YC4A、YC4B、YC4BA、YC4D 工程机械与农业机械系列发动机

使用说明书
YC4A、YC4B、YC4BA、YC4D Off-road Equipment、

Agriculture Machinery Series

Diesel Engine Workshop Manual

使用前请仔细阅读使用说明书
Please read this manual carefully prior to operation
 广西玉柴机器股份有限公司
Guangxi Yuchai Machinery Co., Ltd.
二 00 八年十月

前 言 Foreword
本说明书介绍了 YC4A、YC4B、YC4BA、YC4D 工程机械与农业机械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 manual describes the basic structure, technical parameters,
technical specifications, operation & maintenance,common failures and troubleshooting of
YC4A、YC4B、YC4BA、YC4D Construction Machinery、Agriculture Machinery Series Diesel
Engine.
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 YC4A、YC4B、YC4BA、YC4D 工程机械与农业机
械 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 prior to operation and pay your particular attention to the Percautions for Safe
Operation describd below in order to enable the machine to bring its superior performance into
full play and ensure its safe operation.
随着社会不断发展和需要，发动机将不断优化和提高，并不断增加变型设计的产品，除特别
重大的设计变型外，本说明书不再作更改，因此过了一定的时间后说明书的介绍可能与实际的发
动机有一定的出入，请以实物为准，敬请广大用户加以注意和谅解。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 occurs, this manual will not be altered again. Therefore, after a certain period of
time, there will be any discrepancies between the description in the manual and the real engine
you have, to which kindly ask our customers to pay due attention.
本说明书只对基本型发动机详加说明，变型产品不作列举，请用户注意和谅解。This 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.
本说明书的解释权归玉柴机器股份有限公司。Guangxi Yuchai Machniery Co.Ltd. reserve
the explanation right of this manual

安全行车注意事项! Precautions for safe driving

1.润滑油压力感应塞、水温感应塞、润滑油压力过低报警器这些零件非常重要，凡有失灵者，
须立即更换，以确保这些零件能正常工作。否则会造成因缺油烧坏曲轴或因缺水致使气缸盖过热
而开裂。Such parts as lube pressure sensor plug, water temperature sensor plug and alarm for
too low engine oil pressure are very important. In case any of them is in failure, immediately
replace it with a good one 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.凡在保养过程中更换润滑油滤清器时，应先将新润滑油滤清器灌满润滑油再安装，而且安
装完成后，必须起动发动机，并使其怠速运转 2～３分钟，接着中速运行 1～３分钟后后下车仔
细观察滤清器有无渗漏现象，若有则须及时排除，否则会导致缺油烧坏曲轴、轴瓦等运动副零部
件。When changing the oil filter with a new one in the course of maintenance, replenish the new
filter with the engine oil first and then mount it to the engine. After completion of assembly you
must start the engine and let it run at an idle speed for 2-3 minutes and medium speed for 1-3
mintues, then get off the vehicle to see if there is any oil leakage in the oil filter. If yes,
immediately remedy it; otherwise it will result in burning or damage of moving parts such as
crankshaft, bush etc.
3.每次起动发动机，须怠速运转 3～5 分钟，待各种仪表正常工作后，方可起步运行。不允许
冷车突然加大油门，否则会损坏各种仪表及其相应零件、加速发动机运动件的磨损及损坏增压器，
从而缩短发动机的使用寿命。Each time you start the engine, first run it at the idle speed for 3 to
5 minutes, and then start to move when the engine warms up and all the gauges function
normally. Never put the vehicle to sudden acceleration from cold-start, because it will result
damage of instruments and their corresponding parts & components and quicken the wear of
the engine’s moving parts and break the turbocharger, consequently shortening the engine’s
service life.
4. 不允许高速、大负荷运转状态下突然熄火停机，怠速运转 3～5 分钟后再停机。否则会损
坏增压器及其它运动件，从而缩短发动机的使用寿命。Never stop the engine suddenly when it
runs at a high speed and under heavy loads. The engine can be stopped only after idle running
for 3～5 minutes, otherwise it will result in damage of the turbocharger and other moving parts,
consequently shortening service life of the engine.
5.应经常检查进气管路是否漏气、空气滤清器是否堵塞，若有以上现象则必须及时维护，否
则会损坏增压器和导致拉缸等故障；同时发动机功率会下降，整车只能以较低的车速行驶，应及
时维修。Frequently check the air intake pipeline for air leak and air cleaner for choke, if any of
these cases occurs, make service immediately, otherwise turbocharger may be damaged and
such failures as cylinder scoring may be resulted in; meanwhile, power of the engine will drop
down and the complete vehicle can run only at a lower speed; in such a case, remedy it
immediately.
6.使用发动机时要一档起步，否则发动机可能会熄火。Always use the first gear to start the
engine, otherwise it will be stopped.
7.凡发现发动机工作不正常时，应及时处理。Whenever the engine works abnormally, it shall
be dealt with timely.
8.发动机运转时严禁靠近旋转部件，严禁直接触摸发动机的高温部件（例如排气管和增压器
等）；停机后不要立即打开水箱盖以免烫伤。When engine is running, it is forbidden to approach
to the rotating components and directly touch hot components of the engine (for example,
exhaust pipe and turbocharger etc.); after the engine stops, do not open water tank cap
immediately to avoid being scalded.
9.冷却系统必须使用防冻液，否则由此引起的故障，不予实行免费保修。Antifreeze shall be
used for cooling system, otherwise any failures arised therefrom will not to be included in
warranty coverage
10.严禁用户擅自拔插各接插件。It is strictly forbidden for the customer to pull out or insert
any connector.
11.严禁以水或任何清洗液冲洗发动机。It is strictly forbidden to flush the engine with water or
any solution of detergent.
12 按规定放燃油预滤器积水、更换预滤器滤芯总成和精滤器滤芯总成。Drain off the water
accumulated in the fuel pre-filter; replace the element assemblies of the pre-filter and
secondary filter
13.拆卸蓄电池和断开蓄电池主开关之前，确认点火开关已关闭。Before disassembling the
battery and disconnecting the main switch of the battery, confirm that the ignition switch has
been turned off.
14.发动机起动前应确认故障诊断开关处于关闭位置，然后才能起动和运行。故障诊断开关只
 供读取故障码时使用。The engine can be started and operated only after confirmation of that
the fault diagnosis switch is at OFF position. The fault diagnosis switch is used for reading the
diagnostic trouble code (DTC) only.
15．严禁随意更换排气制动碟阀。Replacing exhaust braking butterfly valve at will is strictly
forbidden.
16．根据包装箱外的注意事项进行吊装、运输，贮存发动机的环境应通风、干燥、清洁、无
腐蚀性物质，发动机有效封存期为见发动机包装箱上注明。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.
Preservation of the engines is effective for a period refer to remarks on the engine package
case
17. 发动机的标牌含有发动机的基本信息包括:标定功率、标定转速、系列号、生产日期、执
行标准等。YC4A、YC4B、YC4BA、YC4D 标牌位于缸盖罩顶面。Name plate of a disesl engine
contains basic information of the engine, including rated power, rated rotation speed, serial
number, date of manufacture, and active standard etc. Nameplate of YC4A、YC4B、YC4BA、
YC4D diesel engine is located on the top surface of cylinder head cover
18. 发动机型号和出厂编号（如下图）还打印在气缸体下缘中间的平台上。The engine model
and the ex-works identification number series number also are stamped on the bottom flange
platform at the middle of cylinder body
19.安全警告包括：敬告用户、曲轴转向、转动危险及高温危险，分别贴在发动机的缸盖罩、
离合器壳、缸盖罩靠排气管侧。Safty warning includes precautions for customers, crankshaft
rotation, rotation danger and high temperature danger, which are sticked on the cylinder head
cover, clutch shell and exhaust pipe sides near to cylinder head cover
20 包装箱内随带下列随机文件（使用说明书、随机备件清单、随机工具清单、合格证、装
箱清单，用户开箱后应及时清点。The attached documents in the package case are operation
manual, spareparts list the attached with engine , tool lists that attached with engine, certificate
and packing list, please be sure that all the attached documents are included.
 目 录 Contents

图 1 YC4A90-T12 系列柴油机外形安装图
Figure I YC4A90-T12 series diesel engine lay-out………………………………………（6）
图 2 YC4D80-T10 系列柴油机外形安装图
Figure II YC4D80-T10 series diesel engine lay-out………………………………………（7）
图 3 YC4D100Z-T10 系列柴油机外形安装
Figure III YC4D100-T10 series diesel engine lay-out……………………………………（8）
1 概述 Overview ……………………………………………………………………………………………………………………………………（16）
2 技术特性
Technicalcharacteristics…………………………………………………………………………………………………………………（16）
2.1 主要性能（基本型）
Performance of basic model………………………………………………………………………………………………………………（16）
2.2 主要技术参数 Specifications…………………………………………………………………………………………………….（20）
3 发动机主要装配要求以及柴油机的调整
Main assembly reqiurments and adjustment ………………………………………………..（25）
3.1 发动机主要装配 Assembly …………………………………………………………………（25）
3.1.1 曲轴安装
Crankshaft assembly …………………………………………………………………………（25）
3.1.2 连杆活塞安装
Connecting rod & piston assembly…………………………………………………………（25）
3.1.3 凸轮轴的安装
Camshaft assembly………………………………………………………………………………（27）
3.1.4 气门及导管的安装
Valve and guide assembly………………………………………………………………………（27）
3.1.5 喷油器的安装
Injector assembly………………………………………………………………………………（27）
3.1.6 气缸盖的安装
Cylinder head assembly…………………………………………………………………………（28）
3.1.7 齿轮系的安装
Gear train assembly……………………………………………………………………………（29）
3.2 发动机的调整 Adjustment………………………………………………………………（30）
3.2.1 供油提前角的调整
Fuel supply advance angle adjustment………………………………………………………（30）
3.2.2 气门间隙的调整
Valve clearance adjustment……………………………………………………………………（30）
3.2.3 喷油压力的调整
 Injection pressure adjustment………………………………………………………………（31）
3.2.4 机油压力的调整
Lubrication oil adjustment……………………………………………………………………（31）
4 发动机的使用和维护保养
Operation and service&maintenace……………………………………………………………（33）
4.1 发动机的使用
Operation…………………………………………………………………………………………（33）
4.2 发动机的维护保养
Service & maintenace……………………………………………………………………………（35）
5 发动机常见故障及排除方法
Common failures and troubleshooting……………………………………………………………（41）
5.1 发动机不能起动
Engine will not start…………………………………………………………………………（41）
5.2 发动机功率不足
Underpower…………………………………………………………………………………………（42）
5.3 发动机运转时有不正常的声音
Abnormal sound when running …………………………………………………………………（43）
5.4 排气冒黑烟
Exhaust with black smoke………………………………………………………………………（43）
5.5 排气冒白烟、蓝烟
Exhaust with black smoke………………………………………………………………………（44）
5.6 润滑油压力异常
Abnormal lubrication oil pressure……………………………………………………………（44）
5.7 润滑油消耗高、消耗量大
High consumption of lubrication oil…………………………………………………………（45）
5.8 出水温度高
High water outlet temperature…………………………………………………………………（45）
5.9 增压器常见故障及排除方法
Turbocharger failures and troubleshooting…………………………………………………（46）
5.10 离合器常见故障、发动机自行熄火
Cltuch failures, engine stop of itself……………………………………………………（46）
5.11 发动机自行熄火
Engine stop of itself……………………………………………………………………………（46）
 图一 YC4A90-T12 系列柴油机外形安装图（配拖拉机、收割机，实际跟配套布置会有小差距，与 YC4B、YC4BA 外形安装图大致相同）
Figure I YC4A90-T12 series diesel engine lay-out (which is similar to that of YC4B and YC4BA, mounting on tractor, harvesting machinery.Lay-out
may differ slightly from mount in actual)
图二 YC4D80-T10（D7100）型柴油机外形安装图（配工程机，实际跟配套布置会有小差距）Figure II YC4D80-T10(D7100) series diesel
engine lay-out (mounted on off-road equipment. Lay-out may differ slightly from mount in actual)
 图三 YC4D100Z-T10（D7700）型柴油机外形安装图（配收割机，实际跟配套布置会有小差距）
Figure III YC4D100-T10 (D7700) series diesel engine lay-out (mounted on harvesting machnine. Lay-out may differ slightly from mount in actual)
图四 YC4B80-T10（B8800）系列总功率曲线图 Figure IV YC4D80-T10(B8800) series engine

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gross power
curve

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图五 YC4B100Z-T10（B9200）系列总功率曲线图 Figure V YC4B100Z-T10(B9200) series engine
gross power curve

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图六 YC4A90-T12（A8300）总功率曲线图 Figure VI YC4A90-T12(A8300) series engine gross
power curve

图七 YC4B90-T10（B7B00）总功率曲线图 Figure VII YC4B90-T10(B7B00) series engine gross

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 power curve

图八 YC4B105Z-T10（B9900）总功率曲线图 Figure VIII YC4B105Z-T10(B9900) series engine

gross power curve

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 外特性曲线图 Figure IX YC4D80-T10(D7100) series engine external
图九 YC4D80-T10（D7100）

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characteristics curve

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 图十 YC4BA95-T10（BA100）总功率曲线图
Figure X YC4BA95-T10(BA100) series engine gross power curve

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1 概述 Overview
1.1 产品特点 Characteristics
YC4A、YC4B、YC4BA、YC4D 工程机械与农业机械系列发动机是在 D 系列发动机
的基础上自主开发而成,秉承了原 D 系列发动机的可靠、省油，动力性好等优点,是一种理想的
配套动力。YC4A, YC4B, YC4BA, YC4D off-road equipment and agriculture machinery series
engines are developed on the base of D series engine, which took the advantages of
reliability, good fuel economy and excellent dynamics etc.

1.2 型号的组成及其代表意义 Model numbering and meaning

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 产品型号由阿拉伯数字和大写英文字母表示，其组成结构如下：Model is shown as Arabic
numberals and Capital English character; pls see its composition as follows:
1.3 主要用途及适用范围 Application scope
发动机适用于环境温度为-15℃～40℃、海拔高度 2000 米以下的环境条件下能正常工
作，禁止在水浸、火灾环境下工作。在环境温度低于-15℃或高于 40℃或海拔高度超过 2500
米时，用户应向玉柴技术、服务部门咨询，采取有效措施或使用相应专用发动机以保证发
动机能正常工作。Engine works normally under the condition of atmosphere temperature
from -15℃ to 40℃, altitude below 2000 miles, running the engine when the atmosphere
is waterlogging or firing is forbiden. When ambient temperature is below -15℃ or above
40℃ or altitude exceeds 2,500m, you should consult technical and service departments
of Yuchai and then take effective measures to ensure normal working of the engine.
1.4 本说明书的适用范围，如下表：
（本表仅作参考，不断增加的机型可能未及时罗列在内）
机型代号 基本型型号 功率 转速 配套机代号
A7D00 YC4A90-T10 66 2200 A7D01～A7D50、A8307、A8360～A8363
A7E01～A7E50、A8302～A8303、A8306、
A7E00 YC4A100-T10 72 2300
A8308
A7N00 YC4A80-T10 58 2200 A7N01～A7N20
A8B00 YC4A95-T10 67 2200 A8301
A8300 YC4A90-T12 66 2300 A8304～A8350
A8600 YC4A125Z-T10 92 2300 A8601～A8625

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 A8A00 YC4A85-T10 62 2200 A8A01～A8A50
A9000 YC4A90-T11 64 2400 A9001～A9020
B7B00 YC4B90-T10 65 2400 B7B00～B7B50、B8862、B8869、B8873
B7N00 YC4B90Z-T20 65 2300 B7N01
B7V00 YC4B105Z-T11 75 2200 B7V01
B8E00 YC4B110Z-T10 81 2300 B8E00～D8E20、B9V04
B9N00 YC4B85-T11 60 2300 B8802、B8815
B9M00 YC4B90-T11 65 2300 B8803 B9M00～B9M10
B7X00 YC4B80-T10 58 2200 B8804，B7X01～B7X10
B8813～B8814、B7T01～B7T40、B8821～
B7T00 YC4B85-T12 62 2200 B8823、B8860～B8861、B8863～B8868、
B8870～B8872
B9P00 YC4B85-T10 62 2400 B8819
B9900 YC4B105Z-T10 74 2300 B9200～B9209、B9906～B9920
B9Q00 YC4B90Z-T10 65 2300 B9210，B9Q00～B9Q20
B7W00 YC4B105Z-T12 77 2300 B9212，B7W00～B7W15
B9S00 YC4B115Z-T11 82 2300 B9213，B9S00～B9S20
B9V00 YC4B115Z-T10 84 2400 B9260～B9263、B9900、B9903～B9904
B7V00 YC4B105Z-T11 75 2200 B9902、B9905
B9V00 YC4B115Z-T10 84 2400 B9V01、B9V03～B9V40
B9Y00 YC4BA105-T10 74 2300 B9Y01～B9Y20、BA101～BA103
D7002、D7005、D7017、D7037，D7J01～
D7J00 YC4D80-K10 58 2400
D7J20
D7004、D7006～D7007、D7010、D7018、
D7021、D7023、D7026～D7029、D7031、
D8400 YC4D80-T11 56 2200
D7033～D7036、D7038、D7100～D7115
D8400～D8420
D7014、D7015、D7019、D7022、D7030、
D8300 YC4D80-T10 58 2400
D7116、D8301～D8340
D8800 YC4D95Z-T10 70 2400 D7703～D7706、D7805，D8800～D8830
D7N00 YC4D95Z-K20 70 2400 D7802～D7804、D7N01～D7N20
D7A00 YC4D85Z-T10 60 2200 D7806、D7807、D7A01，D7A00～D7A20
D7E00 YC4D90Z-T11 70 2200 D7808、D7809、D7E01～D7E40

1 技术特性 Specifications

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2.1 主要性能（基本型）Performance of basic model

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 表1－1 YC4A、YC4B、YC4BA、YC4D工程机械与农业机械系列发动机主要技术参数 Table 1-1 Technical parameters

序 技 术 规 格Specifications
号 名 称Name
Ite B8800 B9200 A8300 B7B00 B9900 D7100 A8600 D7700 BA100

YC4B100Z- YC4A90-T1 YC4B90-T1 YC4B105Z- YC4D80-T1 YC4A125Z- YC4D100Z- YC4BA95-T

1 型 号Model YC4B80-T10
T10 2 0 T10 0 T10 T10 10

2 型 式Type 立式、直列、水冷、四冲程Vertical, in-line. Water-cooled, four stroke

自然吸气 增压 自然吸气 自然吸气 增压 自然吸气 增压 增压 自然吸气

进气方式Air intake
3 Naturally Turbocharg Naturally Naturally Turbocharg Naturally Turbocharg Turbocharg Naturally
way
aspirated ed aspirated aspirated ed aspirated ed ed aspirated

燃烧室形式
4 Combustion chamber 直喷式缩口ω燃烧室Direct injection shrink ora ω
type

气缸数Number of
5 4
cylinders

6 气缸直径 Bore mm 108 110

7 活塞行程 Stroke mm 125 132 125 115 132 115 132

活塞总排量 Piston
8 4.58 4.836 4.58 4.214 4.836 4.214 5.018
total displacement L

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 压缩比Compression
9 17.5:1
ratio
气缸套型式Cylinder
10 湿 式Wet
liner type

表 1（续）Table 1(to be continue)

序 技 术 规 格Specifications
名 称Name
号 B8800 B9200 A8300 B7B00 B9900 D7100 A8600 D7700 BA100
标定功率 Rated
11 58 72 66 65 75 56 92 65 75
power kW
标定转速 Rated
12 2300 2300 2300 2400 2300 2200 2300 2200 2300
rotation speed

13 最大扭矩 Max.torque 305 387 340 295 400 275 ≥450 320 345
N·m
最大扭矩转速
14 Max.torque rotation 1400～1600 1400～1650 1400～1700 1500～1700 1500～1700 1600～1900 1600～1800 ≤1800 1400～1700
speed r/min
标定工况燃油消耗率
Fuel consumption
15 ≤235 ≤235 ≤240 ≤238 ≤230 ≤240 ≤235 ≤230 ≤240
rate at rated working
conditions g/kW·h

25 / 72
 最大扭矩工况燃油消
耗率 Fuel
16 ≤230 ≤230 ≤220 ≤225 ≤220 ≤235 ≤230 ≤220 ≤225
consumption rate at
max. torque g/kW·h

夏季：GB 252-2000优级品或一级品0号、10号轻柴油机,summer: GB252-2000 superior class or first-class 0#, 10# light fuel
17 柴油牌号Fuel brand 冬季：GB 252-2000优级品或一级品0号、-10号、-20号、-35号轻柴油。winter: GB252-2000 superior class or first-class 0#, -10#,-20#,-35#
light fuel
最高空载转速
18 ≤2480 ≤2438 ≤2480 2592~2640 ≤2460 ≤2376 ≤2438 ≤2332 ≤2480
Max.no-load speed
最低空载转速
19 670～730 700～750
Min.no-load speed

工作次序Firing
20 1-3-4-2
sequence

机油燃油消耗比Fuel
21 and lubrication oil ≤0.5 ≤0.8 ≤0.5
consumption ratio％
夏季：CD40、CD15W—40，冬季： CD10W—30或与环境相适应的不低于GB 11122-2006中CD级的其他柴油机油Summer: CD40、
机油牌号Lubrication
22 CD15W—40, while winter: CD10W—30 or other CD grade lubrication oil that not lower than GB11122-2006 and compatible with
oil brand
environment
曲轴旋转方向(面向功
率输出端)Crankshaft
23 rotation direction 逆时针counterclockwise
(facing power output
end)

26 / 72
 供油提前角(上止点前
曲轴转角) °CA Fuel
supply advance
24 15±2 15±2 18±2 15±2 15±2 13±2 15±2 16±2 18±2
angle(crankshaft
rotation angle before
TDC)

油嘴突出高度 （mm）
25 nozzle projection 2.5±0.1 3.6±0.1 2.5±0.1 3.6±0.1 2.5±0.1
hight

排气烟度 FSN
26 ≤4 ≤3.5 ≤5 ≤3.5 ≤3.5 ≤3.6 ≤3.5 ≤4 ≤5.2
Exhaust smoke

噪声限值
27 ≤112 ≤114 ≤112 ≤113 ≤113 ≤112 ≤114 ≤112 ≤113
LwdB(A)Noise limit

压缩压力

28 (n≥200r/min) MPa ≥2.5

Compression
pressure
29 润滑方式Lubrication 压力润滑与飞溅润滑复合式Press lubricating and splash lubricating in combination

30 起动方式Starting way 电起动Electrical starting

27 / 72
 13（其中油 13（其中油
底壳11）(oil 底壳11）(oil
机油容量 L
capacity in capacity in
31 Lubrication oil 12 12 13 11 13
oil pan oil pan
capacity
takes up takes up
11L) 11L)

柴油机净质量 kg
32 400 450 450 400 450 400 450 450 ≤560
Net weight

外形尺寸 长×宽×
高 mm 907×695× 881×725× 907×695×
32 907×649×832 907×649×832 870×670×780
Dimension: 881 805 881
lengthXwidthxhight

28 / 72
 2.2 主要技术参数 Specifications

表 1－2 附 1 表 YC4D 系列工程机械与农业机械系列发动机主要零件配

合间隙及磨损极限 Table 1-2 attached table 1 main parts fitting clearance and
wear limit

单位：mm
配合间隙
序
配合性质 Fitting
号 配合部位 Fitting
图纸尺寸 Drawing dimension Fitting clearance(inte
Ite position rference)
quality
m （过盈）
+0.025 +0.095
排气门座孔/排气门座 Ф44.5 0 /Ф44.5 +0.070

Exhaust valve seat 过 盈

1 0.045～0.095
Interference
hole/exhaust valve

seat
+0.025 +0.139
进气门座孔/进气门座 Ф48.5 0 /Ф48.5 +0.114
过 盈
2 Intake valve seat 0.089～0.139
Interference

hole/intake valve seat

气缸盖气门导管孔/气门
3 导管外径 Cylinder head +0.046 过 盈
Ф16 + 00.018 /Ф16 + 0.028 0.010～0.046
valve guide hole/valve Interference
guide diameter
气门导管孔/排气门杆直
Ф9.5
+0.019 −0.04
/Ф9.5 − 0.062 径向间隙
径 Valve guide 0
4 Radial 0.040～0.081
hole/exhaust valve
clearance
stem diameter
气门导管孔/进气门杆直
Ф9.5
+0.019 −0.04
/Ф9.5 − 0.062 径向间隙
径 Valve guide 0
5 Radial 0.025～0.066
hole/intake valve stem
clearance
diameter
气门摇臂轴座孔/气门摇 +0.021 −0.02
臂轴 Valve rocker arm Ф25 0 /Ф25 − 0.041 径向间隙
6 shaft seat hole/valve Radial 0.020±0.062
rocker arm shaft clearance

径向间隙
+0.022
7 气缸套/活塞裙下部 Ф108 0 /Ф107.86±0.01 Radial 0.130～0.172
clearance

21
 配合间隙
序
配合性质 Fitting
号 配合部位 Fitting
图纸尺寸 Drawing dimension Fitting clearance(inte
Ite position
quality rference)
m
（过盈）

Cylinder liner/piston

skirt lower part

气门挺柱孔/气门挺柱
径向间隙
+0.052 −0.02
8 Valve tappet hole/valve Ф28 0 /Ф28 −0.041 Radial 0.020～0.093
clearance
tappet
凸轮轴衬套底孔/凸轮轴
衬套 Camshaft bushing +0.03 +0.106 过 盈
9 Ф62 0 /Ф62 +0.087 0.057～0.106
bottom hole/camshaft Interference
bushing
凸轮轴衬套孔/凸轮轴轴 径向间隙
+0.03 −0.03 0.03～0.09
10 颈 Camshaft bushing Ф58.5 0 /Ф58.5 − 0.06 Radial
hole/camshaft journal clearance
正时惰齿轮衬套孔/惰轮
径向间隙
轴 Timing idler gear Ф55.5
+0.03 −0.03
/Ф55.5 − 0.06
11 0 Radial 0.03～0.09
bushing hole/idler gear
clearance
shaft
正时惰齿轮/惰轮轴 轴向间隙
0 + 0.17
12 Timing idler gear/idler 28 − 0.08 /28 + 0.07 Axial 0.07～0.25
clearance
gear shaft
活塞环槽/第一道气环 轴向间隙
13 Piston ring groove/the 2.695±0.015/2.605 −−00..0103 Axial 0.085～0.135
clearance
first air ring
+0.10 −0.010
活塞环槽/第二道气环 2.5 +0.08 /2.5 −0.025
轴向间隙
14 Piston ring groove/the Axial 0.09～0.125
clearance
second air ring
+0.04 −0.010 轴向间隙
活塞环槽/油环 Piston 3.5 +0.02 /3.5 −0.025
15 Axial 0.030～0.065
rin groove/oil ring clearance
+0.089
连杆轴瓦孔/连杆轴颈 Ф66 + 0.040 /Ф66 −0.0019
径向间隙
16 Connecting rod bearing Radial 0.040～0.108
clearance
shell hole/connecting
22
 配合间隙
序
配合性质 Fitting
号 配合部位 Fitting
图纸尺寸 Drawing dimension Fitting clearance(inte
Ite position
quality rference)
m
（过盈）
rod journal

+0.036 0
连杆衬套孔/活塞销 Ф38 + 0.025 /Ф38 − 0.011
径向间隙
17 Connecting rod Radial 0.025～0.047
clearance
bushing hole/piston pin
0
Ф38 ++00.012
.005
/Ф38 − 0.011 0.005～0.023
活塞销座孔/活塞销 0
径向间隙
18 Ф40 ++00.012
.005
/Ф40 −0.06 Radial
Piston pin seat clearance 0.005～0.018
hole/piston pin
主轴承孔/主轴颈 Main +0.122
Ф85 +0.060 /Ф85 −0.022
0 径向间隙
19 bearing hole/main Radial 0.060～0.144
journal clearance
凸轮轴隔圈/凸轮轴止推 +0.12 −0.04
5 +0.06 /5 −0.08 轴向间隙
板 Camshaft
20 Axial 0.10～0.20
spacer/camshaft thrust
clearance
plate
机油泵转子厚/泵体孔深 0
22 −0.021 /22
+ 0.08
+ 0.05 轴向间隙
Oil pump rotator
21 Axial 0.05～0.101
thickness/ hole depth
clearance
in pump body
外转子外圆/机油泵体孔 Ф69.7
0
/Ф69.8
+ 0.15 径向间隙
− 0.08 + 0.05
22 outer rotator external Radial 0.15～0.33
circle /oil pump hole clearance
机油泵轴衬套(Ⅰ)机油 Ф19
+ 0.075
/Ф19
+ 0.025
+ 0.050 + 0.012 径向间隙
泵轴 Oil pump shaft
23 Radial 0.025～0.063
bushing(I) oil pump
clearance
shaft
机油泵轴衬套(Ⅱ)机油 Ф15.8
+ 0.075
/Ф15.8
+ 0.024
+ 0.050 + 0.012 径向间隙
泵轴 Oil pump shaft
24 Radial 0.026～0.063
bushing(II) oil pump
clearance
shaft
第一道气环 The first air ring 间 隙
0.4～0.6
Clearance
活塞环闭口间隙 Piston
第二道气环 The second air 间 隙
25 0.35～0.55
ring closed clearance Clearance
ring
间 隙
油环 Oil ring 0.30～0.55
Clearance
26 曲轴轴向间隙 轴向间隙 0.1～0.27
23
 配合间隙
序
配合性质 Fitting
号 配合部位 Fitting
图纸尺寸 Drawing dimension Fitting clearance(inte
Ite position
quality rference)
m
（过盈）
Axial
Crankshaft axial
clearance
clearance
齿轮之间啮合间隙
间 隙
27 Backlash between Clearance
0.07～0.25

gears

表 1－2 附 2 表 YC4B、YC4A、YC4BA 系列工程机械与农业机械系列发

动机主要零件配合间隙及磨损极限 Table 1-2 attached table2 main parts
fitting clearance and wear limit

单位：mm
序 配合间隙
号 配合性质 Fitting
配合部位 Fitting
It 图纸尺寸 Drawing dimension Fitting clearance(inte
position
e quality rference)
m （过盈）
+0.025 +0.095
排气门座孔/排气门座 Ф44.5 0 /Ф44.5 +0.070

Exhaust valve seat 过 盈

1 Interferen 0.045～0.095
hole/exhaust valve ce

seat
+0.025 +0.139
进气门座孔/进气门座 Ф48.5 0 /Ф48.5 +0.114
过 盈
2 Intake valve seat Interferen 0.089～0.139
ce
hole/intake valve seat
气缸盖气门导管孔/气门
过 盈
3 导管外径 Cylinder +0.046
Ф16 + 00.018 /Ф16 + 0.028 Interferen 0.010～0.046
valve guide hole/valve
ce
guide diameter
气门导管孔/排气门杆直
Ф9.5
+0.019 −0.04
/Ф9.5 − 0.062 径向间隙
径 Valve guide 0
4 Radial 0.040～0.081
hole/exhaust valve
clearance
stem diameter

24
 序 配合间隙
号 配合性质 Fitting
配合部位 Fitting
It 图纸尺寸 Drawing dimension Fitting clearance(inte
position
e quality rference)
m （过盈）
气门导管孔/进气门杆直
Ф9.5
+0.019 −0.04
/Ф9.5 − 0.062 径向间隙
径 Valve guide 0
5 Radial 0.025～0.066
hole/intake valve stem
clearance
diameter
气门摇臂轴座孔/气门摇 +0.021 −0.02
Ф25 /Ф25 − 0.041 径向间隙
臂轴 Valve rocker arm 0
6 Radial 0.020±0.062
shaft seat hole/valve
clearance
rocker arm shaft

气缸套/活塞裙下部
径向间隙
+0.022
7 Cylinder liner/piston Ф108 0 /Ф107.86±0.01 Radial 0.130～0.172
clearance
skirt lower part

气门挺柱孔/气门挺柱
径向间隙
+0.052 −0.02
8 Valve tappet hole/valve Ф28 0 /Ф28 −0.041 Radial 0.020～0.093
clearance
tappet
凸轮轴衬套底孔/凸轮轴
过 盈
衬套 Camshaft bushing Ф62
+0.03 +0.106
9 0 /Ф62 +0.087 Interferen 0.057～0.106
bottom hole/camshaft
ce
bushing
凸轮轴衬套孔/凸轮轴轴 径向间隙
1 +0.03 −0.03 0.03～0.09
颈 Camshaft bushing Ф58.5 /Ф58.5 − 0.06 Radial
0 0
hole/camshaft journal clearance
正时惰齿轮衬套孔/惰轮 径向间隙
+0.03 −0.03
11 轴 Ф55.5 0 /Ф55.5 − 0.06 Radial 0.03～0.09
clearance
正时惰齿轮/惰轮轴 轴向间隙
1 28
0 + 0.17
/28 + 0.07
Timing idler gear/idler − 0.08 Axial 0.07～0.25
2
clearance
gear shaft
活塞环槽/第一道气环 轴向间隙
1 2.695±0.015/2.605 −−00..0103
Piston ring groove/the Axial 0.094～0.134
3
clearance
first air ring
+0.10 0 轴向间隙
1 活塞环槽/第二道气环 2.5 +0.08 / 2.5−0.015
Axial 0.08～0.115
4
Piston ring groove/the clearance
25
 序 配合间隙
号 配合性质 Fitting
配合部位 Fitting
It 图纸尺寸 Drawing dimension Fitting clearance(inte
position
e quality rference)
m （过盈）
second air ring

1 活塞环槽/油环 Piston 5++0.06 0

0.04 / 5 −0.02
轴向间隙
Axial 0.040～0.080
5
ring groove/oil ring clearance
连杆轴瓦孔/连杆轴颈 φ 66 ++00..109
006 /Ф66 −0.019
0

Connecting rod bearing 径向间隙

1
Radial 0.060～0.128
6
shell hole/connecting clearance
rod journal
/ φ 40 −0.006
+0.036 0
连杆衬套孔/活塞销 Ф40 + 0.025
径向间隙
1
Connecting rod Radial 0.025～0.042
7
clearance
bushing hole/piston pin
+0.012 0
Ф40 + 0.005 /Ф40 − 0.011 0.005～0.023
活塞销座孔/活塞销 径向间隙
1 Ф40 ++00.012 / φ 40 −0.006
0
8 .005 Radial
Piston pin seat clearance 0.005～0.018
hole/piston pin
主轴承孔/主轴颈 Main +0.122
Ф85 +0.060 /Ф85 −0.022
0 径向间隙
1
bearing hole/main Radial 0.060～0.144
9
journal clearance
凸轮轴隔圈/凸轮轴止推 5++00..18 −0.04
12 /5 −0.08 轴向间隙
2 板 Camshaft
Axial 0.08～0.20
0 spacer/camshaft thrust
clearance
plate
机油泵转子厚/泵体孔深 0
22 −0.021 /22
+ 0.08
+ 0.05 轴向间隙
2 Oil pump rotator
Axial 0.05～0.101
1 thickness/pump hole
clearance
depth
外转子外圆/机油泵体孔 Ф69.7
0
/Ф69.8
+ 0.15 径向间隙
2 − 0.08 + 0.05
outer rotator external Radial 0.15～0.33
2
circle/oil pump hole clearance
机油泵轴衬套(Ⅰ)机油 Ф19
+ 0.075
/Ф19
+ 0.025
+ 0.050 + 0.012 径向间隙
2 泵轴 Oil pump shaft
Radial 0.025～0.063
3 bushing(I) oil pump
clearance
shaft
机油泵轴衬套(Ⅱ)机油 Ф15.8
+ 0.075
/Ф15.8
+ 0.024
+ 0.050 + 0.012 径向间隙
2 泵轴 Oil pump shaft
Radial 0.026～0.063
4 bushing(II) oil pump
clearance
shaft
26
 序 配合间隙
号 配合性质 Fitting
配合部位 Fitting
It 图纸尺寸 Drawing dimension Fitting clearance(inte
position
e quality rference)
m （过盈）
第一道气环 间 隙
Clearanc 0.45～0.65
活塞环闭口间隙 Piston 第二道气环 The second air e
ring 间 隙
2 ring closed clearance Clearanc 0.50～0.70
5
油环 Oil ring e
间 隙
Clearanc 0.30～0.55
e
曲轴轴向间隙 轴向间隙
2
Crankshaft axial Axial 0.1～0.27
6
clearance
clearance
齿轮之间啮合间隙 间 隙
2
Backlash between Clearanc 0.07～0.25
7
e
gears

主要螺栓、螺柱、螺母拧紧力矩
Tightening torque of main bolts, studs and nuts
表 1-3 YC4A、YC4B、YC4BA、YC4D 工程机械与农业机械系列发动机
主要螺栓、螺柱、螺母拧紧力矩 Table 1-3 Tightening torque of main bolts, studs
and nuts

名称 Name 拧 紧 力 矩 （ N.m ） 名称 Name 拧紧力矩（N.m）

Tightening torque Tightening torque
主轴承盖螺母 Main bearing cover nut 220～260 皮带轮减振器螺栓（起动抓）Belt ≥300
pulley vibration damper
bolt(starting jaw)
主轴承螺柱 Main bearing stud 150～170 飞轮壳螺栓 Flywheel shell bolt 100～108
连杆螺栓 Connecting rod bolt 170～210 飞轮螺栓 Flywheel bolt 170～210
气缸盖螺栓或螺母 Cylinder head bolt/nut 210～250 喷 油 器 总 成 螺 母 Injector 20～30
assembly nut
凸轮轴正时齿轮螺母 Camshaft timing gear 160～200 铸铁油底壳螺栓 Cast iron oil pan 27～34
nut bolt 20～30
钢 板 冲 制 油 底 壳 螺 栓
steel-blanking bolt of oil pan
27
 注：高强度螺栓在此基础上加 5 N·m Note: high rigidity bolt should be applied an extral 5
N.m

表 1-4 其它螺栓拧紧力矩推荐值
Table 1-4 Recommended Values of Tightening Torque for other bolts
公制 Metric
螺纹直径（mm）Thread diameter M6 M8 M10 M12 M14
system
扭紧力矩(N·m)Tightening torque 8～12 16～20 27～34 61～68 115～129

2 柴油机主要装配要求以及柴
油 机 的 调 整 Assembly
requirements and adjustment

3.1 柴 油 机 主 要 装 配 要 求
Assembly requirements
3.1.1 曲轴的安装
Crankshaft assembly
曲轴装配时，应从止推档（即第三档）
开始拧紧主轴承螺栓，然后向两端依次拧
紧，主轴承螺栓不允许一次拧紧，应分三次
依次轮流均匀拧紧，三次拧紧力矩为：
第一次拧紧力矩：60～80N.m
第二次拧紧力矩：160～180N.m 图 11

第三次拧紧力矩： 260N.m,
检验 230～300N.m
每拧紧一次，应转动曲轴，以检查灵活性。按规定力矩拧紧后，曲轴应转动
灵活自如，曲轴轴向窜动量（轴向间隙）应在 0.1～0.27mm 范围内。Start tightening
main bearing bolt from thrust (the third one) to each side. Main bearing bolts
should be evenly tightened for both ends by turns in three times:
Tightening torque for the first time 60 N•m ~80 N•m
Tightening torque for the second time 160 N•m ~180 N•m
Tightening torque for the third time 260 N•m
28
Check in 230-300 N.m
After each tightening, rotate the crankshaft to check for its flexibility. Axial play of
the crankshaft should be 0.1~0.27mm.
3.1.2 活塞连杆的安装
Piston connecting rod assembly
活塞环装配时，活塞环上有向上标记的一面
朝上（第二道内扭曲环内倒角朝上），严禁反装。
活塞连杆组装入缸孔时，活塞环的开口位置应依
次错开（如图），并使活塞顶面上的箭头指向发动 Engine
front end Piston
机前端。连杆螺栓装配时应涂抹少许干净机油， pin
然后拧紧，检验力矩为 190～260N.m，应按下列 central
line
要求分三次均匀拧紧，严禁一次拧紧： The side of
piston ring that marked “TOP” should be faced
upwards when fitted. Note that groove of piston
ring should be staggered in turn and arrow in
piston crown should head out towards engine
front end when piston connecting rod fitted.
Apply a few clean engine oil to connecting rod
bolt and tighten afterwards.The tightening torque is 190～260N.m when
inspection
第一次拧紧力矩：50～70N.m
The first tightening torque: 50～70N.m
第二次拧紧力矩：110～130N.m
The second tightening torque: 110～130N.m
第三次拧紧力矩：220N.m
The third tightening torque: 220N.m
：活塞顶部的方向标记。Pay attention to the direction mark in piston
【注意】
crown 图 12

29
 第一道气环 The first air
ring
第二道气环 The second air
ring

油环 Oil ring

安装活塞连杆组件时，必须注意连杆
体和连杆盖上的配对号。Pay attention to
the corresponding mark on rod and rod
cover when assembly
标记 mark

图 13

30
 3.1.3 凸轮轴的安装 Camshaft assembly
小心地将凸轮轴装入机体中，
注意轴颈、凸轮与衬套表面不得碰
Flange
伤，装上隔圈、凸轮轴止推板、凸
轮轴齿轮，上紧锁螺母，其拧紧力
矩应大于 300 N.m，把垫片翻边防
松。凸轮轴应转动自如，其轴向间
隙为 0.10～0.2mm。Enclose
camshaft into cylinder block
carefully to prevent journal, cam
图 14
and bushing surface from
damage, and then mount spacer, camshaft thrust plate and camshaft gear, fit lock
nut with tightening torque that is larger than 300 N.m. Slacken gasket flang, the
camshaft can rotate freely, and its axial clearance should be 0.10～0.2mm.

3.1.4 气门及导管的安装 Valve

and valve guide assembly
气门导管应在常态下压入，导管上端面至
气缸盖弹簧座面的距离在 20±0.3mm 范围内。
进气门密封锥角为 120°、排气门的密封锥角
为 90°，气门与气门座圈均需配对研磨，气门
下沉量控制在 1±0.2mm 范围内，1.7±0.2mm
范围。Press in the valve guide at normal
condition and ensure the distance from valve guide top to spring seat surface of

31
cylinder head should be within 20±0.3mm, seal cone angle of intake valve is 120°
and seal cone angle of exhaust valve is 90°. Valve and valve seat ring should be
grinded in all correspondence, valve sinking is required at 1±0.2mm 1.7±0.2mm.

图 15
3.1.5 喷油器的安装 Injector assembly
在安装气缸盖前，先把喷油器装到
Injector
气缸盖上，检查喷嘴凸出缸盖底面高度， Regulating gasket
此高度控制在要求的范围内，比如 A8300 (copper)

调整为 2.5±0.1mm，具体可参照表 1－1。

超差时通过垫片来调整，然后把喷油器拆
下待后装配。调整好后的喷油器及垫片在
装配时应对号入座，不能调换装配。
Mount the injectors in the cylinder head
图 16
first, and check the height that injectors project over the cylinder head from the
bottom. Ensure the projection height to be met the requirements, for example
A8300 is adjusted to be 2.5±0.1mm, and details please refer to table 1-1. If the
projection is not within the tolerance, adjust gasket. Remove injectors afterwards.
Injectors and gaskets should be assembled in all correspondance after
adjustment.
3.1.6 气缸盖的安装 Cylinder
head assembly
安装气缸盖时，缸盖螺栓应按图
示顺序均匀拧紧，最后检查保证每个
螺栓拧紧力矩为 210～260N.m，不允
许一次拧紧，应分三次依次拧紧：
第一次拧紧力矩：60～80N.m
图 17 Figure 17

32
 第二次拧紧力矩：120～140N.m
第三次拧紧力矩：230N.m
Cylinder head bolts should be tightened evenly in sequence shown in the figure
17, and ensure the tightening torque of bolt should be 210～260N.m, which is
done in three stages as follows:
The first stage: 60～80N.m
The second stage: 120～140N.m
The final stage: 230N.m

33
 3.1.7 齿轮系的安装 Gear
train assembly
曲轴正时齿轮、喷油泵齿轮、凸
轮轴齿轮等均有定时要求，因此，在
上述三部齿轮及正时惰齿轮上均有
定时装配标记，装配齿轮时须对准装
配标记，装配后在齿面上加润滑油，
齿轮啮合侧隙在 0.07～0.25mm 范围
内。Crankshaft timing gear, injection pump
图 18
gear, camshaft gear and timing idle gear all
bear timing assembly marks, with which
should be aligned when assembly.
Lubricate the gears afterwards.Ensure
backlash should be within 0.07～0.25mm.

▲注意事项 Notes:
1． 装配前各零部件均应仔细清洗干净，特别是各油孔油道，不允许有任何杂
质存在。All parts and componens should cleaned thoroughly prior to
installtion, oil galleries and oil holes in particular, which should be kept
free from any impurities
2． 零部件配合表面不允许有锈蚀、毛刺、碰伤等缺陷。Parts fitting surface
should be kept free from rust, burr and damage
3． 零部件的摩擦表面、重要的配合表面应涂以清洁机油再进行装配。Apply
clean lubrication oil to friction surface and fitting surface of parts prior to
assembly.

34
 4. 零部件装配后，零件配合须满足第三章中的“主要零件配合间隙”的要求。
The part fitting should meet the requirements that described under the
heading “main parts fitting clearance”, section III

3.2 柴油机的调整 Adjustment

3.2.1 供油提前角的调整 Fuel supply

advance angle adjustment
技术要求：Technical requirements
A8300 静态供油提前角为上止点前 18°±2
°，D7000 静态供油提前角为上止点前 13°±
2°CA，其它的参照表 1－1。静态供油提前角
检查：松开第一缸高压油管与喷油泵的连接螺
母，慢慢转动曲轴，当出油阀紧帽中的油面开
始波动时即停止转动曲轴，此时装在齿轮室罩
上的定时指针在皮带轮减振器定时刻度上的
指示值即为静态供油提前角度。静态供油提前
角的调整：松开喷油泵前端联接法兰的紧固螺
母，以及松开后端支架，然后把喷油泵适当拨转一角度（喷油泵往内拨转则提前角
度增大，喷油泵往外拨转则提前角度变小），然后拧紧联接法兰的螺母，检查供油
提前角，调整至符合要求后把联接法兰紧固螺母及后端支架螺栓、螺母拧紧。The
static fuel supply angle of A8300 and D7000 are respectively 18°±2°, 13°±2°CA
before TDC (Top dead center), while the others please refer to table 1-1 for the
prescribed values. Check static fuel supply advance angle: unscrew connecting
nut between high pressure fuel line of No.1 cylinder and injection pump,
afterwards rotate crankshaft slowly until the fuel level in cap nut of outlet valve is

35
 shown to be waved, timing pointer in gear housing cover.
Adjustment: slacken front end connecting flange lock nut of injection pump as well
as the rear end bracket. Turn the injection pump in a proper angle (turn the injection
pump inwards will increase the advance angle while turn it outwards will decrease
advance angle), tighten the connecting flange bolt and adjust the advance angle to
meet the requirements. Afterwards tighten lock nut of front end flange and rear end
bracket bolt and nut.
3.2.2 气门间隙的调整 Valve clearance adjustment
技 术 要 求 ：（ 冷 态 ） Technical
reqiuremnets ( cold state)
进气门间隙 0.4±0.05mm，Intake valve
clearance is 0.4±0.05mm
排气门间隙 0.45±0.05mm。Exhaust
valve clearance is 0.45±0.05mm
第一缸压缩上止点判别：转动曲轴至指
针（装在齿轮室罩上）对准曲轴皮带轮减振
器上的“0”刻度，然后连续正反转小角度范围
（10°～20°即可）转动曲轴，若此时第一缸
进、排气摇臂无摆动动作，而第四缸进、排
气摇臂有摆动动作，这时把曲轴转回到指针
对准“0”刻度，此时即处于第一缸压缩上止点的位置。连续正反小角度转动曲轴时第
一缸摇臂有摆动动作而第四缸摇臂无摆动动作，指针对准“0”刻度时为第四缸处于压
缩上止点，此时把曲轴再转动一圈（360°）即变为第一缸处于压缩上止点位置。
Rotate crankshaft until the pointer(fitted on gear housing cover) points at scale
“0” on vibration damper of crankshaft belt pulley, and then rotate crankshaft with
approximately 10°～20° in clockwise and counterclockwise continuously . If

36
intake and exhaust rocker arm of No.1 cylinder don’t swing but intake and
exhaust rocker arm of No.4 cylinder swing, then rotate crankshaft back until the
pointer points at scale 0, crankshaft now is positioned at compression TDC.
When rotate crankshaft with small angle continuously in clockwise and
counterclockwise, intake and exhaust rocker arm of No.1 cylinder swing but
intake and exhaust rocker arm of No.4 cylinder don’t swing, No.4 cylinder is now
positioned at compression TDC as pointer points at scale 0. Rotate the
crankshaft in a further full round（360°）, No.1 cylinder now is positioned at
compression TDC.
气门间隙调整：把曲轴转到第一缸压缩上止点位置，此时可调整 1、2、3、6
气门，再把曲轴转过 360°，此时可调整第 4、5、7、8 气门。调整时先把气门调整
螺钉的锁紧螺母松开，用起子适当旋出调整螺钉，把厚薄规插入摇臂与气门杆端之
间，然后适当旋进调整螺钉，直至摇臂刚好压紧厚薄规，再把锁紧螺母拧紧。正确
的气门间隙应能让厚薄规以微小的阻力来回插过。 Rotate crankshaft to TDC
position, No. 1 cylinder to adjust 1、2、3、6 valve, rotate crankshaft in 360°to adjust
4、5、7、8 valve. Slacken lock nut of regulating bolt and screw regulating bolt out
properly with a screwdriver. Place a feeler gauge between rocker arm and valve
stem and screw the regulating bolt in properly until the rocker arm press on the
feeler gauge, tighten the lock nut afterwards.
The correct valve clearance should be
allowed the feeler gauge to move through
back and forth with silght resistance.

3.2.3 喷油压力的调整 Injection

pressure adjustment
技术要求：Technical requirements

37
 23±0.5MPa
喷油压力 injection
pressure 26±0.5MPa(增压机)(Turbocharged engine )
喷油压力调整：拆下调压螺钉护帽，把调压螺钉按需
要旋进或旋出。调压螺钉旋进则喷油压力增大，调压螺钉旋出则喷油压力减小。喷
油压力的调整应在专用试验台上进行。The adjustment of injection pressure is
carried out in the following manner: remove regulating bolt cap and screw the
regulating bolt in or out where necessary. Screw the regulating bolt will increase
injection pressure while screw the regulating bolt out will decrease injection
pressure. Note: the adjustment of injection pressure should be performed on the
special test bench.

3.2.4 机油压力的调整
Lubrication oil pressure adjustment

技术要求：Technical requirements
怠速时机油压力≥0.1MPa Lubrication oil pressure at idle speed is ≥0.1MPa
标定转速时机油压力 0.25～0.6MPa Lubrication oil pressure at rated speed
is 0.25～0.6MPa
机油滤清器上安装有调压阀，可通过调
整调压阀调节螺丝来进行机油压力的调整，调整
时先把调压阀的螺帽拆下，旋松锁紧螺母，用起
子把调节螺丝旋进，则机油压力升高，调节螺丝
退出则机油压力下降，调整完毕后拧紧锁紧螺母
及螺帽。如果调整后机油压力还不符合要求，则

38

图 22
需认真检查润滑油路中的故障并予以排除。Lubircation oil pressure is adjusted
through regulating bolt of pressure regulating valve that fitted on oil filter. Remove
bolt cap of regulating valve and slacken lock nut, screw the regulating bolt in with
a screwdriver to increase oil pressure while screw the regulating bolt out to
decrease the oil pressure, tighten lock nut and bolt cap afterwards. If oil pressure
fails to meet the requirements after adjustment, check and troubleshooting
lubrication system for failures.

39
4 发动机的使用和维护保养 Operation and maintenance

4.1 发动机的使用 Operation

4.1.1 起动前 Before starting
z 检查油底壳润滑油油面，确保润滑油足够，保证润滑，若不够，则应添加到润滑油标尺规
定的位置; Check the oil level in the sump to make sure the lube is enough to ensure
lubrication effect. If the capacity of oil is not enough, replenish to the level settings of the
oil dipstick.
z 检查水箱中的冷却液，保证正常冷却（玉柴系列增压机要求必须使用防冻冷却液）; Check
the coolant in water tank to ensure normal cooling (Coolant must be used for Yuchai
series charged engines).
z 检查排除燃油管路的空气和柴油滤清器的水，Check and remove air from the fuel pipe
and the water in the fuel filter
z 检查油箱，若不够，添加燃油;Check fuel tank and replenish if deficient.
z 检查电器系统（各连接线路、开关接线等是否牢固可靠，电瓶电解液是否充足，若不够，
加足电解液）; Check the electric system; make sure the connecting wires and joints are
secure. And check the battery power, refill with enough electrolyte if insufficient.
z 检查皮带，松紧度应适宜，皮带过松打滑使水泵、风扇的工作不正常，冷却效果差，发动
机水温高，过紧则使皮带轮轴受力过大、皮带寿命缩短; Check the belt to ensure its
elasticity is suitable, too losse would cause slippery, resulting in water pump and fan
work abnormally and bad cooling and high water temperature of the engine; while too
tight of the belt may cause the pulley shaft to bear greatly which shorten the belt service
life consequently.
z 检查汽车底盘和操纵装置，禁止汽车带病行驶。Check the chassis and the controlling
system; never drive a vehicle with troubles.

4.1.2 起动 Starting
完成起动前准备工作并确认符合要求后，才可以起动发动机（冬天天气寒冷时需对柴油
机预热后才能起动），起动发动机时，持续起动时间不能超过 10 秒钟;二次起动的时间间隔不
应少于 1 分钟;若连续三次均无法起动，则应检查原因，排除故障，再行起动。The engine cannot
be started unless the preparations have been completed and confirmed to comply with
requirements (warming up should be done before starting in cold winter).Starting the engine
for more than 10 seconds is not allowed; interval time is less than 1 min if start at second
time.And if the engine fails after strating for three times successively, then check and

40
eliminate failures before nest starting.
起动后检查:Inspection after starting
机油压力:在怠速时不能低于 0.1Mpa，压力过低， 发动机润滑不良会造成各运动副磨损; The
engine oil pressure should not be less than 0.1 MPa at idle speed.If it is too low, moving parts
may be worn by bad lubrication.
水泵工作情况良好，确认冷却液已进入柴油机水套内循环;无“三漏”、异响现象; The water
pump is working properly.Make sure that coolant has entered the cycle of water jacket,check
the fuel system,lubricating system and cooling system for leakage,check if there are
abnormal noises.
各汽车仪表的工作情况。发现有不正常现象，必须立即停车检查排除，必要时送修。Inspect
the meters. If anything abnormal happens, stop the vehicle immediately and make
troubleshootings. Send to repair if necessary.

4.1.3 运行 Operation
发动机起动之后，依次使发动机在低速和中速下空车暖机，当发动机冷却液温度高于 60℃，
润滑油温度高于 45℃时，才允许带负荷工作。并注意以下各点：After the engine start, run the
engine at low and medium speed for warming up. It’s allowed to work at load when the engine
coolant temperature is above 60℃ and the engine oil temperature is above 45℃. And the
following items should be noticed:
不允许发动机长期在怠速下运转。
It’s not allowed that the engine is running under idle speed for a long time
怠速时机油压力不得低于 0.1Mpa。
The engine oil pressure should not be less than 0.1 MPa at idle speed.
运转期间的机油压力、机油温度及出水温度应正常。
The engine pressure, engine oil temperature and outlet water temperature should be
normal during running
如发现有异响和振动，应立即停车检查。
Stop the engine and check in case of the abnormal noise and vibration.
注意油、气、水的密封情况，如有泄漏，应立即消除。
Pay attention to seal of the oil, air and water. Resolve immediately in case of any
leakage.
新的发动机或大修后的发动机不允许一开始就以高速、重负荷工作，在最初的 2500 公里
或 60 小时之内，应降低功率使用，负荷应不超过 65%，以保证良好的磨合。It’s not allowed that
the new engine or the engine after overhaul should work at high speed and heavy load from
the beginning. Within the first 2,500km or 60 hours, the engine should be used in the
condition of the power is reduced and the load should not exceed 65% so as to ensure the
good run-in.

41
 4.1.4 停车 Stop
发动机应避免急速停车熄火。停车前应低转速运转 3～5 分钟，以使发动机冷却下来，然
后加怠速空转 2～3 分钟，使各部分得到充分的机油，然后停车熄火。
The engine should avoid the emergent stop. Before the stop, run the engine at low
speed for 3~5 mins to be cooled down and then run at idle speed for 2~3 min to ensure
sufficient engine oil for lubricating every parts before engine stop.
另外应注意在环境气温低于 5℃以下时，如果发动机冷却液不能确保不发生冰冻，应及时
把冷却液放完，以免冻坏机件（见 2.6.5）。
When the environment temperature is lower than five degree, draining off all the coolant
in case of freezing parts if engine coolant can’t ensure to be freezed.(Refer to 2.6.5)
当气温低于-30℃时，应将蓄电池拆下，搬入暖室内保温，否则难以起动。
When the temperature is lower than -30℃, it should dismantle the storage battery to
keep it at warm room to avoid hard starting.

4.1.5 燃油 Fuel
为了使发动机拥有更高的可靠性和更低油耗，燃油应选用符合 GB252－2000《轻柴油》
规定的清洁轻柴油，并随着地区环境气温的不同而选用不同牌号的清洁柴油，一般夏季选用 0
号，冬季气温在-5℃以上时选用－10 号，当气温在-14℃以上时应选用－20 号，当气温在-29℃
以上时应选用－35 号。For higher reliability and lower fuel consumption of the engine, you
should select the clean light diesel fuel in conformity to the provisions in GB252-2000 for
Vehicle Diesel Fuel and different brands of the light diesel fuel shall be used according to
different local ambient temperatures in different regions. Generally speakng, use 0# diesel oil
in summer and in winter -10# diesel oil where the temperature is above -5℃, -20# diesel fuel
where the temperature is above -14℃ and -35# diesel oil where the temperature is above
-29℃.
燃油的指标，Fuel indexes
黏度：40 °C 时 为 1.3～5.8 厘沲
十六烷值：环境温度高于 0°C 时，不低于 40
低于 0°C 时，不低于 45
含硫量：不超过 0.5 质量百分比
水和沉积物：不超过 0.05 体积百分比
浊点：低于燃油所要工作的最低环境温度 6°C
Viscosity: 1.3~5.8 centistokes at 40℃
Cetane number: not less than 40 at the ambient temperature of above 0℃;
and not less than 45 at the ambient temperature of below 0℃
Sulphur content (mass %): not more than 0.5
Water and deposit (volume %): not more than 0.05

42
 Cloud point: 6℃ lower than the lowest working ambient temperature of the fuel
用户请注意：Percautions for users
为确保您购买的燃油品质满足以上的要求，避免燃油中可能存在的杂质和水分对发动机燃油系
统零部件的影响，玉柴要求用户到正规加油站购买燃油。有条件的用户，最好自备一个加装燃
油滤清器的储油罐。买来的柴油先在罐中存放两天，待杂质和水分沉淀以后再取出使用。储油
罐要定期排除沉淀下来的杂质和水分并更换加装的滤清器。
In order to ensure that your purchased fuel will meet above requirements of quality and
prevent fuel system parts & components of your engine from the possible negative impact
resulted from the impurities and moisture existing in the fuel, Yuchai requires its customers to
purchase the fuel at the regular fuelling station. If possible, it is better for the customer to
prepare a fuel reservoir installed with the proper fuel filter. It is also advisable that the diesel
fuel purchased should be stored in the fuel reservoir for two days and then used after
impurities and moisture are precipitated. Please periodically remove the impurities and
moisture precipitated from the fuel reservoir and replaces the installed fuel filter with a new
one.

4.2 发动机的维护保养 Service and maintenance

一般首次使用 50-60 小时必须到当地玉柴技术服务站进行保养首次免费保养（俗称“走
保”）,保养需要更换三滤及机油等。Free maintenance for the first time (running-in) should be
done at local Yuchai technical service station after
保养周期
项目 Item Maintenace 保 养 项 目 Maintenance item
period
检查油箱油量 Check oil capacity in oil tank
日
常 检查冷却水量 Check cooling water capacity
维 每日进行 Daily 检查油底壳及喷油泵内的机油量 Check lubrication oil capacity in
护 Daily
maintenance oil pan and injection pump
检查“三漏”情况 Check water, air and oil leakage
一 每 50 小时 for every 所有日常维护项目 All daily maintencance items
50 hours
清洗机油滤清器及输油泵进油滤网 Clean oil filter and fuel supply
级
pump strainer

43
 检查风扇皮带的松紧度 Check fan belt for tension

检查缸盖螺母的拧紧情况 Check cylinder nut for tightening

检查并调整气门间隙 Check and adjust valve clearance

检查喷油器的工作压力 Check injector working pressure

对新机或刚大修好的机更换机油 Replace oil for new engine or

overhauled engine

所有一级保养项目 All normal services

检查供油提前角 Check fuel supply advance angle

更换机油滤清器 Replace oil filter

二
更换柴油滤清器 Replace fuel filter

清洁空气滤清器 Clean air cleaner

级
每 250 小时 For 检查气门密封情况 Check valve for seal

保 Major every 250 hours

给水泵加注润滑脂 Apply lubrication grease to water pump
service
检查电器线路各连接点的接触情况 Check connection of electrical
养 circuit
检查所有重要螺栓螺母的拧紧情况 Check all bolts and nuts for
tightening
若水套结垢严重应清除 De-scaling water jacket

清洗呼吸器滤芯 Clean filter element of breather

更换机油 Replace oil

续表 To be continue
项目 保养周期
保 养 项 目 Miantenance item
Item Maintenance period

44
 解体整机清除油污、积炭、结焦等 Disassmble whole engine and clean
oil dirt, deposited carbon and coking etc.

检查各摩擦副、运动件的磨损变形情况 Check friction accessories and

moving parts for wear and deformation

检查喷油泵的工作情况 Check injection pump function

三
检查喷油器的工作情况 Check injector function
级
保 每 500 小时 for every 检查机油泵的工作情况 Check oil pump function
养 500 hours
检查发电机及起动马达的使用情况，清洗轴承及其它机件，加注润滑
Major
脂 Check alternator and starting motor function, clean bearing and
service
other parts, apply lubrication grease

检查气缸垫及其它垫片的使用情况 Check cylinder gasket and other

gaskets usage condition

排除各种隐患 Eliminate hidden troubles

更换机油 Replace oil

注意：三级保养完成的柴油机应有 50 小时的磨合期，不能马上高速高负荷运转，以免损伤机件，影响使
用寿命。Note:

4.2.1 柴油机的使用： Operation

(1)检查准备：Check and preparation
„ 检查油底壳机油面应在油标尺上下两刻线之间。Oil level in oil pan should be rest ed
between two scales.
„ 检查冷却液是否充足。Check if coolant is sufficient
„ 检查柴油是否充足，并排干净管路中的空气：Check if fuel is sufficient and discahrge air
in pipeline
松开喷油泵上回油管的放气螺塞，逆时针拧转输油泵上的手柄，手柄升起后反复向下压，待放
气螺塞冒出的柴油不带气泡后，将放气螺塞和输油泵手柄拧紧。Slacken air-bleeding screw of
fuel return pipe in injection pump, turn fuel supply pump handle in counterclockwise
afterwards. Keep pressing the raising handle downwards until no bubble appears in fuel that
comes from air-bleeding screw. Tighten the air-bleeding screw and fule supply pump handle.

45
检查进排气管路连接是否密封和牢固。Check intake and exhaust pipeline connection for seal
and secure.
„ 检查水泵皮带松紧程度是否合适：Check if water pump belt tension is suitable.
在水泵与充电机两皮带轮中部向下施加 4-5 公斤的作用力，皮带下沉 10-15mm 为宜。Apply 4-5
kg force to the central pulley between water pump and alternator downwards, 10-15mm
sinking is appropriate.
„ 检查电气线路是否连接牢固，是否有碰线和破损。Check connection of electrical circuit
for secure, damage and struck.
„ 检查是否有的三漏现象（漏油、漏水、漏气）。Check water, oil and air leakage
„ 检查各种仪表、感应元件是否有缺损。Check instruments and induction units for
damage
„ 检查各外围零件连接是否紧固。Check connection of the external parts for secure
(2)起动：Strating
„ 完成起动前准备工作并确认符合要求后，才可以起动柴油机（冬天天气寒冷时需对柴油
机预热后才能起动）The engine cannot be started unless the preparations have been
completed and confirmed to comply with requirements (warming up should be done
before starting in cold winter).
„ 起动柴油机时，持续起动时间不能超过 10 秒钟；二次起动的时间间隔不应少于 1 分钟；
若连续三次均无法起动，则应检查原因，排除故障，再行起动。Starting the engine for
more than 10 seconds is not allowed; interval time is less than 1 min if start at second
time.And if the engine fails after strating for three times successively, then check and
eliminate failures before nest starting.
„ 严禁起动后猛轰油门。Do not acceleration suddenly after starting
„ 机油压力:在怠速时不能低于 0.1Mpa，压力过低，发动机润滑不良会造成各运动副磨损；
„ 检查水泵工作情况良好，检查有无“三漏”、异响现象；Check water pump function; water,
air and oil leakage; abnormal sound
„ 检查各汽车仪表的工作情况。发现有不正常现象，必须立即停车检查排除，必要时送修。
Check vehicle instruments and troubleshooting if any abnormal conditions are found,
have the vehicle serviced at the service station if necessary.
„ 严禁长时间怠速：起动后怠速 3-5 分钟，一般要求不超过 10 分钟，否则易引起烧油嘴、
缸套活塞环磨损等故障。Do not run the engine at idle speed too long, the required
time for idle speed is 3-5 minutes. Run at idle speed over 10 minutes will cause
failures such as nozzle burnt, piston ring of cylinder liner worn etc.
„ (3)运行：Running
„ 柴油机冷机起动后，禁止大油门高速高负荷运转柴油机，应逐渐提高柴油机转速，水温
上升到 60℃以上，发动机充分润滑、受热均匀后才能正常运转。Do not run the engine
at high speed and full load after cold starting, but gradually increase engine speed.
Run the engine normally when water temperature goes above 60℃ and engine is

46
 lubricated thoroughly and warmed up evenly
„ 正 常 运 行 时 机 油 压 力 应 在 0.25-0.6MPa 之 间 。 Oil pressure should be within
0.25-0.6MPa at normal operation
„ 正常运行时水温应在 85-95℃之间。Water temperature should be within 85-95℃ at
normal operation
„ 汽车在行驶阶段，机手应经常注意观察车上各种仪表，随时掌握发动机的运行情况，发
现不正常情况必须立即停车检查排除，必要时送修。Observe vehicle instruments
during driving to be alert to engine operation. Troubleshooting if any abnormal
conditions are found and have it serviced at service station if necessary.
(4)停机：Stop engine
„ 停车前怠速运行 3～5 分钟后才熄火，避免急速停车，特别是高转速高负荷运转时更应
如此。Run the engine at idle speed for 3-5 minutes before stopping. Do not stop
suddenly, engine running at high speed and full load in particular.
„ 每次停车后，必须及时排除在运行期间所发现的故障，并经常进行必要的检查，保证柴
油机正常的技术状态。Check and troubleshooting timely after each stop to ensure
normal operation.
4.2.2 柴油机的维护保养： Maintenance
(1)磨合：Running-in
„ 新柴油机（或刚大修好的柴油机）必须进行先期磨合，以此改善各摩擦副的配合及提高
工作能力，这对保证柴油机工作可靠性及使用寿命至关重要。Running-in is required for
new and overhauled engines to good matching of friction accessories and function,
which is essential to engine service life and reliability.
„ 磨合时间为 40-50 小时，磨合期的功率和转速应由低到高，但最大不应超过标定功率的
80%。Running-in is required to be 40-50 hours.power and speed should be increased
from low to high during running-in period, while the maximum should not exceed 80%
of the rated power.
„ 磨合期结束后更换机油、机油滤清器。Replace lubrication oil and oil filter after
running-in
„ 严禁长时间怠速和低速磨合，否则容易造成早期磨损、烧油嘴等故障。（有些用户将正
常的磨合等同于怠速磨合，机器买回来后长时间怠速磨合，其实这种做法是错误的，磨
合期是可以进行工作的，只要不超负荷就可以了）Avoid running-in at idle speed and
low speed for long, otherwise early worn and burnt nozzle etc. failures will be caused.
Note: some users regard normal running-in as running-in at idle speed, and perform
running-in at idle spped for a long time from the purchase day, which is the wrong
operation. Engine can be operated during running-in period as long as it is free from
overloaded.
„ (2)机油的使用：The lubrication oil usage
CD40、（使用外界温度为 10℃～40℃）(ambient temperature is 10℃～40℃)

47
 CD30（使用外界温度为 0℃～30℃）(ambient temperature is 0℃～30℃)
20W/50（使用外界温度为-5℃～50℃）(ambient temperature is -5℃～50℃)
15W/40（使用外界温度为-10℃～40℃）(ambient temperature is -10℃～40℃)
10W/30（使用外界温度为-20℃～30℃）(ambient temperature is -20℃～30℃)
5W/30、5W/40、0W/30（使用外界温度为-20℃以下）(ambient temperature is lower
than-20℃)
„ 自然吸气柴油机建议选用 CD 级或以上级的机油，增压柴油机建议选用 CF 级或以上级的
机油。CD grade or above lubrication oil is recommended to be used for naturally
aspirated diesel engine, while CF grade or above for turbocharged diesel engine
„ 柴油机在使用过程中，会消耗一定比例的机油。Engine oil is run out in a certain
proportion during engine operation.
„ 不同品牌的机油由于配方不同，混合使用可能会对柴油机产生不良影响。Mix different
brands of oil may have a negative effect on engine.
„ 严禁使用劣质机油，否则将会对柴油机造成严重损害，由此产生的故障玉柴不予保修。
Do not use lesser quality oil, which will cause serious damage to engine. Failures
cause from that are not covered in warranty by Yuchai
„ 当机油变稀、变稠、变黑、失去粘性时，必须及时更换机油，建议更换周期 150-250
小时。 Replace timely when oil becomes thinner, thicker, and black or loses viscosity,
replacemnet cycle is recommended to be 150-250 hours.
„ 更换机油时必须同时更换机油滤清器，请引导用户使用品质信誉好的柴油滤清器
Replace oil filter along with oil at the same time, users should be instructed to use fuel
filter with good credit and quality
(3)柴油的使用：The usage of fuel
„ 0 号柴油（使用外界最低温度≥4℃）0# fuel (ambient temperature≥4℃)
„ -10 号柴油（使用外界最低温度为≥-5℃）-10# fuel (ambient temperature≥-5℃)
„ -20 号柴油（使用外界最低温度为≥-14℃）-20# fuel (ambient temperature≥-14℃)
-35 号柴油（使用外界最低温度为≥-29℃）-35# fuel (ambient temperature≥-29℃)
-50 号柴油（使用外界最低温度为≥-44℃）-50# fuel (ambient temperature≥-44℃)
„ 伸入油箱的油管吸油口应距离油箱底面 25mm 以上，同时避免从油箱底部出油，以防
水分及杂质进入柴油机的燃油系统。Place fuel pipe into fuel tank and ensure the
distance from fuel pipe inlet to fuel tank bottom should be above 25mm. Pay attention
to prevent water and impurities enter into fuel system at the same time
„ 在输油泵进油接头处有一滤网，用于滤除柴油中的杂质，请定期清洗此滤网。One
strainer is provided on fuel inlet adapter of fuel supply pump to filter impurities from
the fuel , clean the strainer periodically
„ 用户应到正规的加油站加注符合要求的柴油，避免使用油贩子经营的散装油，否则极易
卡死油嘴，由于所用柴油不合格造成的故障玉柴不予保修。Refuel at regular gas station
and avoid inferior fuel, which will cause nozzle struck easily. Failures caused of poor

48
 quliaty fuel won’t be covered in Yuchai warranty.
„ 请引导用户使用品质信誉好的柴油滤清器，建议使用 200-300 小时进行更换。Users
should be instructed to the good quality and credit fuel filter. Replace the fuel filter
after 200-300 hours as recommended.

(4)冷却液的使用：Coolant usage
„ 如使用水做为冷却液，应采用清洁干净的软水，不能使用井水、河水、泉水等硬水。If
water is used as coolant, adopt clean soft water and avoid hard water such as in well,
river and spring etc.
„ 常用的硬水软化方法是煮沸沉淀后除去沉淀物。更为彻底的方法是硬水中加软化剂，如
每升水加 0.5～1g 碳酸氢钠（纯碱）或 0.5～0.8g 氢氧化纳（烧碱）。 Boil and filter is
the common method to soften the hard water. Add softener in hard water can works
better, add 0.5～1g sodium bicarbonate (alkali)or 0.5～0.8g caustic soda in one liter
water.
„ 建议使用防冻液做为冷却液，特别是使用环境温度较低、海拔高度较高时。防冻液具有
防冻、防腐蚀 、防穴蚀、防垢、高沸点等功能。Antifrezzer works to persist is
recommended to be used as coolant, especially in cold ambience and higher altitude.
Antifrzze
„ 优质的防冻液是国家指定的检测站检测合格的品牌，从外观上看:清澈透明、无杂质、
不浑浊、无刺激性气味，产品外包装上应有详细的生产单位名称，产品说明书以及明确
的指标说明。The good antifreeze should be the qualified brands that designated by
state specific inspection station, which is clearely and free from dirty, impurity,
pungent odor in appearance. Detailed manufacter information, instrutions and definite
spcifictions should be stated on package.
„ 使用劣质的防冻液不但不能防冻防沸，反而会加速冷却系统的腐蚀。 Poor quality
antifreeze will damage the cooling system rapidly.
(5)空气滤清器的保养：Maintenance of air cleaner
„ 空滤过滤原理：air cleaner function
一级过滤：导风罩（使空气形成涡流，在重力和离心力作用下使灰尘沉淀到底部由排尘袋排出）
First-stage filteration: Wind cowl (function to swirl the air, directing dust to be accumulated at
bottom by the action of gravity and centrfugal force and discharged from dust bag)
二级过滤：主滤芯（起主要过滤作用，过滤效果达 95%以上）The second -stage filteration:Outer
filter element (mainly function to filter with a filteration effect of above 95%)
三级过滤：安全滤芯（起辅助过滤作用，同时防止异物进入）Third-stage filteration:Inner filter
element（function to filter in assistance and prevent foreign matters enter into）

„ 保养：Maintenance
空滤器壳体：清理滤清器内腔、导风罩、排尘袋中的灰尘，注意不能认为导风罩没有用途而扔

49
掉。Air cleaner shell: clean dust out in cavity, wind cowl and dust bag, do not discard the wind
cowl at will considering it is useless.
主滤芯：用毛刷刷除滤芯表面尘土，接着用压缩空气（压力 0.4-0.6MPa)从滤芯里面往外吹。
Main filter element: Brush dust and dirt off filter element surface and blow it from inside to
outside by compressed air （pressure:0.4-0.6MPa) afterwards.
安全滤芯：用手拍打清洁，避免用空气吹。安装：检查密封圈是否破损缺失，拧紧时先旋转一
下滤芯使其到位，一定要注意安装必须密封，不能造成空气短路。Inner filter element: flap with
hand to clean but not blow by air. Check seal ring for any damage; rotate the filter element in
place before tightening, and ensure
„ 注意检查排尘袋口必须向下。Ensure the dust bag opening faced downwards.
(6)增压器的保养 Turocharger maintenance
YC4A、YC4B、YC4BA、YC4D 系列系列柴油机均采用废气涡轮增压系统。其工作原理如下图
所示。柴油机排气管 1 接到增压器的涡轮壳 4 上，柴油机排出的高温和有一定压力的废气经涡
轮壳 4 进入喷嘴环 2，由于喷嘴环的通道面积由大到小，因而废气的压力和温度下降，而速度
却迅速提高。这个高速的废气气流，按着一定的方向冲击涡轮 3，使涡轮高速旋转。废气的压
力、温度和速度越高，涡轮转动越快。通过涡轮的废气最后排入大气。因为涡轮 3 与压气机叶
轮 8 固装在同一根转轴上，所以叶轮与涡轮以相同的速度旋转，将经过空气滤清器滤清过的空
气吸入压气机壳。旋转的压气机叶轮将空气压力提高后进入气缸，由于空气密度增加，进入气
缸的空气量也增加，因而可以增加喷入气缸的油量，从而提高发动机功率，降低燃油消耗率。
Exhaust gas turbocharging system is provided on YC4A、YC4B、YC4BA、YC4D serial diesel
engines.The figure below shows its function: high temperature and pressure exhaust gas that
discharged from engine is directed into nozzle ring through turbine shell 4 of turbocharger,
which is the exhaust pipe 1 connects to. The nozzle ring passage is designed from large to
small in area to decrease exhaust gas temperature and pressure, while increase the speed
rapidly. The high-speed air flow pushes turbine 3 in a direction to run in high speed. The
exhaust gas is discharged into atompshere through turbine afterwards. The turbo 3 and air
compressor impeller 8 rotate in the same speed as they are fitted in the same rotary shaft,
intaking the filtered air by air cleaner into air compressor shell.The amount of fuel is injected
into cylinder more as air density and volume are increased, improving power and reducing
fuel consumption rate consequently.
涡轮增压器和增压柴油机在性能上有着密切的关系，如果增压器的性能改变，将直接影
响到柴油机的性能。为了使增压柴油机保持良好的综合性能，同柴油机一样，增压器在使用
过程中必须用正确的方法和进行良好的保养。由于整个进排气系统各接头处漏气时会影响增
压器的工作，因此必须经常检查外部接头的紧固情况。The turbocharger function is related to
engine performance closely, therefore maintenance and work properly is highly required.
Check connection for secure periodically as turbocharger function is easily affected due to

50
intake and exhaust system leakage.
1.排气管 Exhaust pipe2.喷嘴环 Nozzle ring3.涡轮 Turbine 4.涡轮壳 Turbine shell 5.转
子轴 Rotator shaft 6.轴承 Bearing
7.扩压器 Diffuser 8.压气机叶轮 Air compressor impeller 9.压气机壳 Air compressor shell
10.进气管 Intake pipe

图 23 废气涡轮增压柴油机工作原理图
增压器系统常见故障及排除方法 Common failures and troubleshooting of turbocharging
system
故障原因 Causes 排除方法 Troubleshooting
①进气系统堵塞 Air 检查空气滤清器与压气机之间的管路、压气机出口与进气管管路及进气
intake system is 管、清理通畅。Check pipelines between air cleaner and air compressor,
clogged air compressor outlet and air intake and

② 进 气 泄 漏 Air 检查空气滤清器与压气机之间的管路、压气机出口与进气管之间的管路，
intake has leakage 进气管与发动机连接处等是否有泄漏、可拧紧紧固螺栓、更换垫片等零
件。Check pipe lines between air cleaner and air compressor, air
compressor outlet and air intake pipe, and the connection between air
intake pipe and engine body for leakage. Tighten tightening bolt and
replace gasket etc. parts if it is.
③排气系统阻塞 维修或更换有关部件 Service or replace relative parts and components
Exhaust system is
clogged

51
④排气泄漏 Exhaust 检查排气管与发动机、涡轮进口与排气管，涡轮壳与中间壳，涡轮出口
is leaked 至 排 气 管 连 接 处 ， 如 有 泄 漏 可 更 换 密 封 垫 片 拧 紧 紧 固 螺 栓 Check
connection between exhaust pipe and engine, turbine inlet and
exhaust pipe, turbine shell and intermediate shell, turbine outlet and
exhaust pipe, replace seal gasket and tighten tightening bolt if leak.
⑤压气机转子与压 更换总成 Replace assembly
气机壳体、涡轮与涡
轮 壳 相 碰 The air
compressor rotor
operates against air
compressor shell
and turbine shell
⑥进、回油管漏油 更换 Replace
Fuel inlet and return
pipeline have
leakage
由于增压器属于精密的部件，对装配技术要求很高，为了保证增压器有较长的寿命，属于
增压器本身的故障，请与全国各地玉柴的委托技术服务站联系解决。用户切莫自行解体增压器，
否则，不予质量保修。另外，凡更换润滑油，清洗机油滤清器或发动机长时间停放后（约一周
以上），必须松开增压器的进油接头，注入干净润滑油，使增压器润滑系统中充满润滑油。
Turbocharger is precision, which asks for high requirements in assembly. To prolong the
service life, users’d better have the turbocharger serviced at Yuchai mandatory technical
service stations if turbocharger is defective of itself. It is not covered in warranty if users
dismantle turbocharger by themselves. Unscrew fuel inlet union and fill clean lubrication oil to
circulate the lubrication system on condition that engine has been out of use for more than a
week approximately or replacing lubrication oil, cleaning oil filter or engine

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 图 24 废气涡轮增压器 Turbocharger

5 发动机常见故障及排除方法 Common failures and troubleshooting

5.1 发动机不能起动 Engine will not start

故 障 原 因 Causes 排 除 方 法 Troubleshooting
①起动机转速过低 Too low 检查起动系统，起动转速不得低于 110r/min。Check starting
rotation speed of starter system, and the starting speed can not lower than 110r/min

②供油系统内有空气 There 1．检查供油管路接头是否松动。拧松燃油滤清器总成上的放

气螺钉，用手动泵压送燃油，直到溢出的燃油不带气泡为止。
is air in fuel supply system
Check whether or not the fuel supplying pipe connector is
loosing. Slacken the bleeding screw on fuel filter assembly,
and supply fuel by manual pump until there is fuel flowing
out without air bubbles
2．拧松喷油器端的高压油管接头，用手动泵压送燃油，直到
溢出的燃油不带气泡为止。Slacken the bleeding screw on
fuel filter assembly, and supply fuel by manual pump until
there is fuel flowing out without air bubbles

③燃油管路阻塞 Fuel 检查供油管路是否通畅。Check whether or not the fuel

pipeline is chokced supplying pipeline is unobstructed

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 ④燃油滤清器阻塞 Fuel 更 换 燃 油 滤 清 器 总 成 的 旋 装 式 滤 芯 。 Replace the rotary
filter is chocked element of the fuel filter and water oil separator assembly

⑤输油泵不供油或断续供 检查进油管是否漏气；Check if the fuel intake pipe has air

油 Fuel delivery pump
leaks
does not supply the fuel oe
输油泵是否有故障。Check if the fuel supply pump is failed or
supplies the fuel
not .
interruptedly.
⑥喷油少，不喷油或喷油压 ¾ 检查喷油器雾化情况; Check atomization situation of
力低 Inject less fuel; does fuel injector
not inject fuel or low ¾ 喷油泵柱塞及出油阀是否磨损或卡死、柱塞弹簧及出油阀
弹簧是否折断；Check if the fuel injection pump pluger
injection fuel pressure
and fuel outlet valve is worn or clogged or not, pluger
spring and fuel outlet valve spring is broken or not.

⑦起动系统故障：Starting
system troubles
电路接线错误或接触不良： 检查接线是否正确、可靠。Check whether or not the circuit is
Wrong wiring connection connected correctly and reliably
or poor contact
蓄电池电力不足： 向蓄电池充电。Charge the battery
Underpower of the battery
起动机碳刷与整流子接触 修理或调换电刷，用木砂纸清理整流子表面，并吹净。Repair
不良：Poorr contact of the
or replace the electric brush; clean the commutator surface
starter carbon brush with
by abrasive paper and blow it clean.
commutator

⑧压缩压力不足： 更换活塞环，视情况更换气缸套。Replace piston ring; add

Insufficient compressed cylinder liner as per actual situation
pressure
活塞环过度磨损： 检查气门间隙，气门弹簧、气门导管及气门座的密封性，密封
不好应研磨气门座。Check valve clearance; check the sealing
气门漏气。Piston ring is too
performance of valve spring, valve guide tube and valve
much worn, air leakage in
seat, grind the valve seat if the sealing performance is poor.
valve
⑨燃油切断电磁阀的接头 拧紧、清洗或更换。Tighten, clean or replace

54
 松 动 或 脏 污 、 腐 蚀
Loosened, contaminated
or corroded joint to cut off
the solenoid
⑩装配正时不正确。 检查并调整。Check and adjust
Incorrect assembly timing

5.2 发动机功率不足 Underpower

故 障 原 因 Causes 排 除 方 法 Troubleshooting
①进气堵塞 Air intake is clogged 检查空气滤清器、进气管，清理或更换空气滤清器滤
芯。Check air cleaner, intake pipes, clean or replace
air cleaner element
②排气背压过高 To high exhaust 检查气门定时，必要时调整；清理排气管。Check valve
back pressure timing and adjust if necessary;clean exhaust pipes

③ 增 压 系 统 压 力 不 足 Insufficient 检查并排除管路和连接处的泄漏。Check and remove

pressure of turbocharging system any leakage from pipeline and connectors

④增压器工作失常：压气机、涡轮 清洗或更换压气机壳、涡轮壳。Clean or replace air

气流通道污染堵塞或损坏； compressor&turbine housing
轴承失效； The turbocharger 更换。Replace
works abnormally；the compressor
& turbine gas flow duct is clogged
with contaminants or damaged；
Bearing fails
涡轮、压气机背面间隙处有积碳、 清洗。Clean
油泥 There is any carbon deposit
or oily dirt on the clearance of
turbine and back of air
compressor.
⑤中冷器损坏、漏气 Intercooler is 修补或更换。Repair or replace

55
 damaged or has any air leaks.
⑥ 燃 油 管 路 漏 油 或 堵 塞 Fuel 检查油管及接头处的密封情况、燃油滤清器的堵塞情
pipeline is oil leaking or clogged. 况，更换旋装式滤忒。检查喷油控密封。Check the fuel
pipe and joints for hermetization, the fuel filter for
clogging; replace the rotary element.Check injection
seal
⑦喷油泵柱塞磨损过大 Piston ring 检查、更换。Check and replace
is worn too much
⑧传感器坏 Sensor is damaged 检查、更换 Check and replace
⑨增压补偿管损坏漏气 Boosting 更换。Replace
compensation pipe is damaged
and has air leaks
⑩ 喷 油 器 雾 化 不 良 Poor 检 查 喷 油 压 力 、 清 理 积 碳 、 调 整 及 修 理 。 Check
atomization of fuel injector injection pressure, clean out deposited carbon,
adjust and repair
⑾ 配 气 相 位 不 对 Incorrect air 检查并调整配气定时及气门间隙。Check and adjust
distribution phase air distribution timing and valve clearance
⑿ 供 油 提 前 角 提 前 或 迟 后 Fuel 检查并调整。Check and adjust
supply angle is ahead or lagge d
⒀调速器高速调整过低 Governor 按规定力矩、顺序拧紧气缸盖螺栓或更换气缸垫。
high-speed is under range Tighten the cylinder head bolt to the specified torque
according to the set sequence, or replace the
cylinder head gasket with a new one.
⒁气缸垫漏气 Cylinder gasket has 研磨或更换重新研磨。Lap or replace, relap
leakage
⒂气门密封不良 Poor valve seal 检查并修理散热器、调温器，调整风扇皮带张紧力。
Check and repair radiator and thermostat, adjust the
fan belt tension
⒃发动机过热冷却液温度过高 检查空气滤清器、进气管，清理或更换空气滤清器滤
Engine is too hot due to high 芯。Check air cleaner, intake pipes, clean or replace
coolant temperature air cleaner element
⒄活塞环磨损过大，断裂 Piston 更换 Replace

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 ring is worn severely and broken
down

5.3 发动机运转时有不正常的杂声 Abnormal sound during running

故 障 原 因 Causes 排 除 方 法 Troubleshooting
① 气 缸 内 有 异 响 There is 检查装配正时是否正确 Check if the assembly
abnormal sound in the 检查并调整配气定时。Check and adjust air distribution
cylinder timing

②连杆轴瓦、主轴瓦磨损过大，在 拆检轴瓦，必要时更换，并保持规定的合理间隙。
曲轴箱处可听到撞击声 Dismantle and check the bushing, if necessary,
Connecting rod bearing replace it and keep the reasonable clearance as
bushing and main bearing required.
bushing are worn-out and
clash voice appears in the
crankcase.

③减振器损坏，不起减振作用 The 检查连接螺栓及损坏情况，必要时更换。Check the

Damper is damaged and connecting bolts andif necessary, replace them.
invalid.

④传动齿轮磨损，间隙过大。在正 。Check the gear

检查齿侧间隙，视磨损情况更换齿轮。
时 齿 轮 室 盖处 可 听 到 撞击 声 backlashes and replace them if necessary.
Driving and driven gears
worn-out and has too large
clearance. Clash can be
heard near timing gear
housing

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 ⑤活塞与气缸间隙过大，运转时气 更换活塞，视磨损情况加修理用缸套，注意保持配缸间
缸 壁 处 的 撞 击 声 Too large
隙。Replace the piston; use the repair-used bushing if
clearance between piston and
necessary. Keep a clearance between the piston and
cylinder and clash can be heard
the cylinder.
in cylinder wall when operating
⑥增压器轴承损坏，转动件与壳体 更换增压器总成。Replace the turbocharger assembly.
相 碰 Turbocharger bearing is
damaged and impellers touch
housing
⑦气门间隙过大，在气缸盖处有较 调整气门间隙。Adjust the valve clearance
大响声 Too large valve clearance
and heavy noise around cylinder
head

⑧ 增 压 器 喘 振 Turbocharger 清除压气机通道、废气通道的积碳及污物，运行海拔过
surging 高。Clear the carbon deposit and contaminants in the
compressor and the exhaust passages.running in too
high altitude

5.4 排气冒黑烟 Exhaust with black smoke

故 障 原 因 Causes 排 除 方 法 Troubleshooting

①进气堵塞 Intake is clogged 检查空气滤清器、进气管路并清理。Check and

②燃油质量差 Poor fuel quality 换用规定的燃油。Used the fuel as required

③喷油器雾化不良 Bad atomization of 检查，修复或更换。Check, repair or replace
④ 增 压 系 统 压 力 不 足 Insufficient 检 查 并 排 除 管 路 和 连 接 处 的 泄 漏 。 Check and
boosting pressure eliminate any leaks in pipelines and connection
⑤ 增 压 器 工 作 失 常 Faulty 检查更换总成。Check and replace assembly
turbocharger
⑥中冷器损坏、漏气 Intercooler is 修补或更换。Repair or replace
damaged and air leaks
5.5 排气冒白烟、蓝烟 Exhaust with white and blue smoke

故 障 原 因 Causes 排 除 方 法 Troubleshooting

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 ① 燃 油 质 量 差 、 含 水 份 过 多 Poor 更换燃油。Replace the fuel
②冷却水温度过低 Too low cooling 检查调温器工作温度，必要时更换。Check the
watert temperature working temperature of thermosts and replace it
③配气或供油定时不正确 Incorrect 按专门人员检查和调整。Check and adjust by the
valve timing and injection timing specialized gasket , replace
④压缩压力低、燃烧不完全 Too low 检查活塞环及气缸垫，更换。Check piston ring and
boosting pressure and incomplete
cylinder head gasket ,replace
combustion

⑤活塞环安装方向不对，开口未错开 检查并重新装配。Check and reassemble

Incorrect installing orientation of
piston rings

⑥长期低负荷运转 Running at low 注 意 使 用 适 当 的 工 作 转 速 和 负 荷 。 Use proper

load for a long time working speed and loads
⑦ 增 压 器 密 封 环 磨 损 Seal ring of 检查并更换。Check and replace
turbocharger is worn out

⑧ 增 压 器 止 推 轴 承 磨 损 Thurst 检查并更换。Check and replace

bearing of turbocharger is worn

⑨增压器回油管路阻塞 Oil return pipe 清洗、修理。Clean and repair

of turbocharger is clogged

5.6 润滑油压力异常 Lubrication oil pressure is abnormal

6.6.1 润滑油压力过低 Lubrication oil pressure is too low
故 障 原 因 Causes 排 除 方 法 Troubleshooting
①机油变稀或所用机油不当 Thinned 按规定选用作品适的机油。Use proper engine oil
oil or improper use of oil as required
② 机油 泵转子 磨损 或装配 间隙过大 更换机油泵。Replace engine oil pump
Worn inside/outside rotors of the oil
pump , or too big assembly
clearance
③机油滤清器堵塞 Oil filter is clogged 更换旋装式滤芯 Replace rotary element

59
 ④机油滤清器调压阀失灵 Failure of 修复。Repair
pressure adjustment of oil filter

⑤机油泵齿轮损坏或磨损 Damaged 更换。Replace

or worn oil pump gear

⑥机油泵进油管有裂缝 Cracks on the 修复、更换。Repair and replace

oil inlet pipe of oil pump
⑦机油泵进油管固定螺栓松动 拧紧到规定力矩。Tighten to the specified torque
Loosened bolt fixing the oil inlet pipe
of oil pump
⑧轴瓦间隙过大 Too big clearance of 检查并更换 Check and replace
shaft bush

6.6.2 润滑油压力过高 Lubrication oil pressure is too high

故 障 原 因 Causes 排 除 方 法 Troubleshooting

①气温过低，机油粘度变大 Increased 选用规定牌号的机油，起动后应先低速运转，待油

oil viscosity due to too low ambient 温 正 常 后 再 检 查 。 Select the oil of selected
temperature brand,run the engine at a low speed after it is
started,check it again when the oil temperature is
normal
②溢流阀堵塞 Clogged overflow valve 检查、清洗。Check and clean

5.7 润滑油消耗高、消耗量大 High consumption of lubrication oil is high

故 障 原 因 Causes 排 除 方 法 Troubleshooting

①外部机油管路有泄漏 Leakage in the 检查并修复。Check and repair it.

exterior oil line
② 柴 油 机 负 荷 过 重 Too high diesel 降低负荷。Decrease the load.
engine load
③使用机油牌号不当 Improper use of 按规定选用。Use the oil as required
engine oil brand
④ 活 塞 环 卡 死 或 磨 损 过 大 Clogged 检查、修复、必要时更换。Check and repair, if
piston ring or its severe wear necessary, replace it.

60
⑤缸孔磨损过大 Too severe wear of the 镗缸后换加工尺寸的活塞环，或加修理用缸套。
cylinder bore After cylinder boring replace the piston ring with
newly machined sizes, or repaired cylinder liner.
⑥气门导管磨损过大，气门杆密封失效 检查、更换。Check and replace
Excessive wear of the valve guide pipe,
and failed sealing of valve stem
5.8 出水温度过高 Too high water outlet temperature

故 障 原 因 Causes 排 除 方 法 Troubleshooting
⑴ 冷 却 水 量 不 足 ， 水 流 量 少 检查冷却水量是否足够，不足就添加;
Insufficiency cooling water ,too small Check coolant level and add it if insufficiency
water flow
⑵皮带是否过松 If over-loose of the 调整 adjust it
belt
⑶水泵有漏水 Leakage of the water 及时进行修理 repair it in time
pump
⑷ 节 温 器 失 灵 、 损 坏 failure and 检查更换 check and replace it
damage of the Thermostat
⑸水温表损坏，水温感应塞失灵 检查实际温度与表指示温度是否相符;如不符则更换
damage of the water temperature 感应塞或水温表 Check if the actual temperature is
meter and failure of the water sense in accordance with meter appearance,if
plug not,replace sense plug or water temperature meter
⑹ 冲 缸 垫 cylinder gasket is 检查更换 check and replace it
impacted
⑺改装情况下水箱、风扇匹配问题 重新按要求匹配 rematch it as require
Matching problem of the refitted
water tank and fan

5.9 增压器常见故障及排除方法 Troubles and troubleshooting for the turbocharger:

故 障 原 因 Causes 排 除 方 法 Troubleshooting
① 进 气 系 统 堵 塞 Intake 检查空气滤清器与压气机之间的管路、压气机出口与进气管
system is blocked 路及进气管、清理通畅。Check pipeline between air cleaner
and air compressor, air compressor outlet and the intake
manifold and intake pipe; clean them .

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②进气泄漏 Intake pipes has 检查空气滤清器与压气机之间的管路、压气机出口与进气管
leaks 之间的管路，进气管与发动机连接处等是否有泄漏，可拧紧
紧固螺栓、更换垫片等零件 Check the pipeline between air
cleaner and air compressor, air compressor outlet and the
intake pipe, and connections between the engine and the
intake pipe; Tighten the tightening bolts and replace
gasket etc.parts
③ 排 气 系 统 阻 塞 Exhaust 维修或更换有关零件。Maintain or replace the related parts.
system is blocked
④排气泄漏 Exhaust pipes are 检查排气管与发动机、涡轮进口与排气管，涡轮壳与中间壳，
leaky 涡轮出口至排气管连接处，如有泄漏可更换密封垫片拧紧紧
固螺栓。Check connections between the exhaust pipe and
the engine, turbine inlet and the exhaust pipe, turbine
housing and the middle housing, turbine outlet and the
exhaust pipe connection, replace the seal gasket and
fasten the locking bolt if necessary.
⑤压气机转子与压气机壳体、 更换总成 Replace the assembly
涡 轮 壳 相 碰 The air
compressor rotor bump with
air compressor shell and
turbine shell
⑥进、回油管漏油 Fuel supply 更换 Replace it
and return line are leaky
5.10 离合器常见故障及排除方法 Troubles and troubleshooting of the clutch

故 障 原 因 Causes 排 除 方 法 Troubleshooting
1.离合器抖动 clutch dithering 校正离合器压盘和从动盘的变形，消除不规则接触
revise clutch pressure plate and driven plate
distortion, eliminate irregular contact
2. 油 路 堵 塞 或 有 大 量 空 气 进 入 fuel 清理油污，调整分离轴承位置，更换从动盘总成，
pipeline is clogged or has a great 减 少 负 荷 Clean out oil dirt, adjust separate
deal of air enter into bearing position, replace driven plate assembly,
reduce load
3. 离 合 器分离 不 彻 底:压 盘 或 从动盘 消除变形，调整自由行程或更换离合器 eliminate
变形，传动片变形 Clutch separate not distortion, adjust free strike or replace clutch
thoroughly, platen or driven distortion,
driving plate distortion

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4.离合器异常响动:离合器的零件松动， 将 松 动 零 件 铆 紧 ， 消 除 异 物 或 更 换 从 动 盘 总 成
减 震 弹 簧 断 裂 或 离 合 器 中 有 异 物 tighten loosed parts, remove foreign matters or
abnormal noise of the clutch : clutch replace driven plate assembly
parts is loosed, damping spring is
broken down or has foreign matters in
the clutch
5.11 发动机自行熄火 Engine stops of itself

故 障 原 因 Causes 排 除 方 法 Troubleshooting
1.燃油用完 Fuel is runnin out 检查、添加，注意排除除油路中的空气 Check and
replenish, pay attention to remove air foem fuel
pipeline
2.油路堵塞或有大量空气进入 Fuel 检查、清理油路，排除油路中的空气，找出进气的
pipeline is clogged or has a great 原因并排除 Check and clean fuel pipeline, remove
deal of air enter into air foem fuel pipeline and find out reasons and
eliminate
3.发动机润滑油路不通畅，引起烧轴瓦 如水温正常突然停机多属于此种情况，应拆开油底
Bearing shell is brunt out due to 壳检查、维修，更换相应的损坏零件 Engine stop
engine lubrication pipe is obstructed suddenly in normal temperature which belongs to
this condition, disassemble oil sump and
check,service and replace relative those damaged
parts
4.柴油机过热拉缸，一般是由于缺水或 先让机子自行冷却（绝不允许加入冷水或用冷水
水温过高引起的 Too hot engine 冲），然后试着转动曲轴，如无卡滞现象可加入冷却
causes cylinder scoring which results 水后起动。如转不动则应拆机检查，修复，更换损
from deficient water or too high water 坏的零部件 Have engine cooled of itself(it’s not
temperature allowed to fill cooling water or rinse with cooling
water ), then rotate crankshaft, start after cooling
water is filled if there is no sluggish.Disassemble to
check, repair and replace those damaged parts if it
can’t be rotated

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执行标准：Q/YC 456-2006

Execution standard: Q/YC 456-2006

广西玉柴机器股份有限公司

Guangxi Yuchai Machinery Co., Ltd.

地址：Address:

邮编：Postcode:

销售电话：Sales tel:

服务热线：Serivce hotline:

免费服务热线：Free service hotline:

传真：Fax:

网址：Website:

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