~® SERIES Y90 DIESEL ENGINE OPERATION & MAINTENANCE MANUAL VANGOONG co., LTO.
FOREWORD Series Y90 multi-cvlinder ditsel eneines are ideal power units for lieht vehicle, aeromotor.small tractor,air conditioner in bus,eenerator set and en2ineerine machinery. The normal and reliable operation and lone service life of the eneine depend n'ot only on the manufacturine quality,but also on the reasonable operation and correct maintenance.
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 accordioe to the instruction. 2.It is strictly forbidden to leak out from an intake system(air filters.pipelines and connectin2 components). 3.It is strictly forbidden to have hard water(well water or soprine water)as cooline water,If necessary to apply the hard(water),soften it first. 4.
CONTENTS I . Configuration and Installation Dimensions of Model YSD490Q Diesel Engine I II .Performance Curves of Model YSD490Q Diesel Engine ..........•..................• II SECTION 1. DIESEL ENGINE SPECIFICATIONS AND TECHNICAL DATA I . Specifications of diesel engines .............................••.. ... .•. ••• •.• •.. II . Specifications of the main accessories··· I-I .........•.•.....•... 1-2 III . Main technical data of diesel engines .........•.....•..... 1-3 IV .
v . Camshaft " 5-5 VI . Gear transmission system 5-6 \'lI . Fuel and governing system " 5-7 VIU • [.. ubricating system 5-8 IX . Cooling system X. Electric system ······5-10 5-11 SECTION 6. FAULTS AND REMEDIES FOR DIESEL ENGINE' I .. Hard or refuse to start .........•.. 6-1 . 6-1 II . Power j nsufficiency ......................•••.• III . Stnoking exhaust 62 IV . Knocking noise in engine 6-2 V . Lube oil insufficiency or no pressure··· •..... .•. •........... 6-2 VI .
lxhdUSf viJaet Ceftl~me 215,', j)4.5 ~ CD f"t"I'--- -0. ~ r'-OIIJ'"\ ('-.J ~ ~b I Connecting dimp!1sions of flywhe~l =~----,fl4 135 I 134 17Y - - - - r - n 9 214.7 i 201 and its hDirdng ~-J.Jf 530 ~116H1r:'O~l Exhaust outlet centerline Vie", B View~ I.
....- .....- .....- -.....- ....- - - . - -.....- .....- ..... Me (N·m) 160 ISO 35 ge 25 (glkw·h) 250 1 230 1600' n. 180Q.
SECTION 1. DIESEL ENGINE SPECTFICATIONS AND TECIINICAL DATA I .Specifications of Diesel Engines (see Table 1) Table t Model YSD490Q Number of c;"finder 4 .Bore(mm) 90 I Stroke(.mm) I CompreSSion tatio _._----------_ .... --_._-------------_ .. ---- 100 ! __ ._--------~--.------'\_.. -------_ .. _--_ 18 ........ _------ ....._----_._ ... _--------- Total displacement(L) __ Fuing order 1-3-4-2 Rated PO\\ er(kW) 37.0·~45.6 ... _~-~-_ .. - -- ._--_.._-_._.. - __._--------_._-----_.. _.
n.S~·ification of Main Accessories(see Table 2) Table 2 Nil l-Fuel injection . pump ~+ 2 I Designation I Fl" t Type r== I .. ~ovemor _ Plunger diameter(mm) ~ Series Ior BQ pump all-speed, mechanical centrifugal =t ------ 8 Single-acti;:-:----is--to-n----type---------- I ~~~!e set i F YSD490Q --------, --i_--~el d~~ pu~ ue InJec or I Specification ZCK154-S427?r CN-DLL~~~~~~~ _ • I ~.E~~t:~~!~~eh~le(~Ei) i ! _ 4 holes,
ill.Main te4:hn.ieal Data of Diesel Enline 1. Valve lash(mm) Intake valve(cold) 0.30- 0.35 Exhaust valve(cold) 0.35- 0.40 2. sinkage ofvalve(mm) 0.7- 0.9 3.Torque limits of main bolts and nuts(N· m) Cylinder head bolts 125- 145 Main bearing cap bolts 140- 160 Connecting rod bolts 100-.." 120 Flywheel bolts 100-.... 120 4.
IV' .•~it Clearance and Wear {.limit of Main Parts(see Table 3) Table 3 I I Assenbly limit' Wear linlit Designation (mm) (mm) Connecting rod journal and connecting rod bushing 0.060-0.172 0.25 2 Piston pin and connecting rod small end bushing 0.025-0.050 0.10 3 Piston skirt and cylinder liner ..._._-_..- .•_._ .. -_.•- --.._ .. _ 0.130-0. 195 '-"'-_- .. _ ~ - .• _._ _ •. _-_ - - -•.... - - - . __•... _ ·1 4 Side clearance bet\veen the .
SECTION2. OPERATION I . Fuel Oil ,Lube Oil and Cooline Water I.Fueloil Users can select the proper the ~eneral fuel.Use area in China,the ~rade fuel.Before ~ade ~de of fuel oil of fuel oil is accrdin~ accordin~ to the local ambient temperature.'.Jn to the standard GB252 li~ht dies~1 "0" light diesel fuel in summer, while in winter, use grade "- 10" light diesel bein~ filled into the engine fuel tank,the diesel fuel must be settled for a long period (normally at least 48 h).
II .Preparation before Startine ti~htness I.Check the control lever and and reliability of ali stoppin~ lever) connectin~ parts. Check control levers (speed 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 pipel~nes are unblocked. 4.
IV . Operatin2 1.00 not load the engine until the cooling water telnperature is over 50°C and the lube oil temperature is over 40 "C . The engine should not be operated undrer rated operated under rated output before the outlet water temperature reaches approximately 80°C . 2.1ncrease or decrase the engine load and speed gradually and evenly.In normal case,do not load and unload the engine suddenly. 3.
SECTION3. MAINTENANCE For reliable engine operation with less wear and longer service life,all maintenance work must be carried out as follows. I . Routine Maintenance I.Check the oil level in the oil SUlnp and it should be between two marks on the dipstick and near the upper one.
6.Check the tension of the fan belt,and readjust it if necessary. 7.Fill the nipple of cooling water pump bearing with ZG- 4 calciumbased grease with a grease gun. 8.Clean out the dust in ,intake manifold'lclean the inside of the aircleaner,brush otT 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 iniection.lf necessary..
8.Check whether the thermostat is in good order.Examine the water dropping out from a weep hole of the water pump. It is necessary to renew the water seal,if flowing out too much of water. 9.Check the wiring contacts of the electric equipment to see whether they are connected firmly and well.Bumt marks should be removed. 1O.After every] ,000 accumulated operating hours,add the following items; (1 )Make an overall check on all parts and components.Make necessary adjustments and repairs.
4.Pour some dehydrated oil into cylinder through injector - assembled holes on the cylinder head,and turn the crankshaft to make sure that the piston,piston ring,cylinder liner and valve seat are alJ covered with a layer of this oil. 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.
SECTION.4 ENGINE ADJUSTMENT I ..-\d.iustJnent of Valve I.J3sh When the engine is maintained and repaired.,it is necessary to check and adjust the valve lashes.'fhe recommended nlethod of adjusting the valve systenl and valve lash is as follows: 1.Remove the cylinder head cover.(~heck and tighten the nuts fastening the rocker aml shaft stands. 2.Turn the crankshaft to rnake sure that the piston of 1st cylinder is at the conlpression TDC position.
2.Check the timing mark on the inspection window of flywheel housing to see whether it aligns with the correct gradulated mark of specified advanced injection angle on the flywheel rim (or on the crankshaft pulley). 3.ln case that they do not match \vith each other,the advanced injection angle can be adjusted by removing, off the front cover on the tinling gear housing and loosening the three screws fastening the injection plunp tilning gear support(see tig.2).
check a fauly iniector,Le.loosen the nuts of iniection pipe from the injector of every cylinder successively,and observe the exhaust smoke. When the cyl1nder with the faulty inlector stops firing~black smoke wouid disappear and engine speed is not appreciably affected or not affected . at all.It may also be checked by listening to the chattering action of the injector of every cylinder \vith the flywheel rotating.
guiding surface of the needle valve and nozzle body is not smooth enough,it may be lapped with a little bit of clean fuel oil,then clean off any metal particulates in clean fue1.While lapping of needle valve with nozzle body..never knock the needle valve against the body. IV . Ad.iustment of Lube 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 may be higher slightly). f\fter adjustment.
SECTION 5. CONSTRUCTION OF DIESEL ENGINE I . Cylinder Head When assembling,cylinder head is fixed on the cylinder block with cylinder head bolts.A torsion spanner should be used during tightening the bolts.T'lle bolts are tightened several times in sequence shown in Fig.4 until they reach the specified torque Bmit.After dismantling and asseJnbling the cvlinder head.it is necessary to shut down the engine \vhen first wanning up period is over.
.A fier service for a and period long regrinding many times. the sinkage '\NiH increase. When it exceeds 2.0mm., replacing the valve seat should be considered. Check valve the trequently.T'hc lashes adjusting recoITunended lnethod is shown ,Fig. 5 on V'alv~ sinkage paragraph I of Section 4, If the lashes are too largc.,it lnay affect the correctness of valve tinting and the noise level o'f valve device dses.On the contrarY'tit rnay cause leakage or valve burnt out. II. .
the diesel engine,flush all lube oil passages,and be sure that they are clean and unb locke~. All passage plugs should be sealed reliably and leakproof. The main bearings are of complete suspension- support type.Since the main bearing caps and cylinder block are matched to bore,the matching marks are both on the bolck and main bearing caps.Misplacement or inverted installation,when assembling,are prohibited.The main bearing shells are made of high- tin aluminium-base alloy.
Check the ring end gap before assembling the piston ring.The method measuring this gap is recommended as follows: Press down the piston ring evenly into the cylinder liner by 15-20mm from the top surface of liner. Measure the clearance with a feeler gauge.In normal case,the 2 measuring 3 Fig. 7 Measurement of piston riog end gap 1. Thickness feeler (gauge) 2. Piston ring 3.. Cylinder liner value should be O.2--0.4mm(Fig.7).In case the gap value is less ,enlarge it by a file.
marks on both the connecting- rod and connecting- rod cap in order to avoid making mistakes. The connecting- rod bearing shell is made of steel with high tin aluminium alloy.When the clearance between the connecting- rod bushes and crankshaft journal exceeds the specified value after wearing or severe stripping and burning occur on their surfaces,they must be renewed in pair.
There is a thrust flange at the front end of camshaft,and a thrust plate of camshaft is located at the front end to control the camshaft axial moving. 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 passage in the cylinder block cOlnmunicate with each other.
Special tools are necessary for 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 staggeringly 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.
The injection pump has been calibrated by the manufacturer.Be sure not to dismantle it at will. When the dismantlement,repairment and adjustment are required,it is forbidden to interchange the pluger sets and discharging valve sets,and be sure to keep clean when assembling. The all speed mechanical- centrifugal governor is applied. The governing handle can be operated to control the speed of diesel engine.
the safety valve while the oil filter loses the function of filtration,so it is necessary for the cartridge to be cleaned or replaced regularly according to the maintenance. ___......... r~........--- 10 11 , 14 4 Fig. 11 Lubricating system 1. Oil sump 2. Strainer 3. Lube oil pump 4. Piston and connecting - rod assembly and cylinder liner S. Lube oil rllter 6. Gear train 7. on pressure gauge 8. Rocker arm 9. Valve push rod, valve tappet and block hole for tappet 10. Rocker arm shaft 11.
IX . Coolin! System 'The cooling system is a forced circular water cooled type,as shown in Fig. 12.~rhe -1 system consists of a radiator,water pump,cooling fan ,thermostat 2 and 3 4 diversion hood, etc. The cooling water,pumped from the 5 radiator into the cylinder block water gallery ,flows tangentially and round to the cylinder liner,then up to the cylinder head. The hot \vater fronl the front end of F'ig.12 Cooling system cylinder head flows back into the radiator 1. Radiator 2.
x . Electric System l~he electric system is composed of the battery,starting motor,dynatno,electrothennal plug'! starting button and instrulnents,ctc...as sho\vn in Fig.13. The parallel excited silicon rectifying dynarno model JFl] comprises the three ._- phase 8 9 Fig. 13Eleetric system 1. Battery 2. Starting motor 3. Wire 4. Glow plug 5. Preheating and starting switch 6. Galvanometer 7. Ignition switch 8. Regulator 9. Dynamo alternator and silicon diode rectifier.
SECTION 6. FAULTS AND REMEDIES FOR DIESEL ENGINE I .Hard or refuse to Start (see Table 4) Table 4 Remedies Causes 1.Fuel filters and fuel pipelines bolcked. J.Clean. 2.Air trapped in fuel system. 2.Exhaust air and tighten all fuel pipdline connector. 3.Advanced fuel injection angle incorrect. 4.Fuel spray abnormal. ~ 3.Readjust it according to specifications. 4.Readjust fuel injection pressure according to specifications and clean or replace injector needle valve sets. 5.-Conlpression preessure low.
III.Smokinl! Exhaust (see Table 6) Table 6 Remedies Causes 1.Engines overloaded. 2.Fuel injectors not well atomized 3.Fuel unqualified 4.('ombustion incolnplete I.Reduce the load properly and in case of unsuited matching. aqjustlnent should be lnade. 2.Check the injection pressure and fuel spray. Replace then in case of damage. 3.Use qualified fuel. 4.Mainly caused by unqualified fuel injectors.. incorrect advanced fuel injection angle,leakage at cylinder head gaskets and lo\\' compression pressure.
VI.Overheatin2 of En2ine (see Table 9) Table 9 Causes Remedies I.Temperature of cooling water too high; (1 )Insufficient cooling water or vapor lock in (1 )Fill the rank to make cooling water level water pipes. higher rhan the center line of water pump. (2)Bad working state of water pumps. (2)Check water pump clearance and tightness of (3)Water scale in cooling systems too thick. (3)Remove it. belts. Eliminate leakage. 2.0il temperature too high: (1 )Insufficient or excessive oil.
MANUFACTURING LICENSE: XK06 -205 -00141 PRODUCT STANDARD: 0/321284 JCA06 -2002 LICENSE APPROVAL DATE: JULY 2,2003