A-CHECK (DAILY MAINTENANCE)
1. Cleaning - Clean engine and premises.
2. Checking of engine oil level. - Check engine oil level before starting the engine, top-up if required. It should be between H and L mark of dipstick
3. Checking of coolant system - Check coolant level in radiator, top-up if required with premix coolant. Check belt condition.
4. Checking of fuel system - Check fuel strainer, clean breather on fuel tank, Drain sediments/water from fuel water separator. Fill up the fuel tank at the end of each working day.
5. Checking of air system - Check vacuum indicator for air restriction (red band). Check sealing and condition of air filter.
6. Other checks
a. Check for leaks and rectify if required.
b.Run engine and record all parameters.
7. Checking Battery System –
a. Check battery voltage (should be above 26V).
b.Check battery terminal tightness.
c.Check battery terminal tightness with insulated spanner.
d.Check specific gravity of battery by Hydrometer (between 1.21 and 1.24 or 1220 and 1250)
B-CHECK (EVERY 225-250 HRS. OR 6 MONTHS WHICHEVER IS EARLIER)
1. Changing of lubrication oil - Warm up the engine and stop. Remove drain plug and drain engine oil in a pan. Refit drain plug. Fill the recommended new engine oil to H mark on dipstick.
2. Changing of lube oil filter - Clean filter head and its surroundings before removing it. Remove the filter and clean the gasket surface. Fill the new filter with clean lubricating oil and apply a light film of lube oil to the gasket sealing surface. Fit the filter manually.
3. Checking of cooling system - Repeat all A- checks. Check fan hub and fan drive arrangement. Check seal of radiator cap.
4. Changing of fuel filter and water separator - Repeat all A- checks. Remove the two filters from the dual filter adapter. Fill the new filters with clean fuel and apply a light film of lube oil to the seal. Fit the filters manually. Drain sediments from fuel tank.
5. Checking of air filter/system - Repeat all A- checks. Clean air filter in reverse direction using dry air with maximum pressure 0.5 kg/sq.cm.
6. Other checks. Repeat all A checks. Check electrolyte level and specific gravity of battery. Add distilled water if required. Check terminals tightness and clean the battery. Secure all connectors in engine electrical system.
C-CHECK (EVERY 475-500 HRS. OR 12 MONTHS WHICHEVER IS EARLIER)
1. Checking of lubrication system - Repeat all A & B checks. Clean breather.
2. Checking of cooling system - Repeat all A & B checks. Check coolant condition. Check recovery bottle and seal. Check connections and sealing of radiator. Clean radiator externally by blowing pressurised air in the reverse direction of the flow of radiator fan.
3. Checking of fuel system - Repeat all A & B checks. Check all joints in fuel lines and tighten. Check feed pump and clean baby filter.
4. Checking of air filter/ system - Repeat all A & B checks.
5. Other checks - Repeat all A & B checks. Check AVMs (anti vibration mountings) and replace if required.
D-CHECK (Every 950-1000 hrs. or 24 months whichever is earlier)
1. Checking of lubrication system - Repeat all A, B & C checks. Clean breather. Check Blow Bye.
2. Checking of cooling system - Checking of belt, belt tension, belt tensioner. Replacement of coolant. Repeat all A, B & C checks. Remove the dive belt and inspect the belt for damage. Check the tensioner bearing by spinning pulley under hand pressure, it should spin freely with no rough spots feelings. Check the fan hub bearing by spinning fan hub under hand pressure, it should spin freely without excessive end play. Install the good/new drive belt. Measure the belt deflection at the longest span of the belt. Replace coolant by premix coolant. Replace radiator cap.
3. Checking of fuel system - Cleaning of fuel tank. Checking of fuel hoses. Repeat all A, B & C checks. Clean the fuel tank thoroughly with diesel. Check fuel hoses condition and replace if required.
4. Checking of air filter/ system - Repeat all A, B & C checks. Check turbocharger end clearances.
5. Other checks - Repeat all A, B & C checks - Tighten all clamps. Check valve clearances and adjust if required. Intake clearance = 0.254mm. Exhaust clearance = 0.508 mm
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