Best 10 tips on How to overhaul a Diesel Engine

How to overhaul a Diesel Engine

In this Post, students are taught about diesel engines maintenance. We are writing this post mainly for the benefit of young marine Engineers starting their careers onboard ships. This post contains the right procedures so it makes it easy for the Engineers to undertake the maintenance. We have made our best efforts in defining the correct guidelines with required important documentation also.

This chapter first establishes the significance of complete technical manuals to efficient and trouble-free diesel engine maintenance. Statics has inside the article.

The key to diesel engines maintenance is regularly in techniques – involving the regular inspection and servicing of all the plant objects inside the facility. Operating staff ought to be successful in recognizing trouble symptoms and taking fast corrective action.

All the equipment requires regular Maintenance for its efficient function. Establish maintenance strategies at the starting phase. Preventive Maintenance following the condition-based Maintenance will reduce the chances of failure. This practice will extend the Engine’s life.

The engineer in charge should provide trained staff with proper training and instructions. To ensure the training program for the staff from the original equipment manufacturer.

Have the best parts cleaning rags like discarded beach towels.

Instruction Manuals

  • The instruction manual should be available before the start-up of the plant.
  • Edit all the manuals as a ready reference for the operation and maintenance

Preventive maintenance

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Supplier’s Manuals with Following Contents

  • The checks required before start-up;
  • Starting and stopping procedure.
  • Operating procedures;
  • Safety precautions and operational hazards.
  • Normal operating checks;
  • Practices in the event of malfunctioning- fault conditions, fault diagnosis, and rectification procedures.
  • Maintenance instructions defining tests, reviews and inspections, and maintenance jobs (routine schedules and all major and minor overhauls);
  • Schedule of maximum permissible wear of moving parts;
  • List of all the elements with an amount no. for ordering purpose of the wear, scheduled maintenance, emergence spares, and experience-based spares;
  • Factory acceptance test results;

Provide the following documents to meet its need for the understanding and diesel engines maintenance of the systems.

  • For the clear understanding of the function of components within the system so that it describes the function.
  • Provide the logical fault finding and the maintenance procedures because it is related to the Powerplant’s successful operation and maintenance.
  • Safety instructions
  • General arrangement drawings
  • Charts of test and signal data for each functional diagram
  • location diagrams for equipment and test points
  • Procedures for adjustments and examination
  • Procedures charts for replacement and repairs
  • Spare parts lists

Factors affecting Power Plant Life

  • Normal wear and tear on usage.
  • Natural fractures as corrosion.
  • Damage due to operating errors.

NOTE:-Overlooking the significance of diesel engines maintenance can lead to continual neglect and result in irreparable damage to the plant because it will cause severe consequences for the power networks and supplies.

Maintenance strategies

The strategic terms are defined as follows.

Unplanned Maintenance:-Following unplanned Maintenance always leads to catastrophic failures. In such cases, a plant runs without any supervision unless there is a failure or breakdown.

Strategic Maintenance

  • Corrective Maintenance
  • Emergency maintenance

The aim of planned maintenance (diesel engines maintenance) is to reduce or eliminate breakdowns and failures and to minimize the resulting plant stoppages or damage. Planned and preventive maintenance are compliment of each other, breakdown maintenance may not be the part of planned and preventive maintenance.

Types of Preventive maintenance

  • Timebase
  • Condition base

Techniques for assessing Machine Condition.

  • Vibration monitoring ;
  • Shock pulse monitoring for rolling bearings;
  • Side-band analysis for checking gear teeth condition;
  • Install the Proximity probes to match for the proper working of piston rings. The Piston Rings should not be in contact with the liner surface. No to detect the damaged piston rings.
  • For the detection of liner wear rate, mount the flush thermocouples.
  • Monitor the sound, similar to vibration monitoring.
  • Chromatographic techniques:-for the detection of the gaseous products evolved in electrical insulation breakdown due to arcing or overheating.
  • The detection of high-frequency emission from generator stator windings, signaling the inception of electrical discharge from voids in the insulation;
  • Spectroscopy

Lube Oil Analysis Predictions

  1. Sodium or boron in an engine oil sample shows the symptoms of coolant ingress.
  2. High levels of iron and chrome would indicate excessive wear on the piston rings;
  3. The presence of excessive lead, copper, and tin is an indication of bearing wear
  4. Rises in water and soluble contents would suggest a pump seal failure
  5. An increase of nickel and molybdenum would point to wear on the pump shaft;

The Object or preventive maintenance program for diesel engines maintenance

  • Prepare the  list of the scheduled maintenance of each machinery in the plant.
  • To establish and to allocate specific maintenance tasks to specific periods;
  • Undertake the scheduled maintenance as per the manual’s instructions because it provides the correct information and procedures.

OEM’s operation and service manuals must be the guiding factor for the preventive maintenance program. Because the manuals provide the correct procedure, so the overhauling is undertaken as per the procedure.

Planned schedules should, at first, rigidly adhere to the engine manufacturer’s recommended frequencies for inspection checks and maintenance tasks and will allow assessing achievement against the maker’s wear and renewal limit schedules. The base data fed into the microprocessor of the condition mo

Servicing schedules will differ in detail between slow-speed, medium-speed, and high-speed engines to cover all types of machines. Intervals between major overhauls on well-maintained machines have widened considerably over the years so the maintenance cost has reduced.. Typically, one expects intervals of 10000 – 15000 hours for high-speed engines and between 20000 and 30000 hours for medium- and slow-speed engines.

Conditions Checked By Sensors(diesel engines maintenance)

  1. Battery voltage and battery chargers;
  2. Engine coolant, lubricating oil, and exhaust temperatures;
  3. Lubricating oil pressure;
  4. Engine coolant and lubricating oil levels;
  5. Daily service fuel tank levels;
  6. Fuel head so that positive pressure is available at fuel pumps.
  7. Drip tray levels so that to detect low-level leakage of fuel, oil, or coolant
  8. Plant room ambient temperature;
  9. Generator winding temperature;
  10. Rotating diode failure;
  11. Generator speed/frequency;
  12. Generating set vibration;
  13. Electrical parameters such as kW, kVA, etc.; Status of plant room ventilation louvers and plant room security;
  14. Switchgear status (e.g., to ascertain if key isolators are in the correct positions);
  15. Fire valve status.

Maintenance records.(diesel engines maintenance)

  1. Printing works orders
  2. Printing reports for control and follow-up
  3. Making availability a parts inventory because it helps in the proper forecast of required spares.
  4. Maintenance of store equipment history because it helps the Engineers in proper planning of maintenance.
  5. Creation of a detailed database
  6. Pinpointing out problems by reports so that Engineer has a clear understanding.
  7. Providing other detailed information because it helps in forecasting the scheduel

Information in Maintenance records (diesel engines maintenance)

  1. Information index;
  2. Record of past performance;
  3. Analysis of historical information;
  4. Timely indication of future events.

The information index (diesel engines maintenance)

  • Installed Equipment inventory because it will help in proper planning of spares budget.
  • Data on each item of plant  
  • Location of Workshop Manual.
  • Drawings location.
  • Any limitations regarding access for maintenance, e.g., only available when its associated generator is shut-down.
  • Maintenance Application form.
  • Scheduled, condition-based, fault-related, etc.
  • Any other specific information, such as special service tools required, spare part numbers, modifications made, etc.

Performance History (diesel engines maintenance)

  • A record of all previous maintenance work so that engineers understand the jobs for the next maintenance.
  • history of the dates of all previous maintenance work
  • Condition of the item/equipment during the last inspection helps forecast the schedule.
  • critical (wear) dimensions;
  • Insulation value, etc.
  • A record of maintenance costs on the item: labor, materials, and spares.
  • A record of behavior or the results of any tests using different materials, lubricants, etc.


  • Subsequent due scheduled maintenance work on an item.
  • Statutory inspection is due on an item, e.g., lifting tackle, air receivers, etc.

Overhauling data Sheet

Sheet 1

  • Subsequent due scheduled maintenance work on an item.
  • Statutory inspection is due on an item, e.g., lifting tackle, air receivers, etc.

Sheet 2

  • Cylinder Liner Gauging wears measurements.

Sheet 3

  • Piston gudgeon pin bore Measurement
  • Piston Pin measurement and examination;
  • Data of Piston ring groove measurement 
  • Piston ring data

Sheet 4

  • Crankshaft measurement
  • Deflection/ alignment data

Sheet 5

  1. Crankshaft Measurement
  2. Deflection/ alignment data
  1. Crankshaft Measurement
  2. Deflection/ alignment data
  • Cylinder head valves, valve guides, and valve seat details

Sheet 7

  • Governor Overhaul data

Sheet 8

  • Turbocharger overhaul data with measurements. Carry out the Turbocharger’s overhaul because Turbocharger is a high-speed machine. If we observe any abnormality in the running parameter, then the Engineers will take extra care.

Sheet 9

  • Statistic and Dynamic tuning data

Sheet 10

  • Initial running: balancing cylinders and load testing.

Best Book On Marine Engineering

The Best Book On Operation and Maintenance

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The book is intended to serve as an engineering guide to all those who may be concerned with the selection, specifications, testing, commissioning, operation and maintenance of Diesel generator plant. It should therefore be valuable to ;- the plant or service engineers to non-specialist engineers and users; and to young technicians and engineers who are embarking on a career in the supply industry.

Fundamentals of Medium/Heavy Duty Diesel Engines

Based on the 2014 National Automotive Technicians Education Foundation (NATEF) Medium/Heavy Truck Tasks Lists and ASE Certification Test Series for truck and bus specialists, Fundamentals of Medium/Heavy Duty Diesel Engines is designed to address these and other international training standards. The text offers comprehensive coverage of every NATEF task with clarity and precision in a concise format that ensures student comprehension and encourages critical thinking. Fundamentals of Medium/Heavy Duty Diesel Engines describes safe and effective diagnostic, repair, and maintenance procedures for today’s medium and heavy vehicle diesel engines, including the most current, relevant, and practical coverage of: • HD-OBD emission diagnostics • Common rail injection systems

Power Plant Performance

Power plant Performance

“Power Plant Performance” Book Review: This book provides an overview on the operations of power plants. It describes the various concepts required in understanding the functioning of power plants. It provides details on how testing is performed and what monitoring should be applied to optimize performance. It covers aspects like steam cycles, boilers, turbines, condenser and feed heaters, and related topics. It provides numerous solved and unsolved examples for enhanced understanding. The book is designed for students, teachers, and professionals in the field of engineering and science.

Pounder’s Marine Diesel Engines and Gas Turbines

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Pounder’s Marine Diesel Engines has served seagoing engineers, students of the Certificates of Competency examinations and the marine engineering industry throughout the world.

Now in its ninth edition, Pounder’s retains the directness of approach and attention to essential detail that characterized its predecessors. There are new chapters on monitoring control and HiMSEN engines as well as information on developments in electronic-controlled fuel injection. It is fully updated to cover new legislation including that on emissions and provides details on enhancing overall efficiency and cutting CO2 emissions.
After experience as a seagoing engineer with the British India Steam Navigation Company, Doug Woodyard held editorial positions with the Institution of Mechanical Engineers and the Institute of Marine Engineer

* Helps engineers to understand the latest changes to marine diesel engineers
* Careful organisation of the new edition enables readers to access the information they require
* Brand new chapters focus on monitoring control systems and HiMSEN engines.
* Over 270 high quality, clearly labelled illustrations and figures to aid understanding and help engineers quickly identify what they need to know.

Power Plant Equipment Operation and Maintenance Guide 

Powerplant Maintenance

Power Plant Equipment Operation and Maintenance Guide provides detailed coverage of different types of power plants such as modern co-generation, combined-cycle, and integrated gasification combined cycle (IGCC) plants. The book describes the design, selection, operation, maintenance, and economics of all these power plants. The best available power enhancement options are discussed, including duct burners, evaporative cooling, inlet-air chilling, absorption chilling, steam and water injection, and peak firing.

This in-depth resource addresses the sizing, selection, calculations, operation, diagnostic testing, troubleshooting, maintenance, and refurbishment of all power plant equipment, including steam turbines, steam generators, boilers, condensers, heat exchangers, gas turbines, compressors, pumps, advanced sealing mechanisms, magnetic bearings, and advanced generators.

Coverage includes:

  • Methods for enhancing the reliability and maintainability of all power plants
  • Economic analysis of modern co-generation and combined-cycle plants
  • Selection of the best emission-reduction method for power plants
  • Preventive and predictive maintenance required for power plants
  • Gas turbine applications in power plants, protective systems, and tests

A Pocket Book of Marine Engineering: Questions and Answers

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A Pocket Book of Marine Engineering: Questions and Answers is a book that covers the topic of air filter for engine in great detail. This book is a great resource for anyone who wants to learn more about this topic. The author, John Myatt, is a world-renowned expert on marine engineering. In this book, he covers everything from the basics of how these engines work to more advanced topics like choosing the right air filter for your engine. If you’re looking for a comprehensive guide to air filter for engine, this is the book for you.

This handy pocket-sized guide is filled with hundreds of questions and answers on marine engineering, covering all the basics from engines and propulsion to steering and safety. It’s perfect for anyone who wants to learn more about this fascinating subject, whether they’re studying for a qualification or just interested in how boats work. With clear explanations and plenty of diagrams, this book is an essential reference for anyone with an interest in maritime engineering.

Lamb’s Questions and Answers on the Marine Diesel Engine

Lambs Questions and Answers 6

The book is comprehensive and includes almost all topics needed to understand marine diesel engines. The book explains the role of heat in engineering science, the principles behind internal combustion engines, the role of fuels and lubricants, the cooling systems, the lubricating systems and the heat exchangers.

The book also explains the various parts of the marine engines and their functions. Air-storage tanks and air compressors are also dealt with in the book. Information on balancing and vibration, various instrumentation and control methods, along with the safety measures are covered in the book.

Lamb’s Questions and Answers on the Marine Diesel Engine was published by Butterworth-Heinemann in 1990. The eighth revised edition is available in hardcover.

Diesel Generator Handbook

Diesel Generator Handbook 1 6

Diesel Generator Handbook meets the need for an authoritative reference work covering the range of mechanical and electrical topics embodied in the practical design and application of diesel generating plant. It will be particularly welcomed in many parts of the developing world where the diesel generator is basic to the electricity supply system.

The discussion covers, in fifteen chapters, the prime mover, power ratings, synchronous generators, load assessment, control principles and systems, switchgear and controlgear, standby power, fuels and lubricating oilss, installation and commissioning, noise reduction, and plant operation and maintenance.

The book thus caters for all who are concerned with the selection, specification, testing, commissioning, operation and maintenance of diesel-based generator systems: not only the practising plant or services engineers, but also non-specialist engineers and users. The young technician or trainee engineer who is embarking on a career in the supply industry will find this handbook an invaluable investment.

L L J Mahon, FIEE, FBIM, after an engineering apprenticeship with BTH in Rugby, gained over 30 years’ experience in the design, development, manufacture, installation and commissioning of both stationary and highly specialised mobile diesel generator plant for a range of applications.

Power Plant Engineering 

Powerplan Engineering

“Power Plant Engineering” Book Review: This book provides a fundamental overview on concepts required for understanding the functioning of power plants. It covers the basics and advanced topics in detail. It is written in an easy to understand language. It provides numerous real-world problems and their detailed solution. It provides theoretical and mathematical explanations of problems. The book is designed for students, teachers, and professionals in the field of engineering and science who need to work with power plants on a regular basis.

Blog Conclusion

We hope you enjoyed our blog post about diesel engines maintenance! In this article, we discussed the importance of diesel engines maintenance, and helped the readers understand how diesel engines maintenance works. If you would like to learn more about the stuff we discussed in our blog post, please visit us at Thanks for reading and please let us know what you think!

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