VUCHAI Eales YC4108T/G series Operation and Maintenance Manual for Diesels Guangxi Yuchai Machinery Co.,Ltd.Operation and Maintenance Manual for Diesels —YC4108T/G series Yuchai Machinery Co, Ltd.Preface The YC4108T/G series diesel engine is developed by Yuchai in order to meet the requirements of the consumer market on construction and agro machinery. It has the advantages of YC4108Q and is integrated with technical future of construc- tion and agro machinery, much experience of enterprise and overseas advanced man- ufacturing technology. The series have guaranteed power. high fuel efficiency, op- eration security and reliability, universal applicability and so on, Therefore, it is an excellent choice to power agro machinery for transportation and harvest. The manual presents the technical specifications, the main accessories. the main technical structure, basic matching requirements and knowledge about operat- ing, adjusting and maintaining the engine, Meanwhile, it also illustrates some of the primary troubles and troubleshooting methods. Correct operation and mainte- nance are critical for diesel engine to run securely and prolong life-span, therefore, the users should understand and master the operation and maintenance of the YC41108T/G series diesel engine by reading this manual in detail, which would in- crease its economic benefit, Along with the development of the consumer market and manufacturing tech- niques, the diesel engine would be improved and modified continually, In general, the manual will not be changed except for great design modification, and so some contents may differ from the actual diesel engine after a period of time. Please pay special attention to the differences. The manual only shows the basic type diesel engine and does not enumerate product modifications. The technical development center of Yuchai company is responsible for the ex- planation of the manual, and the technical service center for advising the customers. Yuchai Company reserves the rights of improving the products in manual with- out notice, Yuchai Machinery Co. Ltd. March 2003Contents Fig. I Overall and mounting dimensions of model YC4108G (17000) diesel engine a ) Fig. [| Overall and mounting dimensions of model YC4108T (1D7100) diesel engine - (6) Fig. Il Speed regulation and full load characteristic curve of model YC4108G (D700) diesel engine +++ sD) Fig. IV Speed regulation and full load characteristic curve of model YC4108T (D7100) diesel engine --- + (8) 1 Employment of diesel engine - + (9) 1.1 Unpacking, check and accept of the diesel engine -@ 1.2 Assembling of the diesel engine «+++ -@ 1.3 Selection of fuel, lubricating oil and coolant +++ + @) 1.3.1 Fuel +) 1.3.2 Oil + (9) 1.3.3 Coolant 10) 1.4 Preparations before starting the diesel engine ap 1.5. Starting the diesel engine « ap 1.5.1 Procedures of starting the diesel engine ap 1.5.2 Check following items after start ap 1.6 Operating the diesel engine -- 2) 1.6.1 Requirements of using engine ++ + 2) 1.6.2 Points that always need careful check when engine is running - (a2) 1.7 Stopping the diesel engine (13) 1.8. Storage a3) 2 Diesel engine maintenance +++ + (15) 2.1 Running-in of the diesel engine + (15) 2.2 Requirements of technical maintenance + 5) 2.3 Maintenance methods - 7) 2.3.1 Check and replace oil - dD 2.3.2 De-aerate the fuel in the fuel pipe + 8) 2.3.3 Check and adjust the belt tension - 8) 2.3.4 Discharge the coolant +--+ - 18) 2.3.5 Clean the inlet screen of the oil pump + 9) 32.3.6 Clean the air cleaner - (19) 2.3.7 Add lubricating grease + + (20) 2.3.8 Scrub the water deposit off - » (20) 3 Engine specifications and accessories +++*- * (21) 3.1 Engine specifications -@) 3.2 Technical data of adjustment and control for engine + (23) 3.3. Tightening torques of the connecting screw thread + (23) 3.4 Main parts fit clearances + (24) 3.5 Specifications of main parts and accessories + (26) 4 Main installing requirements + (28) 4.1 Installation of the crankshaft + (28) 4,2 Installations of the piston and the connecting rod = (28) 4.3 Installation of the camshaft -- + (29) 4.4 Installation of the valves and valve guides +++ + (29) 4.5 Installation of the injectors + (30) 4,6 Installation of the cylinder head + (30) 4.7 Installation of the gear train «+ + (30) 5 Diesel engine adjustment + (32) 5.1 Fuel supply advance angle adjustment « (32) 5.2 Adjustment of the valve clearance + (32) 5.3 Fuel injection pressure adjustment + (33) 5.4 Oil pressure adjustment + (34) 6 Troubleshooting -- + (35) 6.1 Diesel engine can not start = (35) 6.2 Insufficient power output + (36) 6.3 Abnormal noise during engine operation + (37) 6.4 Exhaust with abnormal smoke color + (38) 6.5 Too low oil pressure ++ ~ (39) 6.6 Too high oil pressure, much diluted oil, excessive oil consumption sere (40) 6.7 Too high water outlet temperature ~ (40) 6.8 Engine stops by itself » (4D 6.9 Engine over-speeding(Speed rises sharply) +++ + (4D 6.10 Common trouble and troubleshooting remedies for injection pump + (42) 6.11 Common trouble and troubleshooting remedies for governor + (43) 6.12 Common trouble for fuel supply pump ++ + (44) 6.13 Common trouble and troubleshooting remedies for injector + (44) 6.14 Common trouble and troubleshooting remedies for clutch + (45)eursue yasaip (QOOLA)OSOLPOA JPpouw jo sucrsuaump SuNunou pue 1122949, groudoop stare Topod jo wonssod omg Senred a PF judine ww rou aepeanp 9 EL emer aT a = BB £85 E B82 Boake Lee we 0 8 sa ue ur TTT J omany toyed y |e. aN Same sore sor 68 66 o su ug Lge Sere Susp Seer sere S06t sedzop aay OT} HoT aman joy *Tesudoop ae HeE 1 Hod po oy SL: © se Tzsveudoop TT aoe ve Hs BOEaui8ue asap (QOLZG).L80LVOA [pow fo suoisuatip Suunouw pur ype1aQ, = |] ena] szesauloap apoq zzesoudonp wORTERNS 'OTHCT zeesoudoap ajoy gyssoudoap Ose scovoudloop sjnrzceeudoop| ony he pT JO Wood wonssod opr judyno wowmwut EL wonoanp 9 uopoanp pepe OHO zssoudoop rey 88 est st se 0 oe Titan sosuos amesand (yo ae ae g Be B at900 1100 1300 1500 1700 1900 2100 (r/min) Figure Ill Speed regulation and full load characteristic curve of model YC4108G(D7000) diesel engineRb (Bosch) Tr (°C) Me(N.m) Ge (gkW.h) 230 1000 1200 1400 1600 1800 2000 2200 +2400 2600 n (r/min) Figure |\ Speed regulation and full load characteristic curve of model YC4108T(D7100)diesel engine1 Employment of diesel engine 1.1 Unpacking, check and accept of the diesel engine 1. When unpacking the diesel engine, check the model types series number of the diesel engine according to the product certificate. 2. After unpacking the diesel engine, check the corresponding accessories, tools and papers according to the accessory list. 3. Check if the diesel engine is intact. If not, report back to the engine supplier. 1.2 Assembling of the diesel engine 1. Diesel engines for construction and agriculture are not equipped with water tank originally, The requirements of the water tank for diesel engine should be de- termined by the operating conditions and ambient environment of the diesel en- gine. For detail information, contact the technical center of Yuchai Machinery. 2, Diesel engine is not equipped with fuel tank originally. Requirement for the as- sembling of the fuel tank: @ = The inlet of the fuel pipe should be 25mm higher than the bottom of the fuel tank. 1.3 Selection of fuel, lubricating oil and coolant 1.3.1 Fuel The fuel should be selected according to ambient temperature. The selection should comply with Light Diesel Fuel (GB252 choice fuel and first class fuel). Ambient temperature | above 4°C | above —5°C |above —14°C| above —29°C] above —44°C Light Diesel Fuel # 0 —10 —20 —35 —50 1.3.2 Oil Oil should be selected according to the ambient conditions. The class of oil should not be lower than CD class of GB11122—1997:Ambient temperature Oil # Oil # summer 15W/40CD or 40CD 15W/40CD or 50CD above —18°C 15W/30CD or 30CD 15W/40CD or 40CD above —23°C 10W/30CD 10W/40CD above — 32°C 5W/30CD 5W/40CD Attention: Oils of different type cannot be mixed, 1.3.3 Coolant The coolant should be anti-freezing, especially when the engine is used in the plateau and in cold weather (below 0°C). It is good for the engine. The most often used anti-freezer is glycol-water, which is a mixture of glycol and water (soft water is best, If well water, spring water or other hard water is used, it should be mixed with 2g tri-sodium phosphate and a liter water in order to be softened), Selection of different proportionality coolant should vary with the ambient temperature. Glycol percentage Density of glycol-water g/cm? Freezing point °C 28 1,034 Ap 38 1.050 —20 48 1,063 —30 55 1,072 —40 60 1.078 —50 63 1.087 —60 Attention; When the percentage of the glycol is above 68%, its freezing point rises. So the percentage of the glycol should not be above 68% when you make up anti-freezer, Glycol is a transparent, viscid, poisonous liquid. Wash your skin with water immediately if it contacts your skin, Glycol is flammable. So, do not weld or light fire when there is coolant leakage. @ = When there is an emergency, anti-freeze can be replaced by soft water, such as tap water and rain water. @ Following measures should be taken before using mineral water as a replace- ment of coolant: (1) Heat the water until it boils. Then, wait until it deposits. (2) Add 2g tri-sodium phosphate per liter in order to soften the water. If mineral 10water is not softened before using as a coolant, there will be scale on the wall of water passage of diesel engine, and the deposit will weaken cooling effect and cause the engine to heat up. It can also result in scraping reduced power and higher fuel consumption, Attention; (1) Do not use sea water as a replacement of coolant water. (2) Do not use the pure coolant as coolant water. 1.4 Preparations before starting the diesel engine Check the oil level in the oil sump. The level should be within the upper and lower scale limits of the oil gauge. If the oil volume is not enough, add some oil as required, 1. Check the diesel fuel level in the fuel tank, add some fuel if necessary. 2. Check the coolant level, add some coolant if necessary. 3. Check if there is air in the fuel pipe. De-aerate fuel if there is air in the fuel Pipe. 4. Check the electrical system to see whether it operates properly or not. 5. Check if electrical system works properly. 6. Check the tension of the driving belt. The tension should be moderate as re- quired, 7. Perform every kinds of technical maintenance as required. 1.5 Starting the diesel engine The engine cannot start unless the preparations have been completed and con- firmed to comply with requirements, 1.5.1 Procedures of starting the diesel engine (1) Disengage the clutch, put the transmission in neutral gear and keep the throt- tle stay in idling or middle position. (Keep the throttle stay in idling position after the engine starts, ) (2) Switch on the start switch. After the engine starts, switch it off, 1.5.2 Check following items after start (D)_ Check the oil pressure. It should not be lower than 0. 1MPa. i(2) Check whether the water pump operates properly and whether the coolant runs into water jacket of the diesel engine. (3) Check the leakage of oil, fuel, and oil, And if there is leakage, shoot the trouble, (4) Check if there are abnormal noises. @ = Attention: 1. Do not crank the engine for more than 10 seconds a time. And if the engine fails to run after the cranking, the cranking should not be repeated within at least one minute, If the engine fails after cranking for three times successively, troubleshoot and crank again, 2. Switch off start switch immediately after starting the engine. If not, diesel en- gine, through the flywheel gear, will drive the starter rotating at a very high speed and the starter will burn. 3. After the start, engine should not speed up abruptly. 4, When the engine must be cold-started, it should not run at a high speed imme- diately. In this case, the engine should keep idling for 5 minutes with no load. 1.6 Operating the diesel engine 1.6.1 Requirements of using engine (1) When the diesel engine is cold-started, it should keep idling for 3 minutes with no load ( 5 minutes of on winter). Even if it is warm-started, the engine must run after the oil pressure being established, (2) When the diesel engine is cold-started, it should not run with the throttle completely open and should not run with full load and at high speed. It should steadily speed up and run after water temperature rising to above 60°C. (3) New engine or an engine after overhaul needs 2000~ 2500Km mileage ( or 40~50 hours) break-in period, during which the engine should run under no more than its 80% full load. Only after this break-in period can engine oper- ate as normal, 1.6.2 Points that always need careful check when engine is running (1) Check if the lubricating oil pressure is normal, The pressure should be lower than 0. 1MPa when the engine is idling and should be within 0. 25MPa and 12(2) @) @ 0. 6MPa when the engine is running at high speed. Check if the coolant temperature is normal, The temperature should be con- trolled within 75~90°C, Always observe abnormal noises when the engine is running. If there are ab- normal noises, stop the engine and troubleshoot, Pay attention to the sealing of every water passage and the fuel pipe. If there is leakage, remedy it immediately. Attention; Do not keep the engine idling for more than 5 minutes, not more than 10 mi- nutes at its minimum, Do not operate the engine by “accelerate-stop-glide in neutral gear-start the en- gine with the gear on”. Do not run the engine if it malfunctions. The exhaust manifold temperature is very high when the diesel engine is oper- ating. Do not touch the exhaust manifold lest skin be scalded. Do not place in- flammables or explosives near the exhaust manifold in case of accident. Both of the lubricating oil and the fuel are inflammable. If there is oil or fuel leakage, fix it in time in case of fire accident. 1.7 Stopping the diesel engine 2. 5. Keep the engine idling for 3 to 5 minutes before stopping it, especially when the engine runs with heavy load and at high speed. Do not stop the engine sharply unless there is an emergency. When the ambient temperature is below 5°C and the coolant is not anti-freez- ing, discharge all of the coolant water after stopping the engine to avoid engine damage by frost crack, Generally, discharge all of the coolant water when the engine will be parked for a long time. Shoot troubles that occurred when engine was running after engine stops. Al- ways check the engine and make sure that the engine runs in proper technical state, Maintenance must be available as required after diesel engine stops. 1.8 Storage 1, Diesel engine should be stored in warehouse, which is dry, with ventilation, 13and without corrosive matter, 2. If diesel engine will be stored for a long time, discharge all of the coolant, Diesel engine must be well cleaned with necessary oil sealing in case of rusting. M42 Diesel engine maintenance 2.1 Running-in of the diesel engine It is very important for new engine or an engine just after overhaul to have a 2000~2500km (or 40~50-hour) running-in. This break-in period can improve per- formance of friction pair and is essential to ensure the operating dependability and li- fespan of diesel engine. Special attentions during running-in period: (1) Do not accelerate abruptly when the diesel engine just starts, (2) Before running vehicle, keep the engine idling with no load and at low to me dium speed for at least 3 minutes (5 minutes if in winter). (3) When vehicle is running, do not accelerate abruptly. Speed up slowly. (4) Do not keep diesel engine idling more than 5 minutes, (5) Always change the speed, Do not keep the engine running at an unchanged speed for a long time. (6) Transmit at proper time to prevent the engine from operating overload at low speed, (7) Avoid running engine with heavy load and at high speed for a long time. (8) Replace the oil after running-in period (2500km/50 hours). Since then, oil can be replaced as required in maintenance procedures that will be mentioned afterwards, 2.2 Requirements of technical maintenance Maintenance period Ttems . Check the fuel level in the fuel tank. . Check the coolant level in the radiator. ih st . Check the oil level in the oil sump. Daily maintenance : . Check if there is coolant, oil, or fuel leakage . Check the tension of the driving belt, ane he . Clean the air cleaner, 15Maintenance period Items Tn addition to item 1 to item 6 above, 7. Check the sureness of the bolts on cylinder head. 8. Check the clearance of the intake and exhaust valves, After every 1500 ~ 2000km or every 30 ~40 hours) Adjust it if necessary, 9. Check the injection advance angle. 10. Check the operating pressure of the injector and check the atomization condition, 11. Clean the inlet screen of the oil pump. In addition to item 1 to item 11 above, 12. Check the electrical wirings and the contact condition of the circuit joints. After every 5000 ~ | 13. Add calcium-sodium base grease on the water pump 6000km (or every bearings. 100 hours) 14. Check the torque of main bolts and nuts, 15. Please remove the scale in the water jacket if there is excessive water deposit. 16. Replace the lubricating oil. Prescribed period (or ; . ‘, 17. Replace or clean the fuel filter, mileage) on filters @ Attention: 1. When the engine runs for 30000~40000km mileage or 600~800 hours, take a- part the oil sump, disassemble the main bearing shells, thrust plate, connect ing rod bearing shells, crankshaft bearing shells and check their wear condi- tions, Replace the one that wears out and clean the oil sump at the same time. Then assemble them altogether. 2. Ifanyone or more is replaced, such as crankshaft, piston, piston ring, cylinder sleeve, connecting rod, connecting rod bearing shell, main bearing shell, crankshaft thrust plate, camshaft, camshaft bushing, tappet, cylinder block etc. , diesel engine can run properly only after the break-in period, Engine can- not run with heavy load and at high speed just after replacement lest the com- ponents be destroyed and engine lifespan be reduced, 163. When engine is used under clean ambient condition, the maintenance period can be observed as detailed in the diagram shown before, But if the ambient condi- tion is harsh and there is heavy dust (such as dust storm), reduce the mainte- nance period of the air cleaner according to specific case, 4. As for diesel engine on harvester or on engineering vehicles pay special atten- tion to the cleanness of the fuel system. Clean the inlet screen of the oil pump and fuel filter in time. 2.3 Maintenance methods 2.3.1 Check and replace oil Always check the oil level in the oil sump; There is an oil gauge at the left side of the cylinder block (look from behind), Before chec- king the oil level, bring out the oil gauge and wipe it dry, Then, put the gauge in and bring it out again to check the oil level. The level should be within the upper and lower limits of the oil gauge (as shown in Figure 1). If the level is not enough, add some oil, as re- quired. from the cylinder head cov- er. Total oil volume in the oil tank is about 13L, and the oil volume in the oil sump is about 11L, At the bottom of the oil sump, there is an oil passage screw plug, which can add the oil discharge the oil Figure 1 Check and replace the lubricating oil be used when we need to replace the oil Replacing oil should be done just after stopping engine. At this time, foreign matters and oil are mixed and can be replaced together. Waste lubricating oil should be collected after being replaced in order to prevent polluting environment, (Note: For some agriculture vehicle, the oil passage screw plug is located on the front at the bottom of the oil sump. ) Ti2.3.2 De-aerate the fuel in the fuel Outside the fuel injection pump, there is a fuel supply pump, which is e- quipped with a hand priming pump. The hand priming pump can be used to de-a~ erate the fuel in the fuel pipe, When u- sing the hand priming pump, revolve the handle cap and it will rise up. Push the cap down again and again, the fuel can be pumped from the fuel tank to each fuel passage and the fuel chamber. At the pipe Figure 2 De-aerate the fuel in the fuel pipe same time, loosen the air outlet screw plug and expel the air out. After using the hand priming pump, revolve back the handle cap in case that the air go into the fuel supply system. 2.3.3 Check and adjust the belt tension Driving belt must be properly ten- sioned. Inspect the driving belt deflection by pushing on the belt with a force of about 4~5kg midway between pulleys. If the belt deflects about 10~ 15 mm, the tension is just as required, If the belt tension is too loose or too tight, adjust the tension by re- locating the position of the generator. 2.3.4 Discharge the coolant There is a water drain valve on the case of the oil cooler at the left side of the cylind (look from behind). It is used to drain the water- coolant in the water jacket of the diesel engine. Af- ter draining the water coolant, close the valve. 18 tighten loosen ler block Figure 4 Discharge the coolant2.3.5 Clean the inlet screen of the oil pump There is an oil pump outside the fuel injection pump. At the joint of the fuel inlet of the fuel supply pump, there is a filter screen, which is used to filter contaminants. It needs cleaning timely, When cleaning, screw down the hinged screw on the fuel control lever, take out the filter screen and clean the screen with fresh diesel fuel. After cleaning, install back the screw. 2.3.6 Clean the air cleaner Do timely maintenance to the air cleaner as required. During maintenance, take out the air cleaner element, brush dust off the surface of the ele- ment and then, blow it inside out with compressed air of 0.4 ~ 0.6MPa (4 ~ 6kg/ cm’), Check the element, the filter paper and the sealing ring to see if there is damage. If there is, replace it, At the same time, clean the dust off the dust chamber, Watch out that the filter paper cannot be cleaned with fuel, water, or other liquids. Under Figure 6 Cleaning of the air cleaner harsh condition, reduce the maintenance period of the air cleaner according to actual facts, 192.3.7 Add lubricating grease Bearings in the water pump should be lubricated with calcium sodium _ base grease. Add lubricating grease in time, as required, to prevent damage to compo- nents, There is a cup for adding lubricating grease on a part of water pump. When adding grease, point the oil gun into the cup and shoot the grease into the bearings. 2.3.8 Scrub the water deposit off Figure 7 Adding of the lubricating grease Scrub the water deposit off the coolant tank wall and the water jacket with cleaning liquid in time, in order to ensure cool- ing effectiveness and avoid overheating of the diesel engine. Generally, the cleaning liquid is appropriated as follows: add 750~800g sodi- um hydroxide and 150g kerosene per 10-liter water and mix the three evenly. Cleaning procedures: Drain the water coolant in the water tank and add the cleaning liquid into the tank, Run the diesel engine with cleaning liquid as coolant water in medium speed for about 10~15 minutes. warming up cleaning liquid. Let the cleaning liquid re~ main in the tank for about 12~15 hours and run the engine again in medium speed for about 10~15 minutes, Then, discharge all of the cleaning liquid and add water into the tank, Again, run the engine in medium speed for some time and drain the water, At this time, the cleaning is completed. If the water deposit is serious, re~ peat the procedure aforementioned 2~3 times. Attention: Sodium hydroxide is strongly alkaline. Do not eat or touch it, If your skin contacts it, please rinse you skin immediately with water. 203 Engine specifications and accessories 3.1 > Engine specifications Specification No, Name 7000 D7100 1 | Model code YC4108G YC1108T f 7a vertical, in-line, liquid-cooled and four-stroke engine 3 | Intake natural aspirated 4 | Combustion chamber directing injection and wtype 5 | Cylinder number 4 6 | Cylinder bore (mm) 108 7 | Stroke (mm) 115 8 | Displacement 4.214 9 | Compression ratio 1:1 10| Liner ‘wet type 11| Rated power (kW) 48 56 12] Rated speed (r/min) 2000 2200 18 | Max. torque (N. m) 265 275 14| Max. torque speed (r/min) 1200~1500 1600~1900 15| Rated fuel consumption (g/kW. h) <240 <240 1g| Mim specific fuel consumption at full =e = load (g/kW. h) 17| Blow-by (L/min) <1 21Specification No. Name D7000. D7100 In summer; GB252 choice fuel or first class fuel, such as 04+ or 10 # light diesel fuel 18} Fuel In winter: GB252 choice fuel or first class fuel, such as 0+ or — 104, or —20# light diesel fuel (dependent on the environment) 19 | Max. idle speed <2200 <2376 20| Min, idle speed 700~750 21) Fire order 1—3—4—-2 22] Oil consumption (g/kW. h) <0.8 23} Oil In summer; 40CD or 15W/40CD. In winter: 30CD or 10W/30CD. The oil should be Class CD or higher, as required by BG11123. 24 | Rotation direction of crankshaft counterclockwise (face to output end) 25 | Exhaust smoke number(Rb) <3.6 <3.6 26 | Soot at free acceleration (Rb) S45 27 | Noise limit (dB(A) ] <1l2 <113 28 | Lubrication system combination of splash and pressure] 29| Start system electric 30 | Cooling system pressurized circulating liquid cooling 31 | Net weight (kg) 350 32] Battery capability (Ah) area in South; = 120 Cor 135) north area and plateau and cold ar- ca; 150 (or 165) 33 (mm) Dimensions (length X width X height) 870 670X780 Note; Dimensions will be changed because of different configuration a: for loader diesel engine 223.2 Technical data of adjustment and control for engine Description Technical data Oil pressure | At rated speed 0. 25-0. 6 (MPa) At idle speed 20.1 Oil temperature (°C) <100 Coolant outlet temperature (‘C) 75—95 Static fuel supply advance angle (°CA) 13°2°before TDC 2340.5; 2640.5 Opening pressure of injector [MPa] eed oo for turbocharged Cold valve clear- | Intake valve 0.4240. 05 ance (mm) Exhaust valve 0. 45-£0. 05 Intake valve advance open angle U4+6° Valve timing | Intake valve lag close angle 446° CCA) Exhaust valve advance open angle 566° Exhaust valve lag close angle 12+6° Valve recession height (mm) 10.2 Protrusion height of fuel injector over cylinder head bot- tom surface ha Cylinder compression clearance (mm) 140.1 Oil capacity (L) 13 (11 in sump) 3.3 Tightening torques of the connecting screw thread Tightening torques of main bolts and nuts are shown below: : ; Tightening torque Description Tightening torqueCN + m) | Description (Nem Cylinder head bolt 210-250 Flywheel bolt 170-210 Main bearing bolt 20-260 Crankshaft belt pulley fastening bolt >300 Connecting rod bolt 160—200 Camshaft gear locking bolt 2300 23Except the important connecting screw thread, tightening torque of other bolts and nuts can be selected according to the table below: Screw thread specifications} © M6 M8 Mio M12 Mi4 Tightening torque(N, m) | 10—20 20-30 35—55 70—90 | 110—130 3.4 Main parts fit clearances Prescribed Assembly No, Description Type of fit dimensions (mm) tolerance Exhaust valve seat insert/exhaust 5 1 4d. 5S ° 8 /eptd. 58:99 | interference | 0. 045~0. 095 valve Intake valve seat insert/exhaust ? : 2 O18, 5%" //OH8. STS: 1H | interference | 0.089~0. 139 seat Valve guide/cylinder head valve 3 DIGS % "8 /D1GL}. B35 interference | 0. 010~0. 046 guide hole 4.| Valve guide/exhaust valve stem 09. 5°19 /9. radial clearance | 0. 040~0. 081 5 | Valve guide/intake valve stem 9. 58° 9 /9. 5-2-225 —| radial clearance | 0.025~0. 065 Rocker arm bush/ rocker arm = 3 Og 255% 25-3: 8%, | radial clearance | 0. 020+0. 062 shaft Cylinder bore/diameter of the 7 1085"? H107. 860.01 | radial clearance | 0. 130~0. 172 lower part of the piston skirt Valve tappet/cylinder block tap- 028, 0~28. 052/ 8 radial clearance | 0. 020~0. 093 pet hole 927. 959~27. 98 Camshaft bearing bore in cylinder 062. 0-~62, 03/ 9 A interference | 0. 057~0. 106 block /eamshaft bearing bush 52. 087~62. 106, Camshaft bearing bush/camshaft 10 058. 58:8, /058. 5=7-93 | radial clearance | 0.03~0.09 journal Timing idle gear bush/idle gear 1 ee Sr | 955. 54881, /865, 529% | radial clearance] 0.03~0.09 shaft 24Prescribed Assembly INo, |Description ‘Type of fit dimensions (mm) tolerance 12) Timing idle gear/idle gear shaft | 27. 92~28.0/28.07~28.17 | axial clearance | 0.07~0. 25 Top ri we height/top gas |. ay 2..695:£0. 015/ 2.605283! | axial clearance | 0.085~0. 135 ring hei Second ring groove height/second 14 ve ta biighe 2.54818 72, 572-010: axial clearance | 0.09~0. 125 BE Oil ring groove height /oil ring 15 ah 3, SESO8/ 3. 53-832 axial clearance | 0. 030~0. 065, gl Connecting rod beating ( with 16) mene B65 T5:813/46620,o9 | radial clearance | 0. 040~0. 108 shell) /erankpin 17) Connecting rod bush/piston pin 383935 /438Lo.1. | radial clearance | 0. 025~0. 047 0, 005~0. 023 038-8: 808 /488L0.011 lean 0..005~0. 0 18] Piston pin/pin boss radial clearance DHE 8 / P1020. og (turbocharged) Cylinder block main bearing (with ae ere , 19 niet Jebel D859: 175 /O85% oo | radial clearance | 0..080~0. 144 shaft journal 20 | Camshaft spacer/thrust disk axial clearance | 0. 10~0, 20 Width of the oil pump rotor / BEN a ore cl fo 229 oom /2248.8 axial clearance | 0.05~0. 101 lepth of bore in oil pump body Outer diameter of outer rotor/ 22 ie 4 te P69. 72 o,08/69. 8$f:32 | radial clearance} 0.15~0. 33 re in oil pump body Oil pump shaft bushing (1) oil . 23 ak DI9T§: S85 /o19+8. oes radial clearance | 0. 025~0. 063 pump sha Oil pump shaft. bushing (11) cil 4 radial clearance | 0. 026~0. 063 pump shaft 25Prescribed Assembly INo.| Deseription Type of fit dimensions (mm) tolerance top gas ring clearance 0.4~0.6 End gap when ring inserted in 25 second gas ring clearance | 0. 35~0.55 Bauge oil ring clearance | 0. 30~0.55 26 | Crankshaft axial clearance axial clearance | 0.1~0.27 27) Backlash of gear in mesh gear backlash | 0.07~0. 25 3.5 Specifications of main parts and accessories Specifications / model code No. Name YC4108G YC4108T rmodel code 4495 ‘ype inline plunger pump Riel “injection 1 plunger diameter | 9.5mm pump assembly plunger stroke | 8mm governor ype | mechanical variable-speed governor 2 Fuel injector as- | model code CKBL68S001 sembly ‘spe Jong mul-hole nozle 3 | Fux fier (CX0710 paper element and rotation or ZCSO712A 4 | Oil filter JX0818 paper element and rotation model code + 145 sspeisarax 5 | Thermostat eis opening temperature + 70:2°C full opening temperature 782°C 6 | Fan (2490 axial flow and plastic fan 26Specifications / model code INo,] Name YC#1086 YCA108T voltage: 24V voltage; 12V 7 | Starter generator power: 4. 8kW power: 3. 7KW, 4. KW. . voltage : 28V 24¥/500~1000W 8 | Charging generator power : 750kW 12¥/500~1000W type : single cylinder piston air-cooled working speed + 2150rpm 9 | Air compressor working pressure : 0. 8MPa displacement ; 1001,/min 10] Belt 8PK1760 V-ribbed belt used in vehicle 204 Main installing requirements 4.1 Installation of the crankshaft During crankshaft installation, the main bear- ing bolts should be tightened from thrust gear (the third gear) to both ends in order, and in three steps: First, tighten to 60~80N. m; Then, tighten to 160~180N, m; Finally, tighten to 220~260N, m. During cach time, the crankshaft should be ro- tated to check the mobility. It should be able to ro- tate freely after the final tightening, The axial clearance should be between 0. 1 and 0. 27mm. 4.2 Installations of the piston and the connecting rod When installing the piston rings, put the sur- faces marked upward (the second positive twist ring inner fillet upward). During positioning the piston- connecting rod assembly into the cylinder bore, stagger the joints in turn as shown in Figure 2, and put the arrow marked on the top surface of piston towards the front end of the engine. Remember spread some clean oil before tightening connecting- rod bolts. The tightening torque should be between 160~200N. m, and completed in three steps: First, tighten to 50~70N, m; Then, tighten to 100~120N, m; Finally, tighten to 160~200N, m. 28 Figure 8 Tightening order of the main bearings Figure 9 Orientation of the gap of piston ringsNote: Pay attention to the direct mark on the piston crown and the aligning marks on the connecting rod body and connecting rod cap. (GE EQ the top ring the second ring = SF < oil ring 1 Figure 9 marke 1 Figure 10 4.3 Installation of the camshaft Position the camshaft into the cylin- der body with caution to make sure not scratch the surfaces of the journals, cams, and liners, And then install the circlip, cam thrust plate, cam gear. and cam retainer. Finally, tighten fastening bolt with more than 300N. m tightening torque. The camshaft should be able to rotate freely, and its axial clearance is between 0. 1~0. 2mm, 4.4 Installation of the valves and valve guides The valve guides should be pressed in at normal state with 20 + 0.3mm distances between their top surfaces and the surfaces of the cylinder head spring seats. Both the intake valve face angles are 30 and the exhaust valve face angles are 45°, The valves and valve seat inserts should be grinded Figure 12in pair, The valve sinkage heights of the valves should be between 1-0. 2mm, Figure 4) 4.5 Installation of the injectors Before mounting the cylinder adjusting washer head, the injectors should be installed wiector (copper washer) in the cylinder head first. The nozzles should protrude 3. 40. 1mm from the bottom surface of the cylinder head, which can be ensured by adjusting the width of the injector washer. And then remove the injectors to prepare for following installation. As long as adjusted, the injectors and washers cannot be exchanged during installa- Figure 13 tion, 4.6 Installation of the cylinder head During cylinder head in- titBye at +1 3 +7 ths stallation, the cylinder head bolts should be tightened to a tightening torque of between te. 210~ 250N, m and following 8 2 +10, + ar rai é 18 +14 +477 4+ the sequence shown in Figure 6 Figure 14 in three step: First, tighten to 60~80N, m; Then, tighten to 120~140N. m; Finally, tighten to 210~250N. m. 4.7 Installation of the gear train The crankshaft timing gear, injec- tion pump gear, and camshaft gear should all be in accordance with the tim- Figure 15 Installation of the gear system 30ing requirement, so there are timing marks, which should be aligned during instal- ling the gears, on them and timing idle gear. Oil the tooth surface after installing. ‘The range of the gear meshing clearance is between 0.07~0. 25mm, Caution 1. Every component should be cleaned before being installed, especially the oil passages, no dirt is permitted in them. 2. No corrosion, burr, or scratch is permitted on the fit surfaces of every compo- nent, 3. Friction surfaces and important fit surfaces should be oiled before installing. 4, Fit clearance (or interference) should be in accordance with the requirement of- fered in the main fit clearance (or interference) in chapter 1. 315 Diesel engine adjustment 5.1 Fuel supply advance angle adjustment Fuel supply advance angle check: Un- screw the nut which connects the high pres- sure fuel line for the No, 1 cylinder and fuel injection pump, crank the crankshaft slowly until the fuel level in the delivery valve hold- er begins to fluctuate, At this time, the tim- ing value indicated by the pointer on the gear housing and the dial on the belt pulley damper is the fuel supply advance angle. The adjustment of the static fuel supply ad- vance angle is as follows: Unscrew the nut used to connect the flange at front of the fuel injection pump and the rear bracket, rotate the pump a proper angle (inner direction which means to increase the fuel supply ad- vance angle, outer direction which means to decrease the fuel supply advance angle), then fasten the bolts on the flange. Checks and adjust the fuel supply advance angle to pre- scription, then fasten the bolts on the flange and the bolts and nuts at the rear bracket, 5.2 Adjustment of the valve clearance Specitication (cold state) : Intake valve clearance; 0. 4-40. 05mm; Exhaust valve clearance: 0. 45-40, 05mm, To determine the compression TDC of the 32 locking nut rocker arm Figure 17first cylinder; Rotate the crankshaft to make the TDC indicator, which is mounted on the gear house cover. point to the “0” position on the belt pulley damper. Then go on rotating in a small range of angles (10°~20°) clockwise and counter- clockwise. When the intake and exhaust rockers of the first cylinder do not swing but those of the forth cylinder swing, rotate the crankshaft back to make the indicator point to the “o” position. At this time. the piston of the first cylinder is on the compression TDC. If counter, that indicates the forth piston is on the compression TDC. The first piston can reach the compression TDC by rotating the crankshaft 360°. To adjust valve clearance: Rotate the crank- Figure 18 Fuel injection pressure adjustment shaft to the position that the first piston is on the compression TDC, when the No. 1,2,3 and 6 valves can be adjusted; and then rotate the crankshaft 360°, when the No. 4,5,7 and 8 valves can be adjusted. First, loose the tightening nut of the ad- justment bolt and screw the adjustment bolt out to the suitable position. Then put the feeler gauge into the gap between rocker and the end of valve stem. Next screw in the adjustment bolt till rocker can fasten the feeler gauge. Finally, tighten the tightening nut, A correct valve clearance should be able to allow the feeler gauge move with slight resistance. 5.3 Fuel injection pressure adjustment Technical data: Injection pressure:23-+0. 5MPa 260. SMPa (turbocharged en- gine) Fuel injection pressure adjustment: Re- move the pressure-adjusting screw thimble, screw in or out the pressure-adjusting screw as required, Screwing in means the increase of the injection pressure, on the contrary, screwing Figure 19 Oil pressure adjustment 33‘out means the decrease of the injec—tion pressure. The fuel injection pressure can be adjusted on special test rig. 5.4 Oil pressure adjustment Technical data ;Oil pressure at idle > 0. 1MPa il pressure at rated speed ; 0. 25~0. 6MPa Oil pressure adjustment: The oil pressure can be adjusted by the screw of relief valve on the oil filter. During adjustment, remove the nut on the relief valve, un- screw the locking nut, screw in the adjusting screw with screwdriver, then the oil pressure will be increased. If the adjusting Screw is screwed out, the oil pressure will decrease. After the adjustment, fasten the locking nut and nut. If the adjusted oil pressure does not meet the requirement, check the trouble in the oil passages carefully and troubleshoot them. 346 Troubleshooting Determine the location of the troubles and remove them immediately when diesel engine does not operate normally. Forbid running a malfunctioning vehicle, The manual presents common troubles and troubleshooting methods only for reference, Because the knowledge about troubleshooting is simple and not compre- hensive, please pay more attention to it, When not being sure of the trouble cause, do not tackle it without authorization to avoid larger damage. It should be done that informing and consulting with technical Yuchai service station, The troubleshooting methods are shown below: 6.1 Diesel engine can not start Possible causes Remedies Charge or replace the battery. Check for 1. Insufficient power or bad ter- | looseness of the contacts of the electrical e- minals connection contact quipment or bad contact due to rustiness and then deal with it. 2. Fuel pipe clogged or insuffi- Determine the location of the clog and cient oil supply clear it. Clean filter element, Check for looseness and damage of the 3. Air exists in the oil line joints of fuel pipe, remove or replace them if necessary and then clear air in the oil line. Close the throttle, rotate the crankshaft 4, Too much oil deposit in cylin- | by motor, drain excess oil deposit in cylin- der der, and especially pay more attention to overhauled engine. Check for leakage of the delivery valve 5. Fuel supply pump does not | and inspect whether injector is worn-out, apply fuel or applies fuel ir-] plunger is seized, and if plunger spring and regularly delivery valve spring is broken, Remove them in time, 35BR Possible causes Remedies 6. Insufficient compression pres- sure due to piston ring or cyl- inder sleeve much worn-out; Check and replace the piston ring or cyl- inder sleeve 7. Blow-by valve Check the valve clearance and seal of valve. Grind or readjust the valve if necessary, 8 Incorrect fuel injection ad- vance angle Check and adjust it 9. In correct valve timing For the overhauled engine, pay attention to the timing marks alignment on timing gears, 6.2. Insufficient power output Possible causes Remedies 1. Intake blocked Check the air cleaner, intake pipe, and clean or replace air cleaner filter element. 2. Faulty injector Check the working pressure or atomiza~ tion of the injector, replace the needle valve precision pair if necessary. 3. Incorrect intake and exhaust valve clearance or bad seal of valve Check and adjust the valve clearance ac- cording to prescription; check the seal of the valve, grind it if necessary. . Overheat engine Check the level of cooling water, add e- nough water if necessary; check for the leak- age of the water pump or the looseness of the belt, remove or require it if necessary; check for thickness of scale in water passage, re- move it if necessary. ov . Air cleaner choking Replace the filter element. 6. Fuel supply pipe clogged Check and clean it, 36aR Possible causes Remedies 7. Faulty injection pump Check for leakage of the delivery valve and inspect whether plunger is worn-out, and if the plunger spring and delivery valve spring is broken, replace the damaged parts, cylinder gasket and readjust oil pump if nec- essary. 8. Cylinder gasket damage or P Replace it. leakage 9. Too high exhaust back pres- Clear the exhaust passage and muffler. sure 10. Excessive blow-by Check the piston, piston ring and cylin- der sleeve, If they are much worn out or ring elasticity is insufficient, replace them. 11. Intake pipe leakage (Turbo- charger) Check the oil pipe and remove leakage. 12. Turbocharger is out of order Determine the location of the troubles and remove it, 6.3 Abnormal noise du g engine operation Possible causes 4 Remedies 1. Incorrect injection timing or injector stuck and high fre- quency knock noise in cylin der. Check the injector, replace the needle ary. Check the fuel injection advance angle, if it changes, valve precision pair if nei adjust to the prescription. 2. Clash due to too large clear- ance between piston and cyl- inder sleeve Check the wear of the piston and cylin- der sleeve, replace them if necessary. 3. Clash due to too large clear- ance between connecting rod bearing bushing, main bear- ing bushing and journal Check if the bearing bushing and crank- shaft are much worn out, replace or press in the oversized bearing bushing if necessary. 37eR Possible causes Remedies 4. Knock due to valve touching cylinder Check and adjust the valve clearance, Inspect the valve timing for the overhauled engine 5. Clash due to too large crank- shaft axial clearance Check the wear of the thrust plate, re- place it if necessary. 6. Abnormal knock due to valve spring crack Stop immediately to check and replace the damaged parts. 7. Too large valve clearance and heavy noise around cylinder head Adjust the valve clearance 6.4 Exhaust with abnormal smoke color Possible causes Remedies 1. Exhaust with black smoke Take proper measures according to the remedies for insufficient power output 2. Exhaust with white smoke 1) Bad atomization of injector Check the working conditions, replace the excessive blow-by if necessary. 2) Water in cylinder or diesel Check diesel, if there is water in it, re- place it, otherwise, check for damage of the cylinder head parts which may cause water leak, replace the damaged ones. 3) Some cylinder doesn’t work when operating at low speed on cold day Close the shutter door when the ambient temperature is low, and make the operating temperature rise quickly to avoid running long time at low temperature. 4) Incorrect fuel injection ad- vance angle Check and adjust it. 3. Exhaust with blue smoke 1) Too much oil in sump Check the level of oil, drain it if neces- sary. 2) Operation at zero load and low speed for too long time 38 Decrease time of the operation at zero load and low speed to avoid oil blow-by and burn in cylinderBO Possible causes Remedies 3) Stucking, much wear or in- verse installing orientation of piston rings, oil blow-by and burn in cylinder Replace the piston ring if necessary. 4) Oil seeps through the gap be- tween valve guide and stem due to valve guide is much worn. Check the clearance between the valve and guide. Replace it if necessary. 6.5 Too low oil pressu re Possible causes Remedies . Insufficient oil in sump Add oil to adequacy. - Oil pipe clog or leakage Check the detailed cause, and then clean the coarse filter element or the oil strainer screen 3. Pressure adjustment valve Check the pressure adjustment valve, failure replace it if necessary. 4, Pressure indicator or trans- ; . 5 Check the cause and then replace it, mitter failure. Check if incorrect brand oil is used or oil 5. Diluted oil temperature is too high. Tf the cause is the former, replace oil, otherwise find out the reason of the latter and then deal with it, . Too large assembly clearance of oil pump Check it, replace if necessary. . Journal bearing wear or too large clearance Check and replace the journal or associ- ated parts, 8. Oil cooling plug clog Clean it, replace if necessary. 396.6 Too high oil pressure, much diluted oil, excessive oil consumption Possible causes Remedies 1. Too high diesel engine load Be careful not to pull out the lead seal on the injection to avoid engine operating at over load, 2. Incorrect engine oil grade Select oil according to the brand pre- scription, 3. Piston ring stuck or seriously worn causing gas blow-by and oil pumping-up. Dismantle, check and clean the piston and piston ring, replace the piston ring and cylinder sleeve if necessary. 4. Oil groove and bore of piston and piston ring clog Dismantle and clean, and then reinstall 5. Oil cooling plug clog Clean, replace if necessary. 6. Diluted oil due to diesel or water in it Check the cylinder sleeve seal ring, oil cooler, injection pump, injector. cylinder head, and cylinder head washer, replace them if necessary, 6.7 Too high water outlet temperature Possible causes Remedies 1. Insufficient cooling water or too small water flow Check the level of cooling water, add water to adequacy if necessary; check for looseness of the belt, adjust it if necessary; check for leakage of the water pump, repair it in time if necessary; check and replace the damaged thermostat, 2. Too much scale in water pas- sage and tank Clear it. 3. Thermostat failure Check and replace the damaged thermostat, 4, Water temperature indicator damaged and transmitter fail- L ure 40 Check and compare the actual tempera- ture with the indica ion, if they are not ac~ cordant, replace the transmitter or water temperature indicator,eR Possible causes Remedies 5. Cooling fan damage Repair or replace. 6. Water pump damage Repair or replace. 6.8 Engine stops by itself Possible causes Remedies . Fuel is used up Check and add fuel, and remove the air in the oil line. Check and clear the oil line; remove the 2. Oil line clogged or much air |. "is , : : oa air in the oil lines determine the location of enteriny : F ; the intake and then remove it. 5 When the water temperature is normal, 3. Bushing burned due to the}. ey eee gee blockaee in lubrication jt | it Will lead to engine to stop immediately. ‘age in lubrication oil | Me ini Dismantle the sump, check and repair it, and line, then replace the damaged parts. At first, make engine cool naturally (make sure not to add cold water or wash en- 4. Overheat piston scraping due | gine with it), then try to rotate the crank- to lack of water or too high water temperature. shaft. If it is jammed, start engine after adding cold water, or else move engine, check and repair it, then replace the damaged parts, 6.9 Engine over-speed ing Speed rises sharply) Possible causes Remedies Injection pump (governor) is in trouble Pull the stop handle when engine over- speeding, if the engine is fail to stop, brake it with engaging a gear in transmission, or other measures should be taken to force it to ealing off the inlet, cutting off Alter engine has stopped, adjust and repair it, replace the stop, such the fuel pipe and etc, damaged parts if necessary. 416.10 Common trouble and troubleshooting remedies for injection pump Possible causes Remedies 1. Injection failure: D No oil in oil tank, Check and add oil to adequacy. Check and drain away air, and stop up 2) Air or leaks in oil line. dhetlealang!: 3) Oil line clogged. Check and remove the blockage. Determine the location of the trouble 4) Fi ilure, 7 ) Fuel pump failure, Spent Ba Plunger precision’ pais carn Determine the location of the damaged out, snapped or — sprin; ie eal part and repair or replace it. cracked 2. Insufficient or uneven outlet oil Check the condition of fuel pump and blockage of oil line, if necessary, remove it. 1) Insufficient inlet oil pressure. 2) Leaky oil outlet valve or If there is leakage, lap in pair; if there spring crack, is damage, replace the parts. 3) Plunger precision pair is out at ORIG duet nee aceach Check and wash the oil line and preci- sion pair, and replace the much worn one. wear, Check for the looseness of the plunger control gear, tighten to the signal if = 4) Loose plunger control geer. Beary tighten t Lee ry; regulate the injection pump on test bench better. 426.11 Common trouble and troubleshooting remedies for governor Possible causes Remedies 1. Unsteady speed: 1) Inflexible flyweight or fly- weight holder of governor. Determine the location of the troubles, and then repair it, replace parts and wash it if necessary. 2) Improper idle adjustment Readjust the idle adjusting screw. 3) Governor components worn out Check and repair it. (By specialist man- ufactures) 2. Speed always lower than cali- brated speed, 1) Adjusting spring deflection, Regulate properly and replace the spring by professionals, do not do it without au- thorization, 2) Control handle mis-positio- ning. Determine the location of the blockage, and then regulate and remove it, 3) Adjusting rack and pull bar jammed or loose. Check and adjust it, then ensure the rack slides flexibly and the gear ring is not loose, otherwise readjust and repair it, 3. Speed rising promptly to ab- normal state 1) Adjusting rack or throttle pull bar stuck, Regulate and repair it, 2) The pin connecting adjusting rack and pull bar drops. Reinstall it and, if necessary, replace the damaged parts. 3) Governor spring crack. (nt Replace it and then readjust the injection pump on test bench. 436.12 Common trouble for fuel supply pump Possible causes Remedies 1. Check valve and piston wear Check and repair, replace it if necessa~ or spring crack ry. 2. Oil leak around joints Tighten or replace the seal gasket. 3. Outlet screen clog Check and clean it. 4. Oil and air-leak around hand Dismantle and repair, replace it if neces- pump sary. 6.13 Common trouble and troubleshooting remedies for injector Possible causes Remedies 1. Bad atomization of injector and insufficient or without fuel injection Clear the carbon deposit and dirt. Clean 1) Needle precision pair stuck ee P ees and grind it, replace if it cannot be recov- and injection orifice clogged ered, 2) High pressure pipe joints Determine the location of the troubles, leakage and then recondition or replace it. 3) Dirt on surface of needle Clean it. 2. Low injection pressure 1) Pressure adjusting screw i A SSHRE | Readjust and tighten the stud. looseness 2) Press: justi sprin; Hie ee Check and replace, crack 3) Pressure adjusting spring de~ Chee and replace flection 4) Spring seat and stem damage Repair or replace the damaged parts. 5) Needle stuck Clean and grind it. 44OR Possible causes Remedies 3. Injector oil leals 1) Bad seal of needle precision pair Grind it after cleaning. replace it if inef- fective. 2) Needle stuck Clean and grind, replace it if ineffective, 3) Nozzle retaining nut damage and deflection Replace it. 4) Sealing surface of injector body and needle body dam- age Lap in pair after cleaning, replace if it can not be recovered clutch 6.14 Common trouble and troubleshooting remedies fo Possible causes Remedies 1. Clutch slippage 1) Oil stain or dirt on rubbing surface Check and clean it with gasoline or kero- sene, reinstall it after blowing dry. 2) Too long separating stroke Check and adjust to make sure the sepa~ rating stroke within 12-15mm, 2. Not through declutching: 1) Too short separating stroke Adjust the minimal separating stroke and make sure it over 10—12mm. 2) The ends of every separating level are not in the same plane Readjust and make sure the end plane | difference between fore levels below 0. 2mm, (or spire spring clutch) 45vucHal Address:N0.88 Tiangiao West Road, Yulin, Guangxi, China Tel:+86-775-3288092; 3282108 Fax:+86-775-3289856; 3289990 E-mail:yciexs@yuchai.cn Postcode:537005 http://www. yuchai.com