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. 90-862792 OCTOBER 2000 2000, Mercury Marine
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 74075-2299 405-743-6566 International Phone Number 001-405-743-6566 90-862792 OCTOBER 2000
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 9 10. Valve timing 9 11. Water injection 9 12. Emulsified fuel 9 13. Exhaust gas recirculation 9 14. 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
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 : 104.39 mm (4.111 in) 1.6. Stroke : 106.20 mm (4.181 in) 1.7. Displacement : 7271 cc (444 ci) 1.8. Number of cylinders : 8 1.9. Firing order : 1-2-7-3-4-5-6-8 1.10. 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 1. 2.3. Type of fluid cooling : 50/50 antifreeze and water 2.1.4. 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)
General Engine family Date (D/M/Y) 7/3/00 Page 4 of 20 5. 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 3 6.2. Feed pump : Cam actuated diaphragm pump 6.3. Fuel filter : Water separating paper element 6.4. Idle speed : 650 min -1 + 25 min -1 in Forward gear 6.5. Start of overspeed control under load : n = 3650 + 50 min -1 6.6. End of overspeed control without load : n = 3950 + 50 min -1 6.7. 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) : 51.2 17.2 Closing (ATDC) : 20.8 42.8 Open/closed angles @ 1.27 mm (.050 in) lift 7.2. Adjusting clearance : N/A (Hydraulic)
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 1379-1655 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.
Illustration 3 Annex 1 Engine family Date (D/M/Y) 7/3/00 Page 6 of 20 FUEL INJECTION SYSTEM (Illustration 3)
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 : 70.08 liters per hour (18.50 gallons per hour) at 3600 rpm 1.3 Dynamic timing : Cal. PMC3AF03.bin / Check sum D4 74 2. Injection Nozzle 2.1 Brand : Navistar 2.2 Type : HEUI 2.3 Part Number : 853280 3. Injection Pump 3.1 Brand : Navistar 3.2 Type : Unit injectors 3.3 Part Number : 853280 4. Fuel Cam 4.1 Part Number : N/A 4.2 Specify Shape : N/A
Parameter check list Annex 2 IMO Engine family Date (D/M/Y) 7/3/00 Page 8 of 20 5. Injection Pressure 5.1 Common Rail : N/A 5.2 Feed Pump Pressure : 28-41 kpa (4-6 psi) 5.3 Injection Pump Pressure : 1241 bar (18,000 psi) 6. Combustion Chamber 6.1 Piston: 6.1.1 Brand : Zollner 6.1.2 Part Number : 737-853013A1 6.2 Cylinder Head 6.2.1 Brand : Navistar 6.2.2 Part Number : 938-853124A1 7. Compression Ratio 7.1 Compression ratio : 15 +.5: 1
Parameter check list Annex 2 IMO Engine family Date (D/M/Y) 7/3/00 Page 9 of 20 8. Turbocharger Type and Build 8.1 Brand : Schwitzer 8.2 Type : Exhaust Gas Turbine 8.3 Part number : 853164 8.4 Wastegate 8.4.1 Brand : N/A 8.4.2 Type : N/A 8.4.3 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: 9.2.1 Brand : Modine 9.2.2 Type : Water-cooled heat exchanger 9.2.3 Part Number : 853369 10. 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
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 L050054 Rated speed 3600-3800 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 104.39 mm (4.111 in) Stroke 106.20 mm (4.181 in) Nominal compression ratio 15 +.5: 1 Cylinder number and configuration Number: 8 V: X In-line: Auxiliaries Tested in onboard configuration per 1.3.1.4 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 80-85 C (176-185 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 open @ 84 C (183 F) Maximum inlet depression Not Adjustable Maximum exhaust backpressure 10. 3 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:
Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 11 of 20 Emissions test results: Cycle ISO 8178-4 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)
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 10.16 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-2000 1 N/A 2 % 2 98.3 2 % 3 967. 2 % 4 4750 2 % CO analyzer Pierburg BINOS 2000 1.464 2 % 2 1.77 2 % 3 9.59 2 % 4 N/A 2 % CO 2 analyzer Pierburg BINOS 2000 1 N/A 2 % 2 N/A 2 % 3 N/A 2 % 4 15.19 2 % O 2 analyzer Pierburg Oxymat 2000 1 N/A 2 % 2 4.98 2 % 3 N/A 2 % 4 N/A 2 % HC analyzer Pierburg FID PM-2000 1 N/A 2 % 2 294. 2 % 3 881. 2 % 4 9110. 2 % Speed Digalog 100-10,000 min -1 1 min -1 per 10,000 Torque Omega 0-1356 Nm + 1.4 Nm Fuel flow Micromotion CMF 010 0-40 lbs.min. Flow: +.10% Density: +.0005 % Temperatures temperatures Omega E-type 0-1000 C + 1 C Pressures Pressures Sensotec Type A-5-103-689 kpa +.689 kpa Humidity Intake air 5-98 % + 1 %
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, API @ 60 F D1298 30.7 min. Sulfur, Wt % D4294.047 min. Cetane index D976 41.0 min Flash point, F, PM @ origin D93 140 min. Viscosity, CST @ 104 F D445 1.9-3.4
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) 2253 1 100 % 100 % 99 24 29.997 2253 2 75 % 91 % 99 24 29.997 2253 3 50 % 80 % 99 24 28.996 2253 4 25 % 63 % 99 24 28.997 2254 1 100 % 100 % 99 26 26 1.003 2254 2 75 % 91 % 99 26 25 1.001 2254 3 50 % 80 % 99 26 23 1.001 2254 4 25 % 63 % 99 26 22 1.001 2255 1 100 % 100 % 99 25 23 1.001 2255 2 75 % 91 % 99 26 22 1.002 2255 3 50 % 80 % 99 26 21 1.001 2255 4 25 % 63 % 99 26 21 1.000 Test Mode NO x concentration wet (% FS) 2253 1 Gaseous emissions data 72.64 CO concentration dry (% FS) 2.18 CO 2 concentration dry (% FS) 36.82 O 2 concentration dry (% FS) 43.1 HC concentration wet (% FS) 3.7 2253 2 2253 3 11.17 12.25 1.43 1.5 32.98 29.68 47.23 50.88 3.53 3.98 2253 4 56.5 3.7 24.79 56.09 9.57 2254 1 73.7 1.84 36.85 43.38 2.95 2254 2 53.68 1.05 32.98 47.45 3.16 2254 3 59.34 1.07 29.66 50.86 3.95 2254 4 56.87 3.32 24.63 55.9 9.2 2255 1 73.96 2.02 36.78 43.19 3.21 2255 2 54.05 1.03 32.83 47.18 3.27
Test report Annex 3 Engine family Date (D/M/Y) 7/3/00 Page 15 of 20 2255 3 60.32 1.08 29.52 50.69 4.16 2255 4 57.13 3.33 24.57 55.91 10.25
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 2253 1.85 Fuel specification factor (FFH) 2253 2.85 1.86 2253 3.85 2253 4.85 2254 1.84 2254 2.84 1.86 2254 3.84 2254 4.85 2255 1.83 2255 2.83 1.86 2255 3.83 2255 4.84 NO x mass flow (g/hr) 1945 1215 946 535 1974 1164 922 544 1988 1178 947 550 1 1 1 CO mass flow (g/hr) 166 89 67 102 140 65 48 92 155 64 49 93 HC mass flow (g/hr) 3 2.32 1.86 2.74 2.39 2.07 1.85 2.66 2.61 2.15 1.97 2.97 NO x specific (g/kw-hr) 8.95 8.81 8.91 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) 2253 1 3604 198 56 276 29 2253 2 276 3274 149 41 228 29 2253 3 2878 99 26 159 29 2253 4 2275 49 14 103 29 2254 1 3605 198 56 276 29 2254 2 276 3273 148 41 228 29 2254 3 2879 99 26 159 29 2254 4 2271 49 14 103 29 2255 1 3606 198 56 276 29 2255 2 277 3273 148 41 228 29 2255 3 2879 99 27 159 29 2255 4 2275 49 14 103 29
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) 2253 1 81 64 71 4 Not adj. 2253 2 81 50 69 4 Not adj. 2253 3 79 37 67 4 Not adj. 2253 4 77 28 64 4 Not adj. 2254 1 82 66 71 4 Not adj. 2254 2 81 52 70 4 Not adj. 2254 3 80 38 67 4 Not adj. 2254 4 77 25 63 4 Not adj. 2255 1 82 66 71 4 Not adj. 2255 2 81 51 71 4 Not adj. 2255 3 80 37 67 4 Not adj. 2255 4 77 26 63 4 Not adj. Engine data Test Mode 2253 1 2253 2 2253 3 2253 4 2254 1 2254 2 2254 3 2254 4 2255 1 2255 2 2255 3 2255 4