YANGDONG YD380D, Operation & Maintenance Manual

Page 1: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 1 YANGDONG DIESEL ENGINE INDUSTRIAL ENGINE SERIES OPERATION MAINTENANCE MANUAL YTO JIANGYAN POWER MACHINERY CO LTD YANGDONG CO LTD...

Page 2: ...the same as one described herein Please pay attention to that when reading the manual Warning Notice 1 It is strictly forbidden to use inferior and dirty diesel fuel or lube oil Please choose to use f...

Page 3: ...he Class CD diesel fuel for turbine charger 3 Make sure the connecting reliable and available between battery and start motor Battery capacity should be conform to specification of manual The total le...

Page 4: ...ling water 2 1 2 Preparation before starting 2 1 3 Starting 2 2 4 Running 2 2 5 Stopping 2 3 6 Security requirements 2 3 Section 3 Maintenance 1 Routine maintenance 3 1 2 Maintenance after 100 accumul...

Page 5: ...governing system 5 6 8 lubrication system 5 8 9 cooling system 5 9 10 electric system 5 10 Section6 Operation notice of turbo charger diesel engine 6 1 Section 7 faults and remedies for diesel engine...

Page 6: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 6 Schematic Diagram of Wiring Dimensions for installation of YD380D and YD385D...

Page 7: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 7 Schematic Diagram of Wiring Dimensions for installation of YD480D...

Page 8: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 8 Schematic Diagram of Wiring Dimensions for installation of YND485D...

Page 9: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 9 Schematic Diagram of Wiring Dimensions for installation of YSD490D and Y495D...

Page 10: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 10 Schematic Diagram of Wiring Dimensions for installation of Y4100D Y4102D and Y4105D...

Page 11: ...O P E R AT I O N M A I N T E N A N C E M A N U A L 11 Schematic Diagram of Wiring Dimensions for installation of Y4102ZLD and Y4105ZLD...

Page 12: ...1 3 2 1 3 4 2 Rated power KW 10 1500 12 1800 11 1500 13 1800 14 1500 16 1800 17 1500 20 1800 21 1500 25 1800 24 1500 28 1800 27 1500 30 1800 30 1500 33 1800 33 1500 36 1800 38 1500 45 1800 48 1500 53...

Page 13: ...ter of nozzle hole mm 0 23 Injection pressure Mpa 22 0 5 19 6 1 0 3 Lube pump Model Rotor type speed r min 1300 capacity L min 26 Pressure kpa 392 441 4 Water pump Model Centrifugal volute single suct...

Page 14: ...21 1 0 3 Lube pump Model Rotor type speed r min 1500 1500 capacity L min 37 5 53 Pressure kpa 400 392 4 Water pump Model Centrifugal volute single suction speed r min 4000 4000 capacity L min 270 230...

Page 15: ...on pressure Mpa 21 1 0 26 1 0 21 75 0 25 0 3 Lube pump Model Rotor type speed r min 1500 capacity L min 53 Pressure kpa 392 4 Water pump Model Centrifugal volute single suction speed r min 4000 capaci...

Page 16: ...0 0 45 1 Valve lash mm Y4102D Y4102ZLD Y4105D Y4105ZLD intake valve cold 0 35 0 40 exhaust valve cold 0 40 0 45 2 Sink age of valve YD380D YD385D YD480D YND485D sink age of valve 0 7 0 9 2 Sink age of...

Page 17: ...olts 140 160 140 160 140 160 4 torque limits of main bolts and nut N m YND485D YSD490D Y490D cylinder head bolts 210 230 130 150 connecting rod bolts 70 80 120 140 main bearing cap bolts 140 160 145 1...

Page 18: ...water or well water should not be used If the water contains more minerals diesel engine cooling water system will have more scale easy to cause failure Therefore If you want to use wells springs and...

Page 19: ...ndle and medium speed position 2 Rotate the ignition switch to the pre heating position to make the thermo switch preheated for 20 to 30 seconds 3 Rotate the ignition switch to open position and press...

Page 20: ...el engine stopping it should reduce the load speed gradually to make the speed at 900rpm around until the water temperature dropped to below 70 C then it can be stopped by manipulation of the handle 2...

Page 21: ...ver of heat changer immediately to prevent burn injury 8 The air outlet of diesel engine and silencer are the surface of high temperature Operator should not touch the surface under the operation stat...

Page 22: ...ery holding parts and connectors whether if connect well 7 Pretend the clear of diesel engine Use the duster that diped some gas to clear oil water and dust especially make sure the clear and dry of e...

Page 23: ...ngine and check its operation Remove errors and abnormal phenomena found 3 The maintenance after 500 hours operation Besides the items in maintenance after 100 hours operation the following jobs shall...

Page 24: ...immediately 10 After 1000 hours of working accumulatively add the following work 1 Generally inspect the parts of the diesel engine and carry out necessary repair and adjustment 2 Dismantle the genera...

Page 25: ...il sump until it reaches the upper scale of the oil gauge and turn the crank to make the whole lubrication system full of oil 4 Add some dehydrated oil to the cylinder from the oil injector installati...

Page 26: ...ir valves The adjustment method for clearance between the air valves and the distribution structure is as follows Please refer to the figure 1 Dismantle the cylinder cover check and fasten the bolt on...

Page 27: ...following 1 Remove the air inside the fuel system and repeated the rotating of crank to make the oil injection pump full of fuel Dismantle the high pressure oil pipe of the first cylinder and slowly...

Page 28: ...shall be even fog without any visible splashed oil foam partially uneven thickness or single side injection abnormal etc Clear sound shall be occur when cutting off the fuel In general abnormal oil in...

Page 29: ...cked before delivery If re adjustment is required it shall be carried out on special oil injection pump test bend fro standard oil injector and standard length high pressure oil pipe according to rele...

Page 30: ...When the air valve and seal surface of the valve seat are burned air leakage grinding is required After grinding is completed check air leakage of the valve and inspect the sealing conditions The val...

Page 31: ...lkhead of each channel shall be sealed and oil leakage is not allowed The main bearing is of fully supported suspending type Matching brazing is employed for main bearing casing and the cylinder body...

Page 32: ...e which can reduce abrasion between cylinder sleeve and piston ring The second gaseous ring is a taper face ring the surface marked TOP faces the top face Reversing assembly is not allowed Caulking ri...

Page 33: ...embly Positioning lip is used for positioning for the connecting rod and connecting rod casing Bolts for connecting rod are made of 40Cr steel The upper and lower shaft bushings for the connecting rod...

Page 34: ...flange is provided for the second shift can bearing casing it can control axial direction drunkenness of the can shaft Bearings for each shift of the can shaft receive lubricant from the main oil chan...

Page 35: ...tions shall be aligned Special purpose tools are employed for assembling and disassembling for timing gear of the crankshaft maybe installed by utilizing the two M8 screws on the wheel spoke of the ge...

Page 36: ...eccentric gear on cam shaft of the fuel injection pump The fuel injection pump has been calibrated by the manufactured Do not dismantle it without permission If dismantling for repair and adjustment...

Page 37: ...will be inbreathed to the oil pump pass the vitta after adding the pressure get to the lubrication filter then put in the engine divide into three ways one of them pass the headstock reach the connect...

Page 38: ...he radiator through the heat retainer and flows into the lower tank through a flat copper pipe During the process the cooling liquid is cooled by the drafting or exhausted by the fan Up to now a big c...

Page 39: ...stem includes storage battery stating motor charging generator electric heating plug starting button instrument and etc diesel without storage battery starting button instrument and etc Storage batter...

Page 40: ...flying wheel After the diesel is connected turn off the starting motor immediately The iron core drives the gear to its original position under the control of spring Continuation for use of the starti...

Page 41: ...se turbocharger is a precise part The faster speed of the rotor the higher temperature of the turbine usual above 640 and the pressure of the lubricant set up rotor shaft called floating bearing to wo...

Page 42: ...e inlet pipe shall be no less then 54mm Keep its inner wall smooth and clean Air leakage is not allowed at any connection of the pipe system The flexible duct for connection adopts rubber pipe with st...

Page 43: ...or you then seal 7 After the diesel is started running at idling speed of 2 3 minutes is required before loading more capacity to ensure lubricate Immediate loading may lead to insufficient lubricatio...

Page 44: ...ot allowed 11 Pay attentions to start diesel under low temperature when the ambient temperature is too low or the vehicle stop for long time strong sticky will affect the diesel have oil pressure and...

Page 45: ...uel atomization is bad readjust the spray fuel pressure according to specification 5 compression pressure low clean or replace the injector needle valves sets 6 clearance between the air vales is wron...

Page 46: ...on pumps fuel injector sets worn off or fuel injection pressure incorrect Replace them with new patrts adjust fuel injection pressure and check fuel spray 7 speed incorrect adjust the speed control ha...

Page 47: ...No Pressure 1 oil lever in oil sump too low Add oil up to mark line on dip sticks 2 serious leakage from oil pipelines Eliminate leakage 3 extract oil filter oil filter and pipe blocked Clean or repl...

Page 48: ...ter scale in cooling systems too thick 3 remove it 2 oil temperature too high 1 insufficient or excessive oil 1 check whether the oil level is between the dip stick scale lines 2 oil pressure too low...

Page 49: ...nce according to our manual to prolong wearing part s life otherwise the life will be shortened seriously No Name No Name 1 Cylinder sleeve 10 Waterproof ring 2 Piston ring 11 Bead apex 3 Piston 12 Be...

Page 50: ...T E N A N C E M A N U A L 50 Production permit No XK06 205 00141 XK06 00141 Product standard Q 321284 JCA03 2002 Q 321284 JCA06 2002 Address Website No 199LuotangEastRoad Jiangyan City Jiangsu Provinc...