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