Bosch ECU System for Diesel Engine

8/10/2019 Bosch ECU System for Diesel Engine

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2007.10.15

2014 11 20

By Customer Service CenterJuly 25th, 2014

---bosch

Yuchai Engine Operation & Maintenance Bosch electronic control system


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I. Dashboard

II. Check Engine Light and Malfunction Indicator Lamp (MIL)

. 1.

2. III. Engine Care & Maintenance1. Develop good driving behavior

Checking before startingOperation

2. Service and maintenance, maintenance items

Table of Contents


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Dashboard

I. Dashboard

Water

thermometer

Voltmeter

Pressure gauge

of engine oil

Engine

tachometer

Speedometer

Warning light for high

water temperature Warning light for low

pressure of engine oil


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I. Dashboard


. 1.




Table of Contents


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Malfunction Indicator Lamp (MIL)

The MIL will come on when ECU detects a problem while engine is operating.

MIL stays on for minor problems.

If the light is flashing it means that something serious has been detected.


MIL


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2

How to operate malfunction indicator lamp (2)


How to read ECU fault codes

1 ON Ignition switch rests at ON position;

2 Fault codes can be read under standby and

working mode ;3

Press down release diagnostic request switch

to activate flash codes, you get only one faultcode flashed every time you proceed in turn, youwill finish reading all the codes .


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High water temperature alarm, water temperature gauge

When high water temperature alarm comes on, run engine at idle speed for a period oftime, and then stop it to check.

watertemperature

gauge

Highwater

temperature alarm



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Low-oil alarm, oil pressure gauge

Oil pressure range

at med-/-high speed 0.3~0.6Mpa

at idle speed 0.1Mpa

oil

pressuregauge

Low-oilalarm



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I. Dashboard


. 1.




Table of Contents


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Checking engine fuel


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Checking oil capacity

Never mix different kinds of oil.

oil dipstick scale mark

high limit

high limit

1

III. 1. Develop good driving behavior


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1 How to choose the right oilCF-4

Be sure to select CF-4 grade beyond ;10000~12000 250

When you do have oil replaced for every 1,000~12,000km (drivingfor 250hr), be sure to also replace the filter element;

Never mix different kinds, grades of oil.

Select the right oil viscosity grade to adapt to environment temperaturein accordance with below chart

AmbientTemperature

ViscosityGrade

AmbientTemperature

Viscosity

Grade

AmbientTemperature

Viscosity

Grade

-35~30 0W-30 -25~30 10W-30 -20~50 15W-50

-35~40 0W-40 -25~40 10W-40 -15~30 20W-30

-30~30 5W-30 -25~50 10W-50 -15~40 20W-40

-30~40 5W-40 -20~30 15W-30 -15~50 20W-50

-30~50 5W-50 -20~40 15W-40 - -

W W Viscosity grade of oils

The smaller the number in front of W, the better the low temperature performance of oils; the largerthe number at back of W, the better viscosity grade of oils.


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Checking coolant level:

Coolant level cannot exceed the high limit of

expansion water tank;

Tighten water tank cap or expansion water

tank cap every time you fill up.

Coolant

scalemarks

Be sure to use anti-freeze on engine

1



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15000

Fan belt pulley:Check fan belt tension for every 15,000km, and

make adjustment to specification if the belt isloose or tight.

Check if belt is cracked (transversal or longitudinalcracks) , replace with new one when it iscracked.

40~50N 10~15mm

Belt tension specifications:Belt deflection is 10~15mm under a force of 40~50N.

Belt is cracked.

40~50N10~15mm

1



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I. Dashboard


. 1.



2. 2. Service and maintenance, maintenance items

Table of Contents


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Start-upON

After you checked, switch on power supply, and set keyto ON position

Start

Set key to STRAT position, engine is getting started. 101~2

Do not work starter successively for more than 10sif it fails to start, and the next start interval shallcome after 1~2 min.

key

rear

controlbox

Powerswitch

1



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1


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2 Operate engine (2)

Drive off vehicle from a standstill as routine operation,

use 1 st gear to start and avoid driving off vehicle in a

higher gear.

Do not step hard on accelerator pedal.

1


1


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3 Operate engine

Shift gears

Important notices to run under condition of wading

Select right gears will begood to improve ridecomfort , and save fuel.

1


1


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4

Operate engine (4)

Do not flush engine with when youre cleaning.

Welding on the whole vehicle: disconnect the main switch of

power supply, and disconnect control unit connector to

prevent control unit being damaged.

Disconnect control unit connector duringwelding

The enginesurface, wiringharness, electricelements cannotbe washed withwater directly

1


1


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Shutdown

3-5

When you pull over, let engine run at idle

speed for 3-5 mins before stopping.

Schematic diagram of turbo lubricated with oil

1



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I. Dashboard


. 1.



2. 2. Service and maintenance, maintenance items

Table of Contents


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30000 200-250 Fuel filter Be sure to drain water off fuel filter everyday; Change fuel filter for every 30,000km (200~250 hr).

2 III. 2. Service and maintenance items


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28

Oil filter 10000-12000 200-250 Change oil filter for every 10,000km~12,000km, or 200~250 hr.


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1 5000

Air filter (1)Do maintenance the air filter when its indicatorflashing red or for every 5,000 km.After maintenance is done, press slightly the indicatorbutton to reset ( red turns into green ).

Air filterassembly

Air filterservice

indicator


Resetbutton


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Air filter 2

Maintenance requirements

Do not operate engine when air filter is not equipped or when air filter is faulty.



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Turbo

60000 Check if turbo impeller can rotate freely, and axial movement is excessive for every 60,000km.



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3000~5000 ( 60~80 )

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36

15000 ( 250 )


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NormalService

Every 15,000 km(or 250 hr)

Clean outer appearance of engine assembly

Check and adjust belt pulley tension

Check acceleration/ de-acceleration performance and exhaust

Check air/water/oil leak

Check fuel tank volume

Check oil condition and oil level

Replace engine oil

Replace oil filter element

Drain off fuel-water separator

Check coolant level

Check electrical power wire connections for contact condition,interference and wear


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30000 ( 500 )


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2nd MajorService

Every 30, 000km(or 500 hr)

Clean outer appearance of engine assemblyCheck and adjust belt pulley tension

Replace entire air filter element


Check air/water/oil leakCheck fuel tank volume

Check oil condition and oil levelReplace engine oilReplace oil filter elementDrain off fuel-water separatorReplace fuel filter element (including fuel-water separator and

secondary fuel filter)Check coolant level

Check electrical power wire connections for contact condition,interference and wear

Check fuel supply advanced angle (engine equipped withmechanical, in-line pump)

Apply lubrication grease to water pump (applicable to water pump that provided with lubrication grease nipple)


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60000 ( 1000 )

1mm

405 4


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3rd Major ServiceEvery 60, 000km(or 1000 hr)

Clean outer appearance of engine assembly

Check and adjust belt pulley tensionReplace entire air filter element


Check air/water/oil leak

Check fuel tank volume

Check oil condition and oil level

Replace engine oil

Replace oil filter elementDrain off fuel-water separator

Replace fuel filter element (including fuel-water separator and secondary fuel

filter)

Check coolant levelCheck electrical power wire connections for contact condition, interference andwear

Check fuel supply advanced angle (engine equipped with mechanical, in-line pump)Apply lubrication grease to water pump( applicable to water pump that providedwith lubrication grease nipple)

Clean cooling system

Check turbocharger performance (if the impeller can rotate freely, and axialmovement is less than 1mm)

41Note: do maintenance the air filter element for every 5,000km, if the main filter element is damaged, badly distorted orhas already been serviced for more than four times , then replace it with a new one, or follow the instructions in AirFilter Manual to perform.


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Taking the Lead & Meeting the Power Needof the General Public

Bosch ECU System for Diesel Engine

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