'i..

l':,,..:
: . i' : ] . , : ..,. ' ,.,,'....r, .:, 'r ..' , '1 ' .t,t

I .
l.t

. r . l , . i . ' . .. ').""a' :
:

.:, : , it

.:..-.,:r:1,

.' : .' ar' :' ' ; I .: 'l: ' ,i

: .

CONTENTS
.........t precautions 1. Gneral .........'.2 2. Introdtrction '..........3 dimension. set overall engine mrinediesel Fig 380J-3 ------.-..4 2.1Descriptionoftheengneset.... . .-.' ...5 d^a.. engtne 3. General ...'......-6 4. Mainsfiucarcofengine.
4.1Fnel system. i .....i . ...'.....6

systm. 42lubrication 4.3 Cootingqystern. 4.4Electric systern. 4.5 Gearbox 4.6Electricaldiagm. parbdescripuon system 4.6. 1Elecfric 4.62 Instrurnentsparel.

......:.

..-..---6 -.....7 ....--8 '......8 .........9 .......-..12 '. '-...12 ...-..12 .....'.'12 ...........13 . .....15 ......15 .....15 ......15 ....16 .....16 . ........17 .....17 ...........18 . .........18 ...........18 ...........18

stating 4.8 Checkbefore 5.Operationofengine. 5.1Sffiing 5.2StatingbySpringstarter(ifinstalted) 5.3 Operation 5.4 Stcpping 6.Routinemaintenance 6.lhritialttention periods. rnaintenmce 6.2Rodine specification 6.3Lubricationoil 6.4Gearbox oilspecification 6.5Mainspmertorqtresefiing. forcylinderheads botts. 6.6Tighten sequence oillevel. 6.7Check oflub'rication 6.8 oilchmge. Lubricmion 6.9Altematorbelttension

6.10 Geabcu< mdcbage oilcheck . ... ......18 6.11 Priming thefuelE/stem. 6.l2Dxainfte coolrrt. filter element 6.l3C}rrrynrfuel .. ... ....19 6.l4ldlingsped adjusment ...........19 6.15Valve adjusfineil cleamce ufrilethelifebod 6.l6sttrting md nmingtheengine . ... .,..19 frl rig. ishooked in davits orfree 6.lTceneralprecarrionaborrelecticalsyslerr.. .....19 ...........20 6.l8Stoage ......21 T.Tronble shooting. .......21 engine. 7.1 Dfficultinsmtingthe .. ...21 7.2Insrffcient oriptf. ... ...22 7.3 Black frm e)fta$t smoking .........22 T.4lnwhrbe oilpressne . .....22 ........ 7.5 Engine knocking. ......23 7.6Engine ovefteaing . . ......23 qpeed ororrcrride 7.7Fafoe over

I.GENERALPRECAUTIONS
(1). mornted. is secrne$ En$retha theengine (z)Enstrre air duss ae not that tlre ralddion rod combustion obstruc'ted. (3).Keep clem aneas andsurrounding fte engine ( )Ne\rer intoconacwith higb my prt of thebodyto come allorv equipment. tdection testing pressure fueloil ufie'n (5)Avoid engine ls,trhas rece'ntly uthsnthe codadwithexbaustprye bums. seve,re patscm beveryhotmd can cituse .These nnuring been (6).Rwti8' assoon aspossble. allfuelwdermd oil leaks (7).Isolate ontheengine working thebdery ufrren (8)Al1&ive receive regulr dention. must belts (9)Kee,p thert fiBefum corrosion etcby srneaing elecfiical csfracB wiilrpe,fioleunjel$. gases, thebdery oplosive trerefore release rndercharge 00).Bderies Nwer allowany d alltimes. corrydnntmustbewellventilded qpalrs ner thebffieries. or flemes snroking (ll).Wem to liquids ishannful goggles hmding ufoich protective ufoen mesplashd Ifmy ofthese srfutmces for ex"mple, b*teryacid. eyes, wder. withclean wash outthorouglrly in theeyes, .Inthe internally in engnes ae hrmful if taken li$ndsused 0DN{my oil, ftlel, difreerc u bdery acid svna[orving eve,nt of accidentally irmediaelv. medical obtain assistmce

2.INTRODUCTION
m type380Ji is based set, mrine disel engne malrc TheSIYAI.IG to dre conforming for lifsod Propulsion md adryted engure 380C diesel I 996Amendments. I 974, include SOI-AS rcqurements latest readcuefullyfte mainpoinein ftis trd tbeoperators It is ase,ffial is ptsitro semice. thee,ngine mrnralbefore to: is made Rdere{Ee
.ffiECI(S BETORE STARIING'" "SIAKIING' "OPERAflON" 'trd

"sToP'. sevre tre most to ffi md qer4|eunder mrstbeable Thee,ngine

in Thercftrethe enginest mu$ be caefirlly mairtained conditions. wi& tris maual. accordmce statements insfitrctions and illustrdions, specification, Theinformdion, md are megi\inwiftornbestinte,ntions coffiinedwiftin&isptrblic*ion technical As orncontinued to press. attlretimegoing to beconect believed wi0t any techicalinformdion Wereserve therigbtto me,lrd dwelopmetr, orwitrott priornotice. fte mrrary of fte pilticultrs b ensure efrrt is made Whileevry in shall rri$er tre mmufuureror dealer wiftin &is ptibtic*ion contained or tre conse4rences be heldliablefor my inrccmacy my cirumstuces the,reof dtails ftd theryecific*ion ryply to Userof ftis mmualue advised of difficul$ In case setmd nctto my urgpdtculil engine. engine 380J-3 tnSinre Fadory,China m a local consgltEa$ Chha Shlpbuilding md techicalassistmce. for fintreradvice disfiibrilor and condition b fte coryary'scttrrenl is sr$ject Theinfumdim givn ad is basd ryon resulsobtaindftomt55 of users is fu fte assirmce gtttrdee trd Orr con4mydoesn't of mmrtrchrre. cffiid orsdfu place mdrditreret$ conditions. elsewhere will beobtained resulb fte smrc for fte cliem rqailrsb pats, c gving insfirrctim Whenpurc,nasing ESCI Facbry.CIr put celogue md speci8' please referto engine fcnmy dmagedsing tom tbefb ftd cannotbereryonsible compmy by orr coryml/. have srryplied notbeen

u) o)

F
)
6J a (l)

a0 (u
6) ItJ 6) (1,)

I
f-

(f,

AB

OFTIM EI\GII{E SET 2.1DESCRIPTION

1. Fuelflter Z. Breatrer 3. Fudiniecfor 4. Injection PumP 5. Inletmanifold 6 Oufletcock 7. LubeoildiPstick & Tachomefiersensor 9. GearboxdiPtick caP tanker 10. ExPansion warcrpump lL Fresn O. Lubeoilfilter Gearbox 13. oilscrew Gearbox 14. 15.Altenator ExPansiontanker 16. Lubefiilingcap 17. 1&ExhaustbodY Lubecooler 19. 20.EitrerPumP 2f'$atlingliquid rtservoir Wabrinlet PiPe 22. 23.WateroudetPiPe 24.Starfugmotor handle 25.Gearbox

-. I

3.GEI{EARALENGINEDATA

Model

In ling vertical, watercooled forr sfuoke

chmber Comhstion
Number ofcylinders

Directinjection 3

BoreXs{rcke(rnn)
(lrtrs) Totaldisplacemeffi Firingonder

80x90
1.357
l+3+2

Coryressionratio
Rated ot$rf Qcdrpm)

18:l

(gAcw.h) Fueloil consuryUon d rdedorfrprs

Llrbeoil consrytion d rded orxpfr(g4flM.h)

255

2.72 16.148
Splashed mdforced Watercoolmt

(m') Air cmsrrytion in 10minfres

I-lrbricdionmethod Methodofcooling ofrotmion Direction Mftod of starting Methodof ope,ration

Mechmical directtmslatng or flexfrleshaftre,mote oper*ioo

Exhausttenpermre dratedouSU(C) (LX WX It (-*) dimension Overall Wei$t (kg)

s550
828x560x638
200

OFENGINE 4.I\,IAIN STRUCTURE

4.1FTIELSYSTEM oftre diesel componerfrs re imporht coffiolling Thefuetsysem md injectionpump fuelfilte,L of injectors, re coryosed They engne. purup Thefeed prpes md rmiouscomections. higfo md lowpressure The fuel,after it tofte filter. fte fueltafter md deliwries drarvs fuelfrom prry. ThefircIpasses p:lsses into&e injection passing thou$ fte filter, thefuelto pipethen atomires to &e injector rryhich intothehi$ pressure fuou$ fte oil arnorffoffuelpasses for combustion Small finedropleb intothefuelmker returnpipe prry fiming . ...2+*27 "TDC Fuel .. New:20.5Mpaiusd:20hdpa .. Injectionpressure No.0orNo.-35 lightdiesel fuelendes G8252-W Deseloil conforming NO.I-D ild 2-D.Iffte 5:77Grades ASTMD-97 orto USAspecificdion use low mbie,nt teinperdres, withortre,mely has to workin areas engine As"C. Clogpoin(CFPP) clogchracteristic. fuelwift good 4' LUBRICAilON SYSTEM m shaine,4 ismade rp of m oil srnp, m srction Thelubricdion sy$m ptpes.The oilptmpdra\E fte lube mdrmious oil pry, lubecooler,filter fte lubeoil sfrainer then in theoil sry dlrou$ oil zuction oil contained is filter. Theltrbe oil in main oil passage md hrbe flowintohrbe cooler passes md flowinfto betring fooughmain seeffid itro lhe flona.One passes ftrougb fte cmsbaft beaing rodbeiling Thesecmd connecting thewlverocker am shaft linec tolubricde oilpassagp and flowthesloping pi$on, piston line,r, idlegeilbetring: Cylinder fte ftird me flowirto timing pin,cmectingrodI Sellsefic re ryla$ or dmired luhicded" If it is added to mtrch, it Tb hrhic*ionoil Souldbeaddd poperty. fte bedingshells behm*. It is if added to less, would would bebuming reaches b*rveen theWpermd low mfllrs ideal fte oil'urtilie level to add doumto fte lowmalg ftrbe Whenfteoil lwd goes oil onthedipsticlc engine strtingfte diesel fte oillevelshouldbe shouldbe addd.Before checked.

Lube otlpressne Oflsry capacity. creaftox sry cryacity

-120bad idle. ........98ha 250-390lpa d rated odprfi. ......5.21i1rs. .. ..... 0.75litss.

43 COOLINGSYSTEM Thecooling setis offorced circulAirre wder E smoffte engine ceoling close type, uihich consists oflubeoil radidor, wderhker, rffier ptmp,n$berpipe etc. Thecooling system oftheengine is closed w*er oooling s5rstm Thecooling liq,od comes fromfte keelcooler thorAhthelubeoil cooler md wderprmpto thee'nsre blocbcytnder hea4u/ater cooling exhastpipemd odletthen feed back to keelcoolerto make circulation cooling Toohi$coohngterye,rmne larr$' wll cansethe infte confiol pmeltolightup mdacoustic altrmtofunction. Wdertenryerdure .......7545 "C. Antifueze concerilnltion of 40Yo should beusd asanallyea round coolm.ThisconceMionwi[ givelowtqerdre protection doumto -25 "C. Additimally, 40%concenfi*ion will protect thecooling sir4stm frurn corrosion. Waming: Antifreeze mntains Glycolando&er constihrcn8 ntich aretoxicif taken intenmlly, andcanbeabsorbed in toxicamormts rmderpmlonged skincontact If antifrrezeis swallowed aeidenhfu medical adviceshould be soughtimmediately.

a
'i --//

Fig PtplnglaYod
4.Lube cil pry 5.I$e cil fftEr6.Prs$ne mler 3.I(d coder we pry 2.Lube l.Coding l0Crerflorrpipell'Fudoilfilu. ccn!,olrnalveT.MainbeiliryS.Cmshaftb{iry9.Roclerum 15. Fuditli(stonmzle16. Frnliqi{simpnry la.Fudhighpcsrepipe l2.Fdfeedpw 13. 17. Rd cll inht We ffhas PiPe

4.4ELECTRICSYSTEI!{. ch4ing altrndor, ofbatrry is cornposed Theelectric E/stm larys md spitcft,almmht?r/f,jr,altrm regulator, relay strtingmotor, insfrumeff.s. be chreingbffieryshould Ifwi&od FQsnng strter,twosepfl'ded diagfms. oftwoelecfric mdrneeifterone choose Thecnrstomers need12V. Volhge: 2.s|r;ot Sffiermotor 750W Alterndor
45 GEARBOX

(Fuwmd/rwerse) 412.67 ...,...2.7 forscG 025-3: ratio re&rction Geabox (futrnd) Clochvise ofprcpeller directim Roadm

4.6ELECTRICALDTAGRAM

Tachometsr

IF

l;
cL E

o
.t

t) e)

o !o

'
oo
J

.l

5 t6

e I r0 | 11| 12
V ol tage regul ator

T ac ho n e te r s e r

ll.-t_J
lt
I 50rnrn2

tl

I l:El I lE +l
lT-T

IIEA

:lEl

; IL hl
-=
t_

pmut_r
lc

tS t a rr e !
+

lcbsrse t-

l-;l
; I
IF

r ar*- r-1 l_J ,o t L-_

\

:]

E
6 E

E bo

mnl

ri 1"r

l rt l

-l

=-r
l,

Chrngeover B at t e r rv y s sv * ii ttcc h

12 Yott

1 2 Y o lr

I t e r n sw i t h d o t t e d I i n e n o r i n c l u d e di n n o r n a t delivery.

Fig Electric diagrm1

Tachoe clroeter

tch S\vi
jlzzer

1)
''l
-l

)tr
d 6
l-.

kl I

el
TN iiv X1 =
J

>
60

Lt2
I
I

3 3
:
I

4
4

5
5

6 6

8 8
Yoltage reguiator

l_ r
lffet

-lE

T]

H
il

Tachm ler sensor

ffi
t-

* d|l| a E+g
q,l [<

EAg et-/

c)

bo

ter Start
t

H , f l r: -' L+J
i
lrI

r5fim2 I -+;Frl
:- 1
Battcry I 1! Yolt
t? I

5ftn2

l"

'l

rr
t

t-

J
htiery 7 12 YoI

Genera tor

over Change Bottery switch Itm with dotted line not inchded in norml delivery.

FigElectric diagm2

10

PARIS DESCRIPTION 4.6.1 ELECTRICSYSTEM sideor pandside Follwing parb is itrstNllod eifrer engine
'
:f,.a..r' '.

'

,t,

Taelometer Slrfing$vitch

zsu109.Y0
JICIgO

zsul(D.Yo
il(290

Buzer Alarm lamp(watertemp) pressure) Alarm tamp(tube indicatfug lamp Charge

FMG2Trs
AD11-16 AD11-16

rMQ271s
AD11-16 ADll-16

ADr.l-16

ADU-r6
7fr912ffi w89311
Y81011 QD138C

Taelom@rsuilrr Tempenafure sNnor

Tfrgtrul6
wB931l
Y81011 QD138C

Lubeprssuresensor
$arting motor

Batteryvoltage
Volhge regulabr Generator Diode

rzv
FT111
$wl?Et':"

lzv
FTIll (Nofitted) (Nofitted) 702R

IN5408

Capacity
Chargingdiode

cw22ruoJ400v
702R

4.6.2 INSTRT]MENTS PAFIEL setis normally fittedore of theengine Aoooding fte ohoioe oftre buyer, pmel. fte twoinstnnne,ms swibh4. ChrginglemF 1.Tachomefiu 2. Alilm btwff md lemf 3.Shrting (nofifred in Electicdiagrm2.)

s;s_ t|eEll

"G)"o

TAOIOIIETER

1 Fig.

PANEL INSTRUMENT
ll

PRECAUTIONS 4.7STARTING in fte hmdsof inexperienced Sffiing my ergne cm be dmgprous sbuld befully people. Befrredryting to $ilt my engine ,fte operdor md comols. wift stiltingproceere conversmt d conectly condition ae in servioeable Ofnsgre ftd thebmeries cornec'ted" re conct md fte gsabox in fte engine @.Ctectt* theoillevels is primed" @.Ctectt* tbefueltmk is fiilI md ftat tbesystem Checkftd ae closed. md codss allur&r &ainplugs @.mtftdfte iffifie4 meopened. uder inlet\rah/es, rp withmisre isfilled erymsionmk @.Chectttwderle\reIinfte ofuaer/difreae (40V1. 4.8CIIECI$ BEFORESTARTING in oil $ry md eBnbox O.Ortle\rel level in fte erysion tmker. @.Cootm lidtt wll li$t md chmging svibh is on .Orlpressure @Sffierymam wll sound. nowbem md thebuzzer

OFENGINE 5 OPERATION
5.I STARIING lhe oprdor$olld be frorrilir @efore afrryting to $ilt fte engine precarilions ealier. asdescribed with thesafety lers intotb milnl posfionby memsofthe tbeWeed/geabox @rdorrc controllwer. to ffigl?r,fte srtiug motor@Inm &e switch it will renrnto posfion ffi immedidebjffte engine Release "ild

nowbeoff. "O".The alrm fuft aswellasfte buzs should should folto silt dueto poorbd6xycondition ,tlm the @fftneengine bmerymdrepe*&estiltingfroceere. to&eseoond stmt bdery switch fril to ffi wiftin 15 secmds ,fupite goodbdry @ f the engine thecase .Th ffiingmotor md inl'esig$e condition deasefte $^'itch bdue dryting to to cml for,d lea$ 15 segotrb be allo$red should

t2

resht fte ffiingby mems b ease it maybenecessry @ et brv te,mperdne offfrestrt gas. asfollou's: is shown method Theoperdion Insert fte potringliq,trd $mage. of fte liqrtrd fl).Aen fte dustcorrer Squeeze thecm b pour prressre cm imotheholeof fte liqtrd$mage. storage. be liquiditro liqutd (z).Setthe gBarbox d. idle of position md ptdfte hryrdle fuelrackd mid-position (3).Str the engine.At fte same timg Werde &e hardanrry untl tre engine nns stably. app{swhile (4).f kxtocking fire engine is ffiing, fte of bmdatry mst ope,rrion tr $rye{ soasto be slowed fte injectingliqrnd regulate fte engine $antty for stuting shbly.

l.Air pipc 2.Hrnd pump

low temp. startingliquid pouring system -3.Liquid j.Injcctor

pipc 4.Liquid-

6.Air inlct pipe

CAUTION: Keep away fium all heat souls (evensun liquid is highly flammable. light)r.The STARIER(IF INSTALLED) 5.2STARIINGBY SPRING

t3

we canin$all md sryly tbe FQ Accorrding to fte brysr rcque$s' sEting. fufte engne engne stilter(hmdshrting) the ib rying to stme to press Thisffier makes useof man-power ardcauses relirtes d a momenb isrctded, Theengine asfte enrg/ enersi. qul*ly, offte engine of gatingrwoh*ion nming orrerfuryeed fte engine is stilting. theengine md then order md method: Operrion 1. hessfteresetbrXton. pness rotation" tre bliisflV Wingto tbehmdlemticlockrrise 2. Insrt redmaft is rypering) state.(Ihe firllypnessing is pressed At lever wrll relieve d a momeffwbtlthe 3. Theenerry qpeed of the rises theffi-tingre'rohfrion orrer thd timetheengine theirthe is stdin& engne engine, prcssure staE in rmaba&d Notr: The sEphver mustbe sifrlatud makes useof theFQ tt?e starter. whenfre engine withthebmd$pessfte reset theengine 4. If it is necffstry to rctate fu reliewrlevermd thenfu engnecm be md drarv-rp buuon bmdle. rotatedwiftthe
reset button
release handle cranking bar

Fig. Spring starting motor

neveropn Nots 1.Whm usefte FQ starter, fre decomprcssion

53 OPERATION nnsb If me ff molahn dond goorf, 6 lidil tp ufrentre engine fte reason frace d orrceto stoeipd shouldbe tre engine gearboxbypushingfte ngagpfte arenormat When allfunction lever fomrudorbackwmd" conaol to wam fte e,ngine allowing ifpossible, Increase fte qpedgradralty sped. rp, befuegomgfull ftll ryed position infio fu lers cm bemoved of emergurry, In case lmmeOlatety. 5.4STOPPING neriralposition. leverinfio confiol Morrc to cool. mirumes idleforap,pr.2 Allorvfteengineto Stopfireengine. offfte bffierynain SwitcbSwitch or$from u/derm$t bedrained isonlyuse4allof cooling IffrcshurAer mti5"C(except isbelow mbie,nttemperdre &ecooling ryste,muihe,nfte fiwocoolmtisusd)

6.ROUTINEME
before teS progrmmer haspassd the lif*om engine Theengine nrnin isnotcorryletely theengine Stillhowever delivery. tte fts during moderately to operate fu engine It is recorrmended priods ptfritro service. Fullryed onlyfor sholt it bs been after hours hours. fuing ee first15-20 61 INIIIALATTT,NTION pa)lngpatcultr l.Chft md ti$Fn all hoseclrys md unions, theftel system afrentionto rub md bolt' paticulalymotnting all $dernal 2.Che* md tighten nmifold boltsand nrs. Saft coqlingboltsmd $fraust botts, BELI TENSION. seeALIERNAf,OR belttension, 3.Check level. coolant oil md water 4.Check tubric*ion

l5

6.2ROUTINEMAINTENAT.{CE PERIODES

After the ftst 15houns cr afterthe See INITIAL AilENTION first3monfts

BeforestartorweeklY Checkerrgne orllerrcl. Checkcooladlwel. Checkfuel levelintaft. Crrease stern dmd Checkgeatox oil lwel Checkbdery condition Chmgegnatox oil md lubeoil Chmgehrbe oilfilter Checkaltem*orbehte,nsion Checkelecricconnect

months Everrr3 or25houn

yer or200hours Every

63 LIJBRICATION OIL SPECITIICATION

T@emtue in satine
Below Between and

-15
-15 4

5w
l0w

5w/30 10d30

15w/30 10d30 15d40 Above 30 30 20v{/40 Theb,ryertrres metriorrcd in thetable ae theanrbient tenperAures dthe timewlrenthe engne is sttrted. However, if fie nming teryerdures ae much highr ftm the$ilhqg tenperdures acompromise mustbe truck md ahi&ervisrnsity oil used, providing strtingis s*isfrcnry.Multi grade oils overcome &e pnoblem, pnovidedtheyha're a suitable specificdion . Theengnes must benn m h\ry ery hrtric*ingoils,meeting the requirerrents ofAPICC-DEF2 10I D, MILL2 1MB orMILLL46 152N8
Between ad

4 30

20D0w

l6

oilsre notsritable, neifter ae oilsof less ftm doergency Stai&t mineral specrfid. API CD, Series 3, u MILL21O4C/Doilscm inhibitfte nnningin procss in new o reconditioned b$ canbe reconmended engine fu pdiculn*y in mqiurction running with hi$ engines d hi$ lmd frc'tor, arnbied teryenafines. types Following of oil cm beused: orequi'ualent BPenergolDS3 Delvac 1300 series Mobile Xoil Gulfuride Seies 3 ShellRimula XD3+ ElfDsalIID3 Essohrbe TocoURSAS3 Srryer3 Che'vonDelco 3 Deusol FinaSolna Cashol RX sper Norollv{rineTI\4A300 Amocol NewSr4perACE3 6.4GEARBOXOIL SPECIFIICATION Asomatic Trmsnnission Fluid-ATF FORDSpecificdion M 2 C-33 G DE)(RON IID GM SpecificuionATF DO(ONATFD orAf,F (orreferto iremmual ) 6.5MAIN SPAI\I{ERTORQUE SETTINGS
.ir

Ftyrfreelbolt Cylinderheadnrr
Comectingrod botb

60 140 70 70 125

prooD Prop. coryling sbaft bolts(acid Crmlabaftmainbearing

6,6TIGHTENTNG FORCYLI\DERHEADBOL;rS" SEQr.rEnrcES

6.7C}IECI( OF LUBRICAUON OIL LE\IEL Thelubricdion orllerrcl should ah^alrs becheckedbefore stilting. Thelevel should nwerbeallowed to frll belower mak. 6.8LUBRICATIONOIL CTIANGE Theoil change wlre,n should bedoum tlreengine is wam. Rrmtheeagine after oil chmge md check for my leal$. Stop fte engne, allow theoil to setlemd topry ifnecessry. 6.9AUIERNATORBELTTENSION. It is iryorffi ftd tbebefttension is chec,ked afterm overtanl or rryhen newbeltis installd. Newbeftte,nsion: rrrm Aforceof3-3.5kgto de,flecttreh3.5 Checking md adjusfrnent d service itrervals: A fme of 24.4 kgto deflst belt3.5nrm 6.10GEARBOXOIL CIIECK Checkfte oil level. Fill W if fte oil lerrcl isbelow themnk. Gearbox $ry cAacity: 0.75liters 6.11 PRIMINGTTIEFI]EL SYSTEM Tb fuelsy$ern has to beprimed bdue initialffiing, after fuelfiltr iftle fuels5dm chmge, has bffi discommed, orifthe engne bas nm orsoffuelmd sops. plugontopofthefirelpry. I J-oosen &e ve,lrt 2.Tum onthehmdleofthefuelfeed prry 3.Sffi thehmdlerpmddoum movm,nt.

tumofffte hdle of noairis left,rfi$tntheve'dplugand 4.When fte fuelfeedpry. 6.12 DRAIN TIIE COOI"ANT ffitker.Drainthecoolm tre cry on the@ of erymsion Remove fte capmd cockafter draining. Close in frontof engine. troughthecock wder atti-fieezing misrc. wift conect systm Refillfre cooling runidlefor 20-30minrmes. Lettheengne 6.13CHANGINGFTJEL FILTER ELEMENT aborrc fte e,ngine, fte cock mu$ Ifthe fireloil hk is installdd a le'vel Unssew fte flter coffiinermd discild firelfiltrchmge. beclosed beforc Ensure fufte ruffierga*etsmd tre Wing ile ccrrectly fte filterele,ment filterchmge. is reinstalled after fined fte filtercodainer before 6.11 . chmge, see section fte firels5rstm after filtereleure,nt Priming AIUUSTMENT 6.14IDLING SPEED isreached . mdmrttrilnumal ope,ratingteryermne Stattrengire CmectidlingWed is lessthrr 900rpm md is frdory stbefore dispdch. Ea$China Adusfinent should onlybe cffiid ott der coDsnlting Factory, Inslihse CHINA shphxlding ADruSTMENT 6.15VALVECLEARANCE Theralve clermceis : mm (colo : 0.25^O.30 Exhar$rnalve (cold) : 0.20^O.25 rnrn Imke valrre 6.16STAKIING AND RI.JI\INING TIIE EI\IGII{E WHILE THE TIFEBOATIS HOOKEDIN DAWIS OR IN FREEEALLRIG The engine sbouldbe ffied mdrunmceaurc* d aftumylcfudof mafutenancework. to 5 mirumes d idleqpeed Thenming Souldbelimitd . Thewderteryerdne alilm $ould bewdched . ABOUTELECTRICSIYSTEM 6T7GEI{ERALPRECAUTTIONS poir6 must Thefrflowing beSrictlyftenrcd uibn wonking onfte sy$em, otreruise dmagecan eleclric seriors occur. anyelectrical cablewiftorf fir* disomecting lNever rcmove ee

l9

bderies. ufrrlefte engneis nming. cables thealternator 2.Nerrcr discomect $oeed ard all svitdresin with engine ihebameries 3.Onlydisconnect fte OFFposition. are cmnrectdto fteir conectterminals 4Always dreckthd cables wrll Areversalofpolrfu cnsbmtcircuit thebmeries recomecting before md regulator. in thealternator desfioy urd trmsistors diodes flow. thecunent to check 5.Never flashmy connections properly tightened. comections 6.Always keepthe elecfiical 6.18STORAGE

for a longpenodof time,It is 1. If tbe engneis to be prtrotlt of senrice is e,ngine ulalsrmd fueluihen to drainor$ttrbric*ingoit cooling nwessary engine. still wrm afur stoppmgthe accordingly. maintenarces 2. Perfomr rnmifoldsandpea into fte cylinda 3. Dismmflebdh intakemd exha:st oil (By he*ing abou0.2@of clemdehydratul liners funn theairpassagBs the lubric*ing oil to 110-120C,Efl all air bubbleon srn&ceof oil cylinder linersand thecrarlahaftsothatthevalves, disryped. And rotate pistons with a layerof this oil.. Theninstallthe irnake etc.ae all covered anderharstbody maarifold ofthe enpe. Smeumti-rus orfrer $xrfrce md du$ fircm 4Re,move sludgs plastic sufrcesof pm of the enpe. Rubbr oil on to e4osedmachined with oil. to be smeaed ae prohrbted corrponents plug or p4e flange with wooden 5. Blocktheiffike mmifoldmd exhau$ clothin m&r to prevsdmy drs! from with plastic wr4 therr rp pnWerly gemmgin. md rte,lrtildion in roornof good should be $Ored 6.The enpe sopriesenred to $tre fte engine brfrwithorilmy du$.It is sfrictlyfofuidden low humidit-v uiherwrihereae chemical. pno..A,ntmay be goodfor thee accodng to aborie The pnesenmion ftis procedtre. Overthispend, repeat months.

20

TTROUBIE SHOOTING
please Ifyouue in difrculry, isirffirdd asagui& only. Thissection CHINAor localour Istihfre Factory, Shlpbutlding EastChina consult prodrct distrihnor. IN STARilNGTIIE ENGINE 7.1DIFFICUUT

ue obsfructed Clem&efilterorpipes (l).Thefuelfiltff orprp,e all fuelPiPe Draintre air d tigbfien (2).Airis locked in thefrrcl

connectors mgle advance drefireliqiection aule is Adjust (3).The ad'mrce fuel iniection asspecification. Oincorrect asrequired. clearm.ce Adju$fuevalrrc is irporrec{ (a).The valrre clearmce the (s).Bdery not fully chrgBdtr Poor Chrg, ee bffieryfirlly or tighten connections. wireconnections (6).No fuelin hlrcr trPoorryaYftom Fill up tu fuelu diust tu pressure asrequired. injector pressureChecftmd cbmgptbe pistonring u (7).Low compression cylindr
head fte cylinder cylinfu liner.ChmgB

7.2INSUMCIENTOUTPUT

7.L(7) Referto 7.1(3) (2) The fuel injectionad\Ece atgle is Referto incorrect. 7.1(4) Referto is incorrect 13)Thewlrrc clearance (a) Fuel stply for each cylinder is Adju$fte firelqurotityof fuelinjection ptmpunequal. to spectficdi@" speed Adjust&e engine qpeed (5) Inw eneine cotryle. newphrnger of Re,new corryle wearofphrnger (6) Excessive Injectionpmp Clem. clogged syste'm (7) Theextraust

2l

7.3BIACK SMOKING FROME)G{AUST

Reduce pnoperty. fte load (2).Fueliqiecror defeds Renewone. (3).Poortuel ChmgB Erality thefuelasqpecification (4Flrefirelinjection advmse 7.1(3) rogte Referto is incorrect. (5pomhrstion is incorylete Check tre injector, fuelinjection advilce angle cylinder ga*f and cylinder 7.4LOWLUBEOILPRESSIJRE

(2)Lubeoilpipeleaks (3)Lube filterobstnrcted (a)Thelube oil is tootrickness (5)Pressure sensororlamp defe*s (6)Crear punp wom ots md clearance is over

Fill rryto fte ri$t rnalc

Tighten all connectors. Replace lubefilter. Replace fte lubeoil asspecification Replace anewone. Replacegeas purnp ild adjust fte clearances

7.5ENGIM rC{OCKING

(l).Thefuelinjection ad\mcmde is Referto 7.1(3) incorrect (2)Air orwater ismixed in firelsystem Referto 7.lQ) (3)Fuelsrpply for each cylinderis Referto 7.2(4) uneqnl. (4)Wean of fte cerhin compone,nn Replace tre wompm. exceeds specification limits

i--

OVERHEATING 7.6ENGINE

a- kt$trcient cmlaf m l4o lockincoolingqystem wAerpury defe# b. Cooling e. Wderprry beftisloose (2)Lrfieoilteryerdre istoohi-S. oillwel chign. a. lnw hrbe wifu b. Low lube oil Pressure insfficie,*flow. is ovedoaded, (3)Theengine

his

coolmt Addunater wder PlrP or replace Rpair 6.9 Refertosection lubeoil Fitl ordrainthe 7.4 Referto 7.3(1) Referto

O\IERSP@ OROVERRIDE 7.7ENGINE

..

'' gausry

(2) Coffiol bu of fuel inje*ion plmp is stuck.

fuelPmP md readjust iheengne prry is Stop of injrection (3)FuelsWplying deli\iery. toolargB. mdrePair andcheck iheengne Stop much (4)Oil gets intocYlindertoo