SINOOUTPUT GROUP LTD.

RM101-13FL, No.258-268 Zhaojiabang Rd, Shanghai, China 200031

Tel:0086-21-36120339 P.H:0086-18665356574 Contact: Ms Amy
Email: sales1@sinooutput.com Web: www.sinooutput.com www.sinooutput.en.alibaba.com

Engine Specification

1, Marine engine（Max. 251kW/2400rpm）SPECIFICATION

1-1 Main Data:

Maximum power speed 2400 r/min

Continuous power 319hp/234.5 kW

Continuous power speed 2330 r/min

Oceangoing rated power 311hp/228.5 kW

Oceangoing overloaded power 340hp/251 kW

Compression ratio 16.0 : 1

Fuel consumption at Rated power≤ 0.36 lb/hp.h (218 g/kW.h)

Lube oil consumption ≤ 0.001lb/hp.h ( 0.8 g/kW.h)

Minimum idle speed 700 r/min

Steady speed governing ratio ≤ 10 %

Exhaust smoke intensity ≤ 2.5 Bosch

Exhaust temperature ≤ 788F(420℃)

Air intake flow 444965 ft3/h (1260 m3/h)

Exhaust flow 1716lbs/h (780 kg/h)

Heat dispersion capacity 2160 kJ/min (2050 BTU/min )

Noisy ≤ 1183 dB(A)

Exhaust emission Compliant with IMO

Starting mode Electric starting

Cooling mode Fresh and raw water dual-cycle system

Rotation direction of crankshaft Anticlockwise (facing flywheel end )

Net weight 1760lbs (800 kg)

Overall dimension 58.98×32.4×39.8Inch(1498×823×1010 mm)

Standard components supplied

Water cooling turbocharger Heat exchanger Air cooler Expansion tank

Gas-oil separator Sea water filter Water-cooling exhaust manifold

SAE 2# flywheel housing Instrument on engine

Available options

Exhaust accordion pipe Pulley (3 or 5 grooves ) Remote instrument SAE 1# flywheel

housing Fuel leak alarm unit Exhaust muffler

Elastic support of engine (vibration insulator) Shield double layer high-pressure fuel pipe

Water-cooling exhaust elbow (connecting after Turbocharger)

1-2 Main technical specifications

Basic parameter

Type: four stroke, water-cooled, 6 in-line, and direct injection

Bore×stroke: 4.5×5.3Inch(114×135 mm)

Total displacement: 8.27 L

Center of gravity (engine only): Distance from front face of cylinder block 427 mm Distance
above crankshaft center line 6.42Inch (163 mm)
Firing order: 1-5-3-6-2-4

Clearance of valve: Intake valve 0.01Inch (0.3 mm) ; Exhaust valve 0.02Inch (0.5 mm)

Rotating direction: count clockwise (facing flywheel)

Installation parameter

Static installation angle ( front up): 0º~10º

Length ways/pitching: 10º/20º

Transverse/rolling: 15º/30º Fuel system

Fuel oil specification: light diesel oil 0 #

Maximum allowable restriction to fuel pump

1)With clean filter 1.23PSI/8.5kPa

2)With dirty filter 1.93PSI/13.3kPa

3)Maximum allowable return line pressure: 10PSI/69 kPa

Lubrication system

Lube oil specification: D683 special lube oil or CF-4 grade lube oil

Lubrication mode: pressure and splash

Pressure of main oil duct:

1)At idle speed minimum: 10PSI/69 kPa

2)Normal operating range: 50.75~73.95PSI/350~510 kPa

3)Maximum allowable oil temperature: 248F(120℃)

4)Oil sump capacity: low/high 13/17L

5)Total system capacity: 22L

Cooling system

Cooling mode: bicirculating cooling (raw and fresh water)

Total coolant capacity with heat exchanger: 26.5L

Pressure of cooling system (at 2200 r/min): 13.92PSI/96 kPa

Thermostat open temperature: 161.6~172.4F(72~78℃)

Thermostat full-open temperature: 194F(90℃)

Thermostat Lift range: 0.35Inch (9 mm)

Maximum allowable coolant temperature: 205F(96℃)

Minimum allowable coolant expansion space: 5% (of system capacity)

Minimum coolant makeup capacity: 2.5L

Maximum raw water pump initial suction lift: 2.0 m

Maximum Raw water pump pressure: 14.94PSI/103 kPa

Maximum Raw water pump inlet restriction: 2.32PSI/16 kPa

Intake and exhaust system

Maximum allowable intake restriction:

Clean air filter element: 0.54PSI/3.7 kPa

Dirty air filter element: 0.9PSI/6.2 kPa

Maximum allowable back pressure: 1000 mm H2O

Electrical system

1)Minimum recommended battery capacity (24V) : 150 Ah

2)Cold soak at 64.6F(-18℃) or above-Cold cranking amperes 900 A

3)Reserve capacity: 320 min.

4)Cold soak at 32F(0℃)or above-Cold cranking amperes640 A

5)Reserve capacity: 240 min.

6)Starting motor (24V ) : 10hp/7.5 kW

7)Generator (28V ) : 5.5 A

 1-3 Technical specification of main accessories

Art NO. Name Item Technical specification

1 Fuel injection pump Type Injection pump (PS7100 type; NB type: P7type)
Mechanical variable speed governor for marine propulsion
2 Governor Type
engines Electronic governor for gen-set engines
3 Fuel injector Type P series fuel injectors With small inertia and six hole
4 Delivery pump Type Plunger pump
5 Fuel filter Type Spin install filter paper type
Type Centrifugal type
6 Fresh water pump Lift head 11 m H2O
Output volume ≥380 L/min
7 Lube oil pump Type Inner and output rotor type
8 Torsion damper Type Silicon oil damper
Air compressor Centrifugal type
9 Turbocharger Turbine Radial flow type
Type Wax type
Initial open temp 77±35.6F(25±2℃)
10 Thermostat
Full-open temp. 194F (90℃)
11 Lube oil filter Type Spin install filter paper type
12 Lube oil cooler Type Plate-fin type
13 Intercooler(air cooler) Type Tube-piece type
14 Heat exchanger Type Pipe-shell type (raw and fresh water)
15 Fuel cooler Type Pipe-shell type (fuel and raw water )
16 Gas-oil separator Type Filter element separation type
① Flexible impeller ith self-priming suction capacity
Type
②Centrifugal type with self-priming suction capacity
①Flexible impeller
Impeller type
17 Raw water pump ②copper impeller
Output volume ≥200 L/min
Lift head 15 m H2O
Self-priming suction capacity ≥2 m
Type Electric motor
Voltage 24 V
Electric starting motor
Power 10.2hp/7.5 kW
Mode of connection Double wire system
18 Compressed Air Type Blade type air starter

Working air pressure 72.5 ~116PSI (0.5~0.8MPa)

starting motor
Power 8.2hp/6 kW
Speed 1420 r/min
Type Integrated brushless self-excitation

19 Charge generator 28 V
Voltage Electric current
55 A
2, Brief introduction of main structure

Special attentions have been paid to following components during the engine design in order to
meet the high-speed vessels’ requirements for high power, high speed, lightweight, and compact
structure.

--Cylinder block: Design of portal-shape cylinder block and short cylinder bore center distance
reduces the engine weight and overall dimension. Strengthening on mains is made by increasing
of height and width of main bearing wall supports and by a good arrangement of ribs around the
main bearing walls to enhance load capacity and rigidity and decrease distortion.
--Cylinder liner: The cylinder liner is high strength, wearable Ni and Mo alloy cast iron, which
improves mechanical and thermo load capacity.
--Cylinder head: Frame type alloy cast-iron cylinder head possesses high intensity and rigidity.
--Piston: The piston material is high silicon-aluminium alloy. It has a low compression height (the
distance between the piston pin center line and the piston top surface is short), a taper pin bore
wall, and three rings structure with the first ring grooves being inserted with austenite material
(the first two ring grooves of high power models being inserted with austenite material). The
piston skirt profile is barrel and a cooling injector is introduced to cool the bottom of the piston
head.
--Piston ring: The first ring is a taper shaped, nodular cast iron with infiltrated ceramics and Mo
plated. The second ring is positive torsion with Cr coated. Oil ring is Cr coated package, which
improves sealing, oil scrape, ring strength and wear resistance.
--Connecting rod: The connecting rod is alloy forging with I-shaped cross section and a flat split
line, and its bearing is steel base with low tin aluminium alloy or steel base with three layers of
cupper and led alloys, which improves load capacity.
--Crankshaft: The crankshaft is one piece of alloy steel forging with seven main bearings. It is
completely balanced with full count-weights to reduce the engine mechanical vibration. The
journal surface is treated by nitriding and the round angle is treated by hard rolling to increase the
fatigue strength and service life. A viscous tensional vibration damper is applied at the front end
to reduce tensional vibration in the whole engine operation speed.
--Fuel injection pump and injector: The engine adopts a high-pressure fuel injection system.
According to different models, they adopt respectively domestic fuel injection pump PS7100pump,
P7 pump and imported NB pump. All models adopt P series fuel injectors with small inertia and
six hole to ensure best combustion within cylinder. Mechanical variable speed governor for
marine propulsion engines and electronic governor for gen-set engines ensure the engine
running stabilization. The combustion system is optimized to ensure quiet and complete
combustion.
--Gear train: The gear train is in front of the engine. The camshaft, fuel injection pump, raw water
pump are driven by gear, and the fresh water pump as well as alternator etc. are driven by a
multiple belt.
--Supercharger: The engine adopts coolant-cooled turbocharger for high-speed models
(2200r/min and upward) and a turbocharger with a heatproof shield on turbine casing to improve
engine room environment and protect personal safety.
--Exhaust manifold: A coolant-cooled exhaust manifold reduces the temperature in cabin and
improves working condition.
--Raw water pump: According to different models, engines respectively equipped with a raw
water pump of flexible impeller with big flow and best self-priming suction capacity and a
centrifugal type raw water pump of copper impeller with self-priming suction capacity. They
possess big flow. Raw water pump is installed on the engine and it is driven by gear to ensure
reliable working.
--Raw water filter: in order to ensure raw water cleanness enter each system of the engine, a
raw water filter is supplied for user, it is installed before the raw water pump to protect raw water
pump, intercooler and heat exchanger etc from being blocked or damaged from rubbish.
--Fuel filter: A fuel filter with fuel-water separation is introduced to separate the water from the
fuel for high power models.
--Fuel cooler: a fuel cooler is installed between the return fuel pipe of the injection pump and fuel
tank to cool down the fuel and improve the engine performance.
--Air filter: An air filter s introduced to further reduce noise for high power models.
--Closed type crankcase ventilation system: The engine adopts a closed type crankcase
ventilation system with a gas-oil separator, gas from the separator inter intake system, oil return
to oil sump. The oil vapour of the crankcase do not vent in the air to improve the environment of
the both the engine room and the atmospheric environment.
--Raw/fresh heat exchanger and intercooler: The cooling radiating pipes in heat exchanger
and intercooler are cupper-nickel pipe with high thermal diffusivity and corrosion proof as, pipe
orifice adopts expanded tube and silver-alloy brazing technology, ensure know clearly nodal heat
dissipating capability, working reliability and long life period.
--Flywheel housing and flywheel: Sizes of connection conform to SAE standard, flywheel
housing: SAE J617C N0.2. It could convenient match different kinds of both here and abroad
gearbox or dynamo.
--Starting: Electric starter with 24V for marine propulsion engines, user could choose electric
starter or compressed air starting as required for auxiliary engine. An alternator on the engine can
charge up for the accumulator.
--Electronic monitored instrument device: A single board computer is used as an instrument
system for the engine control unit that controls engine running safely by giving both sound and
light alarming and then automatically shutting off fuel system whenever the engine runs at over
speed or excessive high water temperature, or excessive low oil pressure. There is a set of
distant display for option.

3, The outline overall and installing dimensions of the mostly models

4, Brief introduction for systems

4-1 Cooling system (sea water and fresh water system )

The main function of the cooling system is to carry away the heat generated in combustion
accomplishing work and the friction between the moving parts in engine, and to guarantee each
component and part of engine to operate reliably at appropriate temperature.

The cooling system of D683 series marine diesel engine is of raw and fresh water bicirculating
forced circulating type.

Fresh water circulating system is of close circuit circulation system, it mainly cools the cylinder
block, cylinder liner, cylinder head, water cooling turbocharger, water cooling exhaust manifold,
lube oil and so on, its schematic drawing for the turbocharged with intercooler models is shown in
figure --1.

Raw water circulating system is of open circuit circulation system, it mainly cools fresh water (in
the heat exchanger), air compressed and heated by turbocharger and lube oil of gear box,
exhaust pipe behind the engine and so on, its schematic drawing for the turbocharged with
intercooler models is shown in figure --2.
 Fig.--1 Schematic drawing of fresh water circulating system

Fig.--2 Schematic drawing of raw water circulating system

Caution:

Clean raw water filter or change the filter element frequently. Otherwise, flow of raw water
pump will decrease, heat exchanger will be blocked, water temperature will be lifted up,
engine cooling will be insufficiency, components and parts will be overheat, engine power
will be reduced and engine will be appeared severe failure. Any raw water pump is not
allowed to operate in condition of water break. It is very dangerous to operate in condition
of water break, which will cause impeller, bearing and water seal ring to be burned out and
temperature of engine cooling water to rises, scuffing of cylinder bore and other
catastrophic failures will occur.
4-2 Lubricating system

The main function of the lubricating system is to lubrication, anti-attrition, cooling, conducting heat,
wash, seal, antitrust and anti-corrosion. The moving parts of the engine are mainly lubricated by
pressure oil; some parts are splash lubricated. The lubrication route for D683 series marine diesel
engine is shown in figure --3.

Fig.--3 Schematic drawing of lubricating system

4-3 Fuel system

The main function of the fuel system is to supply clean fuel, possessing a certainly pressure and
well atomized and to inject into combustion chamber as required time, and to guarantee
combustion and accomplish work The schematic drawing of fuel system for D683 series marine
diesel engine is shown in figure --4.

Its difference between the engine and other engines is to increase a fuel cooler and it is installed
between the return fuel pipe of the injection pump and fuel tank and should utilize raw water to
cooling the fuel being higher temperature and cooled fuel return into fuel tank, so that it should
improve engine performance. The fuel system is one of the key and important system. Its quality
of manufacture and installation of pipes exterior connected and fuel tank and fuel quality all
influence on the performance and reliability of engine.
 Fig.--4 Schematic drawing of fuel system

4-5 Intake and exhaust system

The schematic drawing of intake and exhaust system for D683 series marine diesel engine is
shown in figure --5.

Fig.--5 Schematic drawing of intake and exhaust system

There are turbocharged with intercooler models and turbocharged models for D683 series engine. Intake air
is cooled by raw water in intercooler for turbocharged with intercooler models.
All models for D683series engine are installed an air filter in order to prevent sundries and dust are sucked
into cylinder.
For decrease of temperature in engine cabin and improvement of working conditions, the exhaust system of
all models for D683series engine is a water-cooled exhaust manifold and it uses fresh water-cooling exhaust
manifold.
There are water-cooled turbine housing turbocharger and non-cooled turbocharger in D683 series engine. It
also uses fresh water cooling turbine housing for the water cooled turbine housing turbocharger and the
turbine housing for non cooled turbocharger should be adopted aluminium silicate material thermal
protection shield to heat insulation and shield.

4-6 Starting and electric instrument control system

Generally D683 series engine should be adopted electric starting style. Electric apparatus system is DC 24V,
and it consists of an electric staring motor, a charge generator, an electric magnet valve for shutdown and so
on, which are already installed on the engine. The battery and cables from the battery to starting motor and
generator purchase by users themselves and its specification and requirement refers to chapter 1.
The wire diagram of electric apparatus system is shown in figure --6

Fig.--6 The wire diagram of electric apparatus system

Could provide the compressed air starting system for gen set engine according to users’ requirements.
Users themselves should purchase the components and parts of the compressed air starting system.
Compressed air starting system mainly consists of the air accumulator, the pressure
regulating valve, the air gauge, the starting valve, oil fog generator, air-starter and so on.
The compressed air starting system is shown in Figure --7
 Fig.--7 Schematic drawing of compressed air starting system

4-7 Instrument control system is the automatic detection controlled by monolithic microcomputer and the
warning and protecting electronic instrument for out of limit, and it adopts DC 24V power supply.

There are indicating gauges like engine’s speed, fresh water temperature, lube oil pressure, and lube oil
temperature etc and a run time accumulative meter is superposed on the tachometer, and bottoms like “start”,
“emergency stop”, “deafen”, “reposition” and so on, and alarm indicating light and rest some function lamp
in the instrument panel. The indicating gauges are pointer display for main propulsion engines, and the
indicating gauges are digital display for gen set engines adopted electronic governor.

All instrument control system could outfit remote display and warning function instrument box. Users should
bring up and affirm the wiring harness length at order the long distance instrument box.

The instrument panels for main propulsion engines and gen set engines is shown in figure --8

for main propulsion engines for gen set engines

Fig.--8 remote control Instrument panels
The instrument control system has the warning functions of overs peed, coolant temperature too high, and
oil pressure too low for all models. The main warning value is as follows:
High coolant Low oil
Model Function Overs peed temperature pressure
r/min F/℃ PSI/MPa
2200～2400 r/min Sound, lamplight ≥2650 ≥203±35.6/ ≤29±2.9/
Models alarm ≥95±2 ≤0.2±0.02
Stop engine ≥2650 -- ≤14.5±2.9/
≤0.1±0.02
1800 r/min Sound, ≥2130 ≥203±35.6/ ≤29±2.9/
Models lamplight alarm ≥95±2 ≤0.2±0.02
Stop engine ≥2170 -- ≤14.5±2.9/
≤0.1±0.02
1500 r/min Sound, ≥1700 ≥203±35.6/
≤29±2.9/
Models lamplight alarm ≥95±2 ≤0.2±0.02
Stop engine ≥1750 -- ≤14.5±2.9/
≤0.1±0.02
There is a warning function of low raw water pressure for gen set engines. Its warning value is 4.35±
0.29PSI (0.03 MPa±0.002 MPa).
Warning function for low oil pressure will be in action after engine is stared and speed exceeds 900 r/min,
therefore, when starting and operating in low idle speed, operators should note to observe the engine.

5, Power output
1
Power output of engine is mainly from the crankshaft rear end (flywheel end). Flywheel is SAE J620d 11 /2
(flywheel housing is SAE J617C No: 2) for normal models.
The engine has its partial power output from the crankshaft front end, whose maximum output being less
then 81.6hp/60kW. When output being less then 40.8hp/30kW users can directly utilize 4 piece M10
screwed hole and 135 locating hole on the front end retaining plate of the damper to install belt pulley that is
designed by user oneself. When output being more then 40.8hp/30kW users can utilize 4-pieces M16
special bolt to screw down the belt pulley that is designed by our company. Should balance the tension in the
right and left side of the engine as best as one can when front end has output. The front-end belt pulley is not
installed in the normal engine. If users need the belt pulley, should affirm at order the engine.

6, Installation and connection for engine

6-1 Inboard installation
1) Users and operators should read this instruction in the relevant documents and information carefully
before lifting engine, to be familiar with the structure of engine and installation require. Installation personnel
must be skilled worker possessed installation experience. If having biggish discrepancy between the
structure of the engine and submitted document and material, then should precede installation at supervision
by persons concerned of production unit.
2) When lifting engine should use special lifting tools, hang in the flying rings on the front and
rear end of engine and should kept the engine crankshaft to submit horizontality. Should notice to don’t hit
and scrape the periphery parts and pipelines of engine at lifting.
3) Generally the front of engine should toward bow and engine installed with lengthways inclination is
allowed. The lengthways inclination could not above 10º. In particular cases, D683 diesel engine allow
upside-down installation (that is to say the rear of engine
toward bow is allowed), that requires confirming at subscribe for engine.
4) Engine and boats base should be connected rigidly and tighten with bolts. If engine and gearbox is
connected with a high flexible jointer, what’s more, the flexility of jointer is much more higher then flexible
mats, flexible connection with engine and boat are also allowed. There are 4 supports on the engine, front
supports are located in the front-end face of cylinder block and rear supports are located in the flywheel
housing. The width and height of the front and rear supports are accordant, actual size details refer to
installation diagram in the chapter 2.
5) Connections for engine and raw water pipes, fuel pipes etc must be reliable, firm and with no leak. Other
pipes, such as exhaust manifold, raw water outlet pipe, fuel return pipe also should be firm and reliable.
6) Fuel injection pump regulating lever and direction changing lever for gearbox can be connected to control
room with steel wire or other electric method for remote control. Lever for emergency shut down has been
connected with a magnetic valve. If require to install the other one button for emergency shut down, users
only need connect with magnetic valve, the bottom and power supply together.
7) Fuel injection pump regulating and emergency shut down for engine with an electric
governor have been controlled by the button and switch on the instrumental control panel. No control level
needed any more.

6-2 Air intake system

2
Indrawn air of engine reaches 1050~1200 m per hour. Supply engine with adequate clean, cool and dry
fresh air is the basic requirement to improve power economy and dependability.
Otherwise, the power will be loss, performance will be bad, running will become hard and maintenance costs
also will increase.
1) To insure the air intake for engine, engine room should be ventilated by natural or force. Otherwise, intake
fresh air to engine by a pipe from outside the engine room to the air inlet of the engine.
If engine room is ventilated by natural, there must have some opened ports with adequate size. If it is
ventilated by force or a pipe takes fresh air from outside engine room, adequate fresh air with a certain
temperature range to engine should be demanded.
Air inlet port should be far away form heat sources. At the same time, additional measure (such as vent by
force) should be taken to take the heat radiated by engine. Temperature of inlet fresh air
should less then the normal air temperature for engine:62.6F(17℃).
No matter what method is taken to inlet fresh air, a cap or dustproof cover is needed for inlet port to proof
raw water, drain water, dust or other dirties into the air inlet system.
2)Reduce the elbows of air inlet pipe as you can. Elbow should take a large radian. The effective inner
diameter should not less than 4 . 3 3 I n c h ( 110 mm). The inner wall of inlet pipe should be smooth and
without any leak or gape. Inlet pipe must be sealed well and with no leak.

6-3 Exhaust system

1) A flexible ripple pipe must used to connect the turbocharger and exhaust pipe of engine room for the
distortion of pipe after heated. Pay attention to the air flowing direction of ripple pipe at installation. Don’t
connect it in reverse. The exhaust pipe of engine room should be fixed firmly. Any extra force or torque to
turbocharger and ripple pipe is not allowed to exist. Or, it could influent the structure intensity of engine.
2) A wet exhaust flexible pipe can be connected with turbocharger when engine room adopts a wet exhaust
method. All pipes (hose or tough) should be fixed firmly, and any extra force or torque to turbocharger is
not allowed to exist. Or, it could influent the structure intensity of engine.
3) The inner diameter for exhaust pipe of engine room must not less than 4 . 3 3 I n c h ( 110 mm). The length
should be short as possible as you can. Try your best to reduce the elbows of pipe. Elbows should take a
large radian.
4) The total resistance for exhaust pipe of engine and silencer (the total exhaust backpressure)
could not more than 5 kPa(0.73PSI). Or, it could influent the power and performance of engine.
5) To reduce the temperature of engine room, a water-cooled exhaust pipe for engine room or heat insulation
measure can be adopt. The raw water exited by heat changer can be used as cooling water for exhaust pipe.
6) If more than one engine are used for one engine room, each engine must have a special separate
exhaust pipe to vent exhaust out of engine room. Share one exhaust pipe of engine room is not allowed.
7) The capacity of heat radiated of engine could reach 135000kJ (128000BTU) when operation of engine,
other equipment of engine room should also generate heat at the operation, therefore, ventilation of the
engine room is necessary to limit room temperature rise and to make clean, cool intake air available to the
engine. There must have some exhaust opened ports with adequate size in the engine room. If the exhaust
opened ports are too small, should adopt force exhaust to ensure the temperature is not too high in the
engine room. Exhaust opened ports should be far away the fresh air inlet port.

6-4 Fuel system

1) Fuel tank should be fixed near engine. The distance should be short as possible as can. Fuel outlet port
level of tank should be higher or as high as inlet port of fuel delivery pump and should be higher
1.18~197Inch(30~50 mm) than the button surface of tank to avoid the suction of sedimentary rubbish into
the engine. Fuel level can’t be low 1 m than inlet port of fuel delivery pump. If more than I m, an auxiliary fuel
tank is needed. What is more, an electric fuel delivery pump is needed to deliver fuel to the auxiliary tank.
Auxiliary tank should have an air port and overflow pipe.
2) Steel pipe or knitted rubber pipe can be used to connect fuel tank and fuel pipe of engine. Copper pipe
and zinc-plated pipe cannot be used, for diesel can dissolve them. The inner diameter for intake and return
pipe could not less than 0 . 3 1 I n c h ( 8 mm). The total resistance of fuel pipe (inner diameter, length,
elbows and so on) should be less than 13.3kPa(1.9285PSI).
3) To avoid rubbish sucked, a filter mesh is needed before intake pipe of fuel tank.
4) A water-fuel separator is needed between fuel tank and fuel delivery pump to separate water and
cleaned fuel. As an optional part, water-fuel separator can be bought and fixed by customers. Model
500FG-30 is commended.
5) To close the fuel when replace a new fuel filter, there should have a shutdown valve in pipe.

6-5 Raw water system

Both raw and fresh water dual cooling system is adopted for D683 series engine.
Raw water-cooling system is an open system.

Caution: Must not fill raw water into fresh water-cooling system.
1) Raw water inlet port should be on the lowest place of vessel. There also should have a filter mash before
2
inlet port. The dimension for each mesh should be less than 0.2 cm (the diameter should be less than 0.1
Inch (2.5 mm)). A raw water filter is needed to bar rubbish enter.
2) In order to ensure the cleanness of raw water entered pipe, users should install a mesh in the raw water
entrance and a filter of raw water in the pipe. In addition, a raw water fine filter is reoffered by our company
for users, and the fine filter can be fixed between raw-water coarse filter inboard and engine raw water
pump by customers.
3) A stop return valve is needed for raw water inlet pipe to avoid the raw water back when clean the raw water
filters.
4) The inner diameter of raw water pipe cannot be less than the inlet diameter of raw pump. To reduce the
resistance from pipe and avoid the reduce elbows of pipe as possible as can.
5) Copper or zinc-plated steel pipe should be for raw water pipes to avoid raw water erode.

6-6 Electric instrument control system

DC 24V double-wire system is selected for electric instruments control system.
The outline overall and connecting locations for start motor and recharged generator are shown in figure --1
and figure --2.
 DC 12V 10.2hp/7.5kW

Fig.--1 Outline overall and connecting locations for start motor

Fig.--2 Outline overall and connecting locations for recharged generator

When connecting the battery and start motor, recharged generator, the section for starting wire should be
more than 50 mm2, the section for recharged wire should be more than 4 mm2, other should be more than 2.5
mm2.

The remote instruments fixed in driving room or control room (second instruments) can show the rotation
speed, water temperature, oil pressure, oil temperature and alarm. As optional parts, all these instruments
can be selected and fixed by customers.

The schematic drawing of connecting wire of the instrument for main propulsion engine is shown in figure --3.

The schematic drawing of connecting wire of the instrument for marine gen set engine is shown in figure --4
Fig.--3 Schematic drawing of connecting wire of the instrument for main propulsion engine

a) Connecting wire for control

b) Connecting wire for sensors

Fig.--4 Schematic drawing of connecting wire of the instrument for marine gen set engine
Caution: For correct connection, you must connect instruments control system as the
schematic drawing of connecting wire for the instrument, or, instruments will be damaged
and engine also cannot run.

The pipes should be connected correctly as figure 3-6 for users who adopt compressed air
starting system. The pipes should be seamless steel pipes and should be cleaned cleanness.
Must not be entered any sundries in pipeline when installation and each joint seam should be
sealed rigorously and must have not leaking bleb phenomena.

6-7 Joint of gearbox and dynamo

Engine can be connected with reduction gearbox (or generator) as one unit and located by the
flywheel housing and connecting port of gearbox (or generator). There must have elastic coupling
between flywheel and driving shaft of gearbox (or generator). After engine is connected with
gearbox (or generator), they will be mounted on a common base and tighten on the support by
located blots.

For normal engine and gearbox (or generator), flywheel housing is SAE No: 2, flywheel is SAE
1
No:11 /2. For special requirement, flywheel housing can be SAE No: 1, flywheel be SAE No: 14.

If engine and reduction gearbox (or generator) do not located through flywheel housing, you
should adjust the coaxiality of engine and gearbox (or generator). The coaxiality for input shaft of
gearbox(or generator ) and flywheel should be less than φ0.15. The coaxiality for outlet shaft of
gearbox and propulsive shaft should be less thanφ0.10.

7, Available Options
7-1 Instrument for main propulsion engine

1) Point instrument
2) Instruments installed on engine
No Order No: Applies to Note
1 D31-000-91 1500r/min main propulsion engine
2 D31-000-92 1800r/min main propulsion engine Flywheel housing SAE 2#
1
2200~2400 r/min main propulsion Flywheel SAE 11 /2’
3 D31-000-79
engine
Flywheel housing SAE 1#
4 D31-000-93 2200r/min main propulsion engine
Flywheel SAE 14’
Main function：
1）Starting and stop of engine, display engine speed, oil pressure, oil temperature, fresh water
temperature, running accumulated time and charging indication etc.
2)Overspeed alarm and engine shunt down, low oil pressure alarm and engine shunt down and
high fresh water temperature alarm etc.
Installation: This instrument is already installed on engine when leave factory. If user requires,
could also be installed to rest properly place in engine room by user.
Order: If the instrument is installed to rest properly place in engine room user should order a 2m
length connecting wire (order number D100X-013-01).
Remote instrument
No Order No: Applies to Note
1 D100X-002-05 Above instruments Match above instrument
Main function：
1）Starting and stop of engine, display engine speed, oil pressure, oil temperature, fresh water
temperature, running accumulated time and charging indication etc.
2）Overspeed alarm and engine shunt down, low oil pressure alarm and engine shunt down and
high fresh water temperature alarm etc.
Installation: It is leaved factory following the engine and could be installed to driving room or rest
properly place by user.
Order: this is an available option. If user requires, should inform required wire length except
information of required remote instrument number at subscribe for engine.

7-2 Digital instrument

Instruments installed on engine

No Order No: Applies to Note
1 D31-000-72 2400r/min models
2 D31-000-31 2200r/min models Flywheel housing SAE 2#
1
3 D31-000-33 1800r/min models Flywheel SAE 11 /2’
4 D31-000-40 1500r/min models
Flywheel housing SAE 1#
5 D31-000-48 2200r/min models
Flywheel SAE 14’
Main function：
1）Starting and stop of engine, display engine speed, oil pressure, oil temperature, fresh water
temperature, running accumulated time and charging indication etc.
2）Overspeed alarm and engine shunt down, low oil pressure alarm and engine shunt down and
high fresh water temperature alarm etc.
3）
Installation: This instrument is already installed on engine when leave factory and it has
ready elongation wire for about 1m length, it could be installed properly place in the engine room by
user.
Order: this is an available option. If user requires, could inform the required order number and
other requirements at subscribe for engine.
Remote instrument
No Order No: Applies to Note
1 D100X-002-01 Above instruments Match above instrument
Main function：
1） Display engine speed, oil pressure, oil temperature, fresh water temperature,
running accumulated time and charging indication etc.
2）Overspeed alarm and engine shunt down, low oil pressure alarm and engine shunt down and
high fresh water temperature alarm etc.
Installation: It is leaved factory following the engine and could be installed to driving room or rest
properly place by user.
Order: this is an available option. If user requires, should inform required wire length except
information of required remote instrument number at subscribe for engine.

7-3 Pulley for front output

No Order No: Applies to Note

1 D100X-104-01 All models 3 grooves B type
2 D100X-104-02 All models 5 grooves B type
3 D100X-104-03 All models 3 grooves B,Z type

3 grooves (D100X-104-01) 5 grooves (D100X-104-02) 3grooves (D100X-104-03)

Groove type：B type Groove type：B type Groove type：B,Z type

Installation: Normal models is not installed the belt pulley and commonly installed front end
protective cover. If user needs the belt pulley, should extra purchase and install by user.

Method of assembly: First remove the front-end protective cover, screw out the special 4 pcs
bolts (M16) and remove the retaining plate. Then could install the cleanlily belt pulley according to
the following drawing and the special 4 pcs bolts should be gradually tightened in 3 times (the
torque is separately 50, 100,130 N.m).
Order: If user requires, should inform required order number and other
requirements at subscribe for engine.

7-4 Exhaust system

7-4.1 Exhaust elbow（installed after turbocharger）
No Order No: Applies to Note
1 D100X-001-01a 2200r/min upwards models Water cooling, cast
Water cooling
2 D100X-001-02 2200r/min upwards models Stainless steel
Water cooling
3 D100X-001-04 2200r/min upwards models Stainless steel
4 D100X-102-02 2200r/min upwards models Cast
5 D100X-102-03 1500、1800 r/min models Cast
6 D100X-102-04 2200r/min upwards models Stainless steel

1）Exhaust elbow (Water cooling, cast ) (D100X-001-01a)

Join size of sea inlet：φ45
Join size of sea and exhaust outlet：φ150
Sea inlet position: upward
2）Exhaust elbow (Water cooling, stainless steel ) (D100X-001-02)
Join size of sea inlet：φ45
Join size of sea and exhaust outlet：φ129
Sea inlet position: upward
3）Exhaust elbow (Water cooling, stainless steel ) (D100X-001-04)
Join size of sea inlet：φ45
Join size of sea and exhaust outlet：φ129
Sea inlet position: downward
4）Exhaust elbow (Cast ) (D100X-102-02)
Join size of inlet flange: 6-φ9 uniform distribution at φ121
Join size of outlet flange: 6-φ9 uniform distribution at φ130
5）Exhaust elbow (Cast ) (D100X-102-03)
Join size of inlet flange: 4-φ9 uniform distribution at φ105
Join size of outlet flange: 6-φ9 uniform distribution at φ130
6）Exhaust elbow (Stainless steel ) (D100X-102-04)
Join size of inlet flange: 4 kidney slot, width 9 uniform distribution at φ121
Join size of outlet flange:4 kidney slot, width 9 uniform distribution at φ121
Installation: It is installed after turbocharger by user.
Order: According to different models and whether need for water-cooling to select different
exhaust elbow. If user requires, should inform required order number and other requirements
at subscribe for engine.

7-4.2 Gasket（used between turbocharger and exhaust elbow）

No Order No: Applies to Note
1 D100X-103-01 D100X-001-01a, 02, 04,
D100X-102-04

2 D100X-103-02 D100X-102-02
3 D100X-103-03 D100X-002-03
Installation: It is installed between turbocharger and exhaust elbow by user.
Order: According to different exhaust elbow to select different gasket. If user requires,
should inform required order number and other requirements at subscribe for engine.

7-4.3 Exhaust accordion pipe

No Order No: Applies to Note
1 D100X-003-01 All models
Join size of inlet flange:
6-φ12 uniform distribution at φ130
Join size of outlet flange:
6-φ12 uniform distribution at φ130
There have been gaskets both
end of exhaust accordion
pipe
Installation: It is installed between exhaust
elbow and exhaust pipe in engine room by user.
Order：If user requires, should inform required
order number and other requirements at subscribe for engine.

7-4.4 Exhaust muffler

No Order No: Applies to Note
1 D100X-010-01 All models Water cooling
2 D100X-010-02 All models Non water cooling
Installation: It is leaved factory following the engine and could be installed to properly place
in engine room by user.
Order：If user requires, should inform required order number and other requirements at
subscribe for engine.

7-5 Intake system

Air filter
No Order No: Applies to Note
1 KLK-14-000a All models
2 KLK-14b-000 2200r/min upwards models With decrease noise function
Air filter Air filter with decrease noise function
KLK-14-000a KLK-14b-000

Installation: These filters are already installed on engine according to different models when
leave factory
Order：Normal models have no longer to need choose and purchase air filter and it is already
installed on engine according to different models If user requires especially for one sort among
these filters, should inform required order number and other requirements at subscribe for
engine. (Note: Air filter (KLK-14b-000) should need to have a mount support and its order number is
D00-143-42).

7-6 Engine support elasticity element

No Order No: Applies to Note
Engine with gearbox by not high
1 D100X-009-01
elasticity join
Engine with gearbox by high
2 D100X-009-02
elasticity join

Installation: It is leaved factory following the

engine and could be installed between engine
support and base of hull by user.
Order: this is an available option. If user
requires, should inform required order
number at subscribe for engine.
7-7 Compressed air starting system
7-7.1Schematic drawing of compressed air starting system

7-7.2 Air starter

No Order No: Applies to Note

1 D100X-005-01 Models with air starting system 6.7.
3
Other components
No Order No: Name Applies to Note
1 D100X-006-01 Pressure regulating valve
Models with air
2 D100X-007-01 Starting valve
starting system
3 D100X-008-01 Oil fog generator

Notes: Normal models are not to be installed the compressed air starting system. If user
requires, should purchase and install by user.
Installation: Air starter is installed the mounting hole at left corner of flywheel housing with 4
pcs bolts (M12×30 ) by user.User could install other components to rest properly place in the engine
room.
Order: Usually our company is not to supply parts and components of the compressed air starting
system. If user requires, our company could also substitute for user to purchase and install. But
user should purchase the air accumulator.

7-8 Shield double layer high-pressure fuel pipes

No Order No: Applies to Note
1 D26-020-09 2200r/min upwards models
2 D26-020-10 1500, 1800 r/min models

Installation: It could be installed by user. If

user requires, our company could also install
for user.
Order: If user requires, should inform
required order number at subscribe for
engine.
7-9 Fuel leak warner
No Order No: Applies to Note
1 D100X-011-01 All models

Accessory: Connecting pipe between shield double layer high-pressure fuel pipes and fuel leak
warner. Its length is 1.5m. Order number is D100X-011-02.

Connecting size:
Pedestal mounting hole: 4-φ7 Fuel inlet
Distance of 4 holes: 60×40mm
Fuel inlet size (2pcs , option with one): M10×1
Fuel outlet size: M10×1 Fuel outlet

Installation: It is installed to properly place, which is not more then 1m from the injection
pump in the engine room by user.

Order: If user requires, should inform required order number at subscribe for engine.

7-10 Drain oil pump for sump

No Order No: Applies to Note
1 D100X-012-01 All models

Installation: It is installed to properly place, which is not more then 1m from the engine in the
engine room by user.

Order: If user requires, should inform required order number at subscribe for engine.
8, Supply scope of engine and order instructions
8-1 Engine
The qualified diesel engine passed the routine test in testing bed is conformed to correlative
state standards, industry standards and company standards and is conformed to correlative
criteria of China Classification Society.
According to user needs, can offer the certificates of China Classification Society and compliant
with IMO emission requirement and other certificate.
The offered normal diesel engine should be included all parts and components required for
running, that is to say cover raw water pump, heat exchanger, intercooler, water instrument on
the engine and so on.
The following parts and components are not included at basic diesel engine:
1) Gearbox
2) Belt pulley for front output
3) Exhaust pipe system after turbocharger
4) Remote controlling instrument in the driving room
5) Elastic supports of engine
6) Parts and components of the compressed air starting system
7) Fuel double shielding high pressure injection pipe and fuel leak Alarm Unit
If requirement to aforesaid parts and components, customers could order as the guide of this
manual or design and manufacture by our company as user’ requirement.
8-2 List of carried tools
For reference, the list is varied slightly according to order instance.

No: Order No: Part name Quantity

1 D49-001-01a Kit, oil/fuel filter 1
2 D49-002-01 Kit, fuel injection pump 1
3 D49-003-30a Gauge, valve clearance 1
4 D49-004-30 Kit, valve spring 1
5 D49-006-30 Angle indicator, bolt tightening 1
6 D49-007-30 Kit, front oil seal 1
7 D49-101-01 Kit, engine turning 1
8 D49-121-30 Kit, gear housing cover position 1
9 D49-122-30 Kit, rear cover plate position 1
For electronic 1
10 Small screwdriver for adjustment
governor
 8-3 List of carried documents
For reference, the list is varied slightly according to order instance.
No: Name Qty Note
1 Operation and maintenance manual for D6114 B diesel engine 1
2 Operation and maintenance manual for D683 marine diesel engine 1
3 Parts catalogue for D683 marine diesel engine 1
4 Service manual for heat exchanger 1
5 Service manual for intercooler 1 Supply as require

6 Operating manual for diesel engine monitor (instrument) 1

7 Operation manual for fuel injection pump 1
8 Operation manual for governor 1
9 Operation manual for air starter 1 Supply as require
10 Operation manual for raw water pump with flexible impeller 1 Supply as require
11 Certificate and guarantee card for product 1
12 Packing list for engine. 1
13 Certificate of China Classification Society 1 Supply as require
14 Certificate of China Fishery Vessel Inspection Bureau 1
15 Certificate of compliance on engine international air pollution prevention (CCS) 1 Supply as require
16 Technical file for statement of compliance on engine international air pollution prevention 1 Supply as require
17 Optical disk of operation and maintenance for D114 B diesel engine 1

8-4 List of carried spare parts

For reference, the list is varied slightly according to order instance.
No: Order No: Part name Quantity Note
1 D02A-307-01 Gasket, fresh water pump 1
2 D02B-16-30 Gasket,PTO 1
3 D04-144-30 Gasket, exhaust manifold 2
4 D12-104-33a Rubber connecting hose 2
Gasket, exhaust manifold outlet
6 D17-002-40 Oil filter assembly 2
Supply for models
7 D21-001-30 Flexible impeller of raw water pump 1 with flexible impeller raw water pump
8 Element “DCA4” fresh water filter
8
9 D24A-005-30
D24A-119-30 “DCA4” additive (powder) 1
1（bottle）
10 D24A-317-01a Ventilation hose 2
11 D24A-318-01a Ventilation hose 1
12 D24A-319-01a Ventilation hose 1
13 D35-101-01 Zinc stick 2
Element, crankcase ventilation filter
14
15 D42-003-32
D61-105-01 Zinc stick 2 Supply for models

16 D61-106-01 Seal ring 2 with intercooler

17 D638-002-02 Element, fuel filter 2
18 D638-002-03 Element, fuel filter 2 Supply for models

19 Q/SC1092-65 Spring clamp hoop 2 with high power

20 Q/SC1092-70 Spring clamp hoop 2

21 GB3452.1-9×2.65 “o”type rubber seal ring 2
22 Fuse, monitoring instrument 2

8-5 List of carried accessories

For reference, the list is varied slightly according to order instance.

Order No: Part name Quantity

D24A-007-01 “DCA” inspection box 1

D21B-000-01 Raw water filter 1
LOCTITE 5699 LOCTITE5699 plane sealant 1
As user’ order Parts and components of available options Supply as order

8-6 Order instructions

1) After fully understanding the service feature, load factor, running navigating region, cruise

speed and the structure and so on of vessel, could calculate required power of vessel (refer

to chapter 8). According to calculating required power of vessel and combine with the load

factor, cruise speed of vessel could select engine and gearbox as the power type of

engine (refer to chapter 1 and 2).

2) Carefully understand the supply scope of the D683 series marine engine (refer to chapter
7)and produce your demand.
3) According to nautical requirement, could select available options (refer to chapter 6).

4) As required, select instrument variety and whether need remote instrument. If need

for remote instrument, you should present the length of wire line for the instrument.

5) If ask our company to supply gearbox, you should offer the information for the speed ratio

and installation of the gearbox.

6) Contact with marketing department (021-657455 56-2059, 2060, 2071) or import and

export division (0086-021-55955588, 55965550) of our company and describe you

requirement and engine model, parameter, available options and supply scope. If it is

necessary, first conclude the technical agreement with technical department and then

confirm and conclude supply contract.

7) If this manual could not meet the needs for you or have got special requirement,

please contact with our design department (021-65755555-2649). Our company should

design a special model for you, which could be meeting your requirement.
9, The engine five side display:
10, The engines certificates: