Thornycroft T-10-K Manuel utilisateur

ORIGINAL INSTRUCTION

RDG603A18 –Issue 14

KEEL COOLED BOAT ENGINE MANUAL

For the following engine models:

T-10-K

T-15-K

T-20-K

RDG603A18 –Issue 14

Page 2 of 82

SAFETY

Thornycroft is concerned for your safety. We use safety statements throughout the manual

to call your attention to the potential hazards associated with the operation of your Thornycroft

engine.

Follow the precautions listed throughout the manual before operation, during operation and

during servicing/maintenance procedures for your safety, the safety of others and to protect

the performance of your engine.

Safety alert symbol appears throughout the manual. It meansattention, be alert as your safety

is involved. Please read and follow the message that appears after the safety alert symbol.

NOTICE:

This indicates a situation which can cause damage to the

machine, personal property and/or the environment or cause the

equipment to operate improperly

CAUTION:

This indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

WARNING:

This indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

DANGER:

This indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

RDG603A18 –Issue 14

Page 3 of 82

Engine Details

Engine Serial Number:

Please enter your engine serial number in the space provided above. Please quote the

engine identification number during any enquiry or when ordering spare parts. Information

about the engine serial number and its location on the engine can be found in SECTION 2 of

the manual.

RDG603A18 –Issue 14

Page 4 of 82

Operators Manual

NOTICE:

THIS MANUAL FORMS AN INTEGRAL PART OF THE ENGINE IT ACCOMPANIES, IF

A TRANSFER OF TITLE OCCURS, IT MUST ALWAYS BE HANDED OVER TO THE

NEW OWNER.

Thank you for purchasing this Keel Cooled Boat Marine Engine from Thornycroft. This

manual has been compiled to help you to operate your engine and its associated parts with

safety and pleasure. Please read it carefully in conjunction with the PRM Gearbox Manual

and familiarise yourself with the engine and its parts before operation. The PRM Gearbox

Manual is also available from the PRM website:

www.prm-newage.com

The information and recommendations given in this manual are based on the latest

information available at the time of publication. Thornycroft reserve the right to change the

specification of its products and manuals without prior notice.

Depending upon the equipment specification of the engine and accessories fitted, there may

be discrepancies with the information presented in this handbook. No claims may be

pursued in this respect.

RDG603A18 –Issue 14

Page 5 of 82

WARRANTY

This UK Limited Warranty provides coverage for One (1) year for recreational users and One

(1) year (or 1000 hours whichever occurs first) for commercial usersfrom the date of warranty

registration. The warranty is for non-serviceable items. The repair or replacement of parts, or

the performance of service under this warranty, does not extend the life of this warranty

beyond its original expiry date.

To ensure that you have been registered for your warranty, please ask your Boat-Builder or

Engine supplier to provide your portion of the registration form.

The Warranty will only apply if the following have been carried out:

1/ The Installation Check List in the Installation Section has been fully completed.

2/ The boat builder or engine installer has completed the Boat Builder Section on the Service

Record Card (located at the back of this manual) regarding hand over and commissioning of

boat.

3/ The registration form has been completed and returned to Thornycroft.

PRM Gearboxes are covered by a one (1) year warranty.

Engine alternator, starter motor and electrical components are only covered by a one (1) year

warranty.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

Warranty coverage is only available from an authorised dealer in the country in which the

sale occurred. Routine maintenance outlined in the Owner’s Manual must be performed using

genuine parts in order to maintain warranty coverage. If the customer performs maintenance,

Thornycroft reserves the right to make future warranty coverage possible only with proof of

proper maintenance.

WARRANTY CLAIMS

Warranty claims shall be made by an authorised dealer or boat builder.

The dealer or boat builder will then arrange for the inspection and any necessary repairs. If

the repairs carried out are not covered by the warranty, the purchaser shall pay for all related

labour and material, and any other expenses associated with that service.

RDG603A18 –Issue 14

Page 6 of 82

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, adjustments, normal wear

and tear, damage caused by abnormal use, operation of the productin a manner inconsistent

with the recommended operation/duty cycle section of the Owner’s Manual, accident,

submersion, improper installation (proper installation specification and techniques are set

forth in the Operations and First time running sections in this manual), use of an accessory

or part not manufactured or sold by us, or alteration or removal of parts. Expenses related

to crane-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance

coverage, loan payments, loss of time, loss of income, or any other types of accidental or

consequential damages are not covered by this warranty.

Engine electrical systems fitted with alternator boost charge systems or any other electrical

management systems are not covered by warranty.

Engine and fuel equipment is not covered by warranty if bio-diesel is used in the fuel system.

Also if no type of water trap is incorporated into the fuel system.

 
RDG603A18 –Issue 14 
Page 7 of 82 
Index Page 
SECTION 1 –Safety Precautions .....................................................................................10 
General......................................................................................................................10 
Lifting.........................................................................................................................10 
Rotating Shafts and Belts ..........................................................................................10 
Exhaust System.........................................................................................................11 
Launching and Lifting Boats.......................................................................................11 
Batteries.....................................................................................................................11 
SECTION 2 –Engine Identification...................................................................................13 
SECTION 3 –Component Identification...........................................................................14 
T-10-K / T-15-K / T-20-K............................................................................................14 
SECTION 4 –Control Panel ..............................................................................................15 
Basic Control Panel...................................................................................................15 
Standard Control Panel..............................................................................................15 
Deluxe Control Panel.................................................................................................16 
Control Panel Overview.............................................................................................16 
Warning Light Procedure...........................................................................................16 
Overall Dimensions of the Basic Control Panel .........................................................19 
Overall Dimensions of the Standard Control Panel....................................................19 
Overall Dimensions of the Deluxe Control Panel.......................................................20 
SECTION 5 –Installation...................................................................................................21 
Ventilation..................................................................................................................21 
Engine Beds ..............................................................................................................21 
Cooling System (Keel Cooled with Skin Tanks).........................................................21 
Skin Tanks (Keel Cooled)..........................................................................................21 
Engine Cooling Water Connections...........................................................................22 
Shaft Connection and Propeller Selection .................................................................23 
Engine Anti-Vibration Mounts ....................................................................................23 
Engine Alignment.......................................................................................................26 

 
RDG603A18 –Issue 14 
Page 8 of 82 
Engine Inclination ......................................................................................................26 
Electrics.....................................................................................................................27 
Electrical Options.......................................................................................................27 
Engine Oil..................................................................................................................27 
Fuel............................................................................................................................28 
Coolant ......................................................................................................................29 
Control Cables...........................................................................................................30 
Domestic Battery Bank ..............................................................................................31 
Control Panel.............................................................................................................31 
Exhaust System.........................................................................................................32 
Hydraulic Drive Transmissions ..................................................................................33 
Installation Check List................................................................................................35 
SECTION 6 –Operation.....................................................................................................36 
Starting the engine for the first time...........................................................................36 
Starting Procedure.....................................................................................................36 
Stopping Procedure...................................................................................................37 
Full Load Running......................................................................................................37 
Refuelling...................................................................................................................37 
Diesel Fuel Additive...................................................................................................38 
Exhaust Back Pressure .............................................................................................38 
Single Shift Control Lever Side Mount Operation - Optional (RDG9210055).............38 
SECTION 7 –Service Procedure ......................................................................................39 
Engine Oil and Filter Change.....................................................................................39 
Air Filter Check and Change......................................................................................40 
Gearbox Oil Change..................................................................................................40 
Disposal of Oil and Related Items..............................................................................41 
Fuel Filter Drain –10 /15 / 20 ....................................................................................42 
Fuel Filter Change.....................................................................................................43 
Fuel System Bleeding................................................................................................44 
Cooling System..........................................................................................................44 

 
RDG603A18 –Issue 14 
Page 9 of 82 
9. Belt Adjustment..........................................................................................................45 
10. Belt Maintenance.......................................................................................................46 
11. Belt Replacement ......................................................................................................46 
12. Control Panel Maintenance........................................................................................47 
SECTION 8 –Service Schedule........................................................................................48 
1. Specifications and Capacities....................................................................................48 
2. Service Intervals........................................................................................................49 
SECTION 9 –Wiring Diagrams .........................................................................................50 
1. Engine Wiring Diagram Thornycroft T-10 / T-15 / T-20..............................................50 
2. Basic Control Panel Wiring Diagram..........................................................................51 
3. Standard Control Panel Wiring Diagram....................................................................52 
4. Deluxe Control Panel Wiring Diagram (Additional Option –SS1551)........................53 
SECTION 10 –Technical Data ..........................................................................................54 
1. Engine Data...............................................................................................................54 
2. Return Diesel System................................................................................................55 
3. Dry Weight of Engine Data ........................................................................................55 
SECTION 11 –Service Parts.............................................................................................56 
SECTION 12 –Declarations..............................................................................................58 
1. Declaration of Conformity for Recreational Craft Propulsion Engines to the Directive 
No 2013/53/EU..........................................................................................................58 
2. Declaration of Conformity for Recreational Craft Propulsion Engine with the 
requirements of the Recreational Craft Regulations 2017 (UKCA Marking). .............59 
3. Declaration of Incorporation of Partly Completed Machinery.....................................60 
SECTION 13 –Lubricant Safety Data Sheets ..................................................................64 
1. Ground Force 10W-40...............................................................................................64 
2. Liquimatic Super ATF ................................................................................................73 
SECTION 14 –Thornycroft Service Record Card ...........................................................82 
 

RDG603A18 –Issue 14

Page 10 of 82

SECTION 1 –Safety Precautions

1. General

NOTICE:

NEVER PERMIT ANYONE TO OPERATE THE ENGINE WITHOUT PROPER

TRAINING.

It is the responsibility of the installer/operator to ensure that the finished installation complies

with CE Marking, UKCA Marking, relevant Health & Safety requirements, the Recreational

Craft Directive and or any other legislative requirements before commissioning.

Ensure that the engine battery isolator switch is in the off position and the key removed from

the control panel before carrying out any maintenance or repairs.

2. Lifting

DANGER:

CRUSH HAZARD! NEVER STAND UNDER A HOISTED ENGINE. IF THE HOIST

MECHANISM FAILS, THE ENGINE WILL FALL ON YOU, CAUSING SERIOUS INJURY

OR DEATH.

The Lifting points supplied with the engine are for lifting the engine/gearbox only. A suitable

spreader bar must be employed to prevent over-stressing either bracket during any lift.

3. Rotating Shafts and Belts

WARNING:

SEVERE HAZARD! KEEP HANDS AND OTHER BODY PARTS AWAY FROM

MOVING/ROTATING PARTS. WEAR TIGHT FITTING CLOTHING AND KEEP YOUR

HAIR SHORT OR TIE BACK. REMOVE ALL JEWELLERY BEFORE COMMENCING

WORK. CHECK BEFORE STARTING THE ENGINE THAT ANY TOOLS OR RAGS

USED DURING MAINTENANCE HAVE BEEN REMOVED FROM THE AREA.

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