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O P E R A T I O N & M A I N T E N A N C E M A N U A L

4 Fan of diameter 420mm is a standby accessories for turbcharging diesel.

We recommend to use the fan whose a diameter no less than 420mm when

change it.

Heat radiation area: heat radiation area for turbo charging diesel

according to the power. It shall be adjusted and checked during install the

whole engine. Air guide cover must be installed, 20mm away from the fan in

axial distance. Front end surface of the fan shall be at least 20mm away from

the radiator.

6 Fuel injection pump and adjuster of the diesel have been adjusted to the

best conditions at the leaving factory test and sealed. If the lead seal is

damaged or it is adjusted, the customers shall bear its responsibilities. If any

adjustment is required, please contact the nearest service center of our

factory to conduct for 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 lubrication of bearing in the turbocharger and damage

to the bearing.

8 If customers wants to repair the diesel by itself , need to assembly or

disassembly the turbocharger, please prevent any foreign material from

entering into turbocharger and inlet or inlet system. Otherwise cause deadly

damage to the turbocharger and diesel. If we find the damage of the

turbocharger due to foreign material in the inlet and outlet system, the

customer bears the responsibility. Attention: do not take the push rod for

exhaust valve mounted outside of the bypass type turbocharger as a

carry-gripe. Do not push it without purpose, otherwise, it may affect sensitivity

of the push rod and turbocharger can not work normally. Attention: the diesel

can not work under the conditions of no air filter providing or available, and

leakage of the air inlet and outlet system.

Содержание Y4100D

Страница 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 ...

Страница 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 fuel and lube oil with stipulated number according to the instruction 2 It is strictly forbidden to leak out from an intake system air filter pipelines and connecting components 3 It is strictly forbi...

Страница 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 length of front line ground line should less than 2 meters and area more than 40 mm2 The total length of front line ground line should more than 2 meters and area more than 70 mm2 在 4 The temperature st...

Страница 4: ...ooling 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 accumulated operating hours 3 1 3 Maintenance after 500 accumulated operating hours 3 2 4 Preservation and storage of engine 3 3 Section 4 Engine adjustment 1 adjustment of valve lash 4 1 2 adjustment of i...

Страница 5: ...d 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 1 hard or refuse to start 7 1 2 power insufficiency 7 2 3 smoking exhaust 7 2 4 knocking noise in engine 7 3 5 lube oil insufficiency or no pressure 7 3 6 overheating of engine 7 4 7 engine running ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 12: ...r 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 1800 55 1500 60 1800 Min specific fuel consumption at full load g kW h 260 255 250 5 247 246 243 240 237 235 235 225 220 Intake Type Natural Aspiration Turbo Charger with intercooler Cooling methed ...

Страница 13: ...eter of nozzle hole mm Ø0 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 suction speed r min 3000 4000 capacity L min 80 170 5 Starting motor Type Silicon rectifying shunt dynamo Model QD138Y Voltage V 12 power KW 3 Model JF11 Voltage V 14 Power W 350 7 Fuel filter Type Sing...

Страница 14: ...0 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 5 Starting motor Type Silicon rectifying shunt dynamo Model QDJ1329D QDJ2925D Voltage V 12 24 power KW 3 5 5 Model JFWZ13 JFW24X JFWZ13 JFWZ25 Voltage V 14 28 14 28 Power W 350 500 350 500 7 Fuel fi...

Страница 15: ...ction 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 capacity L min 230 260 5 Starting motor Type Silicon rectifying shunt dynamo Model QDJ2925D Voltage V 24 power KW 5 Model JFWZ25 JFWZ17 JFW25C1 Voltage V 28 14 28 Power W 500 750 500 7 Fuel filter Type S...

Страница 16: ...40 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 valve YSD490D Y490D Y495D Y4100D sink age of valve 0 7 0 9 0 6 0 8 2 Sink age of valve Y4102D Y4102ZLD Y4105D Y4105ZLD sink age of valve 0 6 0 8 3 Temperature and pressure limit YD380D YD385D YD480D...

Страница 17: ...bolts 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 140 160 145 165 flywheel bolts 60 70 105 125 crankshaft belt bolts 140 160 140 160 4 torque limits of main bolts and nut N m Y495D Y4100D Y4102D cylinder head bolts 130 150 160 200 connecting rod bolts 120 140 10...

Страница 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 other water sources must be softening There are two ways to soften 1 boiled 2 in 30 liters of water to add 20 grams of caustic soda caustic soda made solution Can add antifreeze in cold winter Ant fr...

Страница 19: ...andle 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 the start button to make the diesel engine start If the diesel engine cannot be started loosen the button right away and wait for 2 to 3 minutes to restart it If the diesel engine fails in starting ...

Страница 20: ...sel 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 After diesel engine stops it should rotate the ignition switch to the middle Place 3 In Winter when the environmental temperature below 5 C after stopping open the water switch on the body and radia...

Страница 21: ...over 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 state of diesel engine If the user takes the insulation material as a protection make sure the fuel oil not into it to prevent fire 9 When use the diesel engine at follow condition 1 ship use 2 Gasoline ...

Страница 22: ...very 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 electronic equipment also clear the dust of the heat sink on the water tank 8 Should replace the oil at the oil house oil pump and governor at once after the 50 hours running and wash clear the oil fi...

Страница 23: ...engine 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 be added as well 1 Check the oil injection pressure of the injector and observe the pulverization quality of oil injection Clean the needle valve parts and re adjust the oil injection pressure if ne...

Страница 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 generator and the motor to clean the old butter on the bearing and replace new butter meanwhile check the gears on the driving motor 11 After 1500 hours of working accumulatively add the following work 1 D...

Страница 25: ...oil 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 installation hole on the cylinder lid and then turn the crank to make the oil adhere onto piston piston ring cylinder cover and air valve sealed surface 5 The mouths of air inlet and exhaust pipes muffler shal...

Страница 26: ...air 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 the air valve rocker shaft stand 2 Turn the crank to the first cylinder piston stop position when the O scale on the crank belt wheel aims exactly with the indicator in the timing gear cover 3 Inser...

Страница 27: ...s 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 turn the crank in positive directions and pay close attention to the oil surface inside the oil pipe joint hole When the oil surface waves stop rotating the crank 2 Check the scale that the finger ma...

Страница 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 injection occurs caused by the inflexible movement of injection nozzle needle valve The drop of oil on the injection hole usually occurs because of damage on the sealed surface and the oil separation f...

Страница 29: ...ecked 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 relevant instructions on oil injection pump 6 Adjustment of decompression arm lash Turn the Crank to the first cylinder piston stop position when the 0 scale on the crank belt wheel aims exactly with the...

Страница 30: ...e 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 valve seat is made of alloy cast iron Normal width of the air valve and valve seat is 1 2 1 6mm After long term use and grinding for many times if the sealing surface becomes wider which leads to poor s...

Страница 31: ...ulkhead 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 Matching marks are marked on the cylinder body and main bearing casing Any exchange or reverse assembling is not allowed The main shaft bushing is the shafting bushing of high tin broze zergarl When ...

Страница 32: ...me 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 ring is employed for the oil control ring As its resilience reduces by abrasion it still remains a certain of radial resilience therefore it extends service life of the oil control ring Please check cl...

Страница 33: ...sembly 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 are made of copper lead alloy and tin aluminum with support When the clearance exceeds its limit value by abrasion or the surface wears off or burns Please change the new ones in couple Before overh...

Страница 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 channel When installing lining for the front end please check the oil holes of the lining and body are connected or not As the camshaft gear is engaged with the driven gear on the oil pump therefore befo...

Страница 35: ...itions 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 gear and serrated screws Slippage positioning is employed for timing inertia gear and the body The timing gear of fuel injection pump is installed at the advance for oil supply which is fixed on the ca...

Страница 36: ...e 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 are required please keep it clean Plunger piston oil outlet and other couple part can not be exchanged Fully mechanical adjuster is employed Rotation speed of the diesel increase relatively when the ...

Страница 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 connecting rod bearing through the crankshaft hole one reach to oil slot on the back shaft of the cam bush and supply the oil by intermissive one reach to the gear wheel bearing oil pump adopt rotor pump by...

Страница 38: ...the 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 circulation is completed Air drafting or exhausting is adopted for the fan as required Water pump is a centrifugal type The water pump is driven by fan belt surround the shaft belt pulley During use i...

Страница 39: ...ystem 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 battery adopts 6 Q 135 type Charging generator adopt silicon commutate and shunt excitation JF21 model It is comprised of three phase A C motor and silicon diode The negative pole is grounded otherwise it ...

Страница 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 starting motor may not exceed 15 seconds The interval for two starts shall be 2 3 minutes If the diesel can not be started for continual three times please check and remove the faults The duration for powe...

Страница 41: ...use 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 work So the lubricant shall be clear and pressurized with high quality Pressured lubricant filtered from lubricant system be used at turbocharger Speed of turbocharger is much higher than that of diese...

Страница 42: ...he 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 steel inside Meanwhile set a net to prevent aspirating large dust otherwise the dust will block the duck which may cause insufficient air supply low power smoking and oil leakage in the compressor of t...

Страница 43: ...for 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 lubrication of bearing in the turbocharger and damage to the bearing 8 If customers wants to repair the diesel by itself need to assembly or disassembly the turbocharger please prevent any foreign material fro...

Страница 44: ...not 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 flow Check and fill lubrication for the oil filter at the front of the turbo charging and its oil inlet pipe Running 3 5 minutes in idling speed after start the diesel and then running at high speed ...

Страница 45: ...fuel 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 wrong check or replace the piston ring cylinder sleeve and grind valves cylinder head nuts should be tightened in case of leakage on cylinder head gaskets 7 battery lose electricity Charge the battery 8 ...

Страница 46: ...ion 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 handle make the speed to reach rated speed 3 Smoking Exhaust causes remedies 1 over load reduce the load if they are unsuitable matching adjust it 2 spray instruction ill check the spray pressure and a...

Страница 47: ...r 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 replace filter core 4 oil gauges damaged or gauge pipe blocked Repair or replace it 5 oil is too dilute use the eligible oil 6 oil pump gears seriously worn off with excessive clearance Adjust the cleara...

Страница 48: ...ater 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 with insufficient flow 2 refer to paragraph V 3 engines overload Relieve load 7 engine running away CAUSE REMEDIES 1 governor failure Stop immediately then check and repair 2 the fuel pump pull rod l...

Страница 49: ...ance 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 Bearing bush sleeve 4 Oil seal 13 fuel injector 5 Charger 14 injection pump plunger 6 Start motor 15 injection pump fuel out valve 7 Air gate 16 Gaskets 8 Valve retainer 17 Filter element 9 Valve guide...

Страница 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 Province China www yangdong com ...

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