Preparation for Starting New Engines | Step by step

What is the Preparation for Starting New Engines?

Preparation for Starting New Engines

Preparations Before Starting of the Engine | Step by Step

New Engines When Dispatched From The Work Have Their Ports  and Opening Sealed With Appropriate Covers. Ensure That All Covers  are Removed Before Commissioning The Engine .


  • Fill recommended grade of fresh oil  in the sump  to the high mark of the dip stick. Add half litre more  to compensate for the  lub oil filter  .
  • Fill up the fuel pump governor  with the same grade of lub oil  from the plug provider at the top of  the governor housing  . To check oil level in the governor . Loosen the  oil level control plug ,  painted red , provided on the inspection cover at the rear of the governor  housing .
  • After starting the engine again check lub oil level in the oil sump and top up if required .


  • Check the fuel tank is cleaned fro inside .
  • Fill the tank with cleaned HSD .
  • Bleed the system as shown in the maintenance manual  .


  • Fill the radiator with either fresh treated water  or with coolant .
  • Grease the water pump bearings with suitable grease .
  • After starting the engine recheck water level in radiator and top up if required .


  • Check battery for correct voltage and current capacity .
  • Check battery cable are correctly connected and secure .
  • Ensure correct polarity .

Preparations Before Starting of the Engine


Preparation for Starting New Engines, Preparation for Starting New Engines

Before starting:-

  • Check oil , water and fuel levels – top up if required .
  • Check air cleaner choke indicator – on dry type of air cleaner .
  • Clean engine with a dry cloth .
  • Drain water from water separator provided in the fuel line .
  • Crank the engine . As soon as engine fire , release the starter switch . keep the ignition switch in ON position .
  • Do not crank the engine for more than 10 sec at a time .
  • If engine fails to start , wait for a minute and try again .

On Starting:-

  • Check the oil pressure .
  • Check battery charging .
  • Check for leakages .
  • Allow the engine to idle for 3 minute before loading the engine.
  • While the machine is in operation , check engine oil pressure , water temperature and battery charging rate at regular intervals .

Before Stopping:-

  • Unloaded the engine and let it be idle for about 5 minute .
  • Check the lube Oil pressure and water temperature.
  • Stop the engine with the engine stopping lever .

After Stopping:-

  • Check oil level after 30 minute and top up .
  • Top up fuel tank .
  • Check for leaks and rectify


Recommended Schedule:

The following schedule of maintenance is based on normal operation of engine. In case of severe operating conditions like extremely high atmospheric temperatures, extremely dusty atmosphere, severe duty conditions etc., the frequency of this schedule has to be increased.

1: Daily:

1.1: Check lub. oil level and top up if required.

1.2: At the end of day’s work fill the fuel tank completely. Before starting drain the moisture accumulated in the tank by loosening drain plug at the bottom of the tank.

2: Every 50 hours:

2.1: Clean the air cleaner element by lightly tapping it on wooden block.

2.2: After initial run of 50 hours tighten all external nuts and bolts, especially the cylinder head nuts.

3: Every 500 hours:

3.1: Drain the lub. oil from sump and refill with new lubricating oil. Clean lub. oil strainer.

3.2: Clean, cooling air passage and the fins on cylinder liner and head.

3.3: Change the fuel filter element.

3.4: Change the lub. oil filter element.

3.5: Clean ceramic filter at the bottom of fuel tank. If necessary replace it.

3.6: If oil bath type air cleaner is used, change the oil and clean the element.

4: Every 800 hours:

Change the paper element of the air filter.

5: Every 1000 hours:

5.1: Knock out soot from exhaust silencer.

5.2: Check and if necessary decarbonise cylinder head, exhaust port etc. It is advised that a mechanic from your dealer/distributor should check up your engine.

6: Every 3000 hours:

It is recommended that the engine is overhauled at the end of 3000 hours.

Maintenance Procedure:

1: Checking lub. oil

A dipstick is provided on the lub. oil filter casing. It carries minimum and maximum oil level marks. If the level is below the minimum mark add lub oil through the dipstick hole. The quantity of oil required to raise oil level from minimum to maximum mark is 0.7 lit. (1.25 pints) for single cylinder engine and 1.3 lits for twin cylinder engine approximately.

2: Cleaning lub. oil strainer

Remove lub. oil filter casing. The strainer is fixed to the lub. Oil pump body by means of worm clip. Loosen this clip and pull the strainer towards flywheel end. Clean it thoroughly from inside and outside by ‘means of kerosene. Refit it and fix the lub. oil filter casing.

3: Cleaning ceramic filter

First drain all the fuel from fuel tank and disconnect the tank to filter pipe. Unscrew the holder at the bottom of fuel tank. This holder carries the ceramic filter. The filter can be cleaned by washing it in clean oil and by blowing air through it. If it is choked completely, replace it with a new filter.

Fuel oil invariably contains water in moisture form. This will corrode the injection system. Hence, never run your engine without the ceramic filter, which filters the water in the fuel.

4: Flushing the engine:

In order to prevent sludge formation, it is desirable to flush the engine with the flushing oil at the time of changing oil. This is specially to be done when the used oil is excessively dirty.

For flushing the engine use standard engine flushing oil available in the market, preferably of the same SAE number as that of the engine oil. For flushing the engine proceed as follows:-

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