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Engine Specification
Available options
Elastic support of engine (vibration insulator) Shield double layer high-pressure fuel pipe
Basic parameter
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)
Installation parameter
Lubrication system
Lube oil specification: D683 special lube oil or CF-4 grade lube oil
Electrical system
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.
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
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.
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
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
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.
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.
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
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.
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.
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.
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.
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).
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.
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.
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.
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
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
6) Contact with marketing department (021-657455 56-2059, 2060, 2071) or import and
requirement and engine model, parameter, available options and supply scope. If it is
necessary, first conclude the technical agreement with technical department and then
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: