Yuchai YC6A Series Page 2 Operation & Maintenance Manual Download

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广西玉柴机器股份有限公司

Guangxi YuChai Machinery Co., Ltd.

二

八年六月

June.2008

前

言

Foreword

本说明书介绍了

YCA

、

YC6B

、

YC6J

工程用系列发动机的主要结构、技术参数、主要附

件的技术规格与数据以及使用和维护方面的基本知识，并对一些常见故障及其排除方法作了初步
的介绍。

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.

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，请您在使用之前首先详细阅

读本使用说明书，正确认识、了解与掌握

YCA

、

YC6B

、

YC6J

工程用系列发动机的使用和维护

要求，并特别注意以下的

“

安全行车注意事项

”

。

Please read this manual carefully to understand and master the operation and

maintenance requirements about YCA

、

YC6B

、

YC6J series construction engine prior to

Summary of Contents for YC6A Series

Page 1: ...YC6A YC6B YC6J YC6A YC6B YC6J Series Construction Engine Operation Maintenance Manual Please read the Manual carefully before using...

Page 2: ...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...

Page 3: ...l 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...

Page 4: ...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 bl...

Page 5: ...ry 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 c...

Page 6: ...9 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 Va...

Page 7: ...ring 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...

Page 8: ...1 YC6A Fig 1 Assembly Layout for YC6A Diesel Engine may differ from the practical configuration...

Page 9: ...2 YC6B Fig 2 Assembly Layout for YC6B Diesel Engine non Turbocharged may differ from the practical configuration...

Page 10: ...3 YC6B Fig 3 Assembly Layout for YC6B Diesel Engine Turbocharged may differ from the practical configuration...

Page 11: ...4 YC6J...

Page 12: ...Fig 4 Assembly Layout for YC6J Diesel Engine may differ from the practical configuration...

Page 13: ...13 YC6A A8700 YC6A series construction engine A8700 external characteristic curve...

Page 14: ...14 YC6B B8C00 B9C00 YC6B series construction non Turbocharged engine B8C00 B9C00 external characteristic curve...

Page 15: ...15 YC6B B7700 YC6B series construction Turbocharged engine B7700 external characteristic curve...

Page 16: ...16 YC6J J8000 YC6J series construction engine J8000 external characteristic curve...

Page 17: ...loped 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 numbe...

Page 18: ...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...

Page 19: ...jection tube sinking combustion chamber 5 Cylinder number 6 6 mm Cylinder diameter 108 7 mm Piston stroke mm 132 8 L Total piston displacement 7 252 9 Compression ratio 17 1 10 Cylinder sleeve type We...

Page 20: ...17 Diesel oil brand GB 252 2000 0 10 Summer GB 252 2000 top grade or first rater 0 10 light diesel oil GB 252 2000 0 10 20 35 Winter GB 252 2000 top grade or first rater 0 10 20 35 light diesel oil 18...

Page 21: ...nvironment 23 Crankshaft rotation direction face to power output end Anticlockwise 24 CA Fuel supply advance angle Top dead point front crankshaft corner CA 12 1 25 Fuel injector type KBEL P023A 26 Fu...

Page 22: ...ength width height mm 1234 800 1100 1 2 YC6B Table 1 2 YC6B non Turbocharged series engine main technical parameter No Name Technical specification B8W00 B9C00 B9D00 B8Q00 B8C00 1 Model YC6B120 T1 YC6...

Page 23: ...ompression ratio 17 5 1 10 Cylinder sleeve type Wet 11 kW Rated power kW 85 92 92 75 92 12 r min Rated rotation speed r min 2000 2200 2300 1700 2200 13 N m Max torque N m 463 450 460 463 14 r min Spee...

Page 24: ...000 0 10 20 35 Winter GB 252 2000 top grade or firstrater 0 10 20 35 light diesel oil 18 Max rotation speed with no load r min 2200 2420 2464 2530 1870 20 2420 2464 19 Min rotation speed with no load...

Page 25: ...2006 corresponding with the environment 23 Crankshaft rotation direction face to power output end Anticlockwise 24 CA Fuel supply advance angle Top dead point front crankshaft corner CA 13 2 25 Fuel i...

Page 26: ...ing 33 L Capacity of engine oil L 15 18 34 Diesel engine net weight kg 650 35 mm Overall dimension length width height mm 1133 725 889 1 3 YC6B Table 1 3 YC6B Turbocharged series engine main technical...

Page 27: ...mm 108 7 mm Piston stroke mm 125 8 L Total piston displacement 6 871 9 Compression ratio 17 5 1 10 Cylinder sleeve Wet 11 kW Rated power kW 115 102 110 110 12 r min Rated rotation speed r min 2200 200...

Page 28: ...or firstrater 0 10 light diesel oil GB 252 2000 0 10 20 35 Winter GB 252 2000 top grade or firstrater 0 10 20 35 light diesel oil 18 Max rotation speed with no load r min r min 2420 2160 2200 2310 19...

Page 29: ...nkshaft rotation direction face to power output end Anticlockwise 24 CA Fuel supply advance angle Top dead point front crankshaft corner CA 13 2 25 Fuel injector type CKBL68S001 PF68S35 26 Fuel nozzle...

Page 30: ...nsion length width height mm 1133 725 889 1 4 YC6J Table 1 4 YC6J series engine main technical parameter No Name Technical specification J8400 J8500 J8000 J7M00 1 Model YC6J120 T1 YC6J120 T10 YC6J125Z...

Page 31: ...leeve t Wet 11 kW Rated power kW 85 85 92 105 12 r min Rated rotation speed r min 2200 2400 2200 2200 13 N m Max torque N m 405 390 500 550 14 r min Speed at max torque r min 1400 1600 1500 1700 1400...

Page 32: ...0 2420 2420 19 Min rotation speed 700 750 20 Working order 1 5 3 6 2 4 1 4 Table 1 4 continued No Name Technical specification J8400 J8500 J8000 J7M00 21 Oil fuel consumption ratio 0 5 22 Oil brand CD...

Page 33: ...SLA147S071 27 Fuel injector opening pressure MPa 23 24 28 FSN Exhaust smoke level FSN 3 5 29 LwdB A Limit of noise LwdB A 115 30 Compressing pressure n 200r min 2 5 31 Lubricating method Pressure lubr...

Page 34: ...25 0 48 0 122 0 097 48 Interference 0 072 0 122 3 Cylinder cover canal hole diameter valve guide lever outer diameter 0 018 0 6 1 0 046 0 028 16 Interference 0 010 0 046 4 Valve pipe hole diameter exh...

Page 35: ...14 Piston ring groove height oil ring height 04 0 02 0 5 3 0 02 0 5 3 Axial clearance 0 020 0 060 15 00 108 Piston ring opening clearance 108 00 after pressed into measure gauge check First gas ring...

Page 36: ...015 0 3 Axial clearance 0 050 0 085 24 Piston ring groove height oil ring height 06 0 04 0 5 0 015 0 5 Axial clearance 0 04 0 075 25 00 105 Piston ring opening clearance 105 00 after pressed into meas...

Page 37: ...arance 1 0 1 2 1 6 YC6A YC6B YC6J YC6A YC6B YC6J Series Engine Tightening Torque for the Bolts Studs and Nuts Description N m Tightening torque N m Description N m Tightening torque N m Main bearing b...

Page 38: ...der sleeve to avoid water leaking 26 There are 26 screw holes on the top of the cylinder body which are used to fix the cylinder head There are air exhaust pipe starter and oil filter on the right sid...

Page 39: ...il pan The gasket will cracks if too large torque is applied Tighten the bolts gradually according to the cross angle order Oil drain plug is installed at the bottom of the oil pan to drain the oil wh...

Page 40: ...urface is print with anti seize coating When reassembling cylinder head cylinder gasket should be replaced In common sense after run in period of new engine retighten cylinder head cover to regulate t...

Page 41: ...one angle of intake valve and exhaust valve is 90 The sinkage of valve shall be controlled strictly and technical requirement is 1 0 2 mm Fig 2 2 35 0 5mm 2 3 Valve duct can be replaced too In order t...

Page 42: ...led on cylinder head Intake valve and exhaust valve are welded with two kinds of materials the material of lever is silicochromium F203 alloy is welded on exhaust valve cone 0 4 0 05mm 0 45 0 05mm 1 2...

Page 43: ...and the end of the valve stem with a feeler gauge fasten the tightening nut when the checking result is accordance with the requirement Fig 2 4 3 2 4 1 Camshaft group 7 12 Camshaft consists of 7 supp...

Page 44: ...s connected to the middle rocker arm seat there is one oil path at the center of rocker arm shaft the lubricant is delivered to these two rocker arm seats for lubricating through this oil path When di...

Page 45: ...ocating linear motion of the piston into rotating motion of the crankshaft i e turn the force applied by the fuel gas in piston into the torque of the crankshaft which can be output to do work Crank c...

Page 46: ...piston ring refer to The installation direction of the piston ring should meet with the provision Refer to Fig 2 10 The piston is cooled by the splash of the engine oil through the piston coolant inj...

Page 47: ...47 2 12 Install piston into cylinder liner according to the forward mark on the connecting rod body Put the small head of connecting rob into the middle of piston pin put the piston pin into the...

Page 48: ...y with lead tin copper ternary alloy and corrosion resistance coat on the surface 0 1 0 3mm 2 15 240 20N m The crankshaft flywheel consists of crankshaft flywheel and crankshaft belt pulley vibration...

Page 49: ...The fuel system works to inject the spray diesel oil with certain quantity at certain time and pressure according to the fuel supply rules and working requirement of the diesel engine thus the diesel...

Page 50: ...el of the fuel valve begins to fluctuate the angle value on the belt pulley vibration absorber timing scale is the fuel supply angle Fig 2 16 The user shall pay attention to the pointer and scale on t...

Page 51: ...advance angle as required then move the fuel injection pump body or camshaft to first cylinder starting supply position as per Method 1 and Method 2 tighten the tightening bolts and check the fuel su...

Page 52: ...f Yuchai service station 2 18 The fuel transfer pump structure of the high pressure fuel pump is shown as Fig 2 18 manual drive device is designed on the fuel transfer pump tp exhaust the air in the f...

Page 53: ...henomenon of the engine occurs after long operation send it to Yuchai service station or to professional staff for adjustment to avoid accidents Yuchai filter is of rotary paper filter element structu...

Page 54: ...0 The filter element of diesel engine filter shall be replaced for using accumulated 400 hours to avoid too large filter element resistance to lead the lacking of fuel supply YC6A YC6B YC6J 2 21 Refer...

Page 55: ...he pressure adjusting screw and tighten it clockwise to enlarge the fuel injection pressure and tighten it anticlockwise to reduce the fuel injection pressure The fuel injection pressure shall be adju...

Page 56: ...of the fuel injector the height of YC6A series engine shall be controlled at 4 2 0 1mm and 2 4 0 1mm for YC6B and YC6J series The height is not allowed to change when disassembling the fuel injector i...

Page 57: ...ystem is to deliver clean lubricant with appropriate pressure and temperature to all friction surfaces of diesel engine to lubricate them so as to ensure normal operation of all parts and components o...

Page 58: ...oil path to supply oil to main bearing after filtering meanwhile the oil lubricates the connecting rod bearing and camshaft bearing through oil path on the crankshaft the oil is lead to rocker arm sha...

Page 59: ...e the water inlet outlet pipe and fuel inlet outlet pipe then remove the cooler from the engine Open the cover to remove the element if the cooler is of plate type then wash the element plate with die...

Page 60: ...lement JS0818 should be changed or be cleaned Clean diesel oil and petrol should be blow to dry by compressed air JS0818 Prior to installation the new filter should be filled with clean oil and then t...

Page 61: ...e water sleeve in the cylinder block to cool the cylinder then the coolant will flow upwards to cool cylinder cover and flow to the thermostator through water outlet When the coolant temperature is lo...

Page 62: ...g and the oil temperature is 15 20 higher than water temperature 2 28 50 40 50N 10 15mm 2 29 C 2 30 Water pump and fan are key parts of the cooling system and the structure is as shown in Fig 2 26 Fil...

Page 63: ...ent specifications according to various models Bring the old specification when replacing The belt tightness could be adjusted through the adjustment of the positions of charging generator and adjusti...

Page 64: ...64 2 31 Thethermostator is of wax type and installed in the water outlet of the pipe It is not...

Page 65: ...motor with working voltage of DC 24V max power of 6 6KW and single wire negative ground earth lead Electromagnet control mechanism drives the motor small gear and flywheel gear ring engagement with ro...

Page 66: ...ust be connected correctly to avoid the motor from burnt It is forbidden to connect the terminal to terminal F or otherwise the voltage adjustor will be damaged 350 1 4 1 5mm The voltage adjustor is u...

Page 67: ...eater when connecting the wire the terminal connected with 2 heater terminals shall not contact the diesel engine housing to avoid short circuit If preheating start is required shift the start switch...

Page 68: ...the injection ring changes from large to small the pressure and temperature of the gas will decrease but the speed increases rapidly The high speed gas flow will rush the turbo 3 as per certain direct...

Page 69: ...arger attaches much importance to the Turbocharged diesel engine If the performance of the Turbocharger changes it will affect the engine performance directly In order to keep good performance of the...

Page 70: ...and replace the gasket Air exhaust blocked Repair and replace related parts Air exhaust leak Check whether there is leak between air exhaust pipe and engine turbo inlet and exhaust pipe turbo housing...

Page 71: ...e oil filter or the engine stops for a long time more than one week the fuel inlet connector of the Turbocharger shall be released and clean lubricating oil shall be filled in the lubricating system 3...

Page 72: ...e should be over 0 and N68HM N46HM hydraulic oil should be used while N32HM hydraulic oil when the environmental temperature is below 0 25 m It is a must to refill the oil tank only with the new hydra...

Page 73: ...henomenon Phenomenon Solution Slow and ponderous steering Deficient oil in oil tank Refill to the level of oil surface Great viscidity of oil N32 N46 Use the recommended oil N32 N46 Difficult oil suct...

Page 74: ...rear cover is damaged Repair by professionals No boosterr during steering or inefficient Flow valve is blocked Polish the valve core surfaces with metallographic paper clean the valve bore refer to t...

Page 75: ...and control devices avoid vehicle runs in danger 4 1 2 Starting 10 1 Start the engine In cold winter diesel engine should be started after heating for a while after completing preparation and ensurin...

Page 76: ...running at an idle speed The oil pressure temperature and outlet water temperature should be normal during running period Stop and check the vehicle immediately if there is any abnormal noise and vibr...

Page 77: ...l oil according to the regulation of GB252 2000 Light Diesel Fuel Different diesel fuels should be selected based on different areas and different temperatures Commonly 0 diesel fuel should be selecte...

Page 78: ...mers had better have a fuel tank with fuel filter Bought fuel should be put in this tank for two days and can be used after sediment and water deposit Costumer should eliminate sediment and water and...

Page 79: ...ightness of the fan belt Check the tightening of the cylinder cover nut Check and adjust the valve clearance Check the fuel injection pressure and spray of the fuel injector replace the oil for new en...

Page 80: ...emove the oil dirt carbon deposit and coking Check the wearing and distortion of friction parts and moving parts Check the working condition of the fuel injection pump Check the working condition of...

Page 81: ...nd rotate the lever on the fuel transfer pump anticlockwise press the lever several times tighten the exhaust plug and fuel transfer pump until there is no bubble in the diesel oil Check whether the a...

Page 82: ...eck the working condition of the instruments Stop driving and eliminate the fault if there is abnormal phenomenon Send it to repair if necessary 3 5 10 It is forbidden to operate at idle speed for a l...

Page 83: ...bility It is quite important to guarantee the reliability and long lifetime of the diesel engine 40 50 80 The run in period lasts 40 50 hours The power and speed when run in shall be increased gradual...

Page 84: ...mulation mixed usage will lead bad influence to diesel engine n It is forbidden to use poor quality oil or it will lead serious damage to diesel engine The malfunction for this reason shall not be gua...

Page 85: ...200 300 hours Please select diesel oil filter with high reputation and excellent quality Yuchai special part is recommended 4 Application of cooling fluid n If water is used as coolant clean soft wat...

Page 86: ...le in filtering and the filtering impact will reach above 95 Third class filtering security filter element assisting filtering and preventing impurity enter n Maintenance Air filter housing clean filt...

Page 87: ...there is no air bubble in the fuel spilt out 2 Unscrew the high pressure fuel pipe joint at he end of fuel injector feed the fuel by the hand pump until there is no air bubble in the fuel spilt out Fu...

Page 88: ...of the starter carbon brush with commutator Repair or replace the brush clean the commutator surface by abrasive paper and blow it clean Insufficient compression pressure Replace piston ring add cylin...

Page 89: ...clear the leaking from pipeline and connection position The turbocharger works abnormally the compressor turbine gas flow duct is clogged with contaminants or damaged Clean or replace air compressor...

Page 90: ...ution phase Check and adjust air distribution timing and valve clearance Advanced or late of fuel supply advanced angle Check and adjust High speed of the governor too low Check and adjust Air leak of...

Page 91: ...ance as specified Shock absorber is damaged and without function Check the connection bolt for itself its damage and replace it when necessary Driving gear is worn and the clearance is too big Clash c...

Page 92: ...Smoke from Exhaust Manifold Cause Solution Air intake blocked Check and clean the air filter and air intake pipe Poor quality of fuel Replace the fuel as specified Poor atomization of fuel injector C...

Page 93: ...and cylinder head gasket replace Incorrect piston ring assembly direction unstaggered opening Check and reassemble Long time running with low loading Use proper working speed and loads Worn seal ring...

Page 94: ...gear Replace Cracks on the lubricating oil inlet pipe of lubricating oil pump Repair or replace Loosened bolt fixing the oil inlet pipe of lubricating oil pump Retighten it to the specified torque Too...

Page 95: ...d repair replace as necessary Excessive wear of the cylinder bore After cylinder boring replace the piston ring with newly machined sizes or repaired cylinder liner Excessive wear of the valve guide p...

Page 96: ...ssor outlet and air intake pipe Air intake leak Check whether there is leak between air filter and compressor air intake pipe and connecting part tighten the bolt and replace the gasket Air exhaust bl...

Page 97: ...t in the clutch the loosed part eliminate the abnormal object or replace driven plate assembly 5 11 Shut off automatically Cause solution 1 No fuel Check and fill fuel exhaust the air in he fuel pipe...

Page 98: ...98 the engine to check repair and replace damaged parts...

Page 99: ...hinery Green Power Implementation standard Q YC 456 2006 Guangxi Yuchai Machinery Co Ltd Add 88 Tianqiao West Road Yulin Guangxi China Post Code 537005 Sales Tel 00886 775 3226931 Fax 0086 775 3289856...

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