Canaline 38 User guide

Canaline
Marine Engines
Owners Handbook
Engines Models
Canaline 38
Canaline 42
Canaline 52
Canaline 60
Canaline 70T
Failure to read this or carry out the required servic
e programme may invalidate your warranty

2

3
Index
Introduction 4
Engine Identification 5
Symbols in the Manual and on Engines 6
Safety precautions 7
Canaline Engine Technical Data
Starting & Stopping the engine 10
Fuel, Oil & Coolant Specifications 13
Maintenance Schedule 16
Installation Information
Wiring diagrams & battery Cables 24
Anti-Vibration Mounts / Alignment installation 2
Exhaust Systems 30
Calorifier Connections / Position 31
PRM 125 Cable installation 33
Laying-up Considerations 33
Fast Moving Parts list 34
UK Dealer Network 35
Declaration of Conformity Certificate 36
Emission Durability Statement 37
Warranty Terms and conditions 38
Service Record 41
Warranty registration card Loose

4
Introduction
This Canaline Marine diesel engine is based on the Kioti diesel engine which is
manufactured by Daedong Industrial Co Ltd.
Engines Plus Ltd wishes to thank you for urchasing your new Canaline Marine Diesel
engine. Your new engine is the result of many years of research and develo ment,
and high quality manufacturing. This engine is designed based on strict quality
standards a lied to and use of Kioti genuine com onents. Its knowledge on the
o eration of the diesel engine is based on faithful service and reliability for years.
This manual makes users familiar with the diesel engine and rovides useful
information on safety, o eration, and maintenance of the diesel engine.
To get the fullest use and benefit from your marine engine, it is im ortant that you
install, o erate and maintain it correctly. This manual, along with gearbox o erators’
handbook, is designed to hel you do this.
Please read this manual carefully and follow its o erating maintenance
recommendations, along with the installation guidelines. This will ensure many years
of trouble-free and economical engine o eration.
Should you require further advice, technical assistance or an engine service, lease
contact your nearest marine engine outlet, he knows your engine best and is ready to
meet your requirements.
On com letion of the warranty registration card, lease return it to Engines Plus Ltd,
where we can log it.
All information, illustrations, and s ecifications contained in this Manual are based on
the latest roduct information available at the time of ublication.
Engines Plus Ltd is a mariniser of industrial diesel engines, of which the Canaline
roduct is art of our roduct ortfolio. Engines Plus Ltd roduces this manual for use
on the Canaline marine engine based on the Kioti Diesel engine.
Engines Plus Ltd reserves the right to make changes in this manual at any time
without rior notice.
The information given is subject to the com any’s current conditions of Tender and
Sale, is for the assistance of users, and is based u on results obtained from tests
carried out at the lace of manufacture and in vessels used for develo ment
ur oses. We do not guarantee the same results will be obtained elsewhere under
different conditions.

5
Engine Identification
NOTE: In all communications with the Engines Plus Ltd or a local dealer the engine
serial number and engine ty e must be quoted.
The engine serial number is on a decal affixed to the to surface of the Rocker Cover,
as shown below. The Kioti Engine Number is also stam ed on the Engine Block,
outboard of the Injection Pum Flange.
As art of your engine warranty lease return your registration card, which is
su lied loose, as soon as ossible.
Engine Information
Fill in your engine information below, so you have it to hand when contacting your
local dealer.
Engine Ty e:
EP Serial No:
Gearbox Ty e:
Gearbox Number:
Date of Installation:
Engines Plus Ltd
Engine Serial Number Decal
Kioti Engine Serial Number Stam ing

6
Prescription-Indication notices (rectangle);
it is obligatory to adopt the protective
measures shown in the notices to perform
the operation in question in total safety.
Danger arning-Attention Notices
(triangular); General Attention
regarding personal safety and
protection of the engine
Prohibition Notices (Circular)
indicating potentially hazardous
situations.
Identification Notices (No Border)
Symbols in the Manual and on Engines
General o erational note
Protect hands (Gloves)
Protect eyes (Safety Glasses)
Protect res iratory assages (Mask)
Danger! General Danger situation
Danger! Electrical Discharges
Danger! Sources of Heat
Danger! Engine Coolant Pressure
The o eration indicated in the text
is strictly prohibited
Danger! From moving Parts ~ do not
erform maintenance work.
Engine Coolant Level
Engine Oil Level
Engine Lubricating Oil ~ Fill Point
Lifting Point ~ Engine & Gearbox ONLY
Engine Coolant ~ Fill Point
Read the Manual.

7
Safety Precautions
Keep the engine, gearbox and surrounding area clean, including the area
immediately below the engine.
Drives Power Take Off Areas
Gearbox Output Flange
The ur ose of the marine diesel ro ulsion engine is to rovide motive ower to
ro el a vessel. Accordingly the gearbox out ut shaft rotates and its flange is
designed to be cou led to a ro eller shaft by the installer. Ste s must be taken
to ensure adequate guarding.
Forward End Drive
Engines are su lied with unguarded vee and oly vee belt drives to ower the
fresh water um and battery-charging alternator. The installer must ensure that
it is not ossible for injury to occur by allowing accessibility to this area of the
engine. The drives can cause injury if ersonnel or clothing come in contact with
the moving belts or ulleys, when the engine is running.
Exhaust Do not touch Hot Surfaces
Exhaust Outlet
Diesel marine ro ulsion engines emit exhaust gases at high tem eratures –
around 400 - 500°C. Engines are su lied with either wet exhaust outlet (water
injection bend) or dry outlet (dry exhaust stub) – see engine rice list. At the
outlet next to the heat exchange header tank, the exhaust outlet can become
very hot and if touched, can injure. This must be lagged or avoided by ensuring
adequate guarding. It is the res onsibility of the installer to lag the exhaust
system if a dry system is used. Exhaust gases are harmful if ingested, the
installer must therefore ensure that exhaust lines are routed overboard and that
leakage into the vessel does not occur.
Fuel Do not ingest liquids
Fuel Lines
Diesel engines are equi ed with high ressure fuel injection um s, if leakage
should occur, or i es fracture, fuel at high ressure can be harmful. Skin must
be thoroughly cleaned in the event of contact with diesel fuel.
Fuel Supply Connections
Engines are su lied with 8mm fittings. The installer must ensure that when
connections are made, they are clean and free of leaks.

8
Oil Do not ingest liquids
The Canaline marine ro ulsion ackage is su lied with 2 di sticks, one for the
engine and one for the gearbox. Ensure di sticks are returned and secure after
checking. If not, oil leaks can cause infection when touched. Do not remove
di sticks whilst engine is running, as this can cause oil to blow out. All oil must be
removed from the skin to revent infection.
Scalding Do not remove Pressure Cap when Hot
An engine running under load will have a closed circuit fresh water tem erature of
71° to 85°C. The ressure ca on the to of the header tank must not be
removed when the engine is running. It should only be removed when the engine
is sto ed and has cooled down.
Transportation/Lifting
Engines are su lied on trans ortable allets. Lifting eyes on engines are used
for lifting engine and gearbox assembly only, not the allet and associated kit.
GENERAL DECLARATION
This machinery is not intended to be ut into service until it has been incor orated
into or with other machinery. It is the res onsibility of the urchaser/installer/owner,
to ensure that the machinery is ro erly guarded and that all necessary health and
safety requirements, in accordance with the laws of the relevant country, are met
before it is ut into service.
Note: Recreational Craft
Where a licable, the urchaser/installer/owner and o erator must be res onsible for
making sure that Directive 2013/53/EU is com lied with.

9
Canal Boat Engines – Technical Data
Model Canaline
38
Canaline
42
Canaline
52
Canaline
60
Canaline
70T
Cylinders 4 4 4 4 4
Bore mm 83.0 83.0 87.0 87.0 87.0
Stroke mm 92.4 92.4 92.4 102.4 102.4
Displacement
cc 1999 1999 2179 2430 2430
Combustion
Indirect Injection
Cooling Keel Cooled
Power
Output Bh 38 42 52 57 65
ISO 8665
Rated Power
@ Speed
kW 29.2 32.6 32.6 35.2 41.9
r/min 2600 2600 2600 2600 2600
Max Torque
Nm 125 131 145 158 192
r/min 1600 1600 1600 1600 1800
Oil Capacity
litres 8.0 8.0 8.0 9.7 9.7
Weight kg 235 237 248 256 256
Engine
Coolant
Capacity
Litres 7.5 7.5 7.5 8.3 7.3
Alternator Am s 75 & 100
75 & 175
75 & 175
75 & 175
75 & 175
Starter Motor
kW 1.7
Air Intake
restriction kPa 2.45 max
Exhaust Back
Pressure kPA 10.0 max
Ventilation
required M3/min 2.25 2.25 2.65 3.07 3.15
Gearbox PRM 125 PRM 150 PRM 150 PRM 150 PRM 150
Starter
Battery size
Minimum recommended size - 700 CCA / 100 Ah
Note: The specification details above are for standard configurations.
BHP* ~ to EN IS 8665

10
Starting and Stopping
Important checks prior to use
Your engine has been filled with new oil for both engine and gearbox when it leaves
the factory. However, lease check, see the section on engine maintenance.
Ensure the engine is free to turn without obstructions, and daily checks have been
carried out.
Ensure battery is fully charged and connected (the isolator is in the ‘ON’ osition).
Ensure Morse s eed and gearbox cables are fitted correctly and that cable travel
lengths are correct.
Ensure fuel ta s from fuel tank have been turned on
CAUTION: for safety’s sake conduct checks above, with engine stopped,
before starting.
Engine starting
Check the engine and gearbox oil levels are correct ~ see relevant section in this
manual for further information.
• Set the engine throttle to 1/3, out of gear.
• Turn the Key to the “1” Position.
The anel will go through a rocedure to ensure all lights and the buzzer are working,
once this has been com leted you can then start the engine.
• Turn the Key to Pre-Heat, and hold until the Yellow light goes out.
• Turn the Key to the Start/Crank osition and release when the engine fires.
Ensure alarm buzzer is not sounding and red warning lights are off.
Note:
If the alternator warning light is still on then increase the engine s eed to excite the
alternator, then return to idle. The light should then go out.
Make sure the engine is running smoothly, with no smoke and sounds normal.
Re eated engagement of the starter to the flywheel ring gear without a break will
result in damage to the starter inion gear and flywheel ring gear. It will also cause
excessive build-u of heat in the Starter Motor Windings.
It may also cause the Engine Sto Solenoid to burn out due to heat build-u .
Crank for no longer than 20 seconds, with at least a 20 second break between
attem ts.
The oil ressure gauge on the deluxe engine control anel may read high on start-u
and whilst the engine is cold. This is normal, and it will then decrease to the running
level.

11
STOPPING
Every ro ulsion engine is fitted with a sto solenoid. To sto engine sim ly turn the
key to the “0” osition and the engine will sto .
When leaving the boat for an extended eriod, turn off battery isolator.
Canaline Engine Control Panels
Canaline Engine control anels feature LED Module to indicate as listed below. An
Intermediate Panel is shown for illustration only.
1 4
2 5
3 6
1. Yellow ~ Timed Preheat LED
Illuminates when Key is switched to preheat position to indicate Preheat time.
2. Red & Buzzer ~ Engine Coolant Tem erature
LED Illuminates and Buzzer sounds if Engine Temperature is too high.
3. Red & Buzzer ~ Starter Alternator
LED Illuminates and Buzzer sounds if no charge from Alternator or Belt breaks.
4. Green ~ Panel Power
LED illuminates when Key is switched on.
5. Red & Buzzer ~ Engine Oil Pressure
LED Illuminates and Buzzer sounds if Oil Pressure is too low.
6. Red & Buzzer ~ Auxiliary / Domestic Alternator
LED Illuminates and Buzzer sounds if there is no charge from Alternator or Belt breaks.

12
Checks during operation
While o erating the engine, kee checking whether all arts of the engine are
o erating smoothly and correctly.
COOLING SYSTEM Do not remove Pressure Cap when Hot
If steam or coolant is esca ing from the overflow tube; sto the engine, allow it to
cool, and check the following and correct as needed.
1. Check for cooling system leaks.
2. Check for obstructions that block cooling air.
3. Check and adjust the fan belt tension.
4. Ensure that the system is filled to the correct coolant level with the ro er mix of
Coolant Concentrate (anti-freeze) and water.
5. Check the radiator ca for ro er ty e and condition.
IMPORTANT
To avoid personal injury:
DO NOT remove the Manicooler cap while the engine is hot.
Pressurized steam or coolant will escape and cause serious injury to
you and any bystanders.
Open the cap at least 10 minutes after the engine is stopped.
OIL PRESSURE LED
The oil ressure LED comes on when the oil ressure dro s below a safe level. If the
lam comes on while the engine is o erated at or above 850 r m, immediately sto
the engine and check the engine oil level.
FUEL
The fuel tank should never be allowed to become com letely em ty. An em ty tank
will allow air into the fuel system; and the engine will not o erate without bleeding
the fuel system.
EXHAUST SMOKE
The engine exhaust should be colorless during normal o eration within the rated
out ut of the engine. Continuous dark emissions or smoke may indicate im ro er
usage or an engine malfunction.
STOP THE ENGINE IMMEDIATELY:
1. If the engine s eed suddenly changes.
2. If there is an unusual noise.
3. If the engine exhausts suddenly darkens.
4. If the oil ressure, tem erature light or alternator comes on.

13
Fuel and il Specifications
Fuel
Important
• It is advisable to fit a fuel/water se arator in the fuel su ly system. Water in the
fuel can damage the injection system. However if the engine is being fitted into an
existing boat (re-installation), it is com ulsory to fit a fuel/water se arator
• If a fuel su ly shutoff valve is fitted do not use a ta er ta , only use a ball valve
ta . The ball valve ty e are more reliable and less likely to let air into the fuel
system.
• Do not use Kerosene, which is very low in cetane rating and lubricity, and may
adversely affect the engine.
• Be careful not to let the fuel tank become em ty, or air can enter the fuel system,
necessitating bleeding before next engine start.
Fuel selection
The following criteria is required for the diesel fuel…
1. Must be free from minute dust articles.
2. Must have adequate viscosity.
3. Must have high cetane value.
4. Must have high fluidity at low tem erature.
5. Must have low sul hur content.
6. Must have little residual carbon.
Diesel fuels
Applicable standard Recommendation
JIS (Ja anese Industrial Standard)
DIN (Deutsches Institut für Normung)
SAE (Society of Automotive Engineers)
Based on SAE-J-313C
BS (British Standard)
NO. 2
DIN 51601
NO.2-D
BS EN590:2009
If fuel other than s ecified is used, engine functions will be lowered.
Fuel Requirements
NOTICE: The fuel injection um , injector or other arts of the fuel system and
engine can be damaged if you use any fuel or fuel additive other than those
s ecifically recommended by Canaline / Kioti.
Such damage is not the res onsibility of Canaline / Kioti and is not covered by their
Warranty.
To hel avoid fuel system or engine damage, lease read the following:

14
• Some service stations mix used engine oil with diesel fuel. Some manufacturers
of large diesel engines allow this; however for your diesel engine, do not use
diesel fuel, which has been contaminated with engine oil.
• Do not use any fuel additive (other than as recommended under “Biocide” in this
section). At the time this manual was rinted, no other fuel additive was
recommended. (See your authorisation dealer to find out if this has changed).
Fuel system air bleeding
The entry of air into the fuel system will cause difficult engine starting or engine
malfunction. When servicing such as em tying the fuel tank, draining the Water
Sedimenter, and the fuel filter element change, be sure to bleed air.
Air Bleeding Procedure:
1. Please refer to the Changing the Fuel Filter section.
2. Start the engine and thoroughly check the fuel system for leaks.
CAUTION: the water/diesel fuel mixture is flammable and could be hot. To hel
avoid ersonal injury and/or ro erty damage to not touch the fuel coming from the
drain valve and do not ex ose the fuel to o en flames or s arks. Be sure you do not
overfill the container. Heat (such as from the engine) can cause the fuel to ex and.
If the container is too full, fuel could be forced out of the container. This could lead
to a fire and the risk of ersonal injury and/or vehicle or equi ment damage.
Biocides
In warm or humid weather, fungus and/or bacteria may form in diesel fuel if there is
water in the fuel.
NOTICE: fungus or bacteria can cause fuel systems damage by lugging the fuel
lines, fuel filters or injector. They can also cause fuel system corrosion.
If fungus or bacteria has caused roblems, you should have your authorised dealer
correct these roblems. Then, use a diesel fuel biocide to sterilise the fuel system
(follow the biocide manufacturer’s instructions). Biocides are available from your
dealer, service stations, arts stores and other automotive laces. See your
authorised dealer for advice on using biocides in your area and for recommendations
on which biocides you should use.
Smoke suppressants
Because of extensive testing of treated fuel versus untreated fuel, the use of a smoke
su ressant additive is not recommended. This may enhance the ossibility of stuck
rings and valve failure, resulting from extensive ash de osits.
Fuels used should contain no more than 7% Biodiesel. Exceeding this
amount will invalidate Warranty and may affect compliance with Emission
Approval.

15
Lubricant
The quality of engine oil may affect engine erformance, start-ability and engine life.
The use of unsuitable oil may result in iston ring stick, iston and cylinder seizure,
and accelerate sliding surface wear causing increased oil consum tion, lowered
out ut and ossible engine failure.
To avoid this, use the s ecified engine oil.
Engine Oil Selection
Engines Plus Ltd recommends oil to the following s ecifications…
API CC or CD s ecification is used in Canaline 38, 42, 52 & 60 Marine engines.
API CH is used in Canaline 70T Marine engines.
Either 10W/40 or 10W/30 is acce table for tem erate climates.
Do NOT use Synthetic or Semi-Synthetic Oils in Canaline Marine engines.
The correct grade oil is available from your local marine dealer.
• 5 litres API CC 10W/40 – EPL Part No - EP710008 - CL38~60
• 25 litres API CC 10W/40 – EPL Part No - EP710009 – CL38~60
• 5 litres API CH-4 15W/40 – EPL Part No - EP710560 – CL70T ONLY
• 25 litres API CH-4 15W/40 – EPL Part No - EP710561 – CL70T ONLY
Coolant
Two main ty es of Coolant Concentrate (Anti-freeze) are available, and either may be
used…
1. Blue ~ standard Coolant Concentrate, which has a ty ical service life of
12months.
2. Red/Orange ~ Long Life Coolant Concentrate which has a ty ical service life of
2~3 years.
Both ty es should be mixed with clean water, u to a maximum concentration of
50%. Refer to the roduct container or s ecification sheet for frost rotection vs
concentration, and recommended service life.

16
Maintenance
Schedule
Daily or every 8 hours running.
• Check engine oil level.
• Check gearbox oil level, see gearbox manual.
• Check coolant level.
• Check drive belt tension, adjust if necessary.
• Check colour of exhaust fumes and unusual engine noise on start u .
• Check stern gland lubrication.
After first 50 hours.
• Change gearbox lubricant (see se arate gearbox manual).
• Change engine lubricating oil.
• Change oil filter.
• Change fuel filter.
• Check fuel contamination and drain off water tra /Agglomerator if fitted.
• Check Air Filter Element for contamination, and change if necessary.
• Check all water i es are not chaffing and for any leaks, and adjust if necessary.
• Check all fuel i es are not chaffing and for any leaks, and adjust if necessary.
• Check exhaust system for any leaks, etc, and adjust if necessary.
• Check wiring looms and cables are not chaffing, and adjust if necessary.
• Check cou ling alignment and ensure all bolts are tight.
• Check bolts/nuts on the anti-vibration mounts are tight and secure.
• Check control cables installation to ensure gearbox is correctly being engaged, and
adjust if necessary.
Every 200 hours or every year.
• As 50 hours and the following -
• Check air cleaner element and re lace if necessary.
• Change oil and oil filter.
Every 400 hours.
• As 50 & 200 hours and the following -
• Change air cleaner element.
• Change fuel filter.
• Change anti-freeze.
• Check electrical equi ment, condition of hoses and belts, re lace as necessary.
First Service
A new marine engine will require an engine service and check over at 50 hours. The
LCD dis lay in the tachometer shows the engine running hours.
It is very im ortant that this is carried out, as this includes many checks to ensure
the engine has settled down correctly.
This is chargeable and is the owner’s responsibility to organise, failure to do
so may invalidate warranty.

17
Checking engine oil level Do not ingest liquids
For quantities of oil lease refer to age 7. When checking the engine oil level, do so
before starting or more than five minutes after sto ing.
1. To check the oil level, draw out the di stick, wi e clean, re-insert it and draw it
out again. Check to see that the oil level lies between the two major marks on
the di stick. ( lease ignore the middle smaller mark)
2. If the level is too low add new oil via the oil filler ort, to the s ecified level –
do not overfill.
Im ortant
When using oil of different make or viscosity from the revious one, drain old oil.
Never mix two different ty es of oil. Engine oil and filter should be changed after the
first 50 hours running time and then every 200 hours or every year. Oil filter is a
cartridge ty e mounted on the side of the engine.
Engine Di stick
Engine Oil goes in here

18
Sum drain
Pum
-
ta
Changing Engine Oil Do not ingest liquids
1. Run the engine for 10 minutes to warm u the oil.
2. Your engine is rovided with a sum drain um . Turn the ta to “on”. Use
the hand um as shown to um out the oil into a bucket. Turn the ta to off
osition and re lace end ca .
3. Unscrew the oil filter and re lace with a new one. See diagram below
Note: it is best to wra a lastic bag around the filter, to catch any oil left in the
system. (Always kee your bilges clean!) Before screwing in the new filter s read a
thin film of oil round the rubber gasket to ensure a good seal and screw in – hand
tight.
4. Fill the engine with new oil, refer to age 13 for s ecification, as described
above.
Note: once you have re-filled the engine will oil, run the engine for about 5 minutes,
so the oil can be um ed around the engine and into the new filter. Sto the engine,
and let it settle for about 10 minutes, and re-check the oil level, fill if required.
Sum drain
Pum
Oil Filter

19
Changing the fuel filter
1. The fuel filter is a s in-on Cartridge.
Remove by turning anti-clockwise when viewed from
below, see icture….
2. Re lace the fuel filter cartridge every 400 hours
3. Remove metal bung and O Ring from the
old fuel filter and fit to new fuel filter (see below)
4. A ly fuel oil thinly over the filter gasket and tighten
into osition – hand tight
5. Prime fuel system…
Place a rag or rece tacle under the Fuel Filter
Slacken the Bleed Screw
Pum the Fuel Primer until air free fuel comes from
the Bleed Screw, then tighten the Bleed Screw
Continue to um until a reasonable effort is
required.
6. Check for leaks
Note: Do not get fuel on the flexible engine mounts
.
Fuel Filter
Metal bung in Fuel filter, must
be transferred to new fuel filter
Fuel Primer
Bleed Screw

20
Checking Gearbox Oil Level – lease refer to gearbox manual, but on the PRM
120 & 125D mechanical gearboxes, lease ensure the following
Never exceed the maximum oil level on the dipstick!
Always use ATF Dextron II or III for your gearbox
PRM125D
The PRM125D Gearbox is fitted with a Level Plug, as shown below. This should be
used when re-filling the gearbox with oil after draining, to allow an easy and quick
reference.
NOTE: When checking the oil level, ensure the Gearbox is in neutral, start and run
the engine for a short time to circulate oil. Sto the engine and allow the oil to settle
for 2 minutes. Check the oil level with the Di stick.
NOTE: The Di stick should be secured firmly when checking the oil level.
Ensure the oil mark is below the marker
on the dipstick (shaded). Ensure thread (shaded) is fully screwed down
into case with its relevant bonded seal when
measuring the oil level.