Technical File and Copy of United States Environmental Protection Agency (EPA) Statement of Compliance
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1 Technical File and Copy of United States Environmental Protection Agency (EPA) Statement of Compliance MARINE DIESEL ENGINES D7.3L DI LD / D7.3L D-Tronic (Mercury MerCruiser D7.3L LD D-Tronic and D7.3L D-Tronic Models) IMPORTANT: To comply with regulations this document must remain with the engine at all times. Printed in U.S.A OCTOBER , Mercury Marine
2 Technical File for MerCruiser D7.3L DI LD In accordance with the IMO Annex VI NOx Technical Code concerning the exhaust gas emissions of marine engines Trade mark Engine Type Commercial Description Mercury MerCruiser V-8 Cylinder Diesel D7.3L DI LD D7.3L DI D-Tronic Communication Addresses MerCruiser 3003 N. Perkins Road Stillwater, Oklahoma USA International Phone Number OCTOBER 2000
3 INDEX GENERAL INFORMATION 1. Description of Engine 3 2. Cooling System 3 3. Allowable Temperatures 3 4. Air Intake System 3 5. Turbocharger 4 6. Fuel System 4 7. Valves 4 ANNEX 1 Illustrations 1. Cooling System 5 2. Turbocharger System 5 3. Fuel Injection System 6 ANNEX 2 Checklist for Engine Parameter Check Method 1. Injection Timing 7 2. Injection Nozzle 7 3. Injection Pump 7 4. Fuel Cam 7 5. Injection Pressure 8 6. Combustion Chamber 8 7. Compression Ratio 8 8. Turbocharger 9 9. Charge Air Cooler Valve timing Water injection Emulsified fuel Exhaust gas recirculation Selective catalytic reduction 9 ANNEX 3 Test Report Engine information: 10 Specified ambient conditions: 10 Application/Intended for: 10 Emissions test results: 11 Engine family/group information (common specifications): 11 Miscellaneous features: 11 Engine family/group information (selection of parent engine for test-bed test): 11 Exhaust pipe: 12 Measurement equipment: 12 Fuel characteristics: 13 Engine, ambient conditions, and gaseous emissions data: 14-16
4 General Engine family Date (D/M/Y) 7/3/00 Page 3 of 20 General Information 1. Description of the engines 1.1. Brand name : Mercury MerCruiser 1.2. Engine type : V-8 Cylinder Diesel 1.3. Fuel : Diesel 1.4. Working principle : 4-stroke Ignition system : Compression Combustion system : Direct Injection 1.5. Bore : mm (4.111 in) 1.6. Stroke : mm (4.181 in) 1.7. Displacement : 7271 cc (444 ci) 1.8. Number of cylinders : Firing order : Location of the manufacturer's : On top of air plenum housing, plate, engine number aft end of engine 2. Cooling system 2.1. Fresh-water cooling : Yes 2.2. Diagram of the cooling system : See ANNEX 1 Illustration Type of fluid cooling : 50/50 antifreeze and water Cooling pump Type : Impeller Speed : 4490 min -1 at rated engine speed 3. Allowable temperatures 3.1. Liquid cooling : 103 C max. (217 F) 3.2. Radiator/ Heat exchanger : 103 C max. (217 F) 3.4. Fuel temperature -Maximum : 38 o C (100 F) -Minimum : -10 o C (14 F) 3.5. Lubricant : 120 o C max. (248 F) 4. Air-Intake system 4.1. Air intake filter Type : Wire mesh (Metex/853379)
5 General Engine family Date (D/M/Y) 7/3/00 Page 4 of Turbocharger, charge air cooling 5.1 Diagram of the turbocharger system : See ANNEX 1, Illustration 2 6. Fuel System 6.1. Diagram of the complete system : See ANNEX 1, Illustration Feed pump : Cam actuated diaphragm pump 6.3. Fuel filter : Water separating paper element 6.4. Idle speed : 650 min min -1 in Forward gear 6.5. Start of overspeed control under load : n = min End of overspeed control without load : n = min Governor -Type : Electronic (ECM controlled) 7. Valves Exhaust Intake 7.1. Valve stroke : 6.43 mm (.2531 in) 6.44 mm (.2535 in) Opening (BTDC) : Closing (ATDC) : Open/closed 1.27 mm (.050 in) lift 7.2. Adjusting clearance : N/A (Hydraulic)
6 Illustration 1 & 2 Annex 1 Engine family Date (D/M/Y) 7/3/00 Page 5 of 20 COOLING SYSTEM (Illustration 1) TURBOCHARGER (Illustration 2) Air enters the air cleaner where it is compressed by the turbo compressor pump. From there it is forced into the intercooler where it has a boost pressure of mbar (20-24 psi) at rated rpm. It then enters the intake manifold and is compressed into the combustion chamber and exits as exhaust gas. The exhaust passes through the turbocharger and out through the exhaust elbow.
7 Illustration 3 Annex 1 Engine family Date (D/M/Y) 7/3/00 Page 6 of 20 FUEL INJECTION SYSTEM (Illustration 3)
8 Parameter check list Annex 2 IMO Engine family Date (D/M/Y) 7/3/00 Page 7 of 20 Checklist for Engine Parameter Check Method This parameter checklist is to be used to demonstrate compliance with NO x emission limits on board ship. 1. Injection Timing 1.1 Static Timing : Electronically controlled 1.2 Injection quantity at full Load and speed : liters per hour (18.50 gallons per hour) at 3600 rpm 1.3 Dynamic timing : Cal. PMC3AF03.bin / Check sum D Injection Nozzle 2.1 Brand : Navistar 2.2 Type : HEUI 2.3 Part Number : Injection Pump 3.1 Brand : Navistar 3.2 Type : Unit injectors 3.3 Part Number : Fuel Cam 4.1 Part Number : N/A 4.2 Specify Shape : N/A
9 Parameter check list Annex 2 IMO Engine family Date (D/M/Y) 7/3/00 Page 8 of Injection Pressure 5.1 Common Rail : N/A 5.2 Feed Pump Pressure : kpa (4-6 psi) 5.3 Injection Pump Pressure : 1241 bar (18,000 psi) 6. Combustion Chamber 6.1 Piston: Brand : Zollner Part Number : A1 6.2 Cylinder Head Brand : Navistar Part Number : A1 7. Compression Ratio 7.1 Compression ratio : : 1
10 Parameter check list Annex 2 IMO Engine family Date (D/M/Y) 7/3/00 Page 9 of Turbocharger Type and Build 8.1 Brand : Schwitzer 8.2 Type : Exhaust Gas Turbine 8.3 Part number : Wastegate Brand : N/A Type : N/A Part Number : N/A 8.5 Maximum boost pressure : 165 kpa (24 psi) 8.6 Minimum boost pressure : 0 kpa (0psi) 9. Charge Air Cooler or Charge Air Preheater 9.1 Charge Air Preheater : N/A 9.2 Charge Air Cooler: Brand : Modine Type : Water-cooled heat exchanger Part Number : Valve Timing 10.1 Only for four stroke engines with inlet valve closure before BDC : N/A 11. Water Injection : N/A 12. Emulsified Fuel : N/A 13. Exhaust Gas Recirculation : N/A 14. Selective Catalytic Reduction : N/A
11 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 10 of 20 Engine Manufacturer Mercury MerCruiser Engine type V-8 Cylinder Diesel Family or group identification D7.3L DI LD Serial number L Rated speed RPM Rated power 194 kw (260 HP) Intermediate speed 2575 RPM Maximum torque at intermediate speed 549 N m (405 lbs.ft) Static injection timing N/A Electronic injection control No: yes: X Variable injection timing No: yes: X Variable turbocharger geometry No: X yes: Bore mm (4.111 in) Stroke mm (4.181 in) Nominal compression ratio : 1 Cylinder number and configuration Number: 8 V: X In-line: Auxiliaries Tested in onboard configuration per Specified ambient conditions: Maximum seawater temperature 38 C (100 F) Maximum charge air temperature, if applicable Engine air not to exceed air temperature outside engine compartment by more than 17 C (63 F). Cooling system spec. intermediate cooler Operating temperature range C ( F) Cooling system spec. charge air stages Same temperature of incoming sea water Low/high temperature Cooling system set points Thermostat fully closed 65 C (149 F), fully 84 C (183 F) Maximum inlet depression Not Adjustable Maximum exhaust backpressure kpa (1.50 psi) Fuel oil specification Grade 2-D diesel fuel, meeting standards ASTM D975 or DIN 51601, Minimum cetane rating of 45. Fuel oil temperature Minimum -5 C (23 F), Maximum 50 C (122 F) at fuel filter Lubricating oil specification Mercury Precision Parts 4-Cycle Marine Engine Oil 25W-40 Application/Intended for: Customer Pleasure craft (planing hull) Light commercial (Non-planning hull) Final application/installation, ship N/A Final application/installation, engine Main: X Aux:
12 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 11 of 20 Emissions test results: Cycle ISO E3 NO x (g/kw-hr) 8.89 (average of the three tests performed) Date(s) (D/M/Y) 3/2/00, 3/2/00, 3/2/00 Test number(s) 2253, 2254, 2255 Engine family information/group information (common specifications) Combustion cycle 4-cycle Cooling medium Water-cooled heat exchanger Cylinder configuration V-8 Method of aspiration Turbo charged Fuel type to be used on board Diesel Combustion chamber Ref. Annex 2, 6. Valve port configuration Ref. Annex 2, 6. Valve size and number Ref. Annex 2, 6. or proprietary Fuel system type HEUI (ref. Annex 1, illustration 3) Miscellaneous features: Exhaust gas recirculation N/A Water injection/emulsion N/A Air injection N/A Charge cooling system Yes, ref. Annex 1, Illustrations 1 Exhaust after-treatment N/A Exhaust after-treatment type N/A Dual fuel N/A Engine family/group information (selection of parent engine for test-bed test) Family/group identification D7.3L DI Method of pressure charging Turbo charged Charge air cooling system ref. Annex 1, Illustrations 1 Criteria of the selection (specify) Higher NOx emissions Number of cylinder 8 Max. rated power per cylinder 28 kw (37.5 HP) Rated speed 3600 Injection timing (range) 0-40 Max. fuel parent engine 22 g-hr Selected parent engine D7.3L DI D-Tronic (300 HP) Application Pleasure craft (planning hull)
13 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 12 of 20 Exhaust pipe Diameter 7.62 cm (3 in) ID dry exhaust and cm (4 in) OD of water jacketed exhaust Length Determined by the boat builder Insulation Water jacketed up to the exhaust elbow Probe location Exhaust elbow Measurement equipment Manufacturer Model Measurement ranges Calibration Span gas conc. Deviation Analyzer NO x analyzer Pierburg CLD PM N/A 2 % % % % CO analyzer Pierburg BINOS % % % 4 N/A 2 % CO 2 analyzer Pierburg BINOS N/A 2 % 2 N/A 2 % 3 N/A 2 % % O 2 analyzer Pierburg Oxymat N/A 2 % % 3 N/A 2 % 4 N/A 2 % HC analyzer Pierburg FID PM N/A 2 % % % % Speed Digalog ,000 min -1 1 min -1 per 10,000 Torque Omega Nm Nm Fuel flow Micromotion CMF lbs.min. Flow: +.10% Density: % Temperatures temperatures Omega E-type C + 1 C Pressures Pressures Sensotec Type A kpa kpa Humidity Intake air 5-98 % + 1 %
14 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 13 of 20 Fuel Characteristics Fuel type: No. 2 fuel oil - low sulfur Fuel properties: ASTM test method: Specifications: Gravity, 60 F D min. Sulfur, Wt % D min. Cetane index D min Flash point, F, origin D min. Viscosity, 104 F D
15 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 14 of 20 Ambient data Test Mode Power % Speed % Atmospheric pressure (kpa) Intake air temperature ( C) Intake air Humidity (RH %) Atmospheric factor (fa) % 100 % % 91 % % 80 % % 63 % % 100 % % 91 % % 80 % % 63 % % 100 % % 91 % % 80 % % 63 % Test Mode NO x concentration wet (% FS) Gaseous emissions data CO concentration dry (% FS) 2.18 CO 2 concentration dry (% FS) O 2 concentration dry (% FS) 43.1 HC concentration wet (% FS)
16 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 15 of
17 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 16 of 20 Gaseous emissions data Test Mode NO x humidity correction factor Fuel specification factor (FFH) NO x mass flow (g/hr) CO mass flow (g/hr) HC mass flow (g/hr) NO x specific (g/kw-hr) Gaseous emissions data Test Mode Specific fuel (g/kw-hr) Engine data Speed (min -1 ) Power (kw) Fuel flow (kg/hr) Exhaust back pressure (mbar) Coolant in ( C)
18 Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 17 of 20 Engine data Test Mode Coolant out ( C) Intercooler air temperature ( C) Lubricant temperature ( C) Lubricant pressure (bar) Fuel rack (mm) Not adj Not adj Not adj Not adj Not adj Not adj Not adj Not adj Not adj Not adj Not adj Not adj. Engine data Test Mode
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