Rotek YSD490Q Manual

SERIES Y90 DIESEL ENGINE
OPERATION & MAINTENANCE MANUAL

FOREWORD
Series Y90 multi-cvlinder diesel en2ines are ideal power units for 1i2ht vehicle,
a2romotor,small tractor.air conditioner in bus.2enerator set and en2ineerin2 macltinerv.
The normal
and reliable operation and lon2 service life of the en2ine depend not onlv
on the manufacturin2 Quality,but also on the reasonable operation
and correct
maintenance.
In order to provide the detailed description and instruction of this en2ine for
operators to manipulate
it correctlv in short time,we offer this manual which brieflv
describes the performance
of series Y90 diesel en2ines to operators,maintenance workers
and relevant man2ers.
Since the construction of this en2ine is subiect to frequent improvement and
development
durine prod..ction and practice,it is possible that the en2ine supplied is
somewhere not exactlv the same as one described herein.Please pay attention to that when
readin2 the manual.

Warning Notice
l.ft 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.
2.ft is strictly forbidden to leak
out from an intake system(air filters,pipelines and
connectin2 components).
3.ft 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.ft is strictly forbidden to
start under the circumstances of lack of lube oil or water.
5.ft is strictly forbidden to operate at overload or under other conditions a2ainst the
rules.
6.1t is strictly forbidden to Te2ulate
the fuel in.iection pump at will.
7.ft is strictly forbidden to chan2e
the diameter ofthe pulley.
8.To control
the startin2 time(less than 15 seconds) and the startin2 interval (more
than 2minutes) strictly.
9.
lt's amust to maintai. the diesel en2ine techanically in the allotted time.
10.Unskilled
workers are not allowed to dismantle and assemble the en2ine and its
spare parts.

CONTENTS
I .Configuration and Installation Dimensions of Model YSD490Q Diesel EnRine ...•.. I
II .Performance Curves of Model YSD490Q Diesel EOj:~ine , .••..•...•....••...... 11
SECTION 1. DIESEL ENGINE SPECIFICATIONS AND
TECHNICAL DATA
I . Specifications of diesel engines ................•••. ,••. .•. .•• ••. ••• .•. ••• •.• •.• I-I
Il .Specifications of the main accessories'" •.. . ........••...•. ,. 1-2
III .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
111 .Starting .•..•...............• . •....••.•....................•.. 2-2
IV .Operating ,,. ............•........ . ..•.•...•.•.....•...•.••••.•• 2-3
V . Stopping ., ,. ..• .•. ..• .2-3
SECTION 3. MAINTENANCE
I . Routine maintenance 3-1
JI .Maintenance after every 100 accumulated operating hours ..............•......•.. 3-1
III .Maintenance after every 500 accum~lated operating hours'" •.. •.. ..• ••. •.• ••. ..• 3-2
IV .Preservation and storage of engine •.. .•. .•. ..• ..• 3-3
SECTION 4. ENGINE ADJUSTMENT
I . Adjustment of valve lash , 4-1
Il .Adjustlnent of injection timing '" .•... , ....•.............•..............•..•...•. 4-1
III .Adjllstment of injector , '" ., .•. ,.•. '" ., •.•...................•..•.... ,4-2
IV .Adjllstment of lube oil pressure '" '" ...........................•..... 4-4
V . Adjustlnent of injection pump .....................................•................ 4-4
VI .Adiustment of decompression arm lash : '" , ...• '" "'4-4
SECTION 5. CONSTRUCTION OF DIESEL ENGINE
I . Cylinder head 5-1
Il .Cylinder block , , .•..... , , '" ., ,5-2
UI .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
vm .Lubricating system 5-8
IX .Cooling system 5-10
X. Electric system .. · .. ·..• 5-11
SECTION 6. FAULTS AND REMEDlES FOR DIESEL ENGINE
I . Hard or refuse to start 6-1
II .Power insufficiency ··6-1
III .Srnoking exhaust 6-2
N.Knocking noise in engine ,6-2
V . Lube oil insufficiency or no
pressure...... 6-2
VI .Overheating of engine 6-3
VI! .Engine running-a\vay 6-3

ExhalJs! outte! centerline
1:2
207
View A
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2525 25 25 2 525
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-;r
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,
-,-
-
25 25125
25
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Conneding d!mfnsions of flywheel and Its hOlEing
16' 16'
\i I .. , ...
.:b",.J
11.7 "
~
591.5
JI
100
172
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lb
I. Configuration and Installation Dimensions of Model YSD490alYS4901 Diese! Engine

ge
(g/kw·h)
250
1
230
v
."",-
/"-
~
/"
Me
'"
~
"
p
~
~
~
./
V
~
"
ge
~
~
..........
-,
---
,
Me
(N'm)
160
ISO
35
25
...
1600' 1800 2000 2200 2400 2600 2800 3000 3200
n. Performance Curves of Model YSD490Q Diesel Engine
II

SECTION 1. DIESEL ENGINE SPECTFICATIONS AND
TECHNICAL DATA
I.Specifications of Diesel Enldnes (see Table I)
Table 1
Model YSD490Q
Type : Vertical, water cooled,four- stroke.dlrect combustion chamber
_ .. _, __ . ..... ' __ . .. __ . __ ,_., ,_~. . . ._ .. . .. . __ .L_.'_'_"'_" .. _, ~ __ ,_ .. , ~ ~_. __ . __ .. _ _ _._. __ . ., ... __ ._. __ .'._ ....
Number of c~'1inder 4
100 Strokelmm)
Bore(mm) 90
-_ .. _-_._._-._-,~-_ ..._--_ .. _._-----_._._-_ .. _~-_._-,.- _ ... _----_ .... __ ... ------_. ---- .. __ .,----_._------~-- -_. __ . __ ._,-~ ..• _.-
i!
1- .. _._- ---
CompreSSlon ;'lltio
I
18
Total displacement(L): 2.54
- -.----.-- .. ----.----- --.---- .. --.-- .. ----.------- 1--- .. ------.-.-.--.----- -------- --.-. - ------.---------------.- ---
Flring order: 1-3-4-2
·-·--------·--·------------------··r--------·-·- ------. -------------- .. - .... --.-----.--.-----
Rated pouer(kW) I· 37.0-~45.6
~------.----.-.-- - --------·c-·--------· ----.- .. ·---·----·--···-1-- -.----.----.------- --.-----.--- .. ------- -----. ----------------.--.-- - -
Rated speed{r/min)! 2600-3200
_____ . _._.____ . . . . . L .. . _. . . . . . . _
18± 1/2600
Max Torque(N m) ;?: 149.3
----. -.-. -. -------------_ .. -------_._--_._-------1------------------.-----.- ---.--.-------- -----
Min Specific fuel consumption at fullioad ;
(g/kW.h) I ::;2~S.3
---------- ---------------------+-------_._-----_._----_._-_._._-------_._-----------------
Oil- fuel consumption ratio(%) I ~0.8
-----------------·--·-·--------·-·-·-·-----·------r--- ·-·----------·-·-·-------------Ti---·--·-··------------._--- .. --
Advance I njection Angle/Speed I15±I /2800
(Before TDC) ('C)(rpm) , With Advance Device
2.72
Counterclockwise
._-_ .. ---_. __ ._---,---_. __ ._. -- _ .. _._------
Direction of crankshaft rotation
-.-- .--------- _·_---------------_··_-------1- .-~
_____ ~~_ci~~_I~~_~~lc~~~~~~~~ion~~~~~) __ I
ri -- ._-------------- --_._._- --._-----'._ ... _-_. __ .. __ .... __ ._ .... __ ... __ .. _-- ",--,'._-
i
(facing to flywheel)
----~----- .-.----.-.-.---.--,-.---.------.----" -- ----t·~- - -.--.-----.---.-- -..... ----- ---.".'-- '-"'--' .-- .. -.--.--,---------~----.--- - ._.~ .... _--
I
Cooling method iForced water cooling
---_._-_ .. _--, _-_._-_._._._---------~ _------.----------_._ .. ~--_._ .. __ .,~_._._- .- -_ -.- ,---_._-_..- --_._---~--------_._-----_. _.
Ll,bricating method iPressure and spIash Iubrication
~----_ .. -:::---_. __ ._._-,._-_. __ ._._, .. _-----,---_._-+_ .. ----_. __ .. _--_._ ... _----_ .. _-_ .. __ . __ ._-_.- ._---_ .. _._._-----,--
Startting method' Electric
------.- --------------------- .. -- .--.---- --1------- -.-.-.-----.---------------.-- ---------.---.-.----------
i
Net mass(kg) 230
~------_. Ov~;~;ldi~~n~k;~~- .. --[1
1
-------- ---- --. .--;~-:.~~~ :~~~- ---.-.----------
(LXWXH)(mm)
1-1

11 .S~ification of Main Accessories(see Table 2)
Table 2
Shrorded
Specification
N2 accessory
--- i
Air fiter
Dymamo
Lube oil filter 1-
4
5
6
7
8
9
10 . Electrothermic
plug
No ; Designation 1------
1- i _Type .,'~" '1= ~~~~~Se~r-ie~:-~~-r4-:-~~p-um-p~- -.------
II Fuel ~~~~tion [I --Plu~g;:J:~::~~;)---- all-speed, me:h:ni~1 centrifu--=ge-
al
__
I
,-----------;--- ----------.---:---.--;---~~---~
i Fuel dehvery pump ~ Smgle-actmg pIston-type
--T---- ----I'------M~-el--- .------------------ P46" --------------------
! f------ ..---- . -------- .. ---
. r
l
...!l~~le set l ZCK I 54-S427 or CN-DLLA J.~~~~z.. _
2I Fuel injector
! rEi::~::i;!::~~(~~~!~--------- 4 _ho~:~~-10.2!--~------
---i-I----- ----------------------1-----------· --------------~.-------- ------
1i Type I Rotor type
I ' - -- -- - -- - -- -- -1--- -- ---- ------ --~--- - - -
Ii Speed(r/min) 1 1500
3I Lube pump ,.- -- - - --- --- ------ ---- - --- ---- -.-------.-.-----~---- .. -------.---------
I Capacity(Umin) 26.9
i I'" ------------------i--------· - ---- .. ---------- .. --- - . ---------------- ...... -- ... - .. --,,---------
, . : Pressure(kpa)! 400
.. -i--------------- :--- . - .. ---- ---------+- .. - ------------------ .. -------- .... - -.--------------------
Type i Centrifugal. volute, single-suction
------ ------- .. - .- - - ---------+------------ -- ---- ------ -- .. ---- ------------ --------
, Speed(r/min) i 4000
Water pump t-- ~ __L ----------.------.- .... - --------- .. -------- .. ---- .. - .. ---
i Capacity(Umin) I 220
i .. -- -." ------------1----------------- .. ----.------. -.- -----------------.---------
ILift(m) I9
._- --------_._--_._, ._-----. -- ------.--_. -+- ,,-----------. _ .. _-----_._-- .. ----_._------ -------.,,_.-- .. _-------
i--- _Type___ __ _~---------------- . __ Series P.~lllo~r _
Starting motor r-----v~r~:::V)-----I--------------- QD 13 ~~fi:.J)~!~-- .. --- - -- ----.
~- ... --.----- ---------- -.. -t---·--·---·-------·------------·----- - ... --- .-------------
i Power(kw) i 2.5
- ---- i---Typ;--------r--- ------Sil-i~~n r;ctiiyi~g;~~d~~~~'
!- .. --- ----- .--- -- --------i-· - --------.-- --"-,, ---- --------- ----------- ..
Model: JFIIA
.-------.--- . --------1-. ---- .. --.. -- .--------.---.
Power(W)! 350
t----.-- .. ---~----.. - -._--------- --- --~·----·-'-l- -,-~.- .. _ .. ~-- ---~~---.------.---- -'--.' --.-' --------------- .---~--- .. ----- ---
___ ... .. _. __ . Voltage(V) __ ~_ 14
F~~~ fiI~:~ i--~Tye~______I:--·-·~---~~.--:~i~-~~~~~~~~~~~~I~~e~t:=~~~~.~=-~-
I Model C0708A
...... -1----~---- --.---------- -1----·-----------------------·--- ---------- ... ---.- .. ----
Type i Single stage, paper element
. ---~- - .. -- --------t- - -- ------~---- ------.----------
Model . +_ . ~~..<J~J-I _
Type Oil-immersed
-- - ---_._--_._---------------~--_._---,._-- .. _- .. _---
Model i CN212
_ ~ .l_. __
I
Type ~
- - - - - -- ---I -- -------- -------
Model
1-2

rn.Maiß tethnh:al Data of Diesel Eß2iße
1. Valve lash(mm)
Intake valve(cold)
Exhaust valve(cold)
2. sinkage
ofvalve(mm)
0.30~ 0.35
0.35~ 0.40
0.7~ 0.9
3.Torque limits ofmain 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.Temperature
and pressure limits
(l )Exhaust temperatureCC )
n;::: 3200rpm
t::::; 620
3200rpm>n>2600rpm
t~ 600
n::::; 2600rpm
t::::; 550
(2)Lube oil temperatureCC )
~ 100
(3)Lube oil pressure in Main Passage(Mpa)
At normal operation
At min. Steady Speed
5.Govemor Characteristics
Min. idling steady Speed
Steady regulation
0.2- 0.45
?0.05
~ 900rpm
5% ~- 10%
1-3

IV .Fit Clearance and Wear Limit ofMain Parts(see Tablc 3)
Tqblc 3
Designation Assenhly limit Wear limit
(mOl) (mm)
.. ~_ __. + _... . ~!
...........- .. -_.-_ - - - - .. - -- .. --- --+ ,- ~__t- - .
Side clearance between thc oi Iscraper ring and its groove 0.030-0.062 0.15
Connecting rod journal and connecting rod bushing
2Piston pin and connecting rod smaH end bushing
Piston skirt and cylinder liner
ring and its groove
Side clearancc hetween the
2nd ring its groove
Gap
of the 1st ring
8Gap
of the 2nd ring and oii scraper ring
9Crankshaft main journal and main hearing
10 Camshaft journal and bushing
11 Idle gear shatljournal and bushing
12
13 !Exhaust valve stern and valve guide
14 Rocker arm shaft and bushing
15 Axial clearance of crankshaft
16 Axial clearance of camshaft
1-4
0.060-0.172
0.025-0.050
0.130-0.195
0.070-0.102
0.050-0.082
0.300-0.450
0.300-0.450
0.070-0.149
,0.025-0.114
0.025-0.075
0.025-0.077
0.016-0.061
0.075-0.265
0.080-0.250
0.25
0.10
0.40
0.20
0.15
0.25
0.18
0.18
0.15
0.15
0.20

SECTION2. OPERATION
I . Fuel Oil .Lube OU aod Cooli02 Water
I.Fueloil
Users can select the proper ~ade of fuel oil accrdin11; to the local ambient temperature: In
the
11;eneral area in China.the f];rade of fuel oil is accordin11; to the standard GB252 li11;ht dies~1
fuel.Use 11;rade "0" li11;ht diesel fuel in summer, while in winter, use 11;rade "- to" li11;ht diesel
fuel.Before
bein11; filled into the en11;ine fuel tank,the diesel fuel must be settled for a 10n11; period
(normally
at least 48 h).Then draw out the upper part.The fuel should be filterd by silk cloth
while
fillin11; it into the en11;ine fuel tank.It will extend service Iife of iniectors and iniection
pumps by
usin11; the weil settle diesel fuel.
2.Lube oil
In the
11;eneral area in China.users can select the proper 11;rade accordin11; to GB/TlII22
Lube Oil of Diesel En11;ine.Use 11;rade CD40 lube oil in summer,while in winter use 11;rade CD30
lube oil.When
bein11; filled into the en11;ine oil tank,the oil should be filtered by screen.
3.Coolin11; water
It is recommended to use soft water such as rain water,city
tap water,or clean river water for
en11;ine coolin11;. Weil water or tap water from weil water could not be used. Coolin11; water
containin11; too much minerals will form water scall in an en11;ine coolin11; system,affectin11; the
en11;ine cooling efficiency and 11;iving rise to en11;ine troubles.
Hard water(well
or sprin11; water,etc.) should be softened before bein11; used.There are two
softenin11; methods;
(I )Boilin11; up the hard water;
(2)Addin11; 2011; caustic soda (sodium hydroxide) to each 30L hard water to make up a
solution.
When
the engine operates in cold weather where the coolin11; water is liable to freeze,anti -
freezer can be added to the
coolin11; water to prevent it from freezin11;. Glycol or alcohol aqueous
solution
is most ordinary.
If it is difficult to start the engine under lower ambient temperature, heat the water to about
80·C before
fillin11; it into the coolin11; system.
2-1

II .Preparation before Startin2
).Check the tightness and reliability of al1 connecting parts. Check control levers (speed
control lever and stopping lever) to see whethcr they can
be moved freely.
2. Rotate the crankshaft several turns.be sure that all moving parts move freely.
3.Check the
oillevel in the oil sllmp and iniection 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.
4.0pen the fuel tank cock.Cheek whether there is air in the fuel system. Ifnecessary.loosen
the vent screws on the tuel tilter and in;eetion pump,operate the priming pump on the fuel
delivery pump by hand until the fuel flows out
ofthese screws without bubbles,and retighten the
vent screws.After that,loosen the union nuts
of iniection pipes on the iniectors an~ rotate the
cankshaft to bleed air from iniection pipes.then retighten the union nuts.Check all fittings
of the
fuel system to see whether there is any leakage at all ioints.
5.Check the radiator to see whether it is filled fully with water and whether there
is any
leakage at all ioints.
6.Check the accessories to see whether they are tirmly and reliably connected.Check the
electrical system to see whether the battery
is fully charged,all wirings are correct and all
connections are tightened.
7.Cheek the eluteh
to see whether it has disengaged.
m. Startin2
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,release the button immediately.Wait 2minutes 3minutes.before starting the eOJ~ine
again.lfthe 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.Then turn the
ignition switch
to another position to charge the battery. At the same time move the fuet control
lever until the engine runs at idling speed.Check tlle operation eondition
of tlle engine to see
whether there
is any abnormal noise.Especially pay close attention to the readings of oil pressure
gauge.which should be within speeified pressure limits.Then warm the cngine
up with engine
speed gradually increasing to
1800-~ 2000r/min
2-2.

IV .Operatin2
I.Do not load the engine until the cooling water temperature is over 50 oe and the lubc oil
temperature
is over 40 oe .The engine should not be operated undrer rated operated under rated
output before the outlet watcr temperature reaches approximately
80'C .
2.1ncrease 01' decrasc thc engine load and speed gradually and evenly.In normal case,do not
load and unload the engim: suddenly.
3.During operation,observe the gaugcs on the instrument panel frequently where the
readings should be within the specified limits.Pay
dose attention to 1he exhaust gas color and thc
operating noise.lfthcre
is anv fault.stop the engine and inspect it.
v .Stoppin2
I.Before stopping.take off the load and reduce the engine speed gradllaIly.Lct it run at
idling speed for atew minlltes.Do not stop engine until the outlet water temperature falls to
below 70·C .
2.Afiel' stopping the cngine, the ignition switch should be turned to the middle position.
3.1n winter,when ambient temperature fal1s to beJlow 5°C ,after the engine stops und the
cooling water tempenlture
fal1s to below 60'e ,open all drain cocks on the cylinder block and
radiator to drain
off all water remnant within the cooling system,in order to avoid damages 01
parts due to freezing.lf anti freezer is added to the cooling water,it is not necessary to drain
off.
2-3

SECTION3. MAINTENANCE
For reliable engine operation with less wear and longer service life,all maintenance work
must be carried out as foliows.
I . Routine Maintenance
I.Check the oil level in the oil sump and it should be between two marks on the dipstick
and near the upper one.For anew engine 01' the engine reused after stopping for along period,the
lube oil must be filled to the upper mark,and operate the engine at lower speed for 5
~ 10min,
then stop the engine and measure the lube
oillevel onee again.
2.Cheek the eooling water level in the radiator.
3.Check the lube oil level in the govemor
of the inieetion pump,replenish the oil to the
specified level
if needed.
4.Eliminate oil,water and gas Ieakags
ofthe engine.
5.Check tightness and eorreetness
of all eomponents attached to the engine.
6.Cheek tightness and reliability
of engine foundation bolts and the eonneetion between the
englne and the dirven maehinery.
7.Kecp the engine c1ean.Oil,water and dust gathered on the engine surfaee should be wiped
away with adry rag 01' cloth dipped in gasoline.Espeeially keep the electric equipment clean and
dry and clean out the dust on the fins
ofthe radiator.
S.For the new engine,after 50h töal running,renew the lube oil
in the oil sump,fuel inieetion
pump and govemor,and flush the oil filter element,oil sump and oil strainer.
9.Promptly eliminate the troubles and faults found.
11 .Maintenance after Every 100 Accumulated Operatin2 Hours
Besides the "routine maintenance" work,and the following items:
l.Renew the oil in the sllmp.
2.Clean the oil filter 01' renew the paper element
if neeessary.
3.C1ean
th\.: fuel filter 01' renew the paper element if necessary.( It mayas weil be replaced
after every 200 accumulated operating IlOurs.)
4.Clean the oil filter 01' renew the paper element
if necessary.
5.C1ean the valve lashes.readjllst them according to the rceommended procedure
if
nceessary.
3-1

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 calciumhased grease with a
grease gun.
8.Clean out the dust inintake manifold,clean the inside of the aircleaner,hrush off the dust
gathered on the paper element surface,and clean the inside ofthe exhaust manifold and silencer.
9.After every 200 accumulated operating hours,check the injection pressure and spray
pattern
of injection.lf necessary,dismantle the iniector,c1ean the nozzle set,and readjust the
injection pressure.
IO.Check the voltage
of battery and the specitic gravity of battery acid,which should be
within 1.27 ~- 1.28(at ambient temperature of 20 oe ). When it is less than 1.14,the batte!)! should
be recharged.The level of battery acid should be I0 .~ 15mm above the pole plate.lf insufficient.
add distilled water to the required level.
11.AII parts dismantled
tor maintenance should be washed,and cleaned and correctly
reassembled.Afier rcasselllbly.stall the
i:1l~inc and check whether it i~ in proper operation,A11
faults should be remedied.
m.Maintenance after Everv 500 Accumulated Operatin2
Besides the work of maintenance after evel) 100 accumulated operating hours.the
following items are needed:
I.Check the iniection pressure and spray pattern of the iniector.lf necessary,dismantle the
iniector.clean
the nozzle set and readiust the iniection pressure.
2.Check fuel delivery 01' the iniection pump,and recalibrate it on atest bench if possiblc.
Check the iniection timinl!;,and readjust it if necessary.
3.Check the sealing of the intakc and nhaust valves.lf necesarv.grind and lap the valve
seats
and readjust the valve lashes.
4.Check the tightness of the conncctll1~ '.la rot.l,mian bearing cap and llywheel bolts.
5.Retil!;htcn the cv linder head bolts and adiust the valvc lashes accordinl!; to directions given
in section 4.
6.Clean
or replace the paper element of air cleaner.
7.Clean tlle cooling
wstem, The cleaninl!; solution can bc prcpared by addll1l!; 150 grams ot
caustic soda(NaOH) to every litre of \\ ater.Refore cleaning.drain tlle system completely and then
till in tlle
same capacity with c1eaning solution.Let it remain in the system för 8~- 12h.Then start
fhe cn.l2.II1C a11(1 run it until the temperature 01' cleaning solution rcaches normal operating
tempcrature.Stop the engine and drain tlle system immediately in
order 10 avoid settling of scale
within tlle system.finally,tlush the system with clean water until all sediment is tlushed out.
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8.Check whether the thermostat is in good order.Examine the water dropping out from a
weep hole
of the water pump.lt is necessary to renew the water seal,ifflowing out too much of
water.
9.Check the wiring contacts
of the electric equipment to see whether they are connected
firmly and well.Burnt marks should be removed.
IO.After every 1,000 accumulated operating hours,add the following items;
(1 )Make an overall check on all parts and components.Make necessary adiustments and
repairs.
(2)Dismantle the dynamo and starting motor.Clean out the dirty grease in the hearings and
refull them with clean grease.Check the pinion
of starting motor.
II.After every 1,500 accunulated operating hours,add the following items:
(I )Remove the cylinder head,check the valve and valve seats and other parts
of cylinder
head assembl).
(2)Remove the carbüll ,].:posits on the surfaees of eylinder head,liner, piston and piston ring,
ete,and wash down them.
(3)Cheek and measure wear
ofthe pistons and piston rings.
14 )Check and measure wear of the cylinder liner.
(5)Cheek and measure wear
of the erankshaft main journals and crank pins.Clean lube oil
passages
of the crankshatt.
(6)Check. wear ofthc main bearing and eonnecting- rod bearing shells.
(7)Clean oil passages
ofthe eylinder bloek and replaee lube oil.
IV .Preservation and Stora2e of En2ine
If the engine is to bc pur out of service tür aeomparatively long period of time,it is
neeessarv to preserve
it aecording to the following procedure:
I.After the engine stops and still does not cool yet.drain out eompletely the lube oil,cold
water and fuel immediately.C1ean the oil sump and oil strainer.
2.Clear
Ollt thc dust and oil on the cngine surface.With antirust oil smear all the lInpainted
exposed surfaces
of engine except rubber and plastie parts.
3.Heat the tiltered lube
nil Lo I1 (). 120'C .unti) all bubbles in the surtace of oil disappear.
Then pour the dehydrated oil
II1to thc oil sunp untll oil level reaches the lIpper mark,and turn the
engine.in order to make sllre Ihat the lube
svstCI1l is completelv filled up with this oil.
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4.Pour some dehydrated oil into cylinder through iniector -assembled holes on the
cylinder head,and turn the crankshaft to make sure that the piston,piston ring,cylinder liner and
valve seat are all covered with alayer
ofthis 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 aclean room with good ventilation and low humidity,The
engine should be covered.Chemicals near it are strictly prohibited.
The preservation according to the above procedure may be valid for 3months.Over this
period,repeat the procedure.
3-4

SECTION.4 ENGINE ADJUSTMENT
Fig. 1Adjustment oe valve Iashes
2.Turn thc nankshaft to make sure tllat the
I . Adiustment of Valve Lash
When thc engine is maintained and repaired,it is necessary 10 check and adjust the valve
lashes.The recommended methoJ of adiusting thc
valvc system and valve lash is as tollows:
1.Remove the cylinder head cover.Check and
tighten thc Huts thstening thc rocker arm shaft
3. slip afeetel' gauge bctween th·.~ rocker arm
and thc tip of the intake 01' o.:haust valvc stems ot
thc Ist cylinder respective!y to check and adiust the
valve ia;,hö.Jntake vaive lash anu exhal1st valvc
stands.
piston
of Ist cylinder is at the compres~ion TDC
position.Thc timing mark on the inSpl'ction window
0;' the tlywhcel housing exact!y points to thiol" 0"
mark on the tlywhecl rim .ar thc ,. 0" mark on thl~
crankshaft pulley is aligncd with thc pointer on thc
cover oftiming gear housing,
iash in cold must be thc vallic srecifled in seetion I.Th~n uiter turning the crankshafl hy 180
to adjust the valve lash of alher cylinders according to thc engtne firing ordcl\ 1- 3- 4-2)for the
foUl' cylincer engine arId 1-3-2 tor thrcc cylinder cngine.
H. Adiustmcnt of Init~tion Timine
To obtain the most economical specific fl.lei cOllsumption and to ensure normal operation ot
lh~ cngine.inlcction timim! should be adlusteJ properly.For the Model 485 die~el engines,the
an)..'Ic at which inicction begins should be the value specitied in section I .
The adiusting mdhod of iniection timin~ is as j{llim.,\'s:
!, Yent thc air trapped in the fllcl svstem.and t':m thc crankshaH to fill up the iniection
pump wtih fuc!.Disconnect lhe iniection pipe of thc Isi cyiiliderJurn the crankshat1 slowly in the
direction of its rotation and <ll thc same time ohserve the fucl level in the h,"le uf fucl pipe union.
When this fud level just starts to rise,stop turn the crankshaft immediately.
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2.Cheek the timing mark on the inspeetion window of tlywheel housing to see whether it
aligns with the eorreet gradulated mark of speeified advaneed inieetion angle on the tlywheel Tim
(or on the crankshaft pulley).
3.1n case that they do not match with each other,the advanced iniection angle can be
adiusted by removing
off the front cover on the timing gear housing and loosening the three
screws fastening the iniection pump timing gear support(see fig.2).lf the iniection timing
is too
advanced,turn the timing gcar support anticlockwise to the proper angle.Otherwise.turn the
support clockwise.lf adiusting range is not enough
triangular tlange
of injection pump and turn the
injection pump shafLFacing the front end
of engincs.
when the in;cction pump rotates elocbvise,the fuel
inicction will retard:while the pump rotates
anticlockwiseJhe fucl iniection will advance.After
duc to limitation
of the three elongated holes,loosen a
little the three fastening nuts on the triangular tlange
of the iniection pump and turn the iniection pump
Facing the front end of engines,when the iniection
pump rotates c1ockwisc,the fuel iniection will retard;
while the pump rotates anticlockwise,thc fuel
iniection will advance.
4.Additionally,if the engine has iniection angle
advance deviceJhe advanced iniection angle can be
adiusted hy loosening the three nuts on the
Fig. 2Acijustment of spedfled
advanced injection angle
turn the in;ection pump once.it is must to tighten the three nuts and check the advance iniection
angle again untill the advance iniection angle fits the spcified valuc.
m. Adiustment of Iniector
Iniector test and ad;ustment must he performed on ainiector tester in order to adiust
iniecting pressure,inspect sprary pattern and remedy faults.
Too high or too lower iniector iniecting pressure.and abnormal spray on darnaged injector
parts will cause engine troubles.such as black smoking,power and speed dropping.increasing
exhaust temperature aod diesel knocking.etc.GenerallyJhe "shut
off' method is recommended to
4-2