1.

The importance of an effective maintenance program cannot be overlooked because it

plays such an important role in the effectiveness of Lean manufacturing. As in personal health care insurance, maintenance may be considered the heath care of our manufacturing machines and equipment. It is required to effectively reduce waste and run an efficient, continuous manufacturing operation, business, or service operation. The cost of regular maintenance is very small when it is compared to the cost of a major breakdown at which time there is no production. The main purpose of regular maintenance is to ensure that all equipment required for production is operating at 100% efficiency at all times. Through short daily inspections, cleaning, lubricating, and making minor adjustments, minor problems can be detected and corrected before they become a major problem that can shut down a production line. A good maintenance program requires company-wide participation and support by everyone ranging from the top executive to the shop floor personnel.

2. Diesel engines are excellent and reliable engines if regularly and properly maintained. 3. Diesel engine supporting systems
A number of systems are in place for proper operation of an engine Intake and exhaust system Starting system Fuel system Cooling system Lubricating system 3.1 Intake system and exhaust system The function of this system is to allow the purified air to the cylinder Components : The system is composed of Air cleaner, Intake manifold, Intake valve, Super charger etc.

1. Wing nut 2. Washer 3. Air filter cover 4. Rubber Packing 5. Air filter cartridge 6. Rubber packing

7. Air filter body 8. Rubber packing 9. Air filter flange 10. Air filter sleeve 11. Intake pipe

Faults and remedies 1) Air cleaner jammed with dirt 2) Internal manifold cracked 3) Cage --- and bent stem of intake valve 4) Super charger not working properly

-Change -Change -Repair or change -Repair or change

Exhaust system The exhaust takes out burnt gas from the cylinder

Components : The system is composed of exhaust manifold Silencer pipe, Silencer box and Tail pipe Faults and remedies 1) Exhaust manifold broken/cracked 2) Silencer pipe cracked 3) Silencer box jammed due to burnt or leaked carbon 4) Tail pipe leaked or cracked

-Change -Repair or change -Repair or change -Repair or change

3.2 Starting system The system starts the engine by providing the initial rotations via :

Hand-starting system Self-starting system Rope-starting system Pedal-starting system

3.2.1 Hand-starting system: Hand-starting system is generally used in one cylinder diesel engine. There is no fault in this system, one handle is used for starting.( Water, lubricant and fuel must be checked before starting) 3.3 Fuel system Engine fuel system is very important through which the fuel is taken out of the fuel tank for combustion.

Essential components: fuel tank fuel line fuel filter low-pressure feed pump high-pressure fuel pump and injector / atomizer Faults and remedies 1) Fuel tank leaked/cracked -Repair or change 2) Fuel line leaked/cracked -Change 3) Filter jammed due to dirt -Change 4) Low pressure/feed pump faulty -Repair or change after checking 5) High pressure fuel pump faulty -Repair or change after checking 6) Injector faulty -Repair or change after checking

3.4 Cooling system Engine cooling system enables the engine to maintain a constant operating temperature.

There are two types:

Water cooling system

Air cooling system

3.5 Lubrication system Using lubricant, the lubrication system prevents wear and tear of moving components and enables components to move faster and more efficiently. The lubrication system serves three functions : Cooling Sealing Cleaning

Components: Strainer Oil pump Oil filter Oil pressure gauge Oil passage etc

Different Parts of Lubrication Systems

1. Copper Washer 2. Pipe Connection Bolt 3. Oil Pipe 4. Cylindrical Pin 5. Lubricating Oil Pump Body 6. Locating Pin 7. Lubricating Oil Pump Packing 8. Outer Rotor 9. Inner Rotor 10. Oil Shaft 11. Oil Pump Cover 12. Copper Washer 13. Pipe Connection Bolt 14. Oil Strainer Body Section with Pipe 15. Oil Strainer Screen 16. Circlip

Faults and remedies 1) Strainer may be damaged -Change 2) Pump may not work -Repair or change 3) Oil filter jammed due to dirt -Change 4) Oil pressure gauge faulty -Repair or change (after checking) 5) Oil passage jammed -Clean

4. Common maintenance tasks:

Fluids are vital to the health and efficiency of the engine. Samples should be recorded from fluids in the entire system, and analysis should be recorded and tracked. This will help to identify issues before they become failures or lead to costly repairs.

Filters should be inspected and replaced as necessary. A dirty filter drastically reduces engine efficiency. Inspect and rotate tires, and maintain proper tire pressure. Paired tires should be at the same level of wear in order to insure they perform equally. Tires, wheels, and stem caps should be inspected for leaks, damage, and wear. Rear tire rock ejectors should be inspected for free movement. Aligning the front and back end regularly reduces tire wear and improves both performance and driver comfort. Reducing fatigue for the driver results in fewer accidents and improved concentration. Struts (suspension cylinders) are charged with nitrogen and oil. Pressure should be checked at defined intervals to increase tire life and improve handling and driver comfort. Improperly charged struts can even result in accelerated component wear and reduced frame life. Engine, roll-over protection system, and tank mounting brackets and welds should be inspected for damage or loose bolts. Fuel tank should be inspected for drain water and sediment. The radiator should be inspected for fan blockage, debris between the radiator and grill, and leaks. Inspect all hoses for cracks, wear and leaks. Inspect and replace belts if they show signs of tension, wear, or cracks. Windshield should be clean and free of cracks and chips. Inside and outside should be thoroughly inspected for any buildup of debris or grit, and for proper operation of hinges, hydraulics, seat belts, moisture, broken glass, and leaks.

5. 6.

7. The cost of regular maintenance is very small when it is compared to the cost of a
major breakdown at which time there is no production. A recent survey showed the actual cost for a breakdown between four to fifteen times the maintenance costs. When the breakdown causes production to stop, the costs are very high because no parts are being produced.