YANGDONG SERIES Y85 Manual
~®
SERIES
Y85
DIESEL
ENGINE
OPERATION
&
MAINTENANCE
MANUAL
YANGDONG
co.,
LTD.
THE
PEOPLE'S
REPUBLIC
OF
CHINA
FOREWORD
Series Y85 multi-cylinder diesel eneines
are
ideal
power
units for Iieht vehicle,
aeromotor,small
tractor,air
conditioner
in
bus,eenerator
set
and
eneineerine
machinery.
The
normal
and
reliable operation
and
lone service life
of
the
eneine depend
not
only
on the
manufacturine
Quality,but also on
the
reasonable operation
and
correct
maintenance.
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,it
is
possible
that
the eneine supplied
is
somewhere
not
exactly the same as one described herein.Please pay attention to
that
when
readine
the manual.
Warning Notice
1.[t IS strictly forbidden to use inferior
and
dirty diesel fuel
or
lube oil. Please choose
to use fuel
and
lube oil with stipulated
number
accordin2 to
the
instruction.
2Jt
is
strictly forbidden to leak
out
from afl intake system(air filters,pipelines
and
connectill2 components).
3.lt
is
strictly forbidden to have
hard
water(well
water
or
soprin2
water)as
coolin2
water,lf
necessary to apply the hard(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
startin2
i'lterval
(more
than
2minutes) strictly.
9.
It's
amust to maintain the diesel en2ine techanically
in
the allotted time.
lO.Unskilled workers
are
not allowed to dismantle
and
assemble
the
en2ine
and
its
spare
parts.
CONTENTS
I.Configuration and Installation Dimensions
of
Model YND485Q Diesel Engine I
II.
Confi,lluration and Installation Dimensions
of
Model Y485 and YDI485 Diesel Engine
II
Ill. Confi,lluration and Installation Dimensions
of
Model Y385 Diesel Engine'" III
N.
Perfomlance Curves
of
Model YND485Q Diesel Engine N
V . Performance Curves
of
Model YD1485 Diesel
Engine··········
..
· V
VI.
Performance Curves
of
Model Y485 Diesel
Engine'"
VI
VII.
Performance Curves
of
Model Y385 Diesel Engine
VII
SECTION 1. DIESEL ENGINE SPECIFICATIONS AND
TECHNICAL 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
.Maintenance after every ]00 accumulated operating hours
3-1
II1
.Maintenance after every 500 accumulated operating
hours'"
,. 3-2
IV
.Preservation and
storag~
of
engine ,3-3
SECTION
4.
ENGINE ADJUSTMENT
I . Adj
~stment
of
valve lash
..
4-1
II
.Adjustment
of
injection timing
..
4-1
III .Adjustment
of
injector 4-2
N.Adjustment
of
lube oil
pressure'"
4-4
v .Adjustment
of
injection pump 4-4
VI
.Adjustment
of
decompression
ann
lash
"'4-4
SECTION 5. CONSTRUCTION
OF'
DIESEL ENGINE
I . Cylinder head
5-1
II .Cylinder block 5-2
ill
.Piston and connecting
rod·········
5-3
IV
.Crankshaft and flywheel ..·..
····
5-5
V . Camshaft5-5
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
DIESELENGINE
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
.Engine running-away'" 6-3
190
194
•
oc.L.I"\<Ou"'IO
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View
B
!cylinder
block)
A~
~~~~~Ct
~
~
~
C>
~
View
A
(cylinder
block)
510
160
697
~II/IIII~~~£
~jj
..
t¥jill
Y"l==n
~II
~l=fMMWI
~
~
I
a.;
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IBI
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.....
I,
Configuration
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...
~
~
~
~
~
~
~!
I7777
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
o
>--
~
...
~
~
~
co
,.,
...
View
A
Icylinder
bloCkl
--
View
B
Icylinder
blockl
Di~ensicns
of
water
inlet
)01
~~~~~NCI
ClN~~~~V'"!
S?-~
1-M10
::;
;
j
~
J
~I
17
/ / 7
7J
co
~
~
-r
, =
~
...
189
Exhaust
outlet
centerline
11
¢60
494
65
190
,,,~---~~~I
~
Inslallaf,on
dimensIOns
of
engine
base
foot
1.10
o
{
oI
s
[rankS
haft
centerli!}L
i
~
,.,
....
4-¢11
rI
12-M10
Evenly
distrubuled
5805
5637
681
[onneding
d:"lenslons
of
flywheel
and
its
houslrg
15'
=
....
,.,
..
=::I
ll.
Configuration
and
Ins
t
allation
Dimensions
of
Model
Y
485,
YD
1
485
Diesel
Engine
190
I
1S'
---
s
Comcctirg
dmcnsions
of
Ir,whecI
and
ns
houshg
•
supply
be<;m'9
60200
according
locuslomer's
~
roquosl.ThcdlSforcc \
~
Wlweenlhe
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
A
Icythdcr
bIodcl
~~
¥'eN
B
IcyII-dcr
bIodcl
~
Oinensbns
at
wdlef
inlcl/outIct
~I·rq,
r·
III.
Configuration and Installation Dimensions of Model Y385 Diesel Engine
Tr
('t
)
550
500
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
30J
Ne
(kw)
25
20
260
ge
(g/kw
•h)
250
240
230
220
.l!
~
~
..-/'
/
---
./
v
~
~
--
L-
V"'"'
VV
/
'/
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
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