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
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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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.
II. Check Engine Light and Malfunction Indicator Lamp (MIL)
MIL
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2
How to operate malfunction indicator lamp (2)
II. Check Engine Light and Malfunction Indicator Lamp (MIL)
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
II. Check Engine Light and Malfunction Indicator Lamp (MIL)
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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
II. Check Engine Light and Malfunction Indicator Lamp (MIL)
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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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Checking engine fuel
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Checking oil capacity
Never mix different kinds of oil.
oil dipstick scale mark
high limit
high limit
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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
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III. 1. Develop good driving behavior
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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
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III. 1. Develop good driving behavior
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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. 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
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III. 1. Develop good driving behavior
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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.
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III. 1. Develop good driving behavior
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.
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III. 1. Develop good driving behavior
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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
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III. 1. Develop good driving behavior
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
III. 1. Develop good driving behavior
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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. 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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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
2 III. 2. Service and maintenance items
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.
2 III. 2. Service and maintenance items
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Turbo
60000 Check if turbo impeller can rotate freely, and axial movement is excessive for every 60,000km.
2 III. 2. Service and maintenance items
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3000~5000 ( 60~80 )
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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 acceleration/ de-acceleration performance and exhaust
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 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 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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