Yuchai YC 4F for Maintenance Manual

Operation and Maintenance

Manual for Diesel Engine

YC 4F Series

- 1 -

Guangxi Yuchai Machinery Co., Ltd.

June, 2006

Name Plate

Series NO.

- 1 -

YC4F Series Diesel Engine Production License Number

Corporation

Name

Yuchai

Machinery

Co. Ltd.

Yuchai

Machinery

Co. Ltd.

Specification License # Expiration

Date

Multi-cylinder

diesel engine

≤ 58.00kW

Engineering

Machinery

Multi-cylinder

diesel engine

≤ 132.00kW,

>58.82kW,

Vehicle

XK06-2

05-0018

XK06-2

05-0018

July. 1,

2008

July. 1,

2008

Granted

Date

July. 2,

2003

July. 2,

2003

Detail Censorship File # Province

License

granted

License

granted

Department

Machinery

Product

Censorship

Department

Machinery

Product

Censorship

903 GuangXi

- 2 -

Content

Characteristics, advantages of YC4F series diesel engine ................................................... - 5 -

Respected customers of Yuchai：...........................................................错误！未定义书签。

Overall and mounting dimensions of YC4F100-20(F3100) diesel engine

Overall and mounting dimensions of YC4F 90-21(F3400) diesel engine

Overall and mounting dimensions of YC4F 90-20(F3700) diesel engine

Overall and mounting dimensions of YC4F65(F7000) diesel engine

Full load characteristic of YC4F (F3000)

Full load characteristic of YC4F (F3100)

Full load characteristic of YC4F (F3400)

Full load characteristic of YC4F (F3500)

Full load characteristic of YC4F (F3700)

Full load characteristic of YC4F (F7000)

Performance map of Y C4F (F3000) diesel engine

Performance map of Y C4F (F3100) diesel engine

Performance map of Y C4F (F3400) diesel engine

Performance map of Y C4F (F3500) diesel engine

1. Engine and accessories specifications ....................................................................- 20 -

1.1 Engine specifications (Table 1)....................................................................................- 20 -

1.2 Main accessories specifications (Table 2).........................................................................22

1.3 Main technical parameters........................................................................................... - 20 -

1.4 Main component parts tolerance clearance (Table 3)........................................................26

1.5 Tightening torques of main bolts, studs and nuts in diesel engines (Table 4)...................28

2 Fundamental structure and maintenance .....................................................................30

2.1 Cylinder block...................................................................................................................30

2.2 Cylinder head and cylinder head gasket............................................................................32

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2.3 Crankshaft-connecting rod mechanism.............................................................................33

2.4 The valve train and intake and exhaust system.................................................................36

2.5 Fuel system .......................................................................................................................38

2.6 Lubrication system............................................................................................................44

2.7 Cooling system..................................................................................................................47

2.8 Turbochar ger.....................................................................................................................47

2.9 Intercooler.........................................................................................................................49

2.10 Air compressor................................................................................................................50

2.11 Steering pump .................................................................................................................50

2.12 Starter, electrical system, and indicators.........................................................................52

2.13 Exhaust gas recirculation system

3 Operation and maintenance of the diesel engine .........................................................57

3.1 Operating the diesel engine...............................................................................................57

3.2. Maintenance of the diesel engine.....................................................................................58

3.3. Troubleshooting...............................................................................................................61

Appendix: Anti-freeze solution and its application guide.................................................. 66

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Features of YC4F series diesel engine

 The YC4F Series engine is a wholly new model which designed with the

world developed designing conception and means, and combine with Yuchai’s experienced technologies in the turbocharger and depth mechanical development. Its overall design is carried out by a team of worldwide-known automobile experts from Germany at the request of Yuchai, and it has been tested and improved with the cooperation by YUCHAI and the YAMAHA MARINE COMPANY in the performances of marine-used engine and its reliability-improvement.

 Wide output power coverage: powering from 40kW（55Ps）～90kW

（122Ps）.

 Excellent maneuverability: good in climbing and accelerating.  Effective economy: high fuel/lube-effectiveness.  Exceptional comfort: lower vibration and noise.  Completely meeting and even surpassing Euro-II exhaust emission

standards.

 Extensive application range: YC4F is simultaneously put into service for

vehicle, boat and construction machinery. It was delicately built for the clients’ comforts, better-than-expected, no matter for traffic between city and countryside, farming-purpose transport, or medium/top-grade light trucks/buses, passenger vehicles, boat and ship, and others.

 High reliability: The reliability is co-developed in step respectively by

Yuchai Technical Center, the state-level center, and the YAMAHA MARINE COMPANY(Japan), through 3-round improvements(with 20 units of samples per round) to ensure the safety and reliability of the engines.

 Compact construction and Small specific weight: the power and the

torque per litre of YC4F series engine hold the top position in China in comparison with the other engines of the same displacement.

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To Customers

In order to ensure the engine’s normal capability and safety, and also for your great benefits, please pay your attention to the following statements and take them in your heart before you start the engine:

1. Considering the essential importance of the oil-pressure transmitter, the water-temperature sensor and, especially, the oil-pressure (over-low) alarm, do replacement if any wrong happens so to assure the normal operation of the other parts. Abnormal work of any of them should cause the crankshaft burning-out or the cylinder head cracking due to oil or water lack.

2、Do remember to restart the engine and keep it running to normal state after cleaning or replacing the

oil filter element during maintenance. Then checks and make sure there is no any leakage in the filter. Leakage should be eliminated promptly to prevent the crankshaft from burning-out due to the oil lack.

3、Be sure to start the engine and keep it running in idle speed for 10 minutes before getting to work,

especially for those turbocharged engines or those having been kept in store for a long time. Don’t try to get the engine to work in a rush time without warming-up, which would damage the engine’s instruments and key parts and as a result to shorter the engine’s lifespan.

4、Abruptly stop the turbocharged engine should be avoided as far as possible while the engine is

running in a high-speed and heavy load, otherwise we should drop the engine and lower its load gradually and keep it running in idle speed for 5～10 minutes before stop.

5、Adjust the fuel supply advance angle strictly in the ways stated in the manual. Check the

intake system for the leakage before adjustments and maintenance when the engine power drops down.

6、Stop the engine promptly whenever any signs of abnormal happen to the engine or the vehicle.

Never run the engine in its malfunctioning state.

7、Getting the new engine to the authorized YUCHAI service-shop for the break-in maintenance after

running for 1500~2500km, otherwise the warranty maintenance would not be guaranteed.

8、Use a Class CF or higher grade lubricant for the engine depending on the ambient temperature to

ensure the engine’s capability, reliability and durability. Yuchai recommends the CF 15W40

lubricant for the summer time while the CF 10W30 lubricant for the winter time.

9、Use the fuel as per statements specified in the GB252-87<light diesel> and change the fuel vary

from the ambient temperature. Generally use No. O# for the summer time and No. –O# for the winter time, but use the No.-20# when the ambient temperature drops to -20 and No.℃ -35# when the ambient temperature drops to -30 .℃

10、Use the coolant as stated in the manual’s attachment so as to improve the engine’s anti-freeze and

anti-rust functions, and to prevent the engine from fatal troubles as cylinder scoring, engine boiling and the cavitation of the cylinder liner. Therefore to prolong the engine’s working life.

Guangxi Yuchai Machinery Company Limited

- 6 -

- 7 -

Overall and mounting dimensions of

YC4F100-20（F3100

）

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Overall and mounting dimensions of

YC4F90-21 (F3400)

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Overall and mounting dimensions of

YC4F90-20 (F3700)

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Overall and mounting dimensions of

YC4F65(F7000)

(Bosch)

1.5 1

0.5

(N.m)

270 260 250

240 230

220

g/kw.h)

230 225

220

215 210 205 200

1400 1600 1800 2000 2200 2400 2600 2800 3000 3200

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Full load characteristic of YC4F (F3100) diesel engine

r/min

(

500

480

460

440

420

(kw) 75 70

45 40 35

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Full load characteristic of YC4F (F3400) diesel engine

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Full load characteristic of YC4F (F3500) diesel engine

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Full load characteristic of YC4F (F3700) diesel engine

1.5 1

0.5

640

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r/min

Full load characteristic of YC4F (F7000) diesel engine

Performance map of YC4F

(F3000)

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1400

1300

1200

1100

Performance map of YC4F

(F3100)

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1000

900

800

700

596

500

217g/kW.h

215g/kW·h

225g/kW·h

235g/kW·h

240g/kW·h

400

300

200

1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200

70kW

60kW

50kW

40kW

30kW

20kW

Performance map of YC4F (F3400)

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220

Performance map of YC4F (F3500)

F3500万有特性图

N.m

Torque

扭矩

200

180

160

140

120

220

250

225

230

235

240

260

100

270

1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200

280

290

300

310

320

转速r/min

Speed

340

360

功率kW

Power Kw

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1. Engine and accessories specifications

1.1 Engine specifications (Table 1)

Type code

Parameter

Type

Intake type Naturally aspirated

Combustion chamber Direct injection Cylinder number 4 Cylinder bore（mm Cylinder stroke（mm Displacement（L） 2 Compression ratio 17.5∶1 Ignition order Rotation direction Counter-clockwise（crankshaft, power output end） Rated power（kW

）

YC4F55G

(F7200)

40 62.5 85 75 66 85 65

YC4F85-21

(F3500)

Vertical, in-line, six-cylinder, liquid cooled, and four stroke

Turbocharged+DOC

YC4F115-20

(F3000)

YC4F100-20

(F3100)

Turbocharged & inter-cooled

100

．

1—3—4—2

YC4F90-21

(F3700)

YC4F115-21

(F3600)

YC4F90-21

F3400）

（

Turbocharged

+EGR

Rated speed（r/min Max. torque（N·m

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）

2650 3200 3200 3200 3200 3600 3400

165 245 300 245 245 300 220

Speed at Max.torque

r/min）

（

≤

2000

≤

2200

≤

2200

≤

2200

≤

2200

≤

2400

≤

2200

Min. SFC at full load (g/kW·h)

ax. Speed without

loa

r/min）

（

Idle speed（r/min） 7 Oil to fuel

consumption ratio

225 215 215 ≤215

≤

3050

≤

3650

≤

3650

≤

00～750

0.2（%）

≤

3650

≤

215

3650

215 215

≤

4100

≤

3900

Oil type 15W40 CF or 5W30CF

Oil capatity（L） 10 7.5 Exhaust temperature

(after turbo)

3.5

Exhaust smoke(FSN)

≤

Emission EURO

≤

580

≤

2.0

Ⅱ

Cooling Closed forcing water cooling system Lubricating Pressure and splash Starting Electrical Gross weight（kg） 260

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