~® SERIES Y80 DIESEL ENGINE OPERATION & MAINTENANCE MANUAL YANGDONG co., LTD.
FOREWORD Series Y88multi..cylinder diesel engines are ideal power·,' units for liRbt vehicle, aeromotor,small tractor,air conditioner in bus,aenerator set and ensdneeriD2machinery. .Tbenormal and reliable operation aDd lone service life of tbe enRine depend Dot only on the manufacturine quality,but also on the reasonable operation~ and ~orrect main_nance.
Warning Notice 1,lt ~'f§4riC;tlY (orb:idd~~ to, use inferior and .dirtw. die$elfu~I.· o~ "lube, oiL}P'leas~ ~"oose to use.,.... 8tUl:.Jllbo"oil,.witb stipulated Du,mber aceordinz to: the instruction.2.lt; .is ~strittl¥,; forbidden·· to leak Buttrom :an ~intake~system(8ir~rdters.pipeliDes and t()ft~ti"rcombUhents )~ 3.lt is strictly forbidden to have' hard water(well water or soprioe water)8! "endline water.lfrt~cess~ry'~to'~aVPtV· the' hardtw~ter),So~il it 'first. .
CONTENTS I .Configuration and Installation Ditnensions of Model Y480 DieselEn~ine I II .Configuration and Installation Dimensions of Model' Y380 Diesel,Engine II III .Performance Curves of Model YD480 I)ieselEngine " .•. -i- ,~ •• "'li.; III SECTION 1. DIESEL ENGINE SPE,CIFICA1'IONS AND TECHNICA.L DATA U~ I . 'Specifications of diesel engines ••• He II . Specifications of the main acces,sories · .. " TIl,. II .. u U H..
v . Camshaf t •.........•.....................•......•.•......••.•....•...•.•••••.................•. 5-5 VI . Gear.tran.smission system •••••• · •• •••••••••••• ••· •••••.•.•••.•. ••••••• · •· •.• •.•.· · .•. ... 5-6 \'II . Fuel and- ~overning system ..•...•..•.•.,•.•..••••.....•.••.•••••.•..•.•••...•.....•....•.. 5-7 'VIII . Lubricating system ·.....•. · ••• ••• •.• ••. •.• ... •.••.•.•.••.......•.••.••.. ......•.. ~.. 5-8 IX . Cool i.,g system •..••. · .. · · ·.. · .• ••• ..• •.. ..•..••.•.•..••......
578 561.5 Exhaust outlet centerline 183 187 300 62.5 Veil A Icylilder block) 6-MIO ,....,,.... ~ C") ~ C") o ~ l1 t-t 340 475 494 Connecting dinensions of ~ and Its housi1g r·· InstoIlatbn dinensixls of enghe base foot Dinensions of echaust outlet 4NO ~ Crankshaft centertile ... RIO ~ ~' .£: co C") ~ i.2 4-Gl17 424.5" Dinensions of water inlet/outlet 74 I . Configuration and Installation Dimensions of Model Y480 Diesl Engine co C") & ,pl N & C") &. j '5 51 -0 C") &.
Cer.dine of preMUft! 141.3 relief IevH hole I 187 478 46i.5 !xhauatouUet~~... 1-- 200 .1 View A (cyl_ _ block) :1.1 ~! _I ~~2lIiM3'~ I" il i II II ~ o..i ¥ I ! 1:::1 o ;; 4J View B(cyliPder block} ~ 37$ Supply ban. ConnediAI........,ofO,.. .... itabouli. 6820S .362HB( ,..- ) Il«.'OI'didl to aaIIOmer'. requeflL The dilllanCe .between &bt: outer ~Ml /,' .' .' .'18 lattaI..- dimeMio1\4Jol ~ ...... foot :;~ , ~of_~m ~.290 UUIIoilhe Oywheel it ! Craakahaft cenCeru.
Me (N..m) 104 Me _l.- 96 V V V ~ ~ r--....... ~ ~ ~ r---.... ~ 88 ~ .. He (kw) Ne V ~ 20 16 ~ ~ r-....... V ~ /" ~ ----- ~ ....... ---- ------ ~ ~ ~ ge (glkw.h) . , y' ge ~ r---..... _l-..--- ~ ~ l/ 255 245 -. 235 I I. I ' I .
SECTION 1. DIESEL ENGINE SPECIFICATIONS AND TECHNICAL DATA I.Specifications of Diesel En£ines(see Table 1) Table 1 Model i Y380 __. : --.. -----...-.-.... - - - - -...---.---i-..-----.------...--.... Y380T : Y480 : Y480G---1..--·-----·-···-----·--·-1-----·------·--···.. : YD480 YSAD380·YS380 YS480 YSA480 YS.A480 ...-....-- .....-.-....--.--.--.. --.-.-- ....-- .... ----....-._-_ ... --..._-.- ...--.... --_.---_ . .,....._._ Vertical,\vater-cooling,foUr stroke,direct iqjection,dry liner .
II .Specification of Main Accessories(see Table 2) Table 2 Specification Designation Nil YS480 YS~~~.; Y380 'YS380 Y380T Y48OG; Y480 Fuel injection Governor -_.--_. pump _..~!l1.~g~! .. ~iamel~(~!!l) .- .' ... ~--_.- 2 Fuel injector , 7.5 . . 7., 6.5 S~_gl.~~~~ti!l8.P~!~I1_o/~. P21 • __ ••' _ ' .... --_!~_ _..__.__ . ._. S~~~r!.~.j~2 __._._..__ 3 Lube pump PF68509 ___._.... __ ~i~g!~__~!~~pi!1~~~:~p~~~~4.~1_._ .. -..-- ._ -+ ._.__.__.__ . . Four holes t1> 0.23 19.
ill.Main technical Data of Diesel Enldne 1~VaJve lash(mrn) O~25 Intake valve(coJd) 0.20-'- Exhaust valve(cold) 0.25-·,' 0.30 2. sinkage ofvaJve(mr~) O.7~' 0.9 3.Torquefimits ofnlain bolts and nuts(N • "1) CyI;indefhe.ad boits 150""-' 170 (Y380, Y380T, Y480G, Y480, YSv;\480~ YS480" lT~}\.. 480, )'S380) 175"~"''i95 Main bearin~ cap bolts (YD480,\ YS4A..D380) 110---·· 130 Connecting rod bolts 50'-~" 60 Flywheel. bolts 60""~ 70 4.
IV .Fit Clearance and Wear Limit of MaiJl Parts(see '"fable 3) Table 3 2 Assenbly limit Wear limit (~) (D;lm)- Connecting rod'j6umal and connecting rod btishin'g O.()40"0.089 0.20 Piston pin and1c~nnectingxod sm,\U end.bushing . 0.025-0.046 0.10 06-0.160 0.40 I .._-- -+-_ 3 ----.-- -..--- .-- -_._- -- --- -..---- --.. _ _.- ----- . skirt and cylinder liner 4 Side clearance between the Ist ring and its groovt: 0.060-0.092 0.20 5 Side clt~arance between the 2nd ring its groove 0.
SECTION2. OPERATION I . Fuel Oil ,Lube Oil and Cooline Water I.Fueloil Users can select the proper grade of fuel oil the ~eneral fuel.Use area in. China,the ~de fuel.Before Ji~ht "0" bein~ ~de accrdin~ to .the local ambient temperature. In of fuel oil is according to the standard GB252 light diesel diesel fuel in summer, while in winter, use grade "- 10" filled into the en~ine fuel tank,the diesel fuel must be settled for a li~ht diesel lon~ period (normally' at least 48 h).
IT .Preparation before S*ar1ia2 I.Check the·tifdltness and reliability of aU connecting parts. Check control levers (speed control lever and stoppin~ lever) to see whether they can be moved· freely. 2.Rotate the· crankshaft several turns,be sure that all movin~ parts move freely. 3.Check the oil level in the oil sump and injection. pump to see whether it is kept within two marks on the dipsticks.Make .sure that the fuel tank has sufficient fuel and that the fuel pipelines are unblocked'. 4.
IV • Operatioe 1.00 not load the en~ine until the cooling \\'ater tempemture is over 50°C arid the lube oil temperature is over 40 °C . The en~ine should not be operated undrer rated operated under rated output before the outlet water temperature reaches approximately sqoc . 2.Increase or d~crase the engine load and speed gradually andevenly.In normal case!do not load and.unload,the en~ine suddenly. 3.
SECTION3. MAINTENANCE For reliable engine operation with Jess wear and longer service Jife,all maintenance work nlust be carried out as foJlo\vs. I . Routine l\taintenance ] .Check the oil level in the oil sump and it should be between t\VO marks on the dipstick and ncar the upper one.For a new enfl;ine or the engine reused after stoppin~ for. a long period,the lube oillnust be 11.IJed to the upper mar~and op,erate the engine at lower speed for 5 "--.
6.Check the tension of the fan beh,and readjust it if necessary. 7.FiJl the nipple of cooling water 'pump bearing with ZG- 4 calciumbased grease with a grease gun. 8.Clean out the dust in intake manifold,clean the inside of the aircleaner.. brush off the dust gathered on the 'paper element surface,and clean the inside of the exhaust manifold and silencer. 9.After every 200 accumulated operating hours,check the injection pressure and spray pattern of injection.
,8~Check whether the thermostat is in ~ood .order.Examine ·.the .waterdropp.i~out from a weep hole of the -water pump.It is necessary to renew the water seal,if tlowinll;out too much of water. 9.Check the firm~ly and wirin~ contacts of.the electric equipment-to see whether. they :are connected welLBurnt marks should be removed. 10.Afterevery 1,000 accumulatedoperatin~hours,add the' following items; (I)Make an overall check on all' pam and components.Make necessary .adjustments and repairs.
~;'4:Poursome;'~dehydratedbil ,into' cylinder throu~h iniector'"~ assembled holes" Of} the cylindef:heaa,sndtumfhe'crank..4;haft to make sure that the piston,piston rinR,cyJinder liner lind valve seat are all covered \vith a layer of this oil. ,,'5'~Block'theoutletsof intake and exhaust manifolds (silencer)with.wooden plugs Of\Vrap up properly with plastic film in order to prevent any dust froln getting in. 6.
SECTION.4 ENG'INE ADJUSTMENT I . Ad.iustment of Valve Lash When .the en~ine is nlaintained and repaired,it is necessary ·to check and, adi~st the valve lashes.The recommended Jnethod of a4iusting the valve system and valve lash is as follows: I.Remove the, cylinder head cover.Check and tighten the nuts fastening the rocker arm shaft stands. 2.Tum the crankshaft to make sure that the piston of 1st cylinder is at the compression. TOe position.
2.Check the· timin~ mark on the inspection window of flywheel housing to see. whether it aligns with, the. correct gradulated mark of specified, advanced in.iection an~le on. the flywheel rim (or ontbe crankshaft pulley). , 3.In case· that tbey do not match with each other,the adjusted by re.movinfl;' off the front cover on the timing screws fastening thei~iection·. pump timing ~ear advaneed~ ~ear housjn~ support(.,See fi~.2).
check a fauly injector,i.e.loosen the nuts of injection pipe .from the injector of every cylinder sl1ccessivelY,and observe the exhaust smoke.When the cylinder with the faulty iniector stops firin~black smoke would disappear.and en~ine speed is not appreciably affected or not affected at al1.
guiding surface ofthe needle vaJveand nozzle. body is not smooth enougp,it may. be lapped. \\lith a.littlebitofclean fuel o it, th.e n clean off any metaL particulates in clean. fue.l.While needle valve with n(}ZZlebqdY,l1ever knock the needle valve ~ainst lappj~ of the body. IV • Ad.iustmentofLube Oil· Pressure See fig.3.Lossen the lock nut and turn the adjusting screw with a wrench to take the lube oil pressure within 200 ~- 400kPa(in cold state,. the pressure maybe bigh~r slightly).
SECTION 5. CONSTRUCTION OF DIESEL ENGINE I . Cvlinder Head When assembling'lcylinder head··is fixed on the cylinder block with cylinder head-bolts.A . torsion spanner should be used· during tightening the bolts.The bolts are tightened several times in sequence shown in Fig.4 until they reach the specified torque limit.After dismantlin~ and assetnbling the cylinder head.itis necessary to shut down the engine when first wanning up period is over.
.After service for a lon~ period - and many times, rew-inding the sinkage will increase. When it exceeds 2.Qrnm, replacing the valve seat should be considered. Check the valve frequently. The lashes recommended method is para~raph adjusting shown , .Fig. 5 Valve sinkage on I of Section 4. If the lashes are too large,it may affect the corre'ctness of valve timing and the noise level of valve device rises.On the contrary,it may cause leaka~e·or valve burnt out. II .
the diesel engine,tlush all lube oil passages"and be sure that they are clean and unb locked. All passage plugs should be sealed reliably and leakproof. ·-rhe tnain bearing:~\ are of cornplete suspension- support type"Since the main bearing caps and cylinder block are rnatched to bore.Jhe matching marks are both on the bolck and main bearing ~aps.Misplaccnlent or inverted installation,when assembling,are prohibited.The Inain bearing shells are made of high- tin aluminiurn-base alloy.
Check the ring end ,gap before assemblinJ!. the pi,st()~ ring.~rhe Ineasuri~g this gap is .reconlmended as follows:Press .down the method, piston ring evenly into the cylinder Jinerby 15--20mm ft:Q~the top surfa~e of liner. Measure the clearance with a feeler gauge.In nonnal- case,the 2 meas;urin~ Fil. 7 Meuurement of piston ring end gap 1. Tbldmess leeler(puge) 2. Piston ring 3. CyUnder IiDer value should be O.2·--0.4mln(Fig.7).ln case the gap value is less . enlarge it by a fi.le.
nlarks on both the connecting- rod and {;onnecting- rod cap in order to avoid .naking Qlistakes. 'fhe connecting- rod bearing shell is Inade of steel \vith high tin aluminium alloy.When the cJ\~ar3nce between the connecting- rod bushes and crankshaft ;oumal exceeds the specified value after wear'n~~ or severe stripping and burning occur on their surfaces,they must be renewed in pair. , r)urin.
There'is a thrust flan~e at the front end of camshaft,and a thrust plate of camshaft is located at the front end to control the camshaft axial movin~. 1 The lube oil is delivered to the camshaft bushings separately through the main oil line.Before assembling the front bushing of camshaft, check whether the oil holes on the bushing and oil passa~e in the cylinder block communicate with each other. As the camshaft gear is engaged with the driven gear o·~.the oil pump.
Special tools are necessary tor dismantling or assembling the crankshaft timing gear.The camshaft timing gear can be got out by two bolts M8 on the gear spoke which are turned stag,geringly and evenly.The timing idler is located on the cylinder block by slide fit.The injection pump timing gear is assembled on the timing gear seat which is fixed on the camshaft of the injection pump.Whenever three bolts setting the injection pump gear are loosened,the injection pump gear can be drawn out.
'fhe inj-ectionpump has been calibrated by the manufacturer.Be sure not to dismantle it at \vill. When the. dismantlementrepairment and adjustnlent are required,it is t()rbidden to inter("llan~e'the -pluger sets-and discharging valve sets,and,
the safety valve while the oil tilter loses the function of filtration,so it is necessary for the cartridge to be cleaned or replaced regularly accordin~ to. the maintenance. ..---IO .____'1,ih.IIJIii.'IIi..... 11 14 4 Fig. 11 Lubricating s)'stem 1. OU IUIIlp 1. Stralaer 3. Lube 00 pump 4.. Piston and cOnDectiDg- rod assembly and cyUnder Uoer 5. Lube oil ftlte.· 6. Gear traiD 7. Oil pressure puge 8. Rocker arm 9. Valve push rod, valve tappet and block hole lur tappet 10. Rocker ann shaft 11.
IX . Coolin! System The cooling system is a forced cir,eular water cooled type,as shown in Fig. 1 ] 2. '[he systern consists of a radiator, water lhn,thermostat punlp.. cool ing ,/ and diversion hood"etc. 'fhe cooling water,pumpcd fr0l11 the radiator into the cyJinder block water gallery .Jlo\vs tangentially and round to the cylinder IIner"then up to the c.ylinder head. The hot water from the front end of cylinder head tlO\VS . Fig. 12 Coolina. system back into the radiator 1. Radiator 2.
':X' • ,Electric; System The electric system is composed of the battery,starting motor,dynamo,electrothermaJ plug, starting button and instruments,etc.,as shown in Fig.13. The parallel excited silicon rectifYIng dynamo model JF 11 comprises the three - 8 phase 9 = Fig. 13 F;lectric system 1. BaUery 2. Starting motor 3. Wire 4. Glow plUI 5. Preheating and starting switch 6. Galvanometer 7. Ignition switch 8. Regulator 9. Dy~mo alternator and silicon diode rectilier.
SECTION 6. FAULTS AND REMEDIES FOR DIE'SEL~ENGINE I .Hard or refuse to Start (see Table 4) Table 4 ··.·-----·-----··--·-··-·-f·--··-···-·- . Causes .- ....•.•.. ,.. - ' _ _-_ -.-"-- _,- -----_ _--,-,_.~ _,"".- - -.. •.. ,----_. --- .._ 1.Fuel fitters and fuel pipelines bolcked. ,I ~----.-~.,,- _-_ _ _-.-._---_ 1.Clean. -_._.I ~- .--. .. _._ _-._ ---._. Remedies -.--, .•.... 2.Exhaust air and· tighten· all fuel pipdline connector. 2.Air trapped in fuel system. 3.
ill.Smokio2 Exhaust (see Table 6) Table 6 Causes Remedies 1.Engines overloaded. I.Reduce the load properly and in caSt~ of unsuited Inatching. adjustment should be Inade. the injection pressure and fuel spray. Replace 'then in case of damage. 3.Use qualified fuel. 4.rv1ainly caused by unqualifiedfue'linjccto~~ incorrect advanced fuel injection angleJeakageatcytinder'hcad gaskets and low compression pressure.Remdy~it1· accordance with specific problems. 2.('ht~ck 2.
MANUFACTURING UCENSE: XK06 -205 -00141 PRODUCT STANDARD:Q/321284 JCA03(35) -2002 NO. OF EXPORT UCENSE FOR QUALITY: 2000112013 UCENSE APPROVAL DATE: OCT.