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5.10 离合器常见故障及排除方法

Malfunction and Solution of Clutch

故障原因

Cause

排除方法

Solution

离合器抖动

Clutch trembled

校正离合器压盘和从动盘的变形，消除不规则接触

Calibrate the distortion of clutch pressing plate and
driven plate; eliminate abnormal touch

油路堵塞或有大量空气进入

Fuel

pipe blocked or large amount of air in
the fuel pipe

清理油污，调整分离轴承位置，更换从动盘总成，
减少负荷

Clean the oil dirt and adjust bearing

position; replace driven plate assy

离合器分离不彻底

压盘或从动盘

变形，传动片变形

The clutch

separated incompletely ; pressing
plate or driven plate distortion; drive
plate distortion

消除变形，调整自由行程或更换离合器

Eliminate

distortion and adjust free stroke or replace the
clutch

离合器异常响动

离合器的零件松动，

减震弹簧断裂或离合器中有异物

Abnormal sound: clutch parts loosed,
vibration absorber spring broken or
abnormal object in the clutch

将松动零件铆紧，消除异物或更换从动盘总成

the loosed part; eliminate the abnormal object or
replace driven plate assembly

5.11 发动机自行熄火

Shut-off automatically

故障原因

Cause

排除方法

solution

燃油用完

No fuel

检查、添加，注意排除除油路中的空气

Check and fill

fuel; exhaust the air in he fuel pipe

油路堵塞或有大量空气进入

Fuel

pipe blocked or large amount of air in
the fuel pipe

检查、清理油路，排除油路中的空气，找出进气的
原因并排除

Check and clean the fuel pipe; exhaust

the air; find the reason and eliminate the problem

发动机润滑油路不通畅，引起烧轴
瓦

Lubricating oil pipe blocked to burn
the bushing

如水温正常突然停机多属于此种情况，应拆开油底
壳检查、维修，更换相应的损坏零件

If the engine

shuts off at normal water temperature, this
problem appears. Disassemble the oil pan to
check and repair; replace the damaged part

发动机过热拉缸，一般是由于缺水或

水温过高引起的

Engine over heat

caused due to lack of water or too
high water temperature

先让机子自行冷却（绝不允许加入冷水或用冷水
冲），然后试着转动曲轴，如无卡滞现象可加入冷却
水后起动。如转不动则应拆机检查，修复，更换损
坏的零部件

Let the engine cool down itself (Never

add cold water); turn the crankshaft, fill cooling
water to start if unblocked. If blocked, disassemble

Содержание YC6A Series

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

Страница 2: ...and technical parameters the technical specifications and data of its main accessories as well as the basics information on use and service It also describes some common malfunctions and solutions YCA...

Страница 3: ...l engine to which kindly ask our customers to pay due attention The manual gives a detailed description for the basic model engine only and any modifications of it are not laid out to which we ask our...

Страница 4: ...stop the vehicle after 3 5 minutes of engine idle running Otherwise it will damage turbocharger and other moving parts and shorten engine service life consequently 5 Check often for the leakage and bl...

Страница 5: ...ry 15 Hoist and transport the engine in accordance with the precautions described on the outside the packaging case The place for storage of the engine shall be well ventilated dry clean and free of c...

Страница 6: ...9 2 Technical specification 20 2 1 Main specification basic 20 2 2 Main technical parameter 35 3 39 Primary Structures of Engine and working principle 39 3 1 Cylinder Block 39 3 2 Cylinder Head and Va...

Страница 7: ...ring Running of Engine 86 5 4 Black Smoke from Exhaust Manifold 87 5 5 88 White smoke and Blue Smoke from Exhaust Manifold 88 5 6 Abnormal lubricant pressure 88 5 7 90 Large Consumption of Lubricating...

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

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

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

Страница 11: ...4 YC6J...

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

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

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

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

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

Страница 17: ...loped by Yuchai with advantages of reliability fuel consumption saving and strong power It is ideal power for construction 1 2 Model number composition and its specific meaning The product style numbe...

Страница 18: ...engine needs to work at temperature lower than 15 or higher than 40 at the at the height above sea level of higher than 2500 m the user should consults YuChai Technical Dept and Service Dept to adopt...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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