Yuchai YC6A, YC6B, YC6J Service Manual

YC6A YC6B YC6J

YC6A YC6B YC6J Series Construction Engine

Operation & Maintenance Manual

Please read the Manual carefully before using.

Guangxi YuChai Machinery Co., Ltd.

00

June.2008

Foreword

YCA YC6B YC6J

This Instruction Manual introduces the YCA YC6B YC6J series construction engine about its structure and technical parameters, the technical specifications and data of its main accessories as well as the basics information on use and service. It also describes some common malfunctions and solutions.

YCA YC6B YC6J“ ”

Please read this manual carefully to understand and master the operation and maintenance requirements about YCA YC6B YC6J series construction engine prior to

putting the machine into operation and pay your particular attention to the Precautions for Safe Operation described below in order to enable the machine to bring its superior performance into full play and ensure its safe operation.

With continuous development and demand of the society, the engine will be uninterruptedly optimized and improved and its modified products will also be continuously increased. Except for especially great modifications in the design this manual will not be altered again. Therefore, after a certain period, there will be some discrepancies between the description in the manual and the actual engine, to which kindly ask our customers to pay due attention.

The manual gives a detailed description for the basic model engine only, and any modifications of it are not laid out to which we ask our customers to pay due attention and understand it well.

YuChai reserves the explanation right of this manual.

! Precautions for Safe Operation!

1.

Such parts as lubricating oil pressure sensing plug, water temperature sensing plug and alarm for too low lubricating oil pressure are very important. In case any failure, immediately replace it to ensure normal working of these parts, otherwise the crankshaft may be burned due to lack of the oil or the cylinder head may crack due to overheating resulted from lack of the water.

2.

After cleaning the oil filter or during the process of replacing filter gauze, reinstall the filter

only after refilling oil fully, and start the engine on idle running immediately after reinstallation; meantime, check if there is any sign of leakage to any filter. Correct the leaking filters or it may easily lead to crankshaft burn caused by oil shortage.

3. 3 5

Each time you start the vehicle, first start the engine on idle running for 3 to 5 minutes till the engine warms up and all gauges working in normal function, then start to move. Never put the vehicle to sudden acceleration from cold-start. For any dramatic speed-up on cold status will damage the instruments and their corresponding parts and components and accelerate the wear and tear of engine’s kinetic parts, consequently it will shorten the engine’s life cycle.

4. 3 5

Avoid any sudden stall and stop at high speed & high load status, the appropriate way is to gear down gradually and stop the vehicle after 3 5 minutes of engine idle running. Otherwise it will damage turbocharger and other moving parts and shorten engine service life consequently.

5.

Check often for the leakage and blockage of the intake piping and air cleaner to make them work normally. Do make adjustment or maintenance when there is leakage in the intake system and blockage in air cleaner, for they will damage the turbo-charger and cause the cylinder scoring, and will decrease the engine’s power at the same time , therefore maintain timely as the vehicle can be driven at pretty low speed .

6.

Start the engine on first gear, otherwise it may stop. 7.

Whenever the engine works abnormally, it shall be dealt with care. 8.

Don’t approach rotating components and directly touch the high temperature parts (such as exhaust pipe and turbocharger etc.) of the engine when you check it, don’t open the water tank cover immediately just after stop, for this may cause physical burn.

9. 50 60

Send the engine to a consignment technical service station of YuChai for run-in service

when it runs 50-60hour, or you will waive the warranty for this engine. 10.

Anti-freeze coolant shall be used in the cooling system; otherwise the consequent failure will not be included in the free warranty

11.

Customer is prohibited to insert or pull out the connectors. 12.

Water and any other cleaning agent are prohibited to use for washing and cleaning the engine.

13

Follow the instruction to drain water of fuel pre-filter, replace filter element assy. of pre-filter and filter element assy. of precision fuel filter.

14.

Make sure the ignition switch is turned off before dismounting and cutting off the battery.

15

Hoist and transport the engine in accordance with the precautions described on the outside the packaging case. The place for storage of the engine shall be well-ventilated, dry, clean and free of corrosive substances. See the mark on the package for preservation of the engine.

16.:

The basic information of the engine is on the nameplate, including: rated power, rated speed, series number, production date and implement standard. The nameplate of the engine is located at the top of the cylinder cover housing.

The engine type and ex-work number are printed on the platform in the middle of the cylinder lower margin.

18.

The safety warnings include user’s precaution, crankshaft steering/rotating danger and high temperature danger sticking on engine cover, clutch housing and cover on exhaust pipe respectively

19

Random documents are included in the package: user’s manual, parts list, tool list, certification and packing list. Please check after opening.

			Content
1	General introduction ...................................................................................................			18
	1.1	Product Feature ...........................................................................................		18
1.2 Style number composition and its specific meaning
	..........................................................................................................................................			18
	1.3	Main application scope...............................................................		19
2 Technical specification............................................................................................				20
	2.1	Main specification (basic) ............................................................		20
	2.2	Main technical parameter .....................................................................		35
3	.................................................................................................			39
Primary Structures of Engine and working principle .................................................................				39
	3.1	Cylinder Block..................................................................................................		39
	3.2	Cylinder Head and Valve Train.......................................................		40
	3.3	Crank-connecting Rod Mechanism.....................................................		46
	3.4	fuel system ................................................................................................		50
	3.5	Lubrication System ....................................................................................		58
	3.6	Cooling System ............................................................................................		62
	3.7	Start device, electrical system and instrument................		66
	3.8	Turbocharger ...................................................................................................		69
	3.9	Steering pump.................................................................................................		72
4	....................................................................................................			75
Operation and maintenance of engine......................................................................................				75
	4.1	Operation of engine...............................................................................		75

4.2	Engine Maintenance ......................................................................		79
5		....................................................................................................	82
Frequently-possible Troubles ......................................................................and Their Solution			82
5.1	Engine ..........................................................................Fails to Start		82
5.2	Insufficient ..............................................................power of Engine		84
5.3	......................................................................................		86
Abnormal Noise during Running .......................................................................of Engine			86
5.4	Black Smoke ........................................................from Exhaust Manifold		87
5.5	........................................................................................................		88
White smoke and Blue Smoke ......................................................from Exhaust Manifold			88
5.6	...................................................	Abnormal lubricant pressure	88
5.7	.............................................................................................		90
Large Consumption of Lubricating ...............................................................................Oil			90
5.8	Too high .........................................................water outlet temperature		90
5.9	.......................Malfunction and Solution of Turbocharger		91
5.10 ................................Malfunction and Solution of Clutch			92
5.11 .............................................................		Shut - off automatically	92

1 YC6A

Fig 1 Assembly Layout for YC6A Diesel Engine (may differ from the practical configuration)

2 YC6B

Fig 2 Assembly Layout for YC6B Diesel Engine (non-Turbocharged) (may differ from the practical configuration)

3 YC6B

Fig 3 Assembly Layout for YC6B Diesel Engine (Turbocharged) (may differ from the practical configuration)

4 YC6J

Fig 4 Assembly Layout for YC6J Diesel Engine (may differ from the practical configuration)

YC6A A8700

YC6A series construction engine (A8700) external characteristic

curve

13

YC6B B8C00 B9C00

YC6B series construction non-Turbocharged engine B8C00 B9C00 external characteristic curve

14

YC6B B7700

YC6B series construction Turbocharged engine B7700 external characteristic curve

15

YC6J J8000

YC6J series construction engine (J8000) external characteristic

curve

16

1General introduction

1.1 Product Feature

YC6A YC6B YC6J ,,

YC6A YC6B YC6J series engines are developed by Yuchai with advantages of reliability, fuel consumption saving and strong power. It is ideal power for construction.

1.2

Model number composition and its specific meaning

The product style number is consisted of Arabic numbers and capital English letters, and the specific meaning is as follows:

17

Turbocharged

1.3 Main application scope

-15 40 2000-15 40 2500

The engine could work normally under temperature of -15 40 and at the height above sea-level of lower than 2000 m. it is forbidden to work in the water or in the fire. When the engine needs to work at temperature lower than -15 or higher than 40 , at the at the height above sea-level of higher than 2500 m, the user should consults YuChai Technical Dept. and Service Dept. to adopt effective measure or replace special engine to ensure the normal working.

2 Technical specification

2.1 Main specification (basic)

1 1 YC6A

Table 1-1 Main technical parameters of YC6A engine

					Technical specification

18

No.	Name		A8900		A8700
1	Model		YC6A180Z-T11		YC6A190Z-T10
2
	Type		Vertical in-line, water-cooling, 4-stroke
3			Turbocharged
	Air intake way
4			ω Direct injection tube sinking ω combustion
	Combustion type			chamber
5	Cylinder			6
	number
6		mm		108
	Cylinder diameter
7		mm		132
	Piston stroke (mm)
	L
8	Total piston			7.252
	displacement
9	Compression			17:1
	ratio
10	Cylinder			Wet
	sleeve type
11	kW		130		140
	Rated power (kW)
		r/min
12	Rated rotation		2300		2300
	speed(r/min)
13		N·m	670		690
	Max. torque(N·m)
	r/min
14	Speed at max torque		1500 1700		1500 1800
	(r/min)

19

		g/kW·h Fuel
	15	consumption rate at				≤240
		rated working
		condition
	16	Fuel				≤225
		consumption rate at
		max torque g/kW·h
		Name				Technical specification
	No.			A8900				A8700
			GB 252-2000 0 10 ,
			Summer: GB 252-2000 top grade or first rater 0 #, 10 # light
		Diesel oil	diesel oil
	17		GB 252-2000 0 -10 -20 -35
		brand
			Winter: GB 252-2000 top grade or first rater 0 #,-10 #, -20 #, -35
					# light diesel oil
		Max.
	18	rotation speed with	≤2530					≤2540
		no load r/min
		Min.
	19	rotation speed with				700 750
		no load r/min
	20	Working			1—5—3—6—2—4
		order
		Oil
	21	fuel consumption				≤0.5
		ratio

20

			CD40 CD15W—40 CD10W—30
			GB 11122-2006 CD
	22	Oil brand	Summer: CD40 CD15W—40, Winter: CD10W—30 or other
			diesel oil with grade not below CD grade of GB 11122-2006
			corresponding with the environment
		(
		)
	23	Crankshaft rotation	Anticlockwise
		direction (face to
		power output end)
		(
		) °CA Fuel
	24	supply advance	12±1
		angle (Top dead
		point front crankshaft
		corner ) °CA
	25	Fuel	KBEL-P023A
		injector type
	26	Fuel	DSLA147P008
		nozzle type
	27	Fuel injector opening	25 26
		pressure MPa
		FSN
	28	Exhaust smoke level	≤3.0
		(FSN)
		LwdB(A)
	29	Limit of noise	≤115
		LwdB(A)
	30	Compressing	≥2.5
		pressure
		(n≥200r/min) MPa

21

31
	Lubricating method				Pressure lubricating and splattering lubricating combined
32							Electrical starting
	Starting method
		L
33	Capacity of engine							17~20
	oil (L)
	Diesel
34	engine net weight							700
	kg
		× ×
	mm
35	Overall dimension							1234×800×1100
	(length × width×
	height) (mm)
	1 2			YC6B
Table 1-2 YC6B (non-Turbocharged) series engine main technical parameter
									Technical specification
No.	Name
					B8W00		B9C00		B9D00	B8Q00	B8C00
1	Model			YC6B120-T1			YC6B125-T1		YC6B125-T1	YC6B105-K	YC6B125-K
2	Type
							Vertical in-line, water-cooling, 4-stroke
							Natural air intake
3
	Air intake way						Turbocharged
4	Type of						ω
	combustion				Direct injection type tube sinking ω combustion chamber
	chamber

22

5						6
	Cylinder NO.
		mm
6	Cylinder diameter					108
	(mm)
7		mm				125
	Piston stroke (mm)
	L
8	Total piston					6.871
	displacement
9						17.5:1
	Compression ratio
10	Cylinder sleeve					Wet
	type
11		kW	85		92	92	75	92
	Rated power (kW)
		r/min
12	Rated rotation		2000		2200	2300	1700	2200
	speed(r/min)
13		N·m		463		450	460	463
	Max. torque(N·m)
							1300	1400
14	r/min Speed at				1400 1600
							1400	1600
	max torque (r/min)
	g/kW·h Fuel
15	consumption rate					≤240
	at rated working
	condition

23

		Fuel
	16	consumption rate						≤235
		at max torque
		g/kW·h
				GB 252-2000 0 10 ,
				Summer: GB 252-2000 top grade or firstrater 0 #, 10 # light diesel
				oil
	17			GB 252-2000 0 -10 -20 -35
		Diesel oil brand
				Winter: GB 252-2000 top grade or firstrater 0 #,-10 #, -20 #, -35 #
								light diesel oil
	18	Max. rotation		≤2200			2420	≤2530	1870±20		2420
		speed	with no				2464				2464
		load r/min
		Min.
	19	rotation speed						700 750
		with no load r/min
	20	Working					1—5—3—6—2—4
		order
					1-2 Table 1-2 (continued)
			Name					Technical specification
	No.
				B8W00			B9C00	B9D00	B8Q00		B8C00
	21	Oil fuel						≤0.5
		consumption
		ratio

24

			CD40 CD15W—40 CD10W—30
			GB 11122-2006 CD
	22		Summer: CD40 CD15W—40, Winter: CD10W—30 or other
		Oil brand	diesel oil with grade not below CD grade of GB 11122-2006
			corresponding with the environment
		(
		)
	23	Crankshaft rotation	Anticlockwise
		direction (face to
		power output end)
		(
		) °CA
		Fuel supply
	24	advance angle	13±2
		(Top dead point
		front crankshaft
		corner ) °CA
	25	Fuel	CKBL68S001/PF68S35
		injector type
	26	Fuel	CDLLA147S071/DSLA147S071
		nozzle type
	27	Fuel injector	23 24
		opening pressure
		MPa
		FSN
	28	Exhaust smoke	≤3.5
		level (FSN)

25

	LwdB(A)
29	Limit of noise		≤115
	LwdB(A)
	Compressing
30	pressure		≥2.5
	(n≥200r/min)
	MPa
31
	Lubricating method		Pressure lubricating and splattering lubricating combined
32			Electrical starting
	Starting method
		L
33	Capacity of engine		15~18
	oil (L)
34	Diesel engine net		650
	weight	kg
		×
	×	mm
35	Overall dimension		1133×725×889
	(length × width×
	height) (mm)

1 3 YC6B

Table 1-3 YC6B (Turbocharged) series engine main technical parameters

							Technical specification
No.	Name		B7700			B9A00			B9F00	B9K00
1	Model		YC6B160Z-		YC6B140Z-T1				YC6B150Z-T1	YC6B150Z-T1
2	Type
				Vertical in-line, water-cooling, 4-stroke
3
	Air intake way						Turbocharged

26

	Type of		ω Direct injection type tube sinking ω
4	combustion
							combustion chamber
	chamber
5									6
	Cylinder NO.
		mm
6	Cylinder diameter								108
	(mm)
7		mm							125
	Piston stroke (mm)
	L
8	Total piston								6.871
	displacement
9									17.5:1
	Compression ratio
10								Wet
	Cylinder sleeve
11		kW	115			102				110			110
	Rated power (kW)
	r/min
12	Rated rotation		2200			2000				2000			2100
	speed(r/min)
13		N·m	560			550				550			550
	Max. torque(N·m)
14	r/min		1400		1600	1400		1600		1400		1600	1400		1600
	Speed at max
	torque (r/min)

27

	g/kW·h
15	Fuel consumption				≤230
	rate at rated
	working condition
	g/kW·h
16	Fuel consumption				≤225
	rate at max torque
	g/kW·h
			GB 252-2000 0 10 ,
			Summer: GB 252-2000 top grade or firstrater 0 #, 10 # light diesel
	Diesel oil		oil
17			GB 252-2000 0 -10 -20 -35
	brand
			Winter: GB 252-2000 top grade or firstrater 0 #,-10 #, -20 #, -35 #
				light diesel oil
18	Max. rotation		≤2420	≤2160		≤2200		≤2310
	speed	with no
	load r/min r/min
	Min.
19	rotation speed				700 750
	with no load r/min
20	Working			1—5—3—6—2—4
	order
			1-3 Table 1-3(continued)
		Name			Technical specification
No.
			B7700	B9A00		B9F00		B9K00
21	Oil fuel				≤0.5
	consumption
	ratio

28

			CD40 CD15W—40 CD10W—30
	22	Oil	GB 11122-2006 CD Summer: CD40
			CD15W—40, Winter: CD10W—30 or other diesel oil with grade
		brand
			not below CD grade of GB 11122-2006 corresponding with the
		(
		)
	23	Crankshaft rotation	Anticlockwise
		direction (face to
		power output end)
		(
		) °CA
		Fuel supply
	24	advance angle	13±2
		(Top dead point
		front crankshaft
		corner ) °CA
	25`	Fuel	CKBL68S001/PF68S35
		injector type
	26	Fuel	CDLLA147S071/DSLA147S071
		nozzle type
	27	Fuel injector	23 24
		opening pressure
		MPa
		FSN
	28	Exhaust smoke	≤3.5
		level (FSN)
		LwdB(A)
	29	Limit of noise	≤115
		LwdB(A)
		Compressing
	30	pressure	≥2.5
		(n≥200r/min)
		MPa

29

	31			Pressure lubricating and splattering
		Lubricating method				lubricating combined
	32					Electrical starting
		Starting method
			L
	33	Capacity of engine					17~19
		oil (L)
	34	Diesel engine net					650
		weight kg
			×
		×	mm
	35	Overall dimension				1133×725×889
		(length × width×
		height) (mm)
	1 4	YC6J
	Table 1-4 YC6J series engine main technical					parameter
							Technical specification
	No.	Name
				J8400		J8500		J8000			J7M00
	1	Model		YC6J120-T1	YC6J120-T10			YC6J125Z-T2			YC6J145Z-T2
	2	Type
				Vertical in-line, water-cooling, 4-stroke
	3	Air intake way		Natural air intake						Turbocharged
		Type				ω
	4	of combustion
				Direct injection type tube sinking ω combustion chamber
		chamber
	5	Cylinder					6
		NO.

30