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Summary of Contents for YANGDONG YD380D
- 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 YANGDONG DIESEL ENGINE INDUSTRIAL ENGINE SERIES O P E R AT I O N & M AI N T E N AN C E M AN U AL YTO(JIANGYAN)POWER MACHINERY CO.,LTD...
- Page 2 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 Foreword Series Yangdong multi-cylinder diesel engines are ideal power units for light vehicle, agro motor, small tractor, air conditioner in bus, generator set, water pumps, fire-fighting pumps and engineering machinery.
- Page 3 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, All the filters(include air pump filter ) maitain,repair or instead according to the provision Notice of winter Make sure the usual running of engine;...
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Page 4: Table Of Contents
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 Contents …………Ⅰ Dimensional drawings for configuration and installation of diesel engine Section 1. Diesel engine specification and technical dates …... - Page 5 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 …………………………………………………………………5-1 1、 cylinder head ………………………………………………………………………………5-2 2、cylinder block 3、piston 、connecting rod … …………………………………………………………………5-3 ……………………………………………………………………5-4 4、 crankshaft and flywheel 5、camshaft ………………………………………………………………………………………5-5 6、gear transmission system……………………………………………………………………5-5 7、...
- 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 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 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 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 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 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 Schematic Diagram of Wiring Dimensions for installation of Y4102ZLD and Y4105ZLD...
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Page 12: Section 1. Diesel Engine Specification And Technical Dates
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 Section 1. Diesel engine specification and technical dates 1.Specification of diesel engine Model YD380D YD385D YD480D YND485D... -
Page 13: 2、Specification Of The Main Accessories
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 2, Specification of Main Accessories Specification Name YD380D YD385D YD480D YND485D Type BQ pump... - Page 14 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 Specification Name YSD490D Y490D Y495D Y4100D Type BQ pump Fuel Governor All-speed,mechnical centrifugal injection Fuel delivery pump Single-acting piston-type...
- Page 15 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 Specification Name Y4102D Y4105D Y4102ZLD Y4105ZLD Type BQ pump Fuel Governor All-speed,mechnical centrifugal injection Fuel delivery pump Single-acting piston-type...
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Page 16: 3, Main Technical Data Of Diesel Engines
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 3, Main technical Data of diesel engines YD380D YD385D YD480D YND485D 1. Valve lash(mm) intake valve(cold ) 0.20～0.25... - Page 17 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 ）Lube oil pressure in main passage（MPa） （4 At normal operation 0.2～0.4 ≥ At min. steady speed 0.065 4. torque limits of main bolts and nut（N.m） YD380D YD385D YD480D cylinder head bolts 175～195 210～230 175～195 connecting rod bolts 50～60 60～70...
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Page 18: Section 2. Operation And Security Requirements Of Engine
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 Section 2. Operation and security requirements of engine 1, Fuel, lube Oil and Cooling water 1. -
Page 19: 3、 Starting
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 discharge bolts of the diesel filter and injection pump. Then press handle pump on the transmission oil pump until the air inside the oil loop is discharged completely. -
Page 20: 5、Stopping
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 working with load is permitted. When using normal conditions, the water temperature shall reach about 80℃. 2, Increase or decrease of the diesel engine load and rotation speed shall be carried out evenly and gradually. - Page 21 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 2. Diesel engine workplace must be well-ventilated, whenever possible accumulation of flammable, toxic or asphyxiated gas in place, should be installed ventilation facilities.
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Page 22: Section 3 Maintenance
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 Section 3 Maintenance To make engine work reliably, lower abrasion parts, extend service life, make sure the regular maintenance for the engine system according to the following technology rules: 1、Routine maintenance... - Page 23 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. Clean the dust accumulated in the air inlet pipe, dust pan of the air filter and on the surface of paper filtering core, and remove the dust inside the air exhaust pipe and the muffler.
- Page 24 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 water. Discharge the water in cooling system before cleaning, and then fill full it with detergent.
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Page 25: 4、Preservation And Storage Of Engine
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 4、preservation and storage of engine When the diesel engine is to be stopped for a long time, the following methods can be taken for sealing and preservation. -
Page 26: Section 4 Engine Adjustment
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 Section 4 Engine adjustment 1、Adjustment of valve lash When carrying repair or technical maintenance to the diesel engine, it necessary to check the clearance between the air valves. -
Page 27: 3、Adjustment Of Injector
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 The method for adjusting the advance angle for oil supply is as following: 1, Remove the air inside the fuel system, and repeated the rotating of crank to make the oil injection pump full of fuel. - Page 28 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 smoke exhaust. If there is any oil injector with faults, stop the oil injection and no smoke will be discharged;...
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Page 29: 4、Adjustment Of Lube Oil Pressure
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 clean diesel when grinding. Grinding in pairs shall not impact on the needle valve or its stand, and clean after grinding without any metal dirt reserved. -
Page 30: Section 5 Construction Of Diesel Engine
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 Section 5 Construction of diesel engine 1、Cylinder head Fig.4 Tightening sequence of cylinder head bolts Fig.5 Valve sinkage The cylinder head is made of HT200 cast iron (with copper chrome). -
Page 31: 2、Cylinder Block
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 gas distribution and timing and increase noise of the valve structure; insufficient clearance may lead to incomplete closing and burning of the air valve. Fig.6 protruding height of the liner flange plane relative to the plane of cylinder block... -
Page 32: 3、Piston 、Connecting Rod
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 Fig.7 Measu rement o f piston Fig.8 Measurement of side surface gap of piston ring ring end ga p 1. -
Page 33: 4、Crankshaft And Flywheel
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 ring shall be 0.060-0.092mm, and the second gaseous ring shall be 0.040-0.072mm, see figure 8 for detail. Special purpose tool shall be employed for dismantling the piston ring. -
Page 34: 5、Camshaft
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 crankshaft to support the transmission shaft of the transmission case, scale mark of provided at belt pulley of the crankshaft for observing the angle of the advance for blowout. -
Page 35: 7、Fuel And Governing System
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 Fig9: timing gear meshing signs Each timing gear is marked with timing gear except the gear for hydraulic pump. Tooth position is the gear shall be in corresponding position, ( the gear marked with number shall be in the middle of th4e gears adjacent numbers), to ensure mutual motion relation of the parts, see figure 9 for detail. - Page 36 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 Figure 10 fuel adjustment diagrams 1. fuel return pipe 2. Fuel injection pipe 3. Injector 4. injection pump 5. Fuel filter 6.
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Page 37: 8、 Lubrication System
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 Pin valve of the fuel injection nozzle and pin valve body are the precise couple parts by grinding, during dismantling, do not exchange it and keep it clean. -
Page 38: 9、Cooling System
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、Cooling system cooling system is of forcible circulating water-cooled type, see figure 12 for detail. The cooling system contains radiator,... -
Page 39: 10、Electric System
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 According to “Technical Maintenance”, check and adjust tension of the belt between the fan and belt of generator regularly. The adjustment method is press down it 10-20mm. - Page 40 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 electromagnetic switch. When the starting switch is connected, the electromagnetic switch makes tooth of the gear and flying wheel gear ring, connect the circuit for starting the motor and then drive the flying wheel.
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Page 41: Section6 Operation Notice Of Turbo-Charger Diesel Engine
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 Section 6 Operation notice of turbo- charger diesel engine Turbocharger mounted at the exhaust pipe of the diesel engine. Exhaust gas discharged from the cylinder entry turbocharger casing through exhaust pipe drives impeller of the turbine, then drives impeller of the compressor push the pressed air filtered by air filtered into cylinder. - Page 42 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 Selected oil brand under different temperatures Ambient temperature oil brand corresponding oil brand of SAE -10℃...
- Page 43 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 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.
- Page 44 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 Prohibit operations under long-term overload condition. The diesel work overload for a long time, the speed of engine will be slow, cause low speed of the turbocharger, departure high effective area.
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Page 45: Section 7 Faults And Remedies For Diesel Engine
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 Section 7 Faults and Remedies for Diesel Engine 1、 Hard or Refuse to Start causes remedies 1、fuel filter and fuel pipeline blocked... -
Page 46: 2、 Power Insufficiency
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 2、 Power Insufficiency cause remedies 1 Compress pressure in cylinder is too Reference to fifth solution of first fault, replace a new part if exceed its wear limit 2 delivery fuel advance angle incorrect Adjust according to specifications... -
Page 47: 4、 Knocking Noise In Engine
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 4、 Knocking Noise in Engine causes remedies 1 delivery fuel advance angle is incorrect Adjust the angle according to the specification 2 air in fuel system Exhaust air... -
Page 48: 6、Overheating Of Engine
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 、0verheating Of Engine cause remedies 1 temperature of cooling water too high (1)insufficient cooling water or vapor (1)fill the rank to make cooling water level lock in water pipes higher than the center line of water pump... - Page 49 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.Appendix: wearing parts order sheet Name Name Cylinder sleeve Waterproof ring Piston ring Bead apex Piston Bearing bush/sleeve Oil seal...
- Page 50 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 Production permit No.:XK06-205-00141/XK06-00141 Product standard:Q/321284 JCA03-2002;Q/321284 JCA06-2002 Address； No.199LuotangEastRoad.Jiangyan City Jiangsu Province China Website: www.yangdong.com...
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