YC4E(4110)
Operation and Maintenance Manual for Diesels
--------YC4110 series
Yuchai Machinery Co. Ltd
2007.12
Executed standard
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Diesel |
Executed standard |
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type |
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YC4110ZQ |
Q/YA271—2003 |
YC4110ZQ( ) |
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Q/YA271—2003 YC4110ZQ( )series diesel |
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engine technical specifications |
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YC4110ZLQ |
Q/YA292—2003 |
YC4110ZLQ( ) |
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Q/YA292—2003 |
YC4110ZLQ( )series diesel |
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engine technical specifications |
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YC4110ZLQ |
Q/YA414—2003 |
YC4110ZLQ( ) |
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Q/YA414—2003 |
YC4110ZLQ( )series diesel |
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engine technical specifications |
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Diesel Engine License No:
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Issuing |
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Name |
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License |
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date of |
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Filing |
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of |
and |
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license |
crip |
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No. |
vin |
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enterp |
specific |
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validi |
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tion |
reported |
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ce |
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rise |
ation |
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to |
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XK06 |
2008 |
2003.07.0 |
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903 |
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≤ |
205 |
.07.0 |
2 |
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132.00k |
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1 |
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Ind |
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Gu |
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00188 |
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ustr |
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ang |
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58.82k |
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ial |
Inspe |
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xi |
Yucha |
W |
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Pro |
ction |
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duc |
of |
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Mach |
cylinder |
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tion |
Depar |
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inery |
diesel |
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tment |
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Co. |
engine, |
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mit |
of |
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Ltd |
power |
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of |
Mech |
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≤ |
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132.00 |
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na |
Produ |
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KW and |
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cts |
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58.82K |
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W for |
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vehicl |
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Location of the nameplate:
Nameplate of a diesel engine is located on the top surface of the air intake The engine model and the ex-works identification number series number (see the figure left) also are stamped on the bottom flange platform at the middle of exhaust side of the cylinder block
“ ”
Respected customers of Yuchai
Thank you for choosing a product of Yuchai. We sincerely wish it brings you more fortune and good luck. Advanced designs, which guarantee reliability and longevity with high performance and fuel efficiency, are used in our products. In order to enhance engine operation and safety, please first read the manual in detail and pay special attention to following the precautions for safe driving.
Precautions for safe driving
1.
- 1 -
三个零件能正常工作。否则易造成因缺油烧坏曲轴或因缺水致 使气缸过热而开裂。
The oil pressure transmitter, water temperature sensor and, especially, the oil warning lamp are very important; if something goes wrong with any one of them, replace it immediately and ensure that it operates normally. Otherwise, the crankshaft may burn out due to lack of oil and the cylinder head overheat and crack due to lack of water.
2.
If the oil filter element is cleaned or replaced during maintenance, it should first be filled with oil and then re-installed. Moreover, after installation it is necessary to start the engine and run it at idle speed, and then to get out of the driver’s cab and check carefully for leakage. If leakage occurs, repairs should be performed immediately, otherwise this will cause crankshaft failure due to lack of oil.
3. 3 5
Every time before driving the vehicle, the diesel engine should be started first and run at idle speed for 3 to 5 minutes to warm-up and make all instruments function at normal status. Do not press the accelerator pedal abruptly when the engine is cold. Increasing speed rapidly may damage all kinds of instruments and their corresponding parts, accelerate wear of moving parts, and shorten the engine’s life.
- 2 -
4. 3 5
Avoid stopping engine abruptly at high speed and under heavy load operating conditions. Decrease engine speed and load gradually, and then stop the engine after idle operating for 5 to 10 minutes.
5.
The injection advance angle of the turbocharged diesel engine should be adjusted strictly in accordance to the directions in the manual. While the diesel engine power is decreasing, first check for leakage in the intake system and see whether the air cleaner has been clogged or not. Pay attention to the flattening of the hose between the air cleaner and turbocharger inlet when suddenly revving a warm engine and then, if necessary, adjust or repair it.
6.
Whenever the vehicle or diesel engine experiences a problem, stop it promptly and perform repairs immediately. Forbid running a malfunctioning vehicle.
7.
When checking the engine, do not touch the high temperature
- 3 -
components (such as the exhaust pipe) directly, and do not open the
water tank immediately after stopping the engine to avoid being
scalded.
8. 1500 5000
When a new engine has run 1500-2500km, after break-in maintenance should be performed immediately at an authorized technical Yuchai service station otherwise maintenance can not be implemented under warranty.
9.
The coolant of the cooling system must be an anti-freeze solution; otherwise, trouble caused by this can not be remedied under warranty.
10. 15 40 2000 1540 2000
A diesel engine can run normally only under definite environmental conditions. The required temperature range is from –15 to 40 , and the altitude should be below 2000m. It is prohibited to make it run submerged under water and in fire conditions. If the environment is of heavy sand or dust, please pay more attention to cleaning the air filter element and if the filter element is damaged, replace it at once. When the temperature is lower than -15 or higher than 40 or the altitude is higher than 2000m, the user should consult with a technical Yuchai
- 4 -
service station and measures should be taken to ensure the normal operation of the engine.
11.
Please operate and maintain the diesel engine correctly. Otherwise, noise, exhaust soot, and pollutant emission of the diesel engine may increase, causing environmental problems.
12
Hoist and transport the engine in accordance with the precautions described on the outside the packageing case. The place for storage of the engine shall be well-ventilated, dry, clean and free of corrosive substances.
13.
Yuchai Machinery Co., Ltd.
-5 -
1. 供油前角及私自改装发动机。
4. 易损坏增压器并引起窜油、窜气、烧瓦、抱轴等发动机严重 故障。
5. 泵调整。否则非常危险。
●
2. 摸移动或旋转部件
3.1
4.5
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-6 -
件必须有100mm
4. 路更不允许与高低压油管干涉。
5. 橡胶或尼龙管路连接机械直通仪表。
6. 管路破损不许焊接修理。应马上换新件。
7.100
8. 以便接好线路后可以用防护套罩住接线裸露金属部分。
9. 时可能导致摩擦破损的部位加装隔离、防振防护措施。
- 7 -
YC4E(4110)
YC6G
YC4E(4110) series engine is a new product that To meet demand and development of the market. It is self developed by Yuchai on the basis of YC6G engine and an excellent choice to power medium bus and light-duty vehicles.
YC4110 YC4E
The manual presents the technical specifications, the main accessories, the main technical structure and basic knowledge about operating and maintaining of the engine. Meanwhile, it also illustrates some of the primary troubles and troubleshooting methods. The user can understand and master the operation and maintenance of the YC4110 series diesel engine by reading this manual in detail, which would increase its economic benefit.
- 8 -
Along with the development of the consumer market and production techniques, the diesel engine will be improved and modified continually. In general, the manual will not be changed except for great design modification, and so some contents may differ from the actual diesel engine after a period of time. Please pay special attention to the differences.
Moreover, though the product modifications are increasing continually, the manual only shows the basic type diesel engine and does not enumerate them.
The technical development center of Yuchai company is responsible for the explanation of the manual, and the technical service center for advising the customers.
Yuchai Machinery Co. Ltd.
- 9 -
YC4E 4110…………………………………………………… 15
YC4E 4110 series Basic Specification of Engine and Specifications
and Technical Data of Main Components
………………………………… 15
Basic Specification of Engine
……………………… 16
Specifications of Main Components of Engine
………………………… 19
Basic Technical Data of Engine
…………………… 23
Primary Structures of Engine and Their maintenance
………………………………………… 23
Cylinder Block
…………………………… 24
Cylinder Head and Valve Train
………………………………… 30
Crank-connecting rod mechanism
………………………………… 32
Fuel supply system
……………………………………… 37
- 10 -
Lubrication System
……………………………………… 39
Cooling System
……………………………… 40
Turbocharger and Intercooler system
………………… 44
Starter Electrical System and meter
………………………………………… 46
Hydraulic Steering Pump
………………………… 47 operation and maintenance of engine
………………………………… 47
Operation of engine
…………………………… 49
Engine Service and Maintenance
………………… 52
Engine Frequently Possible Troubles and Their Remedy
VE……………………………………………………… 58
Appendix I
……………………… (62)
Appendix I Antifreeze and Its Operating Instruction
…………………… (69)
Precautions for Injector Operation
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- 14 -
YC4CZQ
Test Curve of Gross Power of YC4CZQ Engine
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YC4CZQ
- 16 -
YC4E150-20
- 17 -
YC4E150-20
- 18 -
YC4E160-20
- 19 -
- 20 -
- 21 -
YC4E160-20
YC4E 4110
YC4E(4110) Series Engine
Basic Specification of Engine and Specifications of Main Components
Basic Specification of Engine
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YC41 |
YC4110 |
YC4E160 |
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YC4E15 |
YC4E14 |
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YC4E1 |
model |
10ZQ |
ZLQ |
20 |
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20 |
0 20 |
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35 20 |
type |
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Air |
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intake way |
Turbo |
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Turbocharging and inter-cooling |
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chargi |
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Dry |
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Type of |
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Direct injection type |
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combustion |
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chamber |
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Number |
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4 |
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of cylinders |
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(piece) |
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mm |
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110 |
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Cylinder bore |
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(mm) |
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- 22 -
mm |
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112 |
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Piston stroke |
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(mm) |
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L |
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4.257 |
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Total |
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displacement of |
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pistons (L) |
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17.5 1 |
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Compression |
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ratio |
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Emission |
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kW |
100 |
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110 |
118 |
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110 |
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105 |
100 |
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2800 |
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2600 |
2600 |
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2600 |
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2800 |
2800 |
r/min |
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2800 |
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Rated power |
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(kW) |
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392 |
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490 |
520 |
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490 |
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430430 |
392 |
N·m |
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450 |
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1600 |
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1400 1600 |
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r/min |
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Max. torque |
1800 |
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(N·m) |
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220 |
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215 |
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g/Kw.h |
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Min. fuel |
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consumption |
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rate at full load |
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(g/ kW·h |
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- 23 - |
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≤0.5 |
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≤0.3 |
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Oil-fuel |
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consumption |
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ratio (%) |
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YC41 |
YC4110 |
YC4E160 |
YC4E15 |
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YC4E14 |
YC4E1 |
Model code |
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10ZQ |
ZLQ |
20 |
20 |
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0 20 |
35 20 |
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≤550 |
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Exhaust |
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temperature ( ) |
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≤3.0 |
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FSN |
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Soot (BSU) |
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1 3 4 2 |
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Fire order |
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Rotation |
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Counterclockwise |
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direction of |
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crankshaft (face |
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to output end) |
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Lubrication |
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Combination of splash and pressure |
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system |
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Cooling system |
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Pressurized circulating liquid cooling |
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- 24 -
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Start system |
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Electric |
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380 |
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kg |
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× |
847.5×664×843 |
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952.4×702×930.3 |
× mm |
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2599kPa 1 kPa 100 kPa
±5%±6%
Note: The rated power, max. torque, and Min. specific fuel consumption at full-load refer to the measurement values in the state that the charge temperature is 25 , dry air pressure is 99kPa, vapor pressure is 1kPa, and the total intake pressure is 100kPa. If the experiment condition is not accordance with these, those should be modified in according to the formula mentioned in The Experiment Measurement of Engine Performance. The rated power tolerance is ±5%, and the power tolerances in other speeds are ±6%.
Accessories specifications
1. 530
2.
- 25 -
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YC4110 |
YC4110 |
YC4E160 |
YC4E1 |
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YC4E14 |
YC4E135 |
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ZQ |
ZLQ |
20 |
5 20 |
0 20 |
20 |
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BHT4PA |
VE4/12 |
BHT4PA110R1304 |
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V4E/12 |
BHT4PA1 |
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model |
110R13 |
F1400 |
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F1400 |
10R1304 |
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code |
04 |
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type |
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P-type pump |
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in-line |
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in-line |
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in-line |
Fuel |
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plunge |
P-type |
plunger |
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plunger |
injecti |
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r |
pump |
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on |
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Ф11 |
Ф12 |
Ф11 |
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Ф12 |
Ф11 |
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pump |
mm |
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asse |
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plunger |
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mbly |
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diamete |
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r(mm) |
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11 |
3.2 |
11 |
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3.2 |
11 |
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mm |
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plunger |
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stroke( |
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mm) |
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Ф7 |
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Ф7 |
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Ф7 |
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mm |
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delivery |
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valve |
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diamete |
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r(mm) |
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- 26 -
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