YANGDONG YD380D Manual

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YANGDONG DIESEL ENGINE
INDUSTRIAL ENGINE SERIES
OPERATION&MAINTENANCE MANUAL
YTO(JIANGYAN)POWER MACHINERY CO.,LTD
YANGDONG CO., LTD

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Foreword
Series Yangdong multi-cylinder diesel engines are ideal power units for light vehicle,
agro motor, small tractor, air conditioner in bus, generator set, water pumps, fire-fighting
pumps and engineering machinery.
The normal and reliable operation and long service life of the engine depend not only
on the manufacturing quality, but also on the reasonable operation and correct
maintenance.
In order to provide the detailed description and instruction of this engine for operators
to manipulate it correctly in short time, we offer this manual which briefly describes the
performance of series Yangdong diesel engines to operators, maintenance workers and
relevant mangers.
Since the construction of this engine is subject to frequent improvement and
development during production and practice, it is possible that the engine supplied is
somewhere not exactly the same as one described herein. Please pay attention to that
when reading the manual.
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 according to the instruction.
2,It is strictly forbidden to leak out from an intake system (air filter, pipelines and connecting
components)
3, It is strictly forbidden to have hard water (well water or spring water)as cooling water, if necessary
to apply the hard(water),soften it first.
4, It is strictly forbidden to start under the circumstances of lack of lube oil or water
5, It is strictly forbidden to operate at overload or under other conditions against the rules
6, It is strictly forbidden to regulate the fuel injection pump at will
7, It is strictly forbidden to change the diameter of the pulley
8,To control the starting time(less than 15 seconds) and the starting interval(more than 2
minutes)strictly
9, It’s must to maintain the diesel engine technically in the allotted time
10, Ambient temperature under 0℃, discharge all the coolant to prevent frostbite after stop

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11,All the filters(include air pump filter ) maitain,repair or instead according to the provision
Notice of winter
Make sure the usual running of engine; please pay attention the items as following:
1、please use “-10#”light diesel oil
2、please use Class CC or CD 10W/30 or 5w/30 diesel fuel, and the Class CD diesel fuel for
turbine charger
3、Make sure the connecting reliable and available between battery and start motor
Battery capacity should be conform to specification of manual
The total length of front line, ground line should less than 2 meters, and area more than 40
mm2
The total length of front line, ground line should more than 2 meters, and area more than 70
mm2在
4、The temperature starting should be below -5℃,and add hot water and fuel
5、Eliminate the air of fuel system
6、Check if the pulverization of injector is normal or no

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Contents
Dimensional drawings for configuration and installation of diesel engine…………Ⅰ
Section 1. Diesel engine specification and technical dates
1、specifications of diesel engine …………………………………………………1-1
2、specification of the main accessories ………………………………………………1-2
3、Main technical data of diesel engines …………………………………………1-5
Section 2. Operation and security requirements of engine
1、Fuel oil 、lube oil and cooling water ……………………………………………2-1
2、Preparation before starting ……………………………………………………………2-1
3、Starting ………………………………………………………………………………2-2
4、Running ……………………………………………………………………………2-2
5、Stopping …………………………………………………………………………2-3
6、Security requirements ……………………………………………………………………2-3
Section 3 Maintenance
1、Routine maintenance ……………………………………………………………………3-1
2、Maintenance after 100 accumulated operating hours ………………………………3-1
3、Maintenance after 500 accumulated operating hours ………………………………3-2
4、Preservation and storage of engine ………………………………………………………3-3
Section 4 Engine adjustment
1、adjustment of valve lash ………………………………………………………………………4-1
2、adjustment of injection timing ………………………………………………………………4-1
3、adjustment of injector …………………………………………………………………………4-2
4、adjustment of lube oil pressure … ……………………………………………………………4-3
5、adjustment of injection pump …………………………………………………………………4-4
6、adjustment of decompression arm lash ……………………………… ……………………4-4
Section 5 Construction of diesel engine

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1、cylinder head …………………………………………………………………5-1
2、cylinder block ………………………………………………………………………………5-2
3、piston 、connecting rod … …………………………………………………………………5-3
4、crankshaft and flywheel ……………………………………………………………………5-4
5、camshaft ………………………………………………………………………………………5-5
6、gear transmission system……………………………………………………………………5-5
7、fuel and governing system ……………………………………………………………………5-6
8、lubrication system …………………………………………………………………………5-8
9、cooling system …………………………………………………………………………………5-9
10、electric system …………………………………………………………………………… 5-10
Section6 Operation notice of turbo-charger diesel engine ………………………………6-1
Section 7 faults and remedies for diesel engine
1、hard or refuse to start ……………………………………………………………7-1
2、power insufficiency ………………………………………………………………………7-2
3、smoking exhaust ……………………………………………………………………7-2
4、knocking noise in engine ……………………………………………………………………7-3
5、lube oil insufficiency or no pressure ………………………………………………………7-3
6、overheating of engine ……………………………………………………………………7-4
7、engine running-away ………………………………………………………………………7-4

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Schematic Diagram of Wiring Dimensions for installation of YD380D and YD385D

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Schematic Diagram of Wiring Dimensions for installation of YD480D

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Schematic Diagram of Wiring Dimensions for installation of YND485D

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Schematic Diagram of Wiring Dimensions for installation of YSD490D and Y495D

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Schematic Diagram of Wiring Dimensions for installation of Y4100D、Y4102D and Y4105D

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Schematic Diagram of Wiring Dimensions for installation of Y4102ZLD and Y4105ZLD

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Section 1. Diesel engine specification and technical dates
1.Specification of diesel engine
Model
YD380D
YD385D
YD480D
YND485D
YSD490D
Y490D
Y495D
Y4100D
Y4102D
Y4105D
Y4102ZLD
Y4105ZLD
Type
Vertical,water cooling, four stroke
Combustion chamber type
Direct injector
Number of cylinders
3
4
Bore(mm)
80
85
80
85
90
90
95
100
102
105
102
105
Stoke(mm)
90
95
100
105
118
Compression ratio
18
Total displacement(L)
1.357
1.532
1.809
2.156
2.54
2.67
2.997
3.707
3.875
4.1
3.875
4.1
Firing order
1-3-2
1-3-4-2
Rated power (KW)
10/1500
12/1800
11/1500
13/1800
14/1500
16/1800
17/1500
20/1800
21/1500
25/1800
24/1500
28/1800
27/1500
30/1800
30/1500
33/1800
33/1500
36/1800
38/1500
45/1800
48/1500
53/1800
55/1500
60/1800
Min.specific fuel
consumption at full load
(g/kW.h)
≤260
≤255
≤250.5
≤247
≤246
≤243
≤240
≤237
≤235
≤235
≤225
≤220
Intake Type
Natural Aspiration
Turbo-Charger with intercooler
Cooling methed
Forced watercooling
Starting methed
Electric
flywheel size
SAE7.5″
SAE10″or SAE11.5″
Bell housing size
SAE4#
SAE3#
Net mass
165
175
195
200
230
240
250
300
320
330
340
350
Overall dimensions
(L*W*H) (mm)
587*474*628
587*474*615
687*494*610
820*590*638
716*530*670
716*530*670
716*530*670
892*618*718
892*618*740
892*618*740
892*618*740
892*618*740

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2, Specification of Main Accessories
No.
Name
Specification
YD380D
YD385D
YD480D
YND485D
1
Fuel
injection
pump
Type
BQ pump
Governor
All-speed,mechnical centrifugal
Fuel delivery
pump
Single-acting piston-type
2
Fuel
injector
model
S Series
Diameter of
nozzle hole
（mm）
Ø0.23
Injection
pressure（Mpa）
22±0.5
19.6
1
0
+
3
Lube
pump
Model
Rotor type
speed（r/min）
1300
capacity（L/min）
26
Pressure（kpa）
392-441
4
Water
pump
Model
Centrifugal, volute, single-suction
speed（r/min）
3000
4000
capacity（L/min）
80
170
5
Starting
motor
Type
Silicon rectifying shunt dynamo
Model
QD138Y
Voltage（V）
12
power（KW）
3
Model
JF11
Voltage （V）
14
Power （W）
350
7
Fuel filter
Type
Single stage, paper element
Model
C0506C
8
Lube oil
filter
Type
Single stage, paper element
Model
JX0810K

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No.
Name
Specification
YSD490D
Y490D
Y495D
Y4100D
1
Fuel
injection
pump
Type
BQ pump
Governor
All-speed,mechnical centrifugal
Fuel delivery
pump
Single-acting piston-type
2
Fuel
injector
model
S Series
Diameter of
nozzle hole
（mm）
Ø0.255
Ø0.27
Ø0.29
Injection
pressure
（Mpa）
19.6
1
0
+
20
1
0
+
21
1
0
+
3
Lube
pump
Model
Rotor type
speed（r/min）
1500
1500
capacity
（L/min）
37.5
53
Pressure
（kpa）
400
392
4
Water
pump
Model
Centrifugal, volute, single-suction
speed（r/min）
4000
4000
capacity
（L/min）
270
230
5
Starting
motor
Type
Silicon rectifying shunt dynamo
Model
QDJ1329D
QDJ2925D
Voltage（V）
12
24
power（KW）
3.5
5
Model
JFWZ13
JFW24X
JFWZ13
JFWZ25
Voltage （V）
14
28
14
28
Power （W）
350
500
350
500
7
Fuel filter
Type
Single stage, paper element
Model
CXZ0708A
CX0708B
8
Lube oil
filter
Type
Single stage, paper element
Model
JX0810
JX0810K
JX0814D2

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No.
Name
Specification
Y4102D
Y4105D
Y4102ZLD
Y4105ZLD
1
Fuel
injection
pump
Type
BQ pump
Governor
All-speed,mechnical centrifugal
Fuel delivery
pump
Single-acting piston-type
2
Fuel
injector
model
S Series
Diameter of
nozzle hole
（mm）
Ø0.29
Ø0.26
Ø0.28
Injection
pressure
（Mpa）
21
1
0
+
26
1
0
+
21
75.0
25.0
+
−
3
Lube
pump
Model
Rotor type
speed（r/min）
1500
capacity
（L/min）
53
Pressure
（kpa）
392
4
Water
pump
Model
Centrifugal, volute, single-suction
speed（r/min）
4000
capacity
（L/min）
230
260
5
Starting
motor
Type
Silicon rectifying shunt dynamo
Model
QDJ2925D
Voltage（V）
24
power（KW）
5
Model
JFWZ25
JFWZ17
JFW25C1
Voltage （V）
28
14
28
Power （W）
500
750
500
7
Fuel filter
Type
Single stage, paper element
Model
CX0708B
8
Lube oil
filter
Type
Single stage, paper element
Model
JX0814D2
JX0814

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3, Main technical Data of diesel engines
（1）exhaust temperature（℃）refer to above chart
（2）Cooling water temperature （℃）80-95
（3）Lube oil temperature （℃）≤100
1. Valve lash(mm)
YD380D
YD385D
YD480D
YND485D
intake valve(cold )
0.20～0.25
exhaust valve(cold)
0.25～0.30
1. Valve lash(mm)
YSD490D
Y490D
Y495D
Y4100D
intake valve(cold )
0.30～0.35
0.35～0.40
exhaust valve(cold)
0.35～0.40
0.40～0.45
1. Valve lash(mm)
Y4102D
Y4102ZLD
Y4105D
Y4105ZLD
intake valve(cold )
0.35～0.40
exhaust valve(cold)
0.40～0.45
2. Sink age of valve
YD380D
YD385D
YD480D
YND485D
sink age of valve
0.7～0.9
2. Sink age of valve
YSD490D
Y490D
Y495D
Y4100D
sink age of valve
0.7～0.9
0.6～0.8
2. Sink age of valve
Y4102D
Y4102ZLD
Y4105D
Y4105ZLD
sink age of valve
0.6～0.8
3. Temperature and pressure limit
YD380D
YD385D
YD480D
YND485D
exhaust temperature (℃)
500
3. Temperature and pressure limit
YSD490D
Y490D
Y495D
Y4100D
exhaust temperature (℃)
500
550
3. Temperature and pressure limit
Y4102D
Y4105D
Y4102ZLD
Y4105ZLD
exhaust temperature (℃)
550
600

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（4）Lube oil pressure in main passage（MPa）
At normal operation 0.2～0.4
At min. steady speed ≥0.065
5. Governor characteristics
800≤Min .Idling steady speed （r/min）≤900 steady regulation（%）≤5
6. Battery (engine not include) capacity (A) ≥150
4. torque limits of main bolts and nut（N.m）
YD380D
YD385D
YD480D
cylinder head bolts
175～195
210～230
175～195
connecting rod bolts
50～60
60～70
50～60
main bearing cap bolts
110～130
115～135
110～130
flywheel bolts
60～70
60～70
60～70
crankshaft belt bolts
140～160
140～160
140～160
4. torque limits of main bolts and nut（N.m）
YND485D
YSD490D
Y490D
cylinder head bolts
210～230
130～150
connecting rod bolts
70～80
120～140
main bearing cap bolts
140～160
145～165
flywheel bolts
60～70
105～125
crankshaft belt bolts
140～160
140～160
4. torque limits of main bolts and nut（N.m）
Y495D
Y4100D
Y4102D
cylinder head bolts
130～150
160～200
connecting rod bolts
120～140
100～140
main bearing cap bolts
145～165
200～240
flywheel bolts
105～125
130～150
crankshaft belt bolts
140～160
200～260
4. torque limits of main bolts and nut（N.m）
Y4105D
Y4102ZLD
Y4105ZLD
cylinder head bolts
160～200
connecting rod bolts
130～150
main bearing cap bolts
200～240
flywheel bolts
130～150
crankshaft belt bolts
200～260

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Section 2. Operation and security requirements of engine
1, Fuel, lube Oil and Cooling water
1. Fuel. Users can choose diesel adopted according to local ambient temperature. In
China, we choose according to GB252 light diesel. In summer adopt No.”0” light
diesel, in winter adopt No.”10” light diesel. The diesel must be a long time precipitation
before inject into tank (not less than 48h). During refueling should us cloth filters. Thus
can extended fuel pump and injector life.
2. Oil. In China generally adopt according to GB11122 Diesel Oil. In summer adopt
No.CC40 diesel oil; in winter adopt No.30 diesel oil, used CD class diesel oil for turbo
diesel engine. Must filter through strainer when inject in to diesel engine.
3. Coolant. Applications of rainwater, tap water or clean water are suitable. The water
wells for water or well water should not be used. If the water contains more minerals,
diesel engine cooling water system will have more scale, easy to cause failure.
Therefore, If you want to use wells, springs and other water sources, must be
softening. There are two ways to soften: (1) boiled (2) in 30 liters of water to add 20
grams of caustic soda (caustic soda), made solution. Can add antifreeze in cold winter.
Ant freezing Fluid is the most commonly used public glycol (TEG) aqueous or alcohol.
Diesel difficult to start in low temperature, cooling water can be heated to 80 °C to use.
2．Preparation before starting
1, Check if the joints that fix the diesel engine are reliable and if the operating handle
is flexible.
2, Rotate the crank for several times to check if the moving parts are flexible and if
there is any obstacle.
3, Check if the oil surfaces inside the oil sump and injection pump are within
regulated scale range, and if the oil tank is full and if the fule loop is smooth.
4, Turn on the fuel tank valve to check if there is are inside the loop, if yes; loosen the

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discharge bolts of the diesel filter and injection pump. Then press handle pump on
the transmission oil pump until the air inside the oil loop is discharged completely.
Then screw up the discharge bolt before loosening the high pressure oil pipe joint
nut at the end of the oil injector. Rotate the rank to discharge the air inside the high
pressure oil pipe. After air is totally discharge, screw up the pipe joint nut and
meanwhile check if there is any oil leakage at each oil pipe joint.,
5, Check if the water tank is filled with coolant, and if there is any water leakage at
the water pipe joints.
6，Check if the joints of the parts of diesel engine are reliable or not. Check if the
storage battery is charged sufficiently, and if the joints of the lines of electric
appliance system are correct and reliable.
7, Check if the clutch is out of position.
3. Starting
1, Position the timing handle and medium speed position;
2, Rotate the ignition switch to the pre-heating position to make the thermo switch
preheated for 20 to 30 seconds;
3, Rotate the ignition switch to open position, and press the start button to make the
diesel engine start. If the diesel engine cannot be started, loosen the button right
away and wait for 2 to 3 minutes to restart it. If the diesel engine fails in starting for
three times successively, check the fault cause and eliminate the faults before
restart.
4, After the diesel engine is started, loosen the button, and rotate the ignition switch
to another position. Connect the generator charging circuit to charge the generator.
At the same time, adjust the gun to observe the rotation velocity meter. Make the
diesel engine runs in 600~800rpm and check if the diesel engine is normal or if
there are any abnormal sounds. Especially pay attention to see if the pressure of oil
is correct. Then pull the timing handle gradually to make the rotation speed of diesel
engine reach 1800~2000 rpm, and warm the machine without load.
4, Running
1, when the coolant temperature reaches 50℃and the oil temperature over 40℃,

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working with load is permitted. When using normal conditions, the water
temperature shall reach about 80℃.
2, Increase or decrease of the diesel engine load and rotation speed shall be
carried out evenly and gradually. Under normal conditions, it is not allowed to add or
remove the load suddenly.
3. During the operation time of the diesel engine, pay attention often to seek if the
reading on the instruments on the instrument panel is normal. Pay attention to the
exhausted gas color and the operation sound. Stop the machine for inspection if
there is anything abnormal.
5、Stopping
1. Before diesel engine stopping, it should reduce the load speed gradually to make
the speed at 900rpm around until the water temperature dropped to below 70 °
C, then it can be stopped by manipulation of the handle.
2. After diesel engine stops, it should rotate the ignition switch to the middle
Place.
3. In Winter, when the environmental temperature below 5 ° C, after stopping, open
the water switch on the body and radiator when temperature is below 60 ° C, give
out the cooling water to prevent frozen machine. There is no need of giving water
out if water has been added Ant freezing Fluid.
6、Security requirements
1. When engine works for generating-set, all the exposed parts and rotation parts
that may be danger to operators must device with a warning mark.
Protective Shell, partition steel should have sufficient rigidity, that only be removed
in the use of tools.