Yuchai Bosch ECU System for Diesel Engine Yuchai – Bosch ECU System for Diesel Engine

2007.10.15

玉柴客户服务中心

2023年2月3日

By Customer Service Center

July 25th, 2014

玉柴发动机使用与维护

---bosch发动机控制系统

Yuchai Engine Operation & Maintenance

—Bosch electronic control system

一．仪表盘介绍

I. Dashboard

一．发动机故障灯和警报灯说明

II. Check Engine Light and Malfunction Indicator Lamp (MIL)
三. 发动机维护与保养

1. 养成良好的驾驶操作习惯

① 发动机起动前的检查
② 发动机的使用

2. 维护保养与检查项目

III. Engine Care & Maintenance

1. Develop good driving behavior

① Checking before starting
② Operation

2. Service and maintenance, maintenance items

目录

Table of Contents

仪表盘介绍

Dashboard

一、仪表盘介绍

I. Dashboard

水温表

Water

thermometer

电压表

Voltmeter

机油压力表

Pressure gauge

of engine oil

发动机转速表

Engine

tachometer

车辆速度表

Speedometer

水温高警示灯

Warning light for high

water temperature

机油压力低警示灯

Warning light for low

pressure of engine oil

一．仪表盘介绍

I. Dashboard

一．发动机故障灯和警报灯说明

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

三. 发动机维护与保养

1. 养成良好的驾驶操作习惯

① 发动机起动前的检查
② 发动机的使用

2. 维护保养与检查项目

III. Engine Care & Maintenance

1. Develop good driving behavior

① Checking before starting
② Operation

2. Service and maintenance, maintenance items

目录

Table of Contents

发动机故障灯的介绍：Malfunction Indicator Lamp (MIL)

发动机运行中，若故障指示灯点亮，表示发动机有当前故障。

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

一般故障……故障指示灯常亮；MIL stays on for minor problems.

严重故障……故障指示灯常亮并闪烁；

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

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

发动机故
障指示灯

MIL

发动机故障灯的使用（2）：
How to operate malfunction indicator lamp (2)

二、发动机故障灯和警报灯说明

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

发动机故
障指示灯

故障

请求开关

故障闪码读取方法：

How to read ECU fault codes

◆1，点火开关处于ON状态

◆Ignition switch rests at ON position;

◆2，待机及运行工况下均可进行

◆Fault codes can be read under standby and

working mode ;

◆3，按下—松开诊断请求开关即可 以激活闪

码，每次操作只闪一个故障码依次进行，即可

读完所有故障码。

◆Press down—release diagnostic request switch
to activate flash codes, you get only one fault
code flashed every time you proceed in turn, you
will finish reading all the codes .

8

故障码清除方法：How to clear fault codes

◆1，发动机熄火

◆1. Engine shutdown

◆2，将点火钥匙关闭，至少20秒以上（等ECU内部主继电器断开）

◆2. Turn off ignition key for more than 20s (wait ECU main relay to be disconnected)

◆3，打开故障请求开关

◆3. Turn on malfunction request switch

◆4，打开点火钥匙

◆Turn on ignition key

◆5打开点火钥匙后4-8秒迅速关闭故障请求开关

◆5. Turn off malfunction request switch ASAP after you switch on ignition key for 4-8s

◆6，再打开故障请求开关，故障码清除。

◆6. Turn on malfunction request switch again, fault codes are cleared

水温高警示灯、水温表 High water temperature alarm, water temperature gauge

当发动机水温高警示灯点亮时，怠速运转一段时间再停机检查

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

水温表water

temperature

gauge

水温高
警示灯

High

water

temperat

ure alarm

二、发动机故障灯和警报灯说明

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

机油压力低警示灯、机油压力表

Low-oil alarm, oil pressure gauge

机油压力正常范围：Oil pressure range

中高速 at med-/-high speed →0.3~0.6Mpa
怠 速 at idle speed → ≥0.1Mpa

机油

压力表oil

pressure

gauge

机油压力
低警示灯

Low-oil

alarm

二、发动机故障灯和警报灯说明

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

一．仪表盘介绍

I. Dashboard

一．发动机故障灯和警报灯说明

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

三. 发动机维护与保养

1. 养成良好的驾驶操作习惯

① 发动机起动前的检查

② 发动机的使用

2. 维护保养与检查项目

III. Engine Care & Maintenance

1. Develop good driving behavior

① Checking before starting

② Operation

2. Service and maintenance, maintenance items

目录

Table of Contents

发动机起动前检查 Checking before start-up

三漏的检查 Oil/water/air leaks

每天出车前检查发动机外围是否存在三漏（漏油、漏水、漏气）现象。

Check if there are oil/water/air leaks at engine peripherals before driving.

III. 1. Develop good driving behavior

检查发动机燃料情况：Checking engine fuel

机油量的检查：

禁止两种以上不同牌号的机油混用。

Checking oil capacity
Never mix different kinds of oil.

机油尺刻度

oil dipstick scale mark

上限

刻度线

high limit

上限

刻度线

high limit

III. 1. Develop good driving behavior

机油的使用（1）：How to choose the right oil

必须选用CF-4级以上级别的机油。

Be sure to select CF-4 grade beyond ;

每10000~12000公里（或行驶累计时间250小时）更换一次新机油

，同时更换机油滤芯；

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

不同牌号的机油禁止混用。

Never mix different kinds, grades of oil.

请根据下表选用与环境温度对应的机油粘度级别的机油

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

环境温度℃

Ambient

Temperature ℃

粘度级别

Viscosity

Grade

环境温度℃

Ambient

Temperature ℃

粘度级别

Viscosity

Grade

环境温度℃

Ambient

Temperature ℃

粘度级别

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 - -

油品粘度级别：
W前数字越小，表明油品低温性能越好，W后数字越大，表明油品粘度越大。

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

冷却液位的检查：

冷却液面不能高于膨胀水箱的上刻线，

每次加注冷却液后，必须拧好水箱盖或

膨胀水箱盖。

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.

冷却液刻

度

Coolant

scale

marks

发动机的冷却液必须使用防冻液

Be sure to use anti-freeze on engine

III. 1. Develop good driving behavior

风扇皮带

每15000公里检查风扇皮带的松紧度，过紧过

松请按技术要求调整；

检查皮带是否有裂纹（含横纹或纵纹）断裂现
象，有则需更换新件。

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

make adjustment to specification if the belt is

loose or tight.

Check if belt is cracked (transversal or longitudinal

cracks) , replace with new one when it is
cracked.

皮带松紧度要求：

在40~50N压力作用下，皮带挠度为10~15mm为合适。

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

皮带龟裂 Belt is cracked.

皮带松紧度要求：
在40~50N压力作用下，皮带
挠度为10~15mm为合适。

皮带龟裂

III. 1. Develop good driving behavior

冷却风扇的检查：

检查冷却风扇叶、导风罩是否存在变

形、裂纹等现象，

Checking cooling fan:
Check to see if fan blades and shroud

are deformed, or cracked.

维修窗口

Service

中冷器
迎风面

intercooler

风扇

fan

导风罩

shroud

III. 1. Develop good driving behavior

一．仪表盘介绍

I. Dashboard

一．发动机故障灯和警报灯说明

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

三. 发动机维护与保养

1. 养成良好的驾驶操作习惯

① 发动机起动前的检查

② 发动机的使用

2. 维护保养与检查项目

III. Engine Care & Maintenance

1. Develop good driving behavior

① Checking before starting

② Operation

2. 2. Service and maintenance, maintenance items

目录

Table of Contents

起动：Start-up

检查结束后，打开电源总开关，将钥匙依次旋转到ON

档位置。

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

将钥匙打到Start档，发动机起动。

Set key to STRAT position, engine is getting started.

若起动不成功，请不要让起动机持续工作超过10秒，
且等待1~2分钟后再进行第二次起动。

Do not work starter successively for more than 10s

if it fails to start, and the next start interval shall
come after 1~2 min.

钥匙锁

key

后控制盒

rear

control

box

电源

总开关

Power

switch

III. 1. Develop good driving behavior

使用发动机（1）Operate engine (1)

发动机成功起动后，应先怠速运行3~5分钟，并检查

以下各项指标是否正常：

Let engine run at idle speed for 3~5 mins after

starting, and check the following items:

起动后15秒内，必须有机油压力显示，否则立

即停机；

You should have oil pressure within 15 seconds
after starting, otherwise stop engine right away;

机油压力不低于0.15MPa（水温60℃以上时，
机油压力不低于0.1Mpa）；

Oil pressure is not less than 0.15Mpa (oil
pressure is not less than 0.1 Mpa when water
temperature is getting higher than 60℃)

发动机运转无异响；

Engine is running fine without unusual noise;

水温表有动作，温度逐渐上升；

Water temperature gauge is working fine,
temperature is in gradual increase.

发动机在怠速运转时间不允许超过10分钟；

Do not let engine run at idle speed for more than 10
mins.

III. 1. Develop good driving behavior

使用发动机（2）Operate engine (2)

车辆起步：按常规操作，要求用一档起步，避免高档位

起步。

Drive off vehicle from a standstill as routine operation,
use 1stgear to start and avoid driving off vehicle in a
higher gear.

不能猛踩油门

Do not step hard on accelerator pedal.

III. 1. Develop good driving behavior

使用发动机（3）Operate engine

换挡 Shift gears

涉水行驶注意事项

Important notices to run under condition of wading

选用合适的档位行驶，有

利于提高驾驶舒适性和节

省燃油。

Select right gears will be
good to improve ride
comfort , and save fuel.

III. 1. Develop good driving behavior

使用发动机（4）

清洁时不能用水冲洗发动机。

在整车上电焊作业时：断开电源总开关，同时断开控制器的
插接件，防止控制器损坏！

Operate engine (4)

Do not flush engine with when you’re cleaning.

Welding on the whole vehicle: disconnect the main switch of
power supply, and disconnect control unit connector to

prevent control unit being damaged.

电焊时拔开控制器插接件

Disconnect control unit connector during
welding

能用水直接冲洗

The engine

surface, wiring
harness, electric
elements cannot
be washed with
water directly

III. 1. Develop good driving behavior

停机 Shutdown

当车辆在停稳之后，发动机怠速运转3-5分钟后
熄火 When you pull over, let engine run at idle

speed for 3-5 mins before stopping.

增压器机油润滑冷却示意图

Schematic diagram of turbo lubricated with oil

增压器机
油润滑冷
却示意图

III. 1. Develop good driving behavior

一．仪表盘介绍

I. Dashboard

一．发动机故障灯和警报灯说明

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

三. 发动机维护与保养

1. 养成良好的驾驶操作习惯

① 发动机起动前的检查
② 发动机的使用

2. 维护保养与检查项目

III. Engine Care & Maintenance

1. Develop good driving behavior

① Checking before starting
② Operation

2. 2. Service and maintenance, maintenance items

目录

Table of Contents

柴油滤清器：

•请每天放掉柴油滤清器滤除水分

•每30000公里（200-250小时）更换柴油滤清器

•Fuel filter

•Be sure to drain water off fuel filter everyday;

•Change fuel filter for every 30,000km (200~250 hr).

三、2、发动机维护与检查项目

III. 2. Service and maintenance items

28

机油滤清器 Oil filter

•每10000-12000公里或200-250小时更换机油滤清器。

•Change oil filter for every 10,000km~12,000km, or 200~250 hr.

空气滤清器（1）

空滤指示器显示红色信号或每5000公里必须保养一次

空气滤清器
当空气滤清器保养完毕后，轻按空滤指示器复位按钮

复位（红色变为绿色）。

Air filter (1)

Do maintenance the air filter when its indicator
flashing red or for every 5,000 km.

After maintenance is done, press slightly the indicator
button to reset (red turns into green).

空滤

总成

Air filter
assembly

空滤保养

指示器

Air filter

service

indicator

三、2、发动机维护与检查项目

III. 2. Service and maintenance items

复位按钮

Reset

button

空气滤清器 Air filter（2）

保养要求：Maintenance requirements

绝对禁止发动机在不装空气滤清器或空气滤清器失效的情况下工作！

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

三、2、发动机维护与检查项目

III. 2. Service and maintenance items

增压器 Turbo

每60000公里检查增压器叶轮转动是否灵活、轴向窜动量是否过大

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

三、2、发动机维护与检查项目

III. 2. Service and maintenance items

10.发动机保养规定及项目

1. 本规定适用于玉柴生产出厂的所有系列发动机。

2. 本规定是玉柴服务站进行保养服务的依据。

3. 保养里程或时间要求：

根据使用条件对整车分类：

（一）、YC I类：

1. 1）使用条件恶劣（最低气温低于-20℃、或最高气温高于35℃、或环境含尘 量高的沙

漠、矿区、工地、煤场等），运距短的工程、自卸、矿用车；

2. 2）或年行驶里程≤25000km（或年工作时间≤600小时）的商用车；

（二）、YC II类：年行驶里程≥25000km的各种用途的商用车。

行驶里程（时间） YC I 类 YC II 类

行驶至3000～5000km（60～80小时） 首次保养

首次保养

每15000km或250小时 二级保养 一级保养

每30000km或500小时 三级保养 二级保养

每60000km或1000小时 三级保养

三、2、发动机维护与检查项目

1. This regulation is applicable to all engine series manufactured by Yuchai.

2. This regulation is the reference when Yuchai service station do engine maintenance or repair;

3. Maintenance mileage or intervals：

Note：Vehicles can be classified on the basis of operation conditions

1. YC I：

1. 1) Short-distance-drive construction vehicles, dump trucks and mining vehicles that working under
extremely hard conditions (lowest temperature can fall below -20℃ and highest temperature can get

higher than 35℃, and heavy sandy desert, mining, construction site and coal-field, etc.)

2. 2) Commercial vehicles with annual mileage ≤25,000km (or working hour ≤600 a year)

2. YC II：Commercial vehicles fit for various applications with annual mileage≥25,000km

Driving mileage(time) YC I YC II

After a 3,000～5,000km drive（60～80 hours）

Initial Service Initial Service

For every 15,000km or 250 hours

2ndMajor Service Normal Service

For every 30,000km or 500 hours

3rdMajor Service 2ndMajor Service

For every 60,000km or 1,000 hours

3rdMajor Service

III. 2. Service and maintenance,

maintenance items

项目 保养周期 保 养 项 目

日

常
维
护
★

每日进行

检查油箱油量

检查冷却水量

检查油底壳及喷油泵内的机油量
检查“三漏”情况

油水分离器放水
起动发动机检查机油仪表压力

起动发动机检查仪表水温情况

首
次
保
养

每3000~5000公里
(或60~80小时)

检查并调整皮带松紧度

检查加速和减速性能及排气状况

检查发动机“三漏”情况
检查燃油箱油量

检查机油状况和液面
更换发动机机油
更换机油滤清器滤芯
油水分离器放水

检查冷却液面

34

Item Maintenance interval Maintenance items

Routine

★

Daily

Check fuel tank volume
Check cooling water capacity

Check oil sump volume and injection pump oil

volume
Check air/water/oil leak
Drain off fuel-water separator

Start engine to check oil gauge pressure indication
Start engine to check gauges for water temperature

pressure

Initial Service

Every 3,000~5,000km
(or 60~80 hr)

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

35

36

一
级
保
养

每15000公里
(或250小时)

清洁发动机总成外表

检查并调整皮带松紧度

检查加速和减速性能及排气状况

检查发动机“三漏”情况

检查燃油箱油量

检查机油状况和液面

更换发动机机油

更换机油滤清器滤芯

油水分离器放水

检查冷却液面

检查电气线路各连接点的接触、干涉、磨损情况

37

Normal
Service

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

38

二
级

保

养

每30000公里

(或500小时)

清洁发动机总成外表
检查并调整皮带松紧度

整体更换空气滤清器滤芯

检查加速和减速性能及排气状况
检查发动机“三漏”情况

检查燃油箱油量
检查机油状况和液面
更换发动机机油
更换机油滤清器滤芯

油水分离器放水

更换燃油滤清器滤芯（含油水分离器和精滤器）

检查冷却液面

检查电气线路各连接点的接触、干涉、磨损情况

检查供油提前角（机械直列泵发动机）

给水泵加注润滑脂（适用于润滑油嘴结构的水泵）

39

2

nd

Major

Service

Every 30, 000km
(or 500 hr)

Clean outer appearance of engine assembly

Check and adjust belt pulley tension
Replace 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 element
Drain off fuel-water separator

Replace 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 with

mechanical, in-line pump)
Apply lubrication grease to water pump (applicable to water

pump that provided with lubrication grease nipple)

三
级
保
养

每60000公里
(或1000小时)

清洁发动机总成外表
检查并调整皮带松紧度
整体更换空气滤清器滤芯

检查加速和减速性能及排气状况

检查发动机“三漏”情况

检查燃油箱油量
检查机油状况和液面
更换发动机机油
更换机油滤清器滤芯

油水分离器放水

更换燃油滤清器滤芯（含油水分离器和精滤器）

检查冷却液面
检查电气线路各连接点的接触、干涉、磨损情况

检查供油提前角（机械直列泵发动机）

给水泵加注润滑脂（适用于润滑油嘴结构的水泵）
清洁发动机冷却系

检查增压器工作情况（叶轮转动是否灵活、轴向窜动量

小于1mm）

40

注：每5000公里保养空气滤清器滤芯，发现主滤芯破损、严重变形或保养超4次，应更换主滤芯，或参考

空气滤清器说明书有关规定执行。

3rdMajor Service

Every 60, 000km
(or 1000 hr)

Clean outer appearance of engine assembly
Check and adjust belt pulley tension
Replace 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 element
Drain off fuel-water separator

Replace 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 with mechanical, in-line
pump)

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

Clean cooling system
Check turbocharger performance (if the impeller can rotate freely, and axial

movement is less than 1mm)

41

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

以卓越与领先，满足公众的动力需求

Taking the Lead & Meeting the Power Need
of the General Public

谢谢

Thank you！