YANGDONG SERIES Y80, Operation & Maintenance Manual

Page 1: ... SERIES Y80 DIESEL ENGINE OPERATION MAINTENANCE MANUAL YANGDONG co LTD THE PEOPLE S REPUBLIC OF CHINA ...

Page 2: ...e In order to provide the detailed description and instruction of tbis eneine for operators to manipulate it correctly in sbort time we offer this manual which briefly describ the performance of series Y80 diesel eneines to operators maintenance workers and relevant maneers Since the construction of this eneine is sub iect to frequent improvement and development durine production and practice it i...

Page 3: ...r So il it first 4_1t s tric yr rbidden 16slarfunder the ircu stanc oflatk oil be oilorWiltet 5 lt isJ ii il f rbidd n t oper te at overload r underothel9 co ditions 8eainst the rules 6 It is strictly forbidden to re2ulate the fuel io iection pump at will 7 lt is strictly forbidden to chanee the diameter of the pulley 8o To control tbe startio2 time less than J5 seconds and the startio2 interval m...

Page 4: ...8 1 0 2 2 III Starting 10 c 2 2 N Operating H 2 3 V Stopping 10 iD 2 3 SECTION 3 MAINTENANCE I ROlltille maintenaJ1Ce It or to to 3 1 II Maintenance after every 100 accurriulated operating hours 3 1 III Maintenance after every 500 accurnulated operating hours 3 2 N Preservation and storage of engine e fl 11 3 3 SECTION 4 ENGINE AnJUSTl tIENT J Adj ustment of valve lash it e 4 1 II diustment of inj...

Page 5: ...8 IX Cooli g system 0 5 10 X Electric system 5 11 SECTION 6 FAULTS AND REMEDIES FOR DIESEL ENGINE I Hard or refuse to start 6 1 II Power insufficiency 6 1 III Smokin exhaust 6 2 IV Knockin g noise in en ine 6 2 V Lube oil insufficiency or no pressure 6 2 VI Overheating of engine 6 3 W En ine running away 6 3 ...

Page 6: ... 6 MIO 494 InstoIlatbndinensixlsofenghe basefoot Dinensions ofwater inlet outlet pl co C N C i j 5 2 51 co 0 C C RIO 4NO 74 Dinensionsofechaust outlet 4 Gl17 424 5 Crankshaftcentertile Connecting dinensionsof and Itshousi1g r I Configuration and Installation Dimensions of Model Y480 Diesl Engine ...

Page 7: ...25 1 1 _I 2lIiM3 I il i II o i II I Craakahaft cenCeru e 8 lattaI dimeMio1 4Jol foot 37 478 46i 5 6 MI xhauatouUet 1 200 1 ConnediAI ofO itabouli Supply ban 6820S 362HB Il OI didl to aaIIOmer requeflL The dilllanCe 18 between bt outer Ml of_ m UUIIoilhe Oywheel it 290 1 1 n Configuration and Installation Dimensions of Model Y380 Diesl Engine ...

Page 8: ... 104 96 88 He kw 20 16 Me _l V r V V r Ne V V r ge y l r _l ge glkw h 255 245 235 I I I I I 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2880 m Pertonnance Curves of Model YD480 Diesel Enging m ...

Page 9: ...i 1 709 1 809 1 _ _ _ _ 1 _ _ _ t _ Firingorder I 1 3 2 1 3 4 2 1 3 2 i 1 3 4 2 t _____t_ r t _ __ Rated po et kW t__ 30 __L _ _29 J l 0 _ _ L _ _ 1 __0_ _ __2 __8_ _5 _ 10 29 Ratedspee r min I 2200 3000 I 2200 3200 I 2200 2800 2200 3200 J _ __ 1 Max torque N rn i 43 4 _ _ r Min s c lco rn i 274 7 I 278 8 i 272 i 247 272 270 269 3 _______ _ _ _ l _ __ _ 10 1 lUfU k 18 ln800 before TDC JI rpm 16 11...

Page 10: ...or BQ pump I J j c _t t if g 1 _ _ _ __ _Ty _ __ Model _ _ _ _ _ _ _ II _ Model Designation pump Dynamo Fuel filter Lube pump Water pump Fuel injector Lube oil filter Air filter Fuel injection Electrothennic plug Starting motor Governor _ _ _ _ l1 g iamel l _ iye Y _ _ Model __ _ _ _ _ __ _ _ _0 __ w __ _ Nozzle set _ _ _ _ _ _ DiaQleter of nozzle hole mm r _ _ _ r _ _ _ _ _ _ __ __ t p r __ ___ _...

Page 11: ...80 lT 480 S380 175 i95 YD480 YS4A D380 Main bearin cap bolts Connecting rod bolts Flywheel bolts 4 Temperatureand pressU Te limits 1 Exhaust temperature C n 3200rpJn 3200rpm n 2600rpm n 2600rpm 2 Lube oil teolperature OC 110 130 50 60 60 70 t 620 t 600 t 550 100 3 Lube on pressure in fIain Passage Mpa At norrnal operat on At nlin Steady Speed 5 Govemor Characteri stics Mift idling ste dY Speed Ste...

Page 12: ...the 2nd ring and on scraper ring 0 250 0 400 1 60 2 20 9 rankshaft mainjoamai and main bearing 0 070 0 139 O 25 0 18 O 050 0 1 O I 0 025 0 075 i i I __ __ _ J_ i O T _ i i i 0 040 0 077 i 0 15 _ _ _ j _ _ _ _ 1 _ _ 0 016 0 061 0 20 I _____ __ __ _ _ _ _ __ __ __ __ _ __ L e i OJ 75 0 265 1 I _ __ _ _ _ _ _ _ _ _ _ _ _ 1 _ _ _ _ 1 14 Rocker arm shaft and bushing 13 11xhaustvaive stem and valve guid...

Page 13: ...winter use de CD30 lube oil When bein filled into the en ine oil tank the oil should be filter d by screen 3 Coolin water It is recommended to use soft water such as rain water city tap water or ciean river water for en ine coolin We water or tap water from well water could not be used Coolin water containin too Inuch minerals will form water scali in an en ine cooling system affecting the engine ...

Page 14: ...er and whether there is any leakage at all ioints 6 Che ck the accessories to see whetber they arefinnly and reliably connected Check the electrical system to see whether the battery is fully char ed alJ wirings are correct and all connections are ti tened 7 Check the clutch to see vvhether it has disengaged ill StartiR2 I Set the speed control lever at the middle speed position 2 Turn the ignitio...

Page 15: ...gas color and the operatin noise Ifthere is anyJault stop the engin and inspectit v Stoppine I Before stopping take off the load and reduce the engine speed gradually Let it run at idlin speed for a few minutes Do not stop engine until the outlet water tetnperature falls to belo v 70 C 2 After stopping the engine the ignition switch should be turned to the middle position 3 In winter when ambient ...

Page 16: ... foundation bolts and the connection between the engine and the dirven machinery 7 Keep the engine clean Oil vater and dust gathered on the engine surface should be wiped away with a dry rag or cloth dipped in gasolinc Especial1y keep the electric equipment clean and dry and clean out the dust on the fins ofthe radiator 8 For the new engine after SOh tr ial running renew the lube oil in the oil su...

Page 17: ...work of Inaintenance atter every 100 accumulated operating hours the following items are needed 1 Check the injection pressure and spray pattern of the injector If necessary dismantle the injector c lean the nozzle set and readjust the injection pressure 2 Check fuel delivery of the injection pump and recalibrate it ona test bench if possible Check the injection timing and readjust it ifnecessary ...

Page 18: ...3 Check and measure wear ofthe pistons and piston rings 4 Check and measure wearofthe cylinder lUler 5 Checkand measure wear ofthe crankshaft main joumalsandcrank pins lean htbe oil passa es ofthe crankshaft 6 Check wear ofthe main bearin and connecting rod bearing shells 7 C lean oil passages ofthe cyJinderblockand replace lube oil W Preservatioo and Steraaeof Enaine If the engine is to be put ou...

Page 19: ...5 Block theoutletsof intake and exhaust manifolds silencer with wooden plugs Of Vrap up properly with plastic film in order to prevent any dust froln getting in 6 rhe engine shouldbe stored in a clean room with goodventiJationandJow humidity The erit iine sh ulElbe covered Chemicals near it are strictly prohibited The preservation according to the above procedure may be vaJid tor 3 nlonths Over th...

Page 20: ...ust the valve lashes fntake valve lash and exhaust valve lash in cold nlust be the value specified in section I Then after turning the crankshaft by 18 J to adjust the valve lash of other cytinders a cording to the engine firing order 1 3 4 2 for the tour cylinder engine arid l 3 2 for three cylinder engine II Adjustment of lo iection Timing ro ohtain the most econolnical specific filet consumptio...

Page 21: ...e fuel i icctif n win t etard hile the pump rotates anticlockwise the fuel injection wi ll advance 4 Additionally if the engine has injection an gle advan edevice the advanced injection angle can be adjusted by loosening the three nuts on the triangular flan e of injection pump and turn the injection pump shaft Facing the front end ef engines when the injection pump rotates clockwise the fuel inje...

Page 22: ...spray The fuel spray should be even and well atomized in a shape of cone At any cros section of the cone the atomized fuel should be finely and evenly distributed Fuel droplets and irregular pattern wh ch can be seen by naked eyes should not be present in the spray There should be a distinct clear sharp sound at the end of iniection Generally irregular pattern of the spray is caused by needle valv...

Page 23: ...to readiust the readjustment must be perfonned in a injection pump test bench with astandard injector and injection pipes of standard len haccording to the instructions in Operation M anual of the Injection Pump I Fig 3 Adjustment of lube oil pressore VI Adiustment of Decompression Arm Lash Turn the crankshaft to make that the piston of 1st cylinder is at the conlpressionT D C position I unl the d...

Page 24: ...nical pitting and wear appeared on the sealing fa ce of valve and valve seat When grinding apply a grinding paste fine valve sand on the conic sealing surface of valve Then the valve and valve seat are lapped in pair unit a even continuous and lustreless sealing band appears Itis strictly forbidden that the grinding paste enters the valve guide After lapping clean the valve valve seat and valve gu...

Page 25: ...re holes leading water to the cylinder head Near the rear end of the block there are channels delivering lube oil upward to the cylinder head The water pump is mounted on the upper front face of cylinder block and the gear FIg 6 Protruding height of the liner ftange plane relative to the plane of cylinder block system is on the lower part The flywheel housing is installed at the rear face of the b...

Page 26: ...plates in th sanle plane fhen tighten the bolts until t hey reach the sp ecified tightening torque When completing the crankshaft assembly turn it at the flywheel end by hand to check whether it can be rnoved freely T he liner is slipped into the cylinder bore vertically so that deformation of the liner may be avoided I he liner flange plane should protrude out the top plane of cylinder block by 0...

Page 27: ...07 O 102mm and o 05 0 082mm for the second ring as shown in FiRS When dismantling and asselnbling the piston ring a special tool may be lIsed The ring end gap of piston rings should be set off with each other by J20 ljC to prevent being in line with the piston pin seat hole If the piston rin1 is seized and could not nlove when checking soak it in diesel fuel kerosine or gasoline for 24h or more Th...

Page 28: ... the cylinder line r carefullY and tighten in turn the connecting rod bolts according to the specified tightening torque Unlit in several separate times A fter finishing the assembly turn the c rankshaft be Sllre that it rotates smoothly IV Crankshaftand Flywheel rhe crankshaft timing gear and pulley are fitted on the front output end of crankshaft Positioned by the locating pin the flywheel is fi...

Page 29: ...he camshaft out from the front end fhe axis of the tappet deviates from the center line of cam width During operating the tappet rotates so as to provide an even wearing on the bottom surface and the cylindrical surface oftappet VI Gear Transmission Svstem The gear transmission system consists of the crankshaft timing gear timing idler camshaft timing gear injection pump timing gear and hydraulic ...

Page 30: ...g section of the diesel engine It is composed of the fuel delivery pump uel filter injection pump governor fuel injection and fuel combustion chamber return pipes etc as shown in Fig 10 The fuel is pu nped by the fuel delivery pump from the fuel tank into the injection pump through the fuel tilter The diesel fuel is delivered through the injection pipe under high pressure produced in the plunp and...

Page 31: ...them clean I LubricatioeSvstem l hc lubricating system is composed of the strainerj ube oilpurnp oil filter and pipelines as sho n in Fig II l he engine adopts pressure and splash Jubrication l hepressure lubrication is applied to the main bearjn connectin rodbearing carnshaft bushing The cylinder sleeve piston piston pin connccting rod bushing camand its tappet as l vell as valve and its guide ar...

Page 32: ...h IIJIii IIi IO 11 14 Fig 11 Lubricating s stem 1 OU IUIIlp 1 Stralaer 3 Lube 00 pump 4 Piston and cOnDectiDg rod assembly and cyUnder Uoer 5 Lube oil ftlte 6 Gear traiD 7 Oil pressure puge 8 Rocker arm 9 Valve push rod valve tappet and block hole lur tappet 10 Rocker ann shaft 11 Valve and valve guide 12 Camshaft and bushing 13 Oil lines in the block 14 CraDbIaaft and bearing 5 9 ...

Page 33: ...adiator during hich the cooling vater is l ooJed by the fan andcOTnpletes the regular cir tllation l ht c oltng t ln can be 1 either suction or hlast type according to its application T he entrifugal vater pUInp i driven by lhe fan belt on the crankshaft pulleyJn ase of severe vater dropping out forn the veep hole at the lo ver part of the purnp housing due to the danlace of vatcr seal durirl opcr...

Page 34: ...n rectifying dynamo for the operation and maintenance ofthe dynatno t fter turning on the starting switch the Hy vheeJ gear ring IS engaged vith the 111otor pinion by the solenoid lneanwhile the flywheel is driven oy closing the current ircuit of starting Inotor As soon as the engine is started thc starting s ltch 111ust he turned off ilTIlncdiatel rhen the core along with the pinion returns to th...

Page 35: ...lign gear marks 7 Battery charge insuffcient 8 Vire connections loosened 9 Ambient temperature too lo v and oil too viscous II Power Instlfficient see Table 5 Table 5 Causes 7 Charge it 8 Checkand tighten wire connections Clean up contact points 9 Preheat cooling water and lube oil Remedies l ompression pressure inside cylinddcrs too low 2 Advanced fuel injection angle incorrect 3 ah rc lash incor...

Page 36: ...of certain cOlnponent exceeds lilnits Remedies 1 ReacUust it according to specitlcation 2 Exhaust air 3 Readjust fuel supply j 4 lJse qualified supply I 5J eplace thelTl V Lube Oilln ufficientor No Pressure see l able 8 Table 8 Causes 1 0illevel in oil sumps too low 2 Serious leakage from oil pipelines 3 0il strainers oil filters and pipe lines clogged 4 011 gauges damaged or gauge lines clogged 5...

Page 37: ...MANUFACTURING UCENSE XK06 205 00141 PRODUCT STANDARD Q 321284 JCA03 35 2002 NO OF EXPORT UCENSE FOR QUALITY 2000112013 UCENSE APPROVAL DATE OCT 10 2000 ...