Rotek YSD490Q Operation & Maintenance Manual Download | Manualshive

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Summary of Contents for YSD490Q

Page 1: ...SERIES Y90 DIESEL ENGINE OPERATION MAINTENANCE MANUAL...

Page 2: ...nce In order to provide the detailed description and instruction of this en2ine for operators to manipulate it correctlv in short time we offer this manual which brieflv describes the performance of s...

Page 3: ...ter soften it first 4 ft is strictly forbidden to start under the circumstances of lack of lube oil or water 5 ft is strictly forbidden to operate at overload or under other conditions a2ainst the rul...

Page 4: ...ing 2 2 111 Starting 2 2 IV Operating 2 3 V Stopping 2 3 SECTION 3 MAINTENANCE I Routine maintenance 3 1 JI Maintenance after every 100 accumulated operating hours 3 1 III Maintenance after every 500...

Page 5: ...X Cooling system 5 10 X Electric system 5 11 SECTION 6 FAULTS AND REMEDlES FOR DIESEL ENGINE I Hard or refuse to start 6 1 II Power insufficiency 6 1 III Srnoking exhaust 6 2 N Knocking noise in engin...

Page 6: ...fnsions of flywheel and Its hOlEing 16 16 i I b J 11 7 591 5 J I 100 172 iIIo I t I 1 _ _ t _ _ 1 J 1 8 J t I 7 V C I f I I rrt I jI i _ I I f L I 1II r 42 _ 1 m l Fr4 XIII I aw I 11 lL I J lI l I C 9...

Page 7: ...ge g kw h 250 1 230 v Me p V ge Me N m 160 ISO 35 25 1600 1800 2000 2200 2400 2600 2800 3000 3200 n Performance Curves of Model YSD490Q Diesel Engine II...

Page 8: ..._ L _ _ 18 1 2600 Max Torque N m 149 3 _ _ _ _ _ 1 Min Specific fuel consumption at fullioad g kW h I 2 S 3 _ _ _ _ _ _ _ _ _ _ _ Oil fuel consumption ratio I 0 8 r Ti _ Advance Injection Angle Speed...

Page 9: ...1 1 i Type I Rotor type I 1 I i Speed r min 1 1500 3 I Lube pump I Capacity Umin 26 9 i I i Pressure kpa 400 i Type i Centrifugal volute single suction Speed r min i 4000 Water pump t __L i Capacity...

Page 10: ...145 Main bearing cap bolts 140 160 Connecting rod bolts 100 120 Flywheel bolts 100 120 4 Temperature and pressure limits l Exhaust temperatureCC n 3200rpm t 620 3200rpm n 2600rpm t 600 n 2600rpm t 550...

Page 11: ...tween the 2nd ring its groove Gap of the 1st ring 8 Gap of the 2nd ring and oii scraper ring 9 Crankshaft main journal and main hearing 10 Camshaft journal and bushing 11 Idle gear shatljournal and bu...

Page 12: ...inter use 11 rade CD30 lube oil When bein11 filled into the en11 ine oil tank the oil should be filtered by screen 3 Coolin11 water It is recommended to use soft water such as rain water city tap wate...

Page 13: ...er and whether there is any leakage at all ioints 6 Check the accessories to see whether they are tirmly and reliably connected Check the electrical system to see whether the battery is fully charged...

Page 14: ...as color and thc operating noise lfthcre is anv fault stop the engine and inspect it v Stoppin2 I Before stopping take off the load and reduce the engine speed gradllaIly Lct it run at idling speed fo...

Page 15: ...ation bolts and the eonneetion between the englne and the dirven maehinery 7 Kecp the engine c1ean Oil water and dust gathered on the engine surfaee should be wiped away with a dry rag 01 cloth dipped...

Page 16: ...of maintenance after evel 100 accumulated operating hours the following items are needed I Check the iniection pressure and spray pattern of the iniector lf necessary dismantle the iniector clean the...

Page 17: ...Cheek and measure wear ofthe pistons and piston rings 14 Check and measure wear of the cylinder liner 5 Cheek and measure wear of the erankshaft main journals and crank pins Clean lube oil passages of...

Page 18: ...lock 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...

Page 19: ...ligncd with thc pointer on thc cover oftiming gear housing iash in cold must be thc vallic srecifled in seetion I Th n uiter turning the crankshafl hy 180 to adjust the valve lash of alher cylinders a...

Page 20: ...ted holes loosen a little the three fastening nuts on the triangular tlange of the iniection pump and turn the iniection pump Facing the front end of engines when the iniection pump rotates c1ockwisc...

Page 21: ...Thc fuel spray shoulJ be cven and well atomized in a shape of cone At uny cross sccti0 1 01 thc conc the atomized fliel should be finely und evenly distributed Fuel droplcts und irregular pattern whi...

Page 22: ...brated at the factory lf it JS necessary to readiustthe readiustment must be performed in a iniection pump test bencll with a standard inicctor and inicction pipes of standard ength according to the i...

Page 23: ...ng out meehanieal pitting and wear appeared on the sealing face of valve and valvc seal When grinding apply a grinding paste finc valve sand on the conie sealing surface 01 valve Then the valve and va...

Page 24: ...hole leading water 10 the cviinder IK ad 1 ar thc rear end 01 the block there are chanllcls delivering ube oil upwRrd to thc cylinder head Thc water pump i mounted on thc upper front face ot __ l Wf _...

Page 25: ...st platcs in thl same plane Then tightcn the bolts until thev n ach thc specified tightcning tarque When completing the crankshaft assembly turn it at thc tlywheel end by hand to check Vvhether it ean...

Page 26: ...shown in Fig8 When dismantling and assembling the piston ring a special tool may be llsed The ring end gap of piston rings should be set off with each other by 120 oe to prevent being in line with th...

Page 27: ...the cylinder liner carefully and tighten in turn the connecting rod bolts according to the specified tightening torque limit in several separate times After finishing the assembly turn the crankshaft...

Page 28: ...camshaft out from the front end The axis of the tappet deviates from the center line of cam width Ouring operating the tappet rotates so as to provide an even wearing on the bottom surface and the cy...

Page 29: ...ion of the diesel engine It is composed ofthe fuel delivery pump fuel filter iniection pump governor fuel iniection and fuel through the fuel filter The diesel fuel 15 delivered through the iniection...

Page 30: ...clean VDI Lubricatin System The lubricating system is composed of the strainer lube oil pump oil filter and pipelines as shown in Fig I I The engine adopts pressure and splash lubrication The pressur...

Page 31: ...1O It 7 EfE8 EflflB aR Fig 11 Lubricating system 1 Oll sump 2 Strainer 3 Lube oft pump 4 Piston and connecting rod assembly and cylinder liner S Lube oi mter 6 Gear train 7 on pressure gauge 8 Rocker...

Page 32: ...he radiator during which the cooling water is cooled by the fan and eompletes the regular circulation The cooling fan ean bc of either suction or blast type aceording to its application The eentrifllg...

Page 33: ...s silicon rectit ling dynamo for the operation and maintenancc ofthe dynamo After tuming on the starting switch the flywhecl gear ring is engaged with the motor pinion by the solcnoid meanwhile the tl...

Page 34: ...ves 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 Clea...

Page 35: ...Wear of certain components exceeds limits Remedies I Rcadjust it according to specification 2 Exhaust air 3 Readjust fucl supply 4 Use qualified suppty 5 Replace them V Lube Oillnsufficient or No Pre...

Page 36: ...Malfunction ofgovernors 2 Control rod fuel injection pump gets stuck 3 1njection pump delicery too much 4 Excessive oil burnt Remedies J Fill the rank to make cooling water level higher rhan the cent...

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

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