Internal combustion engine maintenance

内燃机的正确保养，特别是预防性的保养，是最容易、最经济的保养，因此是延长使用寿命和降低使用成本的关键。必须内燃机使用过程中的日报工作，根据所反映的情况，及时做好必要的调整和修理。可按照本次介绍的内容，并按项目部维修保养，认真填写维修保养记录。
The correct maintenance of internal combustion engine, especially preventive maintenance, is the easiest and most economical maintenance, so it is the key to prolong the service life and reduce the cost of use. Daily report work in the process of internal combustion engine use must be done timely and necessary adjustment and repair shall be done according to the reflected situation. According to the contents of this introduction, and according to the maintenance of the project department, the maintenance record can be filled in carefully.
日报表的内容一般有如下几个方面： 每班工作的日期和起迄时间；常规记录所有仪表的读数；功率的使用情况；燃油、机油、冷却液是否有渗漏或超耗；排气烟色和有否异常声音；发生故障的前后情况及处理意见。
The contents of daily report are as follows: the working date and start-up time of each shift; the reading of all instruments are recorded regularly; the usage of power; whether there is leakage or over consumption of fuel, oil and coolant; whether the exhaust smoke color and abnormal sound; the pre and post fault conditions and treatment opinions.
维修保养的主要内容
Main contents of maintenance
用户根据本节所列技术保养项目进行定期保养。保养分级如下： 例行保养（每班工作）； 一级保养（累计工作100h或每满1月）； 二级保养（累计工作500h或每满半年）； 三级保养（累计工作1000-1500h或每满1年）。 无论进行何种保养，都应有计划、有步骤地进行拆检和安装，并合理地使用工具；用力要适当，解体后的各零部件表面应保持清洁，并涂上防锈油或油脂以防止生锈；注意可拆零件的相对位置，不可拆零件的结构特点，以及装配间隙和调整方法。同时应保持内燃机及附件的清洁完整。
The user shall carry out regular maintenance according to the technical maintenance items listed in this section. The maintenance levels are as follows: routine maintenance (work per shift); level I maintenance (100h or every full month); secondary maintenance (500h or half a year in total); and level III maintenance (1000-1500h or 1 year for each full). No matter what maintenance is carried out, it should be planned and checked and installed step by step, and the tools should be used reasonably; the force should be appropriate. The surface of all parts after disassembly should be kept clean and coated with rust proof oil or grease to prevent rust; pay attention to the relative position of detachable parts, structural characteristics of non detachable parts, assembly clearance and adjustment methods. At the same time, the internal combustion engine and accessories shall be kept clean and complete.
1、例行保养
1. Routine maintenance
例行保养项目以及维修程序可按下表所列进行。
Routine maintenance items and repair procedures can be listed in the following table.
1 检查燃油箱燃油 观察燃油箱存油量，根据需要添足
1. Check the fuel tank, 2. Observe the fuel storage in the fuel tank, and replenish it if necessary
2 检查油底壳中机油平面 油面应达到机油标尺上的刻线标记，不足时，应加到规定量
2. Check the oil level in the oil pan. The oil level should reach the mark on the oil scale. If it is insufficient, add it to the specified amount
3 检查喷油泵调速器机油平面 油面应达到机油标尺上的刻线标记，不足时，应添足
3. Check the oil level of the fuel injection pump governor. The oil level should reach the mark on the oil scale. If it is insufficient, add enough oil
4 检查三漏（水、油、气）情况 消除油、水管路接头等密封面的漏油、漏水现象；消除进、排气管、气缸盖垫片处及涡轮增压器的漏气现象
4. Check the three leaks (water, oil and gas) and eliminate the oil leakage and water leakage on the sealing surfaces of oil and water pipe joints; eliminate the air leakage at the intake and exhaust pipes, cylinder head gasket and turbocharger
5 检查机器附件的安装情况 包括各附件的安装的稳定程度，地脚螺钉及与工作机械相连接的牢靠性
5. Check the installation of the machine accessories, including the stability of the installation of the accessories, the foundation screw and the reliability of the connection with the working machinery
6 检查各仪表 观察读数是否正常，否则应及时修理或更换
6. Check all instruments and observe whether the reading is normal, otherwise repair or replace them in time
7 检查喷油泵传动连接盘 连接螺钉是否松动，否则应重新校喷油提前角并拧紧连接螺钉
7. Check whether the connecting screw of the connecting plate of the fuel injection pump is loose, otherwise, calibrate the fuel injection advance angle again and tighten the connecting screw
8 清洁内燃机及附属设备外表 用干布或浸柴油的抹布擦去机身、涡轮增压器、气缸盖罩壳、空气滤清器等表面上的油渍、水和尘埃；擦净或用压缩空气吹净充电发电机、散热器、风扇等表面上的尘埃
8. Clean the surface of internal combustion engine and auxiliary equipment; wipe off the oil stains, water and dust on the surface of fuselage, turbocharger, cylinder head cover, air filter, etc. with dry cloth or dishcloth soaked in diesel oil; wipe or blow off the dust on the surface of charging generator, radiator, fan, etc. with compressed air
2、一级保养
2. First level maintenance
除例行保养的项目外，尚需增添的工作项目如下。
In addition to routine maintenance items, additional work items are as follows.
1 检查蓄电池电压和电解液比重 用比重测量电解液比重，此值应为1.28-1.30（环境温度为20度时），一般应不低于1.27。同时液面应高于极板10-15mm，不足时应加注蒸馏水
1. Check the battery voltage and the specific gravity of electrolyte. 2. Measure the specific gravity of electrolyte with specific gravity. The value should be 1.28-1.30 (when the ambient temperature is 20 ℃), generally not less than 1.27. At the same time, the level of distilled water should be less than 10-15mm
2 检查三角橡胶带的张紧程度 按皮带张紧度调整方法，检查和调整皮带松紧程度
2. Check the tension of the Triangle rubber belt; 2. Check and adjust the belt tension according to the belt tension adjustment method
3 清洗机油泵吸油粗滤网 拆开机体大窗口盖板，扳开粗滤网弹簧锁片，拆下滤网放在柴油中清洗，然后吹净
3. Clean the oil suction coarse filter screen of the oil pump 1. Remove the cover plate of the large window of the engine body, pull open the spring locking plate of the coarse filter screen, remove the filter screen, clean it in diesel oil, and then blow it clean
4 清洗空气滤清器 惯性油浴式空气滤清器应清洗钢丝绒滤芯，更换机油；盆式空气滤清器，应清除集尘盘上的灰尘，对纸质滤芯进行保养
4. Clean the air filter; for the inertia oil bath air filter, clean the steel velvet filter element and change the engine oil; for the basin air filter, clean the dust on the dust collecting tray and maintain the paper filter element
5 清洗通气管内的滤芯 将机体门盖板加油管中的滤芯取出，放在柴油或汽油中清晰吹净，浸上机油后装上
5. Clean the filter element in the vent pipe. 2. Take out the filter element in the oil filling pipe of the engine door cover plate, blow it out clearly in diesel oil or gasoline, and then install it after soaking in engine oil
6
six
清洗燃油滤清器 每隔200h左右，拆下滤芯和壳体，在柴油或煤油中清洗或换芯子，同时应排除水分和沉积物
Clean the fuel filter every 200 hours or so, remove the filter element and shell, clean or change the core in diesel or kerosene, and remove the water and sediment at the same time
7 清洗机油滤清器 一般每隔200h左右进行：
7. Clean the oil filter every 200 hours
a、清洗绕线式粗滤器滤芯
a. Cleaning the filter element of wound primary filter
b、对刮片式滤清器，转动手柄清除滤芯表面油污，或放在柴油中刷洗
b. For the blade filter, turn the handle to remove the oil on the surface of the filter element, or brush it in diesel oil
c、将离心式精滤器转子放在柴油或煤油中清洗
c. Clean the rotor of centrifugal fine filter in diesel oil or kerosene
8 清洗涡轮增压器的机油滤清器及进油管 将滤芯及管子放在柴油或煤油中清洗，然后吹干，以防止被灰尘和杂物沾污
8. Clean the oil filter and oil inlet pipe of the turbocharger. Clean the filter element and pipe in diesel oil or kerosene, and then blow dry to prevent contamination by dust and debris
9 更换油底壳中的机油 根据机油使用状况（油的脏污和粘度降低程度）每隔200-300h更换一次
9. Change the oil in the oil pan every 200-300h according to the service condition of the oil (oil dirt and viscosity reduction)
10 加注润滑油或润滑脂 对所有注油嘴及机械式转速表接头等处，加注符号规定的润滑脂或机油
10. Add lubricating oil or grease. Add grease or oil specified in the symbol to all oil nozzles and mechanical tachometer joints
11 清洗冷却水散热器 用清洁的水通入散热器中，清除其中沉淀物质至干净为止
11. Clean the cooling water radiator. Put clean water into the radiator to remove the precipitates until it is clean
3、二级保养
3. Secondary maintenance
除一级保养的项目外，尚需增添的工作项目如下表所列。
In addition to the first level maintenance items, the additional work items are listed in the table below.
1 检查喷油器 检查喷油压力、观察喷雾情况，进行必要的清洗和调整
1 check the injector to check the injection pressure, observe the spray condition, carry out the necessary cleaning and adjustment.
2 检查喷油泵 必要是重新调整
2. Check the fuel injection pump and readjust it if necessary
3 检查气门间隙、喷油提前角 必要时重新调整
3. Check the valve clearance and injection advance angle, and readjust if necessary
4 检查进、排气门的密封情况 拆下气缸套，观察配合锥面的密封、磨损情况，必要时研磨修理
4. Check the sealing condition of the intake and exhaust valves, remove the cylinder liner, observe the sealing and wear condition of the matching cone, and grind and repair if necessary
5 检查水泵漏水情况 如溢水口滴水成流时，应调换封水圈
5. Check the water leakage of the water pump. If the water drops from the overflow, replace the water seal ring
6 检查气缸套封水圈的封水情况 拆下机体大窗口盖板、从气缸套下端检查是否有漏水现象，否则应拆出气缸套，调换新的橡胶封水圈
6. Check the water sealing condition of the water sealing ring of the cylinder sleeve. Remove the cover plate of the large window of the engine body and check whether there is water leakage from the lower end of the cylinder sleeve. Otherwise, remove the cylinder sleeve and replace it with a new rubber water sealing ring
7 检查传动机构盖板上的喷油嘴 拆下前盖板，检查喷油塞喷孔是否畅通，如有堵塞，应清理
7. Check the nozzle on the cover plate of the transmission mechanism. 2. Remove the front cover plate and check whether the nozzle hole of the injection plug is unblocked. If it is blocked, clean it
8 检查主要零部件的紧固情况 对连杆螺钉、曲轴螺钉、气缸盖螺母等进行检查，必要时拆下检查并重新拧紧至规定扭矩
8. Check the fastening of main parts and components; check the connecting rod screw, crankshaft screw, cylinder head nut, etc. if necessary, remove them for inspection and re tighten them to the specified torque
9 检查电气设备 各电线接头是否接牢，有烧损的应更换
9. Check whether the electrical equipment and wires are firmly connected, and replace those with burning damage
10 清洗机油、燃油系统管路 包括清洗油底壳、机油管道、机油冷却器、燃油箱及其管路、清除污物并应吹干净
10. Clean the oil and fuel system pipeline, including cleaning the oil pan, oil pipeline, oil cooler, fuel tank and its pipeline, removing dirt and blowing clean
11 清洗冷却系统水管道 除厂商供应的清洗液外，也可用每升水加150g苛性钠（HaOH）的溶液灌满内燃机冷却系统，停留8-12h后开动柴油机，使出水温度到75度以上，放掉清洗液，再用干净水清洗冷却系统
11. In addition to the cleaning fluid supplied by the manufacturer, the cooling system of internal combustion engine can also be filled with 150g caustic soda (haoh) solution per liter of water. After staying for 8-12h, start the diesel engine to make the outlet water temperature above 75 ℃, discharge the cleaning fluid, and then clean the cooling system with clean water
12 检查冷却水散热器和机油散热器、机油冷却器 如有漏水、漏油，应进行必要的补修
12. Check the cooling water radiator, oil radiator and oil cooler. If there is water leakage or oil leakage, make necessary repair
13 清洗涡轮增压器的气、油道 包括清洗导风轮、压气机叶轮、压气机壳内表面、涡轮及涡轮壳等零件的油污和积碳
13. Clean the air and oil passages of the turbocharger, including oil stains and carbon deposits on the guide vane, compressor impeller, inner surface of compressor casing, turbine and turbine casing
4、三级保养
4. Three level maintenance
除二级保养的项目外，尚需增添的工作项目如下表所列。
In addition to the secondary maintenance items, the additional work items are listed in the table below.
1 检查喷油器 检查喷油压力、观察喷雾情况，进行必要的清洗和调整
1 check the injector to check the injection pressure, observe the spray condition, carry out the necessary cleaning and adjustment.
2 检查喷油泵 必要是重新调整
2. Check the fuel injection pump and readjust it if necessary
3 检查气门间隙、喷油提前角 必要时重新调整
3. Check the valve clearance and injection advance angle, and readjust if necessary
4 检查进、排气门的密封情况 拆下气缸套，观察配合锥面的密封、磨损情况，必要时研磨修理
4. Check the sealing condition of the intake and exhaust valves, remove the cylinder liner, observe the sealing and wear condition of the matching cone, and grind and repair if necessary
5 检查水泵漏水情况 如溢水口滴水成流时，应调换封水圈
5. Check the water leakage of the water pump. If the water drops from the overflow, replace the water seal ring
6 检查气缸套封水圈的封水情况 拆下机体大窗口盖板、从气缸套下端检查是否有漏水现象，否则应拆出气缸套，调换新的橡胶封水圈
6. Check the water sealing condition of the water sealing ring of the cylinder sleeve. Remove the cover plate of the large window of the engine body and check whether there is water leakage from the lower end of the cylinder sleeve. Otherwise, remove the cylinder sleeve and replace it with a new rubber water sealing ring
7 检查传动机构盖板上的喷油嘴 拆下前盖板，检查喷油塞喷孔是否畅通，如有堵塞，应清理
7. Check the nozzle on the cover plate of the transmission mechanism. 2. Remove the front cover plate and check whether the nozzle hole of the injection plug is unblocked. If it is blocked, clean it
8 检查主要零部件的紧固情况 对连杆螺钉、曲轴螺钉、气缸盖螺母等进行检查，必要时拆下检查并重新拧紧至规定扭矩
8. Check the fastening of main parts and components; check the connecting rod screw, crankshaft screw, cylinder head nut, etc. if necessary, remove them for inspection and re tighten them to the specified torque
9 检查电气设备 各电线接头是否接牢，有烧损的应更换
9. Check whether the electrical equipment and wires are firmly connected, and replace those with burning damage
10 清洗机油、燃油系统管路 包括清洗油底壳、机油管道、机油冷却器、燃油箱及其管路、清除污物并应吹干净
10. Clean the oil and fuel system pipeline, including cleaning the oil pan, oil pipeline, oil cooler, fuel tank and its pipeline, removing dirt and blowing clean
11 清洗冷却系统水管道 除厂商供应的清洗液外，也可用每升水加150g苛性钠（HaOH）的溶液灌满内燃机冷却系统，停留8-12h后开动柴油机，使出水温度到75度以上，放掉清洗液，再用干净水清洗冷却系统
11. In addition to the cleaning fluid supplied by the manufacturer, the cooling system of internal combustion engine can also be filled with 150g caustic soda (haoh) solution per liter of water. After staying for 8-12h, start the diesel engine to make the outlet water temperature above 75 ℃, discharge the cleaning fluid, and then clean the cooling system with clean water
12 检查冷却水散热器和机油散热器、机油冷却器 如有漏水、漏油，应进行必要的补修
12. Check the cooling water radiator, oil radiator and oil cooler. If there is water leakage or oil leakage, make necessary repair
13 清洗涡轮增压器的气、油道 包括清洗导风轮、压气机叶轮、压气机壳内表面、涡轮及涡轮壳等零件的油污和积碳
13. Clean the air and oil passages of the turbocharger, including oil stains and carbon deposits on the guide vane, compressor impeller, inner surface of compressor casing, turbine and turbine casing