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YC4E(4110)系列
柴油机使用维护说明书
Operation and Maintenance
Manual for Diesels
--------YC4110 series
Yuchai Machinery Co. Ltd
玉柴机器股份有限公司
2007.12
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Executed standard
本说明书执行标准
型号
Diesel
Executed standard
执行标准
type
YC4110ZQ Q/YA271—2003 YC4110ZQ(Ⅰ)系列柴油机技术条件
Q/YA271—2003 YC4110ZQ(Ⅰ)
engine technical specifications
YC4110ZLQ Q/YA292—2003 YC4110ZLQ(Ⅰ)系列柴油机技术条件
Q/YA292—2003 YC4110ZLQ(Ⅰ)
engine technical specifications
YC4110ZLQ Q/YA414—2003 YC4110ZLQ(Ⅱ)系列柴油机技术条件
Q/YA414—2003 YC4110ZLQ(Ⅱ)
series diesel
series diesel
series diesel
engine technical specifications
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柴油机生产许可证编号：
Diesel Engine License No:
企业
名称
Name
of
enterp
rise
玉柴
机器
股份
有限
公司
Yucha
i
Mach
inery
Co.
Ltd
柴油机标牌位置：
Location of the nameplate:
品种
规格
Variety
and
specific
ation
多缸柴
油机≤
132.00k
W、＞
58.82k
W 车用
Multi
cylinder
diesel
engine,
power
≤
132.00
KW and
＞
58.82K
W for
vehicl
e
许可证
编号
License
No.
XK06
－205
－
00188
有效
Term
validi
2008
.07.0
1
期
of
ty
发证日期
Issuing
date of
license
2003.07.0
2
说
明
Des
crip
tion
发
证
Ind
ustr
ial
Pro
duc
tion
Per
mit
of
Chi
na
上报
部门
Depart
ment
reported
to
机械
产品
审查
部
Inspe
ction
of
Depar
tment
of
Mech
anical
Produ
cts
存档
号
Filing
No.
903
省
别
Pro
vin
ce
广
西
Gu
ang
xi
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柴油机标牌位于进气管顶面。发动机型号和出厂编号打印
在气缸体排气侧中间的下缘平台上。
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
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尊敬的玉柴顾客：
欢迎您加入玉柴机器用户行列，中心希望玉柴机器能给您
带来滚滚财源和长久的好运。本系列产品采用先进的技术设计，
质量可靠、使用寿命长，具有良好的动力性和经济性。为了使
机器的优越性能得到更好的发挥，并保证机器的安全运行，青
年在使用之前首先详细阅读本使用说明书，并特别注意以下的
“安全行车注意事项”。
Respected customers of Yuchai：
Thank you for choosing a product of Yuchai. W e 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.
安全行车注意事项！
Precautions for safe driving
1.机油压力感应塞、水温感应塞、特别是机油压力过低报警
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器这三个零件非常重要，凡有失灵者，须立即更换，以确保这
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.凡在保养过程中清洗了机油滤清器滤芯或更换滤芯时，应
先灌满机油再安装，而且安装完成后，必须起动柴油机，并使
其怠速运转，然后下车仔细观察各滤清器有无渗漏现象，若有
则须及时排除，否则容易造成缺油烧坏曲轴。
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.再次出车时，启动柴油机后怠速运转 3～5 分钟后再轻踩
油门踏板加速，待柴油机热机，各种仪表正常工作后，方可起
步运行。切莫冷车突然加大油门。在冷态下突然大幅升高转速，
会损坏各种仪表及其相应零件，加速柴油机运动件的磨损，从
而缩短柴油机的使用寿命。
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.
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4.应避免高速、大负荷运转这台下突然熄火停机，应逐渐降
速、降负荷，带速运转 3～5 分钟后再停机。
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.增压柴油机要按照说明书的要求严格控制好供油提前角。
当柴油机功率下降时，应先检查进气管路是否有漏气现象，空
气滤清器是否已堵赛，并特别注意热态下空滤至增压器进气口
之间的管路再突然加速时有无被吸扁现象，然后再作进一步的
调整或维修。
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.凡发现汽车及柴油机工作不正常时，要立即停车及时拆除
故障，决不能让汽车带病运行。
Whenever the vehicle or diesel engine experiences a problem,
stop it promptly and perform repairs immediately. Forbid running a
malfunctioning vehicle.
7.检查发动机时，不要直接触摸发动机的高温部件（例如
排气管），不要停机后马上打开水箱盖，以免烫伤。
When checking the engine, do not touch the high temperature
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components (such as the exhaust pipe) directly, and do not open the
water tank immediately after stopping the engine to avoid being
scalded.
8.凡新机运行达 1500～5000 公里时，须及时到玉柴的委托
技术服务站进行走合保养，否则不予实行柴油机的质量保修。
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.冷却系统的冷却液必须是防冻液，否则由此引起的质量故
障，不予实行三包。
The coolant of the cooling system must be an anti-freeze solution;
otherwise, trouble caused by this can not be remedied under warranty.
10.柴油机在气温为－15℃～40℃，海拔高度为 2000 米以下
（高原机除外）的环境条件下能正常工作，禁止在水浸、火灾
环境下工作。在风沙大、粉尘多的环境下，应注意清理空气滤
清器滤芯灰尘，滤芯如有破损应马上更新。在气温低于－15℃
或气温高于 40℃或海拔高度超过 2000米时，用户应向玉柴技术、
服务部门咨询，采取有效措施以保证柴油机能正常工作。
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
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service station and measures should be taken to ensure the normal
operation of the engine.
11.正常使用和维护保养柴油机，否则会增加柴油机的噪声、
烟度、排放污染物，从而造成环境污染。噪声、烟度、排放污
染物增加的主要原因及排除方法在第四章中的第三、第四部分
已有说明。
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 根据包装箱外的注意事项进行吊运、运输，贮存柴油机
的环境应通风、干燥、清洁、无腐蚀性物质。
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.天气寒冷用户在仿效柴油机冷却水时必须同时打开水箱
盖。
玉柴机器股份有限公司
Yuchai Machinery Co., Ltd.
安全警示
● 为了使您的柴油机保持良好的排放，请您注意以下事项：
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1. 不得随意扩大发动机的应用范围，如放大发动机油量、提高
供油前角及私自改装发动机。
2. 更换喷油器时应把喷油气铜垫和各缸喷油器总成一对一应装
好。
3. 柴油率氢气的油水分离器应按使用说明书的要求及时放水。
4. 空气滤清器根据使用情况不定期清理滤芯灰尘，安装滤芯时
检查有无破损，如有破损应马上换新件，经空滤后到增压器
进气口连接管路及接头卡钻箍应保证绝对密封可靠，否则容
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. 用户不能有意请油泵维修人员加大油量，更不能自行进行油
泵调整。否则非常危险。
● 有可能让您受到伤害的事，千万莫做！
1. 发动机运行时，不得擦拭、加注润滑油或调整发动机。
2. 宽松的衣服和长发不得解禁移动或转动部件，更不要用手触
摸移动或旋转部件！
3. 发动机工作时及工作后 1 小时内，排气管及增压器等零部件
表面温度很高，身体不能接触，否则容易烫伤。
4. 在发动机高温时，不得马上打开冷却水箱加注盖，因为危险
的高温冷却液将会泄出伤人，柴油机如发生开锅，不要马上
停机加冷却水或冷却液，应使柴油机在怠速运行至少 5 分钟
以上，然后停机加冷却水，再怠速运行，利用放气开关放气，
再停机加液，再怠速，如此反复多次才能加够冷却液，确保
安全及柴油机正常工作。
5. 在发动机高温时，或冷却液加压时，不得打开冷却系统的加
注盖，因为危险地高温冷却液将会泄出。
● 有可能引起火灾甚至爆炸的事，要牢记心中！
1. 每天出车前应仔细检查发动机的工作情况，有无漏油、漏气、
漏水现象，特别是有漏燃油、机油及排气泄漏时，应及时排
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除。
2. 向油箱加注燃油时，不得吸烟或有货源靠近。
3. 发动机及汽车上的电线、油管、橡胶或塑料气管、水管等易
燃件不得靠近排气管、增压器等高温或高速旋转部件。转向
助力泵油罐、转向泵、方向机只见的连接管路如有漏油应马
上排除，橡胶连接管等可燃物距离排气管、增压器等高温部
件必须有 100mm 以上的安全距离，并有可靠的隔热措施。
4. 燃油系统高低压管路不允许与硬件相碰撞摩擦，各种电器线
路更不允许与高低压油管干涉。
5. 油压感应塞原装为电器线路及仪表，决不允许私自改装为用
橡胶或尼龙管路连接机械直通仪表。
6. 排气管及增压器安装部位不允许漏气，垫片破损应即使更换
玉柴正宗配件，排气管与消声器连接法兰处决不允许漏气，
管路破损不许焊接修理。应马上换新件。
7. 转向助力泵油罐、转向泵、转向方向机只见的连接管路如有
漏油应马上排除，橡胶连接管路距排气总管 100 毫米以上。
8. 对于启动马达、充电发电机接线，要求在接线两端加防护套，
以便接好线路后可以用防护套罩住接线裸露金属部分。
9. 汽车厂接线时不得把柴油管路、电器线路捆绑在一起固定；
如果柴油管路、通气通油管路等捆绑在一起固定，也应在管
路建加装隔离、防振防护措施。建议柴油管路、电器线路、
通气通油管路等单独固定，固定时应考虑在与其他物体接触
时可能导致摩擦破损的部位加装隔离、防振防护措施。
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前 言
YC4E(4110)系列柴油机是玉柴机器股份有限公司为满足市场需
求而开发的新产品，该机型是在 YC6G型柴油机的基础上开发设计的，
是轻中型载重骑车及中巴车等理想的配套动力。
YC4E(41 10) series engine is a new product that To meet demand
and developmen
basis of YC6G engine and an excellent choice to power medium bus
and light-duty vehicles.
本说明书主要介绍 YC4110、YC4E 系列柴油机的基本结构和使用
保养方面的初步知识，同时，对如何处理柴油机一般常见故障也作了
简单的介绍。希望用户在使用柴油机的保养维护工作，保证发动机的
正常工作，这样才能确保用户获得最大的经济效益。
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.
t of the market. It is self developed by Yuchai on the
随着生产的发展和不断满足用户的要求，该系列机型也会不断地
改进和提高，除特殊的变型设计和大的结构改进外，本说明书不再作
更改，因此过了一定的时间后，说明书的介绍与柴油机的时机结构可
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能有一定的出入，请用户给予谅解并加以注意。
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.
另外，由于我公司的柴油机配套的汽车品种波段增加，因此其变
型品种也不断增加，本说明书只对基本型详加说明，其余变型产品的
改进，本书不再一一列举，请用户给予谅解并加以注意。
Moreover, though the product modifications are increasing
continually, the manual only shows the basic type diesel engine and
does not enumerate them.
玉柴技术中心负责对本说明书的解释，并由玉柴技术服务中心负
责对用户的技术咨询工作。
The technical development center of Yuchai company is
responsible for the explanation of the manual, and the technical service
center for advising the customers.
玉柴机器股份有限公司
Yuchai Machinery Co. Ltd.
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目 录
第一章 YC4E（4110）系列柴油机主要技术规格及主要附件规
格……………………………………………………（15）
YC4E（4110）series Basic Specification of Engine and S pecifications
and Technical Data of Main Components
一、主要技术规格…………………………………（15）
Basic Specification of Engine
二、主要附件的规格及型号………………………（16）
Specifications of Main Components of Engine
三、柴油机主要技术数据…………………………（19）
Basic Technical Data of Engine
第二章 柴油机的基本结构及维护方法……………………（23）
Primary Structures of Engine and Their maintenance
一、气缸体………………………………………… （23）
Cylinder Block
二、气缸盖与配气机构…………………………… （24）
Cylinder Head and Valve Train
三、曲柄连杆机构…………………………………（30）
Crank-connecting rod mechanism
四、燃油供给系统………………………………… （32）
Fuel supply system
五、润滑系统……………………………………… （37）
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Lubrication System
六、冷却系统……………………………………… （39）
Cooling System
七、增压和中冷系统………………………………（40）
Turbocharger and Intercooler system
八、起动装置、电器系统与仪表…………………（44）
Starter、Electrical System and meter
九、转向泵…………………………………………（46）
Hydraulic Steering Pump
第三章 柴油机的使用和维护保养…………………………（47）
operation and maintenance of engine
一、柴油机的使用…………………………………（47）
Operation of engine
二、柴油机的维护保养……………………………（49）
Engine Service and Maintenance
第四章 柴油机的一般故障及其排除方法…………………（52）
Engine Frequently Possible Troubles and Their Remedy
附录一 博世 VE 型分配泵装配及供油提前角度的检查
与调整……………………………………………………… （58）
Appendix I
附录二 防冻液及使用说明……………………… (62)
Appendix I Antifreeze and Its Operating Instruction
附录三 喷油器使用注意事项…………………… (69)
Precautions for Injector Operation
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YC4CZQ 柴油机总功率试验曲线
Test Curve of Gross Power of YC4CZQ Engine
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YC4CZQ 柴油机万有特性曲线
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YC4E150-20 柴油机外特性性能曲线
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YC4E150-20 柴油机万有特性曲线
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YC4E160-20 柴油机外特性性能曲线
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YC4E160-20 柴油机万有特性曲线
第一章 YC4E（4110）系列柴油机
YC4E(4110) Series Engine
主要技术规格及主要附件规格
Basic Specification of Engine and Specifications of Main Components
一、 主要技术规格
Basic Specification of Engine
机型
model
型式 type
进气方式 Air
intake way
YC41
10ZQ
立式、直列、水冷、四冲程
增压
Turbo
chargi
气缸型式 干式 Dry
燃烧室型式
Type of
combustion
chamber
气缸数 Number
of cylinders
(piece)
气缸直径（mm）
Cylinder bore
(mm)
ng
YC4110
ZLQ
YC4E160
－20
YC4E15
－20
YC4E14
0－20
增压中冷
Turbocharging and inter-cooling
直喷式
Direct injection type
4
110
YC4E1
35－20
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活塞行程（mm）
Piston stroke
(mm)
活塞总排量（L）
Total
displacement of
pistons (L)
压缩比
Compression
ratio
排放执行指标
Emission
标定功率（kW）
标定转速
（r/min）
Rated power
(kW)
最大扭矩
（N·m）
最大扭矩转速
（r/min）
Max. torque
(N·m)
全负荷最低燃
油耗（g/Kw.h）
Min. fuel
consumption
rate at full load
(g/（kW·h）
112
4.257
17.5：1
欧Ⅰ 欧Ⅱ
100 110 118 110 105 100
2800
2600；
2600 2600 2800 2800
2800
392
490；
520 490 430430 392
450
1600
≤1700 1400～1600 1600～1800
～
1800
220 215
- 23 -
Page 28
机燃油消耗比
（％）
Oil-fuel
consumption
ratio (%)
续表
机型
Model code
排气温度（℃）
Exhaust
temperature (℃)
最大烟度
（FSN）
Soot (BSU)
工作顺序
Fire order
曲轴旋转方向
Rotation
direction of
crankshaft (face
to output end)
润滑方式
Lubrication
system
冷却方式
Cooling system
≤0.5 ≤0.3
YC41
10ZQ
YC4110
ZLQ
YC4E160
－20
YC4E15
－20
≤550
≤3.0
－3－4－2
1
逆时针（从飞轮端看）
Counterclockwise
压力、飞溅混合式
Combination of splash and pressure
闭式强制循环水冷却
Pressurized circulating liquid cooling
YC4E14
0－20
YC4E1
35－20
- 24 -
Page 29
起动方式
Start system
整机净质量
（kg）
外形尺寸（长×
宽×高）（mm）
847.5×664×843 952.4×702×930.3
电起动
Electric
380
注：标定功率、最大扭矩、全负荷最低燃油指进气温度 25℃，
进气干空气压 99kPa，水蒸气分压 1 kPa，进气总压 100 kPa 时
测量值。如实验时环境温度与此不符时，应按《汽车发动机性
能试验办法》中列出的计算公式进行修正，标定功率允差±5%，
其他转速下功率允差±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%.
二、 主要附件的规格及型号
Accessories specifications
（注：1.除 530 机型的喷油泵以外，其余机型喷油泵型号以
龙口厂为准，增压器以上海联信、喷油器以无锡欧
亚为准，其余各厂家产品参考排放公告。
2.起动机、发电机、空气压缩机邓福建可因配套不同
车型调整）
- 25 -
Page 30
机型 YC4110
型式
model
code
喷
油
泵
Fuel
injecti
on
pump
asse
mbly
型号
type
柱塞直
径（mm）
plunger
diamete
r(mm)
柱塞行
程（mm）
plunger
stroke(
mm)
出油阀
直径
（mm）
delivery
valve
diamete
r(mm)
YC4110
ZQ
BHT4PA
110R13
04
单列柱
塞式
in-line
plunge
r
Ф11 Ф12 Ф11 Ф12 Ф11
11 3.2 11 3.2 11
Ф7 Ф7 Ф7
ZLQ
VE4/12
F1400
轴向柱
塞分配
式
P-type
pump
YC4E160
－20
BHT4PA110R1304 V4E/12
单列柱塞
式
in-line
plunger
YC4E1
5－20
轴向柱塞分配式
P-type pump
YC4E14
0－20
F1400
YC4E135
－20
BHT4PA1
10R1304
单列柱
塞式
in-line
plunger
- 26 -
Page 31
调
速
器
gover
nor
type
泵
fuel
suppl
y
pump
type
高压
油管
型号 TRQKV3
15/140
0PA130
4
型式 全程式 mechanical minimum-maximum governor
型式 活塞式 叶片式 活塞式 叶片式 活塞式 输油
供油压
力 fuel
supply
pressur
e(MPa)
长×外
径×内
径（mm）
Dimensi
ons
(length
×width
×
height)
(mm)
型式 多孔针阀式 P 型
喷油器
壳体型
号
590×
Ф6×
Ф1.8
KBEL-P
004D
TRQKV375
/1400PA1
590×
Ф6×
Ф1.8
KBEL-P
004
590×Ф6
KBEL-P00
304
≥0.10
×Ф1.8
4D
TRQKV
315/1
400PA
1304
560×Ф6×Ф1.8 590×
KBEL-
P004
TRQKV31
KBELP
KBE
-004
LP-
004
B
5/1400P
A1304
Ф6×
Ф1.8
KBE
LP-0
04
- 27 -
Page 32
机型
喷
油
器
滤清
器
Fuel
filter
增压
器
Turbo
charg
er
机油 型式 纸质滤芯旋转式
mode
code
喷油嘴
壳体型
号
开启压
力(MPa)
injection
pressur
e(MPa)
喷孔数 5×
型式
type
型号
model
code
型式
type
型号
model
code
YC4110ZQ YC411
0ZLQ
DLLA150
P082
Ф0.28 6×Ф0.2
DLLA1
48P08
纸质滤芯旋转式 paper element and rotation 柴油
TB28 GT2559 TB31 GT2559 TB28 GT255
YC4E160－20 YC4E15
DLLA150P082 DLLA148
2
26±0.1
5×
Ф0.286×Ф0.2
4
2CX0710
径流式
－20
P153
4
YC4E140
－20
DLLA139
P005
6×
Ф0.255×Ф0.2
7
YC4E
135
－20
DLLA
148P
152
6
×
Ф
0.
24
9
- 28 -
Page 33
滤清
器 Oil
filter
泵
Oil
pump
Water
pump
水泵
Water
pump
水泵
Water
pump
皮带
Belt 型号model
机型 model code YC4110Z YC4110Z YC4E160－ YC4E15 YC4E140 YC4E1
型号
model
code
型式
type
流量
（L/min
）flow
rate(30
00rpm,
0.45MP
a)(L/min
)
型式 机械离心式 axial flow 水泵
标定转
速
（r/min
）
流量
（ L/min
） flow
rate
扬程（mH
２O）
code
JS0818
转子式 rotor 机油
转速 3000r/min,压力 0.45Mpa 时为 65L/min
3800
260
14
充电机皮带 B960，水泵皮带 belt B960 for charging generator
belt A1200 for water pump
- 29 -
Page 34
Q LQ 20 －20 －20 35－
型式 type 腊式 wax
调
型号 model
温
器
Th
er
m
os
tat
起
动
机
St
art
er
发
电
机
Ch
code
开启温度
（℃）
opening
temperatur
e(℃)
开启温度
（℃）
opening
temperatur
e(℃)
型式 type 直流电机
功率（kW）
power(kW)
电压（V）
voltage(V)
型式 永磁式或无刷励磁式
型式 model
code
功率（kW）
power(kW)
4.8 5.2
0.75 1 0.75 1
20
EQ145
70±2
78±2
24
- 30 -
Page 35
ar
电压（V）
voltage(V)
gi
ng
ge
ne
rat
or
接地方式
发
电
机
发
电
机
空
气
压
缩
机
Air
co
m
pr
es
so
r
earth
connection
type
转向
rotational
direction(fr
om driving
end)
型式 type 永磁式或无刷励磁式
型式 type 单缸水冷活塞式 single cylinder air-cooled
额定排量
（L/min）
flow
rate(2000r
pm)(L/min)
排气最大压
力（MPa）
working
pressure(M
ax.)
175 248 175 248
负极搭铁 negative earth terminal
顺时针（从驱动端看）clockwise
28
0.8
- 31 -
Page 36
发
润滑方式 压力强制飞溅润滑
电
机
三、柴油机主要技术数据
Main technical data for diesel engine
1.配气定时（以曲轴转角计）：
Valve timing (at crankshaft angle)
（冷态气门间隙：进气门 0.4mm、排气门 0.45mm 时）
(Cold valve clearance: where intake valve 0.4mm, exhaust valve
0.45mm)
进气提前角： 14°± 5°
Intake valve advance open angle: 14±5º
进气滞后角： 44°± 5°
Intake valve lag close angle: 44±5º
排气提前角： 56°± 5°
Exhaust advance angle: 56±5º
排气滞后角： 12°± 5°
Exhaust Intake valve lag close angle: 12±5º
2.静态供油提前
角：（℃A）
YC4110ZQ YC4110
ZLQ
11~13 8~10 7~9 7~9 7~9
Static
YC4E160-
20
E0400 E0500 E0800
YC4E15
0-20
YC4E1
40
- 32 -
Page 37
fuel supply
advance angle
(before TDC) (º
CA)
3.喷油器开启压力
（ MPa ）：
nozzle opening
pressure(Mpa):
Fuel
26±0.5 26±0.5
4. 气缸压缩余隙(mm)：
Cylinder compression clearance (mm)
0.8~1.2 0.8~1.2
5. 各种主要螺栓拧紧力矩 (N·m) ：
Various tightening torque (N.m) of main bolts
气缸盖螺栓： 180～260
Cylinder cover bolt: 180-260
主轴承螺栓： 180～260
Main bearing bolt : 180-260
连杆螺栓： 150～230
26~27 26~27 26~27
Connecting rod bolt: 150-230
飞轮螺栓： 170～220
Flywheel bolt: 170- 220
飞轮壳螺栓： M12：100～120
M16：140～160
图 1 配齐相位图
调速器控制转速 YC4110ZQ YC4E（4110ZLQ）
6.
- 33 -
Page 38
Crucial speed controlled by governor (engine crankshaft):
最低空车转速(r／min)： 700～750 700～750
Minimum speed for zero load (r/min): 700--750 700—750
最高空车转速(r／min)：≤3150 ≤3220
≤2950
Maximum speed for zero load (r/min):
(标定 2800(标定 2600r／min 时)r／min 时)
7. 机油压力(Mpa) Oil pressure (MPa)
0.3~0.6 0.3~0.6
8. 各种温度范围 Various temperature range
排气温度(℃)： ≤580 ≤550
Exhaust gas temperature(℃):
机油温度(℃)： ≤105 ←
Oil temperature(℃):
出水温度(℃)： ≤95 ←
Water outlet temperature(℃):
9. 机油容量(L)： 18（其中油底壳 16）
Oil capacity (L): 18 (16 in oil sump)
10. 主要零件配合间隙(详见表 1)
表 1 柴油机主要零件的配合间隙（或过盈）表
Main parts fit clearances (shown in Table 1)
Table 1 Main parts fit clearances (interference)
序 配合部位 规定值 Prescribed 配合 Type
- 34 -
配合公差
Page 39
号
Ser
ial
nu
mb
er
Description dimensions (mm) of fit
1 排气门座孔/
Φ44
+0.025
0
/Φ44
+0.12
过盈
+0.10
性质
（mm）
Assembly
tolerance
(mm)
0.075~0.12
排气门座
Exhaust valve
seat
insert/exhaust
valve seat
2 进气门座孔/
进气门座
Intake valve
seat insert/
intake valve
seat
3 气缸盖气门
导管孔/气门
Cylinder
导管
head valve
Φ 50.5+0.03 0/ Φ
50.5+0.14 +0.12
Φ 15.9 0 -0.025/ Φ
15.9+0.023 +0.013
interference
过盈
interference
过盈
interference
0.09~0.14
0.013~0.048
- 35 -
Page 40
guide
hole/valve
guild
4 气门导管孔/
排气门
guide/exhaust
valve stem
Valve
5 气门导管孔/
进气门
guide/intake
valve stem
Valve
6 气门下沉深
度
recession
height
Valve
7 气门摇臂轴
座孔/气门摇
Rocker
臂轴
Φ 9.4+0.095 +0.069/Φ
9.4+0.018 +0.001
Φ 9.4+0.095 +0.069/Φ
9.4+0.044 +0.026
Φ 25 ± 0.02/ Φ 25-0.04
-0.07
Φ110+0.035 0/Φ109.86
±0.0075
径向
radial
间隙
clearance
径向
radial
间隙
clearance
径向
radial
间隙
clearance
径向
radial
间隙
clearance
0.051~0.094
0.025~0.069
0.9±0.15
0.020~0.09
arm seat
insert/ rocker
arm shaft
8 气缸套/活塞 Φ 110+0.035 0 / Φ径向 0.133~0.175
- 36 -
Page 41
裙下部
109.86±0.0075 间隙
radial
Cylinder
sleeve/lower
part of piston
skirt
9 气门挺柱孔/
气门挺柱
Valve
tappet/cylinder
block tappet
hole
10 凸轮轴承孔/
凸轮轴衬套
Camshaft
bearing bore
in cylinder
Φ 25.146+0.025 0/ Φ
25.1+0.031 +0.018
Φ 64.376+0.026 0/ Φ
64.4+0.102 +0.066
clearance
径向
radial
间隙
clearance
过盈
clearance
0.015~0.053
0.064~0.126
block
/camshaft
bearing bush
11 凸轮轴衬套
孔/凸轮轴衬
Camshaft
套
Φ60.7+0.070 +0.044/Φ
60.7-0.032 -0.058
- 37 -
径向
radial
间隙
clearance
0.076~0.128
Page 42
bearing
bush/camshaft
bearing bush
12 正时惰齿轮
衬套孔/惰轮
Timing idle
轴
gear bush/idle
gear shaft
13 正时惰齿轮/
惰轮轴
Timing idle
gear/idle gear
shaft
14 活塞环槽高/
第一道气环
Top ring
高
groove
Φ 50.813+0.025 0/ Φ
50.813-0.043 -0.056
径向
radial
间隙
clearance
轴向
axial
间隙
clearance
2.695±0.015/2.605-0.01
-0.03
轴向
axial
间隙
clearance
0.043~0.081
0.05~0.38
0.085~0.135
height/top ring
height
15 活塞环槽高/
第二道气环
Second
高
2.5+0.10
+0.08/2.5+0.030 +0.015
- 38 -
轴向
axial
间隙
clearance
0.05~0.085
Page 43
ring groove
height/second
ring height
16 活塞环槽高/
油环高
ring groove
height /oil ring
height
Oil
17 活塞环压入
Φ110 00
内径量规内
闭口间隙
End gap when
ring inserted in
the gauge of
Φ
110.00( inner
3.5+0.04
+0.02/3.5-0.010 -0.025
轴向
axial
间隙
clearance
第一道气
环
第二道气
环
第三道气
first gas
环
ring
second gas
ring
third gas ring
0.03~0.065
0.40~0.60
0.35~0.55
0.30~0.55
diameter)
18 连杆大头轴
承孔( 带轴
瓦)/连杆轴颈
Connecting
红：Φ66.040~66.075/
Φ65.985~66.000
蓝：Φ66.035~66.070/
Φ65.970~65.985
- 39 -
径向
radial
间隙
clearance
0.04~0.09
0.05~0.10
Page 44
rod bearing
(with
shell)/crankpin
19 连杆衬套孔/
活塞销
Connecting
rod
bush/piston
pin
20 活塞销座孔/
活塞销
pin/pin boss
Piston
21 主轴承孔(带
轴瓦)/主轴颈
Cylinder block
main bearing
(with shell)
4110ZQ/ZLQ Φ
40+0.032 +0.025/Φ40 0
-0.006
4110ZQ/ZLQ Φ
40+0.012 +0.005/Φ40 0
-0.006
红：Φ85.731~85.765/
Φ85.644~85.656
蓝：Φ85.721~85.751/
Φ85.631~85.644
径向
间隙
interference
径向
radial
间隙
clearance
径向
radial
间隙
clearance
0.025~0.038
0.005~0.018
0.075~0.121
0.077~0.120
/crankshaft
journal
22 机体气缸套
孔/气缸套外
Bore in
径
红：
Φ115+0.018 0/Φ115 0
-0.011
- 40 -
径向
radial
间隙
clearance
0.012~0.040
0.018~0.046
Page 45
cylinder block
蓝：
for cylinder
sleeve/outer
diameter of
cylinder
sleeve
23 曲轴止推面/
曲轴止推片
Crankshaft
thrust
face/thrust
disk
24 凸轮轴止推
面/凸轮轴止
推板
Camshaft
Φ115+0.035 +0.018/Φ
115+0.011 0
轴向
axial
间隙
clearance
4.7+0.024 -0.026 轴向
axial
间隙
clearance
0.10~0.2
0.05~0.22
thrust face
/thrust plate
25 齿轮之间的
啮合侧隙
Backlash of
gear in mesh
齿侧
gear
间隙
backlash
- 41 -
0.07~0.30
Page 46
26 进气门与摇
间隙
0.40±0.05
臂间隙( 冷
Intake
态 )
valve/ rocker
arm (cold
state)
27 排气门与摇
臂间隙( 冷
Exhaust
态 )
valve/ rocker
arm (cold
state)
28 压缩余隙
Compression
clearance
29 上止点时活
clearance
间隙
clearance
间隙
clearance
间隙
0.45±0.05
0.8~1.2
0.20~0.45
塞高出机体
顶面值
crown over
cylinder block
top surface at
TDC
clearance
Piston
- 42 -
Page 47
30 缸套凸肩高
The height
度
from the
cylinder block
surface to the
cylinder liner
flange top
0~0.08
surface
第二章 柴油机的基本结构及维护方法
Fundamental structure and maintenance
一、 气缸体
Cylinder block
气缸体采用整体式龙门结构，机体裙部采用曲面设计，布
置了合理的加强筋，与油底壳的结合面较宽。整个气缸体有足
够的强度和刚度。
The cylinder block uses an integral portal shaped structure and is
made of the alloy grey cast iron and strengthened with equally spaced
reinforced ribs. The whole cylinder block has adequate strength and
- 43 -
Page 48
rigidity due to its wider junction plane with oil sump.
气缸体采用干式缸套结构，缸套与缸孔之间采用间隙配合，
并分组装配。
The cylinder block matched with dry liner which is fastened in the
cylinder bore through interference fit and assembled in group to
guarantee the heat transfer well.
气缸体顶面有 18 个螺孔，通过这些螺孔固定气缸盖。底面
有安装主轴承盖的螺栓孔。主轴承盖装配须对号入座，主轴承
盖上的箭头指向发动机前端，不允许互相调换或装错方向。安
装主轴承螺栓时，不允许一次拧紧到位，应从中间档开始，依
次向两端分三次均匀拧紧。
There are 18 threaded holes in the top surface used to fasten the
cylinder head by cylinder head bolts. The threaded holes in the bottom
of the cylinder block are used for mounting the main bearing covers
which should in their own shoes, and the arrows on them should point
to the front end of the engine. Exchange and mis-direction are not
allowed. Main bearing bolts should be evenly tightened for both ends
by turns in three times:
第一次拧紧力矩：60N·m～80N·m
Tightening torque for the first time: 60N·m～80N·m
第二次拧紧力矩：120N·m～140N·m
Tightening torque for the second time: 120N·m～140N·m
第三次拧紧力矩：180N·m～260N·m
- 44 -
Page 49
Tightening torque for the third time: 180N·m～260N·m
每拧紧一次，应回转曲轴，以检查其灵活性。
After each tightening, rotate the crankshaft to check for its flexibility.
机体上装有活塞冷却喷钩。
气缸体右侧(从前端看)装有排气管、空压机、机油冷却器、
机油滤清器。左侧装有进气管、喷油泵、起动机、发电机等。
The exhaust manifold, turbocharger, air compressor, bottom ventilator,
and oil cooler are mounted on the right of the cylinder block (as seen
from the front of the cylinder block). The intake manifold, generator,
injection pump and starting motor are mounted on the left.
气缸体前端面是正时齿轮室，室内装有正时齿轮、机油泵
等。齿轮室采用齿轮室盖板加齿轮室结构。齿轮室上装有上止
点指针，减振器上打有刻度标志，用来检查供油正时和配气正
时齿轮安装时对准装配记号，以免影响使用性能。齿轮侧向间
隙要求为 0.07～ 0.3mm(图
2)。
In the front of the cylinder block
is the timing gear housing
containing the timing gear.
There is cover on it. The marks
on the timing gear housing and
damper are used to check fuel
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supply timing and valve timing. During gear installation, the marks must
be aligned to prevent affecting the engine performance, and the gear
backlash should be set to be between 0.07~0.30mm
气缸体后端装有飞轮壳、飞轮、曲轴后油封座、离合器等。气
缸体的下部装有储存润滑油的油底壳。油底壳横跨于正时齿轮
室后油封座之间。
The flywheel housing, crankshaft rear seal retainer and clutch are
mounted on the back of the cylinder block.The oil pan to store
lubricating oil is mounted on the bottom of the cylinder block. It is
spanned between the timing gear housing and rear oil seal.
图 2 齿轮系级齿轮间隙
二、 气缸盖与配气机构
Cylinder head and valve train
气缸盖采用四缸一盖整体式结构，
结构紧凑。每缸设有进排气门各一个，进、排气道分置两侧，
这样可以防止进气加热。按直喷式燃烧系统的要求，进气道为
螺旋气道。喷油器安装于进气道一侧。在进排气门与喷油器之
间的高温度区，设有专门喷水孔冷却，使缸盖
底面温度分布趋向均匀。气缸盖底面的进排气口装有高强度耐
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热钢制成的气门座圈，磨损后可
以更换。气门装入气缸盖后，气
门与气门座进行研磨，研磨后密
封带宽度为 2.12±0.5mm，气门
下沉量为 0.9±0.15mm(图 3)。
The cylinder head appears as an
integral structure. Every cylinder
has one intake valve and one
exhaust valve, and intake and exhaust ports are arranged on opposite
sides of the cylinder head respectively to prevent heating up the charge.
As required by the direct injection combustion system, the intake port
should be spirality . Injectors are mounted on the side of the inta ke ports.
Special cooling spray water hole are designed in the high temperature
area which is between the intake valve and injector to make the
temperature of the bottom of the cylinder head distribute well. Valve
seat inserts made of high quality heat resistant steel are mounted in the
intake and exhaust ports of the cylinder head to form durable
valve-seat pairs and can be replaced after wearing out. The valves rub
with valve seats after installed into the cylinder head, which can
produce seal zones whose width is 2.12±0.5mm. The recession height
after valves are installed on the cylinder head is 0.9±0.15mm.
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气门导管也可以更换。
为了防止机油从气门导管间
隙中进入气道，在气门导管
上方装有密封装置。为保证
使用性能，气门导管压入气
缸盖后，保证导管顶面至气
门弹簧座面的距离为 20.3±
图 3 气门下沉量检查
0.6mm(图 4)。
The valve guides can also be replaced. Valve stem seals are mounted
at the top of the valve guides to prevent oil from entering the intake
ports from the valve guide clearance. After the valve guide pressing
into the cylinder head, the distance between the valve guide top
surface and valve spring seat surface should be 20.3±0.6mm for
guaranteeing the performance,
图 4 气门导管安装
气缸盖螺栓按每缸 6 只布置，每两缸之间有两只螺栓共用，
共 18 只(其中 5 只长螺栓同时起固定摇臂轴支座的作用)。
There are 18 cylinder head bolts, 6 bolts per cylinder, 2 of which are
shared by the two neighboring cylinders. Among these bolts, 5 longer
bolts are also used to fix the rocker arm supports.
由于气缸盖螺栓所受的预紧力较大，为减少变形，保证密封
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可靠，对气缸盖螺栓拧紧力矩的大小及顺序应予严格控制，其
最后拧紧力矩为 180～260N·m，注意需分三次均匀拧紧(图 5)。
Because cylinder head bolt bears a larger pretightening force,
magnitude and sequence of tightening torque of cylinder head bolts
should be strictly controlled to reduce deformation and ensure reliable
sealing. The cylinder head bolt should be tightened by hand first and
then tightened in place by using a torque wrench or wrench; it is not
allowed for the bolt to have any interference with the cylinder head bolt
hole.The last time cylinder head bolts should be tightened to a torque
of between 180~260N.m .
第一次：60～80N·m
First time, tighten it to 60～80N·m
第二次：120～140N·m
Second time, tighten it to 120～140N·m
第三次：180～260N·m
Third time, tighten it to 180～260N·m
图 5 缸盖螺栓拧紧顺序图
气缸垫置于气缸盖底面与气缸体顶面之间。在气缸盖螺栓拧紧
后，与气缸盖底面、活塞顶部等组成燃烧室，同时对循环冷却
水和机油起密封的作用。
The cylinder gasket is located between the bottom of the cylinder head
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and the top of the cylinder block. After the cylinder head bolts are
tightened, the gasket with the bottom of the cylinder head and the top
of piston forms the combustion chamber , and seals cooling water and
oil.
本机采用顶置式气门机构，由气门组和气门传动组构成。气
门组包括气门、气门内外弹簧、气门锁夹、气门杆油封、气门
导管、气门弹簧座(图 6)；气门传动组包括凸轮轴、挺柱、推杆、
摇臂、凸轮轴正时齿轮等零件。其部分装配关系见下页（图 7）。
The engine overhead valve mechanism is composed of the valve assembly and
its driving train. The valve assembly includes the valves, valve springs, spring seats,
and lock halves and so on, as seen in Figure 6, as well as valve stem seals, valve
guides and valve seats. The valve driving train contains the camshaft, tappet, push
rod, rocker arm, and camshaft timing gear. Their relationship is shown in Figure 7.
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图 6 进、排气门结构
1. 排气门座 2.排气门 3.气门导管 4.气门外弹簧 5.气门内弹簧
6.气门杆油封 7.气门弹簧上座 8.气门锁夹 9.进气门 10.进气门
座
Figure 6 intake valve and exhaust valve
1, exhaust valve seat; 2, exhaust valve; 3, valve guide; 4, valve outer
spring; 5, valve inner spring; 6, valve stem oil seal; 7, valve spring
upper retainer 8, valve locker; 9, intake valve; 10, intake valve seat
图 7 摇臂、推杆与挺柱
Figure 7 Rocker arm, push rod and tappet
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凸轮轴为全支承下置式结构，凸轮
表面采用冷激处理。第Ⅰ道凸轮轴衬套
上有输送机油至气缸盖的油孔，装配时
应注意保持油道畅通。凸轮轴的轴向间
隙靠止推片来控制，其值为 0.05～
0.22mm，应注意止推片内装有隔套，
其有大倒角的一面装配时应朝向凸轮
轴轴颈。(见图 8)
The side arranged camshaft is of fully
supported structure and cold quenched on
the cam lobe surface. There is a hole in the first bushing to deliver oil to
the cylinder head, so it is important to make sure the oil passage is
unobstructed during installation. The axial clearance of the camshaft
controlled by thrust washer must be between 0.05~0.22mm. The thrust
washer has a spacer in it. During installation, the face with the big
chamfer should be towards the camshaft journal, Figure 8.
图 8 凸轮轴前端装置图
Figure 8 Components in front of the camshaft
摇臂轴为整体式，支撑在 5 个摇臂支座上，应注意，摇臂
轴的一端有一个作为标记的槽口，装配时应注意使该槽口朝上，
并以这一端作为摇臂的前端。摇臂轴上的孔和油槽应朝下，见
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（图 9）。
图 9 摇臂和摇臂支座
Figure 9 Rocker arms and rocker arm shaft supports
The rocker arm shaft is integral and supported on 5 rocker arm shaft
supports. There is a groove mark on one end of the shaft which should
be upward and taken as the front end during assembly. The oil holes
and grooves on the shaft should be downward
拆装气门弹簧时要使用专用工具见（图 10）。
Dismantling and installing valve springs requires use of a special tool,
shown in Figure 10
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图 10 气门弹簧的拆装
Figure 10 Removal and installation of the valve springs
为保证柴油机的正常工作状态，用户应按要求定期检查调
整气门间隙。在冷态时，进气门的间隙为 0 4±0 05mm。
排气门的间隙为 0.45±0.05mm。气门间隙检查调整的方法是：
把曲轴转到第一缸压缩上止点位置，此时可检查调整第 l、2、3、
6 气门，再把曲轴转过 360°，此时，可检查调整第 4、5、7、8
气门，气门间隙的调整可通过调整螺钉来实现，调整时先把锁
紧螺母拧松，用起子把气门调整螺钉按需要旋进或旋出，然后
用厚薄规检查摇臂与气门端的间隙，符合要求后拧紧锁紧螺母
(图 11)。
In order to ensure the diesel engine work normally, the valve
clearances should be checked and adjusted in regular. When the
engine is in a cold state, the intake valve clearance is 0.4±0.05mm,
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and the exhaust valve clearance is 0.45±0.05mm. The method of
checking and adjusting valve clearances is as follows: Rotate the
crankshaft to the position that the first piston is on the compression
TDC, when the No. 1,2,3 and 6 valves can be adjusted; and then rotate
the crankshaft 360°, when the No. 4,5,7 and 8 valves can be adjusted.
The adjustment can be achieved by adjusting bolts. First, loose the
tightening nut of the adjustment bolt and screw the adjustment bolt out
and in. Then check the clearance between rocker arm and the end of
valve stem with feeler gauge. If it is accordance with the requirement,
fasten the tightening nut, Figure 11.
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气缸盖罩顶面设有加机
油口和呼吸器。进气管为铸铝
件，进气管垫片为整体式，更
换垫片时，要将缸盖和进气管
的相应部位清洗干净。排气管
为整体式铸铁件，支管垫片为
4 片。
Page 60
There is a hole on the cylinder head cover top surface for adding oil
and a crankcase ventilation pipe on the side of the cylinder block. The
intake manifold is made of cast aluminum. Its gasket is integral. When it
is replaced, the corresponding surfaces on the cylinder head and
intake manifold should be cleaned. The exhaust manifold is of integral
cast aluminium construction and has 4 gaskets to the cylinder head.
图 11 气门间隙的检查及调整
Figure 11 Checking and adjustment of the valve clearance
三、 曲柄连杆机构
Crankshaft-connecting rod mechanism
活塞与活塞销采用间隙配合，装配时，将连杆小头置于活
塞两销孔中间，把销装入销孔内，用软金属锤轻轻敲打。装入
后活塞与连杆应能摇动自如，无阻滞现象。
The piston and piston pin are clearance fit. Position the small end
with a soft metal hammer, and then insert the piston pin into the pin
bore and tap it lightly. Make sure the piston and connecting rod wiggle
smoothly after installation.
活塞连杆组装入缸套时，活塞顶部
箭头必须指向发动机前端，连杆螺栓的
拧紧力矩为 150～230N·m，需分三次
均匀拧紧(图 12)。上紧后应保证曲轴转
动灵活。每个活塞上装有两道气环和一
道油环，第一道为梯形环，具有很好的
抗粘结卡环效果，第二道为锥面环，具
有很好的封气封油效果。安装时活塞环
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上有标记“TOP”的一面向上，第三道为螺旋胀圈式组合油环。
为保证密封性能，活塞环的轴向间隙及闭口间隙必须符合表 1
的规定。闭口间隙测量的方法是将活塞环平放入气缸套孔内(可
用活塞推平)用厚薄规测量环的闭口处间隙(图 13)。
During installing the piston-connecting rod assembly into the liner, the
arrow on the piston top should point to the front end of the engine. The
tightening torque of connecting-rod bolt is between 150~230N.m, and
should be tightened in three steps (Figure 13). Make sure the
crankshaft rotates freely after tightening.
Figure 12 Piston- connecting rod assembly
图 12 活塞连杆图
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图 13 活塞的安装及闭口间隙的测量
1．活塞
2.第一道气环
3.第二道气环
4.油环
Figure 14 Installation of the piston and measurement of the piston ring end clearance
1, piston; 2, top compression ring; 3, second compression ring; 4, oil ring
活塞连杆组装入缸套时，活塞环开口应置于规定的位置(图
14)，以保证密封性能。活塞环的印记应在活塞环开口的左侧。
活塞通过活塞冷却喷钩喷机油冷却，它可保证活塞有效的冷却
而不至于过热。注意不可拆掉活塞冷却喷钩不用。
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During
piston-connecting rod
assembly installation,
the orientation of the
piston ring gap is
shown in Figure 15,
which can guarantee
good sealability. The
mark of piston ring
should be in the left of the ring gap. The piston is cooled by oil sprayed
by the piston cooling nozzle, which can prevent the piston overheating.
Do not remove the piston cooling nozzle. There is one cooling nozzle
per cylinder in normal engine, but two in turbocharged engine.
曲轴中间档装有止推轴瓦，防止曲轴前后窜动，必须保证
曲轴轴向间隙为 0.07 ～ 0.2mm( 图 15) 。
The crankshaft idle gear has a thrust shell to prevent the crankshaft
from endwise movement. The axial clearance of the crankshaft must
be between 0.07~0.2mm, Figure 15.
图 14 活塞环开口方向
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图 15 曲轴轴向间隙图
1.曲轴
2.第三档主轴承
3.连杆
Figure 15 Crankshaft axial clearance
1, crankshaft; 2, the third main rearing; 3, connecting rod
曲轴后油封装在后油封座内。后油封座装在气缸体后端面，在
垫片的相应部位涂上密封胶，见（图 16）后油封装好之后，按
（图 17）的顺序拧紧螺栓，分两次拧紧，第一次至 8～11N·m，
第二次至 12～20N·m，装后油封时要使用专用工具，见（图
16）。
The rear oil seal is mounted in the rear oil seal bracket which is on the
rear end of the cylinder block. Sealant should be spread on the
corresponding bracket gasket, Figure 16. After the installation of the
rear oil seal assembly, tighten the bolts following the order shown in
Figure 18 in two steps. First, tighten all bolts to 8~11N.m and, once this
is done, then tighten all bolts again to 12~20N.m. Special tools should
be used during installation, Figure 17.
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图 16 曲轴后油封座垫片的涂胶 图 17 后油封座螺栓的拧紧顺序
Figure 16 Position of spreading sealant on crankshaft rear seal bracket
gasket and tool for installing rear seal Figure 17 Tightening order of
rear seal bracket bolts
飞轮以 7 只螺栓固定在曲轴后端的安装法兰上，飞轮螺栓
应以对角交叉分多次均匀拧紧，拧紧力矩为 170～220N·m。
The flywheel is fixed on the rear end flange of the crankshaft with 7
bolts. The bolts should be tightened in several times in a cross
sequence. The tightening torque is between 170~220N.m.
离合器为膜片弹簧离合器或螺旋弹簧离合器。
The clutch is a diaphragm spring clutch or coil spring clutch.
曲轴皮带轮减振器与曲轴前端为过盈配合，螺栓拧紧力矩为
270～300N·m。
The crankshaft belt pulley damper and the front end of crankshaft are
clearance fit, the tightening torque of bolts is between 270~300N.m.
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四、燃油供给系统
Fuel system
燃油供给系统的功用是根据柴油机的工作要求定时、定量、
定压地将柴油以雾化的状态按一定的供油规律喷入气缸内，并
使其与空气迅速而良好地混合和燃烧。它的工作情况对柴油机
的动力性和经济性有着重要的影响。柴油机夏季使用 0 号、10
号，冬季使用 0 号、－10 号、－20 号、－35 号，(GB252 一级
品或优级品)轻柴油。
The diesel fuel system must inject the right amount of clean fuel to
each cylinder at the correct time with a controlled rate and pressure,
adequately atomize the fuel and rapidly mix it with the air in the cylinder
for good combustion. The diesel power output, fuel economy, noise
and emissions (including exhaust soot) are all dependent on the fuel
system. YC4110 series diesel engines use 0#, 10# fuel in summer, and
0#, -10#, -20#, -35# (GB252— first grade or high-quality grade) light
diesel fuel in winter.
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图 18 ：P 性喷油泵外型结构示意图
Page 67
Figure 18 Outline of A-type fuel injection pump
柴油机喷油泵为 P 型泵或分配泵，P 型泵其外形结构
如图 18 所示。分配泵使用说明见附录一。使用时应注意：
(1)放完油泵内腔空气。
De-aerate in the fuel injection pump should be completed
(2)检查供油提前角是否正确，若不正确需调整。
Check whether the fuel supply advance angle is correct, and
adjust it if necessary.
(3)检查断油装置是否起作用，若不起作用需妥善修复。
Check whether the fuel cut-off device works, and repair it properly
if necessary.
YC4110ZQ 柴油机静态供油提前角为 11 ～ 13 ° CA ，
YC4110ZLQ 柴油机为 8～10°CA。 提前角不符时应进行调
整，检查提前角时，松开第一缸高压油管与油泵的连接螺母，
慢慢转动曲轴，当出油阀紧帽中
的油面开始波动时即停止转动
曲轴，此时定时指针在减振器定
时刻度上的指示值即为供油提
前角度。
The static fuel supply advance
angle of the YC4110Q is 11±2℃A,
that of the YC4110ZLQ is 8° ～
10°CA. The static fuel supply advance angle should be adjusted if
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necessary. When checking the advance angle, Unscrew the nut which
connects the high pressure fuel line for the No.1 cylinder and fuel
injection pump, crank the crankshaft slowly until the fuel level in the
delivery valve holder begins to fluctuate. At this time, the timing value
indicated by the pointer on the gear housing and the dial on the belt
pulley damper is the fuel supply advance angle.
图 19 输油泵结构图 Figure 19 Outline of P-type fuel injection pump
输油泵的结构如图 19，输油泵上设有手动驱动装置，用来
排除燃油管路的空气，使用时拧转手柄紧帽，手柄即会升起，
然后向下压手柄，如此往复运动，即能从油箱里吸取柴油供给
油路各油腔，同时松开放气螺塞，排除空气，使用完毕，应将
手柄紧帽旋紧，以免柴油机工作时 空气进入供油系中，另外，
进油接头螺栓内有一小滤网，用了一段时间后应取下清洗，以
免因堵塞而影响供油。
The construction of the fuel supply pump is shown in Figure 19. The
hand priming pump on the fuel injection pump aims to de-aerate in the
fuel line. The process is as follows: unscrew the locking nut for the
knob, and the knob will lift, then press the knob repeatedly in order to
suck fuel from fuel tank to all fuel passages and chambers. At the same
time, loose the de-aeration bolt to let out the air. At last screw the
locking nut for the knob to avoid the air entering into the fuel supply
system during the engine operation. Meanwhile there is a small strainer
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Page 69
in the inlet fuel line joint bolt. After a period of time, remove and clean it
in order not to detriment the fuel supply because of clogging.
YC4110ZQ 柴油机使用的是 R801 全程式调速器(见图 20)，
调速器及冒烟限制器上的调整螺钉均有铅封，发生故障时用户
不能拆除铅封自主调整，应送交玉柴在各地的维修中心。
The adjusting bolts for governor and soot limiter on the YC4110ZQ
engines is of lead sealing before their leaving the manufacturer. Users
should not remove the lead sealing and adjust them freely, otherwise
the engine's operation will be detriment, Figure 20.
图 20 油门限位
1.怠速限位
2.二级油门限位
3.全油门开
注：柴油机工作 70 小时或汽车
行驶 2500 公里后把二级油门限
位螺钉退除
Figure 20 Control lever's limiting position
1. idle position; 2. second grade position; 3. maximum position
Note: After 70 hours or 2500km of the engine operation, quit the
bolt used to limit the second grade position for the control lever
冒烟限制器(或称增压补偿器)通过真空补偿管路与进气管
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联接，限制发动机低转速时增压器低增压压力期间的燃油量，
使供油量与燃烧室的有效空气量密切配合，以确保烟度不超标，
而又能发出足够大的
动力。结构见（图 21），
当增压压力下降时，弹
簧推动膜片，沿减油方
向拉动控制拉杆，这样
就限制了发动机的供
油量。注意真空管路不
能随意拆除或有堵塞
和穿孔现象，否则将影
响柴油机的正常使用。 图 21 冒烟限制器
YC4110ZLQ 柴油机调速器为 RQV-K 型机械全程式调速器，
结构见（图 22）。
该调速器能稳定怠速和限制超速，而且能自动调节油量，
控制柴油机在允许转速范围内的任何转速下稳定地工作。各种
转速下的油量控制，是通过摇臂与全负荷限位块的不同位置的
接触实现的。调速器发生故障时，不宜自行拆修，应及时送交
玉柴维修站。
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图 22 RQV–K 调速器
柴油滤清器为纸质滤芯旋装式，如图 23。汽车每行驶 10000
公里(或每累计工作时间 250 小时)，应更换柴滤器整体滤芯，以
免因滤芯阻力过大而引起供
油不足。安装柴滤器时，先
用清洁的柴油加满新的滤清
器，以免因燃油系中进入空
气，引起起动困难，运转不
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稳。然后用少量清洁的机油润滑橡胶密封圈，再安装滤清器。
特别注意：应同时更换汽车底盘上燃油箱之后的初级柴油滤清
器滤芯。
The fuel filter is of paper element rotation type, Figure 23. The
whole filter element should be replaced every 100000km (or
accumulated 250 hours) in order to avoid the insufficient fuel supply
with too large resistance through the element. During the installation of
the fuel filter, fill with the filter with clean fuel to prevent the air from
entering the fuel supply system, thus making the engine start difficultly
and run unstably. Then lubricate the seal ring with little clean fuel and
install the filter. Pay special attention to this: the element of the first fuel
filter which locates after the fuel tank on the vehicle chassis should be
replaced at the same time.
图 23 柴油滤清器
Figure 23 Fuel filter
喷油器为长型多孔式，该偶件精
度高，不能互换。喷油器的喷油压力
为 26±0.5MPa。喷油器的开启压力
的调整是通过改变调压弹簧的预紧
力来实现，拆下喷油器壳体，增加或
减少弹簧座上垫片的厚度，可增大或
降低喷油压力。喷油压力的调整应在
专用试验台上进行，如图 24 所示。
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The fuel injector belongs to long multi-hole type. The precision pair of
the injector is of DLLA150P082. As it has high precision, it should not
be interchanged. The opening pressure of the injector is 26±0.5MPa.
It is determined by the preload of the pressure adjusting spring. The
preload can be adjusted by changing the pressure spring shim
thickness on the spring seat and checked on the injection test rig,
Figure 24.
图 24 喷油压力调整示意图
喷油器喷射的油束应均匀。雾化质量应良好，即油粒细小
均匀，喷油时声音清脆，无滴油现象，见图 25。
The spray should be uniform. Its atomization should be good, that
is the granularity should be small and uniform and the sound should be
with high frequency and the dripping should be avoided.
图 25 油束雾化图
Figure 25 Schematic for spray atomization
喷油器安装在气缸盖上，应保证喷嘴突出气缸盖底面的高
度，YC4110ZQ 喷嘴凸出高度为 3.6±0.1mm，YC4110ZLQ 为
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3.0±0.1mm，可通过调整喷油器前端的铜垫来调整(图 26)，拆
装喷油器时应注意其前端垫片不能丢失或错装，否则会影响喷
嘴伸出高度，从而影响柴油机的性能。
The injector is installed on the cylinder head. The height over the
bottom surface of the cylinder head should be guaranteed with 3.6±
0.1. It can be adjusted through the copper shims at the front of the
injector, Figure 26. During the removing and installing the injector, the
copper shims should not be lost or mis-installed, otherwise it will affect
the protrusion height of the injector and detriment the engine's
performance.
图 26 喷油器的安装
1.气缸盖
2.喷油器
3.铜垫
Figure 26 Installation of injector
1. cylinder head; 2. injector; 3. copper shim
五、润滑系统
Lubricating system
润滑系统的任务就是把清洁的、压力和温度适宜的润滑油
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送至各磨擦表面进行润滑，使柴油机各零件能正常工 作。
YC4E、YC4110 系列柴油机使用 20W／50CD、20W／50CF－4
／SG 级(使用外界温度为-15℃～50℃)或 10W／40CD、10W／
40CF－4／SG 级(使用外界温度为-25℃～30℃)机油，或与环境
相适应的不低于 GB11123CD 级的其他机油。
应定期检查油底壳内油面的高度，油面高度应保证处于油标
尺上下限刻度之间(图
27)，不足时应及时加
足。YC4110ZLQ、YC4E
机油容量为 18 升，其
中油底壳容量约 16 升。
油底壳下部设有放油
螺塞，供更换机油时放
油用。
图 27 机油量的检查
Figure 27 checking of the oil level
The task of the lubrication system is to deliver clean oil that has
suitable press and temperature to the friction surfaces, which can make
every component work well. YC4112 series diesel engine usually use
20W/50CD, 20W/50CF-4/SG grades oil (surrounding temperature
should be between –15 and 50℃) or 10W/40CD, 10W/40CF-4/SG
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grades oil (surrounding temperature should be between –25 and 30℃),
e
or other oil which grade lower than GB11123CD grade.
机油滤清器为纸质滤芯旋装式，型号为 JS0818(图 28)。汽
车每行驶里程 10000 公里(或每累计工作时间 250 小时)，应更换
滤清器。安装滤清器时，先用清洁的机油加满新的滤清器，然
后用少量清洁的机油润滑橡胶封圈，再安装滤清器。
The oil filter is of paper screw-on type (Js0818), Figure 28. It
should be changed after driving 1000 km or 250 hours (accumulative
total). During new filter installation, fill it with clean oil at first, next
lubricate the rubber seal washer with a little clean oil, and finally new
filter can be mounted.
柴油机运行时，如机油压力低，可用起子调整机油限压阀
调整螺钉，旋进油压升高，退出油压降低，直调至 0.4MPa，如
不行，则需认真检查润滑油路中的故障(图 29)。
If the oil pressure is low when the diesel engine is running, the pressure
can be adjusted to 0.4 MPa by the oil pressure limiting valve adjusting bolt. If
The oil filter is of paper screw-on type (Js0818), Figure 28. It should be
the bolt is screw in, the pressure will rise; If the bolt is screw out, the pressure
changed after driving 1000 km or 250 hours (accumulative total).
will drop. If that do not work, the lubrication line should be checked, Figure
During new filter installation, fill it with clean oil at first, next lubricat
the rubber seal washer with a little clean oil, and finally new filter can be
29.
mounted.
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图 28 机油滤清器 图 29 机油压力的调整
Figure 28 oil filter Figure 29 adjustment of oil pressure
六、冷却系统
Cooling system
冷却系统采用强制闭式循环水冷却系统。冷却液应采用防
冻液，具体参看附录一防冻液及使用说明。柴油机出水温度控
制在 80～95℃，机油温度控制在 90～105℃较适宜。
The YC4110 series diesel engine adopts the closed water cooling
system with pressurized circulation engine. The coolant should be
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anti-freeze. Please refer to "Anti-freeze solution and its application
guide". During the normal operation, the outlet coolant temperature is
generally controlled from 80 to 95℃. Oil temperature is generally
controlled from 90 to 105℃.
水泵及风扇是冷却系统的主要部件，一般汽车每行驶
2000～2500 公里，应从水泵上的黄油嘴给水泵轴承腔加注一次
黄油。
The water pump and fan are the main parts in the cooling system.
Generally speaking, every 2000～2500km, lubrication grease should
be injected into the water pump's bearing chamber through the filler.
图 30 皮带传动及松紧度检查
Figure 30 Belt driving and the check of its
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looseness 图 31 节能其安装图 Figure 31 Installation of thermostat
皮带的松紧度应适宜，不能过松或过紧，一般在两带轮之
间向里加 20～40N 作用力时，皮带能弯进 10～15mm 为宜(图
30)。皮带的规格型号为：充电机皮带 B960、水泵皮带 A1200。
The tension of the belt should be proper. Insufficient tension or
Excessive tension must be avoided. The belt deflection by pushing on
the belt midway between pulleys with 20~40N should be 10~15mm.
The belt's specification is as follows: the belt for charging generator is
of B960 and that of the water pump is of A1200.
皮带松紧度的调整可通过调整充电发电机与调节板的相对位置
来达到，充电机往外摆，则皮带张紧，往内摆则皮带放松。
The tension of the belt can be adjusted through the relative position
between the charging generator and the adjusting plate. When the
charging generator is swung outwardly, the tension increases, and
inwardly decreases.
柴油机使用过程中，不要轻易把节温器拆掉，以免影响柴
油机的正常工作状态(图 31)。
During the engine operation, the thermostat should not be removed
freely, otherwise it will detriment the engine's normal operation.
、增压和中冷系统
七
Turbocharger
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YC4110ZQ、YC4110ZLQ 和 YC4E 型柴油机均采用废气涡
轮增压系统。其工作原理（如图 32）所示。柴油机排气管 1 接
到增压器的涡轮壳 4 上，柴油机排出的高温和有一定压力的废
气经涡轮壳 4 进入喷嘴环 2，由于喷嘴环的通道面积由大到小，
因而废气的压力和温度下
降，而速度却迅速提高。这
个高速的废气气流，按着一
定的方向冲击涡轮 3，使涡
轮高速旋转。废气的压力、
温度和速度越高，涡轮转动
越快。通过涡轮的废气最后
排入大气。因为涡轮 3 与压
气机叶轮 8 固装在同一根转
轴上，所以叶轮与涡轮以相
同的速度旋转，将经过空气
图 32 废气涡轮增压柴油机工作原理图
1.排气管 2.喷嘴环 3.涡轮 4.涡轮壳 5.转子轴
6.轴承 7.扩压器 8.压气机 叶轮 9.压气机壳 10.进气管
Figure 32 The working principle of turbocharger diesel engine
1. exhaust pipe; 2. nozzle ring; 3. turbine impeller; 4. turbine housing;
5. rotation shaft;6. bearing; 7. diffuser; 8. compressor impeller; 9.
compressor housing; 10. intake pipe
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Page 81
滤清器滤清
过的空气吸入压气
机壳。旋转的压气
机叶轮将空气压力
提高后进入气缸，
由于空气密度增
加，进入气缸的空
气量也增加，因而
可以增加喷入气缸
的油量，从而提高
发动机功率，降低
燃油消耗率。
YC4110ZQ and YC4110ZLQ and YC4E series engines are
turbocharged diesels. Its working principle is shown in Figure 32. The
exhaust pipe (1) is connected to the turbine housing (4). The exhaust
gases from cylinders are of high temperature and some pressure and
enter into the nozzle ring (2) through turbine housing (4). Because the
passage area in the nozzle ring decreases gradually, after passing the
nozzle ring (2), the pressure and temperature of the exhaust gases
decrease, but speed increase immediately. The high speed flow
impinges the turbine impeller (3) with a certain direction to make it spin
with high speed. The higher pressure, temperature and velocity of the
exhaust gases are, the higher speed does the turbine impeller spin.
The exhaust gases through the turbine are emitted to the environment.
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Since the turbine impeller (3) is mounted on the same shaft as the
compressor impeller, the compressor is forced to spin with same speed.
The compressor pulls the air cleaned by the air filter into the
compressor housing. The air pressurized by spinning compressor
impeller goes into the cylinder. The increased density can make more
air go into the cylinder and under the good matching with the fuel
injection system, increase engine power output and improves fuel
economy.
图 33 旁通式涡轮增压器示意图
Figure 33 Schematic of turbocharger with waste gate
旁通阀式增压器是在涡轮进气口处增加一个废气旁通阀及
受增压压力控制使其开启、关闭的执行机构。当增压压力大于
某一预定值，足以克服执行器中弹簧预紧力时，曲柄使旁通阀
打开，使部分废气通过旁通阀流入涡轮后排气管，从而减少进
入涡轮的废气流量，使增压器的转速下降，避免增压器因超速
损坏。旁通式涡轮增压器与柴油机的匹配是以中低速区域进行
的，所以带旁通阀增压柴油机具有良好的低速性能。
涡轮增压器和增压柴油机在性能上有着密切的关系，如果
增压器的性能改变，将直接影响到柴油机的性能。为了使增压
柴油机保持良好的综合性能，同柴油机一样，增压器在使用过
程中必须用正确的方法和进行良好的保养。由于整个进排气系
统各接头处漏气时会影响增压器的工作，因此必须经常检查外
部接头的紧固情况。
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The turbocharged diesel engine is dependent on the turbocharger. The
changing of the turbocharger's performance will affect the engine's
performance. In order to guarantee the turbocharged engine with good
integrating performance, the turbocharger must be used correctly and
maintained well. As the leakage at the joints in the intake and exhaust
system will affect the turbocharger operation, the outer joint's fasten
condition must be often checked.
增压器系统常见故障及排除方法：
The turbocharger's troubles and troubleshooting methods are as follows:
故障原因 Possible
causes
①进气系统堵塞 Intake
blocked
②进气泄漏 Intake
leaky
排除方法 Remedies
检查空气滤清器与压气机之间的管路、压气机
出口与进气管管路及进气管。清理通畅。Check
the pipes between the air cleaner and the
compressor, between the intake pipe and the
compressor outlet. Clear them.
检查空气滤清器与压气机之间的管路、压气机
出口与进气管之间的管路，进气管与发动机连
接处等是否有泄漏、可拧紧紧固螺栓。更换垫
片等零件。
between the air cleaner and compressor, between
the compressor outlet and the intake pipe, between
the engine and the intake pipe. Replace the seal
Check the leakage at the connections
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Page 84
gasket and fasten the locking bolt if necessary.
③排气系统阻塞
Exhaust blocked
④排气泄漏 Exhaust
leaky
⑤压气机转子与压气机
壳体、涡轮与涡轮壳相
碰。Turbocharger
维修或更换有关部件 Maintain or replace the
related parts.
检查排气管与发动机、涡轮进口与排气管，涡
轮壳与中间壳，涡轮出口至排气管连接处，如
有泄漏可更换密封垫片拧紧紧固螺栓。Check
the leakage at the connections between the
exhaust pipe and engine, between the
turbine inlet and the exhaust pipe, between
the turbine housing and the middle housing,
between the turbine outlet and the exhaust
pipe. Replace the seal gasket and fasten the
locking bolt if necessary.
更换总成 Replace assembly
bearing is damaged
and impellers touch
housing
⑥进、回油管漏油 Fuel
supply and return line
leaky
更换垫片或油管 Replace
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YC4110ZLQ、YC4E 柴油机采用了进气中冷技术，增压后
的热空气通过空气中间冷却器后，进气温度进一步降低，进入
气缸的空气密度提高，辅以供油系统喷入更多燃油以达到提高
功率的目的，并改善经济性和环保性。其主要工作原理如下：
图 34 增压中冷柴油机工作原理
增压器为高速运转的精密机械，对装配技术要求很高，为
保证增压器有较长的寿命，用户切勿自行解体增压器，否则不
予质量保修。使用时应注意以下各点：
Because the turbocharger belongs to a high precision assembly and
has strict assembly requirement, in order to increase the life span of
the turbocharger, When a problem occurs for the turbocharger itself,
send it to an authorized service center by Yuchai, otherwise the quality
maintenance will not be guaranteed.
1. 在发动机起动后，润滑油压力建立以前，必须使发动机
保持在怠速状态 3～5 分钟。
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2. 在发动机停机之前，必须怠速 3～5 分钟，要使它的温
度和转速逐步地从最大值降下来。
3. 预先润滑涡轮增压器。在更换润滑油或做任何维修(包
括放出润滑油)之后或发动机长时间停放后(约一个星期
以上)，涡轮增压器需要进行预先润滑，即先松开增压器
进油接头(参见图 35)，注入干净润滑油，使增压器滑润
系统充满滑润油。在发动机启动前要将曲轴盘动几次。
启动发动机后，在进入高速运转前，让它怠速一段时间，
以建立起整个润滑油循环的压力。
4. 低温启动发动
机时必须谨
慎。当环境温
度过低或车辆
长时间不用时
会影响发动机
建立正常的润
滑油压力和流
量。在这种情
况下，发动机
启动后必须怠
速 3～ 5 分钟才能进入正常工作状态。
5. 同时也要避免发动机长时间怠速运转超过 15 分钟。
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中冷器的故障主要是漏气，漏气将使发动机功率降低，涡
轮增压器增压压力下降，并使排气温度升高。应对漏气的中冷
器进行焊补。裂缝漏气常发生在扁管与板翅、箱体与集气室焊
缝处及箱体等处。检查的最好办法是对中冷器加压至 207kPa，
涂肥皂水以找出漏气的准确部位。同时也应注意检查中冷器联
接管路的密封性，可在上面涂上肥皂水，启动柴油机工作，观
察是否有漏气现象
八、起动装置、电器系统与仪表
starter, electrical system, and indicators
电器系统原理图如图 36 所示。充电发电机采用硅整流发电
机，额定电压 28V、功率 0 75kW，发电机为负极搭铁(接地)
不能接错线，否则将会烧坏发电机(注：电路由于各汽车厂采用
不同的调节器将有所变化，请用户注意相应的汽车使用说明书
的说明)。
图 36 电器系统
1.起动马达
2.发电机
3.调节器
4.加热器
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Figure 35 electrical system
1. starter; 2. generator; 3. regulator;4. pre-heater
The fundamental of the electrical system is shown in Figure 35. The
generator used on YC4110 is integral silicon rectified generator. It has
a rated voltage of 28V and a rated power of 0.75kW. The earth
electrode of the generator is negative. If the positive post of engine is
mistakenly connected to earth, the generator will be burnt. (Attention
please: Circuit varies with different regulator used by different car
makers. Car buyers should pay attention to the respective manual
brochure.)
YC4110ZLQ、YC4E 柴油机起动电机为直流
电机，工作电压 24V，最大输出功率 5.2kW。
起动时应注意，起动电机持续工作时间不要
超过 10 秒钟，否则容易烧坏。电机连续使
用时，每两次的间隔时间应不少于 1 分钟。
柴油机起动成功后，应立即
图 37 起动机的使用 将开关拧回“0”位，否则柴油机将会通过
飞轮齿圈带动起动电机超速运转，使电机烧坏(图 37)。
Figure 37 Usage of the starter
The starter used on YC4110Z
an operating voltage of 24V and maximum output power of 4.8kW. Do
not keep the starter running for more than 10 seconds at a time or it will
Q diesel engine is of AC starter and has
L
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be burnt. And if the engine fails to run after cranking, the cranking
should not be repeated within at least one minute. When engine begins
operating, the key should be switched back to zero position. If not,
driving pinion will still engage flywheel and diesel engine will drive
starter at a high rotating speed and will cause the starter to burn.
(Figure 37)
九、转向泵 Steering pump
1. 转向泵带有滤网，滤网位于转向泵的阀座之中。
The steering pump has a screen filter, located in the valve seat.
2. 请在走保时清洗滤网，走保后按每 5000km 清洗一次滤
网。当转向显得沉重时，有可能是转向泵的滤网不干净，
请拆开阀座清洗滤网。清洗时请注意保持泵体及阀座的
清洁度。
Please clean the screen filter during maintenance after the
break-in period. After that, clean the screen filter every 5000
km. If the vehicle is difficult to steer, the screen filter of the
steering pump might not be clean. Dismantle the valve seat to
clean it. When cleaning, please keep the pump body and valve
seat clean.
3. 其余的维修保养与原来没有加装滤网的转向泵维修保养
要求相同。
Other maintenance should be the same as that of the pump
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without installing the screen filter.
第三章 柴油机的使用和维护保养
Operation and maintenance of the diesel engine
一、柴油机的使用
Operation of the diesel engine
1. 起动前： Preparations before Starting the Engine
检查油底壳机油油面，确保机油足够，保证润滑，若不够，
则应添加到机油标尺规定的位置；Check the oil quantity in the
engine oil sump; if not, replenish the oil to the stipulated position on the
dipstick.
检查水箱中的冷却液，保证正常冷却(玉柴系列增压机要求
必须使用防冻冷却液)；
radiator is sufficient or not; if not, replenish the coolant in sufficient
quantity as specified
Check whether the coolant inside the
检查排除燃油管路的空气和柴油滤清器的水，检查油量，
若不够，添加燃油； Check whether the fuel quantity in the fuel tank
is sufficient or not; if not, replenish the fuel to the sufficient quantity as
specified
检查电器系统(各连接线路、开关接线等是否牢固可靠，电
瓶电解液是否充足，若不够，加足电解液)；Check whether the
whole electrical system works normally and the battery is sufficiently
charged or not, and replenish the battery with a sufficient quantity of
the electrolyte.
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检查皮带，松紧度应适宜，皮带过松打滑使水泵、风扇的
工作不正常，冷却效果差，发动机水温高，过紧则使皮带轮轴
受力过大、皮带寿命缩短；
检查汽车底盘和操纵装置，禁止汽车带病行驶。
2. 起动：
完成起动前准备工作并确认符合要求后，才可以起动柴油
机(冬天天气寒冷时需对柴油机预热后才能起动)，起动柴油机
时，持续起动时间不能超过 10 秒钟；二次起动的时间间隔不应
少于 1 分钟；若连续三次均无法起动，则应检查原因，排除故
障，再行起动。起动后检查：
机油压力：在怠速时不能低于 0 1MPa，压力过低，发动
机润滑不良会造成各运动副磨损；
水泵工作情况良好，确认冷却液已进入柴油机水套内循环
无“三漏”、异响现象；
各汽车仪表的工作情况。发现有不正常现象，必须立即停
车检查排除，必要时送修。
3. 运行： Starting of Engine
柴油机冷机起动后，从怠速到低中速下空载运转热机 5 分
钟后才起步，热机起动时，在柴油机建立油压后才能起步，确
保发动机润滑良好； Warm up the vehicle unloaded by running the
engine successively at the low and medium speeds after it is started.
禁止大油门高速高负荷运转柴油机，应逐渐提高柴油机转
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速，水温上升到 60℃以上，发动机充分润滑、受热均匀后才能
正常运转； Do not accelerate abruptly, Speed up slowly. It is not
allowed for the engine to work with heavy loads and a high speed
only when the engine coolant temperature is higher than 60 ℃ and the
oil temperature higher than 45℃.
一般情况下少用或不用排气制动阀，频繁使用，会对发动
机造成严重损坏，如气门锁夹弹出、气门松脱、断裂，增压器
受损等；
汽车在行驶阶段，司机应经常注意观察车上各种仪表，随
时掌握发动机的运行情况，发现不正常情况必须立即停车检查
排除，必要时送修。
4. 停车：Stopping of Engine
停车前怠速运行 3～5 分钟后才熄火，特别是高转速高负荷
运转时更应如此；避免急速停车，发动机高速运转时增压器叶
轮转速可达 12 万 转/ 分钟以上，急速停车会使增压器无润滑
造成轴承和转子烧坏。这一点，用户必须特别要注意； 每次
停车后，必须及时排除在运行期间所发现的故障，并经常进行
必要的检查，保证柴油机正常的技术状态；
for the engine to stop suddenly. Before stopping run the engine for 3～
It should be avoided
5 minutes at a lower speed to cool down the engine, then run the
engine at the idle speed for 2~3 minutes, and only in this case you can
stop the engine
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按发动机保养规定要求及时切实做好柴油机的技术维护保
养工作。
5. 油品选用： (推荐使用正宗的玉柴牌润滑油)
柴油的选用：使用符合国标 GB252 优级品或一级品轻柴油，
排放要求高的使用低硫柴油。
机油的选用：使用不低于国标 GB11122-1997 中的 CD 级机
油，增压中冷柴油机建议使用更高一级的机油(CF 级或以上)
轻柴油（GB252 优级品或一等品）
使用条件 ≥4℃ ≥-5℃ ≥-14
℃
油品牌号 0号 -10 号 -20 号 -35 号 -50 号
机油（不低于 GB11122-1997 中的 CD 级）
使用条件 夏季 ≥0℃ -15℃ ≥-30℃
油品牌号 15W/40CD
(40CD)
15W/30CD
（30CD）
100W/30CD 5W/30CD
≥-29
℃
≥-44
℃
经常检查机油，发现变稀、变黑时立即换油，建议正常条
件下行驶 10000—11000 公里内更换机油，恶劣条件下要缩短换
油周期。
柴油机的维护保养
二、
●用户必须在新车行驶 1500～2500 公里内到玉柴服务站进
行走合保养并记录走保情况；
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●走保后每 1 万公里内到玉柴服务站进行一次强制保养，
要求 5 万公里内强制保养不少于三次；
●发动机在使用期间，还应按以下要求进行例行维护保养，
其中的第 1、4 项由用户自行进行，第 2、3 项由专业维修保养
人员进行；
●空气滤清器是保证柴油机吸入清洁空气的关键零部件，
要经常检查进气系统密封情况和保养、更换空滤器，确保柴油
机不出现早期磨损。
序 项目 保养周期 保养项目
（一） 日常维护 每日 1.检查燃油箱油量；
2.检查冷却水水箱冷却液量；
3.检查油底壳内油面高度；
4.检查“三漏”情况；
5.检查皮带松紧度；
6.检查各附件装置的紧固情况；
（二） 一级保养 每
2000 ～
2500 公
里（或每
50 小时）
7.排除柴油油水分离器的水。
1.日常维护的所有项目；
2.缸盖螺栓的拧紧力矩；
3.检查、调整气门间隙；
4.检查、调整供油提前角；
5.检查喷油器的工作压力及雾化情况；
6.清洗输油泵进油滤网等。
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（三） 二级保养 10000 ～
1.一级保养的所有项目；
11000 公
里（或每
150 小
时）
（四） 三级保养 50000 ～
60000 公
里
2.各管路、线路连接紧固情况；
3.给水泵加注钠基润滑脂；
4.重要螺栓螺母拧紧情况；
5.必要时更换机油；
6.检查主要零部件的紧固情况。
1.拆开并清洗整机，清除积碳，油污和
结胶，清洗全部润滑油管、油道；
2.检查气门、气门座、气门导管、气门
弹簧、推杆、摇臂等零件的磨损情况，
必要
时修磨更换；
3.检查活塞环、气缸孔、连杆小头衬套
及连杆轴孔的磨损情况，必要时可更换；
4.检查主轴瓦(包括止推轴瓦)的磨损情
况，必要时更换；
5.检查齿轮的磨损情况及齿侧间隙，必
要时更换；
6.检查喷油器雾化情况，必要时研磨喷
油嘴偶件或更换；
7.检查机油泵内外转子及机油泵体，必
要时更换；
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8.检查发电机和起动机，清洗各零件、
轴承，加注新的润滑脂；
9.检查增压器轴承的间隙，必要时更换
涡轮增压器；
10.检查中冷器是否漏气，必要时修理。
（五） 三滤维护 1.经常检查、清洁空气滤清器；
2.按使用周期更换柴油、机油滤清器和
空气滤清器滤芯。
第四章 柴油机的一般故障及其排除方法
柴油机在运行过一段时间之后，难免会出现这样或那样的
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故障，如不及时解决，将会影响柴油机的正常工作。
为了使用户能及时处理一些力所能及的常见故障，我们在
此介绍处理一般故障的简单知识，使用户能及时排除车辆运行
中柴油机出现的一般故障，以便保证柴油机能持续正常运行。
这里介绍的故障排除知识是简单的，也是不全面的。因此
用户在使用时尚请注意，如对柴油
机发生的故障及其原因判断不确切，最好不要擅自处理，以
免造成更大的损失，而应该及时通知我公司或就近请专业单位
协助处理。
柴油机的一般故障处理方法简介如下：
Diesel engine would be in trouble after operating for a period of time. If
the troubles don’t be removed in time, it would result in abnormal
operation of the engine.
The manual presents simple troubleshooting methods, which tell users
how to deal with the common troubles occurring during vehicles
running and have engine operate normally.
Because the knowledge about troubleshooting is simple and not
comprehensive, please pay more attention to it. When not being sure of
the trouble causes, do not tackle it without authorization to avoid larger
damage. It should be done that informing and consulting with technical
Yuchai service center or other specialist company.
The troubleshooting methods are shown below.
一、启动困难或不能启动 Diesel engine can not start
故障原因 Possible
causes
排除方法 Remedies
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1.电力不足或接点接触
给蓄电池充电或更换蓄电池，检查各电器接触
不良 Insufficient
power or bad terminals
connection contact
2.燃油管路堵塞，供油不
足 Fuel pipe blocked
or insufficient oil supply
3.油路中吸进空气 Air
exists in the oil line
点是否有松脱现象或因锈蚀接触不良，查出后
妥善处理。Charge or replace the battery.
Check the loose of contacts of electrical
equipment or bad contact due to rustiness
and deal with it.
检查各油路是否有杂物堵塞。清洗柴油滤芯。
Determine the location of the clog and clear
it. Clean filter element.
检查各油管接头是否有松动、破损现象。如有，
应排除或更换。故障处理后排除油路空气。
Check the looseness and damage of the
joints of the fuel lines, remove or replace
them if necessary and then clear air in the oil
line.
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4.气缸内积油过多 Too
先关闭油门、用马达转动曲轴，排尽缸内的多
much oil deposit in
cylinder
5.喷不出油或喷油很少，
且压力低 Fuel supply
pump does not apply
fuel or applies fuel
irregularly
6.活塞环过度磨损造成
压力不足 Insufficient
compression pressure
due to piston ring much
worn-out;
7.气门漏气 Blow-by
余积油，对大修和三保后的机子更应注意。
Closing the throttle, rotating the crankshaft
by motor, draining excess oil deposit in
cylinder, and especially p ar more attention to
the overhauled engine or the engine after
third order maintenance
检查出油阀是否漏油，柱塞弹簧或出油阀弹簧
是否断裂，喷油器是否卡死，柱塞是否磨损过
度。发现问题应及时排除。Check for leakage
of the delivery valve and inspect whether the
injector is worn-out, plunger is seized, and if
the plunger spring and delivery valve spring
is broken. Remove them in time.
检查并更换新环。Check and replace the
piston ring
valve
8. 配气相位不对 In
correct valve timing
检查气门间隙和气门密封情况，重新调整或研
磨气门 Check the valve clearance and
seal of valve. Grind or readjust the valve if
necessary.
对大修机子或三保后的机子应注意齿轮记号
是否装对 For the overhauled engine or the
engine after third order maintenance, pay
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attention to the timing marks alignment on
timing gears.
二、柴油机功率下降 Insufficient power output
故障原因 Possible causes 排除方法 Remedies
1.进气堵塞 Intake blocked
2.排气背压过高
3.增压系统压力不足
4.增压器工作失常，压气机、涡轮
气流通道污染堵塞或损坏；
5.轴承失效；
6.涡轮、压气机背面间隙处有积碳、
油泥
7.中冷器损坏、漏气
8.燃油管路漏油或堵塞
- 96 -
检查空气滤清器、进气管，清理或
更换空气滤清器滤芯。Check the
air cleaner, intake pipe, and clean
or replace air cleaner filter
elements.
检查气门定时，必要时调整；清理
排气管。Check the working
pressure or atomization of
injector, replace plunger precision
pair if necessary.
检查并排除管路和连接处的泄漏。
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