YANGDONG Y90 Series, Operation & Maintenance Manual

Page 1: ... SERIES Y90 DIESEL ENGINE OPERATION MAINTENANCE MANUAL VANGOONG co LTO THE PEOPLE S REPUBLIC OF CHINA ...

Page 2: ...ce In order to provide the detailed description and instruction of this eneine for operators to manipulate it correctly in short time we offer this manual which briefly describes the performance of series Y90 diesel eneines to operators19maintenance workers and relevant maneers Since the construction of this eneine is sub iect to frequent improvement and development durin production and practice19...

Page 3: ...ater soften it first 4 lt is strictly forbidden to start under the circumstances of lack of lube oil or water 5 It is strictly forbidden to operate at overload or under other conditions aeaiost the rules 6 lt is strictly forbidden to reaulate the fuel in iection pump at will 7 It is strictly forbidden to chao2e the diameter of the pulley S To control the startine time less than 15 seconds and the ...

Page 4: ...ing 2 2 III Starting 2 2 IV Operating 2 3 V Stopping 2 3 SECTION 3 MAINTENANCE 1 Routine maintenance 3 1 II Maintenance after every 100 accumulated operating hours 3 J III Maintenance after every 500 accum lated operating hours 3 2 IV Preservation and storage of engine u 3 3 SECTION 4 ENGINE ADJUSTMENT I Adj ustment of valve lash 4 1 II Adjustlnent of injection timing 4 1 III Adjustment of injecto...

Page 5: ...IX Cooling system 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 jnsufficiency 6 1 III Stnoking exhaust 6 2 IV Knocking noise in engine 6 2 V Lube oil insufficiency or no pressure 6 2 VI Overheatin of engine 6 3 VII Engine running a vay 6 3 ...

Page 6: ...530 214 7 i 201 fl4 I 134 17Y r n9 Vie B 116H1r O l 135 j 4 5 I b lxhdUSf viJaet Ceftl me Connecting dimp 1sions of flywhe l and its hDirdng J Jf CD f t I 0 r OIIJ J I Configuration and Installation Dimensions of Model YSD490Q YS490 Diesel Engine ...

Page 7: ...ge glkw h 250 1 230 Me N m 160 ISO 35 25 1600 180Q 2000 2200 2400 2600 2800 3000 3200 n Performance Curves of Model YSD490Q Diesel Engine n ...

Page 8: ..._ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ Max Torque N m 149 3 _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ __ _ _ _ _ _ _ Min Specific fuel consumption at full load glkW h 1 Oil fuel consumption ratioC Advance It ection Angle Speed Before TOC OC rpm Specific lube oil ccnsumption g kw h Direction ofcrankshaft rotation facing to flywheel I O 8 15 1 2800 With Advance Device i 2 72 Counterclo...

Page 9: ...1 I i i i Pressure kpa 400 t r I i Type i Centrifugal volute single suction 1 _ _ _ __ __ Speed r min I 4000 4 i Water pump i 2 4 t j t I Type Series DC motor I 1 I l Model i QD1315A D138Y 5 i Startmg motor 1 Vol ge V I 12 I r I I Power kw I 2 5 t _ _ Typ l sil i n re tifY g huntdymam f i Model I JFIIA Dymamo r t _ Power W i 350 f _ j I Voltage V 1 14 1 f r 7 Fuel filter I J I f gle sta eleme _ 1 ...

Page 10: ...ead bolts 125 145 Main bearing cap bolts 140 160 Connecting rod bolts 100 120 Flywheel bolts 100 120 4 Temperature and pressure limits l Exhaust temperature OC n 3200rpm t 620 3200rpm n 2600rpm t 600 n 2600rpm t 550 2 Lube oil temperature OC 100 3 Lube oil pressure in Main Passage Mpa At normal operation 0 2 0 45 l t luin Steady Speed 0 05 5 Govemor Characteristics Min idling steady Speed Steady r...

Page 11: ... 0 15 6 Side clearance bet veen the oil scraper r ng and its groove 0 030 0 062 0 15 7 Gap of the 1st ring 0 300 0 450 _ _ _ _ _ _ _ _ _ __ t 8 Gap of the 2nd ring and oii scraper ring 9 Crankshaft main journal and main bearing 0 300 0 450 0 070 0 149 0 25 _ c __ rCalTIstlan journal and bushing 1 Idle gear shaft journal nd bushing 0 025 0 114 0 025 0 075 0 18 0 18 _ __ _ _ _ __ _ __ 1 12 Intake va...

Page 12: ...er use grade CD30 lube oil When bein filled into the engine oil tank the oil should be filtered by screen 3 Cooling water It is recommended to use soft water such as rain water city tap water or clean river water for en ine cooling Well water or tap water f om well water could not be used Cooling water containing too much minerals will form water scali in an engine cooling system affecting the eng...

Page 13: ...er and whether there is any leakage at all ioints 6 Check the accessories to see whether they are firmly and reliably connected Check the electrical system to see whether the battery is fully charged all wirings are correct and all connections are tightened 7 Check the clutch to see whether it has disengaged m Startin2 1 Set the speed control lever at the middle speed position 2 Tum the ignition s...

Page 14: ...as color and the operatingnoise lfthere is any fault stop the engine and inspect it v Stoppine 1 Before stopping take off the load and reduce the engine speed gradualJy Let it run at idling speed for a fe minutes Do not stop engine until the outlet water temperature fans to below 70 C 2 Afier stopping the engine the ignition s vitch should be turned to the middle position 3 1n winter when ambient ...

Page 15: ...on bolts and the conn ction between the engine and the dirven Inachinery 7 Keep the engine clean Oil water and dust gathered on the engine surface should be wiped away vith a dry rag or cloth dipped in gasoline Especially keep the electric equiplnent clean and dry and clean out the dust on the fins ofthe radiator S For the new engine after SOh t ial running renew the lube oil in the oil sump fuel ...

Page 16: ... of Inaintenance after every 100 acculnulated operating hours the following items are needed I Check the injection pressure and spray pattern of the injector lf necessary dislnantle the injector lclean the nozzle set and readjust the injection pressure 2 Check fuel delivery of the injection pump and recalibrate it on a test bench if possible Check the injection tilning and readjust it if necessary...

Page 17: ...heck and measure wear of the pistons and piston rings 4 heck and rneasure wear of the cylinder liner 5 Check and measure vear of the crankshaft main journals and crank pins Clean lube oil passages of the crankshaft 6 Check vear of the Inain bearing and connecting rod bearing shells 7 Clean oil passages of the cylinder block and replace lube oil IV Preservation and Stora2e of En2ine If the engine i...

Page 18: ... Block the outlets of intake and exhaust manifolds silencer with wooden plugs or wrap up properly with plastic film in order to prevent any dust from getting in 6 The engine should be stored in a clean room with good ventilation and low humidity The engine should be covered Chemicals near it are strictly prohibited The preservation according to the above procedure may be valid for 3 months Over th...

Page 19: ...r heck and tighten the nuts fastening the rocker aml shaft tash in cold l11ust be tht value specified in section 1l len after turnin the crankshaft by 180 to adjust the valve lash of other cylinders according to the engine firing order 3 4 2 for the four cylinder engine and 3 2 tor three cylinder engine II Adjustment of In it tion Tiolinf 1 1 obtain the tnosl econon1ical specific 111ei conSllInpti...

Page 20: ...ines when the injection pump rotates clockwisc the fuel injection will retard lhile the pump rotates anticlockwise Jhc fuel injection will advance 4 Additionally if the engine has injection angle advance device the advanced injection angle can be triangular flange of injection pump and turn the injection pu np shafLFacing the front end of engines t vhen the injection pump rotates clock vise the fu...

Page 21: ...el spray shoulJ be even and well atomized in a shape of cone At any cross section of the conc the atomizt d thel should be finely and evenly distributed Fuel droplets and irregular pattern vhich 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 ilTcgular pattern of the spray is caused by needle valve seizure ...

Page 22: ...rated at the factory If it is necessary to readjust the readjustment must be perf nned in a injection pump test bench with a standard injector and injection pipes of standard length according to the instructions in Operation Manual of the Injection PUlnp VI Adiustlnent of Decompression Arm Lash Turn the crankshaft to make that the piston of 1st cylinder is at the conlpression T D C position Turn t...

Page 23: ...l pitting and vear appeared on the sealing face of valve and valve seat When grinding lapply a grinding paste tlne valve sand on the conic ealing surface of valve l hen the valve and valve seat are lapped in pair unitJ a even continuous and lustreless sealing band appears 1t is strictly forbidden that the grinding paste enters the valve guide After lapping clean the valve valve seat and valve guid...

Page 24: ... are holes leading vater to the cyiinder h ad N0ar the fear end of the block there are channels delivering Fig 6 Prot rueliog beig bt of the Uner Dange plane relative to the plane of cyUnder block T he vater pump is lnounted on the upper front face of ube oil upvvBrd to the cylinder head cylinder block and the gear system is on the lower part fhe tly vhecJ housing is installed at the rear face of ...

Page 25: ...n the saIne plane Then tighten the bolts until they reach the specified tightening torque When cOlllpleting the c rankshaft assemblY turn it at the flywheel cnd by hand to check vhether it can be rnoved freely l he Iiner is slipped into the cylinder bore vertically so that deformation of the liner Inay be avoided rrhe liner flange plane should protrude out the top plane of cylinder block by 0 07 0...

Page 26: ...shown in Fig8 When disnlantling and asselnbling the piston ring a special tool may be used fhe ring end gap of piston rings should be set off with each other by 120 C to prevent being in line with the piston pin seat hole Fig 8 Measurement of side surface gap of piston ring If the piston ring is seized and could not move when checking soak it in diesel fuel kerosine or gasoline for 24h or more l h...

Page 27: ... the cylinder liner carefully and tighten in tum the connecting rod bolts according to the specified tightening torque limit in several separate times After finishing the assembly turn the crankshaft be sure that it rotates smoothly IV Crankshaft and Flywheel The crankshaft timing gear and pulley are fitted on the front output end of crankshaft Positioned by the locating pin the flywheel is fitted...

Page 28: ...ft out from the front end The axis of the tappet deviates from the center line of canl 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 System l he gear transmission system consists of the crankshaft timing gear tilning idler lCanlshaft timing gear injection pump timing gear and hydraulic pUln...

Page 29: ...n of the diesel engine It is composed of the fuel delivery pump uel filter injection pump governor fuel injection and fuel rrhe diesel fuel IS through the fuel filter delivered through the inlection pipe under high pressure produced in the pUlnp and is then atonlized 5 4 2 1_ _ 3 pump injection return pipes etc as shown in Fig IO The fuel is pumped by the fuel delivery pump from the fuel tank into...

Page 30: ...lean VID Lubricatine System The lubricating system is composed of the strainer lube oil pump oil filter and pipelines as shown in Fig II rrhe engine adopts pressure and splash lubrication The pressure lubrication is applied to the I1lain bearing connecting rod bearing camshaft bushing The cylinder sleeve piston piston pin connecting rod bushing cam and its tappet as well as valve and its guide are...

Page 31: ...__ r 10 11 14 Fig 11 Lubricating system 1 Oil sump 2 Strainer 3 Lube oil pump 4 Piston and connecting rod assembly and cylinder liner S Lube oil rllter 6 Gear train 7 on pressure gauge 8 Rocker arm 9 Valve push rod valve tappet and block hole for tappet 10 Rocker arm shaft 11 Valve and valve guide 12 Camshaft and bushing 13 Oil lines in the block 14 Crankshaft and bearing 5 9 ...

Page 32: ...diator during lhich the cooling vater is cooled by the fan and cOJTIpletes the regular circulation fhe cooling fan can be of either suction or blast type according to its application rrhe centrifugal water punlp is driven by the fan belt on the crankshaft pulley ln case of severe water dropping out fronl the vcep hole at the lo ver part rf the pump housing due to the damage of vater seal during op...

Page 33: ...on rectifying dynamo for the operation and tnaintenancc of the dynanlo After turning on the starting switch the flywheel gear rin is engaged vith the nlotor pinion by the solcnoid lnleanwhile the fly rheel is driven by closing the current circuit of starting motor As soon as the en ine is started thc starting s vitch 111lJst be turned off inllnediately fhen the core along with the pinion returns t...

Page 34: ...es Cylnder head nuts should be tightened in case of leakage on cylinder head gaskets 6 Adjust it according to specifications and align gear marks 7 Charge it 8 Check and tighten wire connections Clean up contact points 9 i1 reheat cooling water and lube oil Remedies 1 Compression pressure inside cylinddcrs too low 2 Advanced fuel injection angle incorrect 3 Valve lash incorrect 4 Fucl supply for e...

Page 35: ... of certain components exceeds limits Remedies I Readjust it according to specification 2 Exhaust air 3 Readjust fuel supply 4 lJse qualified supply 5 Replace theln V Lube Oil Insufficient or No Pressure see Table 8 Table 8 Causes 1 0illevel in oil sumps too low 2 Serious leakage from oil pipelines 3 0il strainers oil filters and pipelines clogged 4 0il gauges damaged or gauge lines clogged 5 0il ...

Page 36: ... Malfunction ofgovernors 2 Control rod fuel injection pump gets stuck 3 hljection pump delicery too much 4 Excessive oil burnt Remedies 1 Fill the rank to make cooling water level higher rhan the center line ofwater pump 2 Check water pump clearance and tightness of belts Eliminate leakage 3 Remove it 1 Cheak whether the oil level is between the dip stick scale lines 2 Refer to paragraph V 3 Relie...

Page 37: ...MANUFACTURING LICENSE XK06 205 00141 PRODUCT STANDARD 0 321284 JCA06 2002 LICENSE APPROVAL DATE JULY 2 2003 ...