Zichai 6250/8250 Diesel Engine — Maintenance Timetable

1.1 Daily Maintenance of Diesel Engine

1. The contents specified in the sections of diesel engine operation, including preparation before starting, starting procedure, maintenance during operation, and shutdown, are the basic requirements for daily maintenance and must be strictly followed.

2. Any minor faults of the diesel engine must be eliminated promptly. Leakage of air, oil, and water from various pipelines must be checked and repaired in time.

3. Keep the external surface of the diesel engine clean. Remove oil stains, water marks, and dust regularly.

4. Keep all filters clean and ensure they are free from blockage.

5. Open the drain plug and check whether the air cooler has any water leakage.

6. Check the quality of lubricating oil and perform oil analysis when necessary.

1.2 Maintenance After Every 300–500 Operating Hours

1. Check the tightening condition and locking devices of the main bearing bolts, connecting rod bolts, cylinder head bolts, foundation bolts, and other fastening components.

2. Check the flexibility of the fuel regulating mechanism.

3. Check the operation of the emergency shutdown device.

4. Check all monitoring instruments and gauges.

5. Inspect the surface condition of the camshaft cams and rollers.

6. Check the tightening condition of the rocker arm seats, fuel injectors, valve rocker arm adjusting screws, and other related components.

7. Clean or replace the lubricating oil filter elements and fuel filter elements.

8. Check whether cleaning of the air cooler and replacement of anti-corrosion zinc blocks are required.

9. Check whether cleaning of the turbocharger silencer, compressor impeller, and diffuser is required.

10. Check the injector opening pressure and fuel atomization quality.

11. Check the water content and contamination level of the lubricating oil. Replace the oil according to the inspection results.

    
    

1.3 Maintenance After Every 1000 Operating Hours

1. Check the intake and exhaust valve clearances and inspect the fuel injection timing.

2. Check the injector opening pressure.

3. Check the temperature regulators of lubricating oil and cooling water.

4. Use a mirror to inspect the condition of the piston skirt and cylinder liner inner surface.

1.4 Maintenance After Every 2500 Operating Hours

1. Check the crankshaft deflection measurement.

2. Check the air starter and replace components if necessary.

3. Check the sealing condition of the fuel injection pump delivery valve assembly.

4. Check the control system valves and pipelines.

5. Clean the inside of the engine base and clean the daily fuel tank.

6. Inspect the turbocharger. If performance decreases significantly (such as reduced speed or reduced boost pressure), disassemble and inspect the internal components.

7. Check the sealing condition of the fresh water pump and seawater pump.

8. Clean deposits from the fresh water cooler and lubricating oil cooler. Replace anti-corrosion zinc blocks if necessary.

9. According to actual conditions, randomly inspect the sealing condition of intake and exhaust valves.

1.5 Maintenance After Every 7500 Operating Hours

1. Inspect the water chambers of the cylinder head and other related parts, and replace anti-corrosion zinc blocks.

2. Check the surface condition of intake and exhaust valves and valve seats. Grind or replace them if necessary.

3. Remove the piston and connecting rod assembly, clean carbon deposits, and measure the dimensions of piston ring grooves and piston pin holes.

4. Inspect the piston pin, measure its outside diameter, and perform non-destructive testing.

5. Inspect and replace piston rings according to actual conditions.

6. Check the connecting rod bolts and supporting surfaces.

7. Inspect the connecting rod big-end and small-end bearings, measure wear, and determine whether replacement is required.

8. Randomly inspect two main bearings, check the wear condition of the main bearing shells, and determine whether further inspection of other main bearings is necessary.

9. Inspect the fuel injection pump. If the plunger and barrel assembly leaks or is damaged, replace the matched pair.

10. Inspect rocker arms and valve train components, especially the wear condition of adjusting screw heads, hard surfaces, and other contact areas.

11. Inspect cams, rollers, and roller pins. Replace according to actual conditions.

12. Inspect all transmission gears, measure gear backlash, and determine whether replacement is required.

13. Inspect the lubricating oil pump, fuel pump, and cooling water pump.

14. Inspect the working surface of the cylinder liner, measure the inner diameter, and calculate wear. Replace cylinder liners with severe wear or damage.

15. Inspect the governor, replace worn parts, and retest performance.

16. Inspect control system pipelines and various valves. Repair by grinding or replace according to actual conditions.

17. Check camshaft bearing clearance. Check the tightening condition of fixing screws for the turbocharger, governor, and other components.

18. Check the tightening condition of diesel engine foundation bolts.

19. Disassemble and inspect the turbocharger according to the turbocharger manufacturer's maintenance instructions.

20. Recalibrate or replace all engine measuring instruments, alarm systems, pipelines, and wiring.

1.6 Maintenance After Every 15000 Operating Hours

1. Inspect all main bearing shells and thrust plates, and determine whether replacement is required according to actual conditions.

2. Remove the cylinder liners and inspect the wear condition of the working surface and corrosion condition of the outer surface. Replace if necessary. All O-rings must be replaced.

3. Inspect all components related to intake and exhaust valves, measure wear, and determine whether replacement is required.

4. Inspect all valve and fuel pump tappet mechanism components.

5. Check camshaft bearing wear and replace if necessary.

6. Remove the rubber flexible coupling and check whether the rubber parts have cracks or damage. Check the tightening condition of output flange bolts.

7. Check the operation reliability and sealing condition of the safety indicator valve and explosion relief door.

8. Inspect the condition of the vibration damper spring assembly and replace if necessary.

   
   

1.7 Maintenance After Every 20000 Operating Hours

Carry out a complete disassembly inspection, overhaul, repair, or replacement of the diesel engine body, engine base, cylinder liners, cylinder heads, crankshaft, main bearings, pistons, connecting rods, camshaft, valves and fuel pump tappet mechanism, transmission gears, as well as fuel system, lubrication system, cooling water system, control system, turbocharger system, and other related systems.

The crankshaft, intake and exhaust valves, piston pins, cams, valve springs, and other major components must undergo magnetic particle inspection.

All connecting rod bolts must be replaced with new ones.

Contact way:

Email:[email protected]

Whatsapp/wechat:+8618766952912

Website:  www.maofupower.com