UNDERSTANDING BASIC OF

MAINTENANCE
 CONTENT

1. BASIC MAINTENANCE TIPS

2. MAINTENANCE SCHEDULES
 DAILY CHECKS- before starting

Ensure oil level is correct

Ensure Coolant level is correct

Ensure Sufficient fuel level in fuel tank

Check and drain out impurities from fuel filter
(pre filter and main filter)

Belt tightness is sufficient, no crack, peel off etc

Cooling fan leaves are intact- no crack,
shearing etc
 DAILY CHECKS- before starting

Ensure no leakage from any of the fluid
systems – water, oil, fuel etc

All electrical control system is in order and
ensure battery is healthy.

All hoses are free from leakage, not
developed any cracks etc.

Ensure sufficient greasing where ever is
required (water pump, belt tensioner pulley
etc)
 DAILY CHECKS- After starting

Keep the engine on idle speed for 2 -3
minutes and let it for warm up

Ensure no leakage in the fluid system –
water, oil etc

Observe water pressure, oil pressure, fuel
pressure are normal

Observe and ensure that no abnormal
noise, vibration etc

Observe the exhaust smoke is normal
 DAILY CHECKS- After starting

Ensure no variation in engine speed (hunting
etc)

Ensure all dashboard meter are in order –
Speedo meter, oil and water and pressure&
temperature gauge, battery health indicator
etc

Any excess gas released by crank case
breather
IMPORTANCE OF PERIODIC MAINTENANCE
 To maintain overall health of engine in proper
order
 To avoid abnormal wear of moving parts - like
bearings, cam & crank shaft, piston ring and
liner etc. Thus ensures maximum life and
performance of the machine.
 Good maintenance will reduce operational cost
and heavy loss of productive time due to break
down
 Ensures optimum performance of all sub
assemblies – like FIP, Turbo Charger etc
WHY FIRST MAINTENANCE WITHIN 50 HRS
 First 60 Hrs is considered as the “running in”
period of the engine.
 Note: During “running in” period engine load
should not cross 75%
 As the engine completes its virgin operations,
hard & abrasive particles will accumulate in the
lube oil from various moving parts and
combustion impurities.
 If the engine oil is not flushed out from the
system, it may lead to aggressive wear of
internal parts like bearing, crank shaft, cam
shaft, parts of Turbo Charger etc.
WHY FIRST MAINTENANCE WITHIN 50 HRS
 By analysing the oil quality, we can judge the
operational performance of internal components
like bearings, piston rings, liner etc.
 Oil Quality analysis will also help us to avoid
major breakdowns by detecting the faults in the
preliminary stage.
 By checking the tightness of all fasteners,
clamps etc will ensure trouble free operation of
the machine.
 Above all, an engine expert can monitor and
ensure healthy performance of the engine, that
is powering the costly machines.
 ROLE OF LUBE OIL AND COOLANT IN
DIESEL ENGINES
LUBE OIL
• As the name highlights, it will give enough lubrication
for the moving & friction parts
• Support the cooling of internal parts where coolant can
not enter
• Act as detergent to keep internal system clean
• Act as sealing support where the combustion area
• Act against acids formed during combustion
• Act as damping agent for shock and vibrations up to
some extend
 ROLE OF LUBE OIL AND COOLANT IN
DIESEL ENGINES
COOLANT
Water is the universally accepted coolant because
of it major advantages like:
• Availability, heat absorption and rejection
capacity, neutral in chemical reaction etc.
• Even though it is accepted universally, water
can not be taken in to the system without
proper treatment.
• Because many harmful element are dissolved
and must be removed/ neutralized before using
 ROLE OF LUBE OIL AND COOLANT IN
DIESEL ENGINES
COOLANT
Coolant chemical are providing following
advantages:
Act as an anti corrosive agent
Reduce deposits
Increase boiling point of the coolant solution
Reduce the freezing point of the coolant
 ROLE OF LUBE OIL AND COOLANT IN
DIESEL ENGINES
COOLANT
CAUTION:
ENGINE OIL COOLER IS INTERNALLY
CONNECTED WITH JACKET WATER. ALWAYS
USE GOOD QUALITY WATER AND
PERIODICALLY CHECK THE COOLANT LEVEL
AND CORRECT IF REQUIRED.

IF NOT MONITORED THE COOLANT LEVEL, OIL

COOLER MAY FAIL AND WATER WILL ENTER IN
OIL SYSTEM
 ROLE OF FUEL QUALITY

The fuel coming from the main source can not be

used by engine with out proper filtration.
The main reason are:
• Adulteration
• Transporter or supplier can not ensure cleanliness
• Some hard elements can not be removed either
by cleaning or purification, it will be formed at the
time of combustion
•
 ROLE OF FUEL QUALITY

• Clean fuel can ensure trouble free operation of the

engine and the machine.
• Can save maintenance cost of critical sub
assemblies like FIP, Injectors, Turbo Charges etc
• Impurities can not deliver the energy (water, sand,
sulphur etc) thus engine fuel efficiency will be poor
with inferior quality fuel
•
 ROLE OF FINE FILTERED AIR

• Air is required to burn the fuel and release the

energy
• From Air Oxygen is contributing in combustion of
fuel
• Normal atmospheric air is having other gases and
other elements in the molecule form
• Hard Particle from the air if entered in the system
will harm the engine system mainly combustion
chamber lube oil and turbo charger
 ROLE OF FINE FILTERED AIR
Composition of dry atmosphere, by volume[4]
Composition
ppmv: parts per million of dry volume
by volume (note: atmosphere, by is
fraction volume[4]
equal to mole fraction for ideal gas only, see volume
(thermodynamics)) ppmv: parts per million by volume (note: volume fraction is equal to mole
Gas fraction for ideal gas only, see volume (thermodynamics))
Volume
Gas Volume
Nitrogen (N2) 780,840 ppmv (78.084%)
Nitrogen (N2) 780,840 ppmv (78.084%)
Oxygen (O2) 209,460 ppmv (20.946%)
Oxygen (O2) 209,460 ppmv (20.946%)
Argon (Ar) 9,340 ppmv (0.9340%)
Argon (Ar) 9,340 ppmv (0.9340%)
Carbon dioxide (CO2) 394.45 ppmv (0.039445%)
Carbon dioxide (CO2) 394.45 ppmv (0.039445%)
Neon (Ne) 18.18 ppmv (0.001818%)
Neon (Ne) 18.18 ppmv (0.001818%)
Helium (He) 5.24 ppmv (0.000524%)
Helium (He) 5.24 ppmv (0.000524%)
Methane (CH4) 1.79 ppmv (0.000179%)
Methane (CH4) 1.79 ppmv (0.000179%)
Krypton (Kr) 1.14 ppmv (0.000114%)
Krypton (Kr) 1.14 ppmv (0.000114%)
Hydrogen (H2) 0.55 ppmv (0.000055%)
Hydrogen (H2) 0.55 ppmv (0.000055%)
Nitrous oxide (N2O) 0.325 ppmv (0.0000325%)
Nitrous oxide (N2O) 0.325 ppmv (0.0000325%)
Carbon monoxide (CO)Carbon monoxide (CO) 0.1
0.1ppmv
ppmv(0.00001%)
(0.00001%)
Xenon (Xe) Xenon (Xe) 0.09
0.09ppmv
ppmv(9 ××
(9 10
−6
10−6%)
%)(0.000009%)
(0.000009%)
Ozone (O3) Ozone (O3) 0.0
0.0to
to0.07
0.07ppmv
ppmv(0(0to ××
to77 10
−6
10−6%)
%)
(2××1010 %)%)(0.000002%)
Nitrogen dioxide (NO2Nitrogen
) 0.02 −6
dioxide (NO2) 0.02ppmv
ppmv(2 −6 (0.000002%)
(1××1010 %)%)(0.000001%)
Iodine (I2) 0.01 −6
Iodine (I2) 0.01ppmv
ppmv(1 −6 (0.000001%)
Ammonia (NH3) Ammonia (NH3) trace
trace
Not included in above
Notdry atmosphere:
included in above dry atmosphere:
~0.25%
~0.25%by bymass
massover
overfull
fullatmosphere,
atmosphere,locally 0.001%–
Water vapor (H2O) Water vapor (H2O) [2]
5%
locally 0.001%–5% [2]
 PERIODIC MAINTENANCE

Regular maintenance can be conduct on as per the following

table. If the operating condition is heavy dust content or the
engine running by frequently starting & stopping, the regular
maintenance period should be shortened accordingly． ．
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
 PERIODIC MAINTENANCE CHART
PERIODIC MAINTENANCE CHART

Periodical Level 2 Level 3 Level 4 Level 5

First Level 1 maintenance
Inspection maintenance maintenance
Maintenance Items Inspection maintenance Maintenance
Every 300 Every 1200 Every 1800 Every 2400
First 50 Hrs Every 600 Hrs
Hrs Hrs Hrs Hrs Every 3000 Hrs
Replace engine oil 15W40 (CI4+
Replace Replace Replace Replace Replace Replace Replace
GRADE)
Replace oil filter Replace it on every oil change
Inspect and adjust valve Check / Adjust Check / Adjust if
clearance if required required
Replace fuel filter Replace Replace Replace Replace Replace Replace
Replace fuel water separator Replace Replace Replace Replace Replace

Check & top Check & top Check & top up Check & top up Check & top up
Check coolant level & fill Replace Replace
up if required up if required if required if required if required

Check tightness of all clamps Check &tight Check &tight Check &tight Check &tight Check &tight Check &tight Replace

Check all belts Check Check Check Replace Check Check Replace
Check all hoses Check Check Check Check Check Check Replace
Check
Clean & check air filter Check &clean Check &clean Check &clean Check &clean Check &clean Replace
&clean
Check starter motor and Service if
Check Check Check Check Check Check
generator required
Check and record all basic Record all Record all Record all Record all Record all Record all Record all
Parameters (after each service) parameter parameter parameter parameter parameter parameter parameter
Check crankshaft end
Check & record
clearance(once a year at list)
Note: 1. Repeat periodical inspection every 300 Hrs.
2. It is suggested to operate the engine at operating temperature once in a week for minimum 5 minutes
3. Detailed maintenance schedule can be availed from ASCs on request.
4. Use SHELL RIMULAR4 (15W40) CI4+ or equallent Grade Engine Oil
POINTS TO BE NOTICED DURING
PERIODIC MAINTENANCE
 Oil Change
• Maximum oil life: 250 to 300 Hrs
• Required Oil Grade: RIMULACI4+ 15W 40
• Required Oil quantity: 25Litres
• Before draining oil, arrange disposing cans
• Drain the oil when the engine is warm
• Change both oil filters with its sealing rings
Oil Change
Oil Change
 Oil Change
• After Changing filters, fill up fresh oil up to
the specified high level.
• After oil change, start the engine and ensure
no leakage from the filter sealing & drain
plug sealing.
• Stop the engine and check the oil level after
5 minutes; top if required to reach the
specified high level.
Oil Change
 Fuel Filter changing
• Close the fuel valve
• Drain the filter to a can
• Loosen and remove the filter
• Clean the mating face, ensure proper
sealing ring on the new filter mating face
• Fill the filter with clean fuel
• Mount the filter and tighten it with sufficient
torque
 Fuel Filter changing
• Open the fuel valve
• Open the air drain screw on the pump body
• Pump the feed pump
• Ensure air is completely drained from the
system
• Close the air drain screw on the pump body
• Clean the fuel spillage from air bleeder valve
Fuel Filter change
 Tappet setting
• Valve clearance:
• Inlet:0.30 mm,
• Exhaust:0.40 mm,
• WEVB:0.25 mm
• Note: When adjusting the tappet clearance,
the engine should be in cool condition <60
Deg.
 Tappet setting – step 1
Keep the first cylinder at combustion TDC and
adjust the valve clearance as per below order
 Tappet setting – step 2
Rotate the engine 360 degree and make
sure 6th Cylinder is on Combustion TDC
 Tappet setting –step3
Adjust the valve clearance as per below order
 Tappet setting summery

CYL NO 1 2 3 4 5 6

STEP1 I E I E I E

STEP2 E I E I I E
 Adjusting V belt
• Measure the flexibility of the V— belt at the
middle of its biggest span, generally the
requirement result should be less than l0mm
under strong press by your thumb.
• If the flexibility is more than l0mm, it means
the V-belt has been loosen. The nut for
tension pulley needs to be relaxed, strain the
V-belt again and tighten the nut.
Adjusting V belt
 Checking air filter
• The maximum air intake resistance of the
engine should be less than 7kpa, it should
check while the engine running at rated
speed and full load. When the resistance
reaches the maximum limit or the indicator
light glows, the air filter element should be
cleaned or replaced as per the maintenance
guide from the manufacture.
 Cleaning air filter
• Don't blow off the air filtering paper
• Don't clean the air filtering paper by water
and oil
• Don't beat the core forcibly.
• High pressure air pipe