Yuchai YC 4F for Maintenance Manual

Operation and Maintenance

Manual for Diesel Engine

YC 4F Series

Guangxi Yuchai Machinery Co., Ltd.

June, 2006

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Name

Plate

Series NO.

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YC4F Series Diesel Engine Production License Number

Corporation	Specification	License	Expiration	Granted	Detail	Censorship	File	Province
Name		#	Date	Date			#
Yuchai	Multi-cylinder	XK06-2	July. 1,	July. 2,	License	Department	903	GuangXi
Machinery	diesel engine	05-0018	2008	2003	granted	of
Co. Ltd.	≤58.00kW	7				Machinery
	Engineering					Product
	Machinery					Censorship
Yuchai	Multi-cylinder	XK06-2	July. 1,	July. 2,	License	Department	903	GuangXi
Machinery	diesel engine	05-0018	2008	2003	granted	of
Co. Ltd.	≤132.00kW,	8				Machinery
	>58.82kW,					Product
	Vehicle					Censorship

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	Content
Characteristics, advantages of YC4F series diesel engine ...................................................			- 5 -
Respected customers of Yuchai ...........................................................
Overall and mounting dimensions of YC4F100-20(F3100) diesel engine
Overall and mounting dimensions of YC4F90-21(F3400) diesel engine
Overall and mounting dimensions of YC4F90-20(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 YC4F (F3000) diesel engine
Performance map of YC4F (F3100) diesel engine
Performance map of YC4F (F3400) diesel engine
Performance map of YC4F (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	Turbocharger .....................................................................................................................	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 90kW122Ps .

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

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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)

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Rb
(Bosch)
2					Rb
1.5
1
0.5									Tr
									(0C)
									500
									480
					Tr				460
									440
Me									420
(N.m)					Me
270
260
250
240
230									Pe
220
									(kw)
									75
									70
					Pe				65
									60
									55
									50
									45
									40
ge									35
g/kw.h)
230
225
220					ge
215
210
205
200
1400	1600	1800	2000	2200	2400	2600	2800	3000	3200
					r/min
- 11 -	Full load characteristic of YC4F (F3100) diesel engine
Rb

	620
590
	560
530						Tr
	500
Tem	470
( )	440
	410
	380
								Me					2284
													219
													210
													201
													192
													183
													174
													165
	71
	64							Pe
	57
50
(kW)	43
	36												SFC
	29
													(g/kW.h)
	22												265
	15												260
													255
													250
													245
													240
													235
								ge					230
													225
													220
	1000	1200	1400	1600	1800	2000	2200	2400	2600	2800	3000	3200	3400
		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

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Rb
(Bosch)
2				Rb
1.5
1									Tr
0.5									( C)
				Tr					680
									640
									600
									560
									520
Me									480
(N.m)
165				Me
160
155
150
145
140									Pe
									(kw)
									50
				Pe					45
									40
									7035
									30
ge									25
(g/kw.h
255
250				ge
245
240
235
230
225
1400	1600	1800	2000	2200	2400	2600	2800	3000	3200
				r/min

Full load characteristic of YC4F (F7000) diesel engine

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Performance map of YC4F (F3000)

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				Performance map of YC4F (F3100)
1400
1300
1200
1100
1000										70kW
900
										60kW
800				215g/kW·h
700		217g/kW.h								50kW
596			225g/kW·h							40kW
					235g/kW·h
500
						240g/kW·h				30kW
400
300										20kW
200
1200	1400	1600	1800	2000	2200	2400	2600	2800	3000	3200

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Performance map of YC4F (F3400)

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				Performance map of YC4F (F3500)
				F3500
	220
	200											kW
						225						Power Kw
	180			220								60
	160					230						50
N.m	140					235
	120				250	240						40
					260
	100
Torque			270									30
	80
		280
	60	290				310						20
	40	300				320		340	360			10
	1000	1200	1400	1600	1800	2000	2200	2400	2600	2800	3000	3200
					r/min
					Speed
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1. Engine and accessories specifications

1.1 Engine specifications (Table 1)

Type code		YC4F55G		YC4F85-21		YC4F115-20		YC4F100-20	YC4F90-21		YC4F115-21	YC4F90-21
Parameter		(F7200)		(F3500)		(F3000)		(F3100)	(F3700)		(F3600)	F3400
Type				Vertical, in-line, six-cylinder, liquid cooled, and four stroke
Intake type		Naturally aspirated		Turbocharged+DOC				Turbocharged & inter-cooled				Turbocharged
												+EGR
Combustion chamber							Direct injection
Cylinder number							4
Cylinder bore mm							92
Cylinder stroke mm							100
Displacement L								2 66
Compression ratio								17.5 1
Ignition order								1—3—4—2
Rotation direction					Counter-clockwise crankshaft, power output end
Rated power kW		40		62.5		85		75	66		85	65
Rated speed r/min		2650		3200		3200		3200	3200		3600	3400
Max. torque N·m		165		245		300		245	245		300	220

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Speed at

Max.torque

≤2000

≤2200

≤2200

≤2200

≤2200

≤2400

≤2200

r/min

Min. SFC at full load

225

215

215

≤215

≤215

≤215

215

(g/kW·h)

Max. Speed

without

≤3050

≤3650

≤3650

≤3650

≤3650

≤4100

≤3900

load r/min

Idle speed r/min

700 750

Oil

to

fuel

≤0.2 %

consumption ratio

Oil type

15W40 CF or 5W30CF

Oil capatity L

10

7.5

Exhaust

temperature

≤580

(after turbo)

Exhaust smoke(FSN)

≤3.5

≤2.0

Emission

EURO

Cooling

Closed forcing water cooling system

Lubricating

Pressure and splash

Starting

Electrical

Gross weight kg

260

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