Do's & Dont's

(For Service & Maintenance)

DO’S - Rail

DO-The rail should be mounted directly and rigidly on the engine block or cylinder head.

DO-Protect the rail assembly against external damages.

DO-Ensure the electrical connectors and wires are not in contact with hot engine parts and sharp edges.

DO-Protection caps to be placed immediately after the rail is removed.

DO’S - Fuel Filter

DO-Ensure filter mounting nut & bolt tighten properly.

DO-Ensure inlet & outlet pipes are not interchanged.

DO-Ensure 250μm strainer is installed in the tank.

DO-Ensure that no leakage after cranking the engine.

DO-Store the filter in room temperature and under dry condition.

DO-Ensure water sensor is tightened properly.

DO-Change the sealing ring of the water sensor on every spin-on exchange.

DONT’S - Rail

DON’T-Do not mount the rail on the intake manifold or on intermediate brackets.

DON’T-Do not mount the rail close to exhaust manifold, EGR valve and other hot devices.

DON’T-Do not paint on the name plate and the add on of the rail.

DONT’S - Fuel Filter

DON’T-Do not use the physically damaged filter for assembly.

DON’T-Do not use hammer for tightening or loosening air vent screw and mounting fasteners.

DON’T-Do not install the filter in tilted angle or horizontally.

DON’T-Do not remove protection caps till fuel lines are connected.

DON’T-Do not fill the spin-on filter with diesel before mounting.

DON’T-Do not use wrenches for mounting.

DON’T-Do not use spin-on sealing ring more than one service interval.

DON’T-Do not unscrew the water level sensor completely.

DON’T-Do not let the diesel drain out from the filter while draining water.

DON’T-Do not repair the flap assembly in hand primer head assembly.

Cooling System

The cooling system consists of :

A.Radiator

B.Surge Tank

C.Fan

D.Thermostat

E.Water Pump

F.Fan Belts

G.Hoses & Connections

To ensure an even temperature within the engine, the cylinder head and cylinder walls of the engine are water cooled. This water is in turn cooled in the radiator. The water is circulated from the radiator to the engine and back through the radiator by means of a water pump.

Radiator

The radiator consists of a cluster of hollow tubes enshrined into a number of fins and enclosed at both ends vide a Top Tank and a bottom tank.

Air drawn by Fan passes through the radiator fins thereby cooling the coolant flowing through radiator tubes.

The fins should be kept clear of mud or dirt accumulation. Over heating may be caused by bent or clogged radiator fins. If the spaces between the radiator fins become clogged, clean them with compressed air or coolant blown from engine side.

Radiator Cap

A pressurised radiator cap is provided which is set at 13 psi (0.9 kg/cm2) pressure. This cap ensures better cooling and avoids loss of coolant due to evaporation. It also reduces corrosion in engine sleeve & crankcase, hence it is strongly recommended that the engine should not be run without radiator cap. Also ensure that rubber gasket is intact & perfectly sealing the system pressure.

Surge Tank

When the engine is in operation, certain amount of coolant passes out of the radiator overflow pipe. This coolant is not allowed to escape into the atmosphere and captured into a Surge tank.

When the engine is not operating and the coolant cools down, certain amount of coolant comes back into the radiator from surge tank. The surge tank thus helps to prevent loss of coolant.

Thermostat

This device prevents coolant circulating through the radiator until the engine reaches its operating temperature. With the thermostat closed, the coolant circulates only through the engine block.

It is important that if the thermostat is defective, do not attempt to repair it, replace with new. When installing a new thermostat, ensure the valve is facing upward. The thermostat operating temperature is 1800F.

When straightening bent fins be careful not to damage the tubes or to break the bond between the fins and tubes.

The cooling system operates under pressure. It is dangerous to remove the radiator cap while the system is hot.

Always turn the cap slowly to the first stop, and allow pressure to escape before removing the cap completely.

Do not run the engine when the cooling system is empty, and do not add cold coolant or cold antifreeze solution if the engine is hot.

The coolant level in surge tank should not fall below the MIN level mark.