Service Manual For YUCHAI Diesel Engine PDF

Service Manual for WD10 Mechanical Pump Series Engine
YUCHAI Engine Service Manual
Preface
All technical information and pictures in this manual are based on Operation and Maintenance
manual of YUCHAI products, part drawings, and design and manufacturing technics of YUCHAI
products. This manual introduces disassembling and assembling process of YUCHAI engine,
provides service technologies and technical requirements of diesel engine to help serviceman
profoundly understand disassembly and assembly methods of the engine, also lays a solid technical
foundation for serviceman to do troubleshooting.
This manual is organized as follows:
Chapter 1 General
This chapter mainly introduces precautions for maintenance of the diesel engine, significance of all
kinds of symbols used in this manual and tightening torque of common bolts.
Chapter 2 Disassembly of Diesel Engine
This chapter tells the serviceman/user how to disassemble each component by step correctly, and
precautions need to be noted during the disassembly.
Chapter 3 Assembly of Diesel Engine
This chapter tells the serviceman/user how to assemble each component step by step correctly, and
precautions need to be noted during the assembly.
Chapter 4 Inspection & Debugging
Chapter 5 Diagnosis and Elimination of Engine Common Faults
This chapter introduces diagnosis and elimination of engine common faults.
Chapter 6 Engine Parameters
ATTENTION
The parts and components that mentioned in this manual may change along with
product improvement, but we do not promise to inform the changes of products
that have been sold, please consult or ask Shandong Lingong Construction
Machinery Co. Ltd for the updated details.
880×1230 mm 16# 18pieces
1st Edition in 2014. 7 1st Print
SHANDONG LINGONG CONSTRUCTION

MACHINERY CO.，LTD
Address: Linyi Economic Development Zone

Tel: 86-0539-8785688
Fax: 86-0539-8785698
Postal code：276023
Website：www.sdlg.cn
Services Tel：8008607999 4006587999 0539-8785800
Services Fax：86-0539-8785671
CONTENTS
1 General.................................................................................................................... 1
11 Safety Precautions .................................................................................................. 1
12 Marks ...................................................................................................................... 4
13 Tools and Gauges ................................................................................................... 4
14 Application of YUCHAI Engine ............................................................................ 5
15 Composition and Significance of YUCHAI Engine Model ................................... 5
2 Disassembly of Diesel Engine ................................................................................ 6

21 Disassembly of Outer Parts .................................................................................... 6
211 Disassembly of Crankcase Ventilation Device .............................................. 6
212 Disassembly of Fan ........................................................................................ 6
213 Disassembly of Turbocharger......................................................................... 7
214 Disassembly of Silencer, Exhaust Pipe and Water Outlet Pipe ..................... 7
215 Disassembly of Air Filter ............................................................................... 8
216 Disassembly of High Pressure Fuel Pipe ..................................................... 10
217 Disassembly of Fuel Coarse Filter ............................................................... 11
218 Disassembly of Hand Fuel Pump ................................................................. 11
219 Disassembly of Fuel Fine Filter ................................................................... 12
2110 Disassembly of Engine Oil Inlet/Return Pipe of Fuel Injection Pump13
2111 Disassembly of Transmission Belt and Generator Assembly ............. 14
2112 Disassembly of Fuel Injection Pump Assembly ................................. 15
2113 Disassembly of DC Starter Motor ....................................................... 16
2114 Disassembly of Engine Oil Cooler...................................................... 16
2115 Disassembly of Water Pump Assembly .............................................. 17
2116 Disassembly of Pulley Damper ........................................................... 17
22 Disassembly of Cylinder Cover Components ...................................................... 19
221 Disassembly of Cylinder Cover Shield ........................................................ 19
222 Disassembly of Rocker arm Assembly ........................................................ 20
223 Disassembly of Fuel Injector ........................................................................ 22
224 Disassembly of Valve Lock Clamp, Valve Spring and Valve ..................... 23
225 Disassembly of Cylinder Cover.................................................................... 24
23 Disassembly of Gear Housing and Camshaft ....................................................... 25

231 Disassembly of Gear Housing ...................................................................... 25
232 Disassembly of Camshaft ............................................................................. 25
233 Disassembly of Idle Gear and Idle Gear Shaft ............................................. 26
234 Disassembly of Air Compressor and Air Compressor Idle Gear ................. 28
24 Disassembly of Engine Oil Sump, Engine Oil Strainer and Engine Oil Pump .... 30
241 Disassembly of Engine Oil Sump ................................................................. 30
242 Disassembly of Engine Oil Strainer ............................................................. 31
243 Disassembly of Engine Oil Pump ................................................................. 31
25 Disassembly of Flywheel and Flywheel Shell...................................................... 33
251 Disassembly of Flywheel.............................................................................. 33
26 Disassembly of Piston Connecting Rod, Crankshaft and Cylinder Sleeve .......... 34
261 Disassembly of Piston Connecting Rod ....................................................... 34
262 Disassembly of Crankshaft ........................................................................... 35
263 Disassembly of Cylinder Sleeve ................................................................... 37
3 Assembly of Diesel Engine .................................................................................. 39

31 Selection of Cleaning Fluid .................................................................................. 39
311 Cleaning of Oil Dirt ...................................................................................... 39
312 Removal of Carbon Deposit ......................................................................... 40
313 Removal of Water Scale ............................................................................... 41
314 Removal of Rust ........................................................................................... 42
32 Assembly of Engine Block ................................................................................... 43
321 Cleaning of Engine Block............................................................................. 43
322 Inspection of Engine Block .......................................................................... 44
323 Assembly of Engine Block ........................................................................... 48
324 Elimination of Engine Block Common Faults ............................................. 53
33 Assembly of Crankshaft ....................................................................................... 56
331 Cleaning of Crankshaft ................................................................................. 56
332 Inspection of Crankshaft ............................................................................... 56
333 Assembly of Crankshaft ............................................................................... 59
334 Maintenance of Crankshaft ........................................................................... 63
34 Assembly of Piston Connecting Rod Assembly ................................................... 66
341 Cleaning of Piston Connecting Rod Assembly ............................................ 66
342 Inspection of Piston Connecting Rod Assembly .......................................... 67
343 Assembly of Piston Connecting Rod Assembly .......................................... 69

344 Common Faults of Piston Connecting Rod Assembly ................................. 74
35 Assembly of Engine Oil Pump ............................................................................. 76
351 Cleaning of Engine Oil Pump....................................................................... 76
352 Inspection of Engine Oil Pump .................................................................... 76
353 Assembly of Engine Oil Pump ..................................................................... 79
354 Common Faults of Engine Oil Pump ........................................................... 79
355 Assembly of Engine Oil Cooler ................................................................... 80
36 Assembly of Gear Housing Cover Plate, Camshaft, Idler Shaft and Gearing
Housing ................................................................................................................. 82
361 Assembly of Gearing Housing Cover Plate ................................................. 82
362 Assembly of Camshaft and Camshaft Gear ................................................. 82
363 Assembly of Idler Shaft and Timing Gear ................................................... 84
364 Assembly of Gear Housing .......................................................................... 87
37 Assembly of Air Compressor ............................................................................... 88
371 Cleaning of Air Compressor ......................................................................... 89
372 Inspection of Air Compressor ...................................................................... 89
373 Installation of Air Compressor ..................................................................... 89
374 Common Faults of Air Compressor ............................................................. 90
38 Assembly of Fuel Injection Pump ........................................................................ 92
381 Cleaning of Fuel Injection Pump .................................................................. 92
382 Inspection of Fuel Injection Pump ............................................................... 92
383 Installation of Fuel Injection Pump .............................................................. 93
384 Common Faults of Fuel Injection Pump ...................................................... 96
385 Installation of Fuel Injection Pump Timing Gear ...................................... 101
39 Assembly of Damper .......................................................................................... 103
310 Assembly of Engine Oil Sump and Components Inside ............................ 105
3101 Oil Strainer Assembly ....................................................................... 105
3102 Assembly of Engine Oil Sump .......................................................... 105
311 Output End Components (Flywheel, Clutch and Flywheel Shell) ............. 106
3111 Flywheel and Gear Ring Assembly .................................................. 106
3112 Clutch ................................................................................................ 106
3113 Installation of Flywheel Shell ........................................................... 107
312 Assembly Of Cylinder Cover and Its Parts ................................................ 109
313 Assembly Of Water Pump, Fan and Steering Pump .................................. 124
314 Assembly of A/C Generator and Starter Motor ......................................... 129
315 Assembly of Intake and Exhaust Pipes and Turbocharger ......................... 134
316 Assembly of Intercooler ............................................................................. 140
317 Assembly of Fuel Filter, Engine Oil Filter, Fuel Cut-off Solenoid Valve and
Other Components .............................................................................................. 142
4 Inspection & Debugging ..................................................................................... 144

41 Inspect Engine Parts and Components for Intactness and Fastening Condition 144
42 Inspection of New Engine .................................................................................. 146
43 Testing of Engine Technical Indexes ................................................................. 149
5 Diagnosis and Elimination of Engine Common Faults ...................................... 151

51 Diagnosis and Analysis of Engine Faults ........................................................... 151
52 Engine Common Faults ...................................................................................... 154
53 Emergency Handling Methods for Engine Common Faults .............................. 172
6 Engine Parameters .............................................................................................. 173

61 Engine Technical Parameters ............................................................................. 173
62 Fitting Clearance of Main Parts and Components .............................................. 182
63 Tightening Torque of Main Bolts ....................................................................... 196
1 General
11 Safety Precautions
Important Safety Notes

Maintenance and repair is vitally important for safety operation of the machine. This
manual mainly expounds techniques about how to correctly disassemble and assemble the
machine.
To protect related personnel against injury, this manual uses as safety label, for
precautions marked with this label, please be careful during the operation and must never
on any account be negligent. For operations that possible dangers are involved, firstly pay
attention to your own safety and necessary security measures shall be taken.
Safety Tips
In the process of assembly and disassembly, wrong operation method may damage the parts or
components, shorten the service life and deteriorate the performance of the machine, even brings
potential safety hazard. Therefore, when assembling and disassembling the components, please read
related content in this manual carefully.
Disassembly:
1. Choose suitable site for the disassembly, standard service shop is preferred, and at least choose
clean cement floor. If the disassembly has to be done in the field, you must use wood board or
hardboard to place the removed parts, in order to keep the parts clean and protect them from
contamination and lost.
2. Drain out all engine oil and coolant (pay attention to prevent pollution of the environment),
clear away the dust and oil dirt on the machine.
3. Pay attention to operation procedures and methods, use the tools correctly and apply your
strength wisely. Follow the disassembling steps strictly and do not strike or pry the machine at
will, to avoid damaging the parts or tools.
4. Place the removed parts reasonably: It’s better to use parts rack, at least place the parts on clean
wood block. Pairing parts (such as connecting rod, piston, bearing shell, shaft cap and injector)
should be placed orderly and marked in pair, the joint of some important parts should be
covered with dust cap. Parts of each cylinder should be placed together orderly, so that no more
1
running-in is needed after reassembly. It’s better to assemble the nuts and screws to their
original positions, to avoid misplacement or lost.
5. For part that cannot be disassembled easily due to wrong operation or serious rust, try to take
assist measures: wet the part with engine oil or diesel oil, or heat the part, or attach adapter by
welding.
6. In the process of disassembly, always pay attention to personnel safety and equipment safety.
Pay special attention to fire safety.
Assembly:
7. Strictly comply with processes and steps specified in related technical documents to perform
the assembly.
8. Each part should be rinsed and inspected by visual before assembling, the part should be free of
sand hole, flash and blur, and no crack, bumping damage, corrosion, residual sealant and other
defect is allowed.
9. All oil galleries, oil chambers, water channels and deep holes of each part should be clean and
free of any residue.
10. All parts must have a certification or proof mark. Old part must be inspected and proved
qualified before reuse.
11. When assembling, pay attention to the mark of pairing parts.
12. Pay attention to special assembling requirements of connectors, safety locking plate and sealing
devices. For parts with tightening torque requirements, the specified tightening order and
tightening torque should be strictly complied with. For parts that connected with two or more
bolts/nuts, the bolts or nuts should be tightened evenly and crosswise in two or more steps. In
addition to special requirements, choose tightening torque according to table 1-1.
Table 1-1 Reference table for tightening torque of common bolts
Bolt specification
M6 M8 M10 M12 M14 M16
(mm)
Tightening torque
10-20 20-30 30 -40 60-70 120-140 180-200
(Nm)
Bolt specification
Z1/8 Z1/4 Z3/8 Z1/2 Z3/4 Z1
(mm)
Tightening torque
8-14 24-34 47-68 47-68 68-95 88-102
(Nm)
13. In the process of assembling, adjusting or parameter measuring should be performed by

complying with requirements in operation manual or related maintenance documents.
14. In the process of assembling, if incorrect structure or installation is found and modification is
2
necessary, please be sure to ask the manufacturer for permission or consult professionals in
advance, do not alter it at will.
15. Choose sealant reasonably. Specifications for sealant selection and application:
(1) The sealing surface and thread should be clean and free of oil dirt before applying sealant.
(2) Thread sealant (262, 242 sealant) is suitable for locking of thread, also exerting a part of
sealing effect. The sealant should be applied on mid-front area of the effective contact
section of the thread.
(3) Pipe thread sealant (545 sealant) is suitable for sealing and locking of tapered thread (NPT)
on pipe, pipe joint and plug screw. The sealant should be applied on mid-front area of the
effective contact section of the thread.
(4) Bowl-shape plug sealant (11747 sealant), the sealant should be applied on effective section
of sealing tape, make sure the sealant is evenly distributed and without discontinuity.
(5) Sealing gasket sealant (515 sealant) is suitable for plane (with or without gasket). the
sealant should be applied on inner side of gasket hole, sealant trace should be continuous
and with width of 1~2mm. Under special requirements, it is allowed to apply two sealant
traces.
(6) Before tightening the plug, joint or bolt that is applied with sealant, be sure screw-in the
sealant part by hand firstly. When applying the sensor transition joint with sealant, make
sure the sealant is evenly applied on middle-rear part of the joint thread and no sealant on
the sensing end.
16. Spare parts must come from the original manufacturers to ensure installation quality.
Note:YC4D80 engine
Oil pressure 0.25-0.6MPa
Injection timing 18±2°
Valve clearance 0.34-0.36mm
At first 250h,check the valve
clearance, and every 500h check
the valve clearance.
3
12 Marks
In order to emphasize the significance of safety and quality visually, and help the user make best
use of this manual, we design the signs in table 1-2 as marks.
Table 1-2
Marks Items Notes
Be careful for the safety during the operation.

Safety
Be quite careful for the safety if there is pressure inside
during the operation.
Emphasize the technical requirements to ensure that the
Attention operation can meet the requirements of standard during
operation.
Weight and installation way of parts or device.
Weight
Carefully select hanging tools and the operation gesture.
Tightening Pay more attention to the tightening torque of assembly
torque parts.
Carefully note the parts need to be coated with grease or
Coating
adhesion agent.
Oil, water Fill a certain amount of water, oil and fuel.
Be careful for the parts where water and oil need to be

Draining
drained, and judge their volume.
13 Tools and Gauges

Table 1-3
Name Application
Feeler gauge Used to measure fitting clearance
Pulley damper disassembling tools Used to disassemble pulley damper
Pulley damper press-in tools Used to assemble pulley damper
Piston-rod assembly assembling tools Used to assemble
XB-A rotary type filter wrench Used to disassemble rotary type engine oil filter
Socket 1-1/8 Used to disassemble damper kingbolts
Used to disassemble rear oil seal seat and fuel injection
Socket 1-2
pump gear
Used to disassemble cylinder cover shield and gear
Socket 3-8
housing cover plate
Cylinder sleeve disassembling tools Used to disassemble cylinder sleeve
4
14 Application of YUCHAI Engine

Table 1-4
Engine model Application
YC4108G LG918
YC4D80-T20 LG920
YC4A105Z-T20 LG926
YC6J125Z LG933L/LG936L/LG936L (downhole)
YC6J125Z LG936L/LG936L (downhole)
YC6M220Z-T20 LG953
15 Composition and Significance of YUCHAI Engine Model
YC 4 D 80 – T2 0
Major improvement
code
Emission standard
Power code
Series code
Number of cyinders
Corporate identify
Table 1-5 Parameter list of series code
Series code Cylinder bore × stroke (mm)
A 108×132
B 108×125
C 108×120
D 108×115
E 110×112
F 92×100
G 112×132
J 112×132
M 105×125
5
2 Disassembly of Diesel Engine
21 Disassembly of Outer Parts

211 Disassembly of Crankcase
Ventilation Device
1. Take the exhaust breather and its vent pipe out

from cylinder cover shield or engine block.
ATTENTION
The exhaust breather is usually installed on
top of cylinder cover shield, while for some
engine models, the breather is installed on
engine block side, and different breather
has different structure.
1
Fig. 2-1
1 Exhaust breather
212 Disassembly of Fan
1. Remove the 4 fixing bolts of fan, take the fan

assembly down.
ATTENTION
Three kinds of fan are equipped on
different YUCHAI products, i.e. steel plate
fan, engineering plastic fan and silicone oil
clutch fan. Fan of different engine model
has different mounting position, some are
1
Fig. 2-2 installed on water pump shaft, some are
1 Fixing bolt installed on independent support and some
are installed on crankshaft small end.
6
213 Disassembly of Turbocharger
1. Disconnect turbocharger oil inlet pipe and oil

return pipe, remove the 4 base fastening nuts
and the two connecting pipes, take the
turbocharger down.
ATTENTION
The 4 nuts are special nuts that made of
heat-resisting material, which shan’t be lost
or wrongly installed. Most turbochargers
are installed with bypass valve, and do not
touch the adjusting rod in the process of
Fig. 2-3 disassembly to prevent affecting engine
1 Turbocharger 2 Bypass valve intake pressure. Be sure not to take the
3 Oil inlet pipe bolt
turbocharger actuator as lifting eye to move
4 Oil return pipe weldment
5 Base fastening nut the turbocharger.
214 Disassembly of Silencer, Exhaust

Pipe and Water Outlet Pipe
1. Remove the fixing bolts of silencer assembly,

take down the assembly.
1 2 3
Fig. 2-4
1 Silencer 2 Bolt
3 Exhaust pipe
7
2. Screw off the fixing bolts of exhaust pipe, take

down the pipe and put it aside.
1 2
Fig. 2-5
1 Bolt 2 Exhaust pipe
3. Remove the connecting bolts between water

outlet pipe and cylinder cover, disconnect
water outlet pipe from water pump and take
down the pipe.
1
Fig. 2-6
1 Water outlet pipe
215 Disassembly of Air Filter
1. Screw off the fastening nut of air filter.
1
Fig. 2-7
1 Fastening nut
8
2. Remove the fixing nut of outer filter element,

take the filter element out.
1
Fig. 2-8
1 Outer filter element
3. Remove the fixing nut of inner filter element,

take the filter element out.
1
Fig. 2-9
1 Inner filter element
4. Loosen the connecting clamp between air filter

and intake pipe, and remove the connecting
bolts. Take the filter down.
1 2
Fig. 2-10
1 Bolt 2 Clamp
9
5. Remove the connecting bolts between air inlet

adapter and intake pipe, take down the adapter.
ATTENTION
According to requirements of different
engine model, intake pipe is divided into
unitary structure type and split-type
(two-section) structure type (only applies to
engine without turbocharger).
2
Fig. 2-11
1 Bolt 2 Air inlet adapter
216 Disassembly of High Pressure
Fuel Pipe
1. Disconnect the connection between each high

pressure fuel pipe and injector.
1
Fig. 2-12
1 High pressure fuel pipe joint
2. Disconnect the connection between each high

pressure fuel pipe and injection pump, screw
off the fixing bolts of clamp that used to fix
intake pipe on engine block. Take down high
pressure fuel pipe.
1 2
Fig. 2-13
1 High pressure fuel pipe joint
2 Pipe clamp
10
217 Disassembly of Fuel Coarse Filter
1. Remove the fixing bolts of fuel pipes that

connected to the filter, take down the pipes.
Screw off the filter fixing bolts and put the
filter aside.
1 2 3
Fig. 2-14
1 Bolt
2 Coarse filter to fuel tank pipe
3 Coarse filter to hand fuel pump pipe
218 Disassembly of Hand Fuel Pump
1. Remove the fixing bolts of coarse filter to

hand fuel pump pipe. Screw off the 3 fixing
nuts of hand fuel pump and take the pump
down.
1 2 3
Fig. 2-15
1 Breather 2 Nut
3 Hand fuel pump
11
219 Disassembly of Fuel Fine Filter
1. Remove the fixing bolts of fuel injection pump

to fuel fine filter pipe.
1 2
Fig. 2-16
1 Fuel injection pump to fine filter pipe
2 Fuel fine filter
2. Remove the fixing nuts of fuel fine filter.
1
Fig. 2-17
1 Fixing nut
12
2110 Disassembly of Engine Oil

Inlet/Return Pipe of Fuel
Injection Pump
1. Remove the engine oil pipe between injector

and fuel injection pump.
1 2
Fig. 2-18
1 Engine oil return pipe 2 Bolt
2. Remove the engine oil inlet pipe and return

pipe of fuel injection pump.
1 2
Fig. 2-19
1 Engine oil inlet pipe of fuel injection
pump
1 Engine oil return pipe of fuel injection
pump
13
2111 Disassembly of Transmission Belt

and Generator Assembly
1. Loosen the adjusting bolt of generator

assembly.
1 2 3
Fig. 2-20
1 Adjusting bolt
2 Generator assembly 3 Fixing bolt
2. Remove the transmission belt by hand. Screw

off the fixing bolts of generator assembly, take
the assembly down.
1
Fig. 2-21
1 Transmission belt
14
2112 Disassembly of Fuel Injection

Pump Assembly
1. Remove the connecting bolts between advance

device and air compressor.
1 2 3 4
Fig. 2-22
1 Connecting bolt
2 Connecting flange
3 Fluted connecting plate
4 Advance device
2. Remove the bolts that used to fix fuel injection

pump bracket on engine block, take the pump
and its bracket down together.
ATTENTION
Before disassembling the fuel injection
pump, rotate the pump shaft until cylinder
1 is in “fuel supply” state and mark this
position to prevent wrong fuel supply
1 2
Fig. 2-23 timing caused by incorrect reassembling.
1 Fixing bolt
2 Fuel injection pump bracket
15
2113 Disassembly of DC Starter Motor
1. Remove the connecting bolts between starter

motor and flywheel shell, take the starter
down.
ATTENTION
For some engine models, a pad is installed
between starter motor and engine flywheel
shell, do not lose it.
1 2
Fig. 2-24
1 Connecting bolt
2 Starter motor
2114 Disassembly of Engine Oil Cooler
1. Disconnect the oil inlet pipe and outlet pipe

from engine oil cooler. Remove the fixing
bolts of oil cooler, take the cooler down and
put it aside.
1 2 3 4
Fig. 2-25
1 Cooler oil inlet pipe
2 Cooler oil outlet pipe
3 Engine oil cooler
4 Fixing bolt
16
2115 Disassembly of Water Pump

Assembly
1. Remove the connecting bolts between water

pump and engine block, take pump assembly
down.
1
Fig. 2-26
1 Water pump assembly
2116 Disassembly of Pulley Damper
1. Remove the connecting bolts between the

pulley and damper.
1
Fig. 2-27
1 Pulley
2. Remove the damper compression bolt.
1 2
Fig. 2-28
1 Damper compression bolt 2 Damper
17
3. Push the damper out with two jackscrews.

Jackscrew: M12
1 2
Fig. 2-29
1 Damper 2 Jackscrew
18
22 Disassembly of Cylinder Cover

Components
Shield
1. Loosen the fastening nuts of cylinder cover

shield.
ATTENTION
In the process of removing cylinder cover
shield, please lift the shield up gently to
prevent damaging the shield gasket.
1 2
Fig. 2-30
1 Nut 2 Cylinder cover shield
YC6L and YC6112 engine adopt unitary

cylinder cover shield (1 shield for 6
cylinders), as shown in Fig. 2-31.
Fig. 2-31 YC6L, YC6112 cylinder

cover shield
YC6108 and YC6105 engine adopt

semi-integral cylinder cover shield (1 shield
for 3 cylinders), as shown in Fig. 2-32.
Fig. 2-32 YC6108, YC6105 cylinder

cover shield
19
YC6M engine adopts independent cylinder

cover shield (1 shield for 1 cylinder), as
shown in Fig. 2-33.
Fig. 2-33 YC6M cylinder cover shield
222 Disassembly of Rocker arm

Assembly
1. Remove the two lubricating oil (engine oil)

pipes.
ATTENTION
Lubricating of rocker arm shaft: For
YC6105 and YC6108 engine, engine oil pipe
on cylinder cover is connected to rocker
arm seat for lubricating; For YC6M engine,
1 engine oil flows into rocker arm seat

Fig. 2-34 through tappet, pushrod and valve
1 Engine oil pipe adjusting screw for lubricating; For other
engine models, oil gallery is designed to
connect cylinder cover and rocker arm seat
for lubricating.
2. Remove rocker arm shaft fixing nuts. Remove

the two rocker arm shafts and take out the
pushrods.
1
Fig. 2-35
1 Fixing nut
20
ATTENTION
Type of rocker arm shaft: One shaft for one
cylinder (for instance, YC6L and YC6M
engine)
Fig. 2-36 YC6L engine valve tappet

assembly
1 Tappet 2 Pushrod bottom ball
3 Pushrod 4 Pushrod head
5 Rocker arm seat bolt
6 Rocker arm shaft bolt
7 Adjusting bolt 8 Rocker arm
9 Linkage ball 10 Exhaust valve
11 Intake valve
One shaft for all cylinders (YC6112,

YC4112, YC4108, YC4110 engine)
Fig. 2-37 YC6112 engine valve mechanism

1 Bolt 2 Rocker arm shaft
3 Exhaust valve 4 Exhaust valve race
5 Valve spring 6 Valve rod oil seal
7 Exhaust valve spring seat
8 Exhaust valve spring teleflex
9 Valve lock clamp
21
One shaft for three cylinders (YC6108,

YC6105 engine)
Fig. 2-38 YC6108ZLQB valve tappet

assembly
1 Big end cover
2 Transmission control valve
223 Disassembly of Fuel Injector
1. Remove the fastening nuts of the six fuel

injectors. Take the injectors and nuts down.
ATTENTION
Copper gaskets should be placed together
with corresponding injectors, paste the
gaskets with grease to prevent lost, and
injectors should be marked with
1 2 corresponding cylinder numbers.

Fig. 2-39
1 Nut 2 Fuel injector
YC4112 fuel injector assembly
Fig. 2-40 YC4112 fuel injector assembly

1 Injector gasket (used to adjust protrusion)
2 Bolt of fuel return pipe joint
22
YC6L fuel injector assembly
Fig. 2-41 YC6L fuel injector assembly

1 Injector nut
2 Hemispheric compression gasket
3 High pressure pipe connecting port
4 Fuel return port
224 Disassembly of Valve Lock Clamp,
Valve Spring and Valve
Valve lock clamp
disassembling and
Valve 1. Before lifting down the cylinder cover, use
assembling tool
Valve spring
valve lock clamp disassembling and
assembling tool to remove valve lock clamp,
valve spring and valve seat. Bind the valve
lock clamp groove with rope to prevent valve
falling into cylinder sleeve.
Fig. 2-42
ATTENTION
When replacing the valve spring, the
corresponding cylinder piston should be
turned to TDC position to prevent the valve
falling into cylinder.
23
1. Take two steps to remove cylinder cover bolts.
1
Fig. 2-43
1 Bolt
ATTENTION
Disassembling order of YC6112 cylinder
cover bolts.
Fig. 2-43 Disassembling order of

YC6112 cylinder cover bolts
Disassembling order of YC6105 cylinder

cover bolts.
Fig. 2-43 Disassembling order of

YC6105 cylinder cover bolts
2. Install the two middle cylinder cover bolts and

lifting eyes. Lift the cylinder cover up slowly,
in the meantime knock the four corners of
cylinder cover with copper hammer so that it
can be detached from engine block easily.
Take down cylinder gasket
ATTENTION
Locating sleeves are used to position
1 2 3
Fig. 2-46 cylinder cover and engine block, do not lose
1 Cylinder cover 2 Cylinder gasket the locating sleeves.
3 Locating sleeve
24
23 Disassembly of Gear Housing

and Camshaft
231 Disassembly of Gear Housing
1. Remove all peripheral fastening bolts and nuts

of gear housing, knock the gear housing with
copper hammer and take down the gear
housing cover plate and gasket.
1
Fig. 2-47
1 Gear housing cover plate
232 Disassembly of Camshaft
1. Rotate camshaft gear, loosen the two fastening

bolts of camshaft thrust plate through the hole
on the gear.
Fig. 2-48
1 Woodruff key 2 Spacer bush
3 Camshaft thrust plate
4 Camshaft timing gear
5 Bolt 6 Gasket
7 Bolt
25
2. Hold camshaft gear with hands, rotate the

camshaft and pull it outward slowly to remove
it in the meantime.
ATTENTION
No big impact is allowed while pulling
camshaft out, to avoid damaging camshaft
or camshaft hole.
Fig. 2-49
1 Fastening bolt
2 Camshaft thrust plate
3 Camshaft gear
3. If the camshaft gear needs to be disassembled

in the meantime: Remove the gear fixing bolts
and gaskets, and then reassemble the fastening
bolt and pull the gear out with drawing tools.
ATTENTION
The woodruff key on the camshaft mustn’t
be damaged or lost.
1 2
Fig. 2-50
1 Fastening bolt 2 Gasket
233 Disassembly of Idle Gear and Idle

Gear Shaft
ATTENTION
If abnormal noise is heard from gear
housing before the disassembly, then you
should check axial clearance of idle gear
first. Refer to 36 Assembly of Gear Housing
Cover Plate, Camshaft, Idle Gear Shaft and
Gear Housing for details.
26
Disassembling method of YC6112, YC4112,

YC4110 engine: Only need to remove the
fastening bolt of idle gear shaft.
Fig. 2-51
1 Anti-wear plate 2 Idle gear
3 Idle gear sleeve 4 Idle gear shaft
5 Fastening bolt of idle gear shaft
Disassembling method of YC6L, YC6108,

YC6105 and YC4108 engine:
1. Remove the locking plate and fixing bolts of
idle gear, take down the pressing plate and idle
gear.
1 2 3 4
Fig. 2-52
1 Locking plate 2 Bolt
3 Pressing plate 4 Idle gear
27
2. Remove the two hexagon bolts.
1 2
Fig. 2-53
1 Bolt 2 Idle gear shaft
234 Disassembly of Air Compressor
and Air Compressor Idle Gear
1. Remove the fixing nut of air compressor idle

gear.
1 2
Fig. 2-54
1 Fixing nut
2 Air compressor idle gear
2. Take down air compressor idle gear.
1
Fig. 2-55
1 Air compressor idle gear
28
Disassembling method of YC6108, YC6112,

YC6L engine:
Air compressor idle gear seat and idle gear are
installed on gear housing cover plate. You just
need to loosen the idle gear seat bolt and
remove the two M6 sunk screws.
Fig. 2-56
10 Air compressor idle gear seat
11 Idle gear sleeve 12 Idle gear
13 Anti-wear plate
14 Idle gear bolt 15 Sunk screw
3. Remove the connecting bolts between air

compressor and gear housing, take down the
air compressor.
1
Fig. 2-57
1 Bolt
29

Sump, Engine Oil Strainer and
Engine Oil Pump
241 Disassembly of Engine Oil Sump
ATTENTION
Engine oil sump fastening type of YUCHAI
products is divided into two kinds: for the
first kind, the sump is fastened on engine
block with bolts, as shown in Fig. 2-58.
1. Remove the fastening bolts and take down
engine oil sump pressing plate (for YC6112
engine) and the sump.
Fig. 2-58
1 Engine oil pump 2 Bolt
3 Safety valve 4 Bolt
4 Bolt 5 Bolt
6 Filter screen 7 Oil drain plug
8 Bolt 9 Rotor
For the second kind, a bearing seat plate is

connected between engine oil sump and
engine block (YC6M adopts this structure),
as shown in Fig. 2-59.
2. Loosen the fastening bolts 3 to remove the oil
sump. Remove fastening bolts 2, and you can
take down bearing seat plate.
ATTENTION
Fig. 2-59
1 Crankshaft 2 Fastening bolt A magnet is place in oil drain plug on
3 Bearing seat plate 4 Pressing block bottom of the sump, do not lose it when
5 Engine oil sump 6 Fastening bolt cleaning the sump.
7 Engine block
30

Strainer
1. As shown in Fig. 2-60, remove the strainer

fastening bolts and strainer support fixing bolts
ATTENTION
Strainer support is vulnerable to rupture,
please pay attention to check it during
normal use.
Fig. 2-60
243 Disassembly of Engine Oil Pump
ATTENTION
The engine oil pump adopted by YUCHAI
products is rotor pump
Pump of YC4110, YC4112, YC6105,
YC6112, YC6M engine is shown in Fig.
2-61.
Fig. 2-61
1 Engine oil pump shaft sleeve
2 Gasket 3 Engine oil pump cover
4 Outer rotor 5 Engine oil pump shaft
6 Safety valve 7 Bolt
8 Safety valve spring
9 Adjusting screw of safety valve spring
10 Bolt 11 Gear
12 Sleeve 13 Inner rotor
31
Gear pump of YC6108 and YC6L engine is

shown in Fig. 2-62, the pump is installed on
front end of engine block.
Fig. 2-62
1 Engine oil pump pressure-limiting valve
2 Pressure-limiting valve spring
3 Engine oil pump driving gear
4 Driving shaft
5 Engine oil pump cover
6 Engine oil pump idle gear
7 Engine oil pump gear 8 Bolt
9 Anti-wear plate 10 Bolt
11 Driven gear shaft
12 Engine oil pump idle gear shaft
13 Locating sleeve
YC6105 engine oil pump is installed on the

first bearing cap of engine block; YC6M
engine oil pump is installed on front end of
engine block, small end of crankshaft is
taken as engine oil pump shaft, as shown in
Fig. 2-63.
Fig. 2-63
1. Remove the connecting bolts between the first
bearing cap of engine block and engine oil
pump.
1 2
Fig. 2-64
1 Engine oil pump 2 Bolt
32
25 Disassembly of Flywheel and

Flywheel Shell
251 Disassembly of Flywheel
1. Put the engine on suitable place, remove the

connecting bolts between compression plate
and flywheel, press the compression plate out
with jackscrews and put it aside.
Jackscrew: M16
1 2 3
Fig. 2-65
1 Bolt 2 Jackscrew
3 Compression plate
2. Remove the connecting bolts between
flywheel and engine block, take down the
flywheel and put it aside.
1
Fig. 2-66
1 Forward low gear clutch assembly
3. Remove the connecting bolts between

flywheel shell and engine block, take down the
shell and oil seals
ATTENTION
Do not damage the oil seals.
1 2
Fig. 2-67
1 Bolt 2 Oil seal
33
26 Disassembly of Piston
Connecting Rod, Crankshaft
and Cylinder Sleeve
261 Disassembly of Piston Connecting
Rod
REQUIREMENTS
(1) The removed piston connecting rod
assembly should be marked with
cylinder number and placed orderly.
(2) Connecting rod bolts, connecting rod
cap and connecting rod bearing shells
should be assembled together in their
original way.
(3) To prevent damaging thread of
connecting rod bolts, please don’t screw
off the bolts with pneumatic impact
wrench.
1. Place the engine upside down. Rotate

crankshaft until the to-be removed piston
connecting rod assembly reaches BDC (bottom
dead center), remove connecting rod bolts with
torque spanner and socket crosswise and
stepwise, take down the connecting rod cap.
12
Fig. 2-68
1 Connecting rod bolt
2 Connecting rod cap
34
2. Hold up the big end of connecting rod with

soft metal (such as copper and aluminum)
plate or clean wood board and then push piston
connecting rod assembly out with soft metal
bar or wood hammer.
ATTENTION
Be careful not to bump or scratch the
crankshaft journal, connecting rod journal
1 2
and cylinder sleeve hole during the
Fig. 2-69
1 Connecting rod assembly operation.
2 Piston
ATTENTION
For YC6L and YC4110 engine, clearance fit
is adopted between cylinder sleeve and
engine block. When disassembling piston
connecting rod assembly, you must fasten a
cylinder bolt on engine block with a piston
pin or compression plate between them to
Fig. 2-70
block the cylinder sleeve, only in this way
can the piston connecting rod assembly be
pushed out.
262 Disassembly of Crankshaft
REQUIREMENTS
(1) In the process of failure predication, if
you suspect that the poor fit failure
between bearing shell and bearing
journal may be caused by insufficient
torque of bearing cap fastening bolts,
then before the disassembly, you should
check whether fastening torque of each
bolt is in required range, and use it as a
35
basis for fault analysis.

(2) Clearance fit is adopted between
bearing cap and bearing seat for
YC4108, YC6105, YC6108 engine, two
locating sleeves in bolt holes on bearing
cap are used for positioning. While for
other engine models, interference fit is
adopted, and positioning is ensured by
machining of engine block bearing seat,
so when disassembling bearing cap, you
may encounter some difficulty, please
proceed with caution, as shown in Fig.
2-71. For YC6L engine, a threaded hole
Fig. 2-71 is processed in the middle of bearing
cap, which is used for lifting. For
YC6M engine, all bearing caps are
designed as a whole (unitary structure),
two locating pins on two ends are used
for positioning.
(3) The removed bearing shells should be
placed together with their
corresponding bearing caps to prevent
confusion.
1. Take two steps to loosen bearing cap fastening
bolts with torque wrench according to the
order marked in Fig. 2-72, take down the caps
respectively.
Fig. 2-72
36
2. Lift the crankshaft out slowly and put it on

clean support.
1
Fig. 2-73
1 Crankshaft
263 Disassembly of Cylinder Sleeve
ATTENTION
(1) Cylinder sleeve of YUCHAI products is
divided into wet type and dry type,
YC6105, YC6108, YC4108, YC6L and
YC6M engine adopt wet-type cylinder
sleeves, clearance fit is adopted between
cylinder sleeve and engine block, you
just need to push the sleeve from lower
end with soft metal bar or wood bar to
remove it.
Dry-type cylinder sleeve (2) YC4112 and YC4110 engine applies

disassembling tool
dry-type cylinder sleeves. For YC4112,
Cylinder block
interference fit is adopted; while for
YC4110, clearance fit is adopted. When
Dry-type disassembling cylinder sleeves of
cylinder sleeve
YC4112 engine, special cylinder sleeve
Disassembling
accessory disassembling tool is needed, as shown
in Fig. 2-74.
Fig. 2-74
37
(3) YC6112 is cylinder sleeve-free engine,

whose piston directly fits with cylinder
hole. Exceptionally, some YC6112
engine is equipped with dry-type
cylinder sleeve (applies bottom-dead
structure), as shown in Fig. 2-75.
Special cylinder sleeve disassembling
tool is also needed to disassemble the
cylinder sleeves. Tips: if no cylinder
sleeve disassembling tool is available,
you can put the engine block on boring
machine and bore the to-be replaced
cylinder sleeve to remove it. But be
careful not to damage the bottom-dead
shoulder.
Fig. 2-75
38
3 Assembly of Diesel Engine
31 Selection of Cleaning Fluid

Before reassembling the engine, all removed parts must be cleaned carefully, including cleaning
part surface, oil dirt in inner cavity, carbon deposit, water scale and rust.
311 Cleaning of Oil Dirt
Generally, volatile solvent is used to dissolve and clear away oil dirt on pats, such as gasoline,
diesel oil and kerosene. These solvents are easy to buy and convenient to use, no damage to the
parts and cleaning effect is good, but their cost is high, what’s more, volatile solvent can easily lead
to fire hazard. Thus, these solvents are usually used to clean precision parts with high cleaning
requirements.
Another cleaning fluid that used to clean oil dirt is alkaline solution (prepared with alkali or alkalic
salt), which is mainly used to clear away oil dirt on steel/iron parts. Formula of commonly used
alkaline solution is listed in table 3-1. Because strong alkalinity is highly corrosive to nonferrous
metals, when cleaning nonferrous metal parts, use the alkaline solution listed in table 3-2.
Table 3-1 Formula of alkaline solution for cleaning of oil dirt on steel/iron parts
Sodium Trisodium
Formula Caustic Sodium Liquid
carbonate phosphate Water (g)
Category soda (g) silicate (g) soap (g)
(g) (g)
A 7.5 50 10 1.5 1000
B 20 50 30 1000
Table 3-2 Formula of alkaline solution for cleaning of oil dirt on nonferrous metal parts
Formula Sodium Sodium silicate Sodium

Water (g)
Category carbonate (g) (g) dichromate (g)
A 10 0.5 1000
B 4 1.5 30 1000
When cleaning the parts with alkaline solution, you should heat the solution to 80~90oC in advance.
After all oil dirt is cleared away, wash the parts with hot water to get rid of the residual alkaline
solution to prevent corroding the parts, and dry them with compressed air at last. We recommend
you to use GF-III metal cleaning fluid for normal circumstances, which is convenient, safe and
effective.
39
ATTENTION
The chemicals listed in the tables above are corrosive, please operate with great caution
and take protective measures.
312 Removal of Carbon Deposit
Carbon deposit is poor combustion product and combustion product of bursting engine oil, mainly
appears on parts around combustion chamber. Harm to the machine caused by carbon deposit:
Inflexible movement, larger resistance and power reduction. If there is too much carbon deposit on
part surface, radiating performance will be greatly affected, overheating will occur. Too much
carbon deposit on piston and piston ring will result in scuffing of cylinder bore. Too much carbon
deposit in fuel injector will block the injector, and engine will not work normally. Thus, when
maintaining the engine, you should pay serious attention to carbon deposit problem.
Tools to remove carbon deposit: scraping knife, perching knife and wire brush. Fig. 3-1 represents
removal of valve carbon deposit, Fig. 3-2 represents removal of piston top carbon deposit. This
method is simple and practicable, but the removal isn’t clear enough, and easy to leave scratch on
part surface.
Fig. 3-1 Removal of valve carbon deposit Fig. 3-2 Removal of piston top carbon deposit
Another method to remove carbon deposit is to use decarbonizer. The way to do this is: keep the
part (with carbon deposit) immersed in decarbonizer (80~90oC) for 2~3h, after the carbon deposit
gets soft, wipe it off with brush or cleaning cloth, wash the part with hot water and dry it with
compressed air at last.
Formula of decarbonizer for removal of carbon deposit on steel/iron parts and aluminum alloy parts
is list in table 3-3 and 3-4.
40
Table 3-3 Formula of decarbonizer for removal of carbon deposit on steel/iron parts
Sodium Sodium
Formula Caustic soda Sodium Liquid soap
carbonate dichromate Water (g)
Category (g) silicate (g) (g)
(g) (g)
A 25 31 1.5 8.5 1000
B 100 5 1000
C 25 31 5 10 5 1000
Table 3-4 Formula of decarbonizer for removal of carbon deposit on aluminum alloy parts
Formula Sodium Sodium Sodium silicate

Liquid soap (g) Water (g)
Category carbonate (g) dichromate (g) (g)
A 18.5 18.5 10 1000
B 20 5 8 10 1000
C 10 5 10 1000
313 Removal of Water Scale
A layer of yellowish-white water scale will be deposited on inner wall of cylinder cover cooling
water jacket and radiator after long-time using cooling water (not coolant). Water scale can block
circulating water channel and result in engine overheating. If hard water is used in the engine, the
water scale problem could get even worse.
Formula of descaling agent is listed in Fig. 3-5. Prepare the descaling agent (A/B) according to the
formula listed in Fig. 3-5 and filter it, fill enough descaling agent into engine cooling system and let
it stand for 10~12h, and then start the engine, increase the engine speed to a little higher than idle
speed and run it for 10~15min to heat the descaling agent to 80oC or higher and then stop the engine.
After the temperature drops to 60oC or lower, start the engine again and run it idly for 2min, and
then stop the engine, drain the descaling agent out. Then fill clean water and start the engine to
clean engine cooling system.
Table 3-5 Formula of descaling agent
Formula Sodium carbonate Hydrous sodium

Kerosene (g) Water (g)
Category (g) carbonate (g)
A 10 15 1000
B 100 50 1000
Advantages of this method are: efficient, less corrosive to copper and welded joint, but you should
41
note that harmful gas will be generated when acid solution reacting with water scale, protective
measures shall be taken.
314 Removal of Rust
Steel/iron parts can be easily rusted by water and oxygen in the air, rust will directly affect surface
quality of the parts and must be thoroughly removed. Common tools to remove rust: steel wire,
scraping knife, perching knife and abrasive cloth. Be careful not to damage the finished surface of
the part.
42
32 Assembly of Engine Block
321 Cleaning of Engine Block
Before the cleaning, you should preliminarily check the engine block and ensure it is in good
condition for use. Check the engine block for casting flaws like crack and sand hole, check whether
machining processes is complete, check the finished surfaces for bumping damage.
1. Remove the peripheral dirt on engine block
with high pressure water, and then clear away
the oil dirt, burnt-on sand and carbon deposit
and sediment on inner and outer surface of
engine block, oil gallery and water channel
with cleaning agent.
Fig. 3-3
2. Clean each oil gallery (especially main oil

gallery and auxiliary oil gallery, this two oil
galleries must be cleaned with clean cloth
pieces), inner cavity, main bearing holes,
camshaft bearing holes, main bearing bolt
holes and cylinder cover bolt holes, and dry
them with compressed air.
Inspection and qualification of engine block
cleanliness:
Fig. 3-4
The white cloth shouldn’t turn black after
getting through oil gallery, check each oil
gallery and inner cavity with strong
magnetic rod, which should be free of iron
particle.
43
3. If there is too much deposited water scale in

water channel and water cavity, descaling
agent should be used to remove it. No iron
particle and debris is allowed in each shaft
hole and bolt hole, carbon deposit and sealant
should be removed with perching knife. Dry
engine block with compressed air at last.
Fig. 3-5
322 Inspection of Engine Block
1. Measure main bearing seat bore diameter: As shown in Fig. 3-6, assemble main bearing cap on
engine block and tighten the bolts to required torque. Calibrate the bore dial indicator (division
value 0.01mm) and use it to measure diameter of main bearing seat bore working section in x
and y direction, group the measured results according to table 3-6.
Fig. 3-6 Measuring of main bearing seat bore diameter

Table 3-6 Main bearing seat bore diameter grouping table for each engine model (mm)
Engine model YC6112, YC4112, YC 6105, YC6108,

YC6113 YC6M
Group YC4110 YC4108
A (Φ) 92.055~92.065 91~91.018 92~92.018

10~108.022
B (Φ) 92.065~92.075 91.018~91.035 92.018~92.035
2. Method to measure diameter of main bearing hole (with bearing shells): Refer to Fig. 3-6.
Install the corresponding main bearing shells on each main bearing seat and bearing cap
according to grouping condition of main bearing seat bore diameter, and then measure the
diameter of main bearing hole according to the method exposed in 1, the measured results
44
should meet the requirements listed in table 3-7.

Table 3-7 Standard diameter of main bearing hole (with bearing shells) for each engine model (mm)
YC6112,
Engine
YC4112, YC6105 YC4108 YC6108 YC6M YC6108ZLB
model
YC4110
Diameter
85.721~85.765 85.06~85.105 85.06~85.122 85.05~85.115 108~108.022 87.05~85.115
(Φ)
3. For the convenience of calculating circular degree and cylindricity deviation of cylinder sleeve
hole, when measuring cylinder sleeve bore diameter, measure it in the vertical direction of the
highest point and lowest point of the second piston ring, as shown in Fig. 3-7, the measured
value should be in the range listed in table 3-8, otherwise, the sleeve should be replaced. For
cylinder sleeve-free engine (YC6112 engine), replace the engine block, bore the cylinder hole
or add a cylinder sleeve to solve the out-of-tolerance problem.
4. Measure the protrusion of cylinder sleeve (to engine block top surface), as shown in Fig. 3-8
and Fig. 3-9. Cylinder sleeve of YC4110 engine is free of waterproof ring, while that of other
engine models is designed with waterproof ring.
Fig. 3-7 Measuring of cylinder sleeve bore diameter Fig. 3-8 Measuring of cylinder sleeve protrusion
Table 3-8 Specified value of cylinder sleeve bore diameter, circular degree, cylindricity deviation
and protrusion for each cylinder model (mm)
Cylinder sleeve
Cylinder sleeve Cylinder sleeve Cylinder sleeve
cylindricity
Item bore diameter circular degree protrusion
deviation
Engine model
Specified value Specified value Specified value Specified value
YC6112 111.778~111.816 0.01 0.01 0.02~0.09
YC4112 111.778~111.816 0.01 0.01 0~0.08
YC6105 105~105.022 0.01 0.01 0.07~0.11
YC6108 108~108.035 0.01 0.01 0.02~0.08
45
YC4108 108~108.022 0.01 0.01 0.04~0.08
YC4110 110~110.035 0.015 0.015 0~0.08
YC6L 113~113.022 0.01 0.105~0.155
YC6M 120~120.022 0.01 0.01 0.02~0.08
Cylinder sleeve
Pay attention to clear away protrusion
carbon deposit and burr on
this surface when replacing
the sleeve
Engine block
Cylinder sleeve
Fig. 3-9 Measuring of cylinder sleeve protrusion
ATTENTION
Adjusting of cylinder sleeve protrusion can be done by switching the cylinder sleeves,
protrusion difference of two adjacent cylinder sleeves should not exceed 0.04mm.
5. Removed main bearing caps should be assembled to their original position, do not interchange
them, side face of each engine block is casted with casting number, and bottom surface is
printed with processing number, engine number is printed on side face of engine block too;
each bearing cap is printed with processing number, installation number and installing direction
(arrow) on the bottom. Refer to Fig. 3-10 and Fig. 3-11.
Bearing cap
Processing number
Casting number
Engine number
Fig. 3-10 YC6105 engine block

6. Bearing shell locating grooves 4 are processed on fitting surfaces of bearing seat and bearing
cap, the two grooves should be on the same side after assembling. As shown in Fig 3-11.
46
1 Cylinder number
A/B mark 2 Installing direction (arrow)
3 Processing number
4 Bearing shell locating grooves
5 Threaded hole (should be clean and free of dirt)
6 No burr on the edge
7 Oil hole
A- Represents matching with red shell
B- A-Represents matching with blue shell
Fig. 3-11 Main bearing cap C-
7. Measuring of camshaft sleeve bore diameter
Refer to Fig. 3-6 for measuring method. Specified camshaft sleeve bore diameter and fitting
clearance between camshaft and camshaft sleeve for each engine model are listed in table 3-9
Table 3-9 Specified camshaft sleeve bore diameter and fitting clearance between camshaft and
camshaft sleeve for each engine model (mm)
YC6108Z
YC6105
Engine model YC6112 QB
6108ZQ YC4108 YC4110 YC6L YC6M
Value YC4112 YC6108Z
6108ZQN
LQB
Specified camshaft 60.744~ 55.5~ 60.0~ 58.5~ 60.744~ 60.0~ 60.01~
sleeve bore diameter (Φ) 60.769 55.53 60.03 58.53 60.770 60.03 60.06
0.0762~ 0.06~ 0.06~ 0.03~ 0.076~ 0.06~ 0.04~
Fitting clearance
0.127 0.109 0.109 0.09 0.128 0.109 0.12
Fitting limit reference
0.152 0.25 0.25 0.25 0.152 0.25 0.25
value
ATTENTION
If the measured value is not in the specified range listed in table 3-9, then the sleeve
should be replaced.
47
323 Assembly of Engine Block
Parts that installed on engine block are numerous, only parts with special assembling requirements
are listed below.
Fig. 3-12 YC6108 cylinder block assembly (1)

1 Bearing cap 2 Cylinder block 3 Main bearing bolt 4 Locating sleeve
5 Timing idle gear 6 Idle gear bearing 7 Idle gear bearing 8 Idle gear shaft sleeve
9 Idle gear baffle 10 Locking plate 11 Small bolt 14 Water seal ring
15 Cylinder sleeve 18 Engine oil pump intermediate drive gear 19 Bearing
27 Cylinder gasket 29 Breather 33 Engine oil pump bracket 34 Adjusting gasket
37 Sphere gasket 40 Bracket bolt 44 Main oil gallery sealing plug
48
Fig. 3-13 YC6108 cylinder block assembly (2)

1 Camshaft sleeve 2 Intermediate main bearing cap 3 Main bearing cap
4 Main bearing bolt 5 Pin 8 Camshaft end cover bolt 15 Low oil pressure alarm
18 Pressure regulating valve assembly 20 Oil pressure alarm
1. Installation of water block and main gallery oil block

Refer to Fig. 3-14 for installing of water block, installation requirements: sealing surface of water
block should be applied with 11747 sealant; after assembling, outer end face of water block should
be level with or lower than engine block.
Fig. 3-14 Installation of engine water block

Installation of main gallery oil block:
Main gallery oil block includes front oil block and rear oil block, front oil block of YC4110,
YC4112 and YC6112 engine is bowl-shape plug, while rear oil block is hexagonal socket head plug.
49
Front oil block of YC4108, YC6105, YC6108, YC6L and YC6M engine is sealing plug (with
O-ring), while rear oil block is bowl-shape plug, as shown in Fig. 3-15.
Hexagonal socket head plug
O-ring
Sealing plug Bowl-shape plug
Fig. 3-15 Main gallery oil block
INSTALLATION REQUIREMENTS:
(1) Middle section of plug screw should be applied with 545 sealant and tightened with
socket head wrench.
(2) Add an O-ring to install the sealing plug, be careful not to damage the O-ring.
(3) After assembling, outer end face of plug or sealing plug should be a little lower than
engine block end face.
(4) When assembling, knock-in with soft metal.
2. Precautions for installation of camshaft sleeve. Refer to Fig. 3-16.
Camshaft sleeve
Rear end
chamfer
Rear end of engine block
Fig. 3-16 Installation of camshaft sleeve

(1) Only rear end of camshaft hole is processed with chamfer, so when installing the sleeve,
insert it from the rear end of engine block, as shown in Fig. 3-16.
(2) Oil hole on the sleeve must be aligned to oil inlet hole on engine block. ATTENTION: Not
every camshaft sleeve is designed with oil hole, for YC6105 and YC6108 engine, the third
50
and sixth (cylinder number) sleeves are designed with one oil hole respectively that
connected to rocker arm seat; for YC6M engine, only one oil hole needs to be aligned
(because there is oil groove processed on bearing shell); for YC4108 engine, the second
and fourth (cylinder number) sleeves are designed with one oil hole respectively that
connected to rocker arm seat; for other engine models, only the first (cylinder number)
sleeve is designed with one oil hole that connected to rocker arm seat. You should pay
special attention to this when assembling.
(3) After the installation, horizontal boring machine should be used to process the sleeve to
specified dimension (refer to table 3-9).
3. Precautions for installation of cylinder sleeve.
(1) Rust and carbon deposit on cylinder sleeve shoulder must be cleared away.
(2) Check whether the cylinder sleeve bore diameter meets the requirements listed in table 3-8
before installing.
(3) Install waterproof ring on cylinder sleeve (YC6112 (with cylinder sleeve), YC4112 and
YC4110 engine apply dry-type cylinder sleeve, no waterproof ring is needed), as shown in
Fig. 3-17.
(4) When assembling the cylinder sleeve to engine block, you should apply some engine oil on
the waterproof ring first, rotate the sleeve while press it in the meantime. If fail to press it
in by hand, place a wood board on the sleeve and knock it in place, as shown in Fig. 3-18.
Interference fit is adopted between cylinder sleeve and engine block for YC4112 and
YC4112 engine, so the sleeve should be cooled in liquid nitrogen for 10min before
assembling. Clearance fit is adopted for YC4110 engine.
(5) After the installation, cylinder sleeve protrusion should be measured according to the
method exposed in Fig. 3-8. For YC6L engine, the protrusion can be adjusted by adding or
reducing number of adjusting gaskets (chamfer side upward).
When matching cylinder sleeves, the color of selected cylinder sleeve should be the same
as engine block grouping color, i.e. red to red, blue to blue (or A to A, B to B).We won't
elaborate here.
TIPS
In principle, grouping assembling is applied between fitting of cylinder sleeve and engine
block.
51
Fig. 3-17 Installation of waterproof ring Fig. 3-18 Installation of cylinder sleeve
1 Waterproof ring 2 Cylinder sleeve 3 Adjusting gasket
4. Installation of engine oil cooled nozzle and hook. Refer to Fig. 3-19 and Fig. 3-20.
Installation method of engine oil cooled nozzle/hook and precautions

(1) Nozzle material is oil-resisting high-temperature engineering plastic, when installing, you
just need to press it into the fitting hole on main bearing seat. The nozzle should be pressed
in place and no protrusion to the fitting hole. After the installation, fill diesel oil with
grease gun to perform injection test: when the piston gets to TDC, the fuel spray must be
injected on cylinder inner wall, and the fuel spay mustn’t be forked.
ATTENTION
When disassembling the oil sump of a long-time used engine, you should pay attention to
check whether the nozzles are aged and damaged, replace if necessary.
(2) Engine oil cooled hook is steel tube weldment, and positioned by locating pin when
assembling, fastened on engine block with bolts. Before assembling, you should check
whether pressure-limiting valve ball is flexible, whether oil hole on the weldment is
unblocked. For engine that requires fuel must be injected into engine oil cooled gallery on
piston (ensured by machining precision of the weldment), this should be checked. And no
interference is allowed between the hook and piston skirt or crankshaft counterbalance
ATTENTION
The piston for assembling must be processed with hook back-off opening. Refer to Fig.
3-19.
52
Applicable to YC6112, YC4110 and YC4108 engine Applicable to YC4112, YC6105, YC6108,
YC6L and YC6120 engine
Fastening bolt
Pressure spring
Nozzle
Hook
Ball valve
Locating pin
Hook
Piston engine oil

cooled nozzle
Fig. 3-19 Installation of engine oil cooled nozzle Fig. 3-20 Installation of engine oil cooled hook
324 Elimination of Engine Block Common Faults
1. If there is sand hole or crack on engine block and the sand hole or crack is not on main oil
gallery, water channel or engine block stress surface, the sand hole or crack can be fixed by
welding with cast iron electrode or inlaying with aluminum strip after being enlarged. As
shown in Fig. 3-21.
Welding repair Crack
Sand hole
Engine block
Fig. 3-21 Repair of engine block Fig. 3-22 Shape of cylinder bore shoulder
2. Main bearing cap damage. Replace the bearing cap, in principle, you can only use half-finished
bearing cap (fasten it on the matching cylinder to specified torque and then bore it to specified
dimension listed in table 3-6.
If boring the bearing cap is not available, you can choose a suitable old bearing cap and fit by
grinding the bearing shells (the requirements are: ensure crankshaft can rotate flexibly and no
engine oil pressure reduction is caused).
3. Fit camshaft sleeve
The method to fit camshaft sleeve is boring and reaming, which has been exposed previously.
53
Here we introduce how to fit when a sleeve is damaged and replaced: press the new sleeve into
the fitting hole according to the method previously exposed, clear away the blur on sleeve, wipe
out the camshaft and fit it into the sleeve and check the flexibility. It is qualified if the camshaft
can rotate flexibly. If the camshaft cannot rotate flexibly (the fitting is too tight), then coat the
sleeves with red lead powder, reassemble and check the flexibility again, bore or ream to fit.
Camshaft sleeve fitting hole of YC6108 and YC6105 engine applies open structure and can use
a scraping knife to fit; while fitting hole of other engine models apply closed structure, only fit
by sanding with waterproof abrasive paper and polishing.
4. After assembling cylinder sleeve, if the protrusion exceeds specified value listed in table 3-8,
then you can interchange the sleeves to meet the requirements, never process the engine block
step surface to prevent damaging the reasonable fitting condition. As shown in Fig. 3-22.
ATTENTION
Clear away the blur and carbon deposit on the step surface, contact area should be more
than 80%. Poor fitting and large protrusion are the main causes for breakage of cylinder
sleeve journal.
5. Abrasion of cylinder sleeve: if abnormal premature wear is happened to the cylinder sleeve,
you should find out the cause as soon as possible: (1) Check engine oil quality and check
whether cooling and ejecting of engine oil is normal; (2) Improperly maintained air filter or
short circuit; (3) Long-term low-temperature (66oC or under) low-speed running; (4)
Disqualified cylinder sleeve material (in this case, abrasion of piston and piston ring is not
serious).
6. Cavitation of cylinder sleeve: common cylinder sleeve cavitation is partial, main causes are:
cylinder sleeve is too close to cylinder wall, poor circulating of cooling water leading to
overheating, bubbles come out from high temperature water, explode and continuously impact
cylinder sleeve outer wall under the vibration of cylinder sleeve. Handling method: properly
grind or polish engine block failure area (protruding area), but without affecting cylinder block
strength.
TIPS
For the planeness problem of engine block upper surface, so far, we didn’t find any
engine failure caused by oversize planeness error, so please do not casually polish this
surface to prevent affecting plane quality of the engine block.
7. Inlay-fit cylinder sleeve: only for YC6112 engine. As shown in Fig. 3-23.
54
0.8×45
Knurling depth of surface A:

0.008~0.012mm
Cross angle: 30~60°
Area: 50%~70%
Half-finished cylinder sleeve Cylinder sleeve fitting hole Inlay-fit cylinder sleeve
Fig. 3-23 Inlay-fit YC6112 cylinder sleeve
55
33 Assembly of Crankshaft
331 Cleaning of Crankshaft
Crankshafts of YUCHAI products have basically the same structure, only the accessories on front
and rear ends are different, here we take YC6108 for example to describe. As shown in Fig. 3-24.
Colored position
Fig. 3-24 YC6108 crankshaft and flywheel assembly

1 Bolt 2 A/C pulley 3 Pulley 4 Silicone oil damper 5 Crankshaft timing gear
6 Thrust plate 7 Bearing gasket 8 Bearing
9 Flywheel bolt 10 Locating pin
1. Clear away oil dirt and anti-rust oil on crankshaft with kerosene. Wash crankshaft external
surface and all threaded holes with soft hairbrush. Rust on the journal should be rubbed with
120-mesh fine sandpaper and polished with sand belt.
2. Spray-wash the oil galleries and oil holes with metal antirust cleaner repeatedly, and poke-wash
them with clean cloth strips to ensure the oil gallery unblocked.
3. Check the oil galleries and oil holes with strong magnetic rod, if there are iron particles, clean it
again according to step 2.
4. Finally, rinse the crankshaft with clean water to remove residual cleaner and dry the galleries
and holes with compressed air, apply suitable engine oil on crankshaft finished surface for
protection timely.
332 Inspection of Crankshaft
Inspection items are: main journal diameter, diameter of crankshaft connecting rod journal, journal
56
roughness, thrust surface roughness, dynamic unbalance value, distance between center lines of
main journal and crankshaft connecting rod journal, and crankshaft run-out, etc.
1. Measure main journal diameter and diameter of crankshaft connecting rod journal, calculate the
cylindricity error. Refer to table 3-10 and Fig. 3-25.
Fig. 3-25 Measuring of main journal diameter and crankshaft connecting rod journal diameter
Table 3-10 Required diameter value and cylindricity error of main journal and crankshaft
connecting rod journal for each engine model. (mm)
YC YC411 YC610 YC YC YC YC 6M YC611
Engine
6112, 0 5 6108 4108 6113 2, YC
model
YC 4112
Item
4112
86.965 99.978
Main journal (Φ) 85.631~85.656 84.965~85
~87 ~100
Crankshaft
65.97 69.97 69.978 65.97 79.97 81.978
connecting rod 69.84~69.86
~66 ~70 ~70 ~66 ~80 ~82
journal (Φ)
Main journal
0.0664 0.005 0.006 0.01 0.006 0.01 0.005 0.006
cylindricity error
Crankshaft
connecting rod
0.0664 0.005 0.005 0.008 0.005 0.008 0.005 0.006
journal
cylindricity error
2. Inspection of surface roughness
Main check points are: surface of main journal and crankshaft connecting rod journal, connecting
rod journal shoulder, round corner of main journal and crankshaft connecting rod journal, finished
surface of front and rear ends.
Inspection method: a. Compare to sample plate by visual, main journal and crankshaft connecting
rod journal should be free of scratch, the round corner should be 100% polished and the transitional
area should be smooth. b. Measure with roughness detector.
3. Measuring of dynamic unbalance value. Every crankshaft has passed tests regarding dynamic
unbalance value before delivery, so you don’t have to perform this inspection under normal
circumstance, but if the engine vibrates excessively during normal use, this inspection must be
57
done. Measuring of dynamic unbalance value should be performed on a dynamic balancer,

crankshaft dynamic unbalance value for each engine model is listed in table 3-11. If the
crankshaft need to be weight-reduced, you can drill holes on circumference surface of
balancing block to remove the material, it is required that the hole diameter should be less than
15mm, depth should be less than 30mm and hole edge space should be greater than 5mm.
Table 3-11 Crankshaft dynamic unbalance value for each engine model
Engine
model YC6112 YC4112 YC6105 YC6108 YC4108 YC4110 YC6L YC6M
Item
Crankshaft
dynamic
≤36 ≤20 ≤50 ≤50 ≤20 ≤20 ≤50 ≤40
unbalance value
(g•cm)
4. Measure crankshaft bending error, refer to Fig. 3-26.
Fig. 3-26 Measuring of crankshaft bending error

Measure the bending error between main journal on two ends and the fourth main journal, the error
value should be in the range listed in table 3-12.
Table 3-12 Crankshaft bending error value
Engine
6-cylinder engine 4-cylinder engine
Value
Specified value ≤0.05 ＜0.04
Limit value ＜0.15 ＜0.13
5. Measure crank radius

If no special gauge is available, measure according to the method exposed in Fig. 3-26, half of the
measured value difference when the connecting rod journal in the lowest point and highest point is
crank radius, which should be in the range specified in table 3-13.
58
Table 3-13 Crank radius

YC6112
Engine
YC4108Z YC6108ZQB YC6105
model YC4108 YC4110 YC6L YC6M
LQ YC6108ZQLB YC6108
Value
YC4112
Crank radius 66.04±0.05 66±0.05 62.5±0.05 57.5±0.05 56±0.05 70±0.06 72.5±0.06
333 Assembly of Crankshaft
1. Assembly of crankshaft gear:

Interference fit is adopted between crankshaft timing gear and crankshaft small end, you should
heat the gear with electromagnetic induction heater (or other way) to about 120oC when assembling,
install the heated gear on crankshaft small end immediately based on its locating requirements
(crankshaft of different engine model has different locating requirement, pin locating: YC6105ZLQ,
YC6108ZLQB and YC6L; key locating: YC4110, YC4112, YC6105QC and YC6108QC; fixture
locating: YC6112), ensure the gear is properly fitted with crankshaft shoulder. As shown in Fig.
3-27.
Heat to
120oC
Fig. 3-27
TIPS
The timing gear is assembled on crankshaft by the manufacturer before delivery, and without
dedicated tools, the gear is difficult to be disassembled. So when replacing the parts, the gear
and crankshaft should be replaced together. Tips: some crankshaft timing gears that delivered in
the second half of 2003 are free of locating pin or key, if valve timing of engine equipped with
this kind of crankshaft gear is changed, check if the gear is loose first.
2. Installation of crankshaft rear end bearing and bearing sleeve. For YC4110 engine, only bearing
59
sleeve needs to be installed; for YC4108, YC6105, YC6108 and YC6L engine, firstly install
the sleeve and then install the 6205-Z bearing; while for YC4112, YC6112 and YC6M engine,
the bearing is installed on flywheel. Refer to Fig. 3-28 and Fig. 3-29.
Fig. 3-28 Installation of crankshaft bearing
Bearing
Sleeve
Fig. 3-29 Crankshaft bearing and bearing sleeve
TIPS
Crankshaft bearing and bearing sleeve should be assembled in place (no clearance to the
stop shoulder). For crankshaft bearing, the side with end cover should face outward, and
fully-enclosed bearing is free of lubricating oil. As engine model varies greatly, assembling
requirements of crankshaft bearing and bearing sleeve were chosen according to
transmission box type, please recover them without change after maintenance.
3. Steps to lift and assemble crankshaft and precautions
(1) Install main bearing shells: when assembling a new engine, color mark on the bearing shell
should be the same as that on main journal. This is not mandatory in normal maintenance,
but you must ensure the fitting clearance is specified range. Bearing shell locating grooves
are processed on fitting surfaces of bearing seat and bearing cap, the bearing shell lip
should be aligned to the grooves after assembling. In the meantime, oil hole on bearing
60
shell should be aligned to that on bearing seat too, refer to Fig. 3-11 (for YC6L engine,
because there is oil groove processed on bearing seat, no oil hole needs to be aligned when
assembling. As shown in Fig. 3-30)
Oil groove
Oil inlet hole

Locating groove
Upper bearing seat
Fig. 3-30 YC6L engine bearing seat

(2) Apply suitable engine oil bearing seat oil holes and bearing shells.
(3) Lift and install crankshaft: place the crankshaft slowly and correctly, apply suitable engine
oil on main journal and journal oil holes, rotate the crankshaft and make sure it is flexible.
After placed the crankshaft, install the thrust plates. For YC6105 and YC6108 engine, the
thrust plates should be installed on the fourth bearing seat; For YC4108 engine, the thrust
plates should be installed on the third bearing seat; For YC6M engine, the thrust plates
should be installed on the second bearing seat. Other engines apply thrust shoes, for YC6L
engine, the bearing shoes should be installed on the fourth bearing seat; for YC4110 and
YC4112 engine, the bearing shoes should be installed on the third bearing seat; for
YC6112 engine, the bearing shoes should be installed on the fifth bearing seat.
Correct installation of thrust plate: as shown in Fig. 3-31.
61
Thrust plate Locating lug

Crankshaft
Upper bearing seat
Thrust plate groove
Lower thrust plate

Axial clearance
Crankshaft
Fig. 3-31 Installation of thrust plate

(4) Install lower bearing shells. Similarly, when assembling a new engine, color mark on the
bearing shell should be the same as that on journal. In the meantime, install the lower thrust
plates on upper bearing caps. Apply suitable engine oil on the shells.
(5) Refer to Fig. 3-10 to assemble the main bearing caps, knock them in place with copper
hammer. Apply suitable engine oil on thread of bearing cap bolts and screw-in the bolts by
hand for a few circles. Take three steps to tighten the bolts from the middle to both ends
orderly. As shown in Fig. 3-32.
ATTENTION
After each tightening step, you should rotate the crankshaft by hand and ensure it is
flexible, otherwise, find out the cause and solve the problem.
Tightening torque of main bearing cap bolts for each engine model is listed in table 3-14.
Table 3-14 Tightening torque of main bearing cap bolts for each engine model
Engine
YC4108 YC4110 YC4112 YC6105 YC6108 YC6112 YC6L YC6M
model
Tightening
torque 220~260 180~260 190~220 220~300 220~260 190~220 220~260 250~270
(Nm)
62
(6) Measuring of crankshaft axial clearance, refer to Fig. 3-31 and Fig. 3-33. The measured
value should meet the requirements listed in table 3-15.
Fig. 3-32 Tightening of main bearing cap bolts Fig. 3-33 Measuring of crankshaft axial clearance
Table 3-15 Specified crankshaft axial clearance for each engine model
Engine
YC6112 YC6L YC6105 YC6108 YC4108 YC4112 YC4110 YC6M
model
Axial
clearance 0.10~0.20 0.10~0.27 0.07~0.20 0.06~0.22
(mm)
During the inspection, if the measured value is far from specified range in table 3-15, you can select
thrust plates with different thickness to meet the requirements. Wear limit should be less than
0.4mm.
TIPS
It is better to measure crankshaft axial clearance after the first tightening step of main
bearing cap bolts, in case a problem occurs.
334 Maintenance of Crankshaft
1. If the crankshaft is slightly scratched or burnt (the damage is not obvious), you can polish with
abrasive cloth (600 grade) to remove the defect, and method to polish is shown in Fig. 3-34.
2. If the crankshaft is severely scratched or burnt (the damage is obvious), you can grind the
crankshaft to remove the defect and fit with an enlarged shell (+0.25). But when grinding, the
requirements regarding crankshaft journal transition fillets (R3 and R5.1) must be addressed.
As shown in Fig. 3-35.
3. When replacing with a new crankshaft, it better to measure dynamic unbalance value with
flywheel and clutch assembled.
63
Vibration of the engine is mainly caused by oversized dynamic unbalance value of crankshaft
module. Including:
Crankshaft, flywheel, clutch and pulley damper, these parts have passed tests regarding
dynamic unbalance value before delivery. But if the vibration problem is serious, you must
check them one by one.
Cloth strip
Crankshaft
journal Abrasive
cloth
Fig. 3-34 Polishing of crankshaft journal Fig. 3-35 Machining of crankshaft journal
4. Deformation of crankshaft: In the process of assembling crankshaft, if found that rotation of
crankshaft is not flexible (bearing shells and the shafting fitting hole are in good condition),
then the crankshaft may have deformation problem, you should measure crankshaft bending
error (refer to Fig. 3-26), if the whole bending error is greater than 0.15mm, the crankshaft
should be replaced.
5. Burning of bearing shell and crankshaft journal.
TIPS
If the crankshaft is scratched in peripheral-radial direction (not axially), and the damage
length is within 2mm, the crankshaft can be reused after being polished.
For most engine models, there are 205 bearing and bearing sleeve installed in crankshaft big-end
fitting hole, so please pay attention to this when replacing the crankshaft, do not neglect or misplace.
Refer to Fig. 3-29.
General rules for select-fit crankshaft bearing shells: When matching crankshaft bearing shells, the
color (or color mark) of selected bearing shell should be the same as that of crankshaft main journal,
i.e. red to red, blue to blue (or A to A, B to B). According to the A/B color mark on top of main
bearing cap, select red bearing shell for A mark and blue for B mark. As shown in Fig. 3-11 and Fig.
3-24.
For YC4110, YC4112 and YC6112 engine, because the oil seal seat is installed on engine block to
64
fit crankshaft rear oil seal, while for other engine models, the seat is installed on flywheel shell. So
the oil seal seat of YC4110, YC4112 and YC6112 engine can be installed at this point. Precautions:
(1) Rear oil seal seat gasket should be applied with sealant. Refer to Fig. 3-36. (2) Tighten the bolts
according to the order exposed in Fig. 3-37. (3) Clearance between oil seal seat bottom surface and
oil sump fitting surface should within 0~0.08mm to prevent oil leaking from oil sump gasket. (4)
Apply suitable engine oil on big end of crankshaft when assembling, place a pressing plate and
knock it into oil seal seat. As shown in Fig. 3-38.
Sealant application
Fig. 3-36 Sealant application position Fig. 3-37 Tightening order of oil seal seat bolts
Rear oil seal Pressing plate
Oil seal seat
Fig. 3-38 Installation of rear oil seal
65
34 Assembly of Piston Connecting Rod Assembly
341 Cleaning of Piston Connecting Rod Assembly
Clean the oil holes on connecting rod small end, wipe off the carbon deposit on piston ring grooves
and top of piston ring groove, clear away the dirt in engine oil holes connecting rod bolt holes.
Refer to Fig. 3-39 and Fig. 3-40.
Fig. 3-39 YC6L piston connecting rod assembly

1 Surface (when connecting rod bolt is loose, this surface will be polished) 2 Processing number
3 Oil hole 4 Oil groove 5 Installing direction mark of connecting rod (face forward)
6 For a few connecting rods, processing number is printed in 7
7 Weight (or weight difference) mark of connecting rod big and small ends
Fig. 3-40 Engine oil gallery in piston

1 Cylinder sleeve 2 Piston 3 Oil gallery 4 Piston hook back-off opening 5 Hook
66
342 Inspection of Piston Connecting Rod Assembly
1. Inspection of connecting rod

(1) Weight difference of connecting rod: allowed weight difference of connecting rod big end,
small end, total weight difference and allowed weight difference for the same engine are
listed in table 3-16. Refer to Fig. 3-39 for weight (or weight difference) mark of connecting
rod big and small ends, choose according to table 3-16 during maintenance.
Table 3-16 Allowed weight difference of connecting rod (g)
Engine model YC4108 YC4110 YC4112 YC6105 YC6108 YC6112 YC6L YC6M
Big end
10 10 10 16 16 16 16 16
allowance
Small end
8 8 8 12 12 12 12 12
allowance
Total allowance 15 15 15 20 20 20 20 20
Allowance for
23
the same engine
(2) Refer to table 3-17, Fig. 3-41 and Fig. 3-42 for measuring of connecting rod big end and
small end bore diameter (with shells), and specified value for each engine model
Fig. 3-41 Measuring of big end bore diameter Fig. 3-42 Measuring of small end bore diameter
Table 3-17 Specified value of connecting rod big and small end bore diameter (with shells) (mm)
YC6112, YC4108,
Engine model YC6105 YC6108 YC6L YC6M
YC4112 YC4110
Big end bore 74.706~ 75~ 75~ 71~ 85~
88~88.022
diameter 74.727 75.03 75.022 71.022 85.022
Small end bore 44.452~ 38.01~ 40.01~ 38.01 45.01 50.01
diameter 44.459 38.02 40.02 ~38.02 ~45.02 ~50.02
(3) Measuring of connecting rod distortion error and bending error: refer to Fig. 3-42 and Fig.
3-44.
67
Feeler gauge
Piston lock
Connecting
rod tester
Fig. 3-43 Measuring of connecting rod distortion error
Feeler gauge
Connecting rod tester
Piston pin
Fig. 3-44 Measuring of connecting rod bending error

Distortion error and bending error of connecting rod doesn’t need to be measured under normal
circumstance, unless the rod is being hit. Distortion error and bending error of connecting rod
should be less than 0.05mm/100mm, while the limit is 0.15mm.
2. Inspection of piston
(1) Piston skirt dimension: Refer to table 3-18 and Fig. 3-45.
Feeler gauge
Fig. 3-45 Measuring of piston skirt dimension

68
Table 3-18 Specified piston skirt dimension for each engine model (mm)
YC6112 YC6108
YC4112 YC4108
Diameter of
Φ111.634~
piston skirt Φ104.86±0.01 Φ107.87±0.01Φ109.86±0.01Φ112.88±0.07 Φ119±0.01
Φ111.672
biggest circle
Wear limit No more than 0.12mm
(2) Specified values for diameter of piston pin and piston pin hole are listed in table 3-19.
Refer to Fig. 3-46 and Fig. 3-47 for measuring methods.
Table 3-19 Specified values for diameter of piston pin and piston pin hole (mm)
YC6112 YC6105 YC4108
Engine model YC6L YC6M
YC4112 YC6108 YC4110
Pin hole
Φ44.455~44.461
diameter
Pin diameter Φ44.437~44.442
Hole diameter
<0.05
limit
Pin diameter
<0.04
limit
Fig. 3-46 Measuring of piston pin hole diameter Fig. 3-47 Measuring of piston pin diameter
3. Inspection of piston ring should be performed in the process of assembling of piston connecting
rod assembly.
343 Assembly of Piston Connecting Rod Assembly
1. Assembling requirements for piston connecting rod and piston rings:

Different engine model has different piston structure, also the incision on connecting rod big
end has flat-type structure and oblique-type structure. Section form of piston ring also varies,
but a uniform requirement must be met when assembling the assembly. Refer to Fig. 3-48 and
Fig. 3-49.
69
View B View A
Fig. 3-48 Piston connecting rod assembly

1 Mark on top of piston 2 Connecting rod journal 3 Direction of motion
4 Connecting rod number 5 Locating lip and locating groove are on the same side
6 When connecting rod bolt is loose, this surface will be polished
7 Do not interchange or substitute connecting rod bolts
8 Connecting rod cap number (in the same position as connecting rod number)
9 Direction of motion 10 Connecting rod journal
11 This side face has “O” mark (face forward)
12 Hook back-off opening should be on the same side as hook
13 Swirl chamber (no eccentricity for YC6L engine) should be aligned to fuel injectors, view A and
View B show the moving direction of connecting rod journal when the piston is in BDC
ATTENTION
1. If the incision on connecting rod big end has flat-type structure, no facing forward or
facing backward problem needs to be addressed (YC4110 engine).
2. View B in Fig. 3-48 is suitable for assembling of YC6112 and YC4112 engine
connecting rod with oblique-type incisions. While view A is suitable for other engines.
70
Piston ring
No.
Second piston Third piston
First piston ring Comment
ring ring
EngineRing type
model
Double-side Cushion spring The first piston
trapezoidal ring Taper-face ring oil ring ring is
YC6108ZQ,
chrome-plated,
YC6112, YC4112,
the second
YC6105ZLQ
piston ring is
phosphatized
Ditto Ditto Ditto
YC6108ZLQB,
Inner chamfer upwards
YC4108, YC6L Ditto Ditto
Ditto Ditto
TOP upwards
YC4110
Ditto Ditto
Pin hole
Pin hole
Opening of cushion spring

Suitable for YC6113 Engine
Suitable for YC4112 Engine
Pin hole

Suitable for YC6108,
YC6105 and YC4108 Engine
Fig. 3-49 Installation of piston rings
ATTENTION
1, 2, 3 in the figure above represent piston ring openings.
When installing piston ring, you must measure the fitting clearance between piston ring and
cylinder sleeve, piston ring and piston ring groove respectively. Measuring method: press the piston
71
ring into cylinder sleeve (the cylinder must in TDC position), as shown in Fig. 3-50. Measure the
opening clearance with feeler gauge, the measured value must meet the requirements listed in table
3-20. Measure the axial clearance between piston ring and piston ring groove, as shown in Fig. 3-51,
the measured value must meet the requirements listed in table 3-20.
Fig. 3-50 Measuring of piston ring opening clearance Fig. 3-51 Measuring of piston ring axial clearance
Table 3-20 Specified value for piston ring opening clearance and axial clearance (mm)
Third piston
First piston ring Second piston ring Piston ring opening
Engine model ring axial
axial clearance axial clearance clearance
clearance
YC6112,
0.12~0.175 0.105~0.155 0.05~0.1 0.35~0.65
YC4112
YC6108 0.065~0.135 0.09~0.125 0.03~0.065
First piston ring 0.4~0.6
YC4108 0.09~0.125 Second piston ring 0.35~0.55
0.085~0.135 0.032~0.065 Third piston ring 0.3~0.55
YC4110 0.05~0.085
YC6105 0.09~0.13 0.07~0.11 0.04~0.08 Second piston ring 0.5~0.7
Third piston ring 0.32~0.55
YC6L 0.108~0.172 0.06~0.11 0.03~0.08 Second piston ring 0.60~0.85
YC6M 0.109~0.180 0.075~0.115 0.05~0.09 Second piston ring 0.60~0.8
ATTENTION
Piston ring opening clearance limit for each engine model is 2mm, and that of piston ring
axial clearance is 0.2mm.
2. Assemble piston connecting rod assembly into engine block.
After assembled piston, connecting rod, piston rings and connecting rod bearing shells, install
the assembly into engine block according the method exposed in Fig. 3-52. Requirements:
72
(1) Connecting rod bearing shells should be applied with clean engine oil.
(2) Put the assembly into cylinder sleeve according to the “face forward” mark on piston top
surface or connecting rod body. If the mark cannot be read, refer to Fig. 3-48 view A or
view B for assembling, ensure swirl chamber in piston is aligned to injectors.
(3) Tighten connecting rod bolts to specified torque listed in table 3-21, ensure rotation of
crankshaft is flexible, and connecting rod journal can move axially for more than 1mm, and
ensure the rod can be stirred easily and flexibly.
Fig. 3-52 Installation of piston connecting rod assembly
ATTENTION
In the process of assembling, you must support the big end of connecting rod with special
tool or clean board to prevent bumping cylinder sleeve and connecting rod journal.
Table 3-21 Specified tightening torque of connecting rod bolts for each engine model (Nm)
YC6112 YC6108
YC4112 YC4108
Step 1 50~80 50~70 60~80 60~90 60~80
Tightening
Step 2 100~130 100~120 110~130 100~120 120~150 110~140
torque
Step 3 160~190 190~270 180~200 150~230 180~220 160~200
3. Measure piston protrusion (to engine block upper surface) and adjust TDC scale of cylinder 1.
As shown in Fig. 3-53.
Pulley damper assembly
TDC scale
Fig. 3-53 Adjust TDC scale of cylinder 1
73
Rotate the engine until piston of cylinder 1 reaches TDC, measure the piston protrusion (to
engine block upper surface) of each cylinder with dial gauge, which should be 0.15~0.45mm,
piston protrusion difference between two cylinders should be less than 0.15mm. If the
measured values have big difference, then volume of combustion chamber will be affected,
even leading to piston bumping problem.
TIPS
When only some connecting rods need to be replaced, you can select-fit according to table
3-17.
344 Common Faults of Piston Connecting Rod Assembly
1. Connecting rod.
(1) Breakage of connecting rod bolts: connecting rod bolts are special purpose parts, you
mustn’t replace them with bolts made of other materials. For bolts that have been blued by
bearing shell burning or have been tightened and loosened 3 times should be replaced.
Breakage of connecting rod bolts is mainly caused by insufficient tightening torque, which
made the bolts subject to severe impact repeatedly. At this point, the contact surfaces
between bolt head and connecting rod cap are usually brightened and smoothed because of
abrasion. Refer to Fig. 3-39. If the connecting rod bolts are burnt blue due to high
temperature, then the bolts are deteriorated.
(2) After replacing piston pin sleeve (note that oil hole on the sleeve should be aligned to the
engine oil gathering hole on connecting rod small end), if fitting clearance between pin and
pin hole is too small, you can grind the sleeve or ream/ broach the pin hole to meet the
requirements. When reaming, it is better to fix the connecting rod on vertical drill or
vertical boring machine and correct perpendicularity of the sleeve hole. Otherwise,
parallelism between center line of connecting rod big end hole and that of sleeve hole will
be out of tolerance.
(3) The connecting rod mustn’t be reused if either of the following situation occurs:
connecting rod body turned blue due to piston pin burning or bearing shell burning,
connecting rod big end hole is seriously worn due to rotating of bearing shells.
(4) Connecting rod bearing shell burning.
TIPS
Connecting rod bearing shell burning is mainly caused by poor machining that leading to
undersized fitting clearance, as shown in Fig. 3-54. When machining the shell, the section
marked with 0.3 and 15 in Fig. 3-54 needs to be removed, which means middle part of the
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shell is thinner than two ends. Test to check whether the shell is qualified: install and
tighten the shell to specified torque, sprinkle some read lead on inner surface of the shell
and then rotate the crankshaft for a few circles. Disassemble and check the shell: the
section marked with 0.3 and 15 in Fig. 3-54 should be free of abrasion, while the
processed section near the locating lip should be subject to abrasion. Otherwise, the
fitting clearance is too small.
Solution: Polish with 180-mesh waterproof abrasive paper.
2. Piston
(1) Scratch on piston skirt: mainly caused by poor lubrication and poor engine oil cooling
effect (low engine oil pressure or blockage of hook oil hole, turbocharger-free engine isn’t
equipped with this device), which result in engine overheating.
Cylinder-scuffing, burn or fracture of piston upper part (above piston ring), causes: bad
atomization of fuel injector, even dripping diesel oil (Blockage of fuel injector, low fuel
opening pressure), oversized fuel feeding angle, long-time overload low-speed
high-temperature running, too much carbon deposit, poor heat dissipation, etc.
(2) Piston ring jamming: mainly caused by undersized axial clearance between piston ring and
piston ring groove, poor machining of piston ring groove, severe gas carry-over and carbon
deposit problem around the piston.
3. Piston ring
(1) Premature wear of piston ring will result in gas carry-over problem in the cylinder (at this
point, exhaust gas pressure in engine block increases and some exhaust gas infiltrates into
the breather) and engine oil bursting into combustion chamber burning problem (blue
exhaust gas, engine oil consumption increased markedly), the main causes are: dirty intake
air, long-time overload running or long-time low-speed running. Sometimes this problem
will also occur if the piston ring or cylinder sleeve is just replaced, this is because the new
piston ring or cylinder sleeve hasn’t been properly run in, and things will get better after
working for a while.
(2) Breakage of piston ring, primary cause: the piston ring gets stuck and couldn’t rotate any
more, at this point, engine oil consumption problem is even severe, working condition of
this cylinder getting worse until the ring gets sintered and broken.
75
35 Assembly of Engine Oil Pump
351 Cleaning of Engine Oil Pump
1. If the engine oil pump needs to replaced, you should pour clean diesel oil into the new pump
and clean it for a few times, and then pour clean engine oil into the pump to perform the last
cleaning (rotate the rotor in this process).
2. For an old engine oil pump, in addition to clean with diesel oil, all parts must be disassembled
and rinsed if necessary.
ATTENTION
When disassembling engine oil pump pressure-limiting valve, pay attention to mark the
original position of the adjusting plug, for the convenience of assembling.
352 Inspection of Engine Oil Pump
YUCHAI products apply two kinds of engine oil pump, namely rotor pump (suitable for YC6112,
YC4112, YC4110, YC6105, YC4108 and YC6M engine) and gear pump (suitable for YC6108ZQB
and YC6L engine). As shown in Fig. 3-55 and Fig. 3-56.
Fig. 3-55 Structure chart of YC4110 engine oil pump assembly

1 Engine oil pump shaft sleeve (II) 2 Engine oil pump cover 3 Outer rotor
4 Engine oil pump spindle 5 Pump body 6 Safety valve
7 Bolt 8 Safety valve spring 9 Safety valve screw 10 Bolt
11 Engine oil pump driven gear 12 Engine oil pump shaft sleeve (I) 13 Inner rotor
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Fig. 3-56 Structure chart of YC6L engine oil pump assembly

1 Gasket 2 Engine oil pump pressure-limiting valve plug 3 Pressure-limiting valve spring
4 Engine oil pump drive gear 5 Engine oil pump drive gear shaft 6 Engine oil pump cover
7 Engine oil pump idle gear 8 Engine oil pump gear 9 Engine oil pump driven gear
10 Engine oil pump idler shaft 11 Locating sleeve
Main inspection items of engine oil pump:
1. Meshing clearance between inner rotor and outer rotor (or gears), refer for to Fig. 3-57 and Fig.
3-58.
Fig. 3-57 Measuring of meshing clearance between inner rotor and outer rotor
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Reference value 0.025~0.15
Fig. 3-58 Measuring of meshing clearance between gear pump drive gear and driven gear
2. Clearance between rotor and pump shell end face, refer to Fig. 3-59.
3. Fitting clearance between rotor and pump shell, refer to Fig. 3-60.
Wear limit of the three above-mentioned clearances should be no more than 0.08mm.
Fig. 3-59 Measuring of clearance between rotor and pump shell end face
Fig. 3-60 Measuring of fitting clearance between rotor and pump shell
78
353 Assembly of Engine Oil Pump
Engine oil pumps of different engine models are not interchangeable. For YC4112, YC4110 and
YC4108 engine, engine oil pump is installed on front end of engine block; for YC6M engine, the
pump is installed on front end of engine block, but driven by crankshaft small end, meshing
clearance of these engines is guaranteed by machining precision of engine block. For YC6112,
YC6105, YC6108 and YC6L engine, the pump is installed on the first main bearing cap or lower
surface of engine block, the meshing clearance can be adjusted via the gaskets of engine oil sump
fastening bolts. As shown in Fig. 3-61.
Meshing clearance Adjusting gasket

0.045~0.065
Meshing clearance
0.07~0.3
Fig. 3-61 Meshing clearance adjusting of YC6105 engine oil pump
354 Common Faults of Engine Oil Pump
1. Premature wear of rotor or drive gear and driven gear. Inner and outer rotors (or gears), engine
oil pump end cover and shaft sleeve tend to wear prematurely, which will result in engine oil
leakage problem and reduce oil pressure. Premature wear is mainly caused by inferior engine
oil or unclean engine oil, or engine oil filter failure.
2. Engine oil leakage caused by loose pump end cover shaft sleeve. This fault is mainly caused by
loose fitting between shaft sleeve and the sleeve fitting hole (on pump end cover) or undersized
fitting clearance between pump shaft and shaft sleeve, the sleeve gets stuck and rotates along
with the shaft.
3. Engine oil pump body is installed with engine oil pressure safety valve (except YC6105 engine
oil pump), you don’t need to adjust this valve under normal circumstance. If you suspect that
the pump is in failure after all other oil circuits are confirmed in good condition, you can try to
adjust the valve opening pressure, as shown in Fig. 3-55, screw-in the adjusting screw 9 to raise
79
engine oil pressure.

4. Engine oil pump oil inlet joint flange gasket 1 should be flat and free of wrinkle, as shown in
Fig. 3-56.
355 Assembly of Engine Oil Cooler
Plate-fin engine oil cooler is applied by YUCHAI products, the inner core plate 6 is engine oil
circulating cooling passage. A by-pass valve is installed on the cooler, its opening pressure is
0.55MPa. The chamber between core plate 6 and cooler housing is filled with circulating water
from water tank to reduce engine oil temperature. As shown in Fig. 3-62.
Fig. 3-62 YC6112 engine oil cooler

1 Cooler cap 2 Gasket (III) 3 Bolt M10×35 4 Gasket (I) 5 Gasket (II)
6 Core plate 7 Oil outlet joint 8 Cooler housing 10 By-pass valve spring
11 By-pass valve plug 12 By-pass valve ball
1. Cleaning: Focus on the oil passage in core plate 6. Fill the passage with diesel oil and waggle
around for a few times, disassemble the by-pass valve and clean the valve spring and inner hole.
Record the number of screw-out turns when disassembling the valve, be sure to screw-in the
same turns when assembling to avoid changing the valve opening pressure.
2. Inspection: If engine oil is found in the water during normal use, pay attention to check whether
the core plate is loose-welded. The method is: block the oil outlet port of core plate, put the
core plate into water and inflate the plate with 0.3MPa air from the oil inlet port to check for air
leakage.
3. Installation: Engine oil cooler is long component, note that the sealing gasket cannot be
distorted when assembling, take two steps to fasten the bolts from middle to two ends orderly.
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4. Common fault of engine oil cooler is oil leakage problem of the core plate, and there will oil in
water under this circumstance, the fault is caused by loose-weld or fake-weld core plate copper
pipe joint. Another fault is housing crack or sealing gasket damage.
ATTENTION
In cold days, be sure to discharge all water in the cooler to avoid frost cracking.
81
36 Assembly of Gear Housing Cover Plate, Camshaft, Idler Shaft

and Gearing Housing
361 Assembly of Gearing Housing Cover Plate
Gear housing cover plate steel-plate part, two pins are used to locate it on engine block, and
fastened on engine block with M8 bolts. When assembling, apply 515 plane sealant on cover plate
and fasten the bolts crosswise.
362 Assembly of Camshaft and Camshaft Gear
1. Cleaning of camshaft
Structure and installation method of camshafts applied by YUCHAI products are basically the
same. Here we take YC6112 for example, refer to Fig. 2-48. When cleaning the camshaft, focus
on oil dirt on camshaft and deposit sediment in the oil holes. For camshaft of YC6105 and
YC6108 engine, the oil holes are processed on the third-cylinder and sixth-cylinder position
(used to feed oil to rocker arm); for camshaft of YC4108 engine, the oil holes are processed on
the second-cylinder and fourth-cylinder position, for camshaft of YC4110, YC4112, YC6112
and YC6L engine, only one oil hole is processed on the first-cylinder position; YC6M camshaft
is free of oil hole.
2. Inspection: check camshaft journal and cam appearance, which should be free of burn damage
and scratch, the key groove should be intact.
(1) Check camshaft journal diameter, specified camshaft journal diameter for each engine
model is listed in table 3-22. Refer to Fig. 3-63 for measuring method.
Fig. 3-63 Measuring of camshaft journal diameter
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Table 3-22 Specified camshaft journal diameter for each engine model (mm)
YC6112 YC6105
YC4112 YC6108
Camshaft
journal Φ60.642~60.688
diameter
(2) Check camshaft straightness: refer to Fig. 3-64. The straightness error should be no more
than 0.05mm.
Fig. 3-64 Measuring of camshaft straightness

3. Installation of camshaft
For the convenience of measuring camshaft axial clearance, generally before installing the
camshaft, you should install camshaft timing gear first (refer to Fig. 2-48). Note that fitting
clearance between the woodruff key and key groove should not be too big, and fasten camshaft
timing gear compression bolt (bolts). Apply engine oil on camshaft journal, hold the camshaft
and timing gear with two hands and turn camshaft left and right, push the gear to the right
position, the camshaft should be flexible and properly fit. Tighten camshaft timing gear bolts
and camshaft thrust pad bolts. Measure camshaft axial clearance according the method exposed
in Fig. 3-65. And the measured value should meet the requirements in table 3-23.
Axial clearance
Fig. 3-65 Measuring of camshaft axial clearance
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Table 3-23 Specified camshaft axial clearance for each engine model (mm)
Engine YC6112 YC6108
YC6105 YC4108 YC4110 YC6M
model YC4112 YC6L
Axial
0.104~0.22 0.16~0.26 0.08~0.20 0.10~0.20 0.05~0.22 0.06~0.22
clearance
Limit 0.4
4. Common faults of camshaft

Camshaft is a durable part, whose service life is more than 500 thousand kilometers. A few
may have problem like burnt by bearing shell. Main causes are: undersized fitting clearance
between camshaft and bearing shell or a certain bearing shell is severely worn, severe leakage
problem occur and leading to lack of oil of camshaft sleeve.
Besides, excessive clearance between camshaft key and key groove will bring severe impact
during working, which can affect engine valve timing.
363 Assembly of Idler Shaft and Timing Gear
1. Installation of idler shaft

(1) Clean idler shaft: idler shafts adopted by YUCHAI products are illustrated in Fig. 3-66.
Each idler shaft is designed with oil holes and passages to lubricate idler shaft sleeve, make
sure these points are unobstructed and clean.
Suitable for YC6108ZLQB, YC6105ZLQ, Suitable for YC6112, YC4112 and

YC4108ZLQ and YC6L engine YC410 engine
Anti-wear plate
This oil hole should be aligned to oil
hole on engine block when assembling Oil outlet port
Oil outlet port
Bolt * 3
The bigger chamfer
should face engine block
Figure A Figure B
84
Suitable for YC6108ZQ and YC6105QC engine Suitable for YC6M engine
Oil outlet port Oil outlet port
Oil inlet port
This oil hole should be aligned to oil

hole on engine block when assembling
Oil outlet port
Figure C Figure D
Fig. 3-66 Structure diagram of idler shaft
(2) Inspection: measure idler shaft diameter and idler shaft sleeve fitting hole diameter, which
should meet the requirements listed in table 3-24, each gear tooth face should be free of
bumping damage and severe abrasion.
Table 3-24 Specified idler shaft sleeve fitting hole diameter and idler shaft diameter (mm)
Engine Idler shaft sleeve fitting hole
Fitting clearance Clearance limit
model diameter/Idler shaft diameter
YC6112 Φ50.813~50.838/Φ50.757~50.770 0.043~0.081 0.2
YC4112,
Φ50.775~50.8138/Φ50.757~50.770 0.05~0.056
YC4110
YC6105 / 0.025~0.075 0.12
YC6108
YC6L / 0.03~0.09
YC4108
YC6M / 0.043~0.081
2. Installation of idler shaft and timing gear

In Fig. 3-66, the idler shaft in Figure C can be assembled independently, while the other idler
shafts must be assembled together with idle gear. Here we take YC6112 engine for example, as
shown Fig. 3-67.
85
Fuel injection pump gear

Timing mark Camshaft timing gear
Steering pump gear
Camshaft intermediate gear

(idle gear)
Crankshaft timing gear
Engine oil pump

intermediate gear
Engine oil pump gear
Fig. 3-67 YC6112 engine gear transmission
ATTENTION
Idler shaft is fixed on engine block with bolts, when assembling idle gear and injection
timing gear, pay attention to the following items:
(1) Crankshaft timing gear, idle gear, camshaft gear and fuel injection pump gear
(except for YC6L fuel injection pump timing gear) are printed with timing mark,
these marks should be aligned accordingly when assembling.
(2) In Fig. 3-66, idler shaft in Figure A is processed with oil inlet hole, this hole should be
aligned to the related oil hole on engine block when assembling.
(3) In Fig. 3-66, the anti-wear plate in Figure B should be installed first before
assembling the idler shaft, the side with bigger chamfer should face engine block.
(4) For Figure A and Figure C in Fig. 3-66, the idler shaft fastening bolt end is installed
with baffle plate and locking plate, while the idler shaft in Figure D only installed
with baffle plate, and the idler shaft in Figure B takes the shoulder as baffle plate.
Install the idle gear on idler shaft and tighten the fastening bolt to specified torque,
check the axial clearance between baffle plate and idle gear front end, which should
be 0.05~0.38mm. As shown in Fig. 3-68.
86
Idle gear
Anti-wear plate
Support
Tighten the bolt to

203~224Nm
Cylinder block
0.05~0.38mm
Fig. 3-68 Idler shaft axial clearance

3. Common faults of idler shaft and idle gear
(1) Premature wear of idle gear copper sleeve. The main cause is bad lubrication.
(2) Idler shaft fastening bolt gets loose, which makes the idle gear swing severely and gear
housing produce abnormal noise.
364 Assembly of Gear Housing
ATTENTION
Gear housing is thin-wall iron casted part, fitting area is large, so pay attention to the
following items when assembling:
(1) Gear housing sealing gasket should be free of distortion and damage, apply sealant on
the gasket when assembling.
(2) When assembling crankshaft front oil seal, be sure to fit the seal properly and apply
engine oil on the oil seal inner bore.
(3) Take two steps to tighten gear housing fastening bolts crosswise and evenly.
87
37 Assembly of Air Compressor

The air compressor adopted by YUCHAI product varies in engine model, some are wind-cooled,
and the others are water-cooled. But their installation methods are generally the same, all fastened
on gear housing with three or four bolts.
Air compressor intake and exhaust structure is illustrated in Fig. 3-69 and Fig. 3-70.
Fig. 3-69 Helical-spring type air compressor intake principle diagram

1 Valve plate 2 Guide holder 3 Valve seat 4 Exhaust connecting nut 5 Cylinder cover
Exhaust
Air exhaust
Intake
Valve seat board valve plate

Air intake
valve plate
Piston
Fig. 3-70 Leaf-spring type air compressor working principle diagram

Structure and working principle of the two air compresses in Fig. 3-69 and Fig. 3-70 are similar
except the intake valve plate, exhaust valve plate and valve seat, thus installation and maintenance
method are basically the same.
88
371 Cleaning of Air Compressor
Clean the intake and exhaust valve plates, valve seat and piston ring, wipe off the carbon deposit on
piston ring. These structures are critical for normal operating of air compressor and demand
absolute cleanness.
372 Inspection of Air Compressor
Check whether the air compressor intake and exhaust valves are normal. Checking method:
1. When the air compressor is not working, blow air into the intake pipe on cylinder cover by
mouth, the air intake valve is normal if the intake valve plate can open; conversely, absorb air
from the intake pipe on cylinder cover by mouth, the air intake valve is normal if no air can be
absorbed (intake valve plate cannot open). Checking method for exhaust valve is similar, the air
exhaust valve is normal if air cannot be blown into exhaust pipe but can be absorbed from the
pipe.
For the air compressor in Fig. 3-69, poke the intake valve plate with iron wire, stroke of the
valve plate controlled by spring should be 1~1.5mm, otherwise, there must be too much carbon
deposit or foreign matters on the valve plate.
2. When the air compressor is working, block the air intake port by hand and you should feel
being absorbed other than pushed, otherwise the intake valve plate is not fully closed. For a
normal compressor, the air pressure should reach 0.7MPa or above after about 5min
intermediate-speed working. If fail to reach this pressure in 10min, then the compressor is in
failure.
3. Fitting clearance between woodruff key and key groove on air compressor shaft should not be
too big, otherwise, the key groove can be easily damaged and cause incorrect fuel supply
advance angle.
373 Installation of Air Compressor
Air compressor of different engine model is installed on different position, connection type between
air compressor gear and intermediate idle gear is different too. For YC6105 and YC4110 engine, air
compressor gear is directly connected with intermediate idle gear; for YC4112, YC6108ZLQ,
YC6112 and YC6L engine, air compressor intermediate gear is connected with camshaft gear and
intermediate idle gear; for YC6M engine, air compressor gear is connected with intermediate gear
via camshaft gear.
ATTENTION
(1) When assembling air compressor, ensure meshing clearance between each gear pair
89
is within 0.07~0.25mm, check and adjust the meshing clearance before fully
tightening air compressor fastening bolts.
(2) For engine for fuel injection pump is installed on rear end of air compressor (such as
YC6105ZLQ), ensure air compressor gear and intermediate idle gear are properly
engaged when assembling.
(3) When assembling YC4108 air compressor, note that the fastening bolt near engine
block is fine tooth thread bolt, do not make mistake.
374 Common Faults of Air Compressor
1. Premature wear of air compressor piston ring. Service life of a new air compressor piston ring
is generally more than 100 thousand kilometers under normal working condition. If the
compressor is hard to compress air in 55 thousand kilometers or under, then it can be
considered that air compressor piston ring is prematurely worn. The main cause is unclean
intake air. Firstly, as an air filter is designed to filter the intake air, improper maintenance of the
filter or air leakage problem in intake pipe joint will cause this fault; secondly, poor lubricating
of air compressor can accelerate the wear process; thirdly, frequently long-time working of air
compressor together with high engine oil temperature can easily cause premature wear.
2. Too much carbon deposit on intake and exhaust valve plates and valve seat will cause the valve
plate unable to close fully. In this case, air compressor cannot work normally and required
compression pressure cannot be attained. The main causes are: firstly, unclean air intake by air
compressor; secondly, sealing performance between piston ring and cylinder bore is poor, too
high air pressure in crankcase (especially when cylinder sleeve and piston ring are severely
worn) or intake blockage of air pump can easily lead to bursting up, combustion of engine oil
can produce carbon deposit, which can block air hole and make the valve plate unable to close
fully. In addition, intake and exhaust valve plate of non-supercharger air compressor applies
spring-return mode, if the spring gets soft or inflexible , the valve plate cannot be closed fully
either, which will cause air leakage.
3. Burning of bearing shell: Lubricating oil for air compressor comes from engine, so if the engine
oil is inferior, engine oil pressure is abnormal or engine oil gallery is blocked by deposit
sediment, lubricating oil to air compressor will be insufficient, and these are main causes for
burning of air compressor bearing shell. Besides the caused mentioned above, poor circulating
of cooling water is another cause (for supercharger).
4. Oil leaking from air compressor rear end. The main cause is ageing failure of air compressor
crankshaft rear oil seal (Loose air compressor bearing can easily bring oil leakage problem).
90
When installing a new air compressor, it’s better to apply suitable engine oil on oil seals.
5. Engine oil bursts into air compressor exhaust port. The main cause is oversized fitting clearance
between air compressor piston ring and cylinder bore or broken piston ring, and blockage of
intake, which will cause too much engine oil in air compress and crankcase, and easily result in
to engine oil bursting.
ATTENTION
If the air compressor bearing (on fuel injection pump side) tends to be damaged easily,
please pay attention to check whether coaxiality of air compressor and fuel injection
pump meets the requirements, refer to Fig. 3-74.
91
38 Assembly of Fuel Injection Pump

Fuel injection pump is a key component for engine performance, and special requirements are
involved when installing, using, maintaining and troubleshooting it.
For YC6112 and YC4112 engine, multiple models of fuel injection pump governor is applied,
YC4110 and YC4108 engine apply mechanical maximum-minimum speed governor, and the other
engine models adopt RQV-K governor.
381 Cleaning of Fuel Injection Pump
Lubrication of fuel injection pump is divided into independent lubrication and forced lubrication.
For independent lubrication, it is required to add engine oil into fuel injection pump governor and
fuel injection pump body periodically; for forced lubrication, an engine oil pipe that connected to
engine block main oil gallery is used to lubricate fuel injection pump, because the oil source is
engine oil sump, the clearness of engine oil is hardly assured. Thus, before installing the fuel
injection pump you should remove the dust and foreign matters on the pump, and more importantly,
you should clean with diesel oil (fill from the engine oil inlet port) to remove the deposit sediment
in the pump. Besides, a strainer is installed in oil inlet port of fuel delivery pump, and should be
removed and cleaned at the same time.
382 Inspection of Fuel Injection Pump
Before assembling the pump, you should check whether the fuel-increase handle and fuel cut-off
handle are flexible, check whether there is dirt on fuel delivery joint and clean it. Fuel injection
pump of YC6108ZLQB and YC6L engine is designed with timer, when installing the pump, you
must make sure the pump is in state of feeding fuel to cylinder 1 (cylinder 1 in TDC), as shown in
Fig. 3-71.
Disassemble
U-shape gasket
Injection
pump shaft Timing indicator pin Timer
Assemble
Shaft-locking
bolt
Pump housing
Fig. 3-71 Fuel injection pump timer Fig. 3-72 VE pump U-shape gasket
92
A shaft-locking bolt is installed on left side of VE pump body cold start accelerating advance unit,
pressed by a U-shape gasket, as shown in Fig. 3-72. When a new pump is delivered, the pump is
adjusted to cylinder-1 fuel-feeding position and no U-shape gasket is needed, pump shaft is pressed
by the shaft-locking bolt directly (at this point, please don’t rotate the pump shaft, otherwise the
pump can be damaged).
383 Installation of Fuel Injection Pump
1. For YC6105ZLQ engine, no matter it is equipped with P pump or VE pump, the pump is
directly connected with air compressor shaft with connecting plate and two bolts. Firstly you
should tighten the pump bracket fastening bolts, and then tightening the connecting bolts
between the pump and air compressor. ATTENTION: you must ensure the pump is adjusted to
cylinder-1 fuel-feeding position in this process. As shown in Fig. 3-71 and Fig. 3-73.
Coaxiality error between fuel injection pump shaft and air compressor shaft should be no more
than 0.4mm. Checking method: keep the dial gauge outfit straightly against the excircle plane
of advance unit, rotate the advance unit for one full circle and record the gauge maximum
reading difference at this same time, and this is coaxiality error. If no dial gauge is available,
refer to the method exposed in Fig. 3-74 to do the measuring. Rotate the crankshaft for one full
circle, measure the clearance between the measuring screw and advance unit when the
measuring screw is in the highest position and lowest position, the clearance should be no more
than 0.4mm.
When these two marks
Shaft-locking mark Woodruff key are aligned, cylinder 1
is being feeded
Air Fuel
compressor injection
pump
Driving shaft
Fig. 3-74 Measuring of coaxiality error between
injection pump shaft and air compressor shaft
1 Connecting bolt 2 Bracket 3 Measuring screw
Fig. 3-73 73YC4110VE pump is adjusted 4 Advance unit 5 Pump support
to cylinder-1 fuel-feeding position 6 Support screw 7 Pump fastening bolt
If the coaxiality error is too big, you can add suitable gasket on pump support or rotate the
pump body to adjust.
93
2. For YC6108ZLQB and YC6L engine, fuel injection pump transmission shaft 4 is connected
with fuel injection pump 3, so when installing the pump, you should install the transmission
shaft on gear housing firstly, and install pump support 14 on engine block, as shown in Fig.
3-75. And then place the pump on pump support, insert the pump external spline 17 into
transmission shaft, press the driving sleeve in position and tighten bolt 9, and then tighten the
fastening bolt 8 between fuel injection pump and the driving sleeve, tightening the fastening
bolt 13 between fuel injection pump and pump support.
Coaxiality between transmission shaft and fuel injection pump is critical for this kind of
connection: As long as the external spline can fit flexibly when the adjusting screw plug 6 is
not tightened, coaxiality between transmission shaft and fuel injection pump is basically
conformed with the request. If the external spline cannot fit-in flexibly, you can wiggle the
driving sleeve 7 inward or outward by using the adjusting screw plug 6, or add suitable copper
gasket on pump support to solve the problem.
Fig. 3-75 YC6L fuel injection pump assembly

1 Fuel injection pump timing gear fastening bolt 2 Fuel injection pump
3 Fuel injection pump gear 4 Fuel injection pump transmission shaft
5 Connecting bolt between driving sleeve and gear housing cover plate 6 Adjusting screw plug
7 Fuel injection pump driving sleeve 8 Fuel injection pump connecting sleeve
9 Connecting bolt between driving sleeve and engine block 10 Supercharger compensating pipe
11 Throttle switch assembly 12 Fuel cut-off solenoid valve 13 Pump support bolt
14 Pump support 15 Fuel injection pump fuel pipe joint
16 Fuel injection pump terminal pad 17 Fuel injection pump external spline
3. For YC6M engine, the fuel injection pump and pump gear are connected by coupling. When
94
installing the pump, you should install the coupling on gear housing cover plate first, and then
install the pump timing gear, install the pump on pump support, and connect the pump and
coupling with key.
ATTENTION
When installing the pump, you must ensure the pump is adjusted to cylinder-1
fuel-feeding position. As shown in Fig. 3-71 and Fig. 3-83.
4. Installation of YC4112 and YC6112 engine fuel injection pump.
Fuel injection pump of these two engine models is connected with gear housing cover plate by
connecting plate, and fastened on pump support. Before tightening the pump fastening bolts,
you should insert the timing locating pin into the pin hole on fuel injection pump firstly, rotate
the pump shaft left and right until the pin is pressed into the timing plate, tightening the pump
fastening bolts and pull the timing locating pin out. At this point, the pump is adjusted to
cylinder-1 fuel-feeding position, as shown in Fig. 3-86.
5. Installation of YC4110 engine fuel injection pump.
Fuel injection pump of these two engine models is connected with gear housing cover plate by
connecting plate, and fastened on pump support. Advance unit is designed on this kind of fuel
injection pump and the pump timing gear is fastened on advance unit with four bolts 8, as
shown in Fig. 3-76. Ensure the pump is adjusted to cylinder-1 fuel-feeding position when
installing, as shown in Fig. 3-77.
Fig. 3-76 YC4108 fuel injection pump assembly

1 Component of advance unit 2 Injection pump timing gear
3 Injection pump fastening bolt 4 Connecting plate 5 Supercharger compensating pipe
6 Engine oil pipe 7 Bolt 8 Bolt
95
Pump body
Woodruff key
Fig. 3-77 YC4108 pump is adjusted to cylinder-1 fuel-feeding position
384 Common Faults of Fuel Injection Pump
1. Premature wear of plunger and plunger sleeve. Phenomena: the most common phenomenon is
diesel oil leakage problem in pump body. For A type fuel injection pump, bubble will come out
from plunger lower spring seat and a significant drop in power is produced when the pump is
working at low-middle speed. Fuel feeding quantity for each marked point is hard to be
adjusted equally. Causes: too much water content in the diesel oil, fuel filter is damaged or
cannot filter normally.
2. The plunger gets scratched or jammed. Phenomena: fuel feeding rate is reduced, engine speed
and power fall simultaneously. Causes: firstly, fitting clearance between plunger and plunger
sleeve is too small, overloaded engine plus high engine oil temperature can easily lead to
scratching and jamming of plunger; secondly, the fuel filter element is inferior or damaged and
the fuel is not properly filtered. Thirdly, delivery valve joint is overly tightened, which can
deform the plunger sleeve and jam the plunger.
3. Breakage of fuel delivery valve and fuel delivery valve spring. Phenomena: the faulty cylinder
doesn’t work or work poorly, engine power is reduced. Cause: the part has quality problem.
4. Insufficient fuel feeding rate of fuel delivery pump. Phenomena: the engine is hard to start or
engine speed is hard to increase. Causes: Firstly, filter screen in fuel delivery pump oil inlet
joint is blocked (needs to be cleaned), a new engine tends to have this kind of problem more
easily, please be sure to clean the filter frequently. Secondly, the check valve is deformed or
contains too much dirt (replace or clean). As shown in Fig. 3-78, simple method to check
whether the check valve can work normally: absorb air from fuel delivery pump oil inlet port
96
by mouth, oil inlet check valve is properly sealed if no air can be absorbed; blow air into fuel
delivery pump oil outlet pipe by mouth, oil outlet check valve is properly sealed if no air can be
blown in. Thirdly, fuel delivery pump piston is worn, piston spring gets weak or broken, which
can result in insufficient fuel feeding rate of delivery pump. Fourthly, the fuel delivery pump
has leakage problem. If diesel oil is found when replacing or filling engine oil into the pump
housing and the leaked diesel oil is not from plunger, then it must be caused by aging and
damaged seal ring of fuel delivery pump roller.
High pressure
Oil seal pump cam Roller Spring
Hand pump piston
Oil outlet port Pump body

Filter screen Oil inlet joint
Check valve
Oil inlet port

Oil inlet filter screen
Hand pump body Piston
Check valve seat
Fig. 3-78 Working principle diagram of fuel delivery pump

5. Rough idling of engine.
Phenomena: when engine is running at about 750r/min, the rotating speed is sometimes fast and
sometimes slow. Causes: Firstly, the preload force of governor idle spring is undersized.
Generally, you can adjust the idle adjusting screw on governor to solve this problem. But if you
want to deal with this problem thoroughly, you have to disassemble the pump to adjust.
Secondly, the pump plungers are unevenly worn, which results in fuel feeding quantity for each
cylinder is not equal when the engine is running at idle speed (little influence at high speed).
TIPS
(1) Sometimes rough idling occurs when retracting the accelerator pedal, and it seems
like the engine is about to flame out at this point. This problem is caused by
insufficient preload force of speed regulator stabilizing spring, increase the preload
force properly can solve this problem.
(2) For engine rough high-medium speed running problem, many causes (such as shape
and structure of plunger and fuel delivery valve , and governor) are involved.
97
6. Engine is difficult to start. If the failure is caused by fuel injection pump, then the pump must
fail to feed enough fuel for starting. Causes: the plungers are severely worn, severe leakage
happens when the engine speed is low or the pump is improperly adjusted. Cause for VE pump:
advance unit failure, which can affect fuel feeding timing and make the engine difficult to start.
7. Insufficient engine power. The so-called insufficient engine power is that the driver can feel the
vehicle is hard to speed up on level road (engine fails to reach specified speed) or the vehicle is
powerless uphill (engine fails to output specified torque). If the failure is caused by fuel
injection pump, then the pump high-speed application point must be improperly adjusted, the
pump prematurely reduces fuel feeding rate at high speed, which causes the engine fails to
reach specified speed. Handling method: Far better to readjust fuel delivery pump high-speed
application point (engine speed at fuel delivery pump high-speed application point is generally
about 1.01 times of the rated speed.). A technically skilled maintenance man is able to increase
the preload force of the speed governor high-speed spring to improve the pump high-speed
application point without affecting other working conditions, as shown in Fig. 3-79; or you can
adjust the full-load oil-volume adjusting screw (screw in for about 1/4 circle) on the governor
to improve engine speed by increasing fuel feeding rate.
Upper spring seat

High-speed spring Locknut
Inner idling spring
Outer idling spring
Fig. 3-79 Working principle of flyweight

Insufficient engine torque is embodied in poor short-time overload adaptability. If the engine
fails to output enough torque at high-medium speed and the problem is caused by fuel injection
pump, then the pump application point must be improperly adjusted (rotating speed and fuel
feeding rate). To solve the problem thoroughly, you must debug the pump and choose suitable
rotating speed and fuel feeding rate for the application point according to the specifications.
Refer to table 3-25 for adjusting parameters of some fuel injection pumps.
98
Fig. 3-25 Adjusting parameters of fuel injection pump

YC6108ZQ YC4110ZQ YC6112ZLQ
Engine model
(118kW/2600r/min) (100kW/2800r/min) (118kW/2600r/min)
Fuel injection pump BHT6PN110R092D
BHF4PW110010 Wuxi CB—BH6P120VAV39
model Hengyang
Rack travel (mm) 11
Rated fuel feeding rate
16.6 19.4±0.5/1400r/min 32.5~33/1150 r/min
(ml/200 times)
Torqueing fuel feeding
19.3 20.4±0.4/800r/min 33.8~34.5/750 r/min
rate (ml/200 times)
Idling fuel feeding rate
2.6 1.25/375 r/min 5.3~6.5/350 r/min
(ml/200 times)
≤1600 (fuel cut-off ≤1450 (high speed fuel
Max. idle speed (r/min) 1380~1480
speed) cut-off)
Starting fuel feeding
16~26/100r/min ＞20/150r/min ≥32/100r/min
rate (ml/200 times)
Method for RQV-K governor to improve output torque: Remove the boost compensator and
then loosen the fastening screw of full-load stop block, move the stop block towards pump
body to improve engine output torque (increase torqueing fuel feeding rate by increasing travel
distance of control handle). As shown in Fig. 3-80.
Fig. 3-80 RQV-K governor

If the engine fails to output enough torque at low-medium speed and the problem is caused by
fuel injection pump, then the boost compensator must be improperly adjusted. Adjust the thread
sleeve of boost compensator appropriately to reduce preload force of boost compensator spring
without affecting low-medium-speed smoke intensity, to increase fuel feeding rate at
99
low-medium speed. As shown in Fig. 3-81.
Vacuum line Membrane Spring
Non-Supercharged Fuel regulator

Full-load fuel-limiting adjusting nut Thread sleeve
Fig. 3-81 Boost compensator

8. Engine produces black smoke. For this problem, three situations are involved: firstly, black
smoke is produced only during starting or at low speed; secondly, black smoke is produced
regardless of engine speed; thirdly, black smoke is produced when accelerating. This problem
is influenced by many factors, in terms of fuel injection pump, the main cause is too high fuel
feeding rate.
(1) Black smoke is produced only during starting. The pump is improperly adjusted, too high
starting fuel feeding rate of smoke limiter (A type pump) or boost compensator. For VE
pump, fuel feeding angle that controlled by cold-start advance unit (KSB) is oversized.
(2) Black smoke is produced at low engine speed. The pump is improperly adjusted, too low
rotating speed at idle point and fuel feeding rate at this point is oversized.
(3) Black smoke is produced regardless of engine speed. The pump is improperly adjusted,
fuel feeding rate is too big. Besides, if the pump advance unit loses efficacy, the engine
will produce black smoke too.
(4) Black smoke is only produced when shifting and accelerating. This problem is caused by
mismatch between acceleration of fuel injection pump and changing of engine load, and is
related to whether the pump is designed reasonable or not. To solve this problem, you can
increase the preload force of boost compensator spring properly to reduce fuel feeding rate.
9. The pump fuel feeding mechanism is not flexible, which results in unstable working of engine,
and impact is involved when traveling. One of the causes is that the plunger is scratched and
jammed; the second reason is that idle spring or high-speed spring (used to control flyweight) is
broken or dislocated; the third reason is overly tightened fuel delivery valve joint, causing
inflexible rotating of plunger (VE pump is free of this phenomenon).
100
385 Installation of Fuel Injection Pump Timing Gear
Installation method of fuel injection pump timing gear for different engine model is different:
1. For YC6108ZLQB, YC6L and YC6M engine, the pump is connected with pump timing gear by
coupling. When installing the pump, you should install the coupling on gear housing cover
plate first, and then install the pump timing gear, install the pump on pump support, and
connect the pump and coupling with key. Make sure the pump is in cylinder-1 fuel-feeding
position. Method to adjust fuel injection pump feeding position: For YC6108ZLQB engine, the
mark on advance unit should be aligned to the pump body cylinder-1 fuel-feeding position, as
shown in Fig. 3-82. For YC6L engine, a timer is used for positioning. Rotate the pump
camshaft until the positioning block is aligned to the timer notch, and this is cylinder-1
fuel-feeding position, as shown in Fig. 3-71. For YC6M engine, when the mark on connecting
set is aligned to the mark on pump connecting plate, the pump is adjusted to cylinder-1
fuel-feeding position, as shown in Fig. 3-83. When the adjustment of cylinder-1 fuel-feeding
position is finished, do not rotate the pump shaft any further, and you should install the timing
gear on pump shaft and fasten the bolts at this point.
Align the Align the marks
Advance unit marks Pump body Pump gear Pump body
transmission shaft
Connecting set Pump connecting

plate
Fig. 3-82 Adjustment of YC6108ZLQB pump Fig. 3-83 Adjustment of YC6M pump
2. For YC6105ZLQ engine, air pump is connected with fuel injection pump shaft. When
assembling, you just need to install the injection pump timing gear and idle gear on air pump
shaft by aligning the timing marks, and then fasten the bolts.
3. For YC4110 and YC4108 engine, the pump timing gear is fastened on advance unit with bolts,
and the advance unit is connected with pump shaft by woodruff key. When assembling, you
should set the pump to cylinder-1 fuel-feeding position firstly, as shown in Fig. 3-84. And then
install the advance unit, as shown in Fig. 3-76.
101
Woodruff key
Locking mark
Driving shaft
Fig. 3-84 Cylinder-1 fuel-feeding position of YC4110 fuel injection pump
ATTENTION
When the locking mark is aligned to the mark on woodruff key, the pump is adjusted to
cylinder-1 fuel-feeding position.
4. For YC4112 and YC6112 engine, you should assemble the timing gear housing cover plate and
crankshaft damper first, and then install the pump timing gear.
102
39 Assembly of Damper
Different engine models apply different dampers, but they are all installed on small end of
crankshaft. Two kinds of dampers are adopted by YUCHAI products, namely rubber damper and
silicone oil damper. Some of YC6112, YC6108 and YC6105 engines apply silicone oil damper, as
shown in Fig. 3-85. Before the assembling, you should check damping rubber and the shell for
looseness, fitting clearance between key and key groove mustn’t be oversized, otherwise it may
damage the damper.
Rear damper
Front damper
Timing gear
housing cap
Crankshaft
Fastening Key
Base
plate
Hexagon bolt
Before assembling, you should
apply graphite-containing engine
oil on this surface
Radiator fin (casted in rear damper)
Fig. 3-85 YC6112 engine damper
TIPS
For some engine models, interference fit is adopted between damper and crankshaft small
end, and no key and key groove is needed, but assembled with special tools. The damper
may rotate if the interference value is undersized, valve timing may change under such
circumstance.
Use pulley disassembling tools to assemble the damper, never knock fiercely and blindly
to prevent damaging pulley and damper rubber.
Major failure of damper is fall-off of damper rubber, which is mainly caused by uneven
force on each pulley belt (installation position of A/C is not reasonable) and loose belt,
leading to excessive vibration of damper.
After the belts are assembled, align the TDC marks: rotate the crankshaft until piston of
cylinder 1 reaches compression TDC, check whether the TDC pointer on front end of
engine block is aligned to “0” mark on pulley, align them if not.
Steps to assemble YC4112, YC6112 fuel injection pump timing gear:
103
Fuel injection timing adjustment（YC4A105 stage Ⅱ）
4 3 1 2
1 Fuel injection pump connecting plate
2 Fuel injection pump
3 Fuel injection pump gear connection plate
4 Fuel pump gear
1.First, connect 1 fuel pump connection plate and 2 fuel injection pump
2.Install the assembly on the body and lock it
3.Install 3 injection pump gear connection plate on the pump shaft and lock with large nut
4.Turn the large nut to observe the first cylinder fuel injection port and turn it to the first cylinder
oil port to generate fuel. Then the crankshaft is reversed at a certain angle, slowly turning
forward, carefully observe the oil level at the oil pipe joint. When the oil surface starts to move,
stop rotating immediately and find the first cylinder fuel injection point.
5.Install 4 fuel injection pump gears, pay attention to the alignment of the marks, do not lock the
oil pump gears
6. Rotate the crankshaft counterclockwise 15° and use the pressure plate to lock the 4 gears
and the 3 fuel injection pump gear connection plate to complete the fuel injection pump
installation.
Step 1: Rotate the crankshaft until piston of cylinder 1 reaches compression TDC, align the TDC
pointer on front end of engine block to required fuel feeding angle mark on pulley, stop rotating the
crankshaft.
Step 2: Rotate the fuel pump camshaft until the centering pin hole on inner timing plate is upright,
install the timing gear and gear compression plate, insert the timing locating pin into the holes on
pump gear compression plate, timing gear connecting plate and inner timing plate, as shown in Fig.
3-86. The pump is adjusted to cylinder-1 fuel-feeding position when the four holes are aligned.
Step 3: Tightening the pump fastening bolts and pull the timing locating pin out.
TIPS
At this point, the fuel feeding angle is not necessarily accurate, and you should check it
again when test-run the machine. The method is: remove the connecting nuts between
high pressure fuel pipe of cylinder 1 and fuel injection pump, and then rotate the
crankshaft, stop rotating when the oil in cylinder-1 fuel delivery valve seat joint is surging
up slightly, loosen the four fastening bolts of fuel injection pump. Rotate the crankshaft
left and right until required fuel injection angle is acquired, install the four fastening
bolts.
O-ring Locating pin
Inner timing plate
Locating pin
Fuel injection pump

and compression plate
Bolt
Fig. 3-86 YC6112 engine fuel-feeding timing
104
310 Assembly of Engine Oil Sump and Components Inside
3101 Oil Strainer Assembly
Structure of oil strainer assembly is very simple, but attention should still be paid to the
requirements regarding its installing and maintaining, because it will always have the possibility of
failure. The oil strainer assembly structure is shown in Fig. 3-87.
Oil dirt and debris on the strainer must be cleared away. During assembly or subassembly, gaskets
must not be distorted or damaged. When installing engine oil pump, the flange gasket 1 must be flat
and free of wrinkle, requirements for oil pump outlet pipe flange gasket are the same. For support
plate of strainer oil pipe, no crack is allowed, and no deformation or big distortion to the plate after
assembling to prevent damage under severe vibration. Flange gasket should not be reused.
If strainer gets clogged during working, engine oil pressure gauge might indicate no pressure
change or little pressure change when engine accelerates from the idle speed to high speed, or
engine oil pressure can reach 0.1~ 0.2MPa when starting, but nearly no pressure rise after
accelerating. This is because the strainer is partially blocked.
Fig. 3-87 YC4108 engine oil strainer

1 Gasket assembly 2 Oil absorption pipe weldment 3 Bolt M8×50
4 Bolt M8×50 5 Strainer 6 Strainer support
3102 Assembly of Engine Oil Sump
The oil sump is a thin-walled part, and generally you should not hit it fiercely, so as to avoid
deformation which affects use. A gasket is installed between oil sump and engine block for sealing,
so the gasket must be completely free of damage. When installing, exert your strength diagonally
and evenly, especially for the fitting surface between gear housing and oil sump front end, no
protrusion to the engine block lower plane is allowed, otherwise the oil sump won't be able to be
sealed.
105
TIPS
An oil drain plug is installed on bottom of the oil sump, there is a magnet inside the plug,
which is used to absorb and collect scrap iron in engine oil. After a period time of working,
you should drain out the engine oil and check whether there is scrap iron on the plug, find out
the and cause and eliminate the problem if so. As shown in Fig. 2-58.
311 Output End Components (Flywheel, Clutch and Flywheel Shell)
3111 Flywheel and Gear Ring Assembly
Interference fit is adopted between flywheel and gear ring assembly. When assembling them, you
should heat gear ring to above 120oC firstly, and then press it into the flywheel. Heating method:
generally heat it directly with fire is feasible. Do not heat it with blow torch or acetylene flame,
because it may cause inhomogeneous heating, and high local temperature may soften the gear ring.
Common faults:
1. Looseness of gear ring: The main reason is that the fit clearance between the flywheel and gear
ring is too large.
2. Bump damage on gear tooth surface: Firstly, this may be caused by time mismatching between
motion of starter gear (trigged by starter electromagnetic switch) and power on of the motor
(quality problem of own); secondly, it may be caused by deformation of the starter motor gear
tooth, which will result in poor engagement problem (repair the tooth surface can solve this
problem).
3. Deflection or vibration of the flywheel: For this problem, you need to check if the runout of
crankshaft big end face (to the axis) is within the prescribed range (less than 0.038 mm), and
whether flywheel bolts are evenly tightened.
TIPS
Pay attention to check if the flywheel bolt and depth of bolt hole match.
3112 Clutch
1. Inspection of clutch
Inspection: Damper spring mustn’t be broken, all rivets mustn’t be loose, driven plate body
mustn’t be fractured, friction plate mustn’t be delaminated or with large crack. The diaphragm
and separation claw should be in the same plane in principle, at least the height difference
should be less than 0.4 mm. The clutch counterweight should be installed in its original
106
position.
2. Installation of clutch
Before the installation of clutch, you should clear away oil dirt and foreign matter on the
friction plates. Connecting bolts between clutch cover and the flywheel should be fastened
uniformly in diagonal way.
3. Clutch common faults
(1) Clutch slipping: Slipping phenomenon mainly manifested in incomplete output of engine
working torque, poor loadability and burning of clutch friction plate, and when the problem
gets more serious, it may be difficult to start the engine. The main causes are: undersized
free stroke of clutch pedal, too small clearance between release bearing and release lever,
too much oil dirt or delamination crack on clutch surface, and burned off layer, and
insufficient force of pressure spring.
(2) Dragging and shaking of clutch. The main causes are: oversized free stroke of clutch pedal,
which may put the clutch in semi-contact status; release spring gets softened, broken or
unbalanced; misadjusting of clutch middle pressure plate stop screw; the driven plate is
wrongly installed (positive & negative); faults in main hydraulic cylinder and booster
cylinder (for hydraulically operated clutch).
(3) Clutch produces abnormal sound. The abnormal sound is caused by bumping or scraping.
The main causes are: release bearing is damaged, and its rotation is not flexible and
produces abnormal sound; looseness or breakage of driven plate steel disc or rivet, which
will result in bumping problem; abrasion and looseness of release lever, control mechanism
is stuck and inflexible, which may result in colliding of friction plates; likewise, abrasion
and looseness of clutch middle pressure plate pin hole and pin can also produce abnormal
sound.
3113 Installation of Flywheel Shell
1. Installation: connect the flywheel shell to the rear end of engine block, and take two steps to
tighten the bolts to required torque with the stipulated torque crosswise, and check the
coaxiality between flywheel shell stop groove (locating surface, such as surface A in Fig. 3-88)
and crankshaft axis, as shown in figure 3-88. Measuring method: attach the magnetic dial
indicator seat to crankshaft big end, stick the meter header vertically the stop groove (surface A)
(preload the meter header for about 1~2mm), rotate the crankshaft for one circle and record the
maximum reading on the meter, and that is coaxiality error between flywheel shell stop groove
and crankshaft axis. The coaxiality error should be no more than 0.4mm, if fail to meet the
107
requirements, you can loosen flywheel shell fastening bolts and adjust, tighten the bolts and
measure again. If still fail to meet the requirements, replace the flywheel shell and check again.
Surface A Flywheel shell Surface A Flywheel shell

Dial indicator Dial indicator
Crankshaft
Crankshaft
Rear oil seal Assembly diagram of

Assembly diagram of YC6105, 4108, YC112, YC4112, YC4110
6108, 6L, 6M flywheel shell flywheel shell
Fig. 3-88 Flywheel shell and crankshaft

2. Flywheel shell common fault is breakage of flywheel shell fastening bolt. One of the main
causes is that the flywheel shell wall is too thin and fails to meet the requirements. The second
reason is that the coaxiality error between flywheel shell and crankshaft axis is oversized. If the
crankshaft bearing is severely worn, vibration of engine can easily crush and damage flywheel
shell. The third reason is matching chassis failure, which can result in severe engine vibration,
and pay attention to this during maintenance.
108
312 Assembly Of Cylinder Cover and Its Parts
3121 Cleaning of Cylinder Cover

1. Clean way the dust, carbon deposit, oil dirt, water scale, and rust on the cylinder cover.
2. Clean the water channels, oil galleries and air passages with diesel or detergent.
3. If there is too much rust or blur, remove them with spatula or 0# sandpaper.
4. Blow-dry the water channels and air passages in cylinder cover.
3122 Inspection of Cylinder Cover (Mainly For Used Cylinder Cover)

1. Check cylinder cover appearance for big bump damage and crack, a cracked cylinder cover
mustn’t be reused.
2. Measure valve sinkage, as shown in Fig. 3-89, which should meet the requirements listed in
table 3-26, wear limit should be no more than 2mm, otherwise the valve seat ring or valve must
be replaced.
Fig. 3-89 Measuring of YC6105 engine valve sinkage

Table 3-26 Standard valve sinkage
YC6108,
YC6108ZQB, YC6112
Type YC6105, YC4110 YC6L YC6M
YC6108ZLQB YC4112
YC4108
Intake
Intake 0.59 1.3~1.6
Value (mm) 0.8~1.2 1~1.3 0.84~1.32 0.75~0.95
Exhaust 0.5 Exhaust
1.12~1.4
3. Measure valve seat ring sealing strip width, refer to Fig. 3-90
If the valve seat ring sealing strip width (or sealing strip width) is too small, the sealing
performance is good, but related parts easy to wear; if the valve seat ring sealing strip width (or
sealing strip width) is too large, leakage problem may occur and related parts easy to burn. So
valve seat ring sealing strip width is generally controlled within 2.5mm. Grinding with reamer
109
or replace it if out-of-tolerance.
Valve seat
Fig. 3-90 Inspection of valve sealing strip width

4. Measure fitting clearance between valve guide pipe and valve, as shown in Fig. 3-91, the
measured value should meet the requirements listed in table 3-27.
Borescope
Micrometer
Fig. 3-91 Measure the valve guide pipe bore diameter

Table 3-27 Fitting clearance between valve and valve guide pipe
Fitting
Specified value (mm) Fit tolerance (mm)
Engine model
YC6112 Intake Ф9.469~Ф9.495/Ф9.46~Ф9.446 0.025~0.069
YC4112 Exhaust Ф9.469~Ф9.495/Ф9.401~Ф9.418 0025~0.094
Intake Ф12.000~12.018/Ф11.90~11.94 0.060~0.118
YC6M
Exhaust Ф12.000~12.018/Ф11.90~11.94 0.060~0.118
YC6108 Intake Ф9.5~9.519/Ф9.401~9.418 0.082~0.118
YC6L Exhaust Ф9.5~9.519/Ф9.401~9.418 0.082~0.118
Intake Ф9.500~9.519/Ф9.483~9.475 0.025~0.060
YC4108
Exhaust Ф9.500~9.519/Ф9.483~9.49 0.040~0.081
Intake Ф9.500~9.519/Ф9.453~9.475 0.025~0.066
YC6105
Exhaust Ф9.500~9.519/Ф9.438~9.46 0.040~0.081
Intake Ф9.469~9.495/Ф9.401~9.418 0.025~0.069
YC4110
Exhaust Ф9.469~9.495/Ф9.401~9.018 0.051~0.094
110
5. Inspection of valve sealing performance, as shown in Fig. 3-92. Fill up the to-be inspected
valve head with gasoline or kerosene, and let it stand for about 3min, the sealing performance is
good if no leakage phenomenon occur. Otherwise, you should grind the valve sealing strip, or
do the grinding work after reaming, as shown in Fig. 3-93 and Fig. 3-94. If grinding or reaming
is temporarily unavailable, you can knock the valve big-end head for temporary use.
Fig. 3-92 Inspection of valve sealing performance Fig. 3-93 Reaming valve sealing strip
Fig. 3-94 Grinding valve sealing strip
ATTENTION
Valve seat angle for different engine models are listed in table 3-28.
Table 3-28 Valve seat angle.
Engine model YC6105 YC6L YC6108
YC4112 YC4110
Item YC6112 YC6M YC4108
Intake valve seat angle 120° 110° 90°
Exhaust valve seat angle 90° 90° 90°
3123 Installation of Cylinder Cover Parts

1. Installation of the valve guide: YC6L engine adopts 4-valve-per-cylinder cylinder cover, while
the other engines adopt 2-valve type.
Valve guide pipe is standard component that has been installed in cylinder cover before
delivery by the manufacturer, so when replacing it during maintenance, it is better to machine a
111
dedicated tool to install it, as shown in Fig. 3-95, note that the end with bigger chamfer should
be upward. To prevent deforming the guide pipe during assembling, it is better to cool it with
liquid-nitrogen for 10~15min before installing. If inner bore of the guide pipe is deformed after
assembling, be sure to ream it with suitable reamer as long as the valve can move up and down
flexibly.
Bigger than the

bottom chamfer
Fig. 3-95 Installation of valve guide pipe

2. Installation of valve seat ring
Valve seat ring has been installed in cylinder cover before delivery. When replacing the valve
seat ring, you should cool the new retainer with liquid-nitrogen for 10~15min and press it in
with dedicated tool, as shown in Fig. 3-96.
ATTENTION
Chamfer is designed on one end of the valve seat ring for convenience of assembling.
The valve seat ring has been preliminary reamed before delivered together with cylinder cover,
but not to its use standard, you should grind it to match the new valve before use. As shown in
Fig. 3-94.
Figure 3-96 Installation of valve seat ring

3. Adjusting of fuel injector protrusion
Fuel spray angle and spraying position in combustion is directly influenced by fuel injector
protrusion (refer to Fig. 3-97). Fuel spray angle and spraying position can directly affect fuel
combustion quality, if the spray angle and spraying position meet the requirements, the fuel can
112
be fully combusted with good combustion quality; conversely, the fuel combustion will be poor
and incomplete. So fuel injector protrusion is vitally important and should be properly
controlled. Refer to table 3-29 for standard fuel injector protrusion of different engine models,
if the measured value is not in the specified range, you can add gaskets to meet the
requirements.
REQUIREMENT
Prior to the measuring, be sure to assemble the injector into cylinder cover and tighten
the fastening bolt/nut to specified torque.
ATTENTION
For some models such as YC6105 YC6108, you should install the injector copper bush 5
and then install the injector assembly.
Injector protrusion
Fig. 3-97 Measuring of fuel injector protrusion

1 Cylinder cover 2 Valve guide pipe 3 Injector adjusting gasket
4 Injector adjusting gasket 5 Injector copper bush
Table 3-29 Standard fuel injector protrusion
Engine model YC6112 YC6108 YC6M YC6M

YC6105 YC6L YC4110
Item YC4112 YC4108 (M3400) (M3000)
Protrusion (mm) 3.4±0.1 3.9±0.1 3.5±0.1 2.5±0.1 2.4±0.1 4.1±0.15 3.6±0.1
4. Installation of air valve

(1) Number of valve springs for different engine model is listed in table 3-30, refer to Fig. 3-98
for installation order.
(2) When installing valve lock clamp, you should firstly press down the spring seat together
with the valve spring, and then install the valve lock clamp in place, shock the spring with
hammer to set the valve lock clamp in place completely after installing, rotation of valve
must be flexible after cylinder cover is installed. As shown in Fig. 2-42.
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Table 3-30 each type valve spring

Item Intake valve Exhaust valve Intake valve Exhaust valve
Method
Engine model spring spring oil seal oil seal
YC6112
1 1 1 1 Commonly used
YC4112
YC6108
YC6105
2 2 1 1 Commonly used
YC4108
YC4110
Outer spring is not
YC6L 1 2 1 YC6L
universal
Inter spring is
universal.
Exhaust valve outer
YC6M 2 2 2 YC6M
spring is a circle
higher than intake
valve outer spring.
ATTENTION
YC6112 and YC4112 engine exhaust valve rod is installed with a spring seat sleeve, other
models is free of this part, refer to part 7 in Fig. 3-98.
Fig. 3-98 YC6112 valve rocker arm module

1 Intake valve 2 Exhaust valve 3 Exhaust valve seat ring 4 Valve spring
5 Valve rod oil seal 6 Exhaust valve spring seat 7 Exhaust valve spring seat sleeve
8 Valve lock clamp 9 Intake valve spring seat 10 Intake valve seat ring 11 Tappet
12 Pushrod 13 Rocker arm shaft support 14 Exhaust valve rocker arm bush
15 Exhaust valve rocker arm 16 Rocker arm shaft spring 17 Intake valve rocker arm
18 Intake valve rocker arm bush 19 Cylinder cover (long one) 20 Lock nut 21 Adjusting
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screw
5. Installation of cylinder cover
(1) Installation of cylinder cover gasket: cylinder cover gasket is divided into two types,
namely unitary type (one gasket for one engine) and split type (one gasket for one cylinder
cover). Divides according to structure, some cylinder cover gaskets are of hybrid type
(asbestos plus steel disc), some are of single steel disc type. YC6L engine adopts unitary
single steel disc cylinder gasket; while YC6M engine adopts split-type single steel disc
cylinder gasket. YC6112 (300PS is of single steel disc type), YC4112, YC6105, YC6108
(YC6108ZC is of single steel disc type), YC4110 and YC4108 engine are designed with
hybrid type cylinder gasket, pay attention to the front and back when assembling, the front
side should be upward and fit with cylinder cover bottom surface, as shown in Fig. 3-99.
Fig. 3-99 Cylinder cover gasket (front side upward)

(2) Connect cylinder cover to engine block, locating sleeves are used to position cylinder cover
and engine block. When fastening cylinder cover bolts, you should take three steps to
tighten the bolts to required torque according to the order listed in Fig. 3-100, required
cylinder cover bolt tightening torque is listed in table 3-31.
Fig. 3-100 YC6112 cylinder cover bolts tightening order

Table 3-31 Standard cylinder cover bolt tightening torque
YC6112 YC6108
Engine model YC6105 YC6L YC6M YC4110
YC4112 YC4108
Main bolt: 250~270

Torque Nm 200~230 160~230 210~250 210~250 180~260
Auxiliary bolt: 150~200
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TIPS
YC6M engine adopts split-type cylinder gasket (one gasket for one cylinder cover), prior
to fastening cylinder cover bolts, you should connect the exhaust pipe to cylinder cover
and fix it with bolts, otherwise the exhaust pipe joint may have air leakage problem. For
YC6M engine, there are two kinds of cylinder cover bolts, namely main cylinder cover
bolts and auxiliary cylinder cover bolts, the main bolt head is bigger, tighten torque of
main cylinder cover bolts and auxiliary cylinder cover bolts are different, please pay
attention to this.
6. Installation of valve rocker arm and rocker arm shaft
(1) Valve rocker arm is divided into intake valve rocker arm and exhaust valve rocker arm. For
all engine models except YC6M, the rocker arm is designed with rocker arm shaft sleeve.
Two kinds of lubricating methods for rocker arm are involved, as shown in Fig. 3-101 and
Fig. 3-102.
Valve adjusting screw Rocker
Pushrod
Rocker shaft seat
Engine oil inlet Rocker shaft
Tappet
oil outlet
Engine
Valve adjusting Rocker Rocker seat

screw
Engine oil inlet
Rocker shaft
Notes: Represents YC6L lubricating oil route

Represents YC6M lubricating oil route
Fig. 3-101 YC6108 rocker arm Fig. 3-102 YC6L and YC6M rocker arm lubricating
oil route
(2) Rocker arm shaft: YC6112，YC4112 and YC4110 engine adopt unitary rocker arm shaft
(one shaft for one engine); while YC6105, YC6108 and YC4108 engine have two rocker
arm shafts respectively; YC6L and YC6M engine adopt spit-type rocker arm shaft (one
shaft for one cylinder), as shown in Fig. 3-103.
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Fig. 3-103 YC6L engine valve tappet assembly

1 Tappet 2 Pushrod bottom ball 3 Pushrod body 4 Pin 6×12 5 Rocker arm
seat
6 Locating sleeve 7 Flat gasket 8 Spring washer 9 Bolt M10×80 10 Pushrod head
11 Bolt M8×40 12 Flat gasket 13 Spring washer 14 Rocker arm shaft 15 Round
pin
16 Adjusting screw 17 Lock nut 18 Valve rocker arm bush 19 Valve rocker arm 20 Ball
head
21 Ball head cushion block 22 Valve bridge 23 Valve lock clamp 24 Valve spring seat
25 Valve inner spring 26 Valve outer spring 27 Exhaust valve 28 Intake valve
The end with
groove should face
front end of engine
Rocker shaft
Spring support
Rocker
Fixing bolt * 7
Fig. 3-104 Rocker arm shaft mark

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(3) Requirements for installation of rocker arm shaft and rocker arm: Firstly, install related
parts on rocker arm shaft and rocker arm shaft seat; secondly, for YC6L engine, oil inlet
hole on rocker arm seat must be aligned to oil hole on cylinder cover; thirdly, for YC6112
and YC4112 engine, one end of rocker arm shaft is processed with groove, the end with
groove should face front end of engine, as shown in Fig. 3-104; fourthly, oil inlet hole or
groove on rocker arm shaft should face downward when assembling, otherwise oil inlet
passage of rocker arm shaft will be blocked; fifthly, when installing rocker arm of YC6L
engine, the injector assembly and valve bridge must be assembled together, as shown in
Fig. 3-105.
Fig. 3-105 YC6L engine injector assembly

1 Nut M8 2 Gasket 3 Packing washer 4 Injector pressing plate 5 Stud M8×35
6 Injector 7 Injector gasket
When installing the valve bridge, the end with back-off groove should face exhaust pipe, as
shown in Fig. 3-106.
Back-off groove
Fig. 3-106 Valve bridge
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Refer to Fig. 3-107 for installation of YC6L engine injector assembly.
Pressing plate Seal ring Bolt Locating

groove Locating
ball
O-shape seal ring
Pressing sleeve
High pressure
fuel pipe joint
Fuel return
pipe joint
Cylinder cover
Injector assemlby
Protrusion adjusting gasket
Fig. 3-107 Installation of YC6L engine injector assembly

Step 1: Press the injector assembly into cylinder cover fully, note that the adjusting gasket
mustn’t be lost, and fuel inlet hole on injector should be aligned to high pressure fuel pipe joint.
Step 2: Press the high pressure fuel pipe joint into cylinder cover fully and pre-tighten it,
pre-tighten the locating groove to 10~20Nm.
Step 3: Tighten the pressing sleeve first, and then tighten the pressing plate fastening bolts
(never tighten the pressing plate fastening bolts first).
Step 4: Tighten the pressing sleeve to specified torque 35Nm.
7. Installation of injector assembly
The quality of injector can greatly affect engine performance, so adjusting and inspection of
injector is vitally important.
(1) For a used injector, you must clean the nozzle with gasoline or detergent to remove the
carbon deposit, otherwise this will have impact on atomization effect, heat dissipation
effect will also be affected.
(2) Inspection of injector: mainly check whether the injector atomization effect meets the
requirements at rated opening pressure. Injector of YUCHAI products adopt two kinds of
pressure adjusting forms: for the first kind, pressure adjusting spring is used to adjust fuel
injection pressure, as shown in Fig. 3-108; for the second kind, fuel injection pressure is
adjusted by adding subtracting adjusting gaskets 9, as shown in Fig. 3-109.
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Fig. 3-108 Injector with pressure adjusting spring

1 Fuel return pipe joint 2 Adjusting screw fastening cap 3 Adjusting screw
4 Fuel inlet pipe joint 5 Pressure adjusting spring 6 Thimble
7 Injector nozzle matching part 8 Needle valve
Fig. 3-109 Injector with pressure adjusting gaskets

1 Fastening cap 2 Cushion block 3 Hole 4 Injector body 5 Fuel pipe
6 Screw cap 7 Needle filter 8 Fuel return joint 9 Adjusting gasket
10 Pressure adjusting spring 11 Lower spring seat 12 Locating pin
13 Needle valve matching part
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Required injector opening pressure for each engine model is listed in table 3-32, and refer to
Fig. 3-110 for inspection and adjusting method.
Table 3-32
YC6112
Engine model YC4112 YC6105 YC4108 YC4110 YC6L YC6M
YC6108
Opening pressure
25~26 26~27 22~24 25~26 25.5~26.5 27.5~28.3 23.5~25.5
(MPa)
Fig. 3-110 Inspection of injector opening pressure
TIPS
1) Requirements for adjusting of injector opening pressure: the opening pressure must
within the required range, injected diesel oil must be atomized enough and has a
certain spray angle, more importantly, and the injector should be free of fuel
dripping phenomenon when the injection process is finished. When inspecting, you
should operate the handle at a speed of 100 times per minute to check atomization
effect. If the fuel can only be properly atomized at high operating speed and bad
atomization effect or dripping fuel at low operating speed, then it means that the
engine low-speed performance is definitely poor, generally the engine produces black
smoke at low speed.
2) Selection of injector opening pressure: in a certain pressure range, the higher the
selected injector opening pressure, the larger the engine output power, but the noise
increases too; on the contrary, the lower the selected injector opening pressure, the
smaller the engine output power, but the noise decreases too, therefore you should
select suitable opening pressure based on real working condition.
(3) When installing injector assembly into cylinder cover, note that the protrusion adjusting
gasket mustn’t be lost; when installing injector high pressure fuel pipe, be sure to take three
steps to tighten the thread sleeve on both ends of the pipe crosswise, the pipe may crack if
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directly tighten the sleeve on one end to required torque.
3124 Common Faults of Cylinder Cover Parts

1. Cylinder cover
Cylinder cover is cracked and leaking water, generally the cracked area is between two adjacent
cylinders, the nose bridge and swirl chamber. Main causes are: casting defects, cylinder cover
wall is thin, too large fuel feeding rate, early fuel timing and bad atomization, which will result
in oil leakage problem, long combustion time and high engine temperature, the cylinder cover
will crack if filling cold water to an overheated engine.
ATTENTION
For YC6105 and YC6108 engine, the water in cylinder cover will leak into combustion
chamber if the injector copper bush is loose and cracked.
2. Premature wear of valve and valve seat ring: main causes are unclean intake air, oversized
intake valve clearance, undersized exhaust valve clearance and valve burning.
3. Valve head is cracked, main causes are: the valve own quality problem, oversized valve
clearance and results in knocking problem; for a vehicle equipped with exhaust brake, if the
exhaust brake is clogged, exhaust bounce-back phenomenon may occur, which can easily lead
to fall off of valve lock clamp and damage the valve.
4. Premature wear of valve rocker arm shaft, valve head (the end with adjusting screw), contact
surface between valve rod head and rocker arm, causes: engine oil pressure is low, insufficient
lubricating of rocker arm; lubricating oil from rocker arm fails to get to adjusting screw and
valve rod head and result in dry friction due to unreasonable structure and shape of rocker arm.
5. Rocker arm shaft module: burning of rocker arm copper bush and rocker arm shaft. Main
causes: engine oil pressure is low and fails to lubricate the rocker arm; the nuts of oil pipe on
rocker arm seat are loose and leaking oil or the oil pipe is cracked.
6. Burning or seizure of tappet, tappet of YC4108, YC6105, YC6108 and YC6L engine is
lubricated by engine oil from cylinder cover rocker arm, if engine oil pressure is low or fitting
clearance between tappet and engine block is too small, a dead end oil chamber will be formed
and will accumulate dirt, which will result in burning damage; besides oil from cylinder cover
rocker arm, tappet of YC4110, YC4112, YC6112 and YC6M engine is also lubricated by
engine oil from main oil gallery, so the common fault of the later four engine models is seizure
of tappet.
7. Common faults of injector assembly
(1) Broken of injector assembly fastening stud, the stud is small (generally M10), it may break
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due to stress concentration if being tightened by open-end wrench or spline end wrench
(the torque is hard to control) rather than torque wrench.
(2) Two situations are involved for jamming of injector matching part: for the first situation,
the needle valve is jammed in open position, at this point the fuel cannot be atomized and
fully combusted, the engine produces black smoke or white smoke; for the second situation,
the needle valve is jammed in close position, at this point this cylinder has no fuel feeding
and doesn’t work. No matter which situation it is, the engine power will reduce and
accompany with noise. Main causes for jamming of injector matching part are: unclean
diesel oil, the needle valve gets jammed by dirt; fuel feeding is abnormal, bad combustion,
injector nozzle is ablated and accumulated with too much carbon deposit; oversized fuel
feeding angle and high fuel feeding rate, which will result in long-time combustion and
high engine temperature.
8. Burning of cylinder (cover) gasket: the fault is manifested in delaminating of cylinder gasket
fire-protection ring sheetmetal and burning of its stuffing (steel gasket is free of this
phenomenon), which will damage the gasket and result in gas carry-over problem (to outside or
water channel) and water leakage (external leakage or internal leakage to cylinder sleeve) of
cylinder cover. Main causes: poor combustion and bad heat dissipation, which will result in
high engine temperature; cylinder cover bolts are not fully or evenly tightened, which will
enlarge cylinder gasket heating surface and lengthen heating time; oversized valve clearance,
high exhaust temperature and oversized fuel feeding angle are also causes of cylinder gasket
burning. When gas carry-over phenomenon occurs, abnormal sound will be produced and
engine power will reduce.
ATTENTION
(1) If burning of cylinder (cover) gasket makes the cylinder and water channel
communicate with each other, many bubbles will rise from water tank.
(2) If a certain cylinder cover gasket is easily to get burnt, you should check whether the
protrusion of cylinder cover locating sleeve meets the requirements, meanwhile, when
tightening cylinder cover bolts, you should start from there. So far, no burning of
cylinder (cover) gasket caused by deformation of cylinder cover is found.
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313 Assembly Of Water Pump, Fan and Steering Pump
3131 Installation of Water Pump

1. Structure of water pump: YUCHAI products adopt cooling water pumps, the water pumps have
different outside shape, but their inner structure are basically the same, as shown in Fig. 3-111.
Fig. 3-111 Exploded view of YC6105 engine water pump assembly

1 Slotted nut 2 Water pump pulley 3, 4 Bearing 5 Minor circulation pipe
6 Thrower 7 Water seal assembly 8 Carbon seal ring 9 Water pump shaft
10 water pump impeller 11, 13 Water pump cover gasket 12 Water pump cover
14 Bolt 15 Water pump rubber gasket 16 Oil cup 17 Bolt M8×45
Refer to Fig. 3-112 for engine cooling water circulating route
Minor circulation pipe
Air compressor
Water pump
Thermostat
Engine oil cooler Cylinder cover
Cylinder block
Water tank
Fig. 3-112 YC6112 engine cooling water circulating route

2. Common faults of water pump:
(1) The most common fault of water pump is water seal leaking water (manifested in water
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dripping from water pump overflow hole). Main causes for damage of water seal are water
seal aging failure and longtime no lubricating of water pump. Wear and looseness of water
pump bearing will also result in water leakage problem, so when replacing the water seal
with a new one, it is better to coat the inner bore of water seal with grease, because the
grease not only can play a role of sealing, but also can prevent damage of water seal due to
dry friction.
(2) Wear of water pump bearing, which can result in sever radial swing of water pump
impeller, even colliding with pump body.
Wear of water pump bearing is of two kinds: wear of bearing ball is the first kind; and wear
of both bearing external circle surface and bearing seat bore. One of the causes is
lubricating oil shortage (you should fill grease via the grease nozzle twice a month), the
other cause is loose fit between the bearing and bearing seat.
(3) Water pump produces abnormal noise: the fault is mainly caused by severely damaged ball
bearing which can result in sever radial swing of water pump impeller, even colliding with
pump body. If the abnormal noise is friction noise and produced by contacting of water
pump shaft and water pump end cover due to oversized axial movement of the shaft, you
can eliminate the problem by adjusting the thickness of gasket between water pump end
cover and water pump body, refer to part 11 and 13 in Fig. 3-111.
When installing the water pump, pay attention apply sealant on the pump gasket and
tighten the bolts to required torque.
3132 Installation of Fan

1. Three kinds of fan are adopted by YUCHAI products, namely steel plate fan, engineering
plastic fan and silicone oil fan.
Silicone oil fan uses silicone oil to transmit friction force, the silicone oil clutch can
aromatically adjust fan rotating speed according to temperature change of hot air from radiator
(water tank), and the specific engaging and separating operation is performed by the metal
inductor, as shown in Fig. 3-113. Advantages of silicone oil fan: automatically control the
engine to keep it working at optimal temperature, reduce fan power consumption, low noise
and save energy.
Working principle of silicone oil fan: when starting or the temperature is low, there is no
silicone oil around the driving plate, the transmission shaft runs idly; when the temperature
rises, the metal inductor will swell to turn the switch valve plate for a certain angle to open the
oil outlet port, silicone oil will fill up the area between the driving plate and driven plate, and
driven plate will be driven by silicone oil friction, thus the fan can rotate. Rotating speed of fan
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is controlled by the metal inductor.

Driven disc
Driven plate
Fan Oil return hole
Silicone oil chamber
Return oil
Transmission shaft Switch valve plate
Metal inductor
Outlet oil
Hot air
Outlet oil
Connecting bolt
Driving plate
Fig. 3-113 Silicone oil fan working principle diagram

2. Common faults of silicone oil fan: the automatic control failure, which is mainly caused by
metal inductor failure and or leakage of silicone oil. During normal use, please pay attention to
clean away the oil dirt and sundries on the metal inductor. The silicone oil clutch has been
properly adjusted before delivery, do not disassemble it casually.
TIPS
Simple method to determine whether the silicone oil is in good condition: cold-start the
engine idly for several minutes, and then shut down the engine immediately, stir the fan
blades by hand and should feel easy and flexible, because at this point the silicone oil
around driving plate has been thrown back to silicone oil chamber; start the engine again
and continue to heat it, and then shut down the engine, stir the fan blades again and you
should feel heavy, because at this point, the temperature is high and the area between
driving plate and driven plate has been filled up with silicone oil, in this case you have to
overcome the silicone oil friction to rotate the fan, which also indicates that the fan is in
good condition.
Outside shape and installing condition of fan have great effect on engine temperature, hence
structural shape and dimensions of fan must conform to its design requirements, and a
deformed fan mustn’t be reused. A fan with poor dynamic balance will produce excessive
vibration during working and provide bad cooling effect, so when installing radiator and fan
cover, you must reasonably fit them with the fan to improve cooling performance.
126
3133 Installation of Steering Pump

Most YUCHAI products have adopted rotor pump as steering pump, while vane pump is not
excluded, as shown in Fig. 3-114.
Fig. 3-114 Vane pump structural diagram

1 Pump body 2 Pump shaft 3 Front oil distribution disc 4 Valve 5 Rotor 6 Vane
7 Stator 8 Rear oil distribution disc 9 Combination gasket 10 Rear cover
11 O-ring 65×2.65 12 O-ring 67×2.65 13 O-ring 21.2×1.8 14 O-ring 63×2.65
15 Oil seal FB16×30×7B 16 Bearing180203 17 Retainer ring
1. Cleaning (the steering pump must be cleaned after longtime use): dismantle the flow steady
valve and safety valve when cleaning, flush the inner cavity of steering pump, flow steady
valve and safety valve with diesel oil. Note that the seal rings and adjusting gasket mustn’t be
lost and damaged in this process. When recovering the steering pump (pump blade cambered
surface be outward), it is unnecessary to adjust the steady flow valve spring and safety valve
spring, if you think the steering pump is abnormal and must be readjusted, you can add gasket
to decrease pressure or subtract gasket to increase pressure.
2. Installation of steering pump
Two situations for installation of steering pump: for the first situation, the steering pump is
directly installed on rear end of air compressor and driven by air compressor shaft; for the
second situation, the steering pump is installed on gear housing cover plate and driven by gear
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in gear housing.
3. Common faults of steering pump
(1) Premature wear of steering pump rotor, stator and front and rear oil distribution disc. The
oil used by steering pump is anti-wear hydraulic oil, if the oil is inferior or the oil seal (part
15 in Fig. 3-114) is damaged, too much dirty engine oil will flow into steering pump and
result in premature wear.
(2) Low oil pressure of steering pump and steering heavy. Under the circumstance of normal
oil supplying and abrasion, main cause for this fault is: steady flow valve spring and safety
valve spring get softened or inflexible due to longtime no cleaning, which will result in
untimely oil discharge and pressure reduce. The solution is to clean the valve springs or
add gaskets on upper end of the spring.
(3) Hydraulic oil level in steering pump oil tank increases, while engine oil reduces. The main
cause is aging and damage of steering pump oil seal (part 15 in Fig. 3-114), which turns the
steering pump into a “engine pump”, engine oil is absorbed into the steering pump oil tank
through the damaged oil seal.
128
314 Assembly of A/C Generator and Starter Motor
3141 A/C Generator

Two kinds of generators are used by YUCHAI products, namely exciting generator and permanent
magnet generator, refer to Fig. 3-115 and Fig. 3-116 for their principles, power range
0.75KW~3KW. Compared to exciting generator, permanent magnet generator has the advantages of
compact size, light weight and excellent low-speed performance (low speed charging voltage is
relatively higher). But it also has disadvantages, the “permanent magnet” is actually not permanent,
especially after bumping and knocking, the magnetic field can be easily weakened. Hence, after
longtime use, the charging voltage of permanent magnet generator will reduce.
Voltage regulator
Fig. 3-115 Principle of brushless exciting generator

1 Generator shell 2 Magnetic field rectifier diode 3 Output rectifier diode
4 Neutral point rectifier diode 5 Stator winding 6 Field winding B+ Armature terminal
D+ Charging indicator lamp terminal N Neutral point terminal
W Rotating speed terminal 〨 Ground wire terminal
Fig. 3-116 Principle of brushless permanent magnet generator

1 Generator shell 2 Positive diode 3 SCR 4 Stator winding
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Common faults of A/C generator and troubleshooting:

Generator faults mainly focused on three points: open circuit or short circuit of exciting coil
(exciting generator); open circuit or short circuit of stator coil (electric output winding); burning of
rectifier voltage stabilizing diode or SCR. More specifically:
1. Generator fails to charge the battery
Generator charging failure can be determined by using an ampere meter, so the first thing you
need to do is to choose a qualified ampere meter.
Two causes may result in generator charging failure (the ampere meter indicates no charging
current): generator fails to generate electricity is the first cause; generator can generate
electricity but fails to charge the battery due to regulator or circuit failure. So when
troubleshooting, you should firstly check whether the generator can generate electricity
normally, inspection method: disconnect terminal B+ wiring, start the engine and run it at
intermediate speed, set the multimeter to DCV and connect the red probe to generator B+
terminal (positive), ground the black probe (generator shell), at this point if the multimeter
indicates voltage reading and the reading keeps going up as engine speed increasing, then it
means that the generator is in good condition and the charging failure must be caused by
regulator or circuit failure. Another simple inspection method: disconnect terminal B+ wiring,
connect a bulb between generator B+ terminal and generator shell, start the engine and run it at
intermediate (or higher) speed, if the bulb doesn’t get lightened, then it must be generator
failure (fail to generate electricity). For exciting generator, an experienced serviceman can use a
wire to instantaneously short-circuit the regulator red wire (positive) and regulator F terminal,
if the pointer of ampere meter swings at this point, the regulator must be in failure; if the
ampere meter indicates no current, then the charging failure must be caused by ampere meter or
circuit failure.
After finding out the cause, you need check related parts one by one:
Fig. 3-117 Inspection of open circuit or short circuit of exciting coil

 Refer to Fig. 3-117 for inspection of open circuit or short circuit of exciting coil, if the
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measured resistance value is large, it indicates coil open circuit; if the measured resistance
value is small, it indicates interturn short circuit. (Refer to generator instruction manual for
standard resistance value).
 Inspection of open circuit and short circuit of armature coil, refer to Fig. 3-115. Disconnect
generator terminal N wiring, use a multimeter to measure the resistance between generator
terminal N and rectifier diode positive (on generator end cover) for three times, if the three
measured values have no big difference, then it indicates that the armature is normal; it is
short circuit if the resistance is very large; and it is short circuit if the resistance is much
smaller than specified value.
 Refer to Fig. 3-118 for inspection of open circuit of rectifier diode
Ohms range, about Ohms range,

800,000Ω about 8Ω
Red Black
Black Red
Component
Diode
Fig. 3-118 Inspection of rectifier diode

2. Low charging current
The so-called low charging current is that the ampere meter indicates 5A or under when engine
is running at intermediate speed.
One of the causes for low charging voltage is undersized voltage limiting value of regulator,
currently all used regulators are nonadjustable, and you have to replace it to do the
troubleshooting. The second cause is partial short-circuit in exciting coil or stator winding. The
third cause is open circuit of diode. The fourth cause is demagnetization of the permanent
magnet. The fifth cause is bad contact.
TIPS
High charging current is generally caused by oversized voltage/current limiting value of
regulator or damaged diode (damaged diode will result in uncontrollable output voltage).
3. Unstable charging current (the charging current is sometimes big, sometimes small)
Disconnect the wire between battery and regulator, set the multimeter to DCV and connect the
red probe armature terminal and ground the black probe. Then increase the engine speed from
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idle speed to intermediate speed, if the charging voltage is stable, then the fault must be caused
by faulty regulator or loose terminal; if the charging voltage is unstable, then the fault is caused
by generator failure.
3142 Starter Motor

Power of selected starter motor for different engine models are different, refer to Fig. 3-119 for its
working principle.
Common faults of starter motor and troubleshooting:
Turn on starter switch, starter motor fails to drive and start the engine. Cause analysis:
1. Check whether the battery has enough power, turn on front lamps, the battery power is enough
if lamp is bright enough.
2. Check the electromagnetic switch: refer to Fig. 3-119. Short-circuit the starter motor terminal 3
and terminal 1, and then check for the following situations:
(1) The moveable iron can be absorbed in by big extraction force and produces sound of
“de-de”, then it means the electromagnetic switch is in good condition, the starter switch
may be faulty.
Terminal 3 Return spring Contact disc
Pull in winding
Starter switch
Holding coil
Power switch
Moveable iron
Terminal 1
Terminal 2
Terminal 4 Rod
Field coil
Rectiblock Starter gear
Carbon brush
Starter Stop nut

motor shell
Return spring Flywheel
Battery Electromagnetic coil
Fig. 3-119 Working principle of starter motor

(2) The moveable iron cannot be absorbed in, short-circuit terminal 2 (connect terminal 2 to
starter motor shell to ground it) at this point, if the moveable iron can be absorbed in, then
it means starter motor interior fault, the pull in winding fails to work due to no power
supply; if the moveable iron still cannot be absorbed in, then there must be open circuit or
short circuit of pull in winding and holding coil in electromagnetic switch.
(3) The moveable iron can be absorbed in but bounces back soon, which indicates open circuit
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or short circuit of holding coil.

(4) The moveable iron can be absorbed in but the starter motor doesn’t rotate, short-circuit
terminal 1 and terminal 2 at this moment, if the starter motor can rotate, then it means the
fault is caused by the contact disc, the terminals on contact disc that connected with
terminal 1 and terminal 2 are burnt and fail to conduct electricity; if after the moveable iron
bounces back the starter motor continues to rotate idly, then it means the contact disc and
terminal 1, terminal 2 are sintering together (at this point, you have to turn off the main
power or knock terminal 1 and terminal 2 to stop the motor).
(5) The moveable iron can be absorbed in but cannot bounce back automatically:
 Starter switch is sintering and cannot be separated (turn off the main power to solve
the problem).
 The electromagnetic switch moveable iron is inflexible due to corrosion or the return
spring is burnt and gets softened (knock the pull in winding to solve the problem).
 When turning on the main power switch, the starter motor starts to rotate without
turning on the starter switch, and stops rotating as soon as the main power is turned off.
This is caused by short circuit of pull in winding terminal and terminal 1 (internal
contact). At this point, you just need to loosen fastening nut of terminal 1, press
terminal 1 and pull it out to solve the problem, fasten the nut.
3. Inspection of starter motor
Instantaneously short-circuit the terminal 1 and terminal 2, and then check for the followings:
(1) The motor is in good condition if the rotor can rotate at high speed idly.
(2) No spark produced when short-circuit the terminals and the motor doesn’t rotate, which
indicates interior short circuit of starter motor, mainly caused by loose rotor coil or severe
burning of rotor rectiblock.
(3) A lot of blue spark produced when short-circuit the terminals and the motor doesn’t rotate,
which indicates interior short circuit of starter motor, mainly caused by contact of field coil
and motor shell, short circuit of carbon brush bracket, contact of rotor coil and carbon
brush bracket.
(4) Small spark produced when short-circuit the terminals and the motor doesn’t rotate or
rotates slowly, which indicates interturn short circuit in starter motor or bad contact of
carbon brush due to burning of rotor rectiblock.
4. Rotating speed of starter rotor is enough, but the crankshaft couldn’t be driven. This is caused
by slipping of starter motor one-way clutch, the tooth surface is damaged and couldn’t engage
normally, or stroke of starter gear is small and the gear fails to engage.
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315 Assembly of Intake and Exhaust Pipes and Turbocharger
3151 Installation of Intake and Exhaust Pipes

Intake and exhaust pipes equipped on YUCHAI products are not the same, some engines adopt
unitary structure, and some adopt double-body or triple-body structure. For intake pipe, all
YUCHAI engines adopt unitary structure except YC6105QC and YC6108Q. Intake pipes of some
engine models are installed with heating device, such as YC4110, YC6108ZLQB, YC6112, YC6L
and YC6M engine, the heating device can be used as start aid in winter, it is better to disconnect its
power source in summer.
For YC4108, YC6105 and YC6108 engine, you should install the water outlet pipe before installing
the exhaust pipe.
Divides according to structure, some intake and exhaust pipe gaskets are of hybrid type (asbestos
plus steel disc), some are of single steel disc type. During assembling, an individual engine should
be installed the same gaskets, and in principle, the gasket is disposal and should not be reused once
removed. When fastening the bolts, it is required to take two steps to tighten them orderly from
middle to two ends. Intake and exhaust pipe connecting flanges are thin-wall part, which should not
be tightened with excessive force.
3152 Installation of Turbocharger

Engine output power can be effectively improve by applying turbocharger. Currently the
turbochargers equipped on YUCHAI products are divided into two types, namely common
turbocharger and turbocharger with bypass valve. Fig. 3-120 presents a turbocharger with bypass
valve. For a common turbocharger, its charging pressure is directly proportional to engine speed,
but engine intake pressure and engine speed cannot be controlled; while for turbocharger with
bypass valve, its charging pressure is controlled within the design scope by the bypass valve, which
prevents high engine fuel consumption and turbocharger overspeed problem due to oversized
cylinder explosion pressure (generally happens to a common turbocharger engine). Meanwhile, a
turbocharger with bypass valve can improve diesel engine low-speed performance (control
low-speed torque and smoke intensity).
Although turbocharger structure is not complex, but technical requirements for turbocharger is very
high. Rotating speed of turbocharger can reach to more than 100,000r/min, so requirements
regarding its bearing lubrication and dynamic balance are very high, the users must follow all
requirements in instruction manual to lengthen service life turbocharger.
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Fig. 3-120 YC6105ZLQ turbocharger assembly

1 Turbocharger 2 Turbocharger oil return pipe 3 Bolt M8×25
4 Connecting bolt (with exhaust pipe) 5 Oil inlet pipe joint 6 Bypass valve
7 Bypass valve adjustment lever
1. Cleaning of turbocharger
Turbocharger is lubricated by engine oil, if the engine oil contains too much carbon granules,
turbocharger bearing can be easily burnt by carbon deposit under high working temperature
(waste gas heat and heat produced by high speed rotation), result in lubricating film damage,
bearing and seal ring damage. It is necessary to clean the turbocharger periodically (clean it
during every engine oil replacement).
Cleaning method: dismantle the turbocharger and fill diesel oil through the engine oil inlet port,
plug up the engine oil return port and shake the turbocharger continuously, finally discharge the
diesel oil and clean the turbocharger again.
2. Inspection of turbocharger
(1) Refer to Fig. 3-121 to measure axial clearance and radial clearance of turbocharger rotor
shaft, standard value: axial clearance 0.10mm, radial clearance 0.15mm. But during normal,
the turbocharger is ok as long as the blades cannot touch the shell.
Measure with dial
indicator
Radial clearance
Axial clearance
Fig. 3-121 Measure axial clearance and radial clearance of turbocharger rotor shaft
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(2) Check two ends of turbocharger for oil leakage, if there is engine oil leakage, then the
turbocharger seal ring must be damaged.
(3) For a normal turbocharger, the bypass valve adjustment lever can be operated by hand with
big strength, otherwise the control valve may be rusted and jammed, check and eliminate
the problem.
3. Installation of turbocharger
Fill up the inner cavity of turbocharger with engine oil, rotate the shaft for a few circles to fully
lubricate the bearings with engine oil, and then discharge the engine oil and install the exhaust
pipe joint, note that the connections between turbocharger and air filter & engine intake pipe
must be firm, no short circuit or air leakage is allowed. The connecting gasket between
turbocharger and exhaust pipe is heat-resistance gasket, do not replace it with other gasket.
4. Common faults of turbocharger
(1) Burn or severe wear of floating bearing, refer to Fig. 3-122. Under normal conditions, you
should feel very easy and flexible when rotating the rotor shaft, otherwise the bearing is
burnt and inflexible. If bearing is severely worn, the shaft will shake if raise the rotor shaft
by hand. Main causes: firstly, engine oil is inferior or insufficient; secondly, the user failed
to follow the requirements in instruction manual to maintain the turbocharger (run the
engine idly for 3~5min after starting and before shutting down); thirdly, longtime overload
working, which will result in poor heat dissipation and accelerate the wear process.
Engine oil Waste gas
Oil seal
Turbine
Rotor shaft
Air
Left-hand thread
Impeller nut
Thrust plate
Seal ring Engine oil outlet port
Bearing
Fig. 3-122 Working principle of turbocharger

(2) Turbocharger leaks engine oil: engine oil leaked into intake pipe or turbine exhaust pipe
from turbocharger inner cavity. The engine will produce blue smoke if engine oil leaked
into intake pipe and engine oil consumption will increase. The exhaust pipe will discharge
engine oil if there is too much leaked oil. Main causes: severe wear of turbocharger seal
rings (opening of the metal seal should face upward); high engine oil pressure, blockage of
turbocharger oil return passage; blockage of turbocharger intake passage, low intake
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pressure; longtime idle running.

(3) Turbocharger produces abnormal noise: the noise is produced by sundries on turbocharger
intake port bumping or scrapping turbocharger impeller; the noise is produced by vibration
of turbocharger due to severe wear of floating bearing or wear of thrust plate; airflow
rushing sound will be produced if turbocharger intake passage is partially clogged.
(4) Fault caused by bypass valve failure: set pressure of bypass valve has been properly
adjusted before delivery, generally the user doesn’t need to adjust it, unless the adjustment
lever is deformed for some reason, refer to Fig. 3-120. Extend the adjustment lever to
reduce the opening pressure, while shorten it to increase the opening pressure. You must
pay attention to engine speed change after the adjustment, if engine speed is too high, be
sure to readjust to prevent accidents.
 Bypass valve opens prematurely, intake pressure and intake air flow are reduced,
which result in black smoke, high fuel consumption, power reduce (disproportion of
oil-gas mixture ratio, poor combustion), and high exhaust temperature.
 Bypass valve opens too late, intake pressure is increased, which result in overspeed of
engine (engine speed goes up with the increasing of intake air flow). Due to overspeed
of turbocharger, the floating bearing is easy to damage and the waste gas contains too
much NOx.
(5) Excessive vibration of turbocharger. A turbocharger with poor dynamic balance will
produce vibration and excessive noise. When the problem gets more serious, the turbine
and impeller may bump against the shell, main causes are: uneven wear of floating bearing,
failed to align the balancing marks on turbine, impeller, oil seal and thrust plate to marks
on turbine shaft.
(6) Precautions for use of turbocharger
 Run the engine idly for 3~5min after starting and before shutting down, because the
bearing can be easily damaged if rashly speed up the engine before bearing oil
pressure is built up. And if suddenly shut down the engine, engine oil will stop flowing
immediately, turbocharger shaft will burn and accumulate carbon deposit due to high
temperature.
 When installing the turbocharger, or replace the engine oil, or before reuse a
turbocharger that has been out of service for long time, it is better to fill engine oil into
the oil inlet port of turbocharger and rotate the rotor shaft to fully lubricate the
bearings and other components inside.
 Idle running time of engine should not exceed 20min, because when idling, pressure in
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turbocharger impeller housing is very low, while engine oil pressure in turbocharger
inner cavity is very high, engine oil is easy to leak into impeller housing.
3153 Installation of Thermostat

Refer to Fig. 3-123.
Fig. 3-123 Thermostat working principle diagram

1. Thermostats equipped on YUCHAI engines are listed in table 3-33.
In Fig. 3, the left valve element is in open and working state (note that the right valve element
is in closed state, minor circulation works). When thermostat is fully open, the small valve is in
closed state and minor circulation doesn’t work.
Table 3-33 Thermostats
Thermostat
530 630 648 B4400 A7100 A39 150 M3000
model
Opening
76 70 70 70 70 57 81 80
temperature oC
Full-open
83 78 78 80 80 70 95 92
temperature oC
TIPS
Thermostat should be selected based on engine model.
2. Before installing the turbocharger, you should put it in hot water for inspection, to check and
ensure the thermostat can open automatically.
3. Common faults of thermostat
The most common fault is malfunction of thermostat, the malfunction is embodied in two
aspects: firstly, the thermostat fails to open at specified temperature; secondly, the thermostat
can open normally, but the stroke of minor circulation is insufficient and minor circulation pipe
cannot be closed fully, in this case, the circulation of water outlet pipe cannot be controlled,
which can result in high engine water temperature. When checking, you should put the
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thermostat in hot water to open it and then place it on thermostat seat immediately, the
thermostat is normal if the minor circulation pipe can be fully blocked by the minor circulation
valve.
Generally, the thermostat should be replaced once malfunctioned. If no new thermostat is
available and engine water temperature is high, you can disassemble the thermostat and plug
the minor circulation pipe orifice for emergency, otherwise, the water temperature will get
higher when there is only minor circulation and no major circulation.
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316 Assembly of Intercooler

Currently, there are two kinds of intercoolers equipped on YUCHAI products: wind-air intercooler
and water-air intercooler, all engines adopt wind-air intercooler except a few YC6112 engines.
Refer to Fig. 3-124 and Fig. 3-125.
Intercooler
Intake pipe
Turbocharger
Fig. 3-124 Wind-air intercooler
Water container welding line
Fig. 3-125 Water-air intercooler

Intercooler is used to lower the temperature of supplied compressed air by turbocharger
(temperature of air in turbocharger outlet port is about 15oC), to further increase the intake air
density, which is helpful to improve engine performance, intercooler is connected between
turbocharger and engine intake manifold, generally installed on front side of water tank.
In the middle of wind-air intercooler, there is a row of air pipes and air from turbocharger needs to
go through these pipes to get to engine intake manifold; there are plate-fins designed on outside
surface of the intercooler to dissipate heat of the air. Water-air intercooler adopts double-layer
structure, the inner layer is water pipe, there are plate-fins designed on outside surface of the water
to dissipate heat; the outside layer is air chamber, air from turbocharger is cooled here by water.
Both wind-air intercooler and water-air intercooler have their advantages and disadvantages,
wind-air intercooler is more efficient, but of bigger volume.
Common faults of intercooler: casting defects, such as sand hole and crack; loose weld or fake weld
of inner pipes, which will result in air leakage or water leakage, if the intercooler leaks air, engine
power will reduce significantly, even produce black smoke. If the intercooler leaks water, the water
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tank will bubble. Intercooler pipe is thin-wall part and welding repair is difficult to perform, so
generally a pipe with welding defect tends to be replaced.
Method to inspect intercooler air chamber rear pipes for air leakage: inflate the intercooler to
0.3MPa via the intake port and put the intercooler into water to check whether there is air bubble
coming out.
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317 Assembly of Fuel Filter, Engine Oil Filter, Fuel Cut-off Solenoid
Valve and Other Components
3171 Installation of Fuel Filter

The fuel filters equipped on YUCHAI products are of different models, but they all adopt the same
structure, they are all paprt cartridge rotary type filters. Some engine models adopt single stage fuel
filter (such as YC4108 and YC6112), while adopt two-state fuel filter. Some filters are disposal,
while some are not (the filter cartridge is replaceable), refer to related instruction manuals for
details.
Common faults of fuel filter: the shell has sand hole defect, the seal ring installed between filter cap
and shell is distorted and deformed and result in diesel oil leakage; the user failed to follow the
requirements in instruction manual to maintain the filter and result in damage or blockage of filter
element, the filter element should be replaced every 20,000kM of driving.
Table 3-34 Engine filter models
Engine
YC6112 YC4112 YC6105 YC6108 YC4108 YC4110 YC6L YC6M
model
Engine oil JX0811 L3000- M3000-
J91023 J91023 CX0818 JS0818
filter model JX1011 1012020 10122210
Fuel filter 2CX0710 RqCov 2CX0710 CX0708 G4600- 150-
CLQ15 CX0710
model CX1011 P60S-2U CX1011 2CX0710 1105410 110502013
3172 Installation of Engine Oil Filter

The engine oil filters equipped on YUCHAI products are of different models, but they all adopt the
same structure, they are all paprt cartridge rotary type filters. Most engine models only installed
with one engine oil filter, directly installed on oil outlet pipe of engine oil pump, only a few engine
models installed with two engine oil filters (such as YC6112),. Some filters are disposal, while
some are not (the filter cartridge is replaceable).
Engine oil filter is designed with bypass valve installed on the filter cap or filter bottom. When
filtering resistance exceeds the specified value (about 0.12MPa) due to blockage or other reasons,
the bypass valve will open automatically to divert engine oil into main oil gallery directly rather
than through the filter cartridge, in order to meet the requirements of lubrication. For non-disposal
filter, please be sure to clean the bypass valve every time you replace the filter cartridge. Some filter
is installed with engine oil pressure regulating valve on the cap, refer to part 4 in Fig. 3-126,
screw-in the adjusting bolt to increase main oil gallery oil pressure, while screw-out to reduce.
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Fig. 3-126 YC4112 engine oil filter assembly

1 Sealing gasket 2 Filter pad 3 Filter gasket 4 Pressure regulating valve assembly
5 Bolt M10×50 6 Filter seat 7 Oil return bolt 8 Paprt cartridge oil discharge pipe
Common faults of engine oil filter: oil leakage or short circuit of oil passage caused by damaged
filter gasket 3, result in main gallery oil pressure reduce; main gallery oil pressure reduce caused by
blockage of pressure regulating valve or damaged pressure regulating valve seal ring; the user failed
to follow the requirements in instruction manual to maintain the filter and result in damage or
blockage of filter element.
3173 Installation of Fuel Cut-off Solenoid Valve

Refer to part 12 in Fig. 3-75.
Fuel cut-off solenoid valve is installed on fuel injection pump flow control handle, when starting
switch is turned on for starting or running the engine, the control handle is lock in fuel feeding
position by the solenoid valve plunger; when the starting switch is in OFF position, the solenoid
valve is out of power and the control handle will reset to stop feeding fuel.
Fuel cut-off solenoid valve is inside-packed type vulnerable part, the most common fault is burning
of inside coil.
3174 Installation of Other Components

Install the cylinder cover shields, high/low pressure fuel pipes, air filter, driving wheels and all
kinds of sensors orderly according to requirements in instruction manual.
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4 Inspection & Debugging
After the assembling process is finished, the next works we should do are to inspect, run-in and
debug the complete engine. These works are very important and special attention should be paid.
41 Inspect Engine Parts and Components for Intactness and

Fastening Condition
1. Lubrication system
1) Retighten the oil drain plug on oil sump.
2) Check whether the engine oil pipe joints, connecting bolts between engine oil filter and
engine block, engine oil filter drain screw, air compressor engine oil inlet joint, engine oil
cooler inlet and outlet joints, oil inlet and outlet joints of high pressure oil pump and
turbocharger are tightened and properly sealed. Check whether oil in engine oil sump is
sufficient (use the oil dipstick).
3) Check whether engine oil filter is fully filled with engine oil.
2. Cooling system
1) Recheck the tensioning degree of fan belt, check whether the water pipes are firmly
connected.
2) Check whether matching of water pipes and fan cover meet the requirements.
3) If the engine is designed with expansion water tank, special attention must be paid when
assembling the breather pipe on water tank to avoid backwater phenomenon.
3. Check the turbocharger for infiltration of foreign matters.
4. Check the air filter and intake pipe for infiltration of foreign matters, check the pipe joints for
air short circuit.
5. Bleed the air in fuel system out by using the hand pump, check the fuel pipelines for air leakage
and oil leakage (check by operating the pump).
6. Check the engine under pan for interference with other parts, eliminate the problem timely.
7. Recheck and tighten pulley damper fastening nuts.
8. Check whether the fuel pump handle is flexible, do not start the engine if not.
9. Check the coaxiality of connection between engine and construction machinery, farm
machinery and A/C generator, check whether the vibration isolation equipment is reasonable
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and reliable.
ATTENTION
When starting the engine for the first time, it is better to close the throttle and just run
the starter motor idly to check whether there is abnormal noise produced by the engine,
to avoid after-starting failure caused by potential quality hazard. Besides, do not install
the air filter when starting the engine for the first time, so as to plug the intake pipe and
stop the engine in case of accident.
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42 Inspection of New Engine

A newly assembled engine must be inspected and tested before use, inspection items are “three
leakages”, abnormal noise and measuring of relevant technical index. For newly assembled engine
without running-in, real contact area of each kinematic pair is still 1/100~1/1000 design contact
area, that is, directly run the engine with rated load without running-in can wear and damage the
kinematic pair severely. Therefore, a proper run-in period is indispensable.
The run-in process can be performed directly on the vehicle or on a testbed. Run-in is divided into
three types: the first type is cold run-in, the engine should be driven by prime motor in this process;
the second type is no-load hot run-in, the engine should be running idly in this process; the third
type is on-load hot run-in, the engine should be loaded gradually in this process. If the run-in is
performed on vehicle, cold run-in is not available. If the run-in is performed on a testbed, the
starting rotating speed should be 20~25% rated speed; if the run-in is performed on road, the
starting rotating speed should be 40~55% rated speed; rotating speed for no-load hot run-in should
be 40~55% rated speed; for on-load hot run-in, the starting rotating speed should be 40~50% rated
speed, final rotating speed should be 80-100% rated speed, starting load should be 10~20% rated
power, and final load should be 80~100% rated power.
As to run-in time, it varies in engine models. Generally, 30min for cold run-in (with speed change),
3min for no-load hot run-in and 27min for on-load hot run-in.
If the run-in is performed on vehicle, it’s better to drive the vehicle at medium or lower speed
without load for the first 60min, and then travel the vehicle at 65% maximum speed and 70% rated
load in the following 500km, travel the vehicle at full speed and rated load after 1500km.
Inspection of the complete engine (at idle speed, medium speed and high speed):
1. Oil leakage
Respectively check the oil sump, cylinder cover shield, gear housing, fitting surface between
engine oil filter and engine block, front and rear oil seals of crankshaft, engine oil cooler and air
compressor connecting pipes for engine oil leakage.
Check the fuel injection pump, fuel filter and fuel pipe joints for diesel oil leakage. Pay special
attention to high pressure fuel pipes and injector fuel return pipes, no oil leakage is allowed in
these points in case of fire hazard.
2. Water leakage
Check the engine for water leakage, especially leakage problem inside the engine. Run the
engine for about 10min, pull out the engine oil dipstick for inspection, if there is water drops on
the dipstick or the engine oil is turned white; or shutdown the engine and remove the oil sump
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drain plug, if the engine oil is turned white (mixed with water), then there must be water
leakage problem, find out and cause and eliminate it.
3. Air leakage
Mainly check air cylinders for gas carry-over, check whether is bubble coming out from water
tank, check air compressor air inlet and outlet pipe joints for air leakage. Check each joint of
turbocharger and intercooler for air leakage.
4. Water temperature
When test-run the engine, the specified valve of water temperature is just for reference, and
cannot be used as basis to judge whether engine water temperature is normal. Because when
test engine on testbed, the water in water tank is circulating water and the engine is not affected
by wind speed; when test engine on vehicle, the engine is temporary not fully loaded, so the
measured water temperature is unrepresentative. Therefore, when estimating engine water
temperature, you should keep the engine under 70% rated load, engine water temperature is
normal if it increases as engine speed increase, but without exceeding 90oC; in addition,
comparison method (compared to other normal engines) can also be used to inspect engine
water temperature, the engine is abnormal if its water temperature rises quickly. Engine
overheating is mainly caused by blockage of water passages in cylinder cover. Real engine
water temperature can only be measured when engine works normally.
5. Engine oil pressure
Engine oil pressure must be measured when engine is running normally. The pressure should be
more than 0.1MPa (0.3MPa for YC6M engine) at idle speed, as engine speed increases, engine
oil pressure goes up stably too. The pressure should be width 0.25~0.6MPa (0.3~0.6MPa for
YC6M engine) at high engine speed, if there is big difference between measured value and
required value, you must find out the cause and eliminate it.
6. Inflation pressure
When engine is running at medium/high speed, air compressor working pressure should reach
above 0.6MPa in 5min, but not exceed 0.8MPa. Air compressor exhaust temperature should be
lower than 200oC, if the air compressor cylinder cover is too, be sure to find out the cause and
eliminate it. The leakage should not exceed 6.9kPa/min, if pressure loss is too serious
(0.069km/cm2), be sure to find out the cause and eliminate it.
7. Charging current
Normal charging current is about 15A when engine is running at medium/high speed, the limit
value is controlled by regulator. For a battery with sufficient electricity, it is normal if charging
current drops to below 5A gradually 1 hour later.
147
For a new battery with adjustable regulator, it is better to adjust the limit value to about 8A, to
ensure battery service life.
8. Run the engine at idle speed, medium speed and high speed respectively to check the color of
exhaust gas.
9. Check whether there is abnormal noise produced by the engine
For engine that matched with construction machinery, farm machinery and generator module,
the connection in engine output end has special requirements, so the generation of abnormal
noise is complex, for instance, the noise may be produced by improper connection, vibration
and interference between parts, the users should pay special attention to this.
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43 Testing of Engine Technical Indexes

Perform bench testing after the assembled engine passing the inspection. Testing steps are as
follows:
Step 1: Start and run the engine idly for 3min, check the engine for oil leakage, water leakage and
air leakage, eliminate the trouble immediately.
Step 2: Hot run-in the engine for 30min.
The run-in parameters (speed and time) should be selected based on engine model, please consult
the manufacturer for help.
Step 3: Carry out performance testing, the performance parameters vary in engine models,
parameters in the attached instruction manual are only for reference.
1. Test condition
(1) After the hot run-in period, check and ensure engine oil temperature, engine oil pressure,
outlet water temperature and exhaust gas temperature meet related requirements, and
perform the test after engine gets stabilized.
(2) Keep generator and air compressor unloaded, ensure steering pump is off work, fan and air
compressor are not driven.
(3) Exhaust backpressure is no bigger than 10kPa.
2. Test under rated working condition
Measure the following parameters when engine is running stably at rated speed and output
rated power, refer to related manuals or consult the manufacturer for standard values.
(1) Rated power (2) Rated rotating speed (3) Rated fuel consumption (for reference) (4) Intake
pressure (5) Exhaust temperature (after turbine) (6) Engine oil temperature (oil sump) (7)
Engine oil pressure (8) Piston air leakage (9) Inlet water temperature (10) Cooling water outlet
temperature (11) Atmospheric pressure (dry) (12) FSN under full load (13) Free accelerating
smoke FSN
Perform the next step if all tests under rated working condition have been passed.
3. Test under maximum torque condition
(1) Maximum torque (2) Rotating speed at maximum torque (3) Fuel consumption at maximum
torque (4) Intake pressure (5) Exhaust temperature (after turbine) (6) Engine oil temperature
(oil sump) (7) Engine oil pressure (8) Cooling water outlet temperature (9) FSN at maximum
torque
4. Other performance tests
(1) Torque at 1000r/min (2) Smoke intensity at 1000r/min (3) Torque when add 150Nm load at
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idle speed (4) Rotating speed when add 150Nm load at idle speed (5) FSN under full load (6)
Free accelerating smoke FSN
TIPS
Parameter requirements can be met by adjusting or replacing parts.
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5 Diagnosis and Elimination of Engine Common
Faults
Quality of diesel engine mainly depends on three aspects: first, quality of product itself
(performance and reliability); second, whether the use and maintenance performed by the user met
related requirements in instruction manual; third, whether the service job performed by the
serviceman reached each term specification of the product. If any of the three aspects appeared
problems, the engine can be adversely affected. This chapter provides service technologies and
troubleshooting methods for user and serviceman to refer to.
51 Diagnosis and Analysis of Engine Faults

Fault sources
1. Natural fault: fault caused by engine own quality problem other than improper maintenance or
service, such as water leakage or oil leakage caused by sand holes on engine block, wear and
out-of-tolerance of crankshaft due to longtime use.
2. Human initiated fault: the user failed to follow the requirements in instruction manual to
maintain the engine and result in failure, or failure caused by service error.
Fault information sources
Ask the user for the following information:
1. Whether it is a sudden fault or a gradual fault? Such as low engine oil pressure.
If the acquired information indicates that the oil pressure is low when the engine is new (lower
at present), then the fault is generally caused by low fuel supply pressure of engine oil pump
(misadjusting of engine oil pump safety valve) or improper adjusting of engine oil pressure
regulating valve.
If the acquired information indicates that the oil pressure is normal when the engine is new and
the pressure reduce is caused by longtime use, then the fault is generally caused by wear of
engine oil pump, oil supply shortage, severe engine oil leakage due to excessive wear of
kinematic pair blockage of engine oil gallery.
If the acquired information indicates that the oil pressure is reduced in a sudden, then the fault
is generally caused by damage of parts, such as damage of pump sealing gasket, blockage of oil
absorption disc by dirt, sudden damage of bearing or breakage of oil pipes.
151
Consult the user or serviceman for operation, maintenance and service situation of the engine:
1. Change of engine oil pressure and water temperature: when did the change happen? What
phenomenon happened? Was it happened before or after the service?
2. What happened to the oil (engine oil, diesel oil) and water?
3. What kind of maintenance, adjusting or part replacement is performed on what day, in where,
by whom?
4. When did the engine start to produce abnormal noise or smoke?
5. What wrong with engine power and speed?
Determine whether it is natural fault or human initiated fault through the work above.
Observe the engine on site:
1. Observe the engine for oil leakage, water leakage and air leakage and find out the cause
(insufficient tightening torque, damage of sealing gasket or part).
2. Listen carefully for noise pattern and position, to identify fault source.
3. Observe the engine smoke color, find out the cause and eliminate the problem.
4. Check engine speed change condition to determine whether the engine is in good condition,
which is helpful for fault judgment.
Generally speaking, one or more of the above four phenomena is/are always involved when it
comes to engine failure.
Fault analysis
Fault analysis contains three aspects:
1. Check and determine whether the engine fault is really exist, do not assume any failure by
suspicion. To do this, you must be familiar with the followings:
(1) Be familiar with fitting parameters and technical data of engine parts. They are basis to
judge whether the part or component is qualified.
(2) Be familiar with engine performance indexes, such as engine rated power, maximum
torque and speed, minimum fuel consumption under full load, exhaust temperature and
smoke intensity (including smoke color), etc. Test the engine on testbed to determine
whether the engine is qualified.
(3) Identify the abnormal noise produced by engine, you must be able to separate abnormal
noise from normal noise produced by engine. There must be fault exist if the engine
produces abnormal noise.
(4) Engine speed stability, whether engine speed is stable or not can directly reflect whether
the engine is in failure. The instability mainly happens at low speed stage and rarely
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happens at high/medium speed stage. At high/medium speed stage, accelerating failure is

the most common problem, unstable engine speed or accelerating failure is by fuel supply
system problem.
2. Analysis and locate the fault, preliminary locate the fault and its seriousness base on the
acquired information and on-site inspection, in order to determine the processes and methods
for troubleshooting.
3. Find out the fault cause by disassembling and inspection.
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52 Engine Common Faults
521 Engine is Hard to Start

The so-called “engine is hard to start”, is that when ambient temperature is about 5oC, fail to start
the engine three times in succession. There are two situations, one is that cold start is difficult, while
hot start is not; the other is that cold start is difficult, so is hot start. To differentiate causes of the
two situations, firstly you must know what the causes are.
1. Causes that may result in engine start failure and phenomena
(1) Inferior starter motor or battery ——fail to drive the crankshaft to required speed.
(2) Ambient temperature (lower than 5oC) ——compressed air in cylinder is hard to reach
required temperature, engine works under low temperature and is easy to produce white
smoke.
(3) Inferior diesel oil (too high water content) ——engine produces white smoke.
(4) Bad compression performance of engine cylinder, temperature is hard to rise ——fitting
clearance between cylinder sleeve, piston and piston ring is oversized (air ,oil and smoke
pumped out from breather, ), valve clearance is too small or valve sealing strip is burnt or
accumulated with too much carbon deposit, sealing performance of cylinder gasket is poor
(gas carry-over noise).
(5) Large resistance of moving parts, which can affect piston speed and result in low
compression temperature ——burning of bearing shell or scuffing of cylinder bore
(abnormal knocking sound will be produced).
(6) There is air in fuel circuit, fuel supplying shortage no fuel supply ——fuel pipe is poorly
connected and leaks air (operate the hand pump to deflate the fuel system and a lot of
bubbles will come out).
(7) Concentration of gas mixture is abnormal ——air intake is insufficient, fuel concentration
is too high (air filter or turbocharger failure, oversized valve clearance), bad atomization of
fuel injector nozzle (injector failure), result in incomplete combustion and black exhaust.
(8) Starting fuel shortage ——jamming of high pressure pump plunger, movement of rack
control linkage is not flexible, starting fuel quantity is improperly adjusted (hard to start in
any case).
(9) Misadjusting of fuel supply advance angle ——the engine will produce black smoke if
advance angle is oversized; and engine will produce while smoke (with carbon granules) if
advance angle is undersized.
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ATTENTION
If a newly assembled engine is hard to start, pay special attention to check whether valve
timing is correct.
Any of the causes above will result in engine hard to start. Therefore, the second situation may be
caused by one or more causes of the nine causes listed above; while for the first situation (cold start
is difficult, while hot start is not), it indicates that engine is easy to start after temperature goes up,
and of the nine causes, causes that affected by temperature are: oversized valve clearance, incorrect
valve timing, air intake shortage; excessive wear of cylinder sleeve, piston and piston ring, the
fitting clearance will reduce after temperature goes up, which is helpful for starting; bad
atomization of fuel injector nozzle (low fuel injection pressure).
2. Diagnosis of engine start failure, turn on the ignition key and engine may show:
(1) Exhaust pipe doesn’t discharge smoke, which indicates that there is no fuel feeding
Cause: ①There is air in fuel circuit
②Fuel cut-off valve is not in fuel feeding/supplying position
(2) Exhaust pipe discharges white smoke, which indicates there is fuel feeding, but isn’t
ignited
Cause: ①Cylinder sleeve is infiltrated with water (cylinder sleeve, engine block or engine
cylinder cover is cracked)
②Opening pressure of fuel injector is too low, too much supplied fuel
③Fuel feeding advance angle is too small
④Cylinder pressure is low (wear of cylinder block, piston and piston ring, valve
closure lax)
(3) Exhaust pipe discharges black smoke and produces explosive sound, which indicates there
is fuel feeding, but ignition condition is poor.
Cause: ①Bad atomization of injector (higher combustion temperature is needed)
②Ambient temperature is too low (lower than 5oC)
③Fuel feeding advance angle is too large
④Intake air shortage
⑤Starting fuel is insufficient or fuel supply circuit is blocked
522 Engine Underpower

The so-called engine underpower, is that engine cannot reach rated speed under no load, or engine
maximum output torque cannot meet requirements in instruction manual.
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It should be noted here that if engine is not reasonably matched, engine output power will be
directly affected. Therefore, before jump to any conclusion, it is better to test the engine on a
testbed. While if the engine is installed on vehicle, you can do some comparison to analysis the
failure, such as check whether no-load speed is enough, whether the rotating sound is strong and
powerful by ear and experience. If you are satisfied with the sound, check whether there is
mismatching between engine and its peripheral components: check whether water tank, fan and fan
cover are properly installed; check the matched clutch meet related design requirements, whether
there is interference between crankshaft output end and transmission box input shaft; check whether
the brake and bearings are smooth and flexible; check whether the A/C transmission mechanism
and A/C power are reasonable; check whether the exhaust pipes and intake pipes for transition
joints, the failure may be caused by too many transition joints or right-angle joints. If the failure still
exists after excluding all the external factors listed above, be sure to fully inspect the engine.
1. Causes that may result in engine underpower and phenomena
Inspection method:
Firstly, run the engine with and without load, preliminary determine whether there is engine
underpower problem by experience.
Secondly, decide whether the underpower is caused by engine self-trouble or by external
factors listed above. If it is caused by engine self-trouble, you need to make further inspection.
Thirdly, talk to the user to know whether it is sudden failure or gradual failure, to narrow down
the fault coverage.
(1) Causes for gradual engine underpower
①Bad cylinder compression, leakage of gas mixture, insufficient burning explosion
pressure ——wear of cylinder piston, cylinder sleeve, piston ring and valve sealing strip,
which result in poor sealing performance
②Fuel feeding shortage ——air leakage of fuel pipe joints, blockage of fuel supply pump
oil inlet filter screen or fuel filter element (fuel feeding shortage problem happens at
high engine speed), worn plunger results in fuel feeding pressure loss
③High engine oil pressure ——too much water scale in water circuit (especially water
tank) and result in poor heat dissipation performance.
④Fuel injection pump fail to inject enough fuel for high speed running ——preload force of
high speed spring is insufficient and need to be readjusted.
⑤Turbocharger high speed failure ——turbocharger bypass valve set pressure is low
(engine speed change is not obvious no matter the turbocharger is used or not used) and
the spring preload force need to be readjusted.
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(2) Causes for sudden engine underpower

①Bad cylinder compression, leakage of gas mixture, high concentration of gas mixture
and bad combustion ——breakage of piston ring, valve sealing strip is burst apart.
②Cylinder sleeve is infiltrated with water or cannot work normally ——cylinder bore or
cylinder sleeve is cracked, cylinder cover water passage is cracked or injector copper bush
is damaged and result in water leakage, water from water passage is infiltrated into
cylinder bore or cylinder sleeve due to damaged cylinder gasket. When that occurs, the
engine will certainly discharge white smoke, even water. Meanwhile, there will be bubbles
and oil dirt in water tank.
③Fuel feeding is abnormal
a. Bad atomization of injector nozzle, which is mainly caused by blockage of fuel
injector, low fuel opening pressure, oversized fuel feeding angle, long-time
overload low-speed high-temperature running, too much carbon deposit, poor heat
dissipation, etc. (There will be abnormal noise)
b. Jamming of fuel injection pump, shortage of fuel feeding.
c. Breakage of fuel injection pump high speed spring, engine high-speed application
point is low, engine speed is hard to raise (for A-type pump, the spring is installed
on governor; for P-type pump, the spring is installed in flyweight; for VE-type
pump, the spring is called as governing spring)
d. Breakage of fuel injection pump delivery valve or delivery valve spring, which
results in fuel feeding shortage.
e. Breakage of valve spring, which can affect air intake and exhaust.
④Misadjusting of other components
a. Valve clearance is oversized or undersized, which can affect air intake and
exhaust. The valve will produce knocking sound if the clearance is oversized,
while sometimes the valve will produce gas carry-over sound if the clearance is
undersized.
b. Fuel supply advance angle is oversized or undersized.
c. When adjusting fuel pump, rated speed and fuel feeding rate at rated speed,
maximum torque and fuel feeding rate at maximum torque are not properly
selected, you must check and readjust.
ATTENTION
Sometimes severe scuffing of cylinder bore or burning of bearing shell will also reduce
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engine power.
2. Diagnosis of engine underpower failure
Engine power should be measured at normal water temperature and elevations below 2000m. it
is normal if there is a certain power reduce when water temperature is about 100oC in the
highland area with altitude over 2000m.
Diagnosis of engine underpower failure, accelerate the engine and it may show:
(1) Exhaust pipe discharges heavy smoke, which indicates that the consumption is poor
Cause: ①Bad cylinder compression ——wear of cylinder piston, cylinder sleeve, piston
ring (blue smoke), valve closure lax (black smoke)
②Bad atomization of injector ——opening pressure of injector nozzle is low,
blockage of fuel injector (black smoke)
③Fuel feeding advance angle is too big ——engine knock (black smoke)
④Fuel feeding advance angle is too small ——more obvious at low engine speed
(white smoke)
⑤Cylinder is filled with water ——cylinder sleeve, engine knock or cylinder
cover is cracked (white smoke)
⑥Air intake is insufficient ——engine produces black smoke, especially at high
speed.
(2) Fuel feeding is insufficient at high speed, but normal at low/medium speed
Cause: ①Blockage of fuel supply circuit
②Fuel injection pump is improperly adjusted, or fuel is cu-off too early at high
engine speed
Tips: The failure may also be caused by low set pressure of turbocharger bypass valve
(black smoke).
(3) Engine can be accelerate to high speed, but engine is powerless and overload capacity is
poor, which indicate that injection pump is improperly adjusted and fuel feeding is
insufficient at maximum torque point, readjust the pump.
523 Engine Produces Abnormal Noise

Engine can produce a lot of noises during working, so are normal noises, while some are not, and it
is hard to distinguish them, besides, the noising position is not easy to locate. In order to correctly
locate the problem and find out the cause, you must be good at comparison (pay attention to engine
noise at ordinary times, compare noises of two engines and be a doing man (handle the problem by
yourself as far as possible), and be good at summing up experience.
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Phenomena and causes

Engine abnormal noise can be subdivided into three types:
1. Sudden abnormal noise
(1) Jamming of fuel injector nozzle, the noise is coming from cylinder cover, and the noise is
always exists no matter the engine is cold or hot. One of the inspection methods is to use
injector testbed, the other is to apply cylinder deactivation method: run the engine idly and
disconnect the high pressure fuel pipe of each cylinder one by one, the just disconnected
injector is jammed if the noise suddenly disappeared.
(2) Bumping cylinder base, the noise is coming from cylinder cover.
(3) Scuffing of cylinder bore, engine produces strike noise and power is reduced significantly,
engine seemed powerless especially at idle speed, even produces black smoke. Breakage of
piston ring, poor combustion, bad cooling effect of piston, abnormal working of fuel
injector and high engine temperature are main causes for this failure.
(4) Dry friction sound produced by air compressor shaft, the failure is mainly caused by
blockage of air compressor oil inlet pipe or crack of oil pipe, in this case, the air
compressor will be very hot and produce abnormal noise, please shut down the engine for
inspection immediately.
(5) Turbocharger (if installed) produces strike noise, the noise is mainly caused by bumping of
turbocharger impeller and shell due to oversized axial movement or radial movement of
turbocharger. If the problem is not serious, the noise may hard to detect when engine is
running stably.
2. Natural gradual abnormal noise (intension of the noise increases gradually)
(1) Valve sealing strip is ablated and accumulated with too much carbon deposit, and result in
gas carry-over, the noise is coming from cylinder cover.
Cause: ① Valve clearance is undersized and result in gas carry-over after engine
temperature
②Valve is burnt or accumulated with too much carbon deposit (cylinder is
infiltrated with engine oil, bad atomization, poor combustion and high engine
temperature)
(2) The crankshaft shaft will produce severe strike sound (coming from oil sump) if the main
bearing shell or connecting rod bearing shell is worn, the sound is more clear at 10m from
the engine. If connecting rod bearing shell is severely worn, there will also be
piston-bumping-valve noise (at this point, the valve will vibrate seriously). Wear of bearing
shell will also result in engine oil pressure reduce, and when draining engine oil, there must
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be alloy debris on the plug.
ATTENTION
Burning of bearing shell is very dangerous, please be sure to shut down the engine for
inspection once abnormal noise produced by bearing is detected.
(3) Severe wear of piston pin and pin hole and scuffing of cylinder bore by piston or cylinder
sleeve will also produce strike sound, but the sound is hard to locate without
disassembling.
(4) Intermittent strike sound from gear housing due to wear of idle gear shaft and oversized
timing gear backlash, the sound is more obvious if engine speed is unstable.
(5) Noise form clutch, strike sound will be produced if release bearing is damaged, or if driven
plate steel disc or rivet is loose or damaged, the higher the engine speed, the louder the
strike sound. If the strike sound gets fainter or disappeared when the clutch is engaged,
then the strike sound must come from flywheel shell.
3. Human initiated abnormal noise (caused by improper installation or adjusting)
(1) Abnormal noise caused by oversized valve clearance generally comes from cylinder cover,
the noise is more obvious when engine speed is low and temperature is high. If valve
clearance is undersized there will be gas carry-over noise, more obvious when engine
temperature is high (especially when air filter or exhaust manifold is removed), check the
valve clearance to identify the problem.
(2) If the fuel injection pump is designed with advance units, each of the advance units will
produce sound when engine is working, and the sound may vary in size, note the sound is
not abnormal noise and wouldn’t affect the work.
Tips: If the fitting clearance between advance unit and hole on injection pump connecting
plate is oversized, the sound produced by advance unit will be louder, meanwhile, too large
coaxiality error between air compressor shaft and fuel injection pump shaft will also result
in loud noise, pay attention to this during inspection.
(3) Resonance noise, sometimes there will be resonance noise produced when engine is
running at a certain speed (sometimes the engine vibrates together with the whole vehicle),
which is caused by chassis structure or engine installation defect, causes for this failure are
complex and detailed examination is indispensable.
(4) Air shock sound produced by exhaust pipe, which is mainly caused by change of valve
timing. Causes: bend or breakage of pushrod, breakage of valve spring; crankshaft timing
gear or pulley is displaced due to no locating pin or key and result in abnormal valve
timing.
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Method to check valve timing: Rotate the crankshaft until cylinder 1 reaches exhaust 30o
BTDC, turn the intake pushrod of cylinder 1 left and right by hand and it should be easy
and flexible, continue to rotate the crankshaft until it is a bit tight to turn pushrod. At this
point, the reading on the dial is cylinder 1 intake valve open angle, which should meet the
requirement in table 5-1. The valve timing is incorrect if the difference is greater than 7o.
Fig. 5-1 Valve timing inspection diagram

1 Pushrod 2 Adjusting screw 3 Intake valve 4 Dial
Table 6-1 Reference values of engine valve timing
YC6M (when intake
Engine model YC6112, YC6105,
YC4108 YC4110 YC6L valve clearance is
Parameter YC4112 YC6108
1±0.05)
Intake valve open
13.5 17 14 14±5 29.5±5 2±5
angle (°)
524 Low Engine Oil Pressure

As indicated in instruction manual for YUCHAI products, engine oil pressure at idle speed is
0.1MPa and lower than 0.6Mpa when engine is running at high speed. If engine idle-speed oil
pressure is lower than 0.1MPa, or medium/high-speed oil pressure is lower than 0.2Mpa (0.4MPa
for YC6M engine), we can determine that engine oil pressure is low.
Whether engine is properly lubricated or not can greatly affect engine performance and service life.
Engine oil can not only act as anti-friction agent, also it can be used for cooling, cleaning, sealing
and anti-rusting. Therefore, only when engine oil pressure is normal can enough engine oil flow be
guaranteed for normal working of engine.
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1. Causes that may result in low engine oil pressure (refer to Fig. 5-2 for YC6112 lubrication
route)
YC6112 engine lubrication route
Main oil gallery
Bypass valve
Cam bearing Main Piston
Idler
Oil cooler bearing cooling
shaft
nozzle
Turbocharger
Rocker
The firstcamshaft bearing sleeve
Air compressor
Injection pump
Bypass valve
Piston
Oil filter
Connecting
rod bearing
Valve
Tappet
Gear train
Oil pump Connecting
rod sleeve
Pressure
limiting valve
Engine oil sump
Fig. 5-2
Low engine oil pressure is divided into three types:
(1) Gradual pressure reduction——engine oil pressure was normal, and then reduces
gradually due to longtime use. Possible causes are as follows:
 Oversized fitting clearance due to gradual wear of related parts, deterioration of
engine oil due to longtime use or long-term high-temperature operation.
 Engine oil pump inner rotor, outer rotor and end cover are worn, engine oil pump
safety valve is inflexible or valve spring is softened.
 Blockage of engine oil filter element, especially for engine with severe worn
cylinder sleeve and piston, the filter element should be cleaned and replaced
periodically.
 Blockage of oil strainer screen. Engine oil pressure will show small or no rise when
accelerating the engine from idle speed to high speed if oil strainer screen or filter
element is blocked. Sometimes the engine oil pressure even reduces as engine speed
goes up.
 Main bearing shell, connecting rod bearing shell, camshaft sleeve and idler shaft
copper bush are worn and result in severe oil leakage.
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(2) Sudden pressure reduction——engine oil pressure reduces in a sudden due to damage of
related parts. Possible causes are as follows:
 Engine oil filter gasket is damaged and result in engine oil short circuit.
 Engine oil cooler shell (some engine models are free of engine oil cooler) is cracked
or loose welded and result in engine oil leakage, in this case, there will be engine oil
in water tank.
 Perforation or sand hole of main oil gallery (this phenomenon is rare).
 Engine oil spray nozzle (plastic part) on main bearing seat is aged, corroded and
damaged or spray hook is loose and result in serious oil leakage.
 Engine temperature is too high and result in decrease of engine oil viscosity.
 Engine oil pump shaft is broken or the shaft sleeve is loose, engine oil pump failure.
(3) Human initiated pressure reduction——caused by improper adjusting or faulty operation.
 Engine oil pressure gauge is faulty, the reading is not correct.
 Main oil gallery pressure limiting valve or pressure regulating valve on engine oil
filter is under-adjusted or dirty and result in failure. Note that YC6112 and
YC6108ZLQB engine is free of this component, but if the safety valve on engine oil
pump is under-adjusted or faulty, engine oil pressure will also be affected.
 The selected engine oil quality is poor and tends to deteriorate and thin quickly.
ATTENTION
Sometimes engine oil pressure may disappear in a sudden, the possible causes: engine oil
pump shaft or engine oil pump transmission gear shaft is broken, causing engine oil pump
unable to rotate; engine oil filter oil inlet pipe weld assembly is fractured or engine oil
pump connecting screws are loose, causing infiltration of air of oil circuit and oil
absorption failure. In the case of no detecting instrument, to identify whether there is
engine oil pressure, you can remove the cylinder cover shield and check if there is oil
surging up from rocker arm oil outlet hole when engine is running idly, there is no engine
oil pressure if not.
WARNING
When engine oil pressure is lower than 0.08MPa at idle speed or lower than 0.15MPa at
medium/high speed, be sure to stop the engine for inspection, do not count on luck.
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2. Refer to the block diagram below for diagnosis of low engine oil pressure fault.
High engine oil temperature fault
Oil pressure is normal when Clean engine oil filter and adjust the pressure limiting valve, and
engine is cold; oil pressure is then seal off the oil inlet gallery of air compressor and fuel injection
low when engine is hot pump for about 1min, observe main oil gallery pressure change
Engine oil is insufficient
Engine oil quality is poor (too thin)
Oil supply from main oil Main oil gallery rear end is
gallery front end is insufficient worn and leaking oil if the oil
if the oil pressure gets larger pressure barely changes
Engine oil pump is worn and leaking oil
Oil absorption plate is blocked
Joint or connector has oil leakage or air leakage porblem
Engine oil filter is clogged due to deformation
Severe wear of bearing shell (abnormal noise)
for rocker is insufficient

Severe wear of camshaft copper bush, oil supply
noise from gear housing)

Severe wear of intermediate gear copper bush (abnormal
Piston cooling nozzle is loose
3. Causes for burning of bearing shell

(1) Low engine oil pressure, even shortage of engine oil
 If the engine oil pressure was reduced gradually, then the bearing shell must be
severely worn (thinned), in this case, the bearing shell surface and connecting rod big
end may not be burnt blue.
 If the engine oil pressure was reduced in a sudden or engine oil is insufficient, in this
case, the bearing shell is generally not thinned, but large area of scratch damage and
burning damage will occur, and usually the shell surface is not smooth, the bearing
shell and connecting rod may be burnt blue.
(2) Poor lubrication caused by undersized or oversized fitting clearance between bearing shell
and journal
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 If fitting clearance is too small, oil film will be hard to form, which will result in direct
friction between bearing shell and journal, and easily leading to wear and scratch
damage (mostly near the separate surface of bearing shell). This kind of scratch
damage can easily result in burning of bearing shell in the first thousands of kilometers
if overloaded. If no burning of bearing shell occurred in the first 10,000km, then the
shell is safe for now.
 If fitting clearance is too big but still within the limit, lubrication action still exists, but
the lubrication performance is poor. Meanwhile, bearing shell is more easily to subject
to bumping, which will result in deformation and burning of bearing shell. This kind of
burning is generally happened after 30,000km, and the bearing shell will be severely
worn (thinned), the connecting rod big end may not be burnt blue.
(3) Disqualification of part material.
 Poor material quality. Such as low rigidity of journal, shrinkage of the structure and
delamination of bearing shell alloy, which can easily result in wear, scratch and
burning of bearing shell. With material like this, the bearing shell may burn at any time
regardless of lubrication, and generally there will be obvious scratch damage on the
burnt shell.
 Poor surface finish. Such as rough journal surface and burr and flashing on bearing
shell, tiny scratch strips will appear on the bearing shell in the first thousands of
kilometers regardless of lubrication.
 Unqualified engine oil. Engine oil viscosity is low, poor lubrication, which will
accelerate the wear and burn the bearing shell, in this case, damage condition of all
bearing shells are basically the same.
 Unclean engine oil, even mixed with sundries. The bearing shell can be scratched at
any time.
 High engine working temperature, and engine oil tends to deteriorate easily, which
will accelerate the wear and burn the bearing shell. Bearing shell will burn severely
and may turn blue under such circumstance.
Causes for burning of bearing shell are diverse and complex, so it is not an easy job to find out
the cause, you must talk to the user to get know of the fault.
ATTENTION: To detect the burning of bearing shell as soon as possible, you must remove the
drain plug of oil sump for inspection regularly.
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525 High Engine Water Temperature

Engine water temperature can be directly read from temperature gauge, the temperature is high if
the reading is bigger than 98oC, or the water in water tank is boiling.
High engine water temperature can adversely affect service life of the engine. But if the temperature
is too low, heat consumption will significantly increase, fitting clearance between parts will enlarge
and the parts will hit against each other; meanwhile, engine oil viscosity is high at low temperature,
lubrication performance will be greatly reduced.
Abrasion loss of a cold start is nearly equal to that of 50km traveling distance. When cold start,
lubrication condition is poor, and minor abrasion damage will be formed between cylinder sleeve
and piston, you must run the engine idly for a few minutes after cold start to rubdown the damage,
do not accelerate the engine immediately.
Normal engine working temperature is 85oC~95oC, in terms of minimum wear, 85oC is best, so
keep a reasonable control on engine water temperature is one of the effect methods to improve
working efficiency of engine, special attention should be paid to this.
1. Causes for high engine water temperature
(1) Effect of circulating water cooling is poor (including water-cooling and air-cooling)
 There is no enough water in water tank, radiating pipe is deformed and clogged, water
passage of engine oil cooler is blocked, too much accumulated water scale in water
tank and result in bad heat dissipation performance (touch the top and bottom of water
tank with hand and there will be great temperature difference).
 Thermostat failure, opening degree of thermostat is not enough, too much water flow
in water pump minor circulation pipe (press the pipe with finger and you can feel that
the water pressure is high).
 Water pump belt is loose or damaged, which results in abnormal rotating speed of
water pump.
(2) Bad combustion in cylinder
 Injection pump feeding rate is too high, combustion time is too long (exhaust pipe
discharge black smoke)
 Fuel supply advance angle is too large, atomization of injector is poor and injector
opening pressure is oversized, cylinder combustion condition is severe under such
circumstance and engine temperature will rise (knocking phenomenon may occur).
 Opening degree of exhaust valve is undersized, heat discharge and exhaust gas
discharge is obstructed.
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 Set value of turbocharger bypass valve high-speed pressure is high, which results in
high intake pressure and increase of engine speed.
 Cylinder bed bumping or crack of cylinder sleeve, high temperature exhaust gas flows
into water passage and result in high water temperature, but real engine temperature
may not be high.
 Scuffing of air compressor, in this case, air compressor temperature and water
temperature are high, but engine temperature is not.
(3) Inappropriate installation and use
 Water tank, fan cover and fan are not reasonably matched (refer to charger 4 for
matching requirements).
 Check whether heat dissipation of water tank is adversely affected by wrong
installation position of turbocharger and intercooler.
 Exhaust valve is not reasonably opened (mostly at low speed stage), heat discharge
and exhaust gas discharge is obstructed.
 Long time overload working.
2. Diagnosis of high engine water temperature fault
High engine water temperature fault
Water temperature of a new The water temperature was The water temperature was
or just repaired engine is high normal, but rises gradually increased in a sudden
(part or installation fault) after longtime use
Cylinder cover water jacket is blocked
Circulation of air or water

(temperature difference between up and down is big)
Water tank is accumulated with too much water scale,
Engine oil cooler is accumulated with too much water scale
rate, exhaust pipe discharges black smoke

Fuel injection pressure is low, too high fuel supplying
Leakage of circulation oil passage
Scuffling of cylinder bore (including air compressor)
Fan is damaged (silicone oil sensor failure)

Overload working
Rotating speed of fan belt or water pump is insufficient
Water pipe is aged, deformed or blocked
Thermostat failure
Water pump belt is loose, rotating speed of fan is insufficient
time, exhaust pipe discharges black smoke

Fuel injector nozzle is jammed, too long fuel supplying
sleeve (water tank produces bubbles)

Bumping cylinder base and cracking of cyinder
cooling is poorly matched

Water tank is too small
Water tank fan cover and fan are poorly matched
Ventilation around engine is poor
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3. Back-water of water tank

The so-called back-water of water tank, is that when suddenly accelerating or slow down the
engine, water flows out from water tank filling port or expansion water tank filling port.
Back-water of water tank can be subdivided into two types, namely with bubbles or without
bubbles. Causes of the bubbles: engine cylinder sleeve (cylinder block) or cylinder cover is
fractured, or cylinder bed is damaged at the area where water holes is involved, result in
infiltration of exhaust gas; the water pipeline from engine water outlet pipe to water tank is
poorly sealed.
Causes for back-water of water tank:
(1) Back-water without bubbles is mainly caused by blockage of water tank radiating pipes, or
ageing, deformation or blockage of water pump air intake rubber hose, when accelerating
the engine suddenly, water flow from water outlet pipe will be bigger than water inflow of
water pump and result in back water of water tank; if the back-water happens when
suddenly slow down the engine, then it is mainly caused by undersized opening degree of
thermostat. When accelerating, water pump will absorb a lot of water, water pressure in
engine block will rise because outlet of thermostat is blocked, slow down the engine at this
point, water abortion rate of pump will reduce significantly, high pressure water in water
tank will burst into water tank and result in back-water.
(2) Back-water with bubbles is mainly caused by unreasonable design of water tank, as shown
in Fig. 5-3, if bottom end of water tank filling port is lower than upper plane of water tank
inner cavity, an air chamber will be formed. When accelerating the engine, the water level
will rise, if the compressed air is not discharged timely, it will coming out from the filling
port together with water. The fault is more common when fan heater water circulation
connecting pipe has air leakage problem.
Compressed air
Water filling port
Water
Air
Fig. 5-3
526 Engine Produces Abnormal Smoke

Four situations for abnormal smoke of engine:
 Abnormal smoke is produced only during starting.
168
 Abnormal smoke is produced at medium/low engine speed.

 Abnormal smoke is produced regardless of engine speed.
 Abnormal smoke is only produced when accelerating suddenly.
Smoke color is subject to working condition of each cylinder, composition of exhaust gas is
complex and different composition will result in different color, basically the smoke is divided into
three colors, block color, white color (grey white) and blue color (dark blue).
1. Causes for abnormal engine smoke
(1) Black smoke (fuel supplying is vast, incomplete combustion)
 Severe wear of cylinder sleeve, piston and piston ring, valve closure lax, oversized or
under sized valve clearance, which result in bad compression.
 Air filter or turbocharger failure, leading to insufficient air intake and result in
disproportion of gas mixture (rich fuel and poor air content).
 The fuel injection pump is improperly adjusted, fuel feeding rate is too big.
Misadjusting of injector nozzle and jamming of injector nozzle, bad atomization, and
incomplete combustion.
 Oversized fuel supply advance angle, fuel is incompletely combusted at low ambient
temperature.
 Exhaust valve opening degree is too small, exhaust passage is obstructed, which can
affect cylinder air intake and exhaust temperature, and bad for normal working of
engine.
(2) Blue smoke (burning of engine oil)
 Piston or piston ring is severely worn or piston is fractured, piston ring is broken,
which result in engine oil entering into cylinder and burning.
 Turbocharger sealing ring is damaged, so that the engine oil enters the combustion
chamber along the intake passage and is combusted, when air filter is blocked, the
phenomenon is more serious.
 Severe wear of valve guide pipe, engine oil enters into cylinder through valve guide
pipe and burns.
 Fitting clearance between piston ring and ring groove doesn’t meet related
requirements, oil from sump is easy to enter into cylinder and burn (a new part can
also has this problem)
(3) White smoke (fuel contains too much water, incomplete combustion), more obvious when
engine speed is low, smoke color is similar to water vapor.
169
 Cylinder sleeve or engine block and cylinder cover are cracked, injector nozzle copper
bush is damaged, water flows into cylinder sleeve directly.
 Low ambient temperature, part of the fuel is incompletely combusted.
 Fuel supply advance angle is too small, some fuel is discharged instead of being
combusted.
ATTENTION
For engine with fuel preheating device installed on intake pipe, when preheating device
(including relay) is in failure, oil in the preheating device will flow into engine intake pipe,
which will result in blue/white smoke at idle speed, blue/black smoke at medium/high
speed. The smoke intensity decreases as engine speed rises.
When troubleshooting, you just need to disconnect the oil inlet pipe and power wire of
preheating device, the preheating device is faulty if the smoke intensity decreases.
2. Diagnosis of abnormal engine smoke fault
Diagnosis of abnormal engine smoke fault
Abnormal smoke Abnormal smoke is Abnormal smoke is produced Abnormal smoke is Abnormal smoke is
is produced only produced at medium/low at high engine speed other produced regardless only produced when
during starting engine speed than low engine speed of engine speed accelerating suddenly
Too high starting fuel feeding rate, the pump is improperly adjusted,
Fuel injection pump smoke limiter is in high fuel feeding rate position
Low ambient temperature (white smoke)
Bad compression of air cylinder

Cylinder sleeve is cracked
feed fuel)
Wear of pump plunger (at high engine speed, leaked fuel is proportionally less than
intake when pressure is high

Turbocharger bypass valve limiting valve is too low and results in insufficient air
Bad atomization of fuel injector (black smoke)

Bad atomization of fuel injector (black smoke)
Undersized fuel supplying advance angle (white smoke)

Insufficient air intake (black smoke)
Turbocharger leaks oil (blue smoke)
insufficient and result in oversized fuel feeding rate at low speed stage
Preload force of fuel injection pump smoke limiter spring is
Oversized fuel feeding rate (black smoke)
Oversized fuel supplying advance angle (black smoke)
Wear of cylinder sleeve (blue smoke)
Air valve leaks air
170
527 Vibration of Engine

The so-called vibration of engine is that when the engine is installed on vehicle, severe vibration is
produced by the whole machine. The vibration is mainly caused by poor dynamic balance of engine
itself, unstable engine speed or unreasonable matching of engine and chassis.
1. Causes for vibration of engine
(1) Parts and components that may affect dynamic balance of engine are crankshaft, flywheel,
clutch and belt pulley (damper plate), these parts and components have passed dynamic
balancing testing before delivery.
Piston connecting rods have been used in pair by weight when assembling. If the engine
was normal at first, then the vibration is not caused by the parts and components mentioned
above.
(2) Unstable engine speed will also result in vibration, and vibration caused by unstable idle
speed is the most common one, the fuel injection pump idle working point is incorrectly
adjusted in this case, and increase the idle speed can temporarily solve the problem. If
engine speed is unstable at medium/high speed stage, the vehicle will show creeping
phenomenon, which is mainly caused by misadjusting or poor quality of high-speed spring,
replace the governor if necessary.
(3) Unreasonable matching of engine and chassis
Whether the matching of engine and chassis is reasonable can greatly affect engine
balancing, so when installing the engine, the four engine legs must fall on the four holders
of chassis simultaneously, otherwise, vibration of engine and chassis will occur
(resonance may occur at a certain engine speed).
2. Diagnosis of engine resonance
Firstly, you must make sure if the vibration is caused by unstable engine speed, adjust or
replace the pump to stabilize the engine if so. Secondly, ask the user to know when did the
vibration started, if it started just after assembled, you should take down the engine and put it
on level floor for inspection, the engine is faulty if the vibration is still obvious; if the vibration
is disappeared, then the vibration must be caused by unreasonable matching of engine and
chassis. If the vibration started after a period of use, and none the dynamic balance related parts
and components is repaired, then the vibration must be caused by deformation of chassis or
loose connections.
ATTENTION
If the vehicle is installed with A/C, interference of A/C will also result in engine vibration,
find out the cause and pay attention to it.
171
53 Emergency Handling Methods for Engine Common Faults

Various faults may happen at any time when using engine, for most faults, you have to shut down
the engine for repairing. And for some faults, repair it at that moment that place may not be
available and short-term running is needed, make appropriate treatment on the fault and you can
continue to use the engine for emergency.
1. Piston, cylinder sleeve or connecting rod bearing of a certain cylinder is burnt or damaged. You
can remove the piston connecting rod assembly of this cylinder and block the oil ducts of the
connecting rod journal with cloth strips to prevent engine oil leakage and pressure reduction.
Meanwhile, you should disconnect the high pressure fuel pipe of this cylinder and unload the
fuel delivery spring, and then plug the fuel delivery joint for temporary use. Do not run the
engine at high speed under such circumstance to prevent large vibration.
2. Engine oil pressure gauge or oil sensor couldn’t reflect real pressure. At this point, you can
remove the cylinder cover shield and check if there is oil surging up from rocker arm oil outlet
hole when engine is running idly, the engine oil pressure is normal if so, but be sure to repair
the pressure gauge or sensor timely.
3. Breakage of high pressure fuel pipe. If there is no available pipe for replacement, you can
loosen the fuel delivery valve of this cylinder and plug the fuel delivery joint, or divert the fuel
back to fuel tank for temporary use, do not run the engine at high speed under such
circumstance.
4. If engine water temperature is affected by thermostat failure, you can disassemble the
thermostat and plug the minor circulation water pipe of thermostat to prevent short circuit and
high water temperature.
5. Fuel injector gets stuck in open position, which can affect engine performance and increase fuel
consumption. Handling method: if there is available new injector, you can replace the faulty
one with the new one and adjust it; if there is no available new injector you can loosen the fuel
delivery valve of this cylinder to stop the fuel feeding.
6. Damage of fuel cut-off device (on fuel injection pump) or A/C idle-speed riser, which result in
no fuel supplying or A/C failure. At this point, you just need to adjust the adjusting screw of
fuel cut-off device or A/C idle-speed riser towards fuel-increasing direction.
7. The engine is installed with silicone oil fan, if engine water temperature is affected by silicone
oil clutch failure, you can drill four thread holes on silicone oil clutch shell and engine front
cover and connect them with M10 bolts to use the silicone oil fan as common fan. But you
must pay attention to that if severe vibration is caused by the modification, be sure to reduce
the engine speed as far as possible.
172
6 Engine Parameters
61 Engine Technical Parameters

Table 6-1 YC4108 series engine technical specifications
Engine model
YC4108Q YC4108ZQ YC4108ZLQ
Parameters
Turbocharged
Air intake type Naturally aspirated Supercharged
inter-cooled
Cylinder diameter (mm) 108
Piston stroke (mm) 115
Total displacement (L) 4.214
Rated power (kW) 75 90 84.5 96
Rated speed (r/min) 2800
Maximum torque (Nm) 268 380 332 380
Speed at maximum torque
1600~1900 1600~1900
(r/min)
Maximum no-load speed
≤3300 ≤3150
(r/min)
Idle speed (r/min) 700~750
External characteristic
minimum fuel consumption ≤225 ≤210 ≤215
(g/kWh)
Exhaust smoke intensity
≤3.5 ≤3.0 ≤2.5
(FSN)
Fire ignition sequence 1-3-4-2
Crankshaft rotation direction Anticlockwise (View from power output end)
(Static) Fuel injection
advance angle (BTDC) 13°±2° 9°~11°
(°CA)
173
Table 6-2 YC4110 series diesel engine technical specifications
Engine model
YC4110Q YC4110ZQ YC4110ZLQ
Parameters
Turbocharged
Air intake type Naturally aspirated Supercharged
inter-cooled
Rated power (kW) 80 100 110
Rated speed (r/min) 3000 2800 2600 (2800)
Maximum torque (Nm) 278 392 490 (450)
Speed at maximum
torque 1900~2200 1600~1800 1400~1700
(r/min)
Full load minimum fuel
228 215 215
consumption (g/kWh)
≤3.8 Euro I Euro II
(FSN)
Maximum no-load speed ≤3080 (Rated 2800rpm)
≤3400 ≤3150
(r/min) ≤2900 (Rated 2600rpm)
advance angle (BTDC) 11°±2° 8°~10°
(°CA)
Crankshaft rotation
Anticlockwise (View from power output end)
direction
174
Engine model YC4112ZQ YC4112ZLQ YC4112ZLQ YC4112ZLQ

Parameters (G0100) (G0200) (G0400) （G0800)
Air intake type Supercharged Turbocharged inter-cooled

Rated power (kW) 105 125~132 125 132
Rated speed (r/min) 2400 2300
Speed at maximum
≤1600 ≤1500 1400~1600 ≤1400
torque (r/min)
≤210 ≤205
consumption (g/kWh)
≤3.5
(FSN)
Emission standard Euro I Euro II
2680~2760 2570~2640 2680~2760 2570~2640
(r/min)
Crankshaft rotation
direction
175
Table 6-4 YC6105ZQC, YC6108ZQ series diesel engine technical specifications

Engine model YC6105ZQC YC6108ZQ
Parameters (J3200) (J3300) B3000 B3200 B3300
Air intake type Supercharged
Cylinder diameter (mm) 105 108
Total displacement (L) 6.494 6.871
Rated power (kW) 105 118 132 118
Speed at maximum
1400~1700 1400~1800 1500~1800
torque (r/min)
Idle speed (r/min) 700~7500
≤218
consumption (g/kWh)
Emission standard Euro I
Fire ignition sequence 1-5-3-6-2-4
advance angle (BTDC) 9°~13°
(°CA)
Maximum no-load
2860~2910
speed (r/min)
Crankshaft rotation
direction
176
Table 6-5 YC6108ZLQB series diesel engine technical specifications
Engine model YC6108ZLQB YC6108ZLQB YC6108ZLQB YC6108ZLQB

Parameters (A3200) (A3500) (A3100) (A4400)
Air intake type Turbocharged inter-cooled

Cylinder diameter
108
(mm)
Rated power (kW) 177 191
Maximum torque
860 950
(Nm)
Speed at maximum
1400~1600
torque (r/min)
Full load minimum
fuel consumption 210
(g/kWh)
Exhaust smoke
3.0 2.5 3.0 2.5
intensity (FSN)
Emission standard Euro I Euro II Euro I Euro II
advance angle
9°~11° 7°~9° 9°~11° 7°~9°
(BTDC)
(°CA)
Crankshaft rotation Anticlockwise (View from power output end)
177

Engine model YC6112 YC6112 YC6112 YC6112 YC6112 YC6112 YC6112
ZLQ ZLQ ZLQ ZLQ ZQ ZQ ZQ
Parameters (G3000) (G3100) (G3200) (3300) (G3500) (G3600) (G3700)
Air intake type Turbocharged inter-cooled Turbocharged
Cylinder
112
diameter (mm)
Piston stroke
132
(mm)
Total
displacement 7.8
(L)
Rated power
155 162 177 199 155 140 147
(kW)
Rated speed
2300 2500 2300
(r/min)
Maximum
814 820 895 980 700 650 735
torque (Nm)
Speed at
1400~ 1300~ 1400~ 1300~
maximum 1400 1400~1700
1600 1500 1600 1500
torque (r/min)
Full load
minimum fuel
≤215
consumption
(g/kWh)
Maximum
2600~
no-load speed 2600~2680 2680~2760 2750~2850
2680
(r/min)
Fire ignition
1-5-3-6-2-4
sequence
Crankshaft
rotation Anticlockwise (View from power output end)
direction
(Static) Fuel
injection
advance angle 9~13 6~9 9~13 11~13
(BTDC)
(°CA)
Emission
Euro I
standard
Noise limits
≤117 ≤118 ≤117
[dB(A)]
178
Table 6-7 YC6112ZLQ series engine technical specifications

YC6112ZL
Engine model YC6112ZLQ YC6112ZLQ YC6112ZLQ
Q
Parameters (G4400) (G4500) (G8600)
(G5400)
Rated power (kW) 147 170 209 221
Rated speed (r/min) 2000 2300 2200
1300~1500 1400~1600
(r/min)
≤210 ≤220 ≤225
consumption (g/kWh)
2300~2380 2500~2580
(r/min)
Crankshaft rotation Anticlockwise (View from power output end)
advance angle (BTDC) 6~8 6~9 8~10
(°CA)
Emission standard Euro II Euro I
Noise limits [dB(A)] ≤116 ≤117 ≤119
179
Table 6-8 YC6L series engine technical specifications
Engine model YC6L350-20 YC6L330-20 YC6L310-20

Parameters (L3000) (L3300) (L3200)

Rated speed (r/min) 2200 2200 2200
Maximum torque (Nm) 1400 1280 1150
≤1400 ≤1400 ≤1400
(r/min)
≤198 ≤198 ≤198
consumption (g/kWh)
≤2.0
(FSN)
Emission standard Euro II
advance angle (BTDC) 8°~10°
(°CA)
180
Table 6-9 YC6M series engine technical specifications
Engine model YC6M220G YC6M240G YC6M-360-20

Parameters (M3000) (M3100) (L3200)
Turbocharged
Air intake type Turbocharged
inter-cooled
Rated speed (r/min) 2200 2100
Maximum torque (Nm) 880 1000 1550
Speed at maximum torque (r/min) 1300~1500 1200~1400
≤210 ≤200
consumption (g/kWh)
Coefficient of torque reserve 1.28 1.316 1.28
Emission standard (g/kWh) Beijing I Euro II
181
62 Fitting Clearance of Main Parts and Components

Table 6-10 Fitting clearance of main parts and components of YC4108 series engine Unit: mm
Fitting
clearance
S/N Fitting position Drawing dimensions Fitting property
(Interference
)
Exhaust valve seat hole
1 Interference 0.045~0.095
/ Exhaust valve seat
Intake valve seat hole /
Intake valve seat
Valve guide pipe bore /
3 Outer diameter of valve Interference 0.010~0.046
guide pipe
Radial
4 Exhaust valve rod 0.040~0.081
clearance
diameter
Radial
5 Intake valve rod 0.025~0.066
clearance
diameter
Valve rocker shaft seat
Radial
6 hole / Valve rocker 0.020~0.062
clearance
shaft
Cylinder sleeve /
Radial
7 Bottom of the piston 0.130~0.172
clearance
skirt
Valve tappet hole / Radial
8 0.020~0.093
Valve tappet clearance
Camshaft sleeve base
hole / Camshaft sleeve
Camshaft sleeve hole/ Radial
10 0.03~0.09
Camshaft journal clearance
Timing idle gear sleeve Radial
11 0.03~0.09
hole / Idler shaft clearance
Timing idle gear / Idler
12 Axial clearance 0.07~0.25
shaft
Piston ring groove /
First compression ring
Piston ring groove /
14 Second compression Axial clearance 0.09~0.125
ring
Piston ring groove / Oil
ring
Connecting rod bearing
Radial
16 shell hole / Connecting 0.06~0.128
clearance
rod journal
Connecting 4108Q
Radial
17 rod sleeve / 0.025~0.042
4108ZQ clearance
Piston pin
182
Fitting
clearance
S/N Fitting position Drawing dimensions Fitting property
(Interference
)
Piston pin 4108Q 0.005~0.018
Radial
18 seat hole /
clearance
Piston pin 4108ZQ 0.005~0.018
Main bearing hole / Radial
19 0.060~0.144
Main journal clearance
Camshaft space ring /
Camshaft thrust plate
Thickness of oil pump
21 rotor / Pump body hole Axial clearance 0.05~0.101
depth
Outer rotor outer ring / Radial
22 0.15~0.33
Oil pump body hole clearance
Oil pump shaft sleeve Radial
23 0.025~0.063
(I) / Oil pump shaft clearance
Oil pump shaft sleeve Radial
24 0.026~0.063
(II) / Oil pump shaft clearance
First compression ring Clearance 0.4~0.6
Piston ring end gap
25 Second compression ring Clearance 0.3~0.45
clearance
Oil ring Clearance 0.25~0.4
Crankshaft axial
clearance
Meshing clearance
27 Clearance 0.07~0.25
between gears
183
Table 6-11 Fitting clearance of main parts and components of YC4110 series engine Unit: mm
Fitting
Fitting
S/N Fitting position Drawing dimensions clearance
property
(Interference)
Intake valve seat
Valve guide pipe
Valve guide pipe bore / Radial
4 0.051~0.094
Exhaust valve clearance
Valve guide pipe bore / Radial
5 0.025~0.069
Intake valve clearance
6 Valve sinkage 0.9±0.15
Valve 4110Q 0.04~0.012
rocker
shaft seat
Radial
7 hole / 4110ZQ/Z clearance 0.02~0.09
Valve LQ
rocker
shaft
8 0.015~0.053
Cylinder Radial
4110Q 0.130~0.185
sleeve / clearance
Bottom
9
of the 4110ZQ/ZL Radial
0.133~0.175
piston Q clearance
skirt
Cam 4110Q 0.114~0.191
bearing
10 hole / 4110ZQ/ZL Interference
Camshaft Q 0~0.126
sleeve
Camshaft sleeve hole / Radial
11 0.03~0.09
Timing
4110Q 0.005~0.056
idle gear
sleeve Radial
12
hole / 4110ZQ/ZL clearance
0.043~0.081
Idler Q
shaft
Timing idle gear / Idler Axial
13 0.05~0.38
shaft clearance
Piston ring groove
Axial
14 height / First 0.085~0.135
clearance
compression ring height
184
Piston ring groove

Axial
15 height / Second 0.05~0.085
clearance
Piston ring groove Axial
16 0.05~0.065
height/ Oil ring height clearance
First compression ring:
0.4~0.6
Piston ring gap (pressed Second compression ring:
17
in Φ110.00 bore gauge) 0.35~0.55
Third compression ring (oil
ring): 0.3~0.55
Connecting
Red 0.04~0.09
rod big end
bearing hole /
Radial
18 Connecting
clearance
rod journal Blue 0.05~0.10
(with bearing
shell)
Connecti 4110Q 0.025~0.042
ng rod
sleeve Radial
19 4110ZQ/ZL
hole / clearance 0.005~0.038
Piston Q
pin
Piston 4110Q
pin seat
Radial
20 hole / 4110ZQ/ZL 0.005~0.018
clearance
Piston Q
pin
Main bearing
Red 0.075~0.121
hole / Main Radial
21
journal (with clearance
Blue 0.077~0.120
bearing shell)
Crankshaft thrust face / Axial
22 0.07~0.2
Crankshaft thrust plate clearance
Camshaft thrust face / Axial
23 0.05~0.22
Camshaft thrust plate clearance
The meshing clearance
24 Backlash 0.07~0.30
between the gears
Engine body Red 0.012~0.40
cylinder hole/
Outside
25 Clearance
diameter of Blue 0.018~0.46
cylinder
sleeve
185
Table 6-12 Fitting clearance of main parts and components of YC6112 and YC4112 series engine
Unit: mm
Fitting
Fitting
S/N Fitting position Drawing dimensions clearance
property
(Interference)
Exhaust valve seat
1 hole / Exhaust valve Interference 0.040~0.086
seat
Intake valve seat
Cylinder cover Valve
guide pipe bore / Outer
diameter of valve
guide
Valve guide pipe bore
Radial
4 / Exhaust valve rod 0.051~0.094
clearance
diameter
Valve guide pipe bore
Radial
5 / Intake valve rod 0.025~0.069
clearance
diameter
Valve rocker sleeve
Radial
6 inner hole / Rocker 0.02~0.09
clearance
shaft
Group I
Cylinder sleeve /
Maximum diameter of Radial
7 0.126~0.164
the bottom of piston Group II clearance
skirt

8 0.015~0.053
Camshaft sleeve base
hole / Camshaft sleeve
Camshaft sleeve hole/ Radial
10 0.076~0.137
Timing idle
6112 0.043~0.081
gear sleeve Radial
11
hole / Idler clearance
4112 0.005~0.056
shaft
Piston ring groove
height / First Axial
13 0.1~0.125
compression ring clearance
height
Piston ring groove
height / Second Axial
14 0.105~0.155
compression ring clearance
height
Piston ring groove Axial
15 0.05~0.1
height/ Oil ring height clearance
186
Piston ring gap

16 (pressed in bore Clearance 0.35~0.65
gauge)
Connecting rod
Radial
17 bearing shell hole / 0.056~0.101
clearance
Connecting rod journal
Connecting rod sleeve Radial

18 0.018~0.03
hole / Piston pin clearance
Piston pin seat hole / Radial

19 0.013~0.024
Piston pin clearance
Main
Red 0.075~0.121
bearing hole Radial
20
/ Main clearance
Blue 0.077~0.124
journal
Crankshaft thrust face Axial
21 37.06~37.11/36.91~36.96 0.1~0.2
/ Crankshaft thrust tile clearance
Spacer bush / Axial
22 4.674~4.724/4.5~4.57 0.104~0.224
Camshaft thrust plate clearance
Meshing clearance
23 Backlash 0.08~0.30
between the gears
187
Table 6-13 Fitting clearance of main parts and components of YC6105ZQC, YC6108ZQ and
YC6108ZQN series engine Unit: mm
Fitting
S/N Fitting position Drawing dimensions Fitting property clearance
(Interference)
Intake valve seat
Cylinder cover guide
3 hole diameter/ Outer Interference 0.010~0.046
diameter of valve guide
4 Radial clearance 0.040~0.081
Exhaust valve
Intake valve
6 Valve sinkage 0.8~1.2
Valve rocker hole /
Valve rocker shaft
Valve tappet hole /
Valve tappet
Camshaft sleeve hole/
Camshaft journal
Timing idle gear sleeve
hole / Idler shaft
Thickness of timing
11 idle gear / Idler shaft Axial clearance 0.07~0.25
height
YC6108ZQ, YC6108ZQN (12~16)
Piston ring groove
12 height / First Axial clearance 0.094~0.134
Piston ring groove
13 height / Second Axial clearance 0.005~0.085
Piston ring groove
height/ Oil ring height
First compression ring: 0.45~0.6
Piston ring gap (pressed Opening
15 Second compression ring: 0.3~0.45
inΦ108.00 bore gauge) clearance
Oil ring: 0.25~0.4
Cylinder sleeve /
16 Bottom of the piston Radial clearance 0.013~0.195
skirt
YC105ZQC (17~21)
Piston ring groove
17 height / First Axial clearance 0.08~0.12
Piston ring groove
height / Second
188

Piston ring groove
First compression ring: 0.4~0.60
Piston ring gap (pressed Opening
20 Second compression ring: 0.5~0.7
inΦ105.00 bore gauge) clearance
Oil ring: 0.3~0.6
Cylinder sleeve /
skirt
Connecting rod big end
bearing hole (with
bearing shell) /
Connecting rod sleeve
hole / Piston pin
Piston pin seat hole /
Piston pin
Main bearing hole /
25 Main journal (with Radial clearance 0.05~0.12
bearing shell)
Crankshaft thrust face /
Crankshaft thrust plate
Spacer bush / Camshaft
thrust plate
Meshing clearance
28 Backlash 0.07~0.30
between the gears
189
Table 6-14 Fitting clearance of main parts and components of YC6108ZLQB series engine
Unit: mm
Fitting
(Interference)
Exhaust valve seat
1 hole/ Exhaust valve Interference 0.045~0.095
seat
Intake valve seat hole/
Intake valve seat
Cylinder cover valve
3 guide pipe bore / Valve Interference 0.010~0.046
guide pipe
Valve guide pipe bore/
Exhaust valve
Intake valve
6 Valve sinkage 1.0~1.3
7 hole / Valve rocker Radial clearance 0.020~0.062
shaft
Cylinder sleeve/ 0.0175~0.05
8 Bottom of the piston Radial clearance
skirt 0.015~0.0475
Valve tappet hole/
Valve tappet
Cam bearing hole/
Camshaft sleeve
Camshaft journal
hole / Idler shaft
Timing idle gear/
Idler shaft
Piston ring groove
height/ First
compression ring
height
Piston ring groove
height/Second
compression ring
height
Piston ring groove
Piston ring gap First compression ring: 0.4~0.6
17 (pressed inΦ108.00 Second compression ring: 0.35~0.55
bore gauge) Oil ring: 0.03~0.55
190

bearing hole /
(with bearing shell)
hole / Piston pin
Piston pin
Main bearing hole /
Main journal
Camshaft thrust face /
Meshing clearance
24 Backlash 0.07~0.25
between the gears
The clearance between
25 intake valve and rocker Clearance 0.40±0.05
(cold state)
26 exhaust valve and Clearance 0.45±0.05
rocker (cold state)
27 Compression clearance Clearance 0.9~1.1
Fuel injection pump
28 transmission shaft Interference 0.057~0.106
sleeve/ Bushing
Sleeve hole/ Fuel
29 injection pump Radial clearance 0.06~0.109
transmission shaft
Fuel injection pump
transmission shaft/
Transmission thrust
ring
191
Table 6-15 Fitting clearance of main parts and components of YC6L series engine Unit: mm
Fitting
(Interference)
Exhaust valve seat
seat
Intake valve seat
guide pipe
Intake valve
Exhaust valve
Intake valve
0.55±0.15
6 Valve sinkage
Exhaust valve
0.6±0.15
Valve rocker shaft
7 sleeve hole/ Valve Radial clearance 0.018~0.048
rocker shaft
Cylinder sleeve/
skirt
Valve tappet hole/
Valve tappet
Cam bearing hole/
Camshaft sleeve
Camshaft journal
hole / Idler shaft
Timing idle gear/
Idler shaft
Piston ring groove
height/ First
compression ring
height
Piston ring groove
height/Second
compression ring
height
Piston ring groove
bore gauge) Oil ring: 0.3~0.55
192
Red(hole) + Red(shaft) +
Red(shell)*2
Red(hole) + Blue(shaft) + 0.040~0.092
bearing hole /
Red(shell) + Blue(shell) 0.045~0.097
18 Connecting rod journal Radial clearance
Blue(hole) + Blue(shaft) + 0.052~0.105
Blue(shell)*2 0.047~0.100
(unit assembly)
Blue(hole) + Red(shaft) +
Red(shell) + Blue(shell)
hole / Piston pin
Piston pin
Red(hole) + Red(shaft) +
Main bearing hole / Red(shell)*2 0.050~0.105
Main journal Red(hole) + Red(shaft) + 0.052~0.108
21 Radial clearance
(with bearing shell) Red(shell) + Blue(shell) 0.055~0.110
(unit assembly) Blue(hole) + Blue(shaft) + 0.053~0.107
Blue(shell)*2
Meshing clearance
24 Backlash 0.07~0.25
between the gears
25 intake valve and rocker Clearance 0.35±0.05
(cold state)
26 exhaust valve and Clearance 0.40±0.05
rocker (cold state)
Fuel injection pump
27 transmission shaft Interference 0.057~1.106
sleeve/ Bushing
Sleeve hole/ Fuel
28 injection pump Radial clearance 0.06~0.109
transmission shaft
Fuel injection pump
transmission shaft/
Transmission thrust
ring
193
Table 6-16 Fitting clearance of main parts and components of YC6M series engine Unit: mm
Fitting
(Interference)
Exhaust valve seat
seat
Intake valve seat
guide pipe
Exhaust valve
Intake valve
1.3~1.6
Intake
Valve
6 sinkage
Exhaust 1.1~1.4

7 hole / Valve rocker Radial clearance 0.012~0.066
shaft
Valve tappet hole/
Valve tappet
Cylinder sleeve/
0.01
skirt
Cam bearing hole/
Camshaft sleeve
Camshaft journal
hole / Idler shaft
Timing idle gear/
Idler shaft
Piston ring groove
height/Second
compression ring
height
Piston ring groove
bore gauge) Third compression ring: 0.25~0.45
194

bearing hole /
hole / Piston pin
Piston pin
Main bearing hole /
20 Main journal Radial clearance 0.103~0.147
Meshing clearance
23 Backlash 0.07~0.25
between the gears
195
63 Tightening Torque of Main Bolts

Table 6-17 Tightening torque of YC4108 engine main bolts
Name Tightening torque (Nm) Name Tightening torque (Nm)
160~230 (Phosphating)
Main bearing bolt 220~300 Cylinder cover bolt
220~300 (Blueing)
Connecting rod
160~200 Flywheel bolt 180~240
bolt
Crankshaft belt Camshaft gear lock
≥300 80~100
fastening bolt bolt

Main bearing bolt 180~260 Cylinder cover bolt 180~260
Connecting rod
bolt

Connecting rod
bolt
Table 6-20 Tightening torque of YC6105ZQC engine main bolts

Connecting rod
bolt
Table 6-21 Tightening torque of YC6108ZQ engine main bolts

Connecting rod
bolt
196
Table 6-22 Tightening torque of YC6108ZLQB engine main bolts

Connecting rod
bolt
Shock absorber Camshaft timing
120~140 100~120
bolt gear bolt

Shock absorber
Main bearing bolt 180~260 271~298
bolt
Connecting rod Camshaft timing
150~230 54~61
bolt gear bolt
Cylinder cover bolt 180~260 Idle gear shaft bolt 200~240
Flywheel bolt 160~240
Table 6-24 Tightening torque of YC6L engine main bolts

Main bearing bolt 30→150→Further 90° Cylinder cover bolt 30→150→Further 100°
Connecting rod
30→60→Further 60° Flywheel bolt 230
bolt
Silicone oil shock Camshaft timing
140 100~120
absorber bolt gear bolt
Table 6-25 Tightening torque of YC6M engine main bolts

Main: 300
Main bearing bolt 250~275 Cylinder cover bolt
Auxiliary: 150
Connecting rod
bolt
Silicone oil shock
100~120
absorber bolt
197

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Service Manual for WD10 Mechanical Pump Series Engine

YUCHAI Engine Service Manual

SHANDONG LINGONG CONSTRUCTION

Address: Linyi Economic Development Zone

2 Disassembly of Diesel Engine ................................................................................ 6

23 Disassembly of Gear Housing and Camshaft ....................................................... 25

3 Assembly of Diesel Engine .................................................................................. 39

343 Assembly of Piston Connecting Rod Assembly .......................................... 69

4 Inspection & Debugging ..................................................................................... 144

5 Diagnosis and Elimination of Engine Common Faults ...................................... 151

6 Engine Parameters .............................................................................................. 173

Important Safety Notes

13. In the process of assembling, adjusting or parameter measuring should be performed by

Be careful for the safety during the operation.

Oil, water Fill a certain amount of water, oil and fuel.

Be careful for the parts where water and oil need to be

13 Tools and Gauges

14 Application of YUCHAI Engine

YC6J125Z LG933L/LG936L/LG936L (downhole)

YC6J125Z LG936L/LG936L (downhole)

15 Composition and Significance of YUCHAI Engine Model

2 Disassembly of Diesel Engine

21 Disassembly of Outer Parts

1. Take the exhaust breather and its vent pipe out

212 Disassembly of Fan

1. Remove the 4 fixing bolts of fan, take the fan

213 Disassembly of Turbocharger

1. Disconnect turbocharger oil inlet pipe and oil

214 Disassembly of Silencer, Exhaust

1. Remove the fixing bolts of silencer assembly,

2. Screw off the fixing bolts of exhaust pipe, take

3. Remove the connecting bolts between water

215 Disassembly of Air Filter

1. Screw off the fastening nut of air filter.

2. Remove the fixing nut of outer filter element,

3. Remove the fixing nut of inner filter element,

4. Loosen the connecting clamp between air filter

5. Remove the connecting bolts between air inlet

1. Disconnect the connection between each high

2. Disconnect the connection between each high

217 Disassembly of Fuel Coarse Filter

1. Remove the fixing bolts of fuel pipes that

218 Disassembly of Hand Fuel Pump

1. Remove the fixing bolts of coarse filter to

219 Disassembly of Fuel Fine Filter

1. Remove the fixing bolts of fuel injection pump

2. Remove the fixing nuts of fuel fine filter.

2110 Disassembly of Engine Oil

1. Remove the engine oil pipe between injector

2. Remove the engine oil inlet pipe and return

2111 Disassembly of Transmission Belt

1. Loosen the adjusting bolt of generator

2. Remove the transmission belt by hand. Screw

2112 Disassembly of Fuel Injection

1. Remove the connecting bolts between advance

2. Remove the bolts that used to fix fuel injection

2113 Disassembly of DC Starter Motor

1. Remove the connecting bolts between starter

2114 Disassembly of Engine Oil Cooler

1. Disconnect the oil inlet pipe and outlet pipe

2115 Disassembly of Water Pump

1. Remove the connecting bolts between water

2116 Disassembly of Pulley Damper