Maintenance Tips For Yuchai YC4108D and YC4108ZD Diesel Engine
by Starlight Generator dieselgeneratortechFollowing
proper guides to maintain diesel engine can help you operate a diesel engine
better. Following are some tips for Yuchai YC4108 series diesel engine,
including requirements of technical maintenance, maintenance methods, de-aerate
the fuel in the fuel pipe, adjusting belt tension, cleaning the inlet screen of
the oil pump, cleaning the air cleaner, adding lubricating grease and scrubbing
the water deposit off.
I Break-In
of The Diesel Engine
It is very
important for new engine or an engine just after overhaul to have a 50 - hour
break -in. This break - in period can
improve performance of friction pair and is essential to ensure the operating
dependability and lifespan of diesel engine. If conditions permit, run the
engine at speed of 1500r/min and under 25% , 50% and 750/o full load, each load
an hour.
Special
attentions during break - in period:
(1) Do not
accelerate abruptly when the diesel engine just starts
(2) Before
running engine, keep the engines idling with no load at low to medium speed for
at least 5 minutes.
(3) When
engine is running, do not increase load abruptly. Increase load slowly.
(4)Replace
the lubricating oil when the engine runs for 50 hours. Replace the oil again
after break-in period (50 hours) . Since then, oil can be replaced as required
in maintenance procedures that will be mentioned afterward.
II
Requirements Of Technical Maintenance
A. Daily
maintenance
1. check the
fuel level in the fuel tank.
2. Check the
water level in the radiator
3. Check the
oil level in the oil sump.
4. Check if
there is coolant, oil, or fuel leakage.
5. Check the
tension of the driving belt.
B. After
every 50 hours
in addition
to item 1 to item 5 above.
6.Check the
sureness of the bolts on cylinder head.
7. Check the
clearance of the intake and exhaust valves.
8. Check the
injection advance angle. Adjust it if necessary.
9. Check the
operating pressure of the injector and check the atomization codition.
10. Clean
the inlet screen of the oil pump.
C. After
every 150 hours
in addition
to item 1 to item 10 above.
11. Clean
the air cleaner.
12. check
the electrical wiring and the contact condition of the circuit joints.
13. Add
calcium- sodium base grease on the water pump bearings.
14. Check
the torque of main bolts and nuts.
15. Please remove the scale in the water deposit.
16. Replace
the lubricating oil.
Attention :
1. When the
engine runs for 1200 ~ 1500 hours, take apart the sump, disassemble the main
bearing shells, thrust plate, connecting rod bearing shells, crankshaft bearing
shells and check their wear conditions.
Replace the
one that wears out and clean the oil sump at the same time. Then assemble them
altogether.
2. If
anymore or more is replaced, such as crankshaft, piston, piston ring, cylinder
connecting rod, connecting rod bearing shell, main bearing thrust plate,
camshaft, camshaft bushing, tappet cylinder block etc. , diesel engine can run
properly only after the break-in period Engine cannot run with heavy load and
at high speed just after replacement lest the components be destroyed and
engine lifespan
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 condition
is harsh and there is heavy dust, reduce the maintenance period of the air
cleaner according to specific case.
III. Maintenance Methods
1. Check and replace the lubricating 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 the side of flywheel). before checking 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). If the level is not
enough, add some oil, as required, from the cylinder head cover. 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 be used when we need to replace the oil. Replacing oil should he 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.
2. De-aerate The Fuel In The Fuel Pipe
Outside the
fuel injection pump, there is a fuel supply pump, which is equipped with a hand
priming pump. The hand priming pump can be used to de-aerate the fuel in the
fuel pipe. When using the hand priming and again 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 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.
3. Check And Adjust The Belt Tension
Driving belt
must be properly tensioned. 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 relocating the position of the
generator.
4. Discharge The Coolant
There is
water drain valve on the case of the oil cooler at the left side of the
cylinder block (look from the side of the flywheel), It is used to drain
coolant in the water jacket of the diesel engine. After drain the water
coolant, close the valve.
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.
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 element and then, blow
it inside out with compressed air of 0. 4-0.6 MPa (4 ~6kg/cm2). 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 off the
dust chamber. Watch out that the filter paper cannot be cleaned with fuel,
water, or other liquids. Under harsh condition, reduce the maintenance period
of the air cleaner according to actual facts.
7. Add Lubricating Grease
Bearing in
the water pump should be lubricated with calcium sodium base grease. Add
lubricating grease in time, as required, to prevent damage. There is a .up 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.
8. Scrub the
water deposit off
Scrub the
water jacket the coolant tank wall and the water jacket with cleaning liquid in
time, in order to ensure cooling effectiveness and avoid overheating of the
diesel engine.
Generally,
the cleaning liquid is appropriated as follows: add 750 ~800g sodium hydroxide
and 150g kerosene per l0 - 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 about 10-15 minutes, warning up cleaning liquid. Let the
cleaning liquid remain in the tank for about 12-15 hours and run the engine
again in medium speed about 10-15 minutes. Then, 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, repeat the procedure aforementioned 2-3 times.
Note: Sodium hydroxide is strongly basic. Do not eat or touch it. If your skin contacts it, please rinse you skin immediately with water.
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Created on Jan 6th 2018 23:52. Viewed 435 times.