6 Service and maintenance of diesel engine

A correct, timely and attentive maintenance is able to effectively minimize wear, prevent faults, prolong
service life and reduce operation cost, thus ensuring the normal running of diesel engine. Users shall subject
the diesel engine to maintenance as scheduled herein.
Table 6-1 Maintenance items and schedule

Designation Items

(1) Check engine oil level;

(2) Check engine coolant level;
(3) Check fuel tank level;
Daily maintenance
(4) Check for fuel leakage, air leakage and water leakage;
(every day)
(5) Check working conditions of instruments;
(6) Keep diesel engine clean;
(7) Check and service electrical circuit;

(1) All daily maintenance items;

(2) Check tension of fan belt;
(3) Check and adjust intake/exhaust valve clearance;
First-level maintenance
(4) Check and charge battery electrolyte;
(every 100h)
(5) Replace oil (applicable for new engines or newly overhauled
engines);
(6) Clean inlet filter strainer of fuel supply pump;

Every 250 ~ 300h

(1) All first-level maintenance items;
(2) Clean air filter;
(3) Check opening pressure of fuel injector;
(4) Check connecting conditions for all connections of electrical
Second-level circuit.
maintenance
Every 400 ~ 500h
(every 250 ~ 500h)
(1) Clear water scale;
(2) Clean fuel tank;
(3) Replace oil and oil filter;
(4) Replace fuel filter;
(5) Check oil mist separator and replace its element.

Third-level maintenance (1) Disassemble the diesel engine block, and clear oil fouling,
carbon deposit or slagging;
(every 1500 ~ 2000h)
(2) Check tightening conditions of major parts;
 (3) Check fiction pairs and moving parts for wear and
deformation;
(4) Check working condition of fuel injection pump;
(5) Check working condition of fuel injector;
(6) Check working condition of oil pump;
(7) Check working condition of starting motor;
(8) Check working condition of generator;
(9) Check working condition of turbocharger;
(10) Check torsional damper;
(11) Check thermostat and gaskets;
(12) Check oil mist separator and its element;
(13) Check fan;
(14) Check water pump.
Every 5000h or every 2 years
Replace anti-freeze.

6.1 Daily maintenance (every day)

6.1.1 Check engine oil level
Check the oil level every 8h continuous running of engine (or every working day), as described in 3.6 and
5.1.1 above.
6.1.2 Check engine coolant level
1) Keep the coolant level in the engine cooler higher than the working plane, and if not, add coolant as
described in 5.1.3 above.
2) Keep the connecting hose fittings free of leakage, making sure that no air is invaded to the inside of
cooling system (except for cooler).
3) To avoid accelerated corrosion of cooler, always fulfill it with coolant;
4) Do not add coolant when the engine is running.
5) Do not clear up cooler, open cooler cap or remove cooler connecting hose until the cooler cools down.
6) Do not open the fan shroud when the fan is working.
6.1.3 Check fuel tank level
See 5.1.2 above for checking method.
See “Foreword 1. Fuel” for grade of fuel.
6.1.4 Check for fuel leakage, air leakage and water leakage
Check and eliminate water leakage, fuel leakage and air leakage.
6.1.5 Check working conditions of instruments
Check if readings given by instruments are normal and if any electrical element is damaged, repair or replace it
timely.
6.1.6 Keep diesel engine clean
Keep the diesel engine clean without dust and dirt, and also its electrical devices clear of oil stains to avoid
short circuit therefrom.
6.1.7 Check and service electrical circuit
1) Check cables for damage, and if any, handle timely.
2) Check if mounting fasteners of electronic elements, battery cables, starter cables, charging generator
become loose, and if so, handle timely.
3) Check connections of all elements, connections of sensors as well as cables and fastening screws for
oil stains or looseness, and if any, handle correspondingly.
4) If the bearing of charging generator is found involving “play” or “unusual noises” when the engine is
running, handle timely.
6.2 First-level maintenance
The following maintenance items are to be added on the basis of daily maintenance every 100h of running:
6.2.1 Check tension of fan belt;
It is acceptable if the belt settles by 10-15mm when pressed in the middle of two belt pulleys with a force of 4-
5kg (or 40-50N.m).
When the belt is undertightened or overtightened:
1) For charger belt: adjust the charger adjusting rod to adjust the tension of charger belt (see Fig. 6-1)

Charger
Fig. 6-1 Diagram for adjusting charger belt
2) For fan belt:

Adjust this bolt

to adjust the
tension of fan
belt

Fan belt

Fig. 6-2 Diagram for adjusting fan belt

6.2.2 Check and adjust intake/exhaust valve clearance

Technical requirements (in cold state):

Intake valve clearance: 0.6±0.05mm;
Exhaust valve clearance: 0.65±0.05mm;
The valve clearance is to be checked and adjusted
as follows: turn the crankshaft to the compression
TDC of 1# cylinder to check and adjust valves 1,
2, 4, 5, 8, 9; and then turn the crankshaft by 360°
to check and adjust valves 3, 6, 7, 10, 11, 12.

Fig. 6-3 Checking valve clearance

The clearance of each valve can be adjusted by its adjusting screw as follows: first loosen the locking nut,
unscrew the adjusting screw properly with a screwdriver, insert a feeler gauge between the rocker bridge and
the rocker, and then screw in the adjusting screw properly until the rocker happens to hold down the feeler
gauge, and when the requirement that the feeler gauge can move forward and backward with little resistance is
satisfied, tighten the locking nut.
6.2.3 Check and charge battery electrolyte
Check the level of battery electrolyte, and if too low, charge electrolyte.
Always keep the battery clean
Keep the battery dry and clean, as dirt and oxidizing products may cause short circuit, discharge or voltage
drop of battery in wet weather. In this case, it is recommended to clear oxidizing products on the terminals and
cables of battery with a brass brush, and apply a layer of lubricating grease (vaseline oil) to avoid secondary
oxidization.
6.2.4 Replace oil (applicable for new engines or newly overhauled engines)
For new engines or newly overhauled engines, it is required during their first-level maintenance to replace
engine oil with engine stopped and cooled down.
Method:
a) Remove the drain plug from the side bottom of oil sump, drain the oil along with potential impurities
therein, and collect the waste oil properly to avoid environmental pollution.
b) Check sealing washers of drain plug for damage, and if any, replace with a new one and tighten torque
as required.
c) Add oil to MAX mark of oil dipstick.
d) Start the engine, and check visually for oil leakage.
e) Stop the engine, wait for 15min, and when the oil flows back to the oil sump, check the oil level by
the oil dipstick again.
Generally, the oil level should locate between the MAX and MIN marks or near the MAX mark, and if too low,
add oil.
If the engine oil pressure is found too low, replace the oil filter (thereafter, replace the oil filter along with the
oil).
6.3 Second-level maintenance
The following maintenance items are to be added every 250 ~ 300h on the basis of first-level maintenance:
6.3.1 Clean air filter
When the air filter has been used for 150 ~ 200h or when the pointer of direct-reading alarm on the air filter
falls in the red area, stop the engine to service the air filter as follows: Unscrew the rear end cap nut, remove
the rear end cap, take out the filter element and put in on the clean ground, clear dirt thereon by tapping or
brushing, and then blow it with compressed air (not higher than 588kPa) from inside to outside. Never clean
filter element with oil or water. After maintenance, check the air filter element carefully. Method: put a light at
the inside of filter element, and if such defects as filter paper damage and end cap debonding occurs or when
the filter element has been normally maintained for 5~6 times, replace the filter element.
After maintenance, refit the air filter element correctly with opening of dust bag downward. In no case should
any part be left unfitted. Never use the air filter without rubber dust bag.
6.3.2 Check opening pressure of fuel injector
Fuel injection pressure: 26 ~ 27 MPa
The fuel injection pressure is to be adjusted as follows: remove the cap of adjusting screw, screw in or screw
out the adjusting pressure to increase or decrease the fuel injection
pressure as demanded.
Opening pressure drop of fuel injector nozzle may degrade the fuel
atomization quality and directly influence the performance of diesel
engine. In normal state, the fuel spray should be uniform and the
atomization should be favorable, that is the fuel droplet is tiny and
uniform, and the fuel injection sounds silvery without oil drip.
If the atomization remains improper after adjustment, replace matched
parts of fuel injector nozzle.
NOTE: Always replace with injector nozzle matched part of same model Fig. 6-4 Checking opening pressure of
and same manufacturer! fuel injector

6.3.3 Check connecting conditions for all connections of electrical circuit

Check connecting conditions for all connections of electrical circuit, and if loosened, handle timely.
6.3.4 Clear water scales
When the water temperature is found too high, clear water scales for a good cooling effect. Pay attention that
both outside cleaning and inside cleaning are required.
Outside cleaning
In dusty or dirty environment, seams on the cooler may be blocked by scraps or insects, thus influencing
cooling effect. For those light deposit, usually apply a low-pressure steam injector for cleaning, and for dirt
hard to clean, use low-pressure hot water with detergent, and inject vapor or water from the front face of cooler
to the fan, or otherwise, such dirt may be forced into the inside. Pay attention that the engine is to be masked
by tape if this method is to be taken.
Inside cleaning
Detergent: a mixture composed of 10L water, 750 ~ 800g sodium hydroxide (caustic soda) and 150g kerosene.
Cleaning method:
a) Drain the coolant out of the engine completely.
b) Add the detergent from the radiator to the cooling system.
c) Start the engine, run it at calibrated speed for 10~15min with detergent as coolant to heat the
detergent, and keep the detergent staying in the engine water pipe and cooler for 10~12h. After this, restart the
engine and run it at calibrated speed again for 10~15min to heat the detergent, and then drain out the detergent.
d) Then, inject fresh water (soft water), run the engine at calibrated speed for a while, and drain out the
fresh water.
e) If there are too many water scales, repeat the procedure above 2~3 times.
NOTE: Sodium hydroxide is a strong base and should not be swallowed or contacted by skin. If it comes into
contact with skin, rinse with running water quickly.
6.3.5 Clean fuel tank
The fuel tank is to be provided by the users, and we recommend them in the process of fuel tank design to
reserve a drain switch or a drain plug at the bottom of fuel tank for the purpose of cleaning.
Since the drain plug locates at the bottom of fuel tank, more condensed water is to be generated in unfulfilled
fuel tank than in fulfilled fuel tank. If the fuel level in fuel tank is too low, then under the influence of cold air,
the fuel tank will cool down faster than the fuel.
In this case, more condensed water is to be generated in the fuel tank due to a higher probability of
condensation. Thus, the fuel tank should be kept nearly fulfilled.
When the working environment is highly moist or more water than usual is found in the fuel tank, we
recommend the user to install a water separator.
6.3.6 Replace oil and oil filter
Replace oil
a) Start the engine, and when the normal running temperature reaches, shut it down.
b) Remove the drain plug from the side bottom of oil sump, and drain the oil.
c) Check sealing washers of drain plug for damage, and if any, replace with a new one.
Clean oil filter strainer
Method:
a) Remove strainer cap, gasket, washer, strainer and other parts from the side of oil sump, as shown in
Fig. 6-5.
b) Brush foreign matters away from the strainer and felt with kerosene;
c) Refit strainer parts and relevant parts, and tighten diagonally 4 bolts with a torque of (20~30)N.m.