Rotek Y80 series Manual

SERIES Y80 DIESEL ENGINE
OPERATION & MAINTENANCEMANUAL

FOREWORD
Series Y88multi .. cylinder diesel engines are ideal power·,' units for liebt vehicle,
aeromotor,small
tractor ,air conditioner in bus,aeneratorsetand ensdneeriD2machinery.
.
Tbenormal and reliable operation and lone service lire of tbe enRine depend Bot only
on the manufacturine quality,but also on the reasonable
operation~ and ~orrect
main_nance.
In order to provide the detailed description and instruction of tbis eneine for
operators to manipulate
itcorrectly in sbort time,we offer this manual which brietly
describ~ the performance of series Y80 diesel eneines to operators,maintenance workers
and relevant maneers.
Since the construction
of this eneine is sub.iect to frequent improvement and
development durine production aod practice,it
is possible that the eneine supplied is
somewhere not exactly the same as one descri.bed herein.Please pay attention to that when
readio2 the manual.
\

Warning Notice
1,lt ~'f§4riC;tlY (orb:idd~~ to, use inferior and .dirtw. die$elfu~I.· o~ "labe, oiL}P'leas~ ~"oose
to use.f .... 8tUl:.Jllbo"oil,.witb stipulated Du,mber aceordinzto: the instruc:tioD.'
2.lt; . is ~stritt~ ,; forbidden·· to leakDtltfrom: 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)8s "CöÖline
water.lfrt~cess~ry'~to'~aVPtV· the' hardtw~ter),So~il it 'first.
.. ··4_1t\s~tric~yr()rbidden lö start· under tbe >~ircu"*stanc~ oflatk 'oil~be oil orWiltet:-
5.It isJ~{~ii~il~~'f~;rbidd~n't~ oper~te at overload ~r"under othel
9
co~ditions 8eainst the
ruJes •.
6.It is strictly forbidden to re2ulate tbe fuel io.iection pump at will.
7~lt is strictly forbidden to chanee the diameter ofthe pullev.
8o)To control tbe startio2 time(less than J5 seconds) and the startin2 interval (more
than 2minutes) strictly.
9. It's amust to maintain the diesel eii2in.e techanicaJlv in tbe allotted time.
lO.Unskilled workers are not allowed to disillantie and assemble the enf!ine and its
spare parts.

CONTENTS
I.Configuration and Installation Ditnensions ofModel Y480 DieselEn~ine I
11 .Configuration and Installation Dimensions 01" Model' Y380 DieseliEngine 11
III .Performance Curves of Model YD480 I)ieselEngine .., .•. -\6" •• ,,' •• ; ,~" 111
SECTION 1. DIESEL ENGINE SPE,CIFICA1'IONS AND
TECHNICA.L DATA
I .'Specifications of diesel engines ••• U~ He eH U u ••• ~u I-I
11 .Specifications of the main acces,sories · .. "u H.. ~ " alt 1-2
TIT '. Main technical data of diesel engines ~u *e6 ••••••• .; 1-3
N"Fit clearance andwear limit of main parts ·u ~. u : 1- 4
SECTION 2~ OPERATION
I . Fuel oiJ!lube oH and cooling water ,. "H •• "u U. floH> 2-1
11 .. Preparation before starting 8$ ""1\ ~ 0 ••••.••••••••• 2-2
111 ~ Starting ~. ".' 10 c ••••• "' ••• ".' ~ 2-2
N .. Operating "H lt ') " " •••••• ·"·2-3
V . Stopping :10 ••• "'iD •••••••••••••••••• ·······························2-3
SECTION 3. MAINTENANCE
I: .. ROtltille maintenaJ1Ce ", "" '* " ••• ••• .. <' 3-1
11 .. Maintenance after every 100 accurriulated operating hours '"' 3-1
111 .. Maintenance after every 500 accurnulated operating hours 3-2
N.Preservation and storage of engine "' " ~e. fl~ ••• ~ ~ " ., 11 3-3
SECTION 4. ENGINE AnJUSTl\tIENT
J .. Ac\j-ustment of vaJve lash ";t •••••• " '" ., " 4-1
11 .. ,\diustment of iniection tinling .., U'l .0. ,. ···4-1
III 4Adjustmetlt ot~ iniector ..•. c •••• ~e •••••••••• 4O fI." c ···4 .. ,2
I\l .Acljustl'nent 01' lube oB pressure u u· uo. 4-4
V . Adjustnlent of injection pump 9.,' .., 4 4
VI. Adjusttnent of decorrlpression aml !ash .u 0 liU ~It$ ···4-4
S.ECTION 5. CONST'RlJCTION OF~ DIESEL ENGINE
I . Cylinder head " ", .•...•.. " " Co ••• " ,,"' ••••••• .... 10." -10 "SI'" ···5-·'
11 . Cylinderblock ~ " "6c. ..... ••••• ~ ~tl " •• "c., 5-2
Irr .Piston and conIlecting rod OS".... • "............ .. "5 3
['\1 • (~rankshaft and fl)t\vlleel " ~ ~ c ••••••••••••••••••••••• ···5-5

v .. Camshaf t •...... '........ .... ......... ...•......•.•......••.•.... • ...•.•••••.................•. 5-5
VI .. Gear.tran.smission system •••• •• · •• •••••••••••• ••· •••••.•.•••.•.•••••••·•·•.• • .•. ··.•. ... 5-6
\'11 .. Fuel and- ~overning system ..•...•..•.•. , •.•..••••.....•.••.•••••.•..•.•••...•.....•....•.. 5-7
'VIII .. Lubricating system · .....•. · ••• ••• •.•••. •.• ... •.••.•.•.••.......•.••.••.. . .....•.. ~.. 5-8
IX .Cooli.,g system •..••.· .. · ·· .. ·.• ••• ..••.. ..•..••.•.•..••......•••... . .. ,.......... 5-10
X .. Electric' system ...... ... ......•...........•........ ..••.••.•......•...•....•.. ••.......... 5-11
SECTION 6. FAULTS AND REMEDlES FOR DIESELENGINE
I . Hard or refuse to start .....••..........•....•. ~.. • .••...•. ~ .•.•.•.••.•...• '.. ~........... . .. 6-1
11 .. Power insufficiency ,.............................................. ..•••.....•• .•.•..6-1
Irr . Smokin~ exhaust ...•.......••.••.•....••••• ••....•...•......••.•.•.... .......•.... .6-2
IV .. Knockin,g noise in en~ine .....••...•..••.•••..•...•.•....•. ,.. •.. •.• ••. .6-2
V . Lube oil insufficiency or no pressure~·· ....•........•.•••.•.•••.• ~ ...... ••. 6-2
VI .Overheating of engine .....•...........•..••..... .• ~ '.•.· ~. ••• ...••. ••...•......... 6-3
W .. En~ine running-away············ .. ····· ·6-3

578
V_ A lcyIi'lder bIockI
6-MIO
~
....
....
~
lri
~
'"
~
View B lcyIi'lder bIockI
6-MIO
~.
475
561.5
-
DinensIons ofwater inleIIoutlet
74
4-1117
424.5
Oonkshall cenlerIhe
lnstc*Ilton dl'nensions cl enghe belse lool
Connecflng dinensklns ofllywheel and Is housi1g
I·
I . Configuration and Installation Dimensions of Model Y480 Diesl Engine

525
V_ AlqI_1IIeck)
~
i i
~
C:Soop __
...
--
:;;
"1_ B(<yIl ..... bIodtl
~
LiI
~
4/8
___ :zoo
.llO
375
eo.-tiac ......... ora,- .... ilI-..c
SoppIr_.flO2OS .H2HB('-)
-.."'...-'.
~1bedi_
-'*- ...- ..'"
r-or -. ..
_or.lwa,-i1
n. Configuration and Installation Dimensions of Model Y380 Diesl Engine

Me
(N .. m)
104
96
88
Ne
(kw)
20
16
Me
_l.-
V
~
~
r--.......
~
V
~
~
V
r---....
~
~
..
~
~
----
------
~
.......
Ne
-----
V
~
~
/"
~
V
~
~
r-.......
~
ge
Y'
,
l/
~
r---.....
~
_l-..---
~
-.
ge
(glkw.h) ..
255
245
235
I I. I' I I. ,
16001700 18001900 2000 2100 2200 2300 2400 2500 2600 2700 2880
mPertonnance Curves·of Model YD480 Diesel·Enging
m

SECTION 1. DIESEL ENGINE SPECIFICATIONS AND
TECHNICAL DATA
l.Specifications of Diesel Eneines(see Table 1)
Table 1
195
587 X 494 x 623
185
676.5 X 494 X 608 687X494X61O
587X494X61O
_~odel L y~~Q ~ y3_~QT __ ~- __ Y48Q __ ~ __ Y~~Q9-----,-_~.ll<L_i_X_S.@}8()_ YS380 _y~~ '_ XS~-t80 J Y~.!A4~Q
Type I Vertical,water-cooling,foUr stroke,direct injection,dry liner -: Vertical,water-cooling,four stroke,direct injection ,wet liner
.·.------------f-.--- ... ·_--.---.-.- .. ------.---- .. - _ .... ....:.. . -. __ .~ __ .. _~ .~._ .. _l __ . .. - --',----.'- ... _ .... ~ .. ~ .. _---._- .----- ._-- ... _ .. _ ... ~ _..... ,., __ "
Combustion Chamber Type I Vortex chamber Direct injection Vortex chamber
__ -.- .. ---'--~------".------t-- --- --.' -0 •••• ' •. • ••• __ • __ " .••• ._ __ .. _ ..••• ..•. __ •. __ .L....... -'.'. . -- __ . __ . __ •. __ ._--- .• _ .•. - _.-_._-~ . ._~
Nwnber of cylinders j3!4 ; 3 i4
.-~~=~f_=----~~=-=-~~--~ __ -~~-~~==~_~=:==--=;~~:.:=~=~is=:---= _" 90
--~rnz:~~)--+---------lj57----~--~21~-----------l809 L
l8
1.357 1.282 i ~.~~9 --------..809---
------------------!--------------------------"---------------- ------------ - - --,.------- -----r--------------- -- ---------- __ L_ -------------
Firingorder I 1-3-2! 1-3-4-2 -t
l
1-3-2 I 1-3-4-2
--.---.----- --+.----.-----.- --.---.------~~.--.-_:_---.------.-, .. ---._-._-.---.-,_.-.-------- .. - .. ----" ._--- --',.--- .. ~ -- --.---4-------.-------- -.', -'._-_. --r ._.- -_ .... _ .. _- ...
z: __ Rate4power(kW) l J~-20.5 L ~O-~ ~I~-':-~9~~c_l--l0--=~~--' 10-:-2~~~ L __ I0-~~ 10-28.5 10-29
Rate4spee«rlmin) l2200-3000 i - 2200-3200 I2200-2800 2200-3200
---------~----f_____------------ ---------- ------- ~ J --------------------------- ---------------- - -- ---- -------
Max.torqlll(N.m) i - ~43.4
------------------+-----------c------------,------------------------.-------- ---------- -- ----------- ------------
Min.spe~cfuel~n i ~274.7 i ~278.8 i ~272 I 247 ~272 ~270 ~269.3
___ .JL ~~ +-----------.J-----------l----- 1_______ _ _ _
-~::C +~ lo±lßOOOiwid;~Jk.O';"~i8± tmoo,-! I2±U>llO\~~o.;;;;;:-- . -,O± U~iOOC(wnhA;;''''';; 0;;,';;;: lS± 112800: - ...
(before1'DCXf(I'JIII)! 16±112600. 15±1124oo. 14±1/22oo iI8±1126OO. 16±112400, 1S±1122OO i16±112600. 15±112400, 14±1/2200
----------r-------------------------------- ---------t------------ ------------ ---- ----i- --- - -------------- ---------------- ------- - -- ---------
InjectionPresslre :13.2±0.5 ! 19.6+0
1
-: 13.2±0.5
~t=~:-= .. ~===_===_===.c-=~~ __ :_~==-====~=:_ ..... _
CooIing metOOd ! Forced _ water Cooling
-----------------+--- ---------- --- ----- -------------------------------------- -- ---------- ----- ---
_._~tarting melhod __ ~---------- ~~i~-- _
____ Ne! _~kgl-.:__ ,165 , 1_ 95 • ---------------1--- _
OveraU dimensioos
(LXWXHXmm)

II.spedfication of Main Accessories(see Table 2)
Table2
4000
160
8
YSAD3S0
No accessory
7.5, 7. 6.5
I.Iw or BQ pump
2.5
1300
IS
J0810H
3000
SO
5
PF68509
ZCK154S423 CN-LLA154S423
Four holes <lJ0.23
19.6+0'
YD4110
QD13l5A, D138Y
Iower inertia series 5
12
Rotor
Series DC motor
--_.,--, .. __ .. _,-_._--_ .. _._-,---
Si~~~~tl!!e,~~r ~lc:ment
K13l7A
0.4
-- ._---,---_. __ __ ._-_.
___ C_c~~!u~!:,:o~'!.te:s~~~~~uet~n
4000
160
S
.
._S~~~l!et.!!YiJ.t.g~l~un~ (\ynaJ1.1()
JFll
350
14
__ .~iggI~. ~!!!!c;J!lI~ 1l_~~I!~.
C0506A
- -- ... _-_ .... _-.- - .. - -_._ .. ~--_._._ .. ,--,_.-
Single stage,paper element
7
S pecification
Y3S0T Y4Soo Y 4S0 YS,A4S0
,IW or BQ pump
.. - ----
i\!I~s~-,m~c~l!I!!~~lcentrifl1j81
Shrouded
10-12-65
J070SorJ081O
I or BQ pump
P21
-_.. ._-_.' ..
_ ~i!lgl~JIO!e,pi~I~~~p~,?:~S 1
I
13.2±0.5
QD1322, QD13l5A, D138Y, QD138C
1·
." -'-'----',- ',-"'-
l.80r2.5
YS380 YS4S0 YSA480 Y3S0
Type
Designation
______ Vol~..se(_"L_ _ _L. _
_ .,-_ ____-R~eri~)
"._---_. __ !~- -
Model
Power(W)
-~ . ---.----~-.- .... - --' ---. .- -._- -1""--_._-------- • _. -+.--.- .. ------ ... --.--. -
Voltage(V)
.---'.'_ .. ---.-_ - _.,._._"---~ --_ .. _. --.
___ TYK _
Model
• .-_.~-_ .•• _ ••.• _- _._--- .,._+. __ ._._.-
Type
---. __ ••.. -~" --._---_ ... ,*. __ ._ ..
Model
__ ..• , __ •••• , __ ., __ •• _ • - _ •• __ ~ '-0""-
T~ __ .
Model
.. _... -_ ..---.- .... --.+.-.----- -
:r~
Model
pump
Governor
,-_. __ ._._-- .. -_.- --
_Plungerdillltlel~(rrtl1l) _
_ .!IJ~I ~~ive,ry.YJJI~p_
Model
"... _._-_ .... _ ... -_ .... --_ ..
Nozzle set
.~--_. --_._- ---
Dial\leter ofnozzle hole(mm)
--"" ._-_._-_ ...•.•.•. _._ ... _-_ .... - '.""f- - - ._.' ------ ..•. ,-- ...
_______________ !nject~~_pre..!~~~
--_!.~
.s~5r!~i~L _. .________ 1300
_~~C!ty(U~i!1L _ __ 150rlS
_ ... _ .. __ !!~s~ur~J'll) _
Type
•. _._- ._ ..... _-----_ ... -
Speed(r/min) 3000
~~_~:-~-c;;~itY<~~in) __ -_~-' ----~=-~_- SO
______ .. __ ~~~I1IL_ 5
• InJe_.
. Model
Lubepump
Waterpump
Fuel injector
Fuel injection
Starting motor
5
2
6
Dynamo
7 Fuel filter
-_ ..... ---_. __ ._ .. -
S Lube oil filter
9 Air filter
10
Electrothermic
plug

rn.Main technicalData of Diesel Enldne
1 ~VaJve lash(mrn)
Intake valve(coJd)
Exhaust valve( cold)
2. sinkage ofvaJve(mr~)
0.20--- O~25
0.25-··- 0.30
O.7~' 0.9
3.Torquelimits ofnlain bolts and nuts(N • "1)
CyI;indefhe.ad bOlts 150""-' 170 (Y380, Y380T, Y480G, Y480,
YSv;\480~ YS480" lT~}\ .. 480, )'S380)
175"~"''i95 (YD480,\ YS4A..D380)
Main bearin~ cap balts
Connecting rod bolts
Flywheel. bolts
4.Temperatureand pressU:Te limits
(1 )Exhaust temperature(~C )
n~ 3200rpJn
3200rpm>n>2600rpm
n~ 2600rpm
(2)Lube oiJ teolperature(OC ')
110---·- 130
50'-~" 60
60"'-~ 70
t~ 620
t~ 600
t~ 550
~ 100
(3)Lube on pressure in ~fIain Passage(Mpa)
At norrnal operat;on
At nlin. Steady Speed
5.Govemor Characteri.stics
Mift. idling ste~dY~Speed
Steady regulation
0.2"" 0.4
~ 0.05
-~ 900rt.,-m -'
'1',;<
5 ~/o -- 10 ~~t;
1.,·3

N .Fit Clearance aod Wear Limit of Mai .. Parts(see Table 3)
Table 3
0.25
Designation
9iCrankshaft-mainjoumar andmainbearing
, 1
:Assenbly limitI Wear limit
!(mm) I
,-
... _ .. - j--' .... -_.- _._-------- .- .. - _. .- --_.- -.-_.-- -+ .. _._- ------_. ----!--- ----_ .. _---_ .. -
1!Connecting rod j6urnal and corinecting Tod bushing 1I 0.040-0.0891' 0.20
i
, ~._.-i-_--- '-' ---.-------- .. -.-~-. ,.---- ---.----- .. --.-----~ ~.,..,.,...- .. -.--" -- -4----- ---.- - --t------. -"--
21' Piston pin and,c<?unectingrod srnall endbushing .I0.025-0.046 l0.10
-- ; ------- ---- -------.----- ----- -----.---------- -.--- -- f . --- - -+----------
3IPiston skirt and cylinder liner !0.106-0.160 i0.46
-T---- .-- .- ... ---. -':--, -:- .. "-,- . -- .... --.---. ---.--- .. - . .,.,- -.-.--~ ..... - .--:,.- ..... --·--···+-··---·-·---···---r··-·---- .-.;-
4iSide clearance between the 1st ring and its groovt: .i0.060-0.092 -: 0.20
, . I . . ,
I ..... __ ... _. .... _ ... _._ .. . __ .. _ .... _. ._.. i1
-.---- ','------ -_. _.... --···-'r------····--··---·--_··· .. _. ----'-1--
5 :Side ckarance between the 2nd ring its groove j 0.040-0.072: 0.18
.-~- .. l- .. _.'._'_' . '_" .... .:.......:----J •.,. __ ~ __ ~ •. __ ,_, .. __ .: •. __ "_' __ '~"_~_~ __ ~"" .. ~~_)i'::": ' __ ' " __ " __ ':~""";""l""".~ __ '_:' _....l,. __ .... ...c._ ... ~. J .... __ . __ ._ .... ,.,...-,- ~ .... __ .....
, I '
.61 Side. cI~rapce. 9P,ween the qi! scraper ring ilnd its .groove i0.030-0.067 j0.18
---"'-" '---" .. - .. - --.--.' - -. '.'--- -.--- .. -----t---- .. -. -··--····---·-1··--·--··-----·--
7igap of thtHst rittg I0.250.:.0.400 I1.60
.... -+.- .... - .. --.- - ... -- -. --.- - .. . .. -'.- '-". - -- -'-'- '-',"-- .-- ... . -----------c-- .. -----------.-- .
8igap of tlle 2nd ring 811d oi! scraper ring ! 0.250-0.400: 2.20
I!I ~
•• --1-. • _._ .•. , __ ._._._. __ .. ,_._"_'_" .... __ .. _. __ .v_ .. ~ ... __ .. _ .. -. . ...... --.-.-.--.- .. --_._. -~- "1 ' __ .. _.-~ •• _ .. _._ ..•. ._ ...•• _ ... _.... _._- -- " .• _••.
t ' !
,0.070-0.139 1
._L
10 ,Carnshaft'journal a~d bushing 0.050-0.100 0.18
11 fldle genr shaftjournal and bushing 0.025-0.075 0.18
_____ L .. .. __ .. _. _
12 :Intakc valve stern and valve guide 0.025-0.069 0.15
... __ ._;-_ .. --_._ .. -- .-
13 ;Exhaust valve stern and valve guide
i0.040-0.077 0.15
t4Rocker arm silaft and bushing 0.016-0.061 0.20
_._,. __ . __ .... _ .. _. .. L.._. __ ~ ..
15 !Axial cJearancc of crankshan
16 :Axial clearance uf camshaft
0.075-0.265 I
0.050-0,220 I
•. __ .;..' l..! ...... _
1-4

SECTION2. OPERATION
I . Fuel on ,Lube Oil and eooline Water
I.Fueloil
Users can select the proper grade of fuel oil accrdin~ to.the Iocal ambient temperature. In
tbe ~eneral area in. China,the ~de of fuel oil is according to the standard GB252 light diesel
fuel.Use
~de "0" Ji~ht diesel fuel in summer, whiJe in winter, use grade "- 10" li~ht diesel
fuel.Before
bein~ filled into the en~ine fuel tank,the diesel fuel must be settled for a lon~ period
(normaJly' at least 48 h).Then draw out the upper part.The fuel should be filterd by silk cloth
while
fillin~ it into the en12;ine fuel tank.!t will extend service life of injectors and injection
pumps by
usin~ the weH settle diesel fuel.
2.Lube oil
In the
~eneral area in China.,users can select the .proper ~rade accordin~ to GB/T11122
Lube
Oil of Diesel En~ine.Use JUade CD40 lube oU in summer,while in winter use ~de CD30
lube oil.When
bein~ fiUed into the en~ine oil tank,the oil should be filter~d by sereen.
3.Coolin~ water
It is recommended to use soft water sueh as rain water,city tap water,or ciean river water for
en~ine coolin~. WeH water or tap water from weil water could not be used. Coolin~ water
containin~ too lnuch minerals will form. water scall in an en~ine cooling system,affecting the
\.
engine cooling efficiency alld givin~ rise to engine troubles.
Hard water(wel"l
or spring water,etc.) should be softened before being used.There are two
. softenin~ methods;
(I )Boi lin~ up the hard water;
(2)Addin~ 20~ caustic soda (sodium hydroxide) to eaeh 30L hard water to make up a
solution.
When the
en~ine operates in cold weather where the cooling water is liable to freeze,anti -
freezer can be added to the cooling water to prevent it from
freezin~. Glycol or alcohol aqueous
solution
is most ordinary.
If it is difficult to start the en~ine under lower ambient temperature, heat the water to about
80Gebefore fil1ing it into the cooling system.
2-1

n .Preparation betore S*ar1ia2
I.Check the' tifdltness and reliability of al1 connecting parts. Check control levers (speed
control lever and stoppin~ lever) to see whethcr they can be moved·freely.
2.Rotate the·crankshaft several turns,be sure
that all movin~ paTts move freely.
3.Check the oillevel in the oil sump and iniection. pump to see whether it is kept within two
marks on the dipsticks.Make.sure that
the fue) tank has sufficient fuet and that the fuel pipelines
are unblocked'.
4.0pen'the fuel tank cock .. Checkwhether there iso air in·the fuet system. If necessary,loosen
the vent screws on the fuel filter and· in;ectien pump,operate the primin~" pump on the fuel
delivery
pump by hand until the fuel flows out Qfthese screws without bubbles,and retighten the
vent screws.After that,loosen
the union nuts of injection pipes on the iQiectors an~ rotate thc
cankshaft
to bleed' air from iniection pipes,then reti~hten the union nuts.Check all fittings of the
fuel system
to se,e whetherthere is any leakage at all joints.
5.Check the radiator to see whether it is filled fully with water and whether there is any
leakage at all ioints.
6.Che·ck the. accessories
to see whetber they arefinnly and' reHably connected.Check the
.electrical system: to see whether the battery is fuHy char~ed,alJ wirings are correct and all
connections are
ti~tened.
7.Check the clutch to see vvhether it has disengaged.
m. StartiR2
I.Set the speed control lever at the middle speed position.
2.Turn
the ignition switch to "preheating~' position to heat the electrothermic plug for 20 .... ~
30s.
3.Turn the ignition switch to "on" position.Press the starting button to start the engine.If it
fails to· start,reJease the button immediately.Wait 2tninutes 3rninutes,before starting the engine
againJfthe engine fails to start after 3attempts,check the cause and remedy the fault.
4.As soon as the engine has been started.,release the press button immediately.T'hen turn the
ignition switch to another position to charge the battery. At the sanle titne move the fuel control
lever untiJ the engine runs at idJing speed.Check the operation
condition of the engine to see
\vhether there is any abnormal' noiseeEspcciaHy pay close attention
to the readings of oil pressure
gauge,which should be
within specifi'ed pressure Hmits.Then wann thc enginc up with engine
speed' ~aduaHy increasing to 1800~-'.J 2000r/m'in
2-2.

IV •Operatioe
1.00 not load the en~ine untiJ the eooling \\'ater tempemture is overSO°C arid the lube oil
temperature is over 40 oe . The en~ine should not be opcrated undrer rated operated under rated
output before the outtet water temperature reaches approximately sqoc .
2.Increase or d~erase tbe engine load and speed gradually andevenly.In normal case!do not
load and.unload,the
en~ine suddenly.
3.During operation,observe thc gauges
on the instrument panel frequentlywher~ the
readin~s should be within the speeified limits.Pay eloseattention to the exbaustgas color and the
operatin~ "noise.Ifthere is any.fault,stop the engin~ aod inspeet it.
v·. Stoppine
1.Before stopping,take off the load ·and reduce the enginespeed gradually.Letit ron at
idlin~ speed for afew minutes.Do not stop engine until the outlet water tetnperature falls to
belo\v
70°C.
2.After stopping the engine .. the ignition switch should be tumed 1'0 the middle position.
3.In winter.,when ambienttemperature falls to bello\v 5 oe ,aftertheen~~ine' stops and thc
cooJing water temperature falls to beJow 60 oe ,open aB drain eocks on "the .cyHnder block. and
ra.diator to drain
otl:' all \vater remnant within the cooling system,in order to avoid damages of
parts due to freezing.If anti -freezer is added to the eooling water,it is not necessary to drain
off.
2-3

SECTION3. MAINTENANCE
For reliable engine operation with Jess wear and Jonger service Jife,all maintenance work
nlust be carried out as foJlo\vs.
I . Routine l\taintenance
].Check the oB level in the oiJ sump and it should be between t\\'o marks on the dipstick
and ncar theupper 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 "--.J 1 Onlin,
then stop the en~ine and measure the ·tube oiIlevel oncea~ain.
2.Check the cooJing \vater level in the radiator.
3.Check the lube oil level in the govemor of the iniection pump,replenish the oH to the
specitied level ifneeded.
4.Eliminate oil'l water and gas )eakags of the engine.
5.Check ti~htness and correctness ofan conlponents attached tothe engine.
6.Check tightness and reliability ofen~ine foundation 'bolts'and theconnectionbetween the
englne and the dirven ·machinery.
7.Keep the engine clean.Oil,\vater and dust gathered on the engine surface should bewiped
away with adry rag or cloth dipped in gasölinc.Especial1y keep the electric equipment clean and ·
dry and clean out the dust on the tins ofthe radiator.
8.For
the new engine .. after 50h tr.ial running,renew the lube oil in the oil sump,fuel injection
pump and govemor~and flush the oi1 filter eJement .. oil sump and oil strainer.
9.Promptly eliminate
the troubles and faults found.·
11 •Maintenance after Every 100 Accumulated Qperatine: Hours
Besides the nroutine maintenance" work,and the fol1owin~ items:
1.Rene"w the oil in the sump.
2.Clean the oil filter
or ,renew the paper element ifnecessary.
3.Clean the fuel filter or renew the paper element if necessary.(lt mayas \vell be replaced
after every
200 accumulated·operating hours.)
4.CJean the oll filter
or rene\\! the papereJementifnecessary.
5.Clean the va.lve lashes .. readjust them accordillg to the recommended procedure jf
necessary.
3-1

6.Check the tension ofthe fan beh,and readjust it ifnecessary.
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,clean the inside of the aircleaner .. brush off thedust
gathered on the 'paper element surtace,and clean the inside of the exhaust manifold and sileneer.
9.After every 200 accumulated operating hours,check the injection pressure and spray
pattern of injection.If necessary,dismantle the iniector"clean the nozzle set,and readjust thc
iniection pressure.
IO.Check the voltage of battery and the specific gravity of battery acid,which should be
~'ithjn 1.27/"---, 1.2~(at ambient temperature of20°C ).W'hen it is less than I. 14,the battery should
be rccharged.The .Ievel of battery acidshould be J 0"-' 15mm above th~ pole plate.lf insufficierlt,
add distilled water to the required level.
1 I.AII' parts dismantled tor maintenance should be ,washed.,and cJeaned and correctly
reassembled.After reassembly,start the engine and check \vhether it is in proper operation"AlJ
faults
should be renledied.
m.Maintenanee after Every 500 Accumulated Operatine
Resides the work of Inaintenance atter every 100 accumulated operating hours,the
foHowing items are needed:
1 ~Check the injection pressure and spray ·pattern of tbe injector.If necessary,dismantle the
injector.,c·lean the nozzle set and readjust the injection pressure.
2~Check fuel delivery of theinjection pump,and recalibrate it ona test beneh if possible.
Check the injection timing,and readjust it ifnecessary.
3.Check the seaJing of the intake and exhaust valves.If necesary,grind and lap the valve
seats and reaQ;ust the valvelashes.
4.Check the tightness ofthe connecting ?a rod,mian bearing cap and tlywheelboJts.
5.Retighten thc cylinder head bolts and ad;ust the valve lashes according to directions given
in section 4.
6.Clcan or replace the paper elelnent 01' air cleaner.
7.Clean
the cooling system.The cleaning solution can be prepared byadding 150 graIns of
caustic soda(NaOH) to every litre of \vater.Before cJeaning~drain the system complctely and then
till in
the salne capacity'with cleanlng solution.Let it remain in the systeln for 8"',-.1 ] 2h:rhen start
the engine and run
it until the temperdture of cleaning solution reaches nonnal operating
telnperature.Stop the engine and drain the system immediately in order to avoid settling of scale
\vithin the system.Finally .. flush the system with clean water untjJ all sediment is flushed out.
3-2

,8~Check whetherthe thermostat is in ~ood ·order.Examine ·.the .waterdropp.i~out froma
weep hole ofthe -water pump.It is necessary to renew the water seal,if tlowinll;out too muchof
water.
9.Check the wirin~ contacts of.the electric equipment-to see whether. they :are connected
firm~ly and welLBumt marks should be removed.
10.Afterevery 1 ,000 accumulatedoperatin~ hours,add the' followingitems;
(I)Make an overall check on an' pafft; and components.Make necessary .adiustments and
repairs.
{2)Dismantle
the dynam'o and startin~ motor.Clean out tlle dirty ~ase··i.n tOO bearin~ and
refuH them -with clean ~rease.rhec·kthe pinion ofstartin~ motor.
II.After every :J ,500 accunulated opera1jn~ hours,add the followioll; items:
(1 )Remove the cylinder head,check the valve and valve seats and other parts of ;cylinder
!lead asselnbly.
(2)Remove.the carbon de,posits
6n the surfacesof cylinder head,Hner,piston andpiston ring,
etc,and wash,down
them.
(3)Check and measure -wear ofthepistonsandpiston rings.
(4)Check and measure wearofthe,cylinder:lUler.
('5)Checkand measurewearof1hecrankshaft main joumalsandcrank .pins;Clean :htbe oil
passa~es of the crankshaft.
(6)Check
wear'ofthe 'main 'bearin~ andconnecting-rod hearing shens.
(7)C·lean,oil "passages ofthe cyJinderblockand replace -Iube oiJ.
:W .PreservatiOll and.Steraaeof,Enaine
'If the -engine is tobe put out of service for acomparativeJy longperiod of time,it is
necessary
to .pr.eserve itaccording to the 1ollowin~ procedure:
I.After tbe ,engine 'steps and st.ill does not coal yet,drain out complete)y the ]'ubeaiJ.,cold
water·and fuel immediate'ly.Clean the oil sump and oB strainer.
2.Clear out the dust andoi:Jon the engine surface.With ,antirnst oil smearal'l tbe UDJ!Ilinted
.ex'posed surfaces 'ofengine e)(cept rubber and .plasticparts.
3
Jieat :the fiJ.tel:ed ,Iube oil to 110r-.., ~120 oe ,unti·)all J!lubbles in the surta.ce oGf·.oil .wsappear.
"fhen pour the dehydrated -,oilintß ·tl:le oil sunp unti·loillev.el :reaches the uppermark,and turn the
engine,in orderto,make s'urelhat thelube system is completely filJed up with this oiL
3-3

~;'4:Poursome;'~dehydratedbil ,into' cylinder throu~h iniector'"~ assembled holes" Oll the
cylindef:heaa,sndtumfhe'crank..4;haft tomake sure that the piston,piston rinR,cyJinder liner lind
valve seat are all covered \vith alayer ofthis on.
,,'5'~Block'theoutletsof intake andexhaust manifolds (silencer)with.wooden plugs Of\Vrap up
properly with plastic film in order to prevent any dustfroln getting in.
6.~rhe engine shouldbe:stored in aclean' roornwith goodventiJationandJow humidity,The
erit-iine- sh<)ulElbe covered.Chemicals neafit'are strictly 'prohibited.
The preservation according to the above procedure may be vaJid tor 3
nlonths~Over tbis
perl00,fe))eattheprocooute. .
3-4

Fig. 1Adjustment oe valve l8shes
SECTION.4 ENG'INE ADJUSTMENT
I . Ad.iustment of Valve Lash
When .thc en~ine is nlaintained and repaired,it is necessary ·to check and, adi~st tbe va)ve
Jashes.The recommended Jnethod of a4iusting the
valve system and valve lash isas folIows:
I.Remove the, cylinder head cover.Check and
tighten the nuts fastening the rocker arm shafl
stands.
2.Tum the crankshaft to rnake sure that thc
piston
of 1st cylinder is at the compression. TDC
position.Thc timing mark on the inspection window
of thc fly\vheel housing exactly points to the " OU
1l1ark ~n the tlywhcel rim ,or the" 0" mark on the
c.rankshaft puJleyis ali~ed \\,ith the pointer on the
cover oftHning gear housing.
3. slip a feeler gauge bet,;veen the rocker arnl
and
the tip of the intake or.exhaust valve sterns of
the 1st cylinder respectiv\;~ly to check and ad,iust the
valve lashes.fntake 'valve lash' and exhaust valve
lash in cold nlust be the value specified in section 1.Then after turnlng the crankshafl by 18()'J
to adiust the valve lashof other cytinders a(,:cording to the engine firing order(1-'3- 4-2)for tlle
tourcylinder enginc arid'l-3-2 für three cylinder enginc.
11. Adiustment of lß"iection Timing
'ro ohtain the most econolnical specific filet consumption and to chsure normal operation of
the enginc,injection titnin.g shouJd be adjusted properly.For the Model 485 diesel en~jncs,the
angle at \vhichinjection be~ins should be the value specified in se'ctionl .
The adiusting method of injection timing is as follo~'s:
I. Vent the air trapped in the tuel system~and turn·the crankshafl'to filJ up tlle" ini"ection
pump wtih fuel.f)isconnect the in;ection pipe ofthelst cyljnder~turn'thecranksh3.ft slowly in the
direction of its rotation and atthe s3tne time obscrve the fuel'level in thc hole offuel pipeunion~
Whenthis fuel level lust starts to rise,stoptum the cranksha1t itnmediately.
4-1