Yuchai YC4D60-D21, Maintenance Manual

Page 1: ...1 YC4D60 D21 YC4D85Z D20 YC4D60 D21 YC4D85Z D20 SERIES DIESEL ENGINE GENERATOR OPERATION MAINTENANCE MANUAL Guangxi Yuchai Machinery Co Ltd...

Page 2: ...important components of which immediate replacement is required for any malfunction It is desired to always maintain the normal function of these components any failure to comply with that may easily...

Page 3: ...the air cleaner for the clog of stuff 7 Anytime you find the vehicle and or engine is not working normally stop it immediately to correct the malfunction never allow the vehicle running under an abnor...

Page 4: ...n the table I table II table III and safety caution 13 Hoisting and transporting the engine according to the notes on the engine s package and store the engine in a condition of dry clean good ventila...

Page 5: ...al introduces the main technical specifications the basic assemblage requirements the engine adjustment the operation and maintenance and the troubleshooting of the YC4D60 D21 YC4D85Z D20 engine Prope...

Page 6: ...he connecting rod I n sta l l at io n of t h e cams h af t I n s t a l l a t i o n o f t h e v a l v e s a n d v a l v e g u i d e s I n s ta l l a t i o n o f t h e i n j e c t o r s I n sta l l at i...

Page 7: ...p u t 4 3 A b n o r m a l n o i s e d u r i n g e n g i n e o p e ra t i o n 4 5 Exhaust with abnormal smoke color 46 Too low oil pressure 48 Too high oil pressure much diluted oil excessive oil cons...

Page 8: ...4 Combustion chamber directing injection and reentrant type 5 Intake natural aspirated turbocharged 6 Cylinder number 4 7 Cylinder bore mm 108 8 Stroke mm 115 9 L Displacement 4 214 10 Compression rat...

Page 9: ...ston average speed m s 5 75 25 Rotation direction of crankshaft counterclockwise face to output end 26 Lubrication system combination of splash and pressure 27 Cooling system pressurized circulating l...

Page 10: ...rature 75 95 Static fuel supply advance angle CA 14 2 Cold valve clearance CA Intake valve O 40 0 05 Exhaust valve 0 45 0 05 Valve timing CA Intake valve advance open angle 14 Exhaust valve lag close...

Page 11: ...ghtening torque N m Cylinder head bolt 210 250 Flywheel bolt 170 210 Main bearing bolt 220 260 Crankshaft belt pulleyfastening bolt 300 Connecting rod bolt 160 200 Camshaft gear locking bolt 300 2 Exc...

Page 12: ...hole 16 018 0 0 16 046 0 028 0 interference 0 010 0 046 4 Valve guide exhaust valve stem 9 5 019 0 0 9 5 04 0 062 0 radial clearance 0 040 0 081 5 Valve guide intake valve stem 9 5 019 0 0 9 5 025 0 0...

Page 13: ...0 08 0 28 17 0 07 0 axial clearance 0 07 0 25 13 Top ring groove height top gas ring height 2 695 0 015 2 605 01 0 03 0 axial clearance 0 085 0 135 14 Second ring groove height second gas ring height...

Page 14: ...021 0 22 08 0 05 0 axial clearance axial clearance 0 05 0 101 22 Outer diameter of outer rotor bore in oil pump body 69 7 0 08 0 69 8 15 0 05 0 radial clearance 0 15 0 33 23 Oil pump shaft bushing I...

Page 15: ...code type precision pairs type injection pressure CKBL685004 long multi hole nozzle ZCKl55S529 23 0 5MPa CKBL685004 long multi hole nozzle ZCKl55S529 23 0 5MPa 3 Fuel filter CX0710 paper element and r...

Page 16: ...ance should be between 0 1 and 0 27mm Installations of the piston and the connecting rod Figure 2 Orientation of the gap of piston rings When installing the piston rings put the surfaces marked upward...

Page 17: ...nd its axial clearance is between 0 1 0 2mm Installation of the valves and valve guides Figure 4 Installation of the valves and valve guides The valve guides should be pressed in at normal state with...

Page 18: ...Figure 6 Tightening orders of the cylinder bolts During cylinder head installation the cylinder head bolts should be tightened to a tightening torque of between 210 250N m don t finish that in once ti...

Page 19: ...ference in chapter 1 Charter three Engine adjustments Fuel supply advance angle adjustment Technical data Static fuel supply advance angle is 14 2 A before TDC Fuel supply advance angle check Unscrew...

Page 20: ...ly advance angle outer direction which means to decrease the fuel supply advance angle then fasten the bolts on the flange Check and adjust the fuel supply advance angle to prescription then fasten th...

Page 21: ...on At this time the piston of the first cylinder is on the compression TDC If counter that indicates the forth piston is on the compression TDC The first piston can reach the compression TDC by rotati...

Page 22: ...sure can be adjusted on special test rig Oil pressure adjustment Figure 11 Oil pressure adjustments Technical data Oil pressure at idle speed 0 1MPa Oil pressure at rated speed 0 25 0 6MPa Oil pressur...

Page 23: ...be lower than CD class of GB11122 1997 3 Coolant The coolant should be anti freezing especially when the engine is used in the plateau and in cold weather below 0 It is good for the engine The most u...

Page 24: ...soften the liquid If hard water is not softened before using as a coolant there will be scale on the wall of water jackets of diesel engine and the deposit will weaken cooling effect and cause the en...

Page 25: ...whether the water pump operates properly and whether the coolant runs into water jacket of the diesel engine 3 Check the leakage of oil fuel and oil And if there is leakage shoot the trouble 4 Check...

Page 26: ...engine is running Check if the lubricating oil pressure is normal The pressure should be lower than 0 1MPa when the engine is idling and should be within 0 25MPa and 0 6MPa when the engine is running...

Page 27: ...stops Storage 1 Diesel engine should be stored in warehouse which is dry with ventilation and without corrosive matter 2 If diesel engine will be stored for a long time discharge all of the coolant Di...

Page 28: ...Check the water level in the radiator 3 Check the oil level in the oil sump 4 Check if there is coolant oil or fuel leakage 5 Check the tension of the driving belt See Chapter 5 See Chapter 5 After ev...

Page 29: ...rust plate connecting rod bearing shells crankshaft bearing shells and check their wear conditions Replace the one that wears out and clean the oil sump at the same time Then assemble them altogether...

Page 30: ...to replace the oil Replacing oil should be done just after stopping engine At this time foreign matters and oil are mixed and can be replaced together Waste lubricating oil should be collected after...

Page 31: ...he position of the generator 4 Discharge the coolant Figure 15 Discharge the coolant There is a water drain valve on the case of the oil cooler at the left side of the cylinder block look from the sid...

Page 32: ...k the element the filter paper and the sealing ring to see if there is damage If there is replace it At the same time clean the dust off the dust chamber Watch out that the filter paper cannot be clea...

Page 33: ...into the tank Run the diesel engine with cleaning liquid as coolant water in medium speed about 10 15 minutes warming up cleaning liquid Let the cleaning liquid remain in the tank for about 12 15 hou...

Page 34: ...l Yuchai service station or asking the near special units to deal with Diesel engine can not start or start difficultly Possible causes Remedies Insufficient power or bad terminals connection contact...

Page 35: ...ind or readjust the valve if necessary Incorrect fuel injection advance angle Check and adjust it Incorrect valve timing For the overhauled engine pay attention to the timing marks alignment on timing...

Page 36: ...ery valve and inspect whether plunger is worn out and if the plunger spring and delivery valve spring is broken replace the damaged parts cylinder gasket and readjust oil pump if necessary Cylinder ga...

Page 37: ...Clash due to too large clearance between connecting rod bearing bushing main bearing bushing and journal Check if the bearing bushing and crankshaft are much worn out replace or press in the oversized...

Page 38: ...maged ones Close the shutter door when the ambient temperature is low and make the operating temperature rise quickly to avoid running long time at low temperature Check and adjust fuel injection adva...

Page 39: ...f necessary Pressure indicator or transmitter failure Check the cause and then replace it Diluted oil Check if incorrect brand oil is used or oil temperature is too high If the cause is the former rep...

Page 40: ...prescription Piston ring stuck or seriously worn causing gas blow by and oil pumping up Dismantle check and clean the piston and piston ring replace the piston ring and cylinder sleeve if necessary Oi...

Page 41: ...ater pump repair it in time if necessary check and replace the damaged thermostat Too much scale in water passage and tank Clear it Thermostat failure Check and replace the damaged thermostat Water te...

Page 42: ...ack of water or too high water temperature At first make engine cool naturally make sure not to add cold water or wash engine with it then try to rotate the crankshaft If it is jammed start engine aft...

Page 43: ...he location of the damaged part and repair or replace it Insufficient or uneven outlet oil Insufficient inlet oil pressure Leaky oil outlet valve or spring crack Plunger precision pair is out of order...

Page 44: ...Control handles mis positioning Adjusting rack and pull bar jammed or loose Regulate properly and replace the spring by professionals do not do it without authorization Determine the location of the...

Page 45: ...d pump Dismantle and repair replace it if necessary Common trouble and troubleshooting remedies for injector Bad atomization of injector and insufficient or without fuel injection Needle precision pai...

Page 46: ...lace Check and replace Repair or replace the damaged parts Clean and grind it Injector oil leak Bad seal of needle precision pair Needle stuck Nozzle retaining nut damage and deflection Sealing surfac...

Page 47: ...irt 2 the freezing point of water is an O it is easy to freez e a jelly crack an air cylinder body and spread a hot machine easily in winter 3 The boiling point of water is 100 because the machine wid...

Page 48: ...at capacity 20 2349J g k Boiling point 760mmHg 197 Vapor pressure 20 8Pa Vapor pressure 100 2133Pa Thermal conductivity 20 2 889 0 004 W cm s Table 2 The glycol concentration density and freezing poin...

Page 49: ...ate Organic salts as Mono carboxylate and dicarboxylate e g sebacic acid and octoic acid Tolyltriazole Pollution sensitivity Hard water Traditional green coolant Average maintenance life 2 to 3 years...

Page 50: ...ty anti freeze solution is made from the distilled water and it contains anti scaling agent hence it does not produce any scale It has the following characters 1 Superior anti freeze performance 2 Ant...

Page 51: ...y limited number of vehicles and they are used in different regions you can choose the direct use type anti freeze solution 1 Use high quality anti freeze solution never use inferior quality ones High...

Page 52: ...n add anti freeze solution Ethanediol s surface tension is low it may easily seep through the crevices Therefore before you change anti freeze solution you should first check and fasten the branches a...

Page 53: ...i freeze solution s tenure of use is usually 1 2 years you should change it when it is overdue To reduce any waste when it is out of its life cycle you may first check the PH value before changing If...