What is the 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 .
STARTING AND STOPPING PROCEDURE – RB SERIES ENGINES
Preparation for Starting New Engines, Preparation for Starting New Engines
- 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 .
- 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 .
- 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 .
- Check oil level after 30 minute and top up .
- Top up fuel tank .
- Check for leaks and rectify
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.
1.1: 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.
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:-
4.1: Drain lub. oil from engine and fit the drain plug.
4.2: Fill the engine with flushing oil upto maximum level mark on the dip stick.
4.3: Run the engine on light load for about 10 minutes and stop it.
4.4: Drain the flushing oil while the engine is still warm. Clean sump, strainer and oil pockets.
The same flushing oil can be used for next time provided it is well preserved in an air tight Container.
STORING OF THE ENGINE
If the engine is going to remain idle for a considerable period (more than 2-3 months), it is necessary to preserve it in a particular way. This would prevent the rusting of both external and internal parts. For this, follow the procedure given below:-
1: Run the engine for a few minutes to warm it.
2: Drain the fuel from fuel tank, filter and all fuel pipes. Fill the system with suitable preservative and turn the engine to remove any fuel remaining in the pressure pipe and the injectors. The recommended preservative is SHELL FUSES OIL OR BOC Calibrating Oil.
3: Drain and flush the lubricating oil system and fill the preservative oil. For this SHELL ENGINE OIL of same SAE No.as that of lubricating oil can be used.
4: Clean the intake and exhaust system and spray the preservative into it.
5: Remove the injector and spray 1lit. of preservative oil for fuel system in the cylinder bores. Replace the nozzles.
6: Clean the engine externally and apply rust-proof oil to all exposed machined parts or unpainted parts. The recommended rust proof oils are Shell ensis fluid 260 or BOC RCF 260 Caltex rust-proof compound.
7: Cover the engine to protect it from rain, sun and dust. When recommissioning such an engine, first remove all preservative from the engine and then fill it with new lubricating oil and fuel oil.