R

SIYANG

380J-3
MARINE DIESEL ENGINE SET
OPERATION MANUAL

EAST CHINA SHIPBUILDING INSTITUTE FACTORY

December 2003
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SIYANG
EAST CHINA SHIPBUILDING INSTITUTE FACTORY

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 1380J-3 diesel engine set delivery list24
Appendix 2Tools supplied with 380J-3 marine diesel engine set 24
Appendix 3Spare parts supplied with 380J-3 marine diesel engine set 25

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1.GENERAL PRECAUTIONS
. Ensure that the engine is securely mounted.
.Ensure that the ventilation and combustion air dusts are not obstructed.
.Keep the engine and surrounding areas clean.
.Never allow any part of the body to come into contact with high
pressure fuel oil when testing injection equipment.
.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.
.Rectify all fuel water and oil leaks as soon as possible.
.Isolate the battery when working on the engine.
.All drive belts must receive regular attention.
.Keep electrical contacts free from corrosion etc by smearing them with
petroleum jelly.
.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.
. 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.
Many 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.

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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 companys 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 doesnt 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.

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Exhaust flange

Note: The dimension in bracket is only for matching ZF12M gearbox.

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

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2.1 DESCRIPTION OF THE ENGINE SET

1. Fuel filter
2. Breather
3. Fuel injector
4. Injection pump
5. Inlet manifold
6. Outlet cock
7. Lube oil dipstick
8. Tachometer sensor
9. Gearbox dipstick
10. Expansion tanker cap
11. Fresh water pump
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

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3. GENEARAL ENGINE DATA

Type 380J-3
In line, vertical, water cooled
Model
four stroke
Combustion chamber Direct injection
Number of cylinders 3
Borestroke (mm) 8090
Total displacement (liters) 1.357
Firing order 132
Compression ratio 18:1
Rated output (kw/rpm) 20.6/2800
Fuel oil consumption at rated output (g/kwh) 255
Lube oil consumption at rated output (g/kwh) 2.72
Air consumption in 10 minutes (m3) 16.148
Lubrication method Splashed and forced
Method of cooling Water coolant
Counter clockwise
Direction of rotation
(Looking on flywheel end)
Method of starting Electric option spring starter

Mechanical direct translating

Method of operation
or flexible shaft remote operation

Exhaust temperature at rated output () 550

Overall dimension (LWH) (mm) 828 (796)560638
Weight kg 200
Note: the dimension in bracket is only for matching ZF12M gearbox

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4.MAIN STRUCTURE OF ENGINE

4.1 FUEL SYSTEM
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 . 24~27TDC
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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Lube oil pressure ...98kpa ~120kpa at idle.

250~390kpa at rated output.
Oil sump capacity5.2liters.
SCG-025/ZF12M Gearbox sump capacity.. 0.75liters/0.56 liters.

4.3 COOLING SYSTEM

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 ..75~95C.
Antifreeze concentration of 40% should be used as an all year round
coolant. This concentration will give low temperature protection down to
-25C.
Additionally, 40% concentration will protect the cooling system from
corrosion.
Warning: Antifreeze contains Glycol and other constituents which
are toxic if taken internally, and can be absorbed in toxic amounts
under prolonged skin contact.
If antifreeze is swallowed accidentally, medical advice should be
sought immediately.

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Fuel
tank

Fig Piping layout

1.Cooling water pump 2.Lube cooler 3. Keel cooler 4.Lube oil pump 5.Lube oil filter 6.Pressure
control valve 7.Main bearing 8.Camshaft bearing 9.Rocker arm 10 Overflow pipe11. Fuel oil filter
12.Fuel feed pump 13. Fuel injection pump 14. Fuel high pressure pipe 15. Fuel injection nozzle 16.
Water exhaust pipe 17. Fuel oil inlet
4.4 ELECTRIC SYSTEM.
The electric system is composed of battery charging alternator,
starting motor, relay regulator, switch, alarm buzzer, alarm lamps and
instruments.
If without FQ spring starter, two separated charging battery should be
need. The customers choose and use either one of two electric diagrams.
Voltage: 12V.
Starter motor: 2.5kw
Alternator: 750W
4.5 GEARBOX
Gearbox reduction ratio for SCG 025-3: ....2.74/2.67 (Forward/reverse)
Gearbox reduction ratio for ZF12M: ...........2.63/1.95 (Forward/reverse)
Rotation direction of propeller .. Clockwise (forward)

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4.6 ELECTRICAL DIAGRAM

Tachometer Switch
Buzzer
6 3 +
4
5 2 1
1 3
Diode

Low oil pressure alarm

High water temp. alarm

Discharge alarm
CAP

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12
Pressure sensor
Temp. sensor

Voltage G
regulator

Magnetic
Armature

Tachometer sensor
Double
charge diode

50mm 2 B+ F
50mm 2
Starter + - G + - G
Generator

Battery 1 Battery 2
12 Volt 12 Volt
G
Change over
Battery switch
Items with dotted line not
included in normal delivery.

Fig Electric diagram 1

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Tachometer Switch
Buzzer
6 3 +
4
5 2 1
1 3

High water temp. alarm

Low oil pressure alarm

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8
Pressure sensor
Temp. sensor

Voltage G
regulator
Magnetic
Armature

Tachometer sensor

50mm2 B+ F
50mm2
Starter + - G + - G
Generator

Battery 1 Battery 2
12 Volt 12 Volt
G
Change over
Battery switch
Items with dotted line not
included in normal delivery.

Fig Electric diagram 2

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4.6.1 ELECTRIC SYSTEM PARTS DESCRIPTION

Following parts is installed either engine side or panel side

Item Electric diagram 1 Electric diagram 2

Tachometer ZS12109.Y0 ZS12109.Y0
Starting switch JK290 JK290
Buzzer FMQ-2715 FMQ-2715
Alarm lamp (water temp.) AD11-16 AD11-16
Alarm lamp (lube pressure) AD11-16 AD11-16
Charge indicating lamp AD11-16 AD11-16
Tachometer sensor ZG912346 ZG912346
Temperature sensor WB9311 WB9311
Lube pressure sensor YB1011 YB1011
Starting motor QD138C QD138C
Battery voltage 12V 12V
Voltage regulator FT111 FT111
Generator JFW17H1 JFW17H1
Diode IN5408 (No fitted)
Capacity CB822 IUOJ400V (No fitted)
Charging diode 702R 702R
4.6.2 INSTRUMENTS PANEL
According the choice of the buyer, the engine set is normally fitted one
of the two instruments panel.
1. Tachometer 2. Alarm buzzer and lamp 3.Starting switch 4. Charging
lamp (no fitted in Electric diagram 2.)

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4.7 STARTING PRECAUTIONS

Starting any engine can be dangerous in the hands of inexperienced
people. Before attempting to start any engine ,the operator should be fully
conversant with starting procedure and controls.
.Ensure that the batteries are in serviceable condition and correctly
connected.
.Check that the oil levels in the engine and the gearbox are correct.
.Check that the fuel tank is full and that the system is primed.
.Check that the all water drain plugs and cocks are closed. Check that
water inlet valves, if fitted, are opened.
.Check that water level in the expansion tank is filled up with mixture
of water/antifreeze (40%).
4.8 CHECKS BEFORE STARTING
.Oil level in oil sump and gearbox.
.Coolant level in the expansion tanker.
.Battery main switch is on .Oil pressure light and changing light will
now be on and the buzzer will sound.

5 OPERATION OF ENGINE

5.1 STARTING
Before attempting to start the engine ,the operator should be familiar
with the safety precautions as described earlier.
Move the speed/gearbox lever into the neutral position by means of the
control lever.
Turn the switch to energize the starting motor.
Release immediately, if the engine start ,and it will return to position
0.The alarm light as well as the buzzer should now be off.
If the engine should fail to start ,due to poor battery condition ,turn the
battery switch to the second start battery and repeat the starting procedure.
If the engine fail to start within 15 seconds ,despite good battery
condition ,release the switch and investigate the cause .The starting motor
should be allowed to cool for at least 15 seconds before attempting to

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restart.
At low temperature it may be necessary to ease the starting by means
of the start gas.
The operation method is shown as follows:
(1).Open the dust cover of the liquid storage. Insert the pouring liquid
pressure can into the hole of the liquid storage. Squeeze the can to pour
the liquid into liquid storage.
(2).Set the gearbox at idle
position and put the handle of
fuel rack at mid-position.
(3).Start the engine. At the
same time, operate the
hand-pump until the engine
runs stably.
(4).If knocking appears while
the engine is starting; the
operation of hand-pump must
be slowed or stopped, so as to
regulate the injecting liquid
quantity for starting the engine
stably.

low tem p. starting liquid pouring system

1.Air pipe 2.H and pum p 3.Liquid 4.Liquid pipe 5.Injector 6.A ir inlet pipe

CAUTION: Keep away from all heat sources (even sun

light).The liquid is highly flammable.

5.2 STARTING BY SPRING STARTER (IF INSTALLED)

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According to the buyer requests, we can install and supply the FQ

engine starter (hand starting) for the engine starting.
This starter makes use of man-power to press its spring to store the
energy. The engine is rotated, as the energy relives at a moments and causes
the engine running over the speed of starting revolution of the engine quickly,
and then the engine is starting.
Operation order and method:
1. Press the reset button.
2. Insert the handle, anticlockwise rotation, press the butterfly spring to
fully pressing state.(The red mark is appearing).
3. The energy will relieve at a moment when the lever is pressed. At
that time the engine speed rises over the starting revolution of the
engine, then the engine is starting.
Note: The step-lever must be situated in unabated pressure state
when the engine makes use of the FQ type starter .
4. If it is necessary to rotate the engine with the hands, press the reset
button and draw-up the reliever lever and then the engine can be
rotated with the handle.
78
reset button
APPROX

release handle

cranking bar
DIR
116
DIR
130

75
287.6 37.75
125.75

Fig. Spring starting motor

Note: 1. When use the FQ starter, never open the decompression.

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5.3 OPERATION
If one or more alarm do not go out, or light up when the engine runs,
the engine should be stopped at once to trace the reason.
When all function are normal, engage the gearbox by pushing the
control lever forward or backward.
Increase the speed gradually if possible, allowing the engine to warm
up, before going full speed.
In case of emergency, the lever can be moved into full speed position
immediately.
5.4 STOPPING
Move control lever into neutral position.
Allow the engine to idle for appr.2 minutes to cool.
Stop the engine.
Switch off the battery main Switch.
If fresh water is only used, all of cooling water must be drained out from
the cooling system when the ambient temperature is below 5(except anti-
freeze coolant is used)

6 .ROUTINE MAINTENANCE

The engine has passed the lifeboat engine test programmer before
delivery. Still however the engine is not completely run in.
It is recommended to operate the engine moderately during the first
hours after it has been put into service. Full speed only for short periods
during the first 15-20 hours.
6.1 INITIAL ATTENTION
1.Check and tighten all hose clamps and unions, paying particular
attention to the fuel system.
2.Check and tighten all external nuts and bolts, particularly mounting
bolts, shaft coupling bolts and exhaust manifold bolts and nuts.
3. Check belt tension, see ALTERNATOR BELT TENSION section.
4.Check lubrication oil and water coolant level .

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6.2 ROUTINE MAINTENANCE PERIODES

Period Attention
After the first 15 hours or after the
See INITIAL ATTENTION
first 3months
Check engine oil level.
Check coolant level.
Before start or weekly
Check fuel level in tank.
Grease stern gland
Check gearbox oil level
Every 3 months or 25 hours
Check battery condition
Change gearbox oil and lube oil
Change lube oil filter
Every year or 200hours
Check alternator belt tension
Check electric connect

6.3 LUBRICATION OIL SPECIFICATION

Temperature in starting Mono-grade Multi-grade

Below -15 5w 5w /30
-15
Between and 10w 10w/30
4
4 15w/30
Between and 20/20 w
30 10w/30
15w/40
Above 30 30
20w/40
The temperatures mentioned in the table are the ambient temperatures
at the time when the engine is started.
However, if the running temperatures are much higher than the starting
temperatures a compromise must be struck and a higher viscosity oil used ,
providing starting is satisfactory. Multi grade oils overcome the problem,
provided they have a suitable specification .
The engines must be run on heavy duty lubricating oils, meeting the
requirements of API CC.DEF2101D, MIL-L-2104B or MILL-L-46152A/B

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Straight mineral oils are not suitable, neither are oils of less detergency than
specified.
API CD, Series 3, or MIL-L-2104C/D oils can inhibit the running in
process in new or reconditioned engine but can be recommended for
engines running at high load factor, particularly in conjunction with high
ambient temperatures.
Following or equivalent types of oil can be used:
Mobile Delvac 1300 series BP energol DS3
Shell Rimula oil Gulfpride Seies 3
Esso lube XD3+ Elf Disal HD3
Chevon Delco Super 3 Texaco URSA S3
Fina Solna 3 Castrol Deusol RX super
Norol Marine TMA 300 Amocol New Supper ACE3

6.4 GEARBOX OIL SPECIFICATION

Automatic Transmission Fluid -ATF

FORD Specification M 2 C-33 G
GM Specification ATF DEXRON D
EXXON ATFD or ATF
(or refer to gearbox manual )
6.5 MAIN SPANNER TORQUE SETTINGS

DESCRIPTION N M

Flywheel bolt 60

Cylinder head nut 140

Connecting rod bolts 70

Prop. shaft coupling bolts (acid proof) 70

Crankshaft main bearing 125

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6.6 TIGHTENING SEQUENCES FOR CYLINDER HEAD BOLTS.

7 5 10
11 14
1 4

3 2
13 12
9 6 8

6.7 CHECK OF LUBRICATION OIL LEVEL

The lubrication oil level should always be checked before starting.
The level should never be allowed to fall be lower mark.
6.8 LUBRICATION OIL CHANGE
The oil change should be down when the engine is warm.
Run the engine after oil change and check for any leaks.
Stop the engine, allow the oil to settle and top up if necessary.
6.9 ALTERNATOR BELT TENSION.
It is important that the belt tension is checked after an overhaul or
when new belt is installed.
New belt tension:
A force of 3~3.5 kg to deflect belt 3.5 mm
Checking and adjustment at service intervals:
A force of 2~2.4 kg to deflect belt 3.5 mm
6.10 GEARBOX OIL CHECK
Check the oil level.
Fill up if the oil level is below the mark.
SCG-025/ZF12M Gearbox sump capacity : 0.75 liters/0.56 liters.
6.11 PRIMING THE FUEL SYSTEM
The fuel system has to be primed before initial starting, after fuel filter
change, if the fuel system has been disconnected , or if the engine has run
out of fuel and stops.
1.Loosen the vent plug on top of the fuel pump.
2.Turn on the handle of the fuel feed pump
3.Start the handle up-and-down movement.

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4.When no air is left, retighten the vent plug and turn off the handle of
the fuel feed pump.
6.12 DRAIN THE COOLANT
Remove the cap on the top of expansion tanker. Drain the coolant
through the cock in front of engine. Close the cap and cock after draining.
Refill the cooling system with correct water anti-freezing mixture.
Let the engine run idle for 20~30 minutes.
6.13 CHANGING FUEL FILTER ELEMENT
If the fuel oil tank is installed at a level above the engine, the cock must
be closed before fuel filter change. Unscrew the filter container and discard
the filter element. Ensure that the rubber gaskets and the spring are correctly
fitted before the filter container is reinstalled after filter change.
Priming the fuel system after filter element change, see section 6.11.
6.14 IDLING SPEED ADJUSTMENT
Start the engine and run until normal operating temperature is reached .
Correct idling speed is less than 900 rpm and is factory set before
dispatch.
Adjustment should only be carried out after consulting East China
shipbuilding Institute Factory, CHINA.
6.15 VALVE CLEARANCE ADJUSTMENT
The valve clearance is :
Exhaust valve (cold) : 0.25~0.30 mm
Intake valve (cold) : 0.20~0.25 mm
6.16 STARTING AND RUNNING THE ENGINE WHILE THE
LIFEBOAT IS HOOKED IN DAVITS OR IN FREE FALL RIG
The engine should be started and run once a week and after any kind of
maintenance work.
The running should be limited to 5 minutes at idle speed .
The water temperature alarm should be watched .
6.17 GENERAL PRECAUTTIONS ABOUT ELECTRIC SYSTEM
The following points must be strictly observed when working on the
electric system, otherwise serious damage can occur.
1.Never remove any electrical cable without first disconnecting the

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batteries.
2.Never disconnect the alternator cables while the engine is running.
3.Only disconnect the batteries with engine stopped and all switches in
the OFF position.
4.Always check that cables are connected to their correct terminals
before reconnecting the batteries .A reversal of polarity or short circuit will
destroy diodes and transistors in the alternator and regulator.
5.Never flash any connections to check the current flow.
6.Always keep the electrical connections properly tightened.

6.18 STORAGE

1. If the engine is to be put out of service for a long period of time, It is

necessary to drain out lubricating oil, cooling water and fuel when engine is
still warm after stopping the engine.
2. Perform maintenances accordingly.
3. Dismantle both intake and exhaust manifolds and pear into the cylinder
liners from the air passages about 0.2 kg of clean dehydrated oil (By heating
the lubricating oil to 110~120, until all air bubble on surface of oil
disappear). And rotate the crankshaft so that the valves, cylinder liners and
pistons etc. are all covered with a layer of this oil.. Then install the intake
manifold and exhaust body.
4.Remove sludge and dust from outer surface of the engine. Smear anti-rust
oil on to exposed machined surfaces of parts of the engine. Rubber plastic
components are prohibited to be smeared with oil.
5. Block the intake manifold and exhaust pipe flange with wooden plug, or
wrap them up properly with plastic cloth in order to prevent any dust from
getting in.
6.The engine so preserved should be stored in room of good ventilation and
low humidity but without any dust. It is strictly forbidden to store the engine
wherever there are chemical.
The preservation according to above procedure may be good for three
months. Over this period, repeat this procedure.

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7 TROUBLE SHOOTING

This section is intended as a guide only. If you are in difficulty, please

consult East China Shipbuilding Institute Factory, CHINA or local our
product distributor.
7.1 DIFFICULT IN STARTING THE ENGINE

Causes Remedial method

Clean the filter or pipes
(1).The fuel filter or pipe are obstructed.
(2).Air is locked in the fuel Drain the air and tighten all fuel pipe
connectors
(3).The fuel injection advance angle is Adjust the fuel injection advance angle
incorrect. as specification.
(4).The valve clearance is incorrect Adjust the valve clearance as required.
(5).Battery not fully charged or poor Charge the battery fully or tighten the
wire connections connections.
(6). No fuel in tanker or poor spray from Fill up the fuel or adjust the injecting
injector pressure as required.
(7).Low cylinder compression pressure Check and change the piston ring or
cylinder liner. Change the cylinder head
gasket if damaged.

7.2 INSUFFICIENT OUTPUT

Causes Remedial method

(1) Low cylinder compression pressure Refer to 7.1(7)
(2) The fuel injection advance angle is Refer to 7.1(3)
incorrect.
(3) The valve clearance is incorrect Refer to 7.1(4)
(4) Fuel supply for each cylinder is Adjust the fuel quantity of fuel injection
unequal. pump.
(5) Low engine speed Adjust the engine speed to specification.
(6) Excessive wear of plunger couple of Renew new plunger couple.
Injection pump
(7) The exhaust system clogged. Clean.

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7.3 BLACK SMOKING FROM EXHAUST

Causes Remedial method

(1). The engine is overloaded Reduce the load properly.
(2). Fuel injector defeats Renew one.
(3).Poor fuel quality Change the fuel as specification
(4)The fuel injection advance angle Refer to 7.1(3)
is incorrect.
(5)Combustion is incomplete Check the injector, fuel injection advance
angle, cylinder gasket and cylinder
compression pressure etc.

7.4 LOW LUBE OIL PRESSURE

Causes Remedial method

(1) Lube oil in oil sumps too low. Fill up to the right mark.
(2) Lube oil pipe leaks Tighten all connectors.
(3) Lube filter obstructed. Replace lube filter.
(4) The lube oil is too thickness Replace the lube oil as specification
(5) Pressure sensor or lamp defeats Replace a new one.
(6) Gear pump worn out and Replace gears pump and adjust the
clearance is over clearances

7.5 ENGINE KNOCKING

Causes Remedial method

(1).The fuel injection advance angle is Refer to 7.1(3)
incorrect.
(2) Air or water is mixed in fuel system Refer to 7.1(2)
(3)Fuel supply for each cylinder is Refer to 7.2(4)
unequal.
(4)Wear of the certain components Replace the worn parts.
exceeds specification limits

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7.6 ENGINE OVERHEATING

Causes Remedial method

(1) Temperature of coolant water too
high
a. Insufficient coolant or vapor Add water coolant
lock in cooling system
b. Cooling water pump defeats Repair or replace water pump
c. Water pump belt is loose Refer to section 6.9
(2) Lube oil temperature is too high.
a. Low lube oil level or high. Fill or drain the lube oil
b. Low lube oil pressure with Refer to 7.4
insufficient flow.
(3) The engine is overloaded. Refer to 7.3(1)

7.7 ENGINE OVER SPEED OR OVERRIDE

Causes Remedial method

(1) Governor malfunction. Stop engine and repair immediately.
(2) Control bar of fuel injection pump Ditto
is stuck.
(3) Fuel supplying of injection pump is Stop the engine and readjust fuel pump
too large. delivery.
(4) Oil gets into cylinder too much Stop the engine and check and repair

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Appendix 1380J-3 diesel engine set delivery list

This list is a standard delivery list.

No. Description Unit Qty Remarks

1 Marine diesel engine set Set 1

2 Tools &spare parts supplied with engine Box 1

3 380J-3 marine diesel engine set operation manual Piece 1

4 Gearbox operation manual Piece 1

5 380J-3 marine engine set parts catalogue Piece 1

6 Instruction for wheel house Piece 1

7 380J-3 Class inspecting certificate Piece 1

8 Product inspecting certificate Piece 1

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

No. Description Unit Qty

1 Valve tapping tools 1

2 Tapping sand (140#) 1

3 Feeler gauge 1

4 8# screw driver 1

5 Spanner810 1

6 Spanne1316 1

7 Spanne1821 1

8 Spanne1719 1

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

No. DWG no or Spec. Description Qty Remarks

1 CZ380Q-030013 Cylinder head gasket 1

2 CZ475Q-020003 Intake valve 1

3 CZ475Q-020003 Exhaust valve 1

4 N85-020003(1) Outer valve spring 2

5 N85-020003(2) Inner valve spring 2

6 N85-020002 Connecting rod bush 4

7 CZ480Q-050006 Valve collets 2

8 CZ475Q-030014 Upper bearing shell 2

9 CZ475Q-030015 Lower bearing shell 2

10 CZ480Q-050001 First piston ring 1

11 CZ480Q-050002 Second piston 1

12 CZ480Q-051000 Oil scraping ring 1

13 ZCK154S423 Injector nozzle 2

14 C0506-1000 Fuel filter element 1

15 JX0706P1 Lube oil filter 1

16 C0506-0003 Fuel filter sealing 1

17 Oil sealing DL8010012 1

18 Oil sealing DR557512 1

19 V13 1050 V-Belt 1

20 Cold starting liquid 1

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