Siyang 380J-3 User manual

SIYANG

四洋

380J-3

MARINE DIESELENGINE SET

OPERATION MANUAL

EASTCHINASHIPBUILDINGINSTITUTE FACTORY

December2003

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

CONTENTS

1.General precautions·························································································· 1

2.Introduction······································································································· 2

Fig 380J-3 marine diesel engine set overall dimension ······························· 3

2.1 Description of the engine set···································································· 4

3.0 General engine data······················································································· 5

4.0 Main structure of engine··············································································· 6

4.1 Fuel system································································································ 6

4.2 Lubrication system ··················································································· 6

4.3 Cooling system ························································································· 7

4.4 Electric system ·························································································· 8

4.5 Gearbox ····································································································· 8

4.6 Electrical diagram····················································································· 9

4.6.1 Electric system parts description························································ 12

4.6.2 Instruments panel················································································· 12

4.7 Starting precautions ················································································ 12

4.8 Check before starting·············································································· 12

5. Operation of engine······················································································· 12

5.1Starting······································································································ 12

5.2Starting by Spring starter (if installed) ··················································· 13

5.3 Operation ································································································· 15

5.4 Stopping··································································································· 15

6.Routine maintenance ····················································································· 15

6.1 Initial attention························································································· 15

6.2 Routine maintenance periods ································································ 16

6.3 Lubrication oil specification ·································································· 16

6.4 Gearbox oil specification ······································································· 17

6.5 Main spanner torque setting··································································· 17

6.6 Tighten sequence for cylinder heads bolts············································ 18

6.7 Check of lubrication oil level································································· 18

6.8 Lubrication oil change············································································ 18

6.9 Alternator belt tension············································································· 18

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6.10 Gearbox oil check and change ···························································· 18

6.11 Priming the fuel system········································································ 18

6.12 Drain the coolant··················································································· 19

6.13 Changing fuel filter element ································································ 19

6.14 Idling speed adjustment ······································································· 19

6.15 Valve clearance adjustment ································································· 19

6.16 Starting and running the engine while the lifeboat

is hooked in davits or free fall rig ························································ 19

6.17General precaution about electrical system········································· 19

6.18Stroage ···································································································· 20

7. Trouble shooting···························································································· 21

7.1 Difficult in starting the engine ······························································· 21

7.2 Insufficient output ··················································································· 21

7.3 Black smoking from exhaust································································· 22

7.4 Low lube oil pressure ············································································· 22

7.5 Engine knocking····················································································· 22

7.6 Engine overheating················································································· 23

7.7 Engine over speed or override······························································· 23

Appendix 1：380J-3 diesel engine set delivery list·········································24

Appendix 2：Tools supplied with 380J-3 marine diesel engine set ···········24

Appendix 3：Spare parts supplied with 380J-3 marine diesel engine set ····25

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

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1.GENERALPRECAUTIONS

⑴. Ensure that the engine is securely mounted.

⑵.Ensure that the ventilation and combustion air dusts are not obstructed.

⑶.Keep the engine and surrounding areas clean.

⑷.Never allow any part of the body to come into contact with high

pressure fuel oil when testing injection equipment.

⑸.Avoid contact with exhaust pipe when the engine is, or has recently

been running .These parts can be very hot and can cause severe burns.

⑹.Rectify all fuel water and oil leaks as soon as possible.

⑺.Isolate the battery when working on the engine.

⑻.All drive belts must receive regular attention.

⑼.Keep electrical contacts free from corrosion etc by smearing them with

petroleum jelly.

⑽.Batteries under charge release explosive gases, therefore the battery

compartment must be well ventilated at all times. Never allow any

smoking, sparks or flames near the batteries.

⑾.Wear protective goggles when handing liquids which is harmful to

eyes, for example, battery acid. If any of these substances are splashed in

the eyes, wash out thoroughly with clean water.

⑿Many liquids used in engines are harmful if taken internally .In the

event of accidentally swallowing oil, fuel, antifreeze or battery acid obtain

medical assistance immediately.

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

2.INTRODUCTION

The SIYANG make marine diesel engine set, type 380J-3 is based on

380C diesel engine and adapted for lifeboat Propulsion conforming to the

latest requirements include SOLAS 1974,1996 Amendments.

It is essential that the operators read carefully the main points in this

manual before the engine is put into service.

Reference is made to:

“CHECKS BEFORE STARTING” “STARTING” “OPERATION” and

“STOP” .

The engine must be able to start and operate under the most severe

conditions. Therefore the engine set must be carefully maintained in

accordance with this manual.

The information , specification, illustrations, instructions and statements

contained within this publication are given with our best intentions and are

believed to be correct at the time going to press. As our continued technical

development, We reserve the right to amend any technical information with

or without prior notice.

While every effort is made to ensure the accuracy of the particulars

contained within this publication neither the manufacturer or dealer shall in

any circumstances be held liable for any inaccuracy or the consequences

thereof.

User of this manual are advised that the specification details apply to

380J-3 engine set and not to any one particular engine. In case of difficulty,

consult East China Shipbuilding Institute Factory, China or a local

distributor for further advice and technical assistance.

The information given is subject to the company’s current condition and

is for the assistance of users and is based upon results obtained from tests

carried out at the place of manufacture. Our company doesn’t guarantee that

the same results will be obtained elsewhere under different conditions.

When purchasing parts, or giving instruction for the clients repairs,

please refer to engine part catalogue and specify ESCI Factory. Our

company can not be responsible for any damage arising from the parts that

have not been supplied by our company.

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

Exhaust flange

Note:Thedimensioninbracketisonlyformatching ZF12Mgearbox.

Fig.380J-3 marine diesel engine set overall dimension

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

2.1 DESCRIPTION OFTHE ENGINE SET

1. Fuel filter

2. Breather

3. Fuel injector

4. Injection pump

5. Inlet manifold

6. Outlet cock

7. Lube oil dipstick

8. Tachometersensor

9. Gearbox dipstick

10.Expansion tanker cap

11.Fresh waterpump

12.Lube oil filter

13.Gearbox

14.Gearbox oil screw

15.Alternator

16.Expansion tanker

17.Lube filling cap

18.Exhaust body

19.Lube cooler

20.Either pump

21.Starting liquid reservoir

22.Water inlet pipe

23.Water outlet pipe

24.Starting motor

25.Gearbox handle

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

3. GENEARALENGINE DATA

Type 380J-3

Model In line, vertical, water cooled

four stroke

Combustion chamber Direct injection

Number of cylinders 3

Bore×stroke (mm) 80×90

Total displacement (liters) 1.357

Firing order 1→3→2

Compression ratio 18:1

Rated output (kw/rpm) 20.6/2800

Fuel oil consumption at rated output (g/kw·h) ≤255

Lube oil consumption at rated output (g/kw·h) ≤2.72

Air consumption in 10 minutes (m3) 16.148

Lubrication method Splashed and forced

Method of cooling Water coolant

Direction of rotation Counter clockwise

(Looking on flywheel end)

Method of starting Electric option spring starter

Method of operation Mechanical direct translating

or flexible shaft remote operation

Exhaust temperature at rated output (℃) ≤550

Overall dimension (L×W×H) (mm) 828 (796)×560×638

Weight （kg）200

Note: the dimension in bracket is only formatching ZF12M gearbox

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

SIYANG

四洋

4.MAIN STRUCTURE OFENGINE

4.1 FUELSYSTEM

The fuel system are important controlling components of the diesel

engine. They are composed of injectors, fuel filter, injection pump and

high and low pressure pipes and various connections. The feed pump

draws fuel from the fuel tanker and deliveries it to the filter. The fuel, after

passing through the filter, passes into the injection pump. The fuel passes

into the high pressure pipe then to the injector which atomizes the fuel to

fine droplets for combustion. Small amount of fuel passes through the oil

return pipe into the fuel tanker

Fuel pump timing ……………………. 24~27゜TDC

Injection pressure ……………………. New: 20.5Mpa/used: 20Mpa

Diesel oil conforming GB252-87 light diesel fuel grades No.0 or No.-35

or to USA specification ASTM D-975-77 Grades NO.1-D and 2-D.If the

engine has to work in areas with extremely low ambient temperatures, use

fuel with good clog characteristic. Clog point(CFPP) -25℃.

4.2 LUBRICATION SYSTEM

The lubrication system is made up of an oil sump, an suction strainer, an

oil pump, lube cooler ,filter and various pipes. The oil pump draws the lube

oil contained in the oil sump through oil suction strainer then the lube oil

flow into lube cooler and lube filter. The lube oil in main oil passage is

separated into three flows. One passes through main bearing and flow into

connecting rod bearing; The second passes through the camshaft bearing

and flow the sloping oil passage to lubricate the valve rocker arm shaft liner;

the third one flow into timing idle gear bearing. Cylinder liner, piston, piston

pin, connecting rod l shells etc are splash or atomized lubricated.

The lubrication oil should be added properly. If it is added to much, it

would be burning; if added to less, the bearing shells would be burnt. It is

ideal to add the oil until its level reaches between the upper and low marks

on the dipstick. When the oil level goes down to the low mark, lube oil

should be added. Before starting the diesel engine, the oil level should be

checked.

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四洋

Lube oil pressure ……………..…………….98kpa ~120kpa at idle.

250~390kpa at rated output.

Oil sump capacity……………………………5.2liters.

SCG-025/ZF12M Gearbox sump capacity….. 0.75liters/0.56 liters.

4.3 COOLINGSYSTEM

The cooling system of the engine set is of forced circulative water

cooling close type, which consists of lube oil radiator, water tanker, water

pump, rubber pipe etc.

The cooling system of the engine is closed water cooling system.

The cooling liquid comes from the keel cooler through the lube oil

cooler and water pump to the engine block, cylinder head, water cooling

exhaust pipe and outlet then feed back to keel cooler to make circulation

cooling.

Too high cooling temperature will cause the lamp in the control

panel to light up and acoustic alarm to function.

Water temperature …………..75~95゜C.

Antifreeze concentration of 40% should be used as an all year round

coolant. This concentration will give low temperature protection down to

-25゜C.

Additionally, 40% concentration will protect the cooling system from

corrosion.

Warning:Antifreeze contains Glycol and otherconstituents which

are toxic if taken internally, and can be absorbed in toxic amounts

underprolonged skin contact.

If antifreeze is swallowed accidentally, medical advice should be

sought immediately.

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