Improper maintenance practices can significantly reduce the lifespan and efficiency of diesel engines and agricultural machinery. One common mistake is the accumulation of engine oil without complete replacement. Instead of fully replacing the old oil, operators often just top up with new oil, thinking this will save costs while still providing adequate lubrication. However, over time, the existing oil degrades, accumulates impurities, and loses its effectiveness. Even adding new oil cannot restore its quality, leading to increased wear on critical components like cylinder liners, pistons, and crankshafts. Additionally, the buildup of contaminants in the oil can clog oil passages, causing serious failures such as seized bearings or damaged connecting rods.
Another frequent error is adjusting valve clearance without using proper tools. Many operators rely on their sense of touch by shaking the rocker arm to estimate clearance, which can lead to improper adjustment. This not only affects engine performance, increasing fuel consumption and reducing power, but in severe cases, it can cause collisions between the piston and valve, resulting in major damage like cracked pistons, bent connecting rods, or even a broken crankshaft.
Failure to regularly clean carbon deposits from the exhaust system is another common oversight. Operators often neglect this maintenance task, allowing carbon buildup to narrow the exhaust pipe’s cross-section. This restricts exhaust flow, increases fuel consumption, reduces engine power, and may even cause overheating. To prevent these issues, it's essential to clean the exhaust system at least once every three months, ensuring smooth operation and optimal performance of the diesel engine.
When a new machine is put into service, some operators skip the break-in period and immediately apply full load, thinking it saves time. However, the manufacturer’s guidelines recommend a gradual process—starting with low speed and light load, then gradually increasing both. This allows the friction surfaces of internal parts to smooth out properly. Skipping this step can lead to premature wear and significantly shorten the machine’s lifespan. Proper break-in is crucial for long-term reliability and performance.
Lastly, many operators fail to conduct thorough pre- and post-operation inspections. Neglecting to check bolts, nuts, washers, and split pins can result in loose or detached components during operation, posing safety risks to both the machinery and the operator. It’s important to inspect all fasteners before and after use, tightening any that have loosened and replacing or repairing worn or deformed parts promptly. These simple checks can prevent small issues from escalating into costly and dangerous failures.
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