YANGDONG SERIES Y85 Operation & Maintenance Manual Download

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Summary of Contents for SERIES Y85

Page 1: ... SERIES Y85 DIESEL ENGINE OPERATION MAINTENANCE MANUAL YANGDONG co LTD THE PEOPLE S REPUBLIC OF CHINA ...

Page 2: ...nce 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 Y85 diesel eneines to operators maintenance workers and relevant maneers Since the construction of this ene ine is subiect to frequent improvement and development durine production and practice ...

Page 3: ...water soften it first 4 t is strictly forbidden to start under the circumstances of lack of lube oil or water S lt is trictly forbidden to operate at overload or under other conditions a2ainst the rules 6 1t is strictly forbidde to re2ulate the fuel iniection pump at will 7 1t is strictly forbidden to chan2e the diameter of the pulley 8 To control the startin2 time less than IS seconds and the sta...

Page 4: ...HNICAL DATA I Specifications of diesel engines 1 1 II Specifications of the main accessories 1 2 1II Main technical data of diesel engines 1 3 IV Fit clearance and wear limit of main parts 1 4 SECTION 2 OPERATION I Fuel oil lube oil and cooling water 2 1 II Preparation before starting 2 2 III Starting 2 2 IV Operating 2 3 V Stopping 2 3 SECTION 3 MAl TENANCE I Routine maintenance 3 1 II Maintenanc...

Page 5: ...l 5 5 V Camshaf t 5 5 VI Gear transmission system 5 6 vn Fuel and governing system 5 7 Vill Lubricating system 5 8 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 insufficiency 6 1 III Smoking exhaust 6 2 IV Knocking noise in engine 6 2 V Lube oil i sufficiency or no pressure 6 2 VI Overheating of engine 6 3 VII E...

Page 6: ...figuration and Installation Dimensions of Model YND48SQ Diesel Engine o I g 1 Dimensions of water inlet and outlet 1 1 0 j I 9 E u u I 7 7 7 7 71 Exhaust outlet centerline 1 2 60 o I o Installation dimensions of engine base foot 1 10 430 I I nkshaft cerrter i UTI I I 11 Hl0 Evenly distrubuted Connecting dimensions of flywheel afld Its housing ...

Page 7: ...co r 189 Exhaust outlet centerline 11 60 494 65 190 I Inslallaf on dimensIOns of engine base foot 1 10 o o I s rankShaft centerli L i 4 11 r I 12 M10 Evenly distrubuled 5805 5637 681 onneding d lenslons of flywheel and its houslrg 15 I ll Configuration and Installation Dimensions of Model Y485 YD1485 Diesel Engine ...

Page 8: ...lhe ouIcrend foee at the bearing 10 lhat of the ftywheells 62 376 587 Instol1otbn dmcnsions of erghe bose fool Oonkshafl cenI Yfhe 324 5 I 65 117 J S 242 340 494 189 74 5 I l eN AIcythdcr bIodcl eN BIcyII dcr bIodcl Oinensbns atwdlef inlcl outIct I rq r III Configuration and Installation Dimensions of Model Y385 Diesel Engine ...

Page 9: ...450 Ne kW 35 30 25 20 15 ge g kw h 255 250 245 40 235 R Tr l r Ne I I ge 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 IV Performance Curver of Model YND48SQ Diesel Engine N R BOSch 35 25 Me N m 125 120 115 110 ...

Page 10: ... ge g kw h 250 240 230 220 l v L V V V v Ji r i ge V J t 550 Tr C 500 450 120 Me N m 110 105 100 95 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 n r min V Performance Curves of Model YD 485 Diesel Engine v ...

Page 11: ...400 Ne kw 32 28 24 20 16 12 ge g kw h 280 270 260 R r r Tr I I M f I Ne V V r ge 1000 1200 1400 1600 1800 2000 2400 2600 n r min VI Performance Curves of Model Y485 Diesel Engine Vl R BOSch 4 3 2 Me N m 120 110 100 ...

Page 12: ... Nom 90 80 70 ge g kw h 280 270 260 R Tr Ne r 1 I l o V V I VII r ge V Tr C 600 500 400 Ne kw 21 19 17 15 13 11 9 1100 1300 1500 1700 1900 2100 2300 2500 2600n r min VII Performance Curves of Model Y385 Diesel Engine vlI ...

Page 13: ... Vertical water cooling four stroke vortex I 587X494X610 165 Model Type 1 _ __Nunlber of0E d rs i _ _ _ _ _ _ 3__ Borei l Stro i1 t J __ __ _ __ _ _9 __ __ __ _ Compres i 9n_ratio j_ ___ __ __ _ _ _ 22 Tf tal dispiacemenl L 1 532 Firing order r 0 2 _ t Z I_Rate w y ___ 19l _ d speed_Crfuli l r 21QQ 3 ___ Ma to _ 84 Min specific fuel consumption 1 267 9 __ t fuilload h I _ Specific lube oil consump...

Page 14: ...ction pressure Mpa I 13 2 0 5 19 6 0 1 I _ ype L l o r__ __ __ _ J _ G _ _ pe dlr mi L _I300__ L 1800 ____ 2748 Capacity lJmin c 18 I 30 22 4 r l Pressure Kpa 0 4 __ __ L _ Type Centrifugal volute single suction r J Spee d r min2 _ __ __ 3090_ _ _ _ _ __ _ _4QOO c pa3 mj t T __ 8f _ _ 1 0 Type I Series DC motor Model QDI322C QDI315A Dl38Y _ Voltage V 12 ower WL _ __I or 2 __ L _ 5_ _ _ __ Typ _ Si...

Page 15: ... 170 Y385 Y385T Y485 Main bearing cap bolts 175 195 YDI485 YND485Q Connecting rod bolts 110 130 140 160 YND485Q Flywheel bolts 50 60 70 80 YND485Q 4 Temperature and pressure limits 60 70 I Exhaust temperatureCC n 3200rpm 3200rpm n 2600rpm n 2600rpm 2 Lube oil temperatureCC 3 Lube oil pressure Mpa At normal operation At min Steady Speed 5 Governor Characteristics Min idling steady Speed Steady regu...

Page 16: ... 0 18 6 I Side clearance between the oil scraper ring and it groove 0 030 0 067 0 18_ 7 Gap of the 1st ring l 8 I Gap of the 2nd ring and oil scraper ring I _ 9 I Crankshaft main journal and main bearing 0 300 0 450 60 __ L _ I 0 25 0 450 2 20 j o070 0 139 0 25 10 ICamshaft journal and bushing 0 05 0 0 100 0 18 11 I Idle gear shaft journal and bushing j I 0 025 0 075 _ __ 1_ 0 18 0 15 0 20 0 15 12...

Page 17: ...winter use grade CD30 lube oil When being filled into the engine oiJ tank the oil should be filtered by screen J Cooling water It is recommended to use soft water such as rain water city tap water or clean river water for engine cool ing Well water or tap water from well water could not be used Cooling water containing too much minerals will form water scaJi in an engine cooling system affecting t...

Page 18: ...l ltcr Clnd whetlwr there lS any leakdge at all ioints 6 Check the accessories to see whether they are firmly and reliably vmn ct ed Check the eleetrical system to see whether the battery is fully charged all wiring an correct amI all connections are tigh tened 7 Check the clutch to see whether it ha wsengaged ill Starting l Set the speed control lever at the middle speed position 2 Turn the ignit...

Page 19: ...as color and the operating noise If there is any fault stop the engine alld inspect it V Stopping l Before stopping tllke off the load and reduce the engine speed gradually Let it run at idling speed for a few minutes Do not stop engine until the outlet water temper ature falls to below 70 C 2 After stopping th engine the ignition switch should be turned to the middle position 3 In winter when amb...

Page 20: ...oundation bolts and the connection between the engine and the dirven machinery 7 Keep the engine clean Oil water and dust gathered on the engine surface should be wiped away with a dry rag or cloth dipped in gasoli e Especially keep the electric equipment clean and dry and clean out the dust on the fins of the radiator 8 FOl the new engine after SOh trial running renew the lube oil in the oil sump...

Page 21: ...s the work l f maintenance after every 100 accumulated operating hours the following items are needed 1 Check the injecion pressure and spray pattern of the injector If necessary dismantle the injector clean the nozzle set and readjust the injection pressure 2 Cheek fuel delivery of the injection pump and recalibrate it on a test bench if possible Check the injection timing and readjust it if nece...

Page 22: ...m 3 Check and measure wear of the pistons and piston rings 4 Check and measure wear of the cylinder liner 5 Check and measure wear of the crankshaft main journalb and crank pins Clean lube oil passages of the crankshaft 6 Check wear of the main bearing and connecting rod bearing shells 7 Clean oil passages of the cylinder b lock and replace lube oil IV Preservation and Storage of Engine If the eng...

Page 23: ...5 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 Thc preservation according to the above procedure may be valid for 3months Over th...

Page 24: ...must be the value specified in section l Then after turning the crankshaft by 1800 to adjust the valve lash of other cylinders according to the engine firing order l 3 4 2 for the four cylinder engine and 1 3 2 for three cylinder engine n Adjustment of Advance angle of supply fuel To obtain the most economical specific fuel consumption and to ensure normal operation of the engine injection timing ...

Page 25: ... will advance 4 dditionally if the ellgine 1m3 injection angle aJvance devjce th aJvancpct injeclirm angle can be tdjl ted by loosening the tl rf e lJU S on the triangu lar flange of mjpction pump and turn the inje tion pumlJ 8haft Fclcin Lhf front end of engines when the injection pump rot tes clockwise the fuel injection will retard while the pump rotates anticlockwise the fuel injection will ad...

Page 26: ...he cone the atomized fuel should be finely and evenly distributed Fuel droplets and irregular pattern which can be seen by naked eyes should not be pre ent in the spray There should be a distinct clear sharp sound at the end of injectioll Generally irregular pattern of the spray is caused by needle valve seizure fuel dripping is generated by damaged conical sealing surface of needle valve a d spra...

Page 27: ...er formed in a injecti n pump test bench with a standard injector and injection pipes of standard length according to the instructions in opp ration Manual of the Injection Pump Fig 3 Adjustment of lube oil pressure VI Adjustment of Decompress ion Arm Lash Turn the crankshaft to make that the piston of 1st cylinder is l1t the compression T D C position Turn the decompressIOn arm to decompression p...

Page 28: ...echanical pitting and wear appeared on the sealing face of valve and valve seat When lapping apply a grinding paste fine valve sand on the conic sealing surface of valve Then the valve and valve seat are lapped in pair unitl a even continuous and lustreless sealing band appears t is strictly forbidden that the grinding paste enters the valve guide After lapping clean the valve valve seat and valve...

Page 29: ...ace structure Besides the fitting bores for the liner and the cylinder head boltholes on the top plane uf the bloc there are holes ieading 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 m0411ted on the upper front face of cylinder block and the gear system is on the lower part The flywheel housing IS in...

Page 30: ...to keep the upper and lower thrust plates in the same plane Then tighten the bolts until they reach the specified tightening torque When completing the crankshaft assembly turn it at the flywheel end by hand to check whether it can be moved freely The liner is slipped into the cylinderbore yertically so that deformation ofthe liner may be avoided The liner flange plane should protrude out the top ...

Page 31: ...g as shown in Fig 8 When dismantling and assembling the piston ring a special tool may be used The ring end gap of piston rings should be set off with each other by 1200 to prevent being in line with the piston pin seat hole If the piston ring is seized and could not move when checking soak it in diesel fuel kerosine or gasoline for 24h or more Then knock the piston ring slightly to make it become...

Page 32: ...n tum the connecttng rod bolts according to the specified tightening torque limit in several separate times Mter finishing the assembly turn the crankshaft be sure that it rotates smoothly IV Crankshaft and Flywheel The cranksh ft timing gear and pulley are fitted on the front output end of crankshaft Positioned by the locating pin the flywheel is fitted on the rear end flange of the crankshaft wi...

Page 33: ...e camshaft ut from the front end The axis of the tappet deviates from the center line of cam width During oper ating the tappet rotates so as to provide an even wearing on the bottom surface and the cylindncal surface of tappet VI Gear Transmission System The gear transmissio n system consists of the crankshaft timing gear timing idler camshaft timing gear injection pump timin gear and hydraulic p...

Page 34: ...turn pipe Fuel injection pipe 3 Jnjector 4 Injection pump 5 Fuel filter 6 Governor 7 Fuel delivery pump The fuel and governing system IS the mam operating section of the diesel engme It IS composed of the fuel delivery pump fuel filter in Fig 10 The fuel IS pumped by the fuel delivery pump from the fuel tank into the injection pump through the fuel filter The dif sel fuel is delivered through the ...

Page 35: ...d to keep them clean vrn Lubricating System The lubricating system is composed of the strainer lube oil pump oil filter and pipelines as shown in Fig ll The engine adopts pres sure and splash lubrica tion The pressure lubrication is applied to the main bearing connecting rod bearing camshaft bushing The cylinder sleeve piston piston pin connecting rod bushing cam and its tappet as well as valve an...

Page 36: ...the maintenance 14 Fig ll Lubricating system 1 0il sump 2 8trainer 3 ube oil pump 4 Piston and connecting rod assembly and cylinder liner 5 ube oil filter 6 Gear train 7 0il pressure gauge 8 Rocker 21nn 9 Valve push rod valve tappet and block hole for tappet 10 Rocker ann shaft 11 Valve and valve guide 12 Camshaft and bushing 13 0il lines in the block 14 Crankshaft and bearing 5 9 ...

Page 37: ...the radiator during which the cooling water is cooled by the fan and completes the regular circulation The cooling fan can be of either suction or blast type according to its application The centrifugal water pump is driven by the fan belt on the crankshaft pulley ln case of severe water dropping out from the weep hole at the lower part of the pump housing due to the damage of water seal during op...

Page 38: ...es ili cn rectifying dynamo for the operation and maintenance of the dynamo After turning on the st rting switch the flywheel gear ring is engaged wilh the motor pinion by the 1 olenoid meanwhile the flywheel is driven by closing the current circuit of starting motor As soon as the enginl is started the starting switch must be turned off immedi ately Then the I core along with the pinion returns t...

Page 39: ...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 Clean up contact points 9 Preheat cooling water and lube oil Remedies l Compression pressure inside cylinders too low 2 Advanced fuel injection angle incorrect 3 Valve lash incorrect 4 Fuel supply for eac...

Page 40: ... 2 Exhaust air 3 Fuel supply for each cylinder unbalanced 3 Readiust fuel suppiy 4 Fuel unqualified 4 Use clualified supply 5 Wear of certain components exceeds limits 5 RepJace them V Lube Oil Insufficient or No Pressure see Table 8 Table 8 Causes Remedies 1 Oil level in oil sumps too low 2 Serious leakage from oil pipelines 3 Oil strainers oil filters and pipelines clogged 4 Oil gauges damaged o...

Page 41: ...Malfunction of governors 2 Control rod of fuel injection pump gets stuck 3 Injection pump delivery too much 4 Excessive oil burnt Remedies 1 Fill the tank to make cooling water level higher than the center line of water pump 2 Check water pump clearance and tightness of belts Eliminate leakage 3 Remove it 1 Cheak whether the oil level is between thl dip stick s ale lines 2 Refer to paragraph V 3 R...

Page 42: ...DUCT STANDARD Q 321284 JCA08 40 2002 NO OF EXPORT LICENSE FOR QUALITY 2000112013 LICENSE APPROVAL DATE OCT 10 2002 ADD Jiangyan City Jiangsu ChiDa TEL 0523 8216774 8213961 FAX 0523 8211950 P C 225 00 http www yangdong com Email yangdong yangdong com ...

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YANGDONG SERIES Y85, Operation & Maintenance Manual

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