MaintenanceManual 226B Series
1. Time table for MaintenanceThere is no need to repeat after following the maintenance schedule.
Working items Operating Time H Re-tighten the connecting bolt and cylinder head bolt 30 Check the belt and tension 30 125 Change the oil and filter element 30 125 Check valve clearance 30 125
Repeat the maintenance procedure following the timetable below
Working items Operating time h 250 500 1000Clean up the air filter element 1) X Check and tension the V belt X Change the oil and oil filter element X Check valve clearance X Change the fuel filter element X Clean up the crankcase ventilation mechanism 2) X
1) The change should be made earlier in dusty place.Wet air filter should be cleaned every 200 hours (at most).2) Only under the circumstances where the crankcase ventilation mechanism does not intake the air.The maintenance instructions for the backup condition and emergencyIf the diesel engine does not operate for weeks, it must be sealed up
Time period RequirementEvery month Trail running with load see 5.106 month If the running time does not reach 500 hours after 6 month, the requied maintenance procedure must be carried out during this periodAfter 12 month If the running time does not reach 1000 hours after 12 month, the required maintenance procedure must be carried out during this period.
The reliability of the engine might be affected because of abrasion and corrosion. In order to avoid any working abnormity of the engine, we recommend the following overhaul. The first overhaul should be preceded after the engine has runner for 2000 hours or after two years (running time less than 2000 hours).
ItemsCheck the nozzleCheck compressive pressureCheck bearing clearance of the water pumpCheck superchargerCheck fuel injection pumpCheck cylinder-headCheck cylinder linerClear the water jacket of the water cooling exhaust pipe and check the corrosionCheck connecting rod and main bearingCheck pistonCheck the crankshaftCheck the camshaftCheck the two-stage balancing mechanismCheck the drive gearOverhaul fuel injection pumpChange oil pumpChange water pumpChange the oil sealing of the crankshaftChange the damper
Above overhaul require expertise and should be carries out by professionals
2. Maintenance procedure
2.1. Cleaning up dry air filterWhen the maintenance indicator of the filter shows a red signal or the engine performance is affected because of the resistance of filter, clean the filter or change the filter element.1. Dismount the main filter element2. Lay the end surface downwards and flap the filter element carefully. Or put the filter element on clean ground and roll it to shake the dust off, Do not beat if forcibly.3. Blow from the inside and outside the surface of the filter element with compressed air (lass than 500 kPa).4. Clean up the seal packing. It should be changed if there is any damage.5. Check the dust outlet in the dust – discharging valve.6. Reinstall if the filter is mounted horizontally, place the dust – discharging valve vertically downward when mounting the cover.
Notice : The main filter element of a filter can only be cleaned up for at most 5 times. It must be changed after a year, and should be immediately changed if there is a damage, Mark the number of times which the main filter element has been cleaned or changed for in the exclusive marking column of the safe filter element. The safe filter element must be changed under following circumstance:1). Main filter element has been maintained for 5 times.2). It has been used for 2 years.3). As soon as the main element is maintained, the maintenance indicator will show immediately.4). After the operation with a defective main filter element.5). Safety filter element is not allowed to be cleaned.
2.2 Check connection bolt.Check the bolts for diesel engine, generator, injector and intake/exhaust manifold and the connection of bolts and hoses, retighten them if necessary.
2.2.1 Tighten cylinder head boltsLoosen the cylinder head bolts about ¼ of rotation when engine warning, and then tighten them up with a force of 200 + 10 Nm immediately according to the sequence as the following figure.
2.3 Check and tension the V – belt.Press the V – belt with hand, the distortion should not be more than 10 – 15 mm, otherwise change the belt with a new one.If tension the through generator, loose bolt 1 and bolt 2 firstly, strain the generator outwards, then tighten up bolt 1 and bolt 2 and check the belt by hand.If tension the belt through tension pulley, loose the bolt 3 and bolt 4 on bracket 5, stain the tension pulley bracket, and then tighten up bolt 3 and bolt 4 then check the belt by hand.Caution: change the damaged or oiled belt.
2.4 Change oil.a. Start the engine and stop it after reaching the operation temperature.b. Place an oil tank under the engine.c. Screw out the drainage screw plug 1, pay attention the seal ring on the screw plug.d. Drain off all oil.e. Screw on the screw plug with seal ring.
2.4.1 Replace oil filtera. Disassemble the oil filter 1 with special wrench.b. Coat some oil on the seal ring 2 and tighten up oil filter by hand.c. Check the oil filter for tightens in running – in.
2.5 Check valve clearancea. Remove cylinder head cover.b. Make the piston reached the firing TDC.c. Check the clearance between rocker arm and valve rod end with a 0,2mm or 0,3mm feeler gauge1. Adjust the clearance according to the following steps if necessary.d. Loose nut 2, adjust the clearances with feeler screw 3.e. Holding the position of screw 3 and tighten nut 2.f. Check the other clearances with feeler gauge 1.g. Set up rocker arm and tighten the screws. The rocker arm cover seal side should be faced with the gasket.Caution: Adjust valve clearance according to the firing order to avoid turning crankshaft unnecessarily.
2.6 Change fuel filter.a. Close the valve on fuel circuit.b. Turn the special tools of fuel counter – clockwise. Disassemble the fuel filter 1.c. Before mounting new filter, coat lubricating oil seal ring 2.d. Tighten the new filter by hand.e. Open the valve on fuel circuit.f. Degas the fuel system.g. Check the sealing of fuel filter.
2.7 Clean breather body.1. Loose the hexagon nut or screw 1.2. Loosen hose clip 2.3. Disassemble breather body 3.4. Pay attention to the O seal ring.5. Clean the breather body in diesel.6. Mount the breather body, change new O seal ring if necessary.7. Tighten the hose clip 2.8. Tighten the hexagon nut or screw 1.
2.8 Clean intercoolerIn the operation of intercooler, if enlarged cooled air resistance and the decreased difference in temperature affect the performance of diesel engine, the intercooler should be cleaned.
2.9 Run – in.If the engine is in standby or emergency state, run it once a month so as to prevent it from corrosion damage.1. After starting, check the instrument meter at once, put 1/3 load on the engine.2. After running for 10 minutes, increase to 3/4 load3. After running for another 10 minutes, increase to full load.4. Check the sealing of the engine.5. Run the engine at 1/3 load for 10 minutes.6. Unload and stop the engine.
5.10 Engine maintenance.If the engine stop for long time ( for several weeks ), the following protective measures must be taken so as to prevent it from corrosion damage:Operating order:1. Rinse the exterior of diesel engine2. Drain off the oil inside the engine and the fuel in injection pump3. Add corrosion preventive to the engine.4. Drain off fuel.5. Mix fuel oil and corrosion preventive on scale of 9 : 1.6. Fill the fuel tank with the mixture above.7. Drain cooling water.8. Add emulsi fable corrosion preventive to the cooling water according to the degree or 5%9. Add above compound to cooling system, and vent air from the system.10. Start the engine and run it for 10 minutes.11. Stop the engine and turn flywheel for several circles to make the combustion chamber sufficiently wet.12. Drain off cooling water.13. Smear exposed parts of the engine with corrosion preventive grease.14. Close the intake manifold and exhaust manifold.15. Repeat the above operations after three months.
When the engine is demanded to put into service, you should :1 Drain off corrosion preventive and mixed fuel.2. Add oil to the engine.3. Add fuel and coolant, vent air from the fuel system and cooling system.4. Remove corrosion preventive grease on the exteriors part.5. Open the ports of intake manifold and exhaust manifold.