pump - 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM
2. Release the four setscrews which fasten the end plate of the raw water pump and remove the plate.
When the end plate of the raw water pump is removed, some raw water will flow from the pump.
3. Remove the rubber end cap (VV1) and then pull the impeller from the shaft.
4. Clean the contact surfaces of the pump body and the end plate.
5. Inspect the rubber impeller for excessive wear or for damage and renew it, if necessary. If pieces have
broken off the impeller blades, it is necessary to remove them from the system to avoid damage later.
6. Remove the outlet hose from the raw water pump. Remove any debris and check for broken pieces of
impeller blades.
7. Fit the outlet hose to the raw water pump and tighten the hose clips. Replenish the coolant circuit.
8. Apply Spheerol SX2 grease or liquid soap to the blades of the impeller and fit the impeller into the housing
with the blades bent counter-clockwise (VV). Fit the rubber end cap.
9. Renew ‘O’ ring seal if necessary. Fit the end plate making sure that the ‘O’ ring remains seated in the
groove and tighten the end plate screws.
Page 76
N39453 Chapter 4
How to check the drive belt - 4.4GM, 4.4TGM, 4.4TWGM & 4.4TW2GM
Press down the belt with the thumb at the centre of the longest free length and check the deflection (R). With
moderate thumb pressure - 45N (10 lbf) 4,5 kgf - the correct deflection of the belt is 10 mm (3/8 in).

Caution: The alternator is driven by a drive belt of a specific design. Use only a Perkins POWERPART drive
belt. If this is not done, an early failure of the belt may occur.
1. Loosen the pivot fastener (WW1) of the alternator and loosen the setscrews (WW2) and (WW3) of the
adjustment link.
2. Change the position of the alternator to give the correct tension. Tighten the pivot fastener of the alternator
and the setscrews of the adjustment link.
3. Check the belt tension again to ensure that it is still correct. If a new belt is fitted, the belt tension must be
checked again after the first 25 hours of operation.
Page 77
Chapter 4 N39453
How to check the drive belt - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad
Press down the belts with the thumb at the centre of the longest free length and check the deflection (XX). With
moderate thumb pressure - 45N (10 lbf) 4,5 kgf - the correct deflection of the belts is 10 mm (3/8 in).
Caution: The alternator is driven by a pair of drive belts of a specific design. Use only Perkins POWERPART
drive belts. If this is not done, an early failure of the belts may occur.
1. Loosen the pivot fastener (XX1) of the alternator and loosen the setscrews (XX2) and (XX3) of the
adjustment link.
2. Change the position of the alternator to give the correct tension. Tighten the pivot fastener of the alternator
and the setscrews of the adjustment link.
3. Check the belt tension again to ensure that it is still correct. If new belts are fitted, the belt tension must
be checked again after the first 25 hours of operation.
Page 78
N39453 Chapter 4
How to renew the element of the fuel filter - 4.4GM, 4.4TGM, 4.4TWGM & 4.4TW2GM
Warning! Discard the used canister and fuel oil in a safe place and in accordance with local regulations.
1. Thoroughly clean the outside surfaces of the fuel filter assembly (YY1).
2. Loosen the drain device (YY2) at the bottom of the filter canister and drain the fuel into a suitable
container.
3. Turn the clamping ring (YY3) to the left to free the filter.
4. Ensure that the inside of the filter head is clean
5. Ensure the locating nodes (YY4) are in the correct position to slot into the filter head.
6. Turn the clamping ring to the right to lock in position.
Fuel pre-filter
Caution: Do not run the electric fuel lift pump for more than 60 seconds without fuel. The fuel pump can be
permanently damaged as it relies on the fuel for lubrication.
Page 79
Chapter 4 N39453
How to renew the element of the fuel filter - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad &
4.4TW2GM rad.
Warning! Discard the used canister and fuel oil in a safe place and in accordance with local regulations.
1. Thoroughly clean the outside surfaces of the fuel filter assembly (ZZ1).
2. Loosen the drain device (ZZ2) at the bottom of the filter canister and drain the fuel into a suitable
container.
3. Turn the clamping ring (ZZ3) to the left to free the filter.
4. Ensure that the inside of the filter head is clean
5. Ensure the locating nodes (ZZ4) are in the correct position to slot into the filter head.
6. Turn the clamping ring to the right to lock in position.
Fuel pre-filter (optional)
Page 80
N39453 Chapter 4
Atomiser maintenance
Atomiser faults
Caution: A faulty atomiser must be renewed by a person who has had the correct training.
Regular maintenance of the atomisers is not necessary. The atomiser nozzles should be renewed and not
cleaned, and renewed only if an atomiser fault occurs. Some of the problems that may indicate that new
nozzles are needed are listed below:
• Engine will not start or is difficult to start

• Not enough power
• Engine misfires or runs erratically
• High fuel consumption
• Black exhaust smoke
• Engine knocks or vibrates excessively
• Excessive engine temperature.
Warnings!
• Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while
the engine runs.
Remove all the atomisers and have them tested by a specialist.
Remove the atomiser cover setscrews (AB1) and remove the atomiser cover (AB2). In order to find which
atomiser is defective, operate the engine . Loosen and tighten the union nuts (AC1) of the high-pressure fuel
pipe at each atomiser. Do not loosen the union nut more than half a turn. When the union nut of the defective
atomiser is released, it has little or no effect on the engine speed.
Page 81
Chapter 4 N39453
How to remove and to fit an atomiser

How to remove
Warning! The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
Cautions:
• Atomisers must be removed and fitted by a person with the correct training.
• Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the
area around the connection. After a component has been disconnected, fit a suitable cover to all open
connections.
1. Release the atomiser cover setscrews (AD1) and remove the atomiser cover (AD2).
2. Release the fastener (K3) and remove the breather pipe (AD4).
3. Remove the fuel leak-off hose from the conn ection (AE2).
4. Remove the union nuts of the high-pressure pipe from the atomiser (AE1) and from the fuel injection pump.
Do not bend the pipe. If necessary, remove the pipe clamps. Fit a plastic cap to cover all open connections.
5. Remove the setscrew (AE3) and remove the clamp (AE4) from the cylinder head.
6. Remove the atomiser and its seat washer (AF1) from its recess in the cylinder head.
Caution: Remove and discard the seat washer (AF1). If the original seat washer remains in the recess, the
nozzle protrusion will be incorrect when a new seat washer is added.
Page 82
N39453 Chapter 4
How to fit
1. Remove all covers and caps from the component and connections.
2. Put a new seat washer into the seat recess in the cylinder head.
Note: Some new atomiser’s have the seat washer (AG3) fitted on the atomiser.
3. Ensure that the atomiser seal is not damaged. Apply a small amount of clean fuel oil to the seal (AG2).
• The atomiser must be fitted so that the pin or the union (AG1) faces away from the atomiser clamp (AH4).
• If fitted the leak-off hose is a push fit and will need replacing if the hose leaks.
4. Put the atomiser (AH1) into its recess in the cylinder head.
5. Fit the clamp (AH4) and the setscrew (AH3). Tighten the setscrew to 35 Nm (26 lbf ft) 3,5 kgf m.
Caution: Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension.
If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet. Do not
tighten the atomiser union nut more, as this can cause a restriction at the end of the pipe. This can affect the
fuel delivery.
6. Remove the plastic cap, fit the high-pressure fuel pipe and tighten the union nuts to 30 Nm (22 lbf ft) 3,0
kgf m.
7. If removed earlier, fit the clamps to the high pressure fuel pipes.
8. Where necessary, fit the fuel leak-off hose to the connectors (AH2).
9. Check the “O” ring on the breather pipe and replace if necessary. Apply a small amount of clean engine
oil to the “O” ring and fit the breather pipe into the rocker cover. Tighten the fastener to 9 Nm (7 lbf ft) 0,9 kgf
m. Fit the breather hose and clip if fitted.
10. If removed, fit the crossover pipe.
11. Run the engine and check for leakage of fuel and air. Correct any leakage.
12. Stop the engine.
13. Refit the atomiser cover and tighten the setscrews to 6 Nm (4 lbf ft) 0,6 kgf m.
Page 83
Chapter 4 N39453
How to eliminate air from the fuel system

Cautions:
• Under no circumstances should any attempt be made to remove the electric fuel lift pump from the filter
head as it is not a serviceable item.
• Do not operate the engine until the air is eliminated from the fuel injection pump.
• After the air is eliminated, operate the engine at no load.
1. Remove the atomiser cover.
2. Loosen the high pressure pipes (AI1) at the atomisers.
3. Switch the control panel to energise the electric lift pump for 30 to 60 seconds.
4. Operate the starter motor until fuel free from air comes from the connections.
5. Tighten the union nuts to 30 Nm (22 lbf ft) 3,0 kgf m.
6. Start the engine and check for leaks.
7. Fit the atomiser cover and tighten its setscrews.
Page 84
N39453 Chapter 4
How to renew the lubricating oil

Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations.
Warning! Do not adjust the oil level while running.
Note: Renew the filter canister when the lubricating oil is renewed.
1. Drain the lubricating oil into a suitable container with a capacity of approximately 10 litres (17.5 pints), the
lubricating oil should be drained while it is still hot.
2. Remove the 3/8” NPTF plug (AJ1) from the tap and attach a length of hose (with a sump pump if available),
to the container.
3. Open the tap (AJ2) and allow the oil to drain out.
4. Remove the container of used lubricating oil, close the tap and replace the plug.
5. Clean the area around the filler cap on top of the rocker cover and remove the cap.
Caution: All these engines are fitted with a ‘closed’ crankcase breather system. Any necessary oil additions to
the sump must be carried out with the engine stationary. Under no circumstances must oil additions be carried
out with an engine running as oil could enter the ‘closed’ crankcase breather system causing the engine speed
to increase rapidly without control. It is important to ensure the correct level of lubricating oil is not exceeded
in the sump. If there is too much oil in the sump the excess must be drained to the correct level. An excess of
engine oil in the sump can enter the ‘closed’ crankcase breather system, which could cause the engine speed
to increase rapidly without control.
6. Add slowly, new and clean lubricating oil (Data section) of an approved specification to the engine. Allow
the oil enough time to pass to the sump, remove the dipstick (AK2) and ensure that the lubricating oil is to the
full mark (AK1). The oil level must not be above the full mark. If it is, the engine could be damaged.
7. Fit the filler cap and ensure that the dipstick is fitted correctly in the dipstick tube.
8. Start the engine and check for lubricating oil leakage. Stop the engine. After 15 minutes check the oil level
on the dipstick and, if necessary, put more lubricating oil into the sump.
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Chapter 4 N39453
How to renew the canister of the lubricating oil filter

Warning! Discard the used canister and lubricating oil in a safe place and in accordance with local
regulations.
1. Clean thoroughly the outside surfaces of the oil filter.

2. Use a strap wrench or similar tool to just loosen the filter canister (AL1). Put a suitable container under
the filter assembly to retain spilt oil. Remove and discard safely the canister.
3. Clean the contact face of the filter housing.
4. Lubricate the seal (AL2) on top of the canister with clean engine lubricating oil.
5. Fit the new canister and tighten by hand until the seal contacts the oil filter housing. Tighten the canister
a further 1/2 to 3/4 of a turn by hand only. Do not use a strap wrench.
6. Ensure that there is lubricating oil in the sump. Start the engine and run until oil pressure is obtained.
Check for leakage from the filter. Stop the engine. After 15 minutes check the oil level on the dipstick and, if
necessary, put more lubricating oil into the sump.
Cautions:
• Do not fill the sump past the full mark on the dipstick.
• The canister contains a valve and special tube to ensure that lubricating oil does not drain from the filter.
Therefore, ensure that the correct Perkins POWERPART canister is used.
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N39453 Chapter 4
Air filter
Caution: Do not operate the engine if there is a blockage in the air filter or the induction hose. This can cause
lubricating oil to enter the cylinders through the breather valve.
Environmental conditions have an important effect on the frequency at which the air filter needs service.
Air filters have automatic dust valves (AM1) through which dust is expelled from the filter. The rubber dust valve
must be kept clean. Ensure that the sides of the valves close completely together and that they can separate
freely.
If a restriction indicator (AN) is fitted, it will indicate precisely when the air filter element needs replacement. This
prevents the premature removal of the filter element which causes extra cost or late removal of the element
which can cause loss of engine power. The filter element must be renewed according to the manufacturers
recommendations.
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Chapter 4 N39453
Restriction indicator
The restriction indicator is fitted on the air filter outlet or between the air filter and the induction manifold.
When the red warning indicator (AO1) is seen through the clear panel (AO2) after the engine has stopped, the
air filter element must be removed for service.
After a clean element has been fitted, press the rubber bottom (AO3) or the button (AO4) of the restriction
indicator to reset the red warning indicator.
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N39453 Chapter 4
How to check the valve tip clearances
The valve tip clearances are checked between the top of the valve stem and the rocker lever (AP), with
the engine cold. The correct clearance for inlet valves is 0,20 mm (0.008 in) and 0,45 mm (0.018 in) for
exhaust valves. The valve positions are shown at (AQ). Slacken the locknut and adjust the gap by turning the
adjustment screw in or out to achieve the correct gap. Re-tighten the locknut, ensuring the adjustment screw
is held from moving.
The sequence of valves from number 1 cylinder is shown in the table below.
Note: Number 1 cylinder is the furthest cylinder from the flywheel end of the engine.
1. Rotate the crankshaft in the normal direction of rotation until the inlet valve (AQ7) of number 4 cylinder
has just opened and the exhaust valve (AQ8) of the same cylinder has not closed completely. Check the
clearances of the valves (AQ1 and AQ2) of number 1 cylinder and adjust them, if necessary.
2. Set the valves (AQ3 and AQ4) of number 2 cylinder as indicated above for number 4 cylinder. Then check
/ adjust the clearances of the valves (AQ5 and AQ6) of number 3 cylinder.
3. Set the valves (AQ1 and AQ2) of number 1 cylinder. Then check / adjust the clearances of the valves
(AQ7 and AQ8) of number 4 cylinder.
4. Set the valves (AQ5 and AQ6) of number 3 cylinder. Then check / adjust the clearances of the valves
(AQ3 and AQ4) of number 2 cylinder.
Cylinder and valve number
1 2 3 4
1 2 3 4 5 6 7 8
Valve
I = Inlet I E I E I E I E
E = Exhaust
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Chapter 4 N39453
Supplementary tools
A general tool kit and an on-board spares kit are available from your Perkins distributor. It is recommended that
the tools and other parts, listed below, are also retained on-board:
Wire, 20 SWG (1 mm in diameter)
Insulation tape
Jointing compound
Magnet (keep this away from the compass)
Mechanical fingers
Self-gripping wrench
Suitable lagging material
A small hacksaw, with extra blades
Power take-off
A power take-off is available, which is either belt driven off the crankshaft pulley, or driven axially off the
crankshaft pulley, for details refer to:
Wimborne Marine Power Centre,
22 Cobham Road
Ferndown Industrial Estate,
Wimborne,
Dorset BH21 7PW
Tel: (44) (0)1202 796000
Fax: 44) (0)1202 796001
Page 90
N39453 Chapter 5
Engine fluids
Fuel specification
To get the correct power and performance from your engine, use good quality fuel. The recommended fuel
specification for Perkins engines is indicated below:
Cetane number: 45 minimum
Viscosity: 2.0/4.5 centistokes at 40OC
Density: 0,835/0,855 kg/litre
Sulphur: 0.2% of mass, maximum
Distillation: 85% at 350OC
Cetane number indicates ignition performance. A fuel with a low cetane number can cause cold start problems
and affect combustion.
Viscosity is the resistance to flow and engine performance can be affected if it is outside the limits.
Density: A lower density reduces engine power, a higher density increases engine power and exhaust
smoke.
Sulphur: A high amount of sulphur (not normally found in Europe, North America or Australasia) can cause
engine wear. Where only high sulphur fuels are available, it is necessary to use a highly alkaline lubricating oil
in the engine or to renew the lubricating oil more frequently, see the table below.
Fuel sulphur Oil change

content (%) interval
<0.5 Normal
0.5 to 1.0 75% of normal
>1.0 50% of normal
Distillation: This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light-weight
hydrocarbons can affect the combustion characteristics.
Low temperature fuels
Special winter fuels may be available for engine operation at temperatures below 0OC. These fuels have a
lower viscosity and also limit the wax formation in the fuel at low temperatures. If wax formation occurs, this
could stop the fuel flow through the filter.
If you need advice on adjustments to an engine setting or to the lubricating oil change periods which may be
necessary because of the standard of the available fuel, consult your nearest Perkins distributor or Wimborne
Marine Power Centre.
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Chapter 5 N39453
Lubricating oil specification

Use only a good quality lubricating oil that is not less than the specification API-CG4/CH4 or ACEA-E3/E5.
Caution: The type of lubricating oil to be used may be affected by the quality of the fuel which is available. For
further details, see “Fuel specification”.
Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature range in
which the engine will run as shown in the chart (A).
Viscosity chart
A = Recommended viscosity
B = Ambient temperature
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N39453 Chapter 5
Coolant specification
The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling system.
The recommendations indicated below can help to maintain a good cooling system and to protect it against
frost and/or corrosion.
If the correct procedures are not used, Wimborne Marine Power Centre cannot be held responsible for damage
caused by frost or corrosion, or for loss of cooling efficiency.
The correct coolant/anti-freeze to use is ‘Extended Life Coolant’ or Powerpart ELC, part number 21820181
Extended Life Coolant

Qty: 5 litres – Part No 60061
Qty: 25 litres – Part No 60062
The coolant mixture must be a 50/50 mix with clean water.
‘Extended Life Coolant’ has a service life of 6000 service hours or 6 years which ever is sooner.
‘Extended Life Coolant’ should not be mixed with other products.
Unlike many protective coolants, ‘Extended Life Coolant’ does not coat components with a protective layer to
prevent corrosion. Instead it uses virtually non-depleting corrosion inhibitors.
An alternative to ‘Extend Life Coolant’ is Havoline (XLC) Extended Life Coolant/Anti-freeze.
Caution: Using a coolant/anti-freeze which coats components with a protective layer to prevent corrosion may
impair the efficiency of the cooling system and lead to the engine overheating.
An anti-freeze which contains the correct inhibitor must be used at all times to prevent damage to the engine
by corrosion, because of the use of aluminium in the coolant circuit.
If frost protection is not necessary, it is still extremely important to use an approved anti-freeze mixture because
this gives a protection against corrosion and also raises the boiling point of the coolant.
Note: If combustion gases are released into the coolant circuit, the coolant must be renewed after repair of
the fault.
Page 93
Chapter 5 N39453
Page 94
N39453 Chapter 6
Fault diagnosis
Problems and possible causes

Engine problem Possible causes
Checks by the user Checks by the
workshop personnel
The starter motor turns the engine too slowly 1, 2, 3, 4
The engine does not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 34, 35, 36, 37, 38, 42,
15, 17 43, 44
The engine is difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 14, 34, 36, 37, 38, 40, 42,
15, 16, 17, 19 43
Not enough power 8, 9, 10, 11, 12, 13, 16, 18, 34, 36, 37, 38, 39, 40,
19, 20, 21 41, 43, 63
Misfire 8, 9, 10, 12, 13, 15, 20, 22 34, 36, 37, 38, 39, 40,
41, 43
High fuel consumption 11, 13, 15, 17, 18, 19, 23, 34, 36, 37, 38, 39, 40,
22 42, 43, 44, 63
Black exhaust smoke 11, 13, 15, 17, 19, 21, 22 34, 36, 37, 38, 39, 40,
42, 43, 44, 63, 69
Blue or white exhaust smoke 4, 15, 21, 23 36, 37, 38, 39, 42, 44,
45, 52, 58, 61, 62
The pressure of the lubricating oil system is too low 4, 24, 25, 26 46, 47, 48, 50, 51, 59,
The engine knocks 9, 13, 15, 17, 20, 22, 23 36, 37, 40, 42, 44, 46,
52, 53, 60
The engine runs erratically 8, 9, 10, 11, 12, 13, 15, 16, 36, 38, 40, 41, 44, 52,
18, 20, 22, 23 60,
Vibration 13, 18, 20, 27, 28 36, 38, 39, 40, 41, 44,
52, 54
The pressure of the lubricating oil system is too high 4, 25 49
The engine oil temperature is too high 11, 13, 15, 19, 27, 29, 30, 34, 36, 37, 39, 52, 55,
32, 64, 65, 66, 67, 68 56, 57, 68, 69
Crankcase pressure 31, 33 39, 42, 44, 45, 52, 61
Bad compression 11, 22 37, 39, 40, 42, 43, 44,
45, 53, 60
The engine starts and stops 10, 11, 12

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Chapter 6 N39453
List of possible causes 44. Piston rings are not free or they are worn or
broken.
1. Battery capacity low.
45. Valve stems and/or guides are worn.
2. Bad electrical connections.
46. Crankshaft bearings are worn or damaged.
3. Fault in starter motor.
47. Lubricating oil pump is worn.
4. Wrong grade of lubricating oil.
48. Relief valve does not close.
5. Starter motor turns engine too slowly.
49. Relief valve does not open.
6. Fuel tank empty.
50. Relief valve spring is broken.
7. Fault in stop solenoid, contacts or cables.
51. Fault in suction pipe of lubricating oil pump.
8. Restriction in a fuel pipe.
52. Piston is damaged.
9. Fault in fuel lift pump.
53. Piston height is incorrect.
10. Dirty fuel filter element.
54. Flywheel housing or flywheel is not aligned
11. Restriction in air induction system. correctly.
12. Air in fuel system. 55. Fault in thermostat or thermostat is of an
13. Faulty atomisers or atomisers of an incorrect incorrect type.
type. 56. Restriction in coolant passages.
14. Cold start system used incorrectly. 57. Fault in water pump.
15. Fault in cold start system. 58. Valve stem seal is damaged.
16. Restriction in fuel tank vent. 59. Restriction in sump strainer.
17. Wrong type or grade of fuel used. 60. Valve spring is broken.
18. Restricted movement of engine speed control. 61. Breather assembly worn or broken.
19. Restriction in exhaust pipe. 62. Vent hole for breather valve is restricted.
20. Engine temperature is too high. 63. Leakage in the induction system.
21. Engine temperature is too low. 64. Spare.
22. Incorrect valve tip clearances. 65. Drive belt for water pump is loose.
23. Too much oil or oil of wrong type is used in wet 66. Insufficient coolant in circuit.
type air cleaner, if one is fitted.
67. Restriction in the heat exchanger or the oil
24. Not enough lubricating oil in sump. cooler.
25. Defective gauge. 68. Fault in raw water pump.
26. Dirty lubricating oil filter element. 69. Restriction in the exhaust system
27. Fan damaged.
28. Fault in engine mounting or flywheel housing.
29. Too much lubricating oil in sump.
30. Restriction in air or water passages.
31. Restriction in breather pipe.
32. Insufficient coolant in system.
33. Vacuum pipe leaks or fault in exhauster.
34. Fault in fuel injection pump.
35. Broken drive on fuel injection pump.
36. Timing of fuel injection pump is incorrect.
37. Valve timing is incorrect.
38. Bad compression.
39. Cylinder head gasket leaks.
40. Valves are not free.
41. Wrong high-pressure pipes fitted.
42. Worn cylinder bores.
43. Leakage between valves and seats.
Page 96
N39453 Chapter 7
Engine preservation
Introduction
The recommendations indicated below are designed to prevent damage to the engine when it is withdrawn
from service for a prolonged period. Use these procedures after the engine is withdrawn from service. The
instructions for the use of POWERPART products are given on the outside of each container.
Procedure models - 415GM, 422GM, 422TGM, 4.4GM, 4.4TGM, 4.4TWGM &

4.4TW2GM
1. Completely clean the outside of the engine.
2. When a preservative fuel is to be used, drain the fuel system and fill it with the preservative fuel.
POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If preservative
fuel is not used, the system can be completely filled with normal fuel but the fuel must be drained and
discarded at the end of the storage period together with the fuel filter canister.
3. Operate the engine until it is warm. Then correct leakages of fuel, lubricating oil or air. Stop the engine
and drain the lubricating oil from the sump.
4. Renew the canister of the lubricating oil filter.
5. Fill the sump to the full mark with new and clean lubricating oil and add POWERPART Lay-up 2 to the oil
to protect the engine against corrosion. If POWERPART Lay-Up 2 is not available, use a correct preservative
fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the lubricating oil
sump must be filled to the correct level with normal lubricating oil at the end of the storage period.
6. Drain the coolant circuit. In order to protect the cooling system against corrosion, fill it with an approved
coolant mixture because this gives protection against corrosion.
Caution: If protection against frost is not necessary and a corrosion inhibitor is to be used, it is recommended
that you consult the Service Department, Wimborne Marine Power Centre.
7. Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the
engine.
8. Close the seacock and drain the raw water cooling system.
purposes or for protection from frost, the system must be filled again with an approved coolant mixture.
9. Remove the impeller from the raw water pump and put the impeller in a dark place for storage. Before the
impeller is fitted at the end of the storage period, lubricate lightly the blades and each end of the impeller and
the inside of the pump with Spheerol SX2 grease or glycerine.
Caution: The raw water pump must never run in a dry condition because this can damage the impeller
blades.
10. Remove the atomisers and spray POWERPART Lay-Up 2 for one to two seconds into each cylinder bore
with the piston at bottom of its stroke.
11. Slowly turn the crankshaft one revolution and then fit the atomisers, complete with new seat washers and
clamps.
12. Spray POWERPART Lay-Up 2 into the induction manifold. Seal the manifold and breather outlet with
waterproof tape.
13. Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold. Seal the manifold
with waterproof tape.
14. Disconnect the battery. Then put the battery into safe storage in a fully charged condition. Before the
battery is put into storage, protect its terminals against corrosion. POWERPART Lay-Up 3 can be used on
the terminals.
15. Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape.
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Chapter 7 N39453
16. Remove the alternator drive belt and put it into storage.
17. In order to prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray the area inside
the alternator cooling fan.
18. If the engine protection is done correctly according to the above recommendations, no corrosion damage
will normally occur. Perkins are not responsible for damage which may occur when an engine is in storage
after a period in service.
How to add coolant to the raw water system for engine preservation purposes
Before coolant is added to the raw water system the system should be flushed out with fresh water. To do this,
operate the engine for one to two minutes with the seacock closed and with a supply of fresh water through the
open top of the raw water strainer.
1. Obtain two empty, clean containers each with a capacity of approximately 9,0 litres (2 UK gallons) 9.6 US
quarts. Also obtain 4,5 litre (1 UK gallon) 5 US quarts of coolant.
2. Remove the hose from the raw water connection on the exhaust elbow and put the end of the hose into
one of the containers.
3. Remove the cover from the top of the raw water strainer, and with the seacock closed, add some coolant
through the open top of the raw water strainer. Start the engine and run the engine at idle speed, then
continue to add the remainder of the coolant through the open top of the strainer.
4. Operate the engine for several minutes. During this period, change the containers around, pour the
coolant/water solution from the container at the outlet (hose end) into the strainer.
5. When the coolant is mixed thoroughly and has been circulated through the raw water system, stop the
engine. Fit the top of the raw water strainer.
6. Connect the hose to the raw water connection on the exhaust elbow.
7. Put a label on the engine to make the operator aware that antifreeze is in the raw water system and must
be drained before the seacock is opened and the engine operated.
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N39453 Chapter 7
Procedure models - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad
1. Completely clean the outside of the engine.
2. When a preservative fuel is to be used, drain the fuel system and fill it with the preservative fuel.
POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If preservative
fuel is not used, the system can be completely filled with normal fuel but the fuel must be drained and
discarded at the end of the storage period together with the fuel filter canister.
3. Operate the engine until it is warm. Then correct leakages of fuel, lubricating oil or air. Stop the engine
and drain the lubricating oil from the sump.
4. Renew the canister of the lubricating oil filter.
5. Fill the sump to the full mark with new and clean lubricating oil and add POWERPART Lay-up 2 to the oil
to protect the engine against corrosion. If POWERPART Lay-Up 2 is not available, use a correct preservative
fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the lubricating oil
sump must be filled to the correct level with normal lubricating oil at the end of the storage period.
6. Drain the coolant circuit. In order to protect the cooling system against corrosion, fill it with an approved
antifreeze mixture because this gives protection against corrosion.
Caution: If protection against frost is not necessary and a corrosion inhibitor is to be used, it is recommended
that you consult the Service Department, Wimborne Marine Power Centre.
7. Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the
engine.
8. Remove the atomisers and spray POWERPART Lay-Up 2 for one to two seconds into each cylinder bore
with the piston at BDC.
9. Slowly turn the crankshaft one revolution and then fit the atomisers, complete with new seat washers.
10. Spray POWERPART Lay-Up 2 into the induction manifold. Seal the manifold and breather outlet with
waterproof tape.
11. Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold. Seal the manifold
with waterproof tape.
12. Disconnect the battery. Then put the battery into safe storage in a fully charged condition. Before the
battery is put into storage, protect its terminals against corrosion. POWERPART Lay-Up 3 can be used on
the terminals.
13. Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape.
14. Remove the alternator drive belt and put it into storage.
15. In order to prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray the area inside
the alternator cooling fan.
If the engine protection is done correctly according to the above recommendations, no corrosion damage will
normally occur. Perkins or Wimborne Marine Power Centre are not responsible for damage which may occur
when an engine is in storage after a period in service.
Page 99
Chapter 7 N39453
Page 100
N39453 Chapter 8
Parts and service
Introduction
If problems occur with your engine or with the components fitted onto it, your Perkins distributor can make the
necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.
Service literature
Workshop manuals, installation drawings and other service publications are available from your Perkins
distributor at a nominal cost.
Training
Local training for the correct operation, service and overhaul of engines is available at certain Perkins
distributors. If special training is necessary, your Perkins distributor can advise you how to obtain it at the
Wimborne Marine Power Centre, Wimborne, Dorset.
On-board spares kit

The contents of this kit has been carefully prepared to ensure that it is correct for the original engine specification
and the owner’s / operator’s needs.
POWERPART recommended consumable products

Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.
POWERPART Extended Life Coolant (ELC) Protects the cooling system against frost and corrosion. Part
number 21820181
POWERPART Easy Flush Cleans the cooling system. Part number 21825001.
POWERPART Gasket and flange sealant To seal flat faces of components where no joint is used. Especially
suitable for aluminium components. Part number 21820518.
POWERPART Gasket remover An aerosol for the removal of sealants and adhesives. Part number
21820116.
POWERPART Griptite To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadseal To retain and seal pipe connections with fine threads. Especially suitable
for hydraulic and pneumatic systems. Part number 21820121.
POWERPART Industrial grade super glue Instant adhesive designed for metals, plastics and rubbers. Part
number 21820125.
POWERPART Lay-Up 1 A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2 Protects the inside of the engine and of other closed systems. Part number
1762811.
POWERPART Lay-Up 3 Protects outside metal parts. Part number 1734115.
Page 101
Chapter 8 N39453
POWERPART Metal repair putty Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer To retain and seal pipe connections with coarse threads.
Pressure systems can be used immediately. Part number 21820122.
POWERPART Radiator stop leak For the repair of radiator leaks. Part number 21820127.
POWERPART Retainer (high strength) To retain components which have an interference fit. Currently Loctite
638. Part number 21820638.
POWERPART Safety cleaner General cleaner in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive An RTV silicone adhesive for application where low pressure tests occur
before the adhesive sets. Used for sealing flange where oil resistance is needed and movement of the joint
occurs. Part number 21826038.
POWERPART Silicone RTV sealing and jointing compound Silicone rubber sealant which prevents leakage
through gaps. Currently Hylosil. Part number 1861108.
POWERPART Stud and bearing lock To provide a heavy duty seal to components that have a light interference
fit. Part number 21820119 or 21820120.
POWERPART Threadlock and nutlock To retain small fasteners where easy removal is necessary. Part
number 21820117 or 21820118.
POWERPART Universal jointing compound Universal jointing compound which seals joints. Currently
Hylomar. Part number 1861117.
Page 102
N39453 Chapter 9
General data
415GM
Number of cylinders..........................................................................................................................................3
Cylinder arrangement................................................................................................................................ In line
Cycle.................................................................................................................................................Four stroke
Induction system:..................................................................................................................Naturally aspirated
Combustion system...................................................................................................................Indirect injection
Nominal bore...........................................................................................................................84,0 mm (3.31 in)
Stroke......................................................................................................................................90,0 mm (3.54 in)
Compression ratio.....................................................................................................................................22.5:1
Cubic capacity......................................................................................................................................... 1496cc
Firing order................................................................................................................................................1, 2, 3
Valve tip clearances (cold)...................................................................................................0,20 mm (0.0078 in)
Lubricating oil pressure (maximum engine

speed and normal engine temperature) ............................................................200 kPa (29 lbf/in2) 2,0 kgf/cm2
Capacity of a typical lubricating oil system: (1)

- includes oil filter................................................................................................................ 6,2 litres (10.9 pints)
- sump only......................................................................................................................... 6,0 litres (10.6 pints)
Typical coolant capacity (engine only):.................................................................................. 8 litres (14.1 pints)
Direction of rotation...................................................................................................... Clockwise from the front
Battery............................................................................................................ One 12V, 540A SAE or 340A IEC
Weight of the engine (wet):..........................................................................................................258 kg (569 lb)
(1)The capacity of the sump will vary according to the installation angle. Fill to the “Full” mark on the dipstick. Do not exceed the “Full”
mark.
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Chapter 9 N39453
422GM
Induction system:..................................................................................................................Naturally aspirated
Stroke....................................................................................................................................100,0 mm (3.94 in)
Cubic capacity........................................................................................................................................ 2216 cc
Firing order............................................................................................................................................1, 3, 4, 2


- includes oil filter.............................................................................................................. 10,6 litres (18.7 pints)
- sump only....................................................................................................................... 10,2 litres (18.0 pints)

(1) The capacity of the sump will vary according to the installation angle. Fill to the “Full” mark on the dipstick. Do not exceed the “Full”
mark.
Page 104
N39453 Chapter 9
422TGM
Induction system:..........................................................................................................................Turbocharged
Stroke....................................................................................................................................100,0 mm (3.94 in)
Cubic capacity........................................................................................................................................ 2216 cc
Firing order............................................................................................................................................1, 3, 4, 2


- includes oil filter.............................................................................................................. 10,6 litres (18.7 pints)
- sump only......................................................................................................................... 8,2 litres (14.4 pints)

(1) The capacity of the sump will vary according to the installation angle. Fill to the “Full” mark on the dipstick. Do not exceed the “Full”
mark.
Page 105
Chapter 9 N39453
4.4GM
Induction system...................................................................................................................Naturally aspirated
Combustion system..................................................................................................................... Direct injection
Nominal bore.......................................................................................................................105,00 mm (4.13 in)
Stroke....................................................................................................................................127,0 mm (5.00 in)
Cubic capacity....................................................................................................................4,4 litres (269.00 in3)
Firing order............................................................................................................................................1, 3, 4, 2
Valve tip clearances (hot or cold)

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
Lubricating oil pressure (max engine speed and normal engine temperature)..207 kPa (30 lbf/in2) 2,1 kgf/cm2
- includes oil filter................................................................................................................... 8,5 litres (15 pints)
- sump only......................................................................................................................... 7.5 litres (13.2 pints)
Typical coolant capacity (engine only)................................................................................. 16.5 litres (29 pints)
Battery:
12V system................................................................................................................ One 12V, 520A to BS3911
24V system.................................................................................................................Two 12V, 440A to BS3911
Weight of the engine (dry).........................................................................................................462 kg (1019 lb)
The sump capacity will vary according to the installation angle. Do not exceed the “Full” mark on the dipstick,
(1)
see “Caution” on page 43.
Page 106
N39453 Chapter 9
4.4TGM
Induction system...........................................................................................................................Turbocharged
Stroke....................................................................................................................................127,0 mm (5.00 in)
Compression ratio........................................................................................................................................18.3
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
Battery:
(1)
Page 107
Chapter 9 N39453
4.4TWGM
Induction system........................................................................................................Turbocharged/aftercooled
Stroke....................................................................................................................................127,0 mm (5.00 in)
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)

Battery:
(1)
Page 108
N39453 Chapter 9
4.4TW2GM
Stroke....................................................................................................................................127,0 mm (5.00 in)
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)

Battery:
(1)
Page 109
Chapter 9 N39453
4.4GM Radiator
Induction system...................................................................................................................Naturally aspirated
Stroke....................................................................................................................................127,0 mm (5.00 in)
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
Lubricating oil pressure (max engine speed and normal engine temperature)
...........................................................................................................................207 kPa (30 lbf/in2) 2,1 kgf/cm2

Battery:
Weight of the engine (dry)..................................................................................................... 495 (1091) kg ( lb)

(1) The sump capacity will vary according to the installation angle. Do not exceed the “Full” mark on the dipstick.
Page 110
N39453 Chapter 9
4.4TGM Radiator
Induction system...........................................................................................................................Turbocharged
Stroke....................................................................................................................................127,0 mm (5.00 in)
Compression ratio......................................................................................................................................18.23
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
...........................................................................................................................207 kPa (30 lbf/in2) 2,1 kgf/cm2

Battery:
Weight of the engine (dry)...................................................................................................... 511 (1127) kg ( lb)

Page 111
Chapter 9 N39453
4.4TWGM Radiator
Stroke....................................................................................................................................127,0 mm (5.00 in)
Firing order............................................................................................................................................1, 3, 4, 2

Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
...........................................................................................................................207 kPa (30 lbf/in2) 2,1 kgf/cm2

Typical coolant capacity (engine only) (2).............................................................................. 17.5 litres (31 pints)
Battery:
Weight of the engine (dry)......................................................................................................543 (1197) kg ( lb)

(2) For engines built after July 2013, the radiator is larger and has a bigger capacity. Please refer to Wimborne Marine Power Centre for
more information.
Page 112
N39453 Chapter 9
4.4TW2GM Radiator
Stroke....................................................................................................................................127,0 mm (5.00 in)
Firing order............................................................................................................................................1, 3, 4, 2
Inlet........................................................................................................................................0,20 mm (0.008 in)
Exhaust.................................................................................................................................0,45 mm (0.018 in)
...........................................................................................................................207 kPa (30 lbf/in2) 2,1 kgf/cm2

Typical coolant capacity (2)................................................................................................... 17.5 litres (31 pints)
Battery:
Weight of the engine (dry)......................................................................................................543 (1197) kg ( lb)

(2) For engines built after July 2013, the radiator is larger and has a bigger capacity of 20 litres. Please refer to Wimborne Marine Power
Centre for more information.
Page 113
Chapter 9 N39453
Page 114
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. N39453 issue 7
Produced in England ©2013 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
Part No RJ30890
GB
Parts Manual
4.4TW2GM KC
Selling code Group Number Part Number Description Qty
RJ30890 AT1_PRIME_GENAUX 1
4.4TW2GM, 1800 RATING, K COOL 1
4328635 PUMP GP-AUXILIARY (SEA WATER) 1
P2318A603 NUT, FLANGED, M8 2
P2314J034 BOLT-FLANGED (M10 X 30, SEALA 1
P2313M058 STUD (M8 X 20) 1
P2313M060 STUD 2
1134597 BOLT (M8 X 10 SETSCREW) 2
33021 O-RING (RAW WATER PUMP) 1
34447 PLATE-CLAMP 1
34448 CLAMP-WASHER 1
W10006 PUMP GP-AUX SEAWATER (1104/6) 1
7555 Fresh water Hoses Keel Cooled 1

19609 HOSE CLIP, SIZE 35, S.S. 4
37035 HOSE, 25.4MM X 50MM LONG 1
33014 HOSE, 1" X 90 DEG 1
7560 Air Filter Assembly (Perkins) 1

P2314H007 BOLT-FLANGED (M8 X 40) 2
P0920443 WASHER, 25MM OD X 8.7MM ID X 2
P26510380 ELEMENT, AIR FILTER (PERKINS) 1
37195 HOSE, AIR FILTER TO TURBO 1
19477 CLAMP-HOSE 1
P2652C201 AIR FILTER ASSEMBLY 1
P26510381 ELEMENT, AIR FILTER 1
7568 Exhaust Manifold, Rear Outlet 1

36864 MANIFOLD, EXHAUST, 4 CYL, REA 1
36610 GASKET, CYLINDER HEAD TO MANI 1
P2314J051 BOLT-FLANGED (M10 X 130, SEAL 8
358063 PLUG, 1/8" NPTF 2
36809 ADAPTOR, 3/4" NPTF X 25MM HOS 1
37016 PIPE, MANIFOLD TO BLOCK 1
7576 Intercooler and Inlet Duct (! 1

N40237 INTERCOOLER (SINGLE PASS & WI 1
1530709 BOLT-FLANGE (M10 X 140) 3
36865 DUCT, INTERCOOLER TO INLET MA 1
P2313M062 STUD M8 X 40 (NOMINAL LENGTH) 1
N37297 STUD, M8 X 149 2
36967 BRACKET, SUPPORT, INTERCOOLER 2
36973 Ò` RING, INTERCOOLER DUCT 1
P2314J002 BOLT-FLANGED (M10 X 20) 2
N41074 SPACER, 11MM ID x 25MM OD x 1 3
10171 Ò` RING 1
36206 STUD, MANIFOLD SECURING, M8 1
358063 PLUG, 1/8" NPTF 1
5P-1075 WASHERS 3/8" ZN 10.9 3
7612 Turbocharger and ancillaries 1

37226 PIPE, OIL FEED, TURBOCHARGER 1
30122 TUBE, 8MM BUNDY (5/16") 0.85
N37474 BANJO OIL FEED TURBO 2
P36568138 `P` CLIP (FUEL PIPE) 2
P3218R036 BOLT, BANJO 2
P2131A506 WASHER 4
P2481D073 CLAMP-HOSE, 40-60 2
N37281 HOSE, 50MM I.D. x 90MM LONG 1
36956 GASKET, EXHAUST, MANIFOLD OUT 1
36977 TURBOCHARGER (VISTA TA) 1
P2313C077 STUD, M10 X 25 NOMINAL LENGTH 7
P2318A604 NUT (M10) 4
P3688A053 JOINT, TURBO DRAIN 1
37216 STUD, M6 X 24 2
P2318A602 NUT-HEX FLANGE (M6) 2
P3688A036 JOINT, TURBO DRAIN 1
P2313M058 STUD (M8 X 20) 2
37223 HOSE ASSEMBLY, TURBO DRAIN 1
P2318A634 NUT (M10 FLANGED - ANTISEIZE) 3
7613 Eng Breather,closed circuit 1

P2652A016 ELEMENT 1
59814 CLIP, SIZE 30, S.S. (HI-GRIP, 4
37196 HOSE, BREATHER TO AIR FILTER 1
34065 ADAPTOR, ENGINE BREATHER 1
3406502 ADAPTOR, ENGINE BREATHER 1
15401 CLIP, PIPE SUPPORT, SIZE 5/0. 1
49074 HOSE CLIP, SIZE 20, S.S. (HI- 2
37213 HOSE, 1/2" BORE (BREATHER DRA 1
P2652A024 O RING 1
P2652A023 BREATHER 1
P2314F007 BOLT-FLANGED (M6 X 30) 2
37197 HOSE, BREATHER 1
7617 Cooling system,K/C,intercoole 1

37003 HOSE, 1.25" DIA TO 30MM REDUC 1
37224 PIPE, 1.1/4", INT TO KEEL COO 1
37004 HOSE, 1.25" DIA TO 30MM X 90 1
37221 PIPE, 1.1/4", R.W.P TO INTERC 1
26667 CLIP, PIPE SUPPORT, SIZE 9/1. 4
36934 SPACER, 11.0MM ID X 20MM OD X 2
P2318A604 NUT (M10) 2
33142 HOSE, 1.1/4" X 2.1/2" LONG 1
37220 PIPE, 1.1/4", PUMP TO INTERC 1
37060 HOSE, R.W.P TO INTERCOOLER PI 1
7623 Keel cooled bleed hardware 1

33845 HOSE END, 1/4" BSPT MALE, STR 2
P2313M060 STUD 1
33484 WASHER 1
27113 CLIP, PIPE SUPPORT, SIZE 38MM 1
7627 Sump drain valve 1

33084 Ò` RING (SUMP ADAPTOR) 1
33006 ADAPTOR, 3/8" BSP MALE X 3/4" 1
N39524 ELBOW (3/8" X 3/8" SWIVEL FEM 1
26901 TAP, BALL VALVE, 3/8" BSP FEM 1
P0650586 PLUG, 3/8" NPTF, SOCKET SETSC 1
7628 Heatshield blanket, Turbochar 1

37207 HEATSHIELD, TURBOCHARGER 1
7632 Low pressure fuel system (PER 1

N40878 LIFT PUMP/ FIL ASSY (BRUSHLES 1
36944 ELEMENT, FUEL FILTER, REVERSE 1
37021 HOSE ASSEMBLY, FUEL LEAK OFF 1
N37846 HOSE ASSEMBLY, INJ PUMP FEED 1
P0650204 PLUG, 1/2" UNF, HEX HEAD 1
P0920154 WASHER, 1/4" BSP, SEALING 1
37023 HOSE ASSEMBLY, INJ PUMP RETUR 1
37024 ADAPTOR, HOSE TAIL 1
37018 WASHER, COPPER, M5 2
37025 VALVE, NON RETURN 1
37026 ADAPTOR, MALE BRANCH TEE 1
37027 CLIP, SWIVEL, HOSE SUPPORT 1
37028 CLIP, SWIVEL, HOSE SUPPORT 1
37029 CLIP, HOSE SUPPORT 1
P0566004 OLIVE, 5/16" OD PIPE 4
P33532129 NUT, COMPRESSION, 1/2" UNS MA 4
34058 NUT, COMPRESSION, 1/4" BSP X 1
N37921 HOSE, LEAK OFF 0.08
P0566003 OLIVE, 1/4" OD PIPE 2
34056 NUT, COMPRESSION, 1/4" BSP FE 2
35350 DRAIN PLUG, FUEL FILTER, META 1
P0566004 OLIVE, 5/16" OD PIPE 1
7634 Keel Cooled System 1

33092 HOSE, 2" X 3" 1
34866 PLUG, 1/8" BSPT, STEEL, HEX H 1
37066 PIPE, THERMOSTAT TO KEEL COOL 1
37045 BRACKET, PIPE SUPPORT 2
P33134418 SPACER, 8.8MM ID X 19MM OD X 2
36135 CLIP, PIPE SUPPORT, SIZE 50MM 2
34383 HOSE, 2" X 1.1/2", REDUCER 2
N39661 CAP, 50.8 MM X 25 MM 2
36886 BRACKET, LIFTING EYE 1
36882 HOSE, REDUCER, 15.9MM X 25.4M 1
37065 PIPE, MANIFOLD TO F/W PUMP 1
15396 CLIP 2
36960 SPACER, 11MM ID X 19MM OD X 3 1
18060 SPACER, 11MM ID X 19MM OD X 9 1
59815 HOSE CLIP, SIZE 70, S.S. (HI- 1
36875 HOSE, REDUCER, F/W PUMP INLET 1
37068 PIPE, F/W PUMP TO KEEL COOLER 1
P34821121 HOSE, 5/8" ID X 90 DEG 1
7639 Exhaust outlet elbow TA 1

37201 ELBOW, EXHAUST OUTLET (VISTA 1
30085 PLUG, 1/8" BSPT, SOCKET SET S 1
N40903 CAP, PLASTIC 1
7643 Mounting bracket,air filter 1

37155 BRACKET, AIR FILTER MOUNTING 1
7646 Mntg bracket,closed circuit b 1

37061 BRACKET, BREATHER MOUNTING 1
P2314H033 BOLT-FLANGED (M8 X 20, SEALAN 2
59060 WASHER, 5/16", FLAT, HEAVY DU 2
B246 Badge, Header Tank, Perkins 1

N41472 BADGE, HEADER TANK, PERKINS 1
7713 Eng core, C4.4TA TAG2, P.No.N 1

N37529 ENG CORE, C4.4TA TAG 2, RJ512 1
7736 Blanket,Dry Exhaust Elbow T.A 1
37205 JACKET, THERMAL, EXHAUST ELBO 1
7784 Magnetic Pick Up 2

N37658 SENSOR AS, (M16) 1
N37657 PICK UP, MAGNETIC 1
37040 PIN, CONNECTOR 2
N37396 RECEPTACLE, WEDGE 1
N37305 RECEPTACLE, CONNECTOR 1
7793 Header Tank, Remote Keel Cool 1

37244 KIT, HEADER TANK, REMOTE MOUN 1
N40386 HOSE, 1/4" TEXTILE BRAID, 6M 1
18396 BAG, POLYTHENE SELF SEAL, 6" 1
18621 COUPLING-HOSE, 1/4" BSP FEMAL 2
30089 PLUG, 1/4" BSPT (STEEL - F/W 2
31000 HOSE, 1 METRE X 5/16" ID, PV 1
PACK15330 BOX, 486 X 399 X 193MM PLAIN 1
37245 FITTING INST, REMOTE HEADER T 1
37232 TEE, 1" x 1" x 1" 1
37231 PIPE, T, 1.1/4" X 1.1/4" X 1" 1
35569 HEADER TANK ASSEMBLY, REMOTE 1
35702 CAP, FILLER, 50KPA 1
33214 CLAMPING RING, TAPPED, FILLER 1
33216 Ò` RING (HEADER TANK FILLER 1
33217 NECK, FILLER (PLATING) 1
33227 SCREW, M4 X 16, CHEESE HEAD, 4
33228 SCREW, M4 X 25, RECESSED PAN 1
35480 HEADER TANK, REMOTE MOUNTED, 1
35481 SIGHT GAUGE, FLUID LEVEL (REM 1
50130 GASKET, CAP, PRESSURE (H.E.) 1
N39483 HOSE, 1" ID X 2M LONG 1
LEW62 HOSE RUBBER 1" I.D. 2
7808 Additional Keel Cooled Materi 1

37247 SCHEMATIC, KEEL COOLING SYSTE 1
7836 Miscellaneous Materials,C4.4 1

60100 GAS OIL, LITRES 25
60115 OIL, SHELL RIMULA SUPER 15W/4 8.5
60060 ANTI-FREEZE, LITRES 8
7838 Plate, Engine Serial Perkins 1

P3181A005 LABEL, ENGINE TYPE 1
1800 Engine Rating, 1800rpm 1
35731 LABEL, GENSET SPEED RATING 18 1
A139 Closed Circuit Breather Valve 1

P2652A015 VALVE 1
37212 ADAPTOR, M16 X 1/2" COMPRESSI 1
SGS169 SAE 3 HOUSING WITH SAE10/11.5 1

7553 Flywheel and SAE 3 Housing 1
P3713M049 FLYWHEEL HOUSING (REPLACES 37 1
P36843154 SEAL 1
P2314J603 BOLT, FLANGED, M12 X 30 2
P2314J204 BOLT-FLANGED M10 X 30 (10.9 G 6
P3245A011 DOWEL 2
P36212132 PLATE 1
P2487382 PLUG 1
1036131 FLYWHEEL AS 1
P31162121 RING GEAR, FLYWHEEL (B.W. HOU 1
P33117127 WASHER 10
1454910 BOLT (FLYWHEEL) 10
SGS189 EXH FLANGE 1

7765 Exhaust Outlet,Gasket Hardwar 1
P33415509 GASKET-TURBO 1
N37588 BOLT (M8 X 40 SS) 6
P2318A663 NUT-HEX FLANGE (M8 SPIRALOCK) 6
5240 Exhaust flange, modular 1

33206 FLANGE, WELD, EXHAUST 1
SGS297 NO HARNESS, ELECTRICAL CONNEC 1

A102 Mating Plugs, Electrical 1
N37304 PLUG, CONNECTOR 3
N37395 PLUG, WEDGE 3
36451 SOCKET, CONTACT, FEMALE 6
N37467 PLUG 1
N37468 CONTACT 1
36447 PLUG, 12 WAY 1
36449 SEAT RETENTION, WITH LOCK, GR 1
36452 FILLER PLUG. 7
N38342 DIAGRAM, WIRING, L-SERIES GOV 1
18357 STRAP-CABLE 1
N39073 KIT, ELECTRICAL MATING PLUGS 1
N37304 PLUG, CONNECTOR 3
N37395 PLUG, WEDGE 3
N37467 PLUG 1
N37468 CONTACT 1
36447 PLUG, 12 WAY 1
36449 SEAT RETENTION, WITH LOCK, GR 1
36452 FILLER PLUG. 7
N38342 DIAGRAM, WIRING, L-SERIES GOV 1
7624 Glow Plugs, 24V (4CYL VISTA) 1

P2666A017 GLOW PLUG, 24V (VISTA) 4
36812 STICKER, 24V 1
SGS175 Alternator,24 Volt 1
7567 Alternator, 24V, Iskra 1

36962 ALTERNATOR, 24V, 55A 1
59068 WASHER, M5, FLAT (ENGINE OIL 1
7641 Alternator Belt 1

P2614B543 BELT 1
7563 Alternator Mounting Hardware 1

11992 LOCKNUT (M8) 1
33078 WASHER, M8, FLAT 1
P2314H052 BOLT-FLANGE HD (M8 X 130) 1
19410 LOCKNUT (M10) 1
P0920465 SPACER, 11MM ID X 19MM OD X 6 1
36975 ADJUSTER ARM, ALTERNATOR 1
P3824A071 BRACKET, ALTERNATOR 1
59074 WASHER, 3/8", FLAT (BRIGHT PR 1
59077 WASHER-HARD ** ILC not for EP 1
P0920497 WASHER 1
7635 Belt Guard 1
37012 BELTGUARD, C4.4 OPEN GENSET 1
33482 GROMMET 3
33484 WASHER 6
58070 *ILC*BOLT-HEX HEAD (M8 X 25) 3
33483 SPACER-SUPPORT 3
N37483 GROMMET 1
N40574 NUT-PUSH ON 3
A348 Belt Guard Mounting Hardware 1

33926 PILLAR, M16 MALE X M8 FEMALE, 2
37013 PILLAR, M8 MALE X M8 FEMALE 1
SGS223 STARTER MOTOR, 24VOLT 1

7787 Starter Motor 24V 1
N40983 STARTER (24V) 1
7788 Adaption Kit, Starter Motor, 1

P2313M078 STUD M10 X 30MM NOMINAL LENGT 3
P2318A604 NUT (M10) 3
SGS177 DUOLINE H.P FUEL PIPES & ALAR 1

7614 Fuel pipes,H.P.Duoline 1
N37499 PIPE, INJECTOR, CYL 1, DUOLIN 1
N37500 PIPE, INJECTOR, CYL 2,DUOLINE 1
N37503 BOLT, M8, SOCKET HEAD 2
36357 WASHER, M8, SHAKEPROOF 3
17364 NUT, M8 (HEX. FULL) 2
36290 O RING, DRAIN MANIFOLD 3
36292 BLANKING CAP (DELPHI) 1
36291 BANJO COUPLING (4T/GM/3054NA/ 1
N37504 BRACKET, MOUNTING, DUOLINE FU 1
36294 6MM BUNDY TUBE (4T/GM/3054NA/ 1
36293 COMPRESSION COUPLING (4T/GM/3 1
33719 ALARM TANK ASSEMBLY 1
33762 MOUNTING KIT, ALARM TANK 1
17364 NUT, M8 (HEX. FULL) 2
59131 WASHER, 5/16", SHAKEPROOF 2
P24865215 SETSCREW, M8 X 40, HEX HEAD 2
58071 SETSCREW, M8 X 20 1
36976 PIPE KIT, F/INJ, D/SKINNED (V 1
200100 (1/4" BSP, FEMALE, PLASTIC CA 1
7633 Cover,fuel pipes (!) 1
37217 COVER, FUEL PIPES 1
37218 BRACKET, COVER SUPPORT 1
37252 BRACKET, COVER FIXING 1
36669 CONDUIT, HARNESSFLEX, SPLIT ( 0.05
36669 CONDUIT, HARNESSFLEX, SPLIT ( 0.03
7737 Mtg,Alarm tank,Dual wall fuel 1

N37635 BRACKET,RESERVOIR MOUNTING, 1
P3656M004 CLIP 1
N37810 PIPE,FUEL,INJ L/OFF TO ALARM 1
A360 Leak Off Pipe Securing Bolt 1

SGS176 Engine barring device only 1

7598 Engine Turning Device 1
37007 ENGINE TURNING DEVICE (VISTA) 1
26729 SETSCREW, 7/16" UNF X 1" 2
59041 WASHER, 7/16", SPRING, SQUARE 2
3034PG Paint, 4.4TGM (Prime Only) 1
26001 PRE - PAINT (PRE - CLEAN) NOW 1.5
26002 STANDARD GUN CLEANER 0.3
35343 PAINT, PRIMER BASE, GREY, LIT 1
35344 22-99 850 CURING AGENT 0.2
35345 NO 1 THINNERS 0.3
35341 800 SERIES CURING AGENT 0.2
35342 THINNERS, (25-03 THINNERS) 0.5
N40436 CONVERTER, VOLTAGE, 24V TO 12 1
37228 CONVERTER, VOLTAGE, 24V TO 12 1
N37546 FITTING INSTRUCTIONS, INVERTE 1
SPK132 Engine stillage, Perkins, Par 1

5521 Engine stillage, Perkins, Par 1
PK132 STILLAGE BASE, KNOCK/DOWN, 4G 1
7917 4.4TW2GM Finishing Materials 1

26531 PAINT, TOUCH UP, PERKINS PRES 1
200007 LABEL, ENGINE DIPSTICK 1
200009 LABEL, EXHAUST CONNECTION 1
N38863 STATEMENT ON WARRANTY 1
33950 CERTIFICATE, DECLARATION OF 1
17398 LABEL, ANTIFREEZE CONTENT 1
200100 (1/4" BSP, FEMALE, PLASTIC CA 2
27309 CAP, 31.8 MM, BLACK 1
N37965 INSTALLATION DATA,PERKINS/SAB 1
35224 (4P-6422) DECAL, CATERPILLAR, 1
P3181D001 LABEL 1
35453 FILM-INFORMATION 1
35102 INSULATOR, STARTER TERMINAL, 1
35146 INSULATOR, STARTER TERMINAL, 1
18357 STRAP-CABLE 1
27322 COACH SCREW, M10 X 60MM (COAC 4
34656 WASHER, M10, PENNY 40MM OD 4
36614 LABEL, SABRE ADDRESS/ENGINE D 1
34962 LABEL, WARNING, COOLANT INHIB 1
7920 Label,Zebra,Sabre Eng Model/S 1

N37990 LABEL,SABRE ENGINE MODEL/SERI 1
N38009 BLANK, LABEL EMISSIONS 1
7921 Label,Zebra,Sabre Eng Model/S 1

N37991 LABEL,SABRE ENGINE MODEL/SALE 1
N38009 BLANK, LABEL EMISSIONS 1
7926 Label,Emissions,P3181A087 1
P3181A087 LABEL, INFORMATION,EMISSION C 1
A076 Packing, Wood Buffer 1

36860 SIDE BUFFER, GENSET STILLAGE 2
A187 Users Handbook, 400 & 4.4 Aux 1

N39453 HANDBOOK, USERS, 400 & C44 AU 1
60414 FOLDER, PLASTIC WITH ZIP 1
N38143 MANUAL, INSTALLATION, PERKINS 1
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Low Voltage Alternators - 4 pole
LSA 44.3
Installation and maintenance
Electric Power Generation Installation and maintenance 5056 en - 2016.06 / e
LSA 44.3
This manual concerns the alternator which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.
SAFETY MEASURES a) During operation, do not allow anyone

Before using your machine for the first time, to stand in front of the air outlet guards,
it is important to read the whole of this in case anything is ejected from them.
installation and maintenance manual. b) Do not allow children younger than 14
to go near the air outlet guards.
All necessary operations and interventions
on this machine must be performed by a A set of self-adhesive stickers depicting the
qualified technician. various warning symbols is included with
this maintenance manual. They should be
Our technical support service will be pleased positioned as shown in the drawing below
to provide any additional information you once the machine has been fully installed.
may require.
The various operations described in this
manual are accompanied by recommenda- WARNING
tions or symbols to alert the user to the po- The alternators must not be put into
tential risk of accidents. It is vital that you service until the machines in which they
understand and take notice of the different are to be incorporated have been
warning symbols used. declared compliant with Directives EC
and plus any other directives that may be
WARNING applicable.
This manual is be given to the end user.
Warning symbol for an operation capable The range of electric alternators and
of damaging or destroying the machine their derivatives, manufactured by us or
or surrounding equipment. on our behalf, comply with the technical
requirements of the customs Union
directives (EAC).
Warning symbol for general danger to © - We reserve the right to modify the
personnel. characteristics of its products at any time in
order to incorporate the latest technological
developments. The information contained in
this document may therefore be changed
without notice.
Warning symbol for electrical danger to This document may not be reproduced in
personnel. any form without prior authorization.
All brands and models have been registered
and patents applied for.
WARNING SYMBOLS
We wish to draw your attention to the
following 2 safety measures which must be
complied with:
2
LSA 44.3
CONTENTS
1 - RECEIPT.............................................................................................................. 4
1.1 - Standards and safety measures................................................................................ 4
1.2 - Inspection.................................................................................................................. 4
1.3 - Identification.............................................................................................................. 4
1.4 - Storage...................................................................................................................... 4
1.5 - Applications............................................................................................................... 4
1.6 - Contraindications to use............................................................................................ 4
2 - TECHNICAL CHARACTERISTICS..................................................................... 5
2.1 - Electrical characteristics............................................................................................ 5
2.2 - Mechanical characteristics........................................................................................ 5
3 - INSTALLATION................................................................................................... 6
3.1 - Assembly................................................................................................................... 6
3.2 - Checks prior to first use............................................................................................. 6
3.3 - Terminal connection diagrams................................................................................... 7
3.4 - Commissioning........................................................................................................ 10
3.5 - Setting up................................................................................................................ 10
4 - SERVICING - MAINTENANCE.......................................................................... 11
4.1 - Safety measures.......................................................................................................11
4.2 - Routine maintenance................................................................................................11
4.3 - Bearings.................................................................................................................. 12
4.4 - Mechanical defects.................................................................................................. 12
4.5 - Electrical faults........................................................................................................ 13
4.6 - Dismantling, reassembly......................................................................................... 15
4.7 - Installation & maintenance of the PMG................................................................... 17
4.8 - Table of characteristics....................................................................................... 17-18
5 - SPARE PARTS.................................................................................................. 19
5.1 - First maintenance parts........................................................................................... 19
5.2 - Technical support service........................................................................................ 19
5.3 - Accessories ............................................................................................................ 19
5.4 - Exploded views, parts list and tightening torque..................................................... 20
Disposal and recycling instructions
EC declaration of incorporation
3
LSA 44.3
1 - RECEIPT 1.4 - Storage
1.1 - Standards and safety Prior to commissioning, machines should
measures be stored :
- away from humidity (< 90%); after a long
Our alternators comply with most period of storage, check the machine
international standards. insulation. To prevent the bearings from
See the EC Declaration of Incorporation on becoming marked, do not store in an
the last page. environment with significant vibration.
1.2 - Inspection 1.5 - Application
On receipt of your alternator, check that it These alternators are mainly designed to
has not suffered any damage in transit. If produce electricity in the context of
there are obvious signs of knocks, contact applications involving the use of
the transporter (you may be able to claim generators.
on their insurance) and after a visual
check, turn the machine by hand to detect 1.6 - Contraindications to use
any malfunction. Use of the machine is restricted to operating
conditions (environment, speed, voltage,
1.3 - Identification power, etc) compatible with the characteri-
The alternator is identified by means of a stics indicated on the nameplate.
nameplate fixed on the machine (see
drawing).
Make sure that the nameplate on the
machine conforms to your order.
So that you can identify your alternator
quickly and accurately, we suggest you fill in
its specifications on the nameplate below.
LSA IP RATINGS
N°: Date : Voltage V
r.p.m. Hz Weight : kg Phase
LSA 000-1-006 e
Th.class. Altitude : m Conn.

P.F. :
A.V.R. Excit. Contin. kVA
Excit. values full load : V/ A B.R. kW
at no load : A 40°C. A
D.E. bearing Std by kVA
N.D.E. bearing P.R. kW
R
27°C. A
C US
166631 Made in ............................
IEC 60034 - 1 & 5. / ISO 8528 - 3. / NEMA MG1 - 32 & 33. Moteurs Leroy-Somer - Boulevard Marcellin Leroy,
CS 10015 - 16915 Angoulême Cedex 9 - France
4
LSA 44.3
2 - TECHNICAL CHARACTERISTICS 2.2 - Mechanical characteristics
2.1 - Electrical characteristics - Steel frame
- Cast iron end shields
This alternator is a machine without
- Protected ball bearings, greased for life
sliprings or revolving armature brushes,
- Mounting arrangements:
wound as “2/3 pitch”, 12-wire, with class H
IM 1201 (MD 35) foot and flange mounted,
insulation and a field excitation system
single-bearing with SAE coupling disc.
available in either SHUNT, AREP or
IM 1001 (B 34) double-bearing with SAE
«PMG» version (see diagrams and AVR
flange and standard cylindrical shaft
manuals).
extension.
• Electrical options - Drip-proof machine, self-cooled
- Stator temperature detection sensors - Degree of protection: IP 23
- Space heater
In order to conform to standard EN 61000- • Mechanical options
6-3, EN 61000-6-2, EN 55011, the R 791 - Air inlet filter
interference suppression kit is needed. - IP 44 protection
MAIN FIELD STATOR : 12-wire (marking T1 to T 12)

SHUNT SYSTEM
T1 T7 T2 T8 T3 T9
EXCITER
Varistor
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
R 250 Power supply / Detection
MAIN FIELD STATOR : 12-wire (marking T1 to T 12)

AREP SYSTEM Aux. windings
T1 T7 T2 T8 T3 T9
EXCITER
Varistor
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
R 438 Voltage reference
MAIN FIELD STATOR : 12-wire (marking T1 to T12)

PMG SYSTEM
T1 T7 T2 T8 T3 T9
EXCITER
Varistor
PMG
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
R 438 Voltage reference
5
LSA 44.3
3 - INSTALLATION • Single-bearing coupling
Personnel undertaking the various Before coupling, check the compatibility
operations indicated in this section must between the alternator and the engine by
wear personal protective equipment performing:
appropriate for mechanical and electrical - undertaking a torsional analysis of the
hazards. transmission (alternators data are available
on request),
3.1 - Assembly - checking the dimensions of the flywheel
and its housing, the flange, coupling discs
and offset.
WARNING
All mechanical handling operations When coupling the alternator to the
must be undertaken using suitable prime mover, do not use the fan to turn
equipment and the machine must be the alternator or rotor.
horizontal. Check how much the machine The holes of the coupling discs should
weighs (see 4.8) before choosing the be aligned with the flywheel holes by
lifting tool. cranking the engine.
During this operation, do not allow Make sure the machine is securely
anyone to stand under the load. bedded in position during coupling.
Check that there is lateral play on the
• Handling crankshaft.
The generously-sized lifting rings are for • Double-bearing coupling
handling the alternator alone. They must not - Semi-flexible coupling
be used to lift the genset. The choice of Careful alignment of the machines is
lifting hooks or handles should be determined recommended, checking that the lack of
by the shape of these rings. Choose a lifting concentricity and parallelism of both parts
system which respects the integrity and the of the coupling do not exceed 0.1 mm.
environment of the machine. This alternator has been balanced with a
1/2 key.
During this operation, do not allow • Location
anyone to stand under the load. The room where the alternator is placed
must be ventilated to ensure that the
ambient temperature cannot exceed the
data on the nameplate.
3.2 - Checks prior to first use

• Electrical checks
Under no circumstances should an

alternator, new or otherwise, be operated
if the insulation is less than 1 megohm
for the stator and 100,000 ohms for the
other windings.
6
LSA 44.3
There are 2 possible methods for restoring - the cooling air is drawn in freely,
the above minimum values. - the protective grilles and housing are cor-
a) Dry out the machine for 24 hours in a rectly in place,
drying oven at a temperature of 110 °C - the standard direction of rotation is clock-
(without the regulator). wise as seen from the shaft end (phase
b) Blow hot air into the air intake, having rotation in order 1 - 2 - 3).
made sure that the machine is rotating with For anti-clockwise rotation, swap 2 and 3.
the exciter field disconnected. - the winding connection corresponds to the
Note : Prolonged standstill site operating voltage (see section 3.3).
In order to avoid these problems, we
recommend the use of space heaters, as 3.3 - Terminal connection diagrams
well as turning over the machine from time To modify the connection, change the
to time. Space heaters are only really position of the stator cables on the terminals.
effective if they are working continuously The winding code is specified on the
while the machine is stopped. nameplate.
WARNING
Ensure that the alternator has the degree
of protection matching the defined
environmental conditions. Any intervention on the alternator
terminals during reconnection or checks
• Mechanical checks should be performed with the machine
Before starting the machine for the first time, stopped.
check that: In no case should the internal
- all fixing screws are tight, connections in the terminal box be
- the length of screw and the tightening subjected to stresses due to cables
torque are correct, connected by the user.
Connection codes L.L. voltage Factory connection
T12
A
L1(U) Winding 50 Hz 60 Hz T6 T11
T5 N
3 phases
T1 T7
6 190 - 208 190 - 240
T4 T10
7 220 - 230 - T9 L3(W)
T4 T10 N
T3
T12 T5
8 - 190 - 208 T8 L2(V)
T9 T2
T11 R 250 voltage sensing: T2
T6 0 => (T8) / 110 V => (T11) T7 L1(U)
R 438 voltage sensing:
L3(W) T3 T8 L2(V)
0 => (T3) / 110 V => (T2) T1 NDE
T12
D T1 L1(U) Winding 50 Hz 60 Hz T11
6 N
3 phases T4 380 - 415 380 - 480
T10
T7
7 440 - 460 - T9 L3(W)
N T6
T10 T3
T12 8 - 380 - 416 T8 L2(V)
T9
T11 T5 R 250 voltage sensing: T5 T2
T3 T6 T8 T2 0 => (T8) / 110 V => (T11) T7 L1(U)
L3(W) L2(V) 0 => (T3) / 380 V => (T2) T4 T1 NDE
7
LSA 44.3
Connection codes L.L. voltage Factory connection
FF Winding 50 Hz 60 Hz T4 T11
T7 M
1 phase 6 220 - 240 220 - 240
T3
T2 T6 T8 T12
7 250 - 260 - T9 L
T3 T10
T5 T11 T9
8 200 220 - 240 T8 T6
T1 T4 T7 T10
L L R 250 voltage sensing: T12 T2
M
0 => (T1) / 110 V => (T4) T5 L
LM voltage = 1/2 LL voltage T1
0 => (T10) / 220 V => (T1) NDE
L1(U)
Winding 50 Hz 60 Hz
F
1 phase T12 T1 6 220 - 240 220 - 240 T6 T3
or
3 phases T9 L
T4
T7 7 250 - 260 - T9 T11 L3(W)
T6
T5
L
T3 T10 8 200 220 - 240 T8 T10 L2(V)
L3(W) L2(V) R 250 voltage sensing: T4 T2
T11 T8 T5 T2
L L 0 => (T8) / 110 V => (T11)
M T7 T12 L1(U)
LM voltage = 1/2 LL voltage T1
0 => (T3) / 220 V => (T2) NDE
Winding 50 Hz 60 Hz T5 T11
G
6 T4 M
1 phase 220 - 240 220 - 240
M T10
T6 T1
T12
T7 7 250 - 260 - T9 L
T4 T3
T3
T10
T2 8 200 220 - 240 T8 L
T5
T9 L
R 250 voltage sensing: T12 T2
L T11 T8 0 => (T8) / 110 V => (T11) T7 T6
LM voltage = 1/2 LL voltage 0 => (T3) / 220 V => (T2) T1
NDE
When coupling alternators in parallel with connected neutral,

it may be necessary to use a reactance (please contact us).
Tightening torque of terminal (M10 / 20 Nm +/-3).
8
LSA 44.3
SINGLE-PHASE 4-WIRE - type M or M1 DEDICATED WINDING
SERIAL CONNECTION Voltage 50/60Hz Output

T2 T3
L-L L-M Link L L M
T1 T4
220 110
230 115 T2 - T3 T1 T4 T2 - T3
M 240 120
L L
R 250 voltage sensing: 0 => (T1) / 110 V => (T2)
Warning: parallel connection not possible.
• Option connection diagram

R 791 T interference suppression kit (standard for CE marking) Voltage potentiometer
A D F B F/F G
Black T1 T1 T1 T1 T1 T2
Black T2 T2 T2 T2 T9 T3 ST4
Black T3 T3 T3 T3 NC NC Voltage adjustment
Blue N N by remote potentiometer
Green/Yellow
Anti condensation heater Thermistor (PTC) temperature

130°C
103 Blue wire
Ph1
101 150°C
Ph2 Black wire
102
Ph3 180°C
104 Red/white wire
9
LSA 44.3
• Connection checks 3.4 - Commissioning
Electrical installations must comply with

the current legislation in force in the The machine can only be started up and
country of use. used if the installation is in accordance
Check that: with the regulations and instructions
- The residual circuit-breaker conforms to
legislation on protection of personnel, in defined in this manual.
force in the country of use, and has been The machine is tested and set up at the
correctly installed on the alternator power factory. When first used with no load, make
output as close as possible to the alternator. sure that the drive speed is correct and
(In this case, disconnect the wire of the stable (see the nameplate). With the
interference suppression module linking the
neutral). regreasable bearing option, we recommend
- Any protection devices in place have not greasing the bearings at the time of
been tripped. commissioning (see section 4.3).
- If there is an external AVR, the connections On application of the load, the machine
between the alternator and the cabinet are should achieve its rated speed and voltage;
made in accordance with the connection however, in the event of abnormal operation,
diagram. the machine setting can be altered (follow
- There is no short-circuit phase-phase or the adjustment procedure in section 3.5). If
phase-neutral between the alternator output the machine still operates incorrectly, the
terminals and the generator set control
cabinet (part of the circuit not protected by cause of the malfunction must be located
circuitbreakers or relays in the cabinet). (see section 4.5).
- The machine should be connected with the
busbar separating the terminals as shown in 3.5 - Setting up
the terminal connection diagram.
- The alternator earth terminal inside the The various adjustments during tests
terminal box is connected to the electrical must be made by a qualified engineer.
earth circuit Ensure that the drive speed specified on
- The earth terminal (ref 28) is connected to the nameplate is reached before
the frame. commencing adjustment.
The connections inside the terminal box
must never be subjected to stress due to After operational testing, replace all
cables connected by the user. access panels or covers.
The AVR is used to make any adjustments
to the machine.
10
LSA 44.3
4 - SERVICING - MAINTENANCE WARNING
4.1 - Safety measures Do not use: trichlorethylene, perchlo-
Servicing or troubleshooting must be
rethylene, trichloroethane or any alkaline
carried out strictly in accordance with
products.
instructions so as to avoid the risk of
accidents and to maintain the machine in
its original state.
These operations must be performed at a
cleaning station, equipped with a
vacuum system that collects and flushes
All such operations performed on the out the products used.
alternator should be undertaken by
The insulating components and the
personnel trained in the commissioning,
impregnation system are not at risk of
servicing and maintenance of electrical
damage from solvents. Avoid letting the
and mechanical components, who must
wear personal protective equipment cleaning product run into the slots.
appropriate for mechanical and electrical Apply the product with a brush, sponging
hazards. frequently to avoid accumulation in the
housing. Dry the winding with a dry cloth. Let
Before any intervention on the machine,
ensure that it cannot be started by a manual any traces evaporate before reassembling
or automatic system and that you have the machine.
understood the operating principles of the • Mechanical servicing
system.
WARNING
Cleaning the machine using water or a
highpressure washer is strictly prohi-
Warning : During and after running, the
bited. Any problems arising from such
alternator will reach temperatures hot
treatment are not covered by our
enough to cause injury, such as burns.
warranty.
Degreasing: Use a brush and detergent
4.2 - Routine maintenance (suitable for paintwork).
• Checks after start-up Dusting: Use an air gun.
After approximately 20 hours of operation, If the machine is fitted with air inlet and outlet
check that all fixing screws on the machine filters, the maintenance personnel should
are still tight, plus the general state of the clean them routinely at regular intervals. In
machine and the various electrical the case of dry dust, the filter can be cleaned
connections in the installation. using compressed air and/or replaced if it is
clogged.
• Electrical servicing
After cleaning the alternator, it is essential to
Commercially-available volatile degreasing
check the winding insulation (see sections
agents can be used.
3.2 and 4.5).
11
LSA 44.3
4.3 - Bearings
The bearings are permanently greased Approximate life of the grease (depending on use) = 20,000
hours or 3 years.
4.4 - Mechanical defects

Fault Action
Excessive overheating of one or - If the bearing has turned blue or if the grease has turned
both bearings black, change the bearing.
Bearing (bearing temperature 80°C above - Bearing not fully locked (abnormal play in the bearing cage)
the ambient temperature) - End shields incorrectly aligned
- Air flow (inlet-outlet) partially clogged or hot air is being
Excessive overheating of recycled from the alternator or engine
Abnormal alternator frame (more than - Alternator operating at too high a voltage (>105% of Un on
temperature 40° C above the ambient load)
temperature) - Alternator overloaded
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibrations - Rotor balancing fault (Engine - Alternator)
Excessive vibration and humming - Phase imbalance
noise coming from the machine - Stator short-circuit
- System short-circuit
- Misparalleling
Alternator damaged by a Possible consequences
Abnormal - Broken or damaged coupling
significant impact, followed by
noise - Broken or bent shaft end
humming and vibration
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR, surge suppressor
12
LSA 44.3
4.5 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and
its voltage is still correct - Lack of residual magnetism
when
the battery is removed
Connect a new
battery of 4 to 12 The alternator builds up but
No voltage volts to terminals its voltage - Check the connection of the voltage reference
at no load on E- and E+, does not reach the rated to the AVR
start-up respecting the value when - Faulty diodes
polarity, for 2 to 3 the battery is removed - Armature short-circuit
seconds
The alternator builds up but -- Faulty AVR
its voltage disappears when - Field windings open circuit (check winding)
Revolving field coil open circuit (check the
the battery is removed resistance)
Check the AVR connections (AVR may be faulty)
- Field windings short-circuited
Correct speed - Rotating diodes burnt out
Voltage too Check the drive - Revolving field coil short-circuited
low speed - Check the resistance
Increase the drive speed (do not touch the AVR
Speed too low voltage pot. (P2) before running at the correct
speed)
Voltage too Adjust AVR voltage Adjustment ineffective Faulty AVR
high potentiometer
- Check the speed: possibility of cyclic
Adjust the If no effect: try normal or fast irregularity
Voltage AVR stability stability - Loose connections
oscillations potentiometer modes (ST2) - Faulty AVR
- Speed too low when on load (or AVR LAM set
too high)
Voltage between E+ and E-
(DC)
Voltage SHUNT < 20V - AREP / PMG - Check the speed (or AVR LAM set too high)
correct at no Run at no load and < 10V
load and too check the voltage
low when on between E+ and
E- on the AVR Voltage between E+ and E- -- Faulty rotating diodes
load SHUNT > 30V - AREP / PMG Short-circuit in the revolving field coil. Check
the resistance.
> 15V - Faulty exciter armature. Check the resistance.
Check the AVR,
the - Exciter winding open circuit
Voltage surge suppressor, - Faulty exciter armature
disappears the rotating The voltage does not return - Faulty AVR
during diodes, and to the rated value - Revolving field coil open circuit or short-
operation replace any circuited
defective
components
13
LSA 44.3
• Checking the winding Assembly A: Connect a 12 V battery in
You can check the winding insulation by series with a rheostat of approximately
performing a high voltage test. In this case, 50 ohms - 300 W and a diode on both exciter
you must disconnect all AVR wires. field wires (5+) and (6-).
ASSEMBLY A
WARNING 6 - Field 5+
Damage caused to the AVR in such Rh. 50 -300W
1A diode
conditions is not covered by our
warranty.
+
4.5.2 - Checking the diode bridge -
A diode in good working order should allow
the current to flow only in the anode-to- 12V battery
cathode direction.
+ -
Anode Cathode Assembly B: Connect a “Variac” variable
+ -
+ -
power supply and a diode bridge on both
exciter field wires (5+) and (6-).
Both these systems should have
A C
A C characteristics which are compatible with
the field excitation power of the machine
(see the nameplate).
3) Run the unit at its rated speed.
4) Gradually increase the exciter field
current by adjusting the rheostat or the
variac and measure the output voltages on
L1 - L2 - L3, checking the excitation voltage
and current at no load (see the machine
nameplate or ask for the factory test report).
When the output voltage is at its rated value
and balanced within 1% for the rated
excitation level, the machine is in good
• Checking the windings and rotating working order. The fault therefore comes
diodes using separate excitation from the AVR or its associated wiring (ie.
sensing, auxiliary windings).
ASSEMBLY B
6 - Field 5+
During this procedure, make sure that 40

50 60 +
the alternator is disconnected from any
30
70
1A diode
20
80
external load and inspect the terminal

10
90
box to check that the connections are

0 100
fully tightened. - DC
Variac AC 12V
1) Stop the unit, disconnect and isolate the 220V
AVR wires.
2) There are two ways of creating an
assembly with separate excitation.
14
LSA 44.3
4.6 - Dismantling, reassembly - Refit the modules.
- Refit the air intake grille [51].
WARNING
• Access to connections and the
During the warranty period, this operation regulation system
should only be carried out in an approved The terminals are accessed directly by
workshop or in our factory, otherwise the removing the terminal box lid [48]. To access
warranty may be invalidated. the AVR adjustment potentiometers, the
Whilst being handled, the machine side plate [59] should be removed.
should remain horizontal (rotor not
locked when moved). Check how much • Replacing the NDE bearing on single-
the machine weighs before choosing the bearing machines
lifting method. - Dismantling
- Remove the terminal box lid [48].
- Unscrew the fixing clamps on the power
output cables, remove the connector from
the exciter and the R 791 module.
- Remove the 4 nuts on the tie rods.
- Remove the NDE shield [36] using a puller:
eg. U.32 - 350 (FACOM).
- Remove the antifriction bearing [70] using
a screw puller.
• Tools required
To fully dismantle the machine, we
recommend using the tools listed below: - Reassembly
- 1 ratchet spanner + extension - Heat the inner slipring of a new bearing by
- 1 torque wrench induction or in a drying oven at 80°C (do not
- 1 set of flat spanners: 7, 8, 10, 12 mm use an oil-bath) and fit it to the machine.
- 1 socket set: 8, 10, 13, 16, 18, 21, 22, - Place the preloading wavy washer [79] in
24 mm the shield and fit a new O ring seal [349].
- 1 Allen key: size 5 (eg. Facom: ET5), size 6 Refit the NDE shield and pass the bundle of
(ET6), size 10 (ET10, size 14 (ET14) wires between the top bars of the shield.
- 1 T20 and T30 TORX bit - Refit the fixing clamps on the cables, the
- 1 puller (U35)/(U32/350) R 791 module and the exciter connector.
- Replace the terminal box lid [48] and also
• Screw tightening torque the earth continuity screw [29].
See section 5.4.
• Access to diodes
- Remove the air intake grille [51].
- Check all 3 modules using an ohmmeter or
a battery lamp.
15
LSA 44.3
• Accessing the main field and stator
- Dismantling
NDE shield Follow the procedure for dismantling the
Rotor bearings (see section 4.6).
Screw rod - Remove the coupling disc (single-bearing
alternator) or the DE shield (twin-bearing
alternator) and insert a tube of the
corresponding diameter on the shaft end.
- Rest the rotor on one of its poles, then slide
it out. Use the tube as a lever arm to assist
dismantling.
- After extraction of the rotor, be careful not
to damage the fan or dismantle it.
- Remove the revolving field coil (rotor) and
place on special V-shaped supports.
NOTE: If intervention is required on the

revolving field coil (rewinding,
WARNING replacement of components), the rotor
assembly must be rebalanced.
When dismantling the shields, you will
need to change the antifriction bearings,
- Reassembling the revolving field coil
the “O” ring seal, the preloading (wavy)
washer and adhesive paste. - Follow the dismantling procedure in reverse
order.
Take care not to knock the windings when
• Replacing the DE bearing
refitting the rotor in the stator.
- Dismantling - Refit the fan with its fixing screws on the
- Uncouple the alternator from the prime hub.
mover.
- Remove the 8 assembly screws. Follow the procedure for refitting the
bearings (see section 4.6).
- Remove the DE shield [32].
- Remove the NDE shield.
- Remove both antifriction bearings [60] and
[70] using a puller with a central screw.
- Reassembly
- Heat the new bearings by induction or in a
drying oven at 80°C (do not use an oil-bath)
and fit them to the machine.
- Check that both the preloading wavy washer
[79] and the new O ring seal [349] have been
fitted on the NDE shield [36].
Refit the NDE shield and pass the bundle of
wires between the top bars of the shield.
- Refit the DE shield [32] and tighten the
8 fixing screws.
- Check that the alternator assembly is
correctly mounted and that all screws are
tightened.
16
LSA 44.3
4.7 - Installation and maintenance of • SHUNT excitation current - 400 V - 50 Hz
the PMG “i exc”: excitation current of the exciter field
The PMG reference is PMG 7. See the PMG Type At no load On load
maintenance manual, ref: 4211. S2 0.74 2.03
S3 0.74 2.27
S4 0.71 2.06
S5 0.71 2.24
M6 0.65 2.39
M8 0.62 2.30
After operational testing, it is essential to L10 0.66 2.36
replace all access panels or covers. Don’t
forget the screw [29] earth continuity.
• AREP resistances at 20°C (Ω)
Exciter
Type L/N stator Rotor Armature
field
4.8 - Table of characteristics S2 0.0503 2.354 7.262 0.422
Table of average values: S3 0.0503 2.354 7.262 0.422
Alternator - 2 and 4 poles - 50 Hz/60 Hz -
S4 0.039 2.578 8.068 0.459
Winding n° 6 and M or M1 connected in
S5 0.039 2.578 8.068 0.459
dedicated single-phase. (400 V for the
excitation values). M6 0.0335 2.805 8.068 0.459
The voltage and current values are given for M8 0.0287 3.032 8.068 0.459
no-load operation and operation at rated L10 0.0236 3.291 8.068 0.459
load with separate field excitation. All values
are given at ± 10% (for exact values, consult • AREP resistances at 20°C (Ω) on the
the test report) and are subject to change auxiliary windings
without prior warning. For 60 Hz machines,
the resistance values are the same and the
excitation current «i exc» is approximately 5 Type Winding X1, X2 Winding Z1, Z2
to 10% weaker.
S2 0.341 0.627
S3 0.341 0.627
• SHUNT resistances at 20°C (Ω)
S4 0.304 0.571
Exciter S5 0.304 0.571
field M6 0.288 0.575
S2 0.0503 2.354 11.647 0.422 M8 0.271 0.559
S3 0.0503 2.354 11.647 0.422 L10 0.247 0.524
S4 0.039 2.578 12.941 0.459
S5 0.039 2.578 12.941 0.459
M6 0.0335 2.805 12.941 0.459 • AREP excitation current - 400 V - 50 Hz
M8 0.0287 3.032 12.941 0.459 “i exc”: excitation current of the exciter field.
L10 0.0236 3.291 12.941 0.459 Type At no load On load
S2 0.96 2.61
S3 0.96 2.92
S4 0.92 2.65
S5 0.92 2.89
M6 0.83 3.08
M8 0.8 2.97
L10 0.85 3.05
17
LSA 44.3
• Voltage on the auxiliary windings i exc excitation current (A) - 240 V - 60 Hz
“i exc”: excitation current of the exciter field.
Type Winding X1, X2 Winding Z1, Z2 Type At no load On load
50 Hz 55 ... 59 11 ... 16 S2 0.8 1.7
60 Hz 66 ... 71 14 ... 19 S3 0.9 1.8
S4 1 1.9
S5 1 2
• 4P dedicated single-phase - Winding M M6 0.6 1.7
SHUNT excitation (50 Hz) L10 0.7 1.5
Resistances at 20°C (Ω)
Exciter • Table of weights
Type L/N stator Rotor Armature (values given for information only)
field
S2 0.012 2.354 11.647 0.422 Type Total weight (kg) Rotor (kg)
S3 0.012 2.354 11.647 0.422
S2 301 120
S4 0.0093 2.578 12.941 0.459
S3 301 120
S5 0.0093 2.578 12.941 0.459
S4 338 136
M8 0.0068 3.032 12.941 0.459
S5 338 136
i exc excitation current (A) - 240 V - 60 Hz M6 374 150
“i exc”: excitation current of the exciter field. M8 404 162
L10 439 178
Type At no load On load
S2 0.7 1.3
S3 0.7 1.5
S4 0.7 1.3
S5 0.7 1.5
M8 0.6 1.3
• 4P dedicated single-phase - After operational testing, it is essential

Winding M1 SHUNT excitation (60 Hz) to replace all access panels or covers.
Resistances at 20°C (Ω)
Exciter
field
S2 0.0084 2.354 11.647 0.422
S3 0.0084 2.354 11.647 0.422
S4 0.0059 2.578 12.941 0.459
S5 0.0059 2.578 12.941 0.459
M6 0.0053 2.805 12.941 0.459
L10 0.0042 3.291 12.941 0.459
18
LSA 44.3
5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an
option. After operational testing, it is essential
They contain the following items: to replace all access panels or covers.
SHUNT repair kit ALT 44.3 KS 001
R 250 voltage regulator -
Diode set assembly -
- 5.3 - Accessories
AREP repair kit ALT 44.3 KS 002 • Space heater for use when stopped
R 450 voltage regulator -
Diode set assembly - The space heater must run as soon as the
- alternator stops. It is installed at the rear of
the machine. Its standard power is 250W
Single-bearing kit ALT 44.3 KB 001
with 220V or 250W with 110V on request.
NDE bearing -
‘O' ring seal -
Preloading wavy washer -
Twin bearing kit ALT 44.3 KB 002
NDE bearing -
DE bearing - Warning: the power supply is present
‘O' ring seal - when the machine has stopped.
Preloading wavy washer -
• Temperature sensors with thermistors
(PTC)
5.2 - Technical support service These are thermistor triplets with a positive
Our technical support service will be pleased temperature coefficient installed in the
to provide any additional information you stator winding (1 per phase). There can be a
may require. maximum of 2 triplets in the winding (at 2
levels: warning and trip) and 1 or 2
When ordering spare parts, you should thermistors in the shields.
indicate the complete machine type, its These sensors must be linked to adapted
serial number and the information given on sensing relays (supplied optionally).
the nameplate. Cold resistance of cold thermistor sensors:
100 to 250 Ω per sensor.
Address your enquiry to your usual contact.
Part numbers should be identified from the
exploded views and their description from
the parts list.
Our extensive network of service centres
can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacturer spare parts.
In the event of failure to comply with this
advice, the manufacturer cannot be held
responsible for any damage.
19
LSA 44.3
5.4 - Exploded view, parts list and tightening torque
• Single-bearing
20
LSA 44.3
• Double-bearing
21
LSA 44.3
Screw Torque Screw Torque

Ref. Qty Description Ref. Qty Description
Ø N.m Ø N.m
1 1 Stator assembly - - 62 2 Fixing screw M6 8.3
4 1 Rotor assembly - - 67 1 Circlip - -
15 1 Fan - - 68 1 Inner bearing retainer - -
16 6 Fixing screw M6 5 70 1 NDE bearing - -
22 1 Key - - 79 1 Washer preloading - -
28 1 Earth terminal M6 10 90 1 Exciter field - -
Earth continuity
29 1 M6 10 91 4 Fixing screws exciter M6 10
screw
30 1 DE shield - - 100 1 Exciter armature - -
31 8 Fixing screw M12 69 107 1 Diode module support M5 6
32 1 S.A.E. washer - - 124 1 Terminal plate M6 5
Voltage regulator
33 2 Air outlet grille M6 5 198 1 M5 3.6
(AVR)
Interference
36 1 NDE shield - - 199 1 - -
suppression module
37 4 Tie rod M14 90 320 1 Sleeve - -
41 2 NDE or DE cover - - 322 2 Coupling disc - -
48 1 Top cover - - 323 8 Fixing screw M16 320
49 - Fixing screw M5 5 325 - Spacer shim - -
Diode module
51 2 Air intake grille M5 3.6 343 3 M5 3
assembly
59 2 Side cover - - 347 1 Surge suppressor M6 4
60 1 DE bearing - - 349 1 ‘O' ring seal - -
22
LSA 44.3
Disposal and recycling instructions The oil and grease from the lubrication
We are committed to limit the environmental system should be considered as a hazardous
impact of our activity. We continuously waste and has to be handled according to
survey our production processes, material local legislation.
sourcing and products design to improve
recyclability and diminish our footprint.
These instructions are for information
purposes only. It is the user responsibility to
comply with local legislation regarding
product disposal and recycling.
Recyclable materials
Our alternators are mainly built out of iron,
steel and copper materials, which can be
reclaimed for recycling purposes.
These materials can be reclaimed through a
combination of manual dismantling,
mechanical separation and melting
processes. Our technical support depar-
tment can provide detailed directions on
products dismounting upon request.
Waste & hazardous materials

The following components and materials
need a special treatment and need to be
separated from the alternator before the
recycling process:
- electronic materials found in the terminal
box, including the Automatic Voltage
Regulator (198), Current Transformers
(176), interference suppression module
(199) and other semi-conductors.
- diode Bridge (343) and Surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
These components are usually marked with
plastic type information.
All materials listed above need special
treatment to separate waste from
reclaimable material and should be handed
to specialized disposal companies.
23
LSA 44.3
24
LSA 44.3
Electric Power Generation
Declaration of EC compliance and incorporation
This Declaration applies to the generators designed to be incorporated into machines complying with the
Machinery Directive Nr 2006/42/EC dated 17 May 2006.
MOTEURS LEROY-SOMER MLS HOLICE STLO.SRO MOTEURS LEROY-SOMER DIVISION LEROY-SOMER

Boulevard Marcellin Leroy SLADKOVSKEHO 43 1, rue de la Burelle STREET EMERSON
16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517 Nr4 Parcul Industrial Tetarom 2
FRANCE CZECH REPUBLIC 45800 ST JEAN DE BRAYE 4000641 CLUJ NAPOCA
FRANCE ROMANIA
Declares hereby that the electric generators of the types:
LSA40 - LSA42.3 - LSA44.2 - LSA44.3 - LSA46.2 - LSA46.3 - LSA47.2 - LSA49.1 - LSA49.3 - LSA50.1 -
LSA50.2 - LSA51.2 - LSA52.2 - LSA52.3 - LSA53.1 - LSA53 - LSA53.2 - LSA54 - LSA54.2 - TAL040 - TAL042 -
TAL044, as well as their derivatives, manufactured by Leroy-Somer or on Leroy-Somer's behalf, comply with the
following International Standards and Directive:
- EN and IEC 60034-1, 60034-5 and 60034-22

- ISO 8528-3 “Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets”
- Low Voltage Directive Nr 2014/35/UE dated 26 February 2014
Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Directives:
- Machinery Directive Nr 2006/42/EC dated 17 May 2006

- EMC Directive Nr 2014/30/UE dated 26 February 2014, as intrinsic levels of emissions and immunity
are concerned
WARNING:
The here mentioned generators should not be commissioned until the corresponding Gen-Sets have been
declared in compliance with the Directives Nr 2006/42/EC and 2014/30/UE, as well as with the other relevant
Directives.
Leroy-Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant
information on the generator.
Technical Managers
J.P. CHARPENTIER - Y. MESSIN
4152 en - 2016.05 / k
The contractual EC Declaration of Conformity and Incorporation can be obtained from your contact on
request.
25
LSA 44.3
26
Service & Support
Our worldwide service network of over 80 facilities is at your service.

This local presence is our guarantee for fast and efficient repair, support and
maintenance services.
Trust your alternator maintenance and support to electric power generation experts.
Our field personnel are 100% qualified and fully trained to operate in all environments
and on all machine types.
We know alternators operation inside out, providing the best value service to
optimize your cost of ownership.
Where we can help:
Conception
•Consulting & specification
•Maintenance
contracts
Life Extension
•Remanufacturing Start-up
•System upgrade
•Commissioning
•Training
Optimization
•Monitoring Operation
•System audit •Genuine spare parts
•Repair services
Contact us:
Americas: +1 (507) 625 4011
Europe & International: +33 238 609 908
Asia Pacific: +65 6263 6334
China: +86 591 88373036
India: +91 806 726 4867
Scan the code or go to:
service.epg@leroy-somer.com www.lrsm.co/support
www.emersonindustrial.com
www.emerson.com/epg
5056 en - 2016.06 / e
X2 Z1 X1 Z2 E+ E- 0V 110 220 380
R 438
A.V.R.
R 438
Installation and maintenance
Electric Power Generation Installation and maintenance 3971 en - 2015.11 / h
R 438
A.V.R.
This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.
SAFETY MEASURES
Before using your machine for the first time,

it is important to read the whole of this instal-
lation and maintenance manual. All servicing or repair operations perfor-
med on the AVR should be undertaken by
All necessary operations and interventions personnel trained in the commissioning,
on this machine must be performed by a servicing and main-tenance of electrical
qualified technician. and mechanical components.
Our technical support service will be pleased

to provide any additional infor-mation you
may require.
The various operations described in this When the generator is driven at a

manual are accompanied by recommen-da- frequency less than 28 Hz for more than
tions or symbols to alert the user to potential 30 seconds with an analogic regulator,
risks of accidents. It is vital that you unders- the AC power must be disconnected.
tand and take notice of the following warning
symbols.
WARNING
This A.V.R. can be incorporated in a ma-
WARNING chine marked C.E.
This manual is be given to the end user.
Warning symbol for an operation capable
of damaging or destroying the machine
or surrounding equipment. © - We reserve the right to modify the cha-
racteristics of its products at any time in or-
der to incorporate the latest technological
developments. The informa-tion contained
in this document may therefore be changed
without notice.
Warning symbol for general danger to
personnel. This document may not be reproduced in
any form without prior authorization.
All brands and models have been registered
and patents applied for.
Warning symbol for electrical danger to

personnel.
2
R 438
A.V.R.
CONTENTS
1 - SUPPLY...............................................................................................................................4
1.1 - AREP excitation system................................................................................................4

1.2 - PMG excitation system..................................................................................................5
1.3 - SHUNT or separate excitation system...........................................................................5
2 - R438 A.V.R.......................................................................................................................... 6
2.1 - Characteristics.............................................................................................................. 6
2.2 - Frequency compared with voltage (without LAM)..........................................................6
2.3 - LAM (Load Acceptance Module) characteristics...........................................................6
2.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only)........... 7
2.5 - R438 A.V.R. options......................................................................................................8
3 - INSTALLATION - COMMISSIONING..................................................................................9
3.1 - Electrical checks on the AVR.........................................................................................9

3.2 - Settings.........................................................................................................................9
3.3 - Electrical faults............................................................................................................ 12
4 - SPARE PARTS.................................................................................................................. 13
4.1 - Designation................................................................................................................. 13
4.2 - Technical support service............................................................................................13

3
R 438
A.V.R.
1 - SUPPLY to that of the alternator (characteristic

1.1 - AREP excitation system Shunt), the second has a voltage in propor-
tion to the stator current (compound charac-
For both AREP & PMG excitation systems, teristic: Booster effect).
the alternator voltage regulator is the R438. The power supply voltage is rectified and
With AREP excitation, the R438 electronic filtered before being used by the AVR moni-
AVR is powered by two auxiliary windings toring transistor. This principle ensures that
which are independent of the voltage match regulation is not affected by distortions ge-
circuit. nerated by the load.
The first winding has a voltage in proportion
STATOR : 6 wires (marked T1 to T6)

MAIN FIELD STATOR : 12 wires (marked T1 to T12)
AREP SYSTEM Aux. windings
T1 T7 T2 T8 T3 T9
Varistor
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
10 Yellow
11 Red
12 Black
9 Green
according voltage
140 mm
X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

F1 Slow fuse
125 mm
115 x 100 mm
250V 8 A
ST5
P1
with LAM without LAM Quad
droop
ST3 AREP
Frequency 50Hz 60Hz ST9
R 438
PMG
ST10 T.I. S2 P2
LAM 13 % 25 %
Option
S1 Ph.1
P1
Excitation
P5 ceiling
ST4 Option
ST11 open
knee-point: 65 Hz
External potentiometer
for adjusting the voltage
ST2 Response
time
normal
fast ST1 P2 Option
Single- Voltage R731 3-ph. detection

P3 Stability phase
detection in 3-ph. detection ST1 open
4
R 438
A.V.R.
1.2 - PMG excitation system alternator winding. As a result the machine

has a short-circuit current capacity and
This excitation system consists of a «PMG»
good immunity to distortions generated by
(permanent magnet generator). This is fitted
the load.
at the rear of the machine and connected to
The AVR monitors and corrects the alterna-
the R438 AVR.
tor output voltage by adjusting the excitation
The PMG supplies the AVR with constant
current.
voltage which is independent of the main
- 50/60 Hz selection via the ST3 jumper.
STATOR : 6 wires (marked T1 to T6)
MAIN FIELD STATOR : 12 wires (marked T1 to T12)
PMG SYSTEM
T1 T7 T2 T8 T3 T9
Varistor
PMG
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
according voltage
14 15 16
140 mm
X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

F1 Slow fuse
125 mm
250V 8 A 115 x 100 mm
ST5
P1
with LAM without LAM Quad
droop
ST3
ST9
AREP
Frequency 50Hz 60Hz PMG
R 438
ST10 T.I. S2 P2
LAM 13 % 25 %
Option
Ph.1
S1
P1
P5
Excitation
ceiling
ST4 Option
ST11 open
knee-point: 65 Hz
External potentiometer
for adjusting the voltage
ST2
normal
ST1
Response
time fast P2 Option
Single- Voltage R731 3-ph. detection

P3 Stability phase
detection in 3-ph. detection ST1 open
1.3 - SHUNT or separate excitation system

A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48V battery).
5
R 438
A.V.R.
2 - R438 A.V.R. 2.1.2 - Setting potentiometers

2.1 - Characteristics function
- Storage : -55°C ; +85°C Delivrery
Pot. Function
- Operation : -40°C ; +70°C position
- Standard power supply: AREP or PMG. 0 P1 Quadrature droop ; // operation with C.T.
- Rated overload current: 8 A - 10 s 400V P2 Voltage
- Electronic protection (overload, short-cir-
Centre P3 Stability
cuit on opening of voltage sensing circuit):
excitation overload current for 10 seconds Maxi P5 Excitation current ceiling
then return to approximately 1A. The alter-
nator must be stopped (or the power swit-
ched off) in order to reset the protection. 2.2 - Frequency compared with
- Fuse : F1 on X1, X2. 8A ; slow - 250V voltage (without LAM)
- Voltage sensing : 5 VA isolated via trans-
former ; Voltage Bend 57.5 Hz
• 0-110 V terminals = 95 to 140 V, 100 %
48 Hz
• 0-220 V terminals = 170 to 260 V, U/UN 50 Hz

• 0-380 V terminals = 340 to 520 V. 60 Hz
- Voltage regulation ± 0.5%.
- Normal or rapid response time via ST2 Frequency
jumper (see below). 50 Hz 60 Hz Hz
- Voltage adjustment via potentiometer P2.
other voltages via adapter transformer
- Current sensing (parallel operation): C.T. 2.3 - LAM (Load Acceptance
2.5 VA cl1, secondary 1 A (optional). Module) characteristics
- Quadrature droop adjustment via potentio- 2.3.1 - Voltage drop
meter P1.
- Max. excitation current adjustment via P5 The LAM system is integrated in the R 438
(see below). AVR as standard.
Role of the «LAM» (Load Adjustment Mo-
2.1.1 - Configuration jumpers function dule) :
On application of a load, the rotation speed
Delivrery
Pot. config. Position Function
of the generator set decreases. When it
Open Closed passes below the preset frequency thres-
ST1 3-ph. Mono
Open for module hold, the LAM causes the voltage to drop by
installation tri detection approximately 13% or 25% and consequent-
ST2 Fast Normal Response time
ly the amount of active load applied is re-
ST3 50 ou 60 Hz Frequency selection
duced by approximately 25% to 50%, until
External
ST4 poten- Without Potentiometer the speed reaches its rated value again.
tiometer Hence the LAM can be used either to reduce
ST5 Without With LAM the speed variation (frequency) and its dura-
Others
ST9
(PMG...)
AREP Supply tion for a given applied load, or to increase
LAM voltage drop the applied load possible for one speed va-
ST10 13% or 25%
amplitude riation (turbo-charged engine).
ST11 65 Hz
48 or U/f function bend To avoid voltage oscillations, the trip thres-
58 Hz position
hold for the LAM function should be set ap-
proximately 2 Hz below the lowest frequen-
cy in steady state.
6
R 438
A.V.R.
- LAM : action eliminated by cutting the ST5 2.4 - Typical effects of the LAM with
jumper. a diesel engine with or without a
Voltage LAM (U/F only)
Underspeed and LAM
ST5 disconnected
UN Voltage 2.4.1 - Voltage
P2
Transient voltage drop
U/f UN
0.85 UN LAM
0,9
(U/f)
48 or 57.5 Hz 50 or 60 Hz with without LAM
0 0,8
ST3 fC fN LAM
Time
0 1s 2s 3s
2.3.2 - Gradual voltage return function

2.4.2 - Frequency
During load impacts, the function helps the
genset to return to its rated speed faster Max speed drop with
thanks to a gradual increase in voltage ac- fN LAM
cording to the principle:

- If the speed drops between 46 and 50 Hz,
0,9
the rated voltage follows a fast gradient as it without
is restored. 0,8
LAM
Time
- If the speed drops below 46 Hz, since the
0 1s 2s 3s
engine needs more help, the voltage follows
a slow gradient as it returns to the reference
value.
2.4.3 - Power
LAM
U
Load on the
Drop N ≤ 46 Hz
shaft (kW)
Variation in the load

Drop N > 46 Hz
Time
0 Load shedding due to "LAM"
Time
0 1s 2s 3s
7
R 438
A.V.R.
2.5 - R438 A.V.R. options - Voltage control: with an isolated

D.C. current source applied to the terminals
- Current transformer for parallel operation used for the external potentiometer:
of ....../1A. 5 VA CL 1. • Internal impedance 1.5 kΩ.
• A variation of ± 0.5 V corresponds to a
- Remote voltage adjustment potentiometer: voltage adjustment of ± 10%.
470 Ω, 0.5 W min: adjustment range ± 5%
(range limited by internal voltage potentio-
meter P2). Remove ST4 to connect the po-
ten-tiometer. (A 1 kΩ potentiometer can also
be used to extend the adjustment range).
For wiring up the external potentiometer;

the “earth” wires must be isolated as
well as the potentiometer terminals
(wires at the same voltage as the power).
- R 731 external module: sensing of 3-phase

voltage 200 to 500 V, compatible with parallel
operation. Disconnect ST1 to connect the
module; set the voltage via the module po-
tentiometer.
- R 734 module: detection of 3-phase current

and voltage for parallel operation on unba-
lanced installations (imbalance > 15%).
- R 726 module: 3 functions (mounted exter-

nally).
P.F. regulation (2F) and voltage sensing cir-
cuit before paralleling (3 F).
8
R 438
A.V.R.
3 - INSTALLATION - COMMISSIONING a) Initial potentiometer settings (see table

3.1 - Electrical checks on the AVR below)
- Remote voltage adjustment potentiometer :
- Check that all connections have been centre (ST4 jumper removed).
made properly as shown in the attached
wiring diagram. Action Factory setting Pot.
- Check that the ST3 frequency selection
jumper is on the correct frequency setting. Voltage 400V - 50 Hz
(Input
- Check whether the ST4 jumper or the re- minimum fully anti-clockwise
0 - 380 V) P2
mote adjustment potentiometer have been
connected. Not set
- Optional operating modes. Stability
(centre position)
P3
• ST1 jumper : open to connect the R 731or
Voltage quadrature droop Not set
R 734 3-phase (// operation with C.T.) (fully anti-
sensing module. - 0 quadrature loop fully clockwise) P1
• ST2 jumper : open if rapid response time anti-clockwise.
used Excitation ceiling
• ST5 jumper : open to suppress the LAM Limit of excitation and 10 A
function. short-circuit current, maximum P5
minimum fully anti-clockwise.
3.2 - Settings
Stability adjustments in standalone
operation
b) Install a D.C. analogue voltmeter (needle
dial) cal. 50V on terminals E+, E- and an
A.C. voltmeter cal 300 - 500 or 1000V on the
The machine is tested and set at the fac- alternator output terminals.
tory. When first used with no load, make
sure that the drive speed is correct and c) Make sure that the ST3 jumper is positio-
stable (see the nameplate). After opera- ned on the desired frequency (50 or 60 Hz).
tional testing, replace all access panels
or covers. d) Voltage potentiometer P2 at minimum,
The only possible adjustments to the fully anti-clockwise.
machine should be made on the AVR.
e) Stability potentiometer P3 to around 1/3
of the anti-clockwise limit.
3.2.1 - R438 settings (AREP or PMG
system) f) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for 60 Hz.
WARNING g) Set the output voltage to the desired va-
lue using P2.
Before any intervention on the A.V.R.,
- Rated voltage UN for solo operation (eg.
make sure that the ST9 jumper is closed 400 V)
with AREP excitation and disconnected - Or UN + 2 to 4% for parallel operation with
with PMG or SHUNT or separate excita- C.T. (eg. 410 V)
tion. If the voltage oscillates, use P3 to make
adjustments (try both directions) observing
the voltage between E+ and E- (approx. 10V
D.C.).
9
R 438
A.V.R.
The best response times are obtained at the 3.2.2 - Max. excitation setting (excitation
limit of the instability. If no stable position ceiling)
can be obtained, try disconnecting or repla-
Depending on
cing the ST2 jumper (normal/fast). Max. excitation the mains frequency
Main
(50/60 Hz supply)
h) Check LAM operation : ST5 closed. ST3

48 V
X2
P5
i) Vary the frequency (speed) around 48 or 50Hz 60Hz Z1
A
58 Hz according to the operating frequency, X1
Z2
and check the change in voltage from that Field
observed previously (~ 15%). P3 R 438 E+ – + ~ 5 ohms
E- A
10 A CC/DC
0V
j) Readjust the speed of the unit to its rated 110 V
no-load value. P2
ST4 220 V
Adjustments in parallel operation 380 V
110/220/380 V D
Before any intervention on the alterna- Voltage

tor, make sure that the speed droop is
identical for all engines. Static adjustment of the current limit,
potentiometer P5 (factory setting: 7.5 A,
k) Preset for parallel operation (with C.T. fuse rating: 8 A - 10 seconds).
connected to S1, S2) The maximum factory setting corresponds
- Potentiometer P1 (quadrature droop) in to that of the excitation current required to
centre position. obtain a 3-phase short-circuit current of
Apply the rated load (P.F. = 0.8 inductive).
approximately 3 IN at 50 Hz for industrial
The voltage should drop by 2 to 3%. If it in-
power, unless otherwise specified(*).
creases, check that V and W and also S1
and S2 have not been reversed. A static method can be used to reduce this
value or adapt the Isc to the actual operating
l) The no-load voltages should be identical power (derated machine), which is safer for
for all the alternators intended to run in pa- the alternator and the installation.
rallel. Disconnect power supply wires X1,X2 and
- Couple the machines in parallel. Z1,Z2 and the voltage reference
- By adjusting the speed, try to obtain 0 KW (0‑110V-220V-380V) on the alternator.
power exchange.
- By altering the voltage setting P2 on one of Connect the mains power supply using a
the machines, try to cancel (or minimise) the transformer (200-240V) as indicated
current circulating between the machines. (X1,X2 : 48V). Install a 10A D.C. ammeter
- From now on, do not touch the voltage set- in series with the exciter field. Turn P5 fully
tings. anti-clockwise and activate the power
supply. If there is no output current from the
m) Apply the available load (the setting is only AVR, turn potentiometer P2 (voltage)
correct if a reactive load is available) clockwise until the ammeter indicates a
- By altering the speed, match the kW (or di- stable current. Switch the power supply off,
vide the rated power of the units proportionally) then on again, turn P5 clockwise until the
- By altering the quadrature droop potentiome- required max. current is obtained (no more
ter P1, match or divide the currents. than 8 A).
10
R 438
A.V.R.
Checking the internal protection : The exciter is switched off by disconnecting

Open switch (D) : the excitation current the AVR power supply (1 wire on each auxi-
should increase to its preset ceiling, remain liary winding) - contact rating 16 A - 250V
at that level for ≥ 10 seconds and then drop A.C.
to < 1A. Connection is identical for resetting the AVR
To reset, switch off the power supply by ope- internal protection.
ning switch (A).
Note: After setting the excitation ceiling as
described, adjust the voltage again (see
section 2.1.1)
(*) In some countries it is a legal requirement
to have a short‑circuit current of 3 In, so as
to offer selective protection. In case of using the de-excitation, pro-
vide a forced excitation.
3.2.3 - Special type of use
3.2.3.3 - R438 field forcing
WARNING (400V - 10A) Diode
X2
Excitation circuit E+, E- must not be left Z1 t - +
open when the machine is running : AVR X1 Battery (B Volt)
damage will occur. Z2
E+
3.2.3.1 - R438 field weakening (SHUNT) E-
Exciter field
X2 Forced excitation
Z1 B Volt
X1 t
Z2 Time
E+
E-
Applications B volts Time t
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2). Guaranteed voltage build-up 12 (1A) 1-2 s
Contact rating 16 A - 250V A.C. Parallel operation, de-energized 12 (1A) 1-2 s
3.2.3.2 - R438 field weakening (AREP/ Parallel operation, at standstill 12 (1A) 5 - 10 s

PMG) Frequency starting 12 (1A) 5 - 10 s
Sustained voltage on overload 12 (1A) 5 - 10 s

X2
Z1
X1
Z2
E+
E-
11
R 438
A.V.R.
3.3 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its
voltage is still correct when the - Lack of residual magnetism
battery is removed.
Connect a new battery The alternator builds up but its - Check the connection of the voltage
No voltage at of 4 to 12 volts to voltage does not reach the rated reference to the AVR
no load on terminals E- and E+, value when the battery is - Faulty diodes
start-up respecting the polarity, removed. - Armature short-circuit
for 2 to 3 seconds - Faulty AVR
The alternator builds up but its
- Field windings disconnected
voltage disappears when the
- Main field winding open circuit - check the
battery is removed
resistance
Check the AVR connections (AVR may be
faulty)
- Field windings short-circuited
Correct speed
- Rotating diodes burnt out
Voltage too - Main field winding short-circuited - Check
Check the drive speed
low the resistance
Increase the drive speed

(Do not touch the AVR voltage pot. (P2)
Speed too low
before running at the correct speed.)
Voltage too Adjust AVR voltage
Adjustment ineffective Faulty AVR
high potentiometer
- Check the speed : possibility of cyclic
irregularity
Voltage Adjust AVR stability If no effect : try normal / fast - Loose connections
oscillations potentiometer recovery modes (ST2) - Faulty AVR
- Speed too low when on load (or U/F bend
set too high)
Voltage between E+ and E-
- Check the speed (or U/F bend set too
Voltage SHUNT < 20 V
Run at no load and high)
correct at no AREP / PMG < 10V
check the voltage
load and too - Faulty rotating diodes
between E+ and E- on Voltage between E+ and E-
low when on - Short-circuit in the main field. Check the
the AVR SHUNT > 30V
load (*) resistance
AREP / PMG > 15V
- Faulty exciter armature.
(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the
operating terminals
Check the AVR, the
Voltage - Exciter winding open circuit
surge suppressor, the
disappears The voltage does not return to the - Faulty exciter armature
rotating diodes, and
during rated value. - Faulty AVR
replace any defective
operation (**) - Main field open circuit or short-circuited
components
(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)
Warning : after operational testing,

replace all access panels or covers.
12
R 438
A.V.R.
4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R. R 438 AEM 110 RE 017
4.2 - Technical support service

Our technical support service will be happy
to provide any information you require.
When ordering spare parts, you should in

dicate the complete machine type, its serial
number and the information indicated on the
nameplate.
Part numbers should be identified from the

exploded views and their description in
the parts list.
Our extensive network of «service stations»

can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacture spare parts.
In the event of failure to comply with this ad
vice, the manufacturer cannot be held res
ponsible for any damage.
13
R 438
A.V.R.
14
R 438
A.V.R.
15
www.emersonindustrial.com
www.emerson.com/epg
3971 en - 2015.11 / h
Cover page
DBR order number : 161014

Name of client : Damen Shipyards
Reference : YN. 513510
Client P.O. : N417740
Package type : Generator set (Marine application)
This drawing remains the property of DBR in Sliedrecht and may without the written premission of the owner not be multiplied, be used for third parties, or be given to third parties for persual.
Operation : Auxiliary operation (parallel / constant speed)
Engine : Perkins 4.4TW2GM
Generator : Leroy Somer LSAM44.3M6
Power : 120kVA / 96,0kWe
Set output : 440/254Vac / 60Hz
Classification : Lloyds Register

Class number :
Notation : LMC-UMS
Tmpl. rev0
Drawing status* : As built Revision : 0

*
Preliminary : The drawings are still a subject to debate and not yet approved for building
For review by customer : The drawings are submitted to the customer
For review by class : The drawings are submitted to the class society
Approved : The drawings are approved for building
Workshop tested : The drawings are according to the system which is tested in the DBR test facility
22-6-2016
As built : The drawings are according to the commissioned system

Plotdate:
Lelystraat 53 - 3364 AH DBR order num ber : 161014 Engine : Perkins 4.4T W2G M Drawing status : As built Page size: Engineered by:
P.O . Box 1039 - 3360 BA A3
DBR
Drawing num ber : 21626 Generator : Leroy Som er LSAM 44.3M 6 Engineering date : 22-3-2016 JdJ
DOK.NR. D04-02/1
Sliedrecht - T he Netherlands
Nam e of client : Dam en Shipyards Power : 120kVA / 96,0kWe Revision : 0 Scale:
T el: +31(0)184 - 61 32 00 Page:
Reference : YN. 513510 Set output : 440/254Vac / 60Hz Revision date : 22-6-2016 N.A.
Generatorsets Fax: +31(0)184 - 61 26 54
1
www.dbr-bv.nl & info@dbr-bv.nl Client P.O. : N417740 Function : Location : Quantity: 2
List of documents (Index)
Page Function (=) Location (+) Description
1 Cover page
2 List of documents (Index)
10 List of revisions
11 General notes
12 Wire & cable coding
13 Alarm, Warning & Shutdown
21 =LCP LCP Outside View
22 =LCP LCP Inside View
30 =LCP 24Vdc & Starter
31 =LCP ID-DCU BI 1-7
32 =LCP ID-DCU BI 8-14
33 =LCP ID-DCU BO 1-7
34 =LCP ID-DCU BO 8-14
35 =LCP ID-DCU AIN 1-8 & RPM IN
36 =LCP ID-RPU (1)
37 =LCP ID-RPU (2)
38 =LCP Speed Controller
39 =LCP Outputs to External
100 List of cables
170 Cable terminal rows

Tmpl. rev0

22-6-2016
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P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
2
List of revisions
Revision date Revision nr. Drawn by Ordered by Checked by Page Description
22-03-2016 0 JdJ HR JdJ All For review.
Tmpl. rev0
22-6-2016
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P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
10
General notes
- Standard cable conduit.

- All cabling shall be halogen free low smoke.
- Wiring tagging (Click on) in panel on incoming & outgoing terminal strip.
- Skid & panel wiring according wire Coding.
- Skid cabling is type (Marine Approval LR)
* Helkama LKM-HF ( unarmoured power and control cable )
* Helkana RFA-HF ( screened instrumentation and communication cable )
-Comap ID-DCU, ID-RPU, (Controller, Redaundancy Protection unit,) covered by TA 06-20044(E1).
Tmpl. rev0
22-6-2016
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DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
11
Wire & cable coding
Description Wire color Color code Wire code Location Wire size Description Wire color Color code Wire code TAG Location Wire size
Neutral Pick-Up (Shielded twisted pair)
Protection earth Green/yellow GN/YE PE Panel 2,5mm² RPM + White WH Skid

1x2x0,75mm²
RPM gnd Blue BU Skid
Power supply <120Vdc
Control power + 24vdc Red RD + 24Vdc Panel 1,5m m ² 4-20mA Transmitter (Shielded twisted pair)
Control power - 0vdc Blue BU - 0Vdc Panel 1,5m m ² 4-20mA signal White WH Skid
1x2x0,75mm²
Normal wiring n.a. - Panel 0,75-1,5m m ² +Sensor supply Blue BU Skid
Switched wire Black BK Panel 0,75-1,5m m ²

PT100 signals (Shielded twisted pair)
Potential free contact Orange OG Panel 0,75m m ²
PT100 signal White WH Skid
PLC digital output Grey GY Panel 0,75m m ² 1x2x0,75mm²
-Sensor supply Blue BU Skid
PLC digital input Grey GY Panel 0,75m m ²
4-20mA active input signal White WH Panel 0,75m m ² (Shielded twisted pair)
Switches
+24Vdc for sensor supply Red RD Panel 0,75m m ²
Switch White WH Skid
PT100 input signal White WH Panel 0,75m m ² 1x2x0,75mm²
Switch common Blue BU Skid
-0Vdc sensor supply White WH Panel 0,75m m ²
Actuators/solenoids (Use 1,5mm² when a seperate (multi-core) cable is used!)
(Shielded twisted pair)

Can-Bus / Pick-up Wiring in Local Control Panel
Positive Brown BN L+ Skid
CAN High / Pick-up Signal Black BK Panel 2x1,5mm²
1x2xAWG22/7 Negative Blue BU L- Skid
CAN Low / Pick-up Ground Clear - Panel
Other Cables (Shielded twisted pair)
Signals White WH Skid

2x2x0,75mm²
Tmpl. rev0
Signals Blue BU Skid

22-6-2016
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P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
12
Alarm, Warning & Shutdown
Analog values via ComAp inputs Monitoring Warning Shutdown Runnning Only Logicol input (switches) to ComAp Wire Break Warning Shutdown Running Only
Lube Oil Temp Sump X >120°C Fuel Leakage High
Coolant Temp HT X >98°C >104°C Coolant Level HT Low
Coolant Temp LT IN X >39°C X Coolant Level LT Low
Lube Oil Press X <1,2Bar <1,0Bar X Governor Failure X X
Coolant Press HT X <0,3Bar X Lube Oil Pressure (connected to RPU) X <1,0Bar
Coolant Press LT X <0,3Bar X Coolant Temperature (connected to RPU) X >104°C
Pickup (redundant to RPU) X 2070rpm X Emergency Stop (connected to RPU) X
Battery A Voltage X <18V & >30V
Battery B Voltage X <18V & >30V Other message shown on Comap display Wire Break Warning Shutdown Running Only
Fuel Solenoid Relay X X
Pickup Fail X X
Start Failure X
Stop Fail X X
Underspeed X X
Tmpl. rev0
22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
13
LCP Outside View
FRO NT VIEW SIDE VIEW
400.00 210.00
150.00
195.00
500.00
500.00
155.00
Tmpl. rev1
*Note:
- Dim ensions in m m
- T he panel should be m ounted as shown
- Allow access to open the doors with a m inim um of 90°
- LCP build up on skid
Panel:
22-6-2016
- Brand: Rittal
- M odel No.: AE 1045.500
- Painted RAL: 7035
- W x H x D: 400m m x 500m m x 210m m
Plotdate:
- Protection: IP54
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
Reference : YN. 513510 Set output : 440/254Vac / 60Hz Revision date : 22-6-2016
21
www.dbr-bv.nl & info@dbr-bv.nl Client P.O. : N417740 Function : =LCP Location : Quantity: 2
LCP Inside View
354.00
45.00
40.00
110.00
324.00
-36P3
-30DM16
-31P18
-33K11
-33K13
-33K15
-33K17
-37K11
-37K13
-30F16
-30F17
-33K5
-33K7
-33K9
-34K4
-34K6
-37K7
-37K9
-38F4
30.00
110.00
475.00
40.00
X1 X2 X3 X4
72.50
+D O O R
320.00
10
11
12
13
14
15
16
17
18
19
20
21
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
1
2
3
4
5
1
2
3
4
5
6
7
8
9
A+
B+
A-
B-
210.00
82.50
137.50
-36S7
60.00
55.00
Tmpl. rev1
Mounting plate Backside door

22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
Reference : YN. 513510 Set output : 440/254Vac / 60Hz Revision date : 22-6-2016
22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
24Vdc & Starter
+24V
31.2
-0V
31.2
12
14
24
22
12
14
-37K9 -33K7 -33K5
37.9 33.7 33.5
-
11
21
11
+
-30DM 16
30A
24
22
-37K7 A+ A- B+ B-
37.7
21
A+
36.2
A-
36.2
B+
36.2
B-
36.2
-30D4 -30D7 -30D9
2
-30F16 -30F17
D+ B06A B06A
32.17
1
A+
B+
A-
B-
1
7
-X2 -X2 -X2 -X2 -X1
1
1
2
1
2
-E1 -E2 -E3 -Batt A -Batt B
=Skid =CLIENT
Tmpl. rev0
+Engine
-BattA -BattB
2
-30K9
-30Y6 Start - +
+
Fuel - 24Vdc 24Vdc

Relay
3
Fuel
+
1
Supply Supply
-
Solenoid SM Start
-30M 4 Pum p M otor (M AIN) (Backup)
+ Battery
22-6-2016
A Redundant
Power Supply
done by Yard
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-DCU BI 1-7
+24V +24V
30.20 32.2
-0V -0V
30.20 32.2
+DO OR
Com Ap ID-DCU M arine - (Binary Inputs) - P/N:
-31P18 Remote Start Remote Stop Spare Coolant HT Level Coolant LT Level Fuel Leakage Spare
+ Vdc
ID-DCU
- Vdc
"1" = Active "1" = Active "1" = "1" = Normal "1" = Normal "1" = Normal "1" =
"0" = Inactive "0" = Inactive "0" = "0" = Warning "0" = Warning "0" = Warning "0" =
- - - - - -
POWER
8 - 36Vdc
Pulse min. 0,2sec Pulse min. 0,2sec - - - - -
GND
BI1
BI2
BI3
BI4
BI5
BI6
BI7
10
11
12
13
14
15
1
9
-X4 -X4 -X4 -X2 -X2 -X2 -X2
1
2
-Client1 -Client2 -Client3 -E4
Tmpl. rev0
=CLIENT =Engine =Skid

+Room +Engine
no
bk
bk
nc
rd
rd -31S15
22-6-2016
c
wh
wh
Cool HT Cool LT Fuel
Level Level Leakage
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P.O . Box 1039 - 3360 BA A3
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DOK.NR. D04-02/1
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31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-DCU BI 8-14
+24V +24V
31.20 33.2
-0V -0V
31.20 33.2
+DO OR
Com Ap ID-DCU M arine - (Binary Inputs) - P/N:
-31P18 Governor Failure T hrottle Failure T hrottle to 0 - - - -

ID-DCU
"1" = Normal "1" = Normal "1" = Normal "1" = "1" = "1" = "1" =
"0" = Warning "0" = Warning "0" = Blocking "0" = "0" = "0" = "0" =
- - Startblocking - - - -
Not active during Stopping - Only active when - - - -

engine not running
D+
BI8
BI9
BI10
BI11
BI12
BI13
BI14
D+
30.13
16
17
-X2
+GF
38.12
Tmpl. rev0
22-6-2016
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DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-DCU BO 1-7
+24V +24V
32.20 34.2
-0V -0V
32.20 34.2
A1
A1
A1
A1
A1
A1
A1
-33K5 -33K7 -33K9 -33K11 -33K13 -33K15 -33K17
A2
A2
A2
A2
A2
A2
A2
+DO OR
120
BO1
BO2
BO3
BO4
BO5
BO6
BO7
Ohm
-31P18 Starter Stop Fail Running Common Blink Alarm Engine Ready to Load Ready for Start Local/Remote
1
1
ID-DCU
6
6
ID-COM*
2
2
"1" = ON "1" = YES "1" = YES "1" = Normal "1" = YES "1" = YES "1" = YES
7
7
"0" = OFF "0" = NO "0" = NO "0" = Alarm "0" = NO "0" = NO "0" = NO
3
3
8
8
3 x pulse - - Fault, Alarm, - - -
4
4
Max. 10 sec. Warning or Shutdown
9
9
5
5
C12-A21FX C12-A21FX C12-A21FX C12-A21FX C12-A21FX C12-A21FX C12-A21FX
Relay 5A Relay 5A Relay 5A Relay 5A Relay 5A Relay 5A Relay 5A
Com Ap ID-DCU M arine (Binary O utputs) P/N:
NO NC NO NC NO NC NO NC NO NC NO NC NO NC
30.9 30.9 30.6 30.6 39.3 39.3 39.5 39.5 39.7 39.7 39.9 39.9 39.11 39.11
Tmpl. rev0
22-6-2016
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DBR
DOK.NR. D04-02/1
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33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-DCU BO 8-14
+24V +24V
33.20 35.2
-0V -0V
33.20 35.2
A1
A1
-34K4 -34K6
A2
A2
+DO OR
BO10
BO11
BO12
BO13
BO14
BO8
BO9
-31P18 Droop Switch Spare - - - - -
5
ID-DCU
9
4
RS 232
"1" = Isochronous "1" = YES "1" = "1" = "1" = "1" = "1" =
8
"0" = Droop "0" = NO "0" = "0" = "0" = "0" = "0" =
3
7
- - - - - - -
2
6
1
- - - - - - -
Com Ap ID-DCU M arine (Binary O utputs) P/N:
NO NC NO NC
38.11 38.11 39.13 39.13
Tmpl. rev0
22-6-2016
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DOK.NR. D04-02/1
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34
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-DCU AIN 1-8 & RPM IN
+24V +24V
34.20 36.2
-0V -0V
34.20 36.2
35.5
+DO OR
Com Ap ID-DCU M arine - (Analog inputs, RPM input & RS232) - P/N:
Lubrication Oil Press Coolant HT Press Coolant LT Press Not used Lube Oil T emp Coolant HT T emp Coolant LT T emp Not used RPM Indication
-31P18
ID-DCU
Warning = <1,2 Bar Warning = <0,3 Bar Warning = <0,3 Bar Warning = Warning = >120°C Warning = >98°C Warning = >39°C Warning = Overspeed= 2070 Rpm
Shutdown = <1,0 Bar Shutdown = N.A. Shutdown = N.A. Shutdown = Shutdown = N.A. Shutdown = >104°C Shutdown = N.A. Shutdown = T eeth = 126
0-10 Bar 0-4 Bar 0-4 Bar - -20 - 150°C -20 - 150°C -20 - 150°C - Pickup on Flywheel
4 - 20mA T ransmitter 4 - 20mA T ransmitter 4 - 20mA T ransmitter PT 100 T ransmitter PT 100 T ransmitter
Running only Running only Running only - - - Running Only - -

Delay 10 sec Delay 60 sec Delay 60 sec Delay 60 sec
4 4 4 4 4 4 4 4
RPM GND
R R R R R R R R
3 3 3 3 3 3 3 3
AIN5+
AIN6+
AIN7+
AIN8+
RPM IN
AIN5-
AIN6-
AIN7-
AIN8-
U U U U U U U U
COM
AIN1
AIN2
AIN3
AIN4
2 2 2 2 2 2 2 2
I I I I I I I I
1 1 1 1 1 1 1 1
Connect
direct to
COM
35.5
RPM+
RPM-
SCR
SCR
SCR
SCR
SCR
SCR
SCR
SCR
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
-X2 -X2 -X2 -X2 -X2 -X2 -X2 -X2
38.19
38.19
1
2
-E5 -E6 -E7 -E8 -E9 -E10
Tmpl. rev0
=Skid
+Engine
3
3
2
1
PT PT PT
PT 100 PT 100 PT 100
1
1
22-6-2016
2
-35T 4 -35T 6 -35T 8 -35T 11 -35T 13 -35T 15
Lube O il Coolant HT Coolant LT Lube O il Coolant HT Coolant LT
Press Press Press T em p T em p T em p
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-RPU (1)
+24V +24V
35.20 37.2
-0V -0V
35.20 37.2
+DO OR nc
Com Ap ID-RPU - P/N:
-
+ Emergency Stop Lube Oil Coolant HT Not Used Not Used Not Used
BAT T COM Pressure T emperature
Status "1" = Normal Status "1" = Shutdown Status "1" = Shutdown Status "1" = Shutdown Status "1" = Shutdown Status "1" = Shutdown
Status "0" = Shutdown Status "0" = Normal Status "0" = Normal Status "0" = Normal Status "0" = Normal Status "0" = Normal
-36P3 - Setpoint = <1,0 Bar Setpoint = >104°C Setpoint = N.A. Setpoint = N.A. Setpoint = N.A.
Broken Wire Detection Broken Wire Detection
- Running Only - - - -
BAT T A BAT T B
STOP
SD1
SD2
SD3
SD4
SD5
EM.
- -
+
15kOhm 15kOhm 11
-36S7
12
A+
30.18
A-
30.18
B+
30.18
B-
30.18
34
35
36
37
7
-X4 -X2 -X2

Link when
not used
7
2
-Client1 -E11 -E12
Tmpl. rev0
=CLIENT =Skid
+Engine
3 10K
2
3
2
10K
P
-36PS9 -36T S11
22-6-2016
Press T em p
Switch Switch
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
ID-RPU (2)
+24V +24V
36.20 38.2
-0V -0V
36.20 38.2
A1
A1
-37K11 -37K13
A2
A2
+DO OR
GND SO L + SOL COM M SD COM M WRN
OT Prefix: 01000 Stop Solenoid Fuel Solenoid Common Shutdonw Common Warning
Speed Preset: 1000 1001

- Fuel Pump Control "1" = Shutdown "1" = Warning
-36P3 "0" = Normal "0" = Normal
Pickup on Flywheel Broken Wire Detection Broken Wire Detection - -
C12-A21FX C12-A21FX C12-A21FX C12-A21FX
Relay 5A Relay 5A Relay 5A Relay 5A
RPM GND ST OP SO L FUEL SOL

A1 Com Ap ID-RPU - P/N:
A1
-37K7 -37K9
A2
A2
SCR
38
39
-X2 NO NC NO NC NO NC NO NC
30.6 30.6 30.4 30.4 39.15 39.15 39.17 39.17
38.4 38.4
1
-E13
Tmpl. rev0
=Skid
+Engine
+
-
22-6-2016
-40B7
Speed
Sensor
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
37
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Speed Controller
+24V
37.20
-0V
37.20
3
-X3
=Skid
+Engine
2
5
-38F4
C04A
1
SPEED CONT ROL UNIT
+12/24
-0vdc
WOODWARD L-SERIES
M OUNT ED ON FUEL PUM P
35.18
35.19
-38P10
TPS OUTPUT
RELAY OUT
RPM-
RPM+
SIG. GND
IGNITION
+5V OUT
AUX2+
AUX1+
AUX3+
AUX4+
+MPU
14
12
-37K7
3
10
12
11
37.7
11
SCR
2
9
-X3 -X3 -X3 -X3 -X3 -X3
12
14
-34K4
34.4
11
SCR
10
11
40
41
9
-X4 -X4 -X4 -X2

+GF
2
32.5 -E14
10
11
9
-Client1
Tmpl. rev0
=Skid
=CLIENT +Engine
-
SPEED SPEED
22-6-2016
UP DOWN Speed
Sensor
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page: Of:
38 27
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Outputs to External
Running Com m on Blink Alarm * Engine Ready to Load Ready for Start Local/Rem ote Spare Com m on Shutdown Com m on Warning
12
14
12
14
12
14
12
14
12
14
12
14
12
14
12
14
-33K9 -33K11 -33K13 -33K15 -33K17 -34K6 -37K11 -37K13
33.9 33.11 33.13 33.15 33.17 34.6 37.11 37.13
11
11
11
11
11
11
11
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
-X4 -X4 -X4 -X4 -X4 -X4 -X4 -X4
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
-Client4
Tmpl. rev0
=CLIENT
*Rem ark
11 & 12 closed when alarm and stays closed
when any alarm is active (at least one item in
Alarm list) and opens for 2 sec when any new
Alarm is activated. T he first activation is
22-6-2016
delayed 2 sec. No Fault reset influence when

at least one alarm is active. Output opens
when Alarm list is em pty.
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
39
List of cables
TAG Description Type Outer diameter From To Length [m] Make
-Batt A +24Vdc Supply 6A 2x2,5mm2 =LCP-X1 =CLIENT-BattA
-Batt B +24Vdc Supply 6A 2x2,5mm2 =LCP-X1 =CLIENT-BattB
-Client1 Control =LCP-X4 =CLIENT-X
-Client2 Coolant Level HT =LCP-X2 =Engine+Room-31LS11
-Client3 Coolant Level LT =LCP-X2 =Engine+Room-31LS13
-Client4 Outgoing contacts =LCP-X4 =CLIENT-X
-E1 Fuel Pump RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-30M4 Helkama
-E2 Fuel solenoid RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-30Y6 Helkama
-E3 Start Relay RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-30K9 Helkama
-E4 Fuel Leakage RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-31S15 Helkama
-E5 Lube Oil Press RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T4 Helkama
-E6 Coolant HT Press RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T6 Helkama
-E7 Coolant LT Press RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T8 Helkama
-E8 Lube Oil Temp RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T11 Helkama
-E9 Coolant HT Temp RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T13 Helkama
-E10 Coolant LT Temp RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-35T15 Helkama
-E11 Lube Oil Press switch RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-36PS9 Helkama
-E12 Coolant Temp HT Switch RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-36TS11 Helkama
-E13 Speed Sensor RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-40B7 Helkama
-E14 Speed Sensor RFA-HF 1x2x0,75mm² 6,5mm =LCP-X2 =Skid+Engine-38B16 Helkama

Tmpl. rev1
22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
100
Path
9
35 17
38 16
38 16
35
30
30
30
Page
Connection 2
-30D7
-30D4
-30D9
-X2:3
-X2:1
-X2:5
Terminal bars
Terminal bar:
10SCR
11SCR
12SCR
13SCR
14SCR
15SCR
16SCR
17SCR
18SCR
19SCR
20SCR
21SCR
22SCR
23SCR
24SCR
25SCR
26SCR
27SCR
28SCR
29SCR
30SCR
31SCR
1SCR
2SCR
3SCR
4SCR
5SCR
6SCR
7SCR
8SCR
9SCR
SCR
SCR
SCR
SCR
No.
4
5
6
7
8
9
-X
Term.
Connection 1
-30D7
-30D4
-30D9
-X2:4
-X2:2
-X2:6
Description Type TAG

P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
143
Path
30 16
30 16
30 17
30 17
Page
Connection 2
-30DM16:A-
-30DM16:B-
-30F16:1
-30F17:1
-36R3:2
-36R4:2
Terminal bars
Terminal bar:
No.
A+
B+
A-
B-
-X1
Term.
Connection 1
=CLIENT-BattA:+
=CLIENT-BattB:+
=CLIENT-BattA:-
=CLIENT-BattB:-
+24Vdc Supply 6A 2x2,5m m 2 =CLIENT -Batt A 1 2
+24Vdc Supply 6A 2x2,5m m 2 =CLIENT -Batt B 1 2

P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
144
DOK.NR. D04-02/1
Fuel Pum p
Start Relay
Fuel Leakage
Fuel solenoid
Speed Sensor
Speed Sensor
Description
Lube O il Press
Lube O il T em p
Terminal bars
Coolant Level LT
Coolant LT Press
Coolant HT Press
Coolant Level HT
Coolant LT T em p
Coolant HT T em p
Lube O il Press switch
Coolant T em p HT Switch
DBR
Generatorsets
Type
RFA-HF 1x2x0,75m m ²
Lelystraat 53 - 3364 AH
Terminal bar:
P.O . Box 1039 - 3360 BA
T el: +31(0)184 - 61 32 00
Fax: +31(0)184 - 61 26 54
TAG
www.dbr-bv.nl & info@dbr-bv.nl

=Engine-E9
=Engine-E8
=Engine-E7
=Engine-E6
=Engine-E5
=Engine-E4
=Engine-E3
=Engine-E2
=Engine-E1
-X2
=Engine-E14
=Engine-E13
=Engine-E12
=Engine-E11
=Engine-E10
=CLIENT -Client3
=CLIENT -Client2
Page
Path
Connection 1 Term. No. Connection 2
1
=Skid+Engine-30M4:+ 1 -37K9:11 30 4
-X:2
Reference
Client P.O.
2
=Skid+Engine-30M4:- 2 -X:2 30 4
Nam e of client
Drawing num ber
1
=Skid+Engine-30Y6:1 3 -37K7:21 30 6
DBR order num ber

-X:1
2
=Skid+Engine-30Y6:2 4 -X:1 30 7
1
=Skid+Engine-30K9:2 5 -33K5:11 30 9
: 21626
-X:3
: 161014
: N417740
2
=Skid+Engine-30K9:3 6 -30DM16:- 30 10
: YN. 513510
-X:3
: Dam en Shipyards
7 +DOOR-31P18:D+ 30 12
1
=Engine+Room-31LS11:rd 8 +DOOR-31P18:BI4 31 11
2
=Engine+Room-31LS11:wh 9 -X4:6 31 11
1
=Engine+Room-31LS13:rd 10 +DOOR-31P18:BI5 31 13
2
=Engine+Room-31LS13:wh 11 31 13
1
2 =Skid+Engine-31S15:nc 12 +DOOR-31P18:BI6 31 15
=Skid+Engine-31S15:c 13 31 15
14 +DOOR-31P18:BI7 31 17
15 31 17
Power
Engine
-X3:7 16 +DOOR-31P18:BI8 32 5
Function
Generator
Set output
17 -0V 32 5
+DOOR-31P18:- Vdc
1
=Skid+Engine-35T4:2 18 +DOOR-31P18:AIN1 35 4
: =LCP
2
=Skid+Engine-35T4:1 19 -34K6:A1 35 5
1
2
=Skid+Engine-35T6:1 21 35 7
: 120kVA / 96,0kWe
1
: Perkins 4.4T W2G M
: 440/254Vac / 60Hz
2
=Skid+Engine-35T8:1 23 35 8
: Leroy Som er LSAM 44.3M 6
24 +DOOR-31P18:AIN4 35 10
25 35 10
1
=Skid+Engine-35T11:1 26 +DOOR-31P18:AIN5+ 35 11
2
=Skid+Engine-35T11:2 27 +DOOR-31P18:AIN5- 35 12
+DOOR-31P18:COM
Revision
Location
1
2
Revision date
Drawing status
+DOOR-31P18:AIN6-
Engineering date
1
:
2
: 0
+DOOR-31P18:AIN7-
: As built
32 +DOOR-31P18:AIN8+ 35 16
: 22-6-2016
: 22-3-2016
33 +DOOR-31P18:AIN7- 35 17
+DOOR-31P18:AIN8-
1
=Skid+Engine-36PS9:2 34 +DOOR-36P3:SD1 36 9
2
=Skid+Engine-36PS9:1 35 -X4:8 36 9
1
=Skid+Engine-36TS11:3 36 +DOOR-36P3:SD2 36 11
2
=Skid+Engine-36TS11:1 37 -0V 36 11
+DOOR-36P3:-
A3
+DOOR-36P3:-
N.A.
Quantity:
Scale:
Page size:
1
=Skid+Engine-40B7:+ 38 +DOOR-36P3:GND 37 5
2
2
=Skid+Engine-40B7:- 39 +DOOR-36P3:RPM 37 5
1
=Skid+Engine-38B16:+ 40 -X3:8 38 16
+DOOR-31P18:RPM IN
JdJ
145
2
=Skid+Engine-38B16:- 41 -X3:9 38 16
Page:
+DOOR-31P18:RPM GND
Engineered by:
Path
38 10
38 10
38 10
38 10
38 11
38 12
38 13
38 16
38 16
Page
Connection 2
=Skid+Engine-38P10:10
-37K9:A2
-37K7:11
-X2:16
-X2:40
-X2:41
-X4:9
Terminal bars
Terminal bar:
No.
1
2
3
4
5
6
7
8
9
-X3
Term.
Connection 1
-34K4:14
-X4:10
-X4:11

P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
146
DOK.NR. D04-02/1
Control
Description
Terminal bars
Outgoing contacts
DBR
Generatorsets
Type
Lelystraat 53 - 3364 AH
Terminal bar:
P.O . Box 1039 - 3360 BA
T el: +31(0)184 - 61 32 00
Fax: +31(0)184 - 61 26 54
TAG
www.dbr-bv.nl & info@dbr-bv.nl

-X4
=CLIENT -Client4
=CLIENT -Client1
Page
Path
Connection 1 Term. No. Connection 2
1
=CLIENT-X 1 +DOOR-31P18:BI1 31 5
2
=CLIENT-X 2 -0V 31 5
Reference
Client P.O.
-30DM16:-
Nam e of client
Drawing num ber
+DOOR-31P18:- Vdc
DBR order num ber

3
4
5 =CLIENT-X 4 31 7
: 21626
6
=CLIENT-X 6 -X2:9 31 9
: 161014
: N417740
7
=CLIENT-X 7 +DOOR-36S7:12 36 7
: YN. 513510
8
=CLIENT-X 8 -X2:35 36 7
: Dam en Shipyards
9
=CLIENT-X 9 -34K4:11 38 8
-X3:1
=CLIENT-X 10 -X3:2 38 9
10 11
=CLIENT-X 11 -X3:4 38 10
1
=CLIENT-X 12 -33K9:11 39 3
2
=CLIENT-X 13 -33K9:14 39 3
3
=CLIENT-X 14 -33K11:11 39 5
4
=CLIENT-X 15 -33K11:14 39 5
5
=CLIENT-X 16 -33K13:11 39 7
Power
6
Engine
=CLIENT-X 17 -33K13:14 39 7
Function
Generator
Set output
7
=CLIENT-X 18 -33K15:11 39 9
8
=CLIENT-X 19 -33K15:14 39 9
=CLIENT-X 20 -33K17:11 39 11
: =LCP
=CLIENT-X 21 -33K17:14 39 11
=CLIENT-X 22 -34K6:11 39 13
=CLIENT-X 23 -34K6:14 39 13
: 120kVA / 96,0kWe
: Perkins 4.4T W2G M
: 440/254Vac / 60Hz
=CLIENT-X 24 -37K11:11 39 15
=CLIENT-X 25 -37K11:14 39 15
: Leroy Som er LSAM 44.3M 6
=CLIENT-X 26 -37K13:11 39 17
9 10 11 12 13 14 15 16
=CLIENT-X 27 -37K13:14 39 17
Revision
Location
Revision date
Drawing status
Engineering date
:
: 0
: As built
: 22-6-2016
: 22-3-2016 A3
N.A.
Quantity:
Scale:
Page size:
2
JdJ
147
Page:
Engineered by:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Cable term inal rows
=LC P
=LC P
=LC P
=LC P
=LC P
-X1
-X1
-X4
-X2
-X2
10
11
10
11
A+
B+
10
11
10
11
1
9
A-
B-
9
10
11
1
2
1
Des: +24Vdc Supply 6A
Des: +24Vdc Supply 6A
Des: Coolant Level HT
Des: Coolant Level LT

Type: 2x2,5mm2
Type: 2x2,5mm2
Des: Control
-Client1
-Client2
-Client3
-Batt A
-Batt B
Type:
Type:
Type:
10
11
1
9
=C LI EN T
=C LI EN T
=C LI EN T
-Bat t A
-Bat t B
-X
10
11
0
9
+
+
-
1
2
1
2
Tmpl. rev0
bk
bk
=Engine =Engine
rd
rd
+Room +Room
-31LS11 -31LS13
wh
wh
Cool HT Cool LT
1
Level Level
22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
170
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
=LC P
=LC P
=LC P
=LC P
=LC P
=LC P
-X4
-X2
-X2
-X2
-X2
-X2
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
12
13
18
19
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
12
13
18
19
1
6
1
6
10
11
12
13
14
15
16
1
2
1
Type: RFA-HF 1x2x0,75mm²

Des: Outgoing contacts
Des: Lube Oil Press

Des: Fuel Leakage
Des: Fuel solenoid
Des: Start Relay

Des: Fuel Pump
-Client4
Type:
-E1
-E2
-E3
-E4
-E5
10
11
12
13
14
15
16
1
9
=C LI EN T
-X
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
2
Tmpl. rev0
no
=Skid =Skid =Skid
nc
=Skid
+
2
-
=Skid +Engine
1
-30Y6 -30K9 +Engine +Engine
+Engine Fuel PT
Pum p Fuel Start
-30M 4
1
2
+Engine
Solenoid Relay
4
-31S15
1
Fuel
-35T 4
1
Leakage
Lube O il
Press
22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
171
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
=LC P
=LC P
=LC P
=LC P
=LC P
=LC P
=LC P
=LC P
=LC P
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
20
21
22
23
26
27
28
29
30
31
34
35
36
37
38
39
40
41
20
21
22
23
26
27
28
29
30
31
34
35
36
37
38
39
40
41
1
2
1
Des: Coolant Temp HT Switch

Des: Lube Oil Press switch
Des: Coolant HT Temp
Des: Coolant HT Press
Des: Coolant LT Temp

Des: Coolant LT Press
Des: Lube Oil Temp
Des: Speed Sensor
Des: Speed Sensor

-E10
-E11
-E12
-E13
-E14
-E6
-E7
-E8
-E9
1
1
2
2
Tmpl. rev0
+
=Skid =Skid =Skid =Skid =Skid =Skid =Skid
3
-
2
3
2
3
2
+Engine +Engine +Engine +Engine +Engine +Engine +Engine

PT PT P =Skid =Skid
+Engine +Engine
PT 100 PT 100 PT 100 -36PS9 -36T S11
1
1
Press T em p
2
-35T 6 -35T 8 -35T 11 -35T 13 -35T 15 Switch Switch -40B7 -38B16

Coolant HT Coolant LT Lube O il Coolant HT Coolant LT Speed Speed
Press Press T em p T em p T em p Sensor Sensor
22-6-2016
Plotdate:
P.O . Box 1039 - 3360 BA A3
DBR
DOK.NR. D04-02/1
T el: +31(0)184 - 61 32 00 Page:
172
JJovrls
K"egrsfer
Type Approval Certificate Extension

Tltis is to certify that Certificate No. 06/00098 for the undernoted products is extended and renumbered
as shown.
This certificate is issued to:
PRODUCER Perkins Engine Company Ltd
PLACE OF Frank Perkins Way

PRODUCTION Eastfield
Peterborough
Cambridgeshire, PE15NA
United Kingdom (UK)
DESCRIPTION Four Stroke, Supercharged Marine Diesel Engines for Auxiliary Power
Generation
TYPE Sabre 4.4 GM (CaterpiUar C4.4)
APPLICATION Four Stroke, Supercharged Marine Diesel Engines for Auxiliary

Power Generation
STANDARD Rules & Regulations for the Classification of Ships, Part 5, Chapter 2
RATINGS Perkins
4.4CM 4.4TGM 4.4TWGM 4.4TW2GM
Sabre
Engine
Designation C4.4 C4.4 C4.4 C4.4
Caterpillar
DINA orr DITA DITA
Leroy Somer Alternator
43.2535 43.2 L8 44.2YS3 44.2 57
Designation "LSAM... "
kW 42.7 56.4 75 93.6
at 1500rpm
Pmaxbar 92 102 117 131
kW 49.1 63.6 82.7 106.8
at1800rpm
Pmaxbar % 108 123 143
Certificate No. 06/00098(El}
~~
Issue Date 7 October 2011
Expiry Date 20 December 2016
Sheet 1 of2 R.J. Parry

London Design Support Office
Lloyd's Register EMEA
Uoyd's Register EMEA
n Frnchurch Street, London EC3M 4BS
lloyd's Register, ns affilliltes and subsidiaries and their respectM! offic~. e~ or agents are. tndNidually and collectJvely. referred to in thiS clause as
the 'lloyd's RegiSter Group'. The Lloyd's RegiSler Group assumes no responstbthty and shall not be liable to any person for any loss. damage or expense
r-;urc:prf hv rPiiAnr., nn th~ •nfnr~tit'\n nr ;:w-ivirp in thi<: lii'VIUY'IPnt nr hnwc;npyp,r nrnvitiPrt un~~ th;e1 nPrc;;nn hAA c:inflPot"' ~ rnntr.¥1 with thP rPiilv~nt llnvti'c;
JJovcls
Kegrsfer
LR Type Approval certifies that a representative sample of the product(s) referred to herei11 lws/luroe been found to
meet the applicable design criteria for the use specified herein. It does not mean or imply approval for any other use
nor approval of any product(s) designed or manufochmd otherwise than in strict cmtJormihJ with the said
representative sample.
This Certificate is not valid for equipment, the design, ratings or operating parameters of which have been varied
from the specimen tested. Tire manufochlrer should notify Lloyd's Register EMEA ofany modification or clwnges
to tire equipment in order to obtain a valid certificate.
LR Type Approval is based on the muierstmtding that tire manufacturer's recommendations and irrstnJctions and
any relevant requirements of the Rules of Lloyd's Register of Shipping are complied with.
This LR Type Approval does not eliminate the need for nomtal inspection and survet; procedures required by the
Rules and Regulations of Lloyd's Register of Shipping.
Llm;d's Register of Shipping reserves tire right to cancel or withdraw this LR Type Approval Certificate in
accordance with the LR Type Approval System Procedure.
The attaclted Design Appraisal Document No. LDS/ENG/6680902 and its supplementary Type Approval Terms
and Conditions fonn part of this Certificate.
All other details remain as the previous Certificate Nos. 06/00098 to which this extension should be attaclted.
Certificate No. 06I 00098(E1)
Issue Date 7 October 2011
Expiry Date 20 December 2016
Sheet 2of2 RJ. Parry

London Design Support Office
Uoyd's Register EMEA
Lloyd's Register EMEA
71 Fenchurch Street, London EC3M 4BS
lloyd's Reg!Stef. ns affiliates and slilsKflilries and thelf respective offiCers. employees or agents are. indiVidually and collectiVely. referred to 1n thiS clause as
the 'lloyd's Register Group'. The Lloyd's Register Group assumes no responsibility and shall not be liable to any person for any loss. damage or expense
r;u KM hv rPI ~IV'P nn thP infnr~ti.nn nr ;:wivirP in fhj( tirv"ull'W)nt nr ~ rvnviriPO unkM;<; ~t I'"''Ptvm ho:K "inf'VIoti ~ r nnh'Mt wrth thP rPIPv~nt 11rM1•"
Type Approval Certificate Extension
This is to certify that Certificate No. 08/30007 (E1) for the under noted products is extended and
renumbered as shown.
This certificate is issued to:
PRODUCER Leroy-Somer
Site de Sillac
Bld Marcellin Leroy
16015 Angouleme
France
PLACES OF Site de Sillac

PRODUCTION Bld Marcellin Leroy
16015 Angouleme
France
Leroy-Somer Holice
Spol s.r.o.
Sladkovskeho 43
Olomouc 77204
Czech Republic
DESCRIPTION Electric alternator
TYPE LSAM 40 series: VS1, VS2, S3, S4, M5, L7

LSAM 42,2 series: S4, S5, M6, M7, L9
LSAM 42,3 series: VS3, S4, S5, M7, M8, L9
Certificate No. 08/30007 E2
Issue Date 28 December 2014
Expiry Date 26 May 2018
Sheet 1 of 4 Ing. G.J. Vromans

Rotterdam Type Approval
Lloyd’s Register EMEA
Lloyd’s Register EMEA , Rotterdam Techonology Support Office, K.P.v.d.Mandelelaan 41a,3062 MB Rotterdam, The
Netherlands
"Lloyd's Register, its affiliates and subsidiaries and their respective officers, employees or agents are, individually and collectively, referred to in this clause
as the ‘Lloyd's Register Group’. The Lloyd's Register Group assumes no responsibility and shall not be liable to any person for any loss, damage or expense
caused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant Lloyd's
Register Group entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions
set out in that contract."
This is a copy of an electronic document. In the event of any conflict or ambiguity between the copy and the electronic document,
which is retained and published by Lloyd's Register, the original electronic and certified version shall always prevail.
LSAM 44,2 series: VS3, VS45, S7, S75, M95, L12
LSAM 44.3 series: S2, S3, S4, S5, M6, M8, L10
LSAM 46,2 series: M3, M5, L6, L9, VL12
LSAM 47,2 series: VS2, S4, S5, M7, L9
LSAM 49,1 series: S4, M5, M6, M75, L8, L9
LSAM 50,2 series: S4, M6, M7, L8, VL10
LSAM 51,2 series: S55, M60, L70, VL80, VL85
Also brand labelled for FG Wilson under LL-series and

Caterpillar under LC-series.
APPLICATION Marine and industrial application
STANDARD IEC 60034, Rules and Regulations of ships 2014
RATINGS
Power in kVA
LS Type / LL Type/ LC Type Class F Class H
380V / 450V / 690V / 380V / 450V / 690V /
50Hz 60Hz 60Hz 50Hz 60Hz 60Hz
LSAM 40 VS1 7 8 - 7 8 -
LSAM 40 VS2 10 11.5 - 10 11.5 -
LSAM 40 S3 13 15 - 13 15 -
LSAM 40 S4 16 19 - 17 19 -
LSAM 40 M5 18.5 21.5 - 20 23 -
LSAM 40 L7 20 24 - 23 25.5 -
LSAM 42,3 VS3 22.5 26 29 27 31 32.5
LSAM 42,3 S4 27 31 34 35 40.5 35.5
LSAM 42,3 S5 32 39 37.5 37 42 41.5
LSAM 42,3 M7 35 41.5 40.5 41 47 45

Netherlands
LSAM 42,3 M8 38 45 43.5 46 54 49
LSAM 42,3 L9 47.5 54.5 51 53 60 57.5
LSAM 42,2 S4 / NA / NA 15 21 - 17.5 22 -
LSAM 42,2 S5 / LL10#4N / LC10#4N 18 24 - 20 26 -
LSAM 42,2 M6 / NA / NA 21 26 - 23 30 -
LSAM 42,2 M7 / LL10#4Q / LC10#4Q 23 29 - 25 32 -
LSAM 42,2 L9 / LL10#4S / LC10#4Q 25 32 - 28 35 -
LSAM 44.2 VS3 / NA / NA 80 100 90 90 110 100
LSAM 44.2 VS45 / LL30#4B / LC30#4B 90 110 100 100 120 110
LSAM 44.2 S7 / LL30#4D / LC30#4D 105 125 110 115 135 123
LSAM 44.2 S75 / NA / NA 110 132 - 121 145 -
LSAM 44.2 M95 / LL30#4F / LC30#4F 127 154 126 140 165 145
LSAM 44.2 L12 / LL30#4H / LC30#4H 135 158 135 150 175 150
LSAM 44.3 S2 64 80 - 70 88 -
LSAM 44.3 S3 73 91 - 80 100 -
LSAM 44.3 S4 82 102 - 90 113 -
LSAM 44.3 S5 91 114 - 100 125 -
LSAM 44.3 M6 108 128 - 118 141 -
LSAM 44.3 M8 120 142 - 132 157 -
LSAM 44.3 L10 135 161 - 147 177 -
LSAM 46.2 M3 / LL50#4D / LC50#4D 160 188 165 170 205 185
LSAM 46.2 M5 / LL50#4F / LC50#4F 170 200 180 187 220 200
LSAM 46.2 L6 / LL50#4H / LC50#4H 210 250 225 230 280 250
LSAM 46.2 L9 / LL50#4J / LC50#4J 240 290 255 260 320 285
LSAM 46.2 VL12 / LL50#4L / LC50#4L 270 320 270 295 355 305
LSAM 47.2 VS2 / LL61#4B / LC61#4B 320 406 402 355 450 443
LSAM 47.2 S4 / LL61#4D / LC61#4D 350 425 415 380 475 456
LSAM 47.2 S5 / LL61#4D / LC61#4D 370 442 437 405 500 480
LSAM 47.2 M7 / LL61#4F / LC61#4F 435 545 520 476 602 580
LSAM 47.2 L9 / LL61#4K / LC61#4K 485 567 540 535 630 605
LSAM 49.1 S4 / LL70#4H / LC70#4H 545 695 620 600 740 690
LSAM 49.1 M5 / LL70#4J / LC70#4J - - 660 - - 732
LSAM 49.1 M6 / LL70#4L / LC70#4L 600 760 710 660 800 786

Netherlands
LSAM 49.1 M75 / LL70#4L / LC70#4L 635 815 760 710 855 840
LSAM 49.1 L8 / NA / NA 42 49.5 830 - - 934
LSAM 49.1 L9 / LL70#4P / LC70#4P 715 890 - 800 1000 -
LSAM 50.2 S4 / LL82#4B / NA 900 1025 970 990 1125 1080
LSAM 50.2 M6 / LL82#4H / NA 1055 1200 1090 1140 1380 1220
LSAM 50.2 L7 / LL82#4L / NA 1145 1285 - 1255 1480 -
LSAM 50.2 L8 / LL82#4N / NA 1230 1400 1290 1355 1600 1440
LSAM 50.2 VL10 / LL82#4P / NA 1365 1545 1450 1495 1760 1625
LSAM 51.2 S55 / LL91#4F / NA 1555 1750 1835 1670 1925 2045
LSAM 51.2 M60 / LL91#4H / NA 1725 1945 2035 1895 2135 2270
LSAM 51.2 L70 / LL91#4L / NA 1855 2090 2120 2035 2290 2365
LSAM 51.2 VL80 / NA / NA - - 2250 - - 2505
LSAM 51.2 VL85 / LL91#4P / NA 1940 2245 - 2130 2460 -
Remarks: -For generators => 100 kW to be surveyed by LR surveyors in the factory.

-Generators used for propulsion to be provided with embedded
temperature measurement.
-When for IP44 extra white filters are installed inside the machine on all
ventilation openings and above mentioned power ratings are to be
reduced by 10%.
“This Certificate is not valid for equipment, the design, ratings or operating parameters of which have been varied
from the specimen tested. The manufacturer should notify Lloyd’s Register EMEA of any modification or changes to
the equipment in order to obtain a valid certificate.”
“LR TA “When Rules and Standards and specifications mentioned in this certificate are changed within the validity
of this certificate, than this certificate becomes no longer valid.”
The Design Appraisal Document No.ROT/1490327 and its supplementary Type Approval Terms and Conditions
form part of this Certificate.

Netherlands
STATEMENT OF MANUFACTURE AND TEST
MANUFACTURER PURCHASERS ORDER NUMBER:
Caterpillar Marine Power UK Ltd 103155454
Wimborne, Dorset, England BH21 7PW WORKS ORDER NUMBER: 561014 (4500023315)
MARINISED BY: INTENDED SERVICE: Auxiliary

Caterpillar Marine Power UK Ltd
Wimborne, Dorset, England BH21 7PW SHIP/YARD REFERENCE: N/A
PURCHASER:
KEMPER EN VAN TWIST DIESEL BV
PARTICULARS:-
Engine:
ENGINE SERIAL NUMBER: RJ30888U624173A NUMBER OF CYLINDERS: 4 DIAMETER: 105mm
MANUFACTURERS DESIGNATION: 4.4TW2GM, 60Hz STROKE: 127mm

SHAFT POWER kW AT REV/MIN (CONTINUOUS RATING): METHOD OF COOLING:
106,8kW @ 1800rpm KEEL COOLED
TESTING:-
THE ENGINE HAS BEEN RUN ON A DYNAMOMETER AND HAS SATISFIED THE APPROVED TEST
SCHEDULE
IDENTIFICATION MARKS:-
Engine serial number – RJ30888U624173A
AUTHORISATION:-
THIS IS TO CERTIFY THAT THE OIL ENGINE AND GENSET DESCRIBED ABOVE HAS BEEN CONSTRUCTED AND TESTED WITH
SATISFACTORY RESULTS IN ACCORDANCE WITH THE LLOYDS CLASSIFICATION SOCIETY RULES AND REGULATIONS AND IN
CONFORMITY WITH APPROVED MANUFACTURING PROCESS AND CONTROL PROCEDURES (DOCS 3770, 5147 & 5119) AND TYPE
APPROVAL 06/00098(E1).
SIGNED ON BEHALF OF THE MARINISING COMPANY:

WIMBORNE MARINE POWER CENTRE
SIGNATURE: DATE:
25th February 2016
NAME IN BLOCK CAPITALS: POSITION IN COMPANY:

BOB CLARK QUALITY SUPERVISOR
1245-2-16
STATEMENT OF MANUFACTURE AND TEST
MANUFACTURER PURCHASERS ORDER NUMBER:
Caterpillar Marine Power UK Ltd 103155454
Wimborne, Dorset, England BH21 7PW WORKS ORDER NUMBER: 511895 (4500003650)
MARINISED BY: INTENDED SERVICE: Auxiliary

Caterpillar Marine Power UK Ltd
Wimborne, Dorset, England BH21 7PW SHIP/YARD REFERENCE: N/A
PURCHASER:
KEMPER EN VAN TWIST DIESEL BV
PARTICULARS:-
Engine:
ENGINE SERIAL NUMBER: RJ30888U585624X NUMBER OF CYLINDERS: 4 DIAMETER: 105mm
MANUFACTURERS DESIGNATION: 4.4TW2GM, 60Hz STROKE: 127mm

SHAFT POWER kW AT REV/MIN (CONTINUOUS RATING): METHOD OF COOLING:
106,8kW @ 1800rpm KEEL COOLED
TESTING:-
THE ENGINE HAS BEEN RUN ON A DYNAMOMETER AND HAS SATISFIED THE APPROVED TEST
SCHEDULE
IDENTIFICATION MARKS:-
Engine serial number – RJ30888U585624X
AUTHORISATION:-
THIS IS TO CERTIFY THAT THE OIL ENGINE AND GENSET DESCRIBED ABOVE HAS BEEN CONSTRUCTED AND TESTED WITH
SATISFACTORY RESULTS IN ACCORDANCE WITH THE LLOYDS CLASSIFICATION SOCIETY RULES AND REGULATIONS AND IN
CONFORMITY WITH APPROVED MANUFACTURING PROCESS AND CONTROL PROCEDURES (DOCS 3770, 5147 & 5119) AND TYPE
APPROVAL 06/00098(E1)
SIGNED ON BEHALF OF THE MARINISING COMPANY:

WIMBORNE MARINE POWER CENTRE
SIGNATURE: DATE:
25th February 2016
NAME IN BLOCK CAPITALS: POSITION IN COMPANY:

BOB CLARK QUALITY SUPERVISOR
1245-2-16
DECLARATION OF MARINE CONFORMITY
DECLARATION DE CONFORMITE MARINE
WITHOUT SURVEY / SANS RECETTE
NON ESSENTIAL FUNCTION / FONCTION NON ESSENTIELLE
Customer Motor/Alternator no
Client DBR Moteur/Alternateur no 333016-1/2
333017-1/2
Customer’s order Customer’s specification

Commande client Spécification Client
Design according to the catalogue / Construction conforme au catalogue rèf. 4715en-2014.02/c
Machine type Nominal Nominal Nominal Frequency Speed

power voltage current
Machine Puissance Tension Intensité Fréquence Vitesse
type nominale nominale nominale synchrone
Description kVA/kWe V A Hz min-1
LSAM44.3
120 / 96 440 157,5 60 1.800
M6 C6S/4
The machine has been tested according to our specifications and complies with following standards :
IEC 60034-1 and IEC 60072-1. In accordance with the test results which have been made, the machine
is in compliance with these standards. The measured values are within the given tolerances.
The machine a été essayé selon nos specifications et est conforme aux normes suivantes :
CEI 60034-1 et CEI 60072-1. En function des essais effectués dans nos ateliers, le machine est jugé
conforme aux exigences de ces normes. Les valeurs mesurées sont dans le cadre des tolérances
définies.
We confirm that this machine can be used at the mentioned ambient temperature according to :
Nous confirmons que ce machine peut être utilise dans l’ambiance définie selon le règlement :
Lloyd’s Register of Shipping rules (45ºC) □ Det Norske Veritas (45ºC)

□ Germanischer Lloyd (45ºC) □ Bureau Véritas (50ºC)
□ American Bureau of Shipping (50ºC) □ Register Italiano Navale (50ºC)
□
Date / Date Service Technique

21 avril 2016 Technical department
Q1 – T 133 Rév 0 du 17.05.01

DBR Gensets DPL120UK Installation, Operation and Maintenance Manual For YN 513510 (MANUAL-I - 2958658 - 1 - A) - 1

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Installation, Operation

& Maintenance Manual

Drawings, Reports & Certificates

Damen YN. 513510

DBR Generatorsets Tel. +31 (0)184 – 61 32 00

1. ID-DCU Operator Guide LCP

2. User Guide Engine

3. Parts Manual Engine

4. Installation and Maintenance LSA Alternator

5. Instruction Manual Voltage Regulator R438

8. Statements Engine & Generator LR

9. Test Certificates & Reports

DBR Generatorsets Tel. +31 (0)184 – 61 32 00

with electronic engines support

Industrial Applications: SS and AS

January 2013 version r2

Copyright © 2004-2013 ComAp a.s. ComAp a.s.

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -2-

aid Archive file extension for InteliDrive controller

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -4-

!!! CAUTION !!!

Adjust set points

The following instructions are for qualified personnel only.

WARNING – VERY IMPORTANT !!!

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -5-

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -6-

Types of Documents on Web page

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -7-

Pushbuttons and LED’s:

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -8-

How to view measured data?

How to view and edit set points?

How to view the HISTORY menu?

How to change the display contrast?

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 -9-

Controller name (see Basic setting group)

How to change the display backlight intensity?

How to change controller language?

How to find active alarms ?

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 10 -

1. Active controller mode (inverse)

Measuring (instrument) screens

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 11 -

Statistic values can be adjusted from DriveMonitor, password 3 level protected.

Events specification Protection Information available on

ID-DCU Battery voltage <, > WRN YES

Battery flat WRN

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 12 -

Button start ID-DCU panel button

RS232 control Start, Stop, Fault reset, On/Off button

Switched on Controller was switched on

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 13 -

Functions available from ID-DCU front panel keys

Fault code reset Fault reset Alarm list

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 14 -

Binary alarms Analog alarms

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 15 -

Three state Alarm list indication

ECU Alarm list - SPN/FMI codes screen

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 16 -

Direct connection to the PC

Required the same

InteliDrive-DCU - Operator Guide, ©ComAp – January 2013 - 17 -