Preventive maintenance starts with daily inspections of the system. Before starting the system, check if the liquid level is normal. Search for: Loose leaking parts, damaged belts, worn low and high voltage wiring harnesses, or any changes in the appearance of the damaged system, the smell of fuel and the smell of electronic devices.
If the operator wants to achieve the most satisfactory use effect, they must keep the mechanical and electronic devices of the system in optimal condition. The maintenance department needs to receive daily operation reports submitted by operators to make necessary adjustments to maintenance schedules. When the report indicates the need for extensive maintenance work, the daily operation report also helps to prepare for it.
Comparing and providing reasonable explanations for daily reports, coupled with practical follow-up measures, will prevent most malfunctions and emergency repairs from occurring.
Any of the following situations that may apply should be reported to the maintenance department:
- Low power
- Power increase or engine surge
- Unstable or throttle control failure or unresponsive
- Any warning light flashing or continuously on
- Low oil pressure
- Abnormal water or oil temperature
- System abnormal noise
- Excessive smoke exhaust
- Excessive use of coolant, fuel, or engine oil
- Any fuel, coolant, or oil leakage
- Loose or damaged parts
- Belt wear or damage
- Wear or damage to low or high voltage wiring harnesses
System abnormal noise
During daily maintenance and inspection, listen to instructions for abnormal noise from the system that the engine needs to be repaired.
Check according to the following steps:
A. Intake pipe
Maintenance and Inspection
The intake pipe should be checked daily for wear and damage, loose clamps, and small holes, which may cause engine damage. If necessary, replace damaged pipes and tighten loose clamps to prevent air system leaks.
Torque value: 8 n•m [ 71 in-lb ]
Check whether the clamps and hoses of the intake system pipeline are corroded. Corrosion can allow corrosive substances and dirt to enter the intake system. If necessary, disassemble and clean.
B, Air filter pre-filter
Maintenance and Inspection
In extremely polluted environments, an air pre-filter can be used. Clean the pre-filter canister and dry air filter dust collection tray daily, or if necessary, regularly clean according to operating conditions
C, Air filter resistance
Maintenance and Inspection
C. 1. Attention to mechanical indicators: Do not operate the engine without an air filter installed. The intake must be pre-filtered to prevent dust and debris from entering the engine and causing premature wear.
Note: Do not remove the felt gasket of the indicator. Felt pads are used to absorb moisture.
The mechanical resistance indicator is used to display whether the air resistance through the dry air filter is too high. This device can be installed at the outlet of the air filter or on the dashboard. As dirt accumulates in the filter element, the red mark (1) in the window gradually rises. After replacing the filter element, press the reset button (2) to reset the indicator.
The resistance or vacuum indicator should be installed as close as possible to the turbocharger inlet to obtain the true resistance.
C. When the air resistance of the vacuum indicator is too high, the vacuum switch will activate the alarm indicator light on the dashboard.
C. 3. Industrial gas mechanical indicator Mechanical resistance indicator is used to display whether the air resistance passing through the dry air filter is too high. This instrument is installed in the outlet of the air filter. As dirt accumulates in the filter element, the red mark (1) in the window gradually rises. When air blockage is indicated, the air filter must be replaced. After replacing the filter element, reset the indicator by pressing the reset button (2).
D. If automatic exhaust valves are used for gas and liquid tanks, please check if the valves are working properly. If a manual exhaust valve is used on a wet air storage tank, open the drain plug on the tank to remove the moisture accumulated in the air system. If there is oil, the air compressor system must be checked. Contact the repair station.
E. Coolant level
Attention: E.1 Do not open the pressure cap from the hot engine. The pressure cap should be removed only when the coolant temperature drops below 50 ° C [122 ° F]. Otherwise, the spraying of high-temperature coolant or steam may cause personal injury. E. Do not use sealing additives to solve cooling system leakage problems. This will cause blockage in the cooling system and poor flow of coolant, leading to engine overheating.
E. 2 It is necessary to check the coolant level daily.
E. 3 Do not add cold coolant to a hot engine. Otherwise, it will damage the engine castings. Wait until the engine temperature drops below 50 ° C [122 ° F] before adding coolant.
The coolant added to the engine must be mixed with antifreeze, supplementary coolant additives, and water in the correct proportion to prevent engine damage.
E. 4 Add coolant to the cooling system. For coolant level, refer to the markings on the radiator or expansion tank, or refer to the OEM manual.
Note: Some radiators have two filling necks, both of which must be filled when draining the cooling system.
F. Fuel/water separator
Drain the water from the oil-water separator into a container and dispose of it according to local environmental regulations.
Note: Long term non-discharge of the oil-water separator will trigger engine protection derating. After the oil-water separator is emptied and the fuel water content is not activated, the derating will be cancelled.
Cummins requires the installation of oil-water separators or fuel filters in the fuel supply system.
Turn off the engine.
Discharge water and sediment from the separator daily.
The opening and closing of the discharge valve may vary depending on the design.
F. 1 can type
Open the discharge valve by hand.
Drain the water from the separator until clean fuel is visible.
Close the discharge valve by hand.
F. 2 spiral installation type
Open the discharge valve by hand. Rotate the valve counterclockwise for about 3 and a half turns until it drops 25.4mm [1 in] and begins to discharge.
Drain the water from the separator until clean fuel is visible.
Attention: When closing the discharge valve, do not tighten the valve too tightly. Excessive tightening can damage the threads.
When closing the valve, lift it up and rotate it clockwise until it is tightened by hand.
G. Oil level
The oil dipstick is located on the left side of the engine.
One side of the oil dipstick is marked with a static indicator and has been calibrated to measure the static oil level.
On specific engines, the other side of the oil dipstick is marked with RUN (flowing) and has been calibrated to measure the flowing oil level.
G. 1. Maintenance and Inspection
Attention: It is strictly prohibited to operate the engine when the oil level is below the L (low oil level) mark or above the H (high oil level) mark. This can lead to a decrease in engine performance or damage to the engine; When checking the oil level, the engine must be placed horizontally to ensure accurate measurement values.
To perform a static oil level check, turn off the engine to obtain an accurate reading.
Wait for 15 minutes after the engine is stopped before starting to check the oil level. During this period, the oil can flow back to the oil pan.
Remove the oil dipstick and evaluate the oil level.
G.2. To perform an oil level check, please let the engine idle and confirm that the coolant temperature is stable at 160 ° F [71 ° C] before conducting the oil level check.
Remove the oil dipstick and evaluate the oil level.
