YC6M系列天然气发动机使用及维护说明书

1、10YC6M系列天然气发动机使用及维护说明书Operation and Maintenance Manual (For YC6M SERIES CNG Engines) 发动机型号说明,如YC6M290N-30型发动机Instruction for Engines Model Code, i.e.YC6M290N-30 model:YC 6 M 290 N - 3 0重大结构改进代号Major improve code排放代号/Emission code功率代号（马力）/Power code (Ps)产品系列代号/Engine series code缸数代号/Cylinder No. code

2、企业代号Enterprise code天然气发动机Natural gas engine说明：本说明书内容包括YC6M290N-30（M2C00）、YC6M320N-30（M2B00）、YC6M340N-30（M2A00）天然气发动机，在文中统称为YC6M系列CNG气体发动机。.Note: This manual is for engines of model YC6M290N-30（M2C00）、YC6M320N-30（M2B00）、YC6M340N-20（M2A00）,which are called as YC6M series CNG engine. 发动机的标牌含有发动机的基本信息，包

3、括:标定功率、标定转速、系列代号、生产日期、执行标准等。发动机的标牌位于气缸体侧面（从飞轮输出端看为左侧）,见下图。铭牌Nameplate The engine nameplate contains the basic information of the engine, including: rated power, rated speed, series code, production date, and implementation standard. The engine nameplate is located at the side surface of the cylinder

4、 block (Observed from the flywheel output end), as shown in following figure.The nameplate of this engine contains the following basic information: rated power, rated speed, engine number, production date and Standard compliance. YC6G Series mono fuel CNG engine has its nameplate at the side of the

5、cylinder block, as the left picture illustrated .发动机型号和出厂编号还打印在气缸体上,打印部位如下图。The information of Engine Model and Number and Ex-Factory Date is also on the lower edge deck in the middle of the exhaust side of cylinder block (Please see the picture below).打印位置Engine Model & No.& Ex-factory Date 致玉柴用户TO

6、 YUCHAIS CUSTOMERS 欢迎您加入玉柴机器用户行列，衷心希望玉柴机器能给您带来滚滚财源和长久的好运。本产品采用先进的技术设计，质量可靠、使用寿命长，具有良好的动力性和经济性。为了使机器的优越性能得到更好的发挥，并保证机器的安全运行，请您在使用之前首先详细阅读该使用说明书，并特别注意以下的“安全行车注意事项”。Welcome to join the Yuchai users and we sincerely wish Yuchai Machinery bring you prosperity and long-term good luck!This product is desig

7、ned with advanced technologies to guarantee highly reliable quality and long lasting life cycle. It is able to deliver both power performance and economic efficiency. In order to maximize engine performance and ensure safety in operation, please read this Instruction Manual carefully before use, and

8、 pay special attention to the following Points of Attention on Safe Driving:安全行车注意事项!CAUTIONS ON SAFE DRIVING:1.机油压力感应塞、水温感应塞、机油压力过低报警器这些零件非常重要，凡有失灵者，须立即更换，以确保这些零件能正常工作。否则会造成因缺油烧坏曲轴或因缺水致使气缸盖过热而开裂。 Oil pressure gauge probe, water temperature gauge probe, and particularly low oil pressure alarm are th

9、e three very important components, of which immediate replacement is required for any malfunction. It is desired to always maintain the normal function of these three components, any failure to comply with that may easily lead to crankshaft burn due to oil shortage or cylinder head crack due to over

10、heat from water shortage.2.凡在保养过程中更换机油滤清器时，应先将新机油滤清器灌满机油再安装，而且安装完成后，必须起动发动机，并使其怠速运转，然后下车仔细观察滤清器有无渗漏现象，若有则须及时排除，否则会导致缺油烧坏曲轴、轴瓦等运动副零部件。After cleaning the oil filter cartridge or during the process of replacing filter cartridge, it should be noted to reinstall the filter only after refilling oil fully,

11、 and start the engine on idle running immediately after reinstallation, meantime, check if there is any sign of leakage to any filter. Correct any leaking filter, or it may easily lead to crankshaft burn caused by oil shortage.3.每次起动发动机，须怠速运转35分钟，待各种仪表正常工作后，方可起步运行。不允许冷车突然加大油门，否则会损坏各种仪表及其相应零件、加速发动机运动

12、件的磨损及损坏增压器，从而缩短发动机的使用寿命。Each time you start the vehicle, first start the engine on idle running for 5 to 10 minutes till the engine warms up and all gauges working in normal function, then start to move. Never put the vehicle to sudden acceleration from cold-start. For any dramatic speed-up on cold

13、status will damage various instruments and their corresponding parts and components and accelerate the wear and tear of engines kinetic parts, consequently it will shorten the engines life cycle.4. 不允许高速、大负荷运转状态下突然熄火停机，怠速运转35分钟后再停机。否则会损坏增压器及其它运动件，从而缩短发动机的使用寿命。Avoid any sudden stall and stop at high

14、speed high load status, the appropriate way is to gear down gradually and stop the vehicle after 5-10 minutes of engine idle running.5.应经常检查进气管路是否漏气、空气滤清器是否堵塞，若有以上现象则必须及时维护，否则会损坏增压器和导致拉缸等故障；同时发动机功率会下降，整车只能以较低的车速行驶，应及时维修。Check often for the leakage and blockage of the intake piping and air filter to

15、make them work normally. Do make adjustment or maintenance when there is leakage in the intake system and blockage in air filter, for they will damage the turbo-charger and cause the cylinder scraping and will decrease the engines power.6.使用发动机时要一档起步，否则发动机可能会熄火。Start the engine on first gear, no chu

16、ggle idling, for it will cause the engine stop.7.凡发现发动机工作不正常时，应参照系统故障诊断手册并及时处理。Anytime you find the vehicle and/or engine is not working normally, stop immediately to correct the malfunction, never allow the vehicle running under sick state.8.发动机运转时严禁靠近旋转部件，严禁直接触摸发动机的高温部件（例如排气管和增压器等）；停机后不要立即打开水箱盖以免烫

17、伤。Dont directly touch the high temperature parts (such as exhaust pipe) of the engine when you check it, dont open the radiator cover immediately after stop, this may cause physical burn.9.凡新机运行达15002500km时，须及时到玉柴的委托技术服务站进行走合保养，否则不予实行发动机的免费保修。Have the new engine run-in serviced at a consignment tech

18、nical service station of Yuchai when it reaches 15002,500 km of mileage, or you will waive the warranty for this engine.10.发动机适用于环境温度为-1540、海拔高度2000m以下的环境条件下能正常工作，禁止在水浸、火灾环境下工作。在风沙大、粉尘多的环境下，应注意清理空气滤清器滤芯灰尘，滤芯如有破损应马上更换原厂同规格滤芯。在环境温度低于-15或高于40或海拔高度超过2500m时，用户应向玉柴技术、服务部门咨询，采取有效措施以保证发动机能正常工作。Normal workin

19、g conditions for the engine is -1540 in temperature and below 2,000m in altitude, prohibit any operation under water or in fire. Clean the air filter cartridge during dusty and windy condition，replace the filter cartridge immediately once it is found to be damaged. Please consult Yuchais technical o

20、r service departments for working below -15 or above 40 or over 2,500m in altitude, so that effective measures can be taken to ensure normal function.11.冷却系统必须使用防冻液，否则由此引起的故障，不予实行免费保修。Anti-freeze coolant shall be used in the cooling system; otherwise no quality guarantee will be born by the Manufact

21、urer.12.严禁自行拆卸或维修电控有关的零件。Dismount or maintain the electronic control parts unauthorized is prohibited.13.严禁用户擅自拔插各接插件。Customer is prohibited to insert or reboot the inserting parts.14.严禁以水或任何清洗液冲洗发动机。Water and any other cleaning agent are prohibited to use for washing and cleaning the engine. 15.拆卸蓄

22、电池和断开蓄电池主开关之前，确认点火开关已关闭。Make sure the engine is switch off before dismounting and switching off the battery.16严禁随意更换排气制动碟阀。Replacement of the exhaust braking disc at will is a strict forbiddance. 17根据包装箱外的注意事项进行吊装、运输，贮存发动机的环境应通风、干燥、清洁、无腐蚀性物质，发动机有效封存期为12个月（从出厂之日算起）。Hoisting and transporting the engin

23、e according to the notes on the engines packing, and store the engine in a conditions of good ventilate, dry, clean and with no corrosiveness things. The engines storage is no longer than 12 months (counted from the ex-factory date).正确使用和维护保养发动机，否则会影响发动机动力性、经济性、排放和使用寿命。Operate and maintain the engin

24、e improperly will lower the engine performance of power, economy, emission and working life.广西玉柴机器股份有限公司Guangxi Yuchai Machinery Co., Ltd. 前 言ForewordYC6M系列CNG系列发动机是玉柴在YC6M型柴油的基础上自主开发而成的。该发动机采用增压中冷和电子控制技术，具有良好的动力性与经济性，排放达欧/标准。适配载重质量为15吨以上的各型载重货车及12m以上客车，40吨以上级的牵引车及专用车辆，稍加改进也可应用于发电机组、船用动力和工程机械等。YC6M

25、series CNG engine is developed by Yuchai based on the YC6M diesel engine, it is a turbo & inter-cooling, and electronic control gas engine. It delivers good power performance and economic efficiency; and its emission reaches the standard of Euro /. YC6M series CNG engine suitable for cargo trucks of

26、 payload over 15 tons, for the medium passenger coaches of over 12m in length, for the tractor trucks of over 40 tons, and also for the genset, marine force and construction machines by easy improvement. YC6M系列CNG系列发动机具有结构紧凑、坚固牢靠、使用维护方便、起动容易、气耗低、加速性能好、噪声低、爬坡能力强、工作安全可靠、使用寿命长、适应性广等诸多优点，是一种理想的配套动力。YC6M

27、 series CNG engine is characterized by its compact structure, solid reliability, convenient service, easy start-up, good acceleration performance, low noise, strong gradeability, safe and reliable operation, long life cycle, and wide adaptability. All these make it an ideal drive.本说明书介绍了YC6M系列CNG系列发

28、动机的主要结构、技术参数、主要附件的技术规格与数据以及使用和维护方面的基本知识，并对一些常见故障及其排除方法作了初步的介绍。希望用户通过详细阅读本说明书达到正确认识、了解与掌握YC6M系列CNG系列发动机的使用和维护，提高经济效益。随着社会不断发展和需要，发动机将不断优化和提高，并不断增加变型设计的产品，除特别重大的设计变型外，本说明书不再作更改，因此过了一定的时间后说明书的介绍可能与实际的发动机有一定的出入，敬请广大用户加以注意。This Instruction Manual introduces the YC6M series CNG engine on its structure and

29、 technical parameters, the technical specifications and data of its main accessories as well as the basics on use and service. It also introduces some preliminaries on diagnosis of frequent malfunctions and their solutions. The user is expected to benefit from these introductions and come to a bette

30、r understanding on how to use and service this engine and how to improve its economic efficiency. However, with the development of market and production, and the continuous optimization and enhancement of the engine, new variants of this model will come out. Apart from some major design variants, th

31、is Instruction Manual will not be modified, so please understand if there is information contained herein slightly different from the actual engine.目录/ CONTENT图1YC6MN-30发动机外形安装图（6）1 发动机主要技术规格及主要附件规格与技术数据Specifications （19） 1.1 发动机主要技术规格Main Technical Specification（19） 1.2 发动机主要附件规格Specification and

32、Model of Main Accessories（21）1.3 机油容量Engine oil capacity（22）1.4主要零件配合间隙及磨合极限Fitting Clearance and Wear limit of the Main Parts（24） 1.5发动机主要螺栓、螺柱、螺母拧紧力矩Tightening Torque for the Main Bolts, Plugs and Nuts（25） 2 发动机主要结构及调整Main Structure & Adjustment（28） 2.1 气缸体 Cylinder Block（28） 2.2 气缸盖与配气机构Cylinder

33、Head & Distribution System（30）2.3曲柄连杆机构Crankshaft connecting rod system（32） 2.4 配气机构及齿轮系Timing Gear and Belt Transmission（34） 2.5 润滑系统Lubrication System（37）2.6冷却系统Cooling System（40）2.7 电控供气系统 Electrical Gasing System(48) 2.8 中冷器 Intercooler（66）2.9 空气压缩机 Air Compressor（67） 2.10 电器系统 Electric System（6

34、9） 2.11 空气滤清器Air Filter（69） 2.12 进气管总成In-take Pipe Assembly（72） 2.13 排气管总成Exhaust Pipe Assembly（73） 2.14 排气制动阀Exhaust Brake Valve（74） 2.15充电发电机Alternator（75） 2.16 直流起动机 D.C.Starter（80） 2.17 液压转向泵Hydraulic Steering Pump（82） 3 发动机的使用Engine Operation（84） 3.1 发动机起动前的准备Preparation Before Starting（84） 3.2

35、 发动机的起动Starting（85） 3.3 发动机的运转Running（85）3.4 发动机的停车Stopping（85）3.5电控发动机的操作Operation of Electric Control Engine（86) 4 发动机的维护保养Engine Care and Maintenance（89） 4.1 日常维护Daily Maintenance（89） 4.2 一级保养Level I Maintenance（89） 4.3 二级保养Level II Maintenance（89） 4.4 三级保养Level III Maintenance（91） 4.5 电控供气系统维护保养

36、Care and Maintenance of Electrical Control Fuel Supply System （92） 4.6 电控供气系统一级保养Level 1 Maintenance of Electrical Control Fuel Supply System （92） 4.7电控供气系统二级保养Level II Maintenance of Electrical Control Fuel Supply System （93）4.8 发动机技术保养汇总表Summary Table of Engine Technical Maintenance（944.9发动机故障的排除E

37、ngine Faults and Solutions（96附录：常用防冻液的规格及使用更换要求Annex: Specification and Use & Replacement Requirement of Common Antifreezes（10101001 发动机主要技术规格及主要附件规格与技术数据Specification 1.1 发动机主要技术规格（基本型）Main Technical Specification (Basic Type)表1-1 YC6M系列CNG 欧系列发动机主要技术参数Table 1-1 Main Technical Parameters of YC6M Se

38、ries CNG Euro Series Engine机型Model参数Spec.M2C00M2B00M2A00型式Type立式、直列、水冷、四冲程Vertical in-line, water-cooling, 4-stroke进气方式Intake type增压中冷Turbocharging, inter-cooling燃烧室形式Combustion chamber type直桶型Straight Barrel Type气缸数（缸）Cylinder NO.6气缸直径（mm）Cylinder diameter (mm)120活塞行程（mm）Piston stroke (mm)145活塞总排量（

39、L）Total piston displacement (L)9.839压缩比Compression ratio11：1标定功率（kW）Rated power (kw)214228250标定转速Rated speed (r/min)2100最大扭矩Max. Torque（Nm）122013001350最大扭矩点转速Speed at max torque (r/min)150015001600活塞平均速度Average Piston Speed（m/s）/全负荷最低比气耗Min. Fuel Consumption at Full Load（g/（kWh）178最高空载转速Max unloaded

40、 speed（r/min）240025着火顺序Working sequence153624曲轴旋转方向Crankshaft rotation direction逆时针（面向功率输出端）Counter clockwise (facing power output)排放EmissionEuro 排气温度(增压器后)Exhaust temperature/the baock of turbo-charger（）600润滑油Lubrication oilCD级或CD以上级天然气发动机专用机油Special Engine Oil for Class CD and Above NG Engine机油容量E

41、ngine oil capacity（L）28冷却方式Cooling type闭式强制循环水冷却Closed-loop forced circulated water cooling润滑方式Lubricating type压力、飞溅混合式Combination of pressure lubrication and splash lubrication起动方式Start type电起动Electrical Start净质量Net Weight（kg）850外形尺寸(长宽高)Shape dimension (L W H)(mm)（mm）135785011951.2 发动机主要附件型号和规格 Sp

42、ecification and Model of Main Accessories表13 YC6M CNG 系列发动机主要附件型号和规格Table 1-3 Main Technical Parameters of YC6M Series CNG Series Engine机型Model参数Spec.M2C00M2B00M2C00机油滤清器Oil Filter型式Type纸质滤芯旋装式Paper Filter Element Rotary Type型号Model水 泵Water pump型式Type离心式Centrifugal标定转速Rated speed(r/min)（r/min）2650流量

43、Flow rate（L/min）560扬程Pump lift（m）15机油泵Oil pump型式Type转子式rotor type标定流量Flow rate（L/min）150标定转速Rated Speed（r/min）3812限压阀开启压力Opening Pressure of Pressure Control Valve（MPa）0.850.1机油冷却器Oil Condenser型式Type板翅式Plate-Fin Type调温器Thermostat型式Type腊式、芯体组合型Combined Type of Wax and Core开启温度Open temperature（）812全开温

44、度Full open temperature（）95增压器Turbocharger型式Type径流式Radical Type型号TypeGT37（Honeywell）中冷器Intercooler型式Type径流式Radical Type渗漏试验压力(Mpa)Leakage test pressure0.3起动机Starter型式Type行星减速直流起动机Planet Reduction DC Starter型号ModelM105R3007SE功率Power（kW）7.5电压Voltage（V）24发电机Alternator型式Type整体式交流发电机Brushless Excitation T

45、ype功率Power（kW）1.54电压Voltage（V） 28型式Type整体式交流发电机Brushless Excitation Type空气压缩机Air compressor型式Type单缸水冷Water cooling, single-cylinder额定排气量Rated displacement（2800r/min）（L/min）520（2520r/min）（L/min）润滑方式Lubricating type压力飞溅润滑Pressure Splash Lubrication注：发电机、空气压缩机根据配套车型不同而会有所不同。Note: The alternator and air

46、 compressor may vary depending on different mounted vehicles.1.3 机油容量Engine Oil Capacity1.3.1油底壳机油容量（用新机油滤清器时）：28升 或把油底壳机油液面加到油标尺两个刻度线之间约2/3位置处，如图8；Engine Oil Capacity of Oil Sump (when use new engine oil filter): 28L 图8 机油油量正确判别Figure 8 Engine oil quantity determination1.3.2 机油Engine Oil YC6M CNG系列

47、发动机是一种使用压缩天然气的电控发动机，零部件精度很高，因此对机油的选用要求也较高，必须选用CD级或以上级别的的天然气发动机专用机油（低灰份机油），见下表： YC6M CNG series engine is an electrical control engine that uses the compressed NR and the precision of its parts is really high, therefore the choice requirement of the engine oil is relatively high. It must choose the g

48、rade CD and above NR engine special engine oil (low dust content engine oil), as shown in the following table: 本机要求机油工作温度（90116），正常工作时机油压力为（0.30.6）MPa，怠速运转时应不低于0.1MPa。This machine requires that the working temperature of the engine oil is at （90116）, the engine oil pressure under normal operation is

49、 at （0.30.6）MPa, and the pressure at idle running should not be less than 0.1MPa. Details as follow: 使用条件Use Condition夏季Summer0C-15C-30C油品牌号Oil Brand15W/40CF-415W/30CF-410W/30CF-45W/30CF-4选择机油时，一定要注意两个指标，一个是机油的黏度指标，即所说的15W40或10W30。另一个是性能等级指标，即所说的性能等级的CF4，CG4等。For the choice of the engine oil, two in

50、dexes must be considerate. One is the engine oil viscosity, namely so-called 15W40 or 10W30. Another index is the performance grade index, namely so-called performance grade such as CF4 and CF5.玉柴发动机要求使用多级粘度的润滑油，这是因为多级机油适合的温度工作范围比较大，这样在早晚温差比较大的地区，发动机工作温度变化比较大的时候，发动机需要跨不同温度地区工作的情况下，以及较长的季节范围内其机油的粘度都可

51、以满足发动机正常工作的需要。还有一个重要的因素是，单级机油的消耗率比多级机油高大约30。Yuchai engine requires using the lubricating oil with multi level viscosity. This is because the multi level engine oil suits for operation in different working temperature range, as in the regions with great temperature difference between the day and the night, with wide variation of engine working temperature, or under the condition that the engine will operate crossing the regions with different temperature, and in l