Maintenance intervals

Daily Maintenance Procedures

- Air intake duct - check.

- Coolant level - check.

- Crankcase breather pipe - check.

- Drive belts - check.

- Cooling fan - check.

- Fuel water separator - drain off sediment.

- Engine oil level - check.

- The level of the liquid for the exhaust systems of diesel engines - check.

Maintenance procedures every 10,000 km [6,000 miles], 250 hours, or 3 months

- Hydraulic pump drive - check.

- Generator - check.

- Air conditioning compressor - check.

- Air filter resistance - check.

- Charge air cooler - check.

Maintenance procedures every 20,000 km [12,500 miles], 500 hours, or 6 months

- Oil and oil filter - replace.

- Fuel filter - replace.

- Cooling system - check.

- Radiator cap - check.

Maintenance procedures every 40,000 km [25,000 miles], 1,000 hours, or 1 year

- Fan belt tensioner - check.

- Belt driven fan hub - check.

Maintenance procedures every 80,000 km [50,000 miles], 2,000 hours or 2 years

- Cooling system - flush.

- Radiator hoses - check.

- Crankshaft pulley / vibration damper - check.

Maintenance procedures every 160,000 km [100,000 miles], 4,000 hours, or 4 years

- Valve mechanism - adjust.

- The unit for dosing fluid for exhaust systems of diesel engines - replace.

Engine oil selection

The choice of engine oil is based on the operating temperature range of the vehicle and the instructions of the vehicle manufacturer.

Make sure that the selected oil with the appropriate viscosity (SAE) also meets the quality requirements (API, ACEA or JACO).

The choice of engine oil viscosity is based on the recommendations of the vehicle manufacturer and the temperature range of vehicle operation.

Cummins recommends:

- at operating temperatures above 15 ° C, use high quality multigrade SAE 15W-40 engine oil.

For operation at lower temperatures, lower engine oils with SAE 10W-30 viscosity and CES 20078 (API CI-4) or CES 20081 (API CJ-4) quality can be used.

Tested by Cummins and Mack, the above engine oils can be used over a wider temperature range than older API 10W-30.

Since these oils are designed to operate in a thinner oil film than 15W-40 oils, use high-quality Fleetguard filters at temperatures above 20 ° C, use engine oils such as Valvoline Premium Blue, Valvoline Premium Blue Extreme Life or their analogues, as well as Fleetguard oil filters or equivalent.

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Use oil with CES, API, ACEA, etc. not lower than specified by the car manufacturer

Choosing an oil grade for Cummins engines

Cummins Classification (CES)

American Petroleum Institute (API) classification

international classification

Note

-

API CD / СЕ / CG-4

ACEA E-1

Deprecated, do not apply

CES-20071

API CH-4, CH-4/SJ

Global DHD-1

Standard oil for engines without exhaust gas recirculation operating worldwide

CES-20072

API CH-4

Global DHD-1 / ACEA E-5

CES-20075

API CF-4/SG

ACEA E-2 / E-3 JAMA DH-1

Lowest grade oil for mid-range engines without exhaust gas recirculation operating outside North America

CES-20076

API CH-4 при одно­временном удовле­творении требований CES-20076*

 

Premium quality engine oil for heavy duty engines outside North America without exhaust gas recirculation.

* CES-20076 / CES-20077 specifications add requirements for compliance with the results of 300-hour tests to the characteristics of API CH-4 / ACE A E-5 oil.

CES-20077

 

ACEA E-5 при одно­временном удовле­творении требова­ний CES-20077*

CES-20078

API CI-4

 

Large and medium-sized engines with exhaust gas recirculation

CES-20081

API-4 CJ-4

 

Large and medium power engines with an exhaust gas cleaning system, running on diesel fuel with a sulfur content of up to 15 ppm.

Caution: Using CES-20081 in SUV engines fueled with high sulfur fuel can cause serious damage to the fuel equipment and engine if engine oil change intervals are not strictly followed.

It is not recommended to mix oils based on different bases (for example, synthetic with mineral). Mixing may result in the precipitation of the additives.

It is undesirable to mix oils from different manufacturers, since each manufacturer uses its own package of additives, which can react and lead to a deterioration in the properties of the oil.

It is not recommended to add any additives to the engine oil, as this can damage the mechanical part of the engine.

When buying engine oil, you should also check the expiration date of the oil. The shelf life of the oil is regulated, and as a rule, the date of packaging of the oil is indicated on the container;

Checking the engine oil level

Place the vehicle on a level, level surface before carrying out this check.

Check with the engine off. If the engine is running, stop it and wait a while before starting the check.

Park the vehicle on a level, level surface. After turning off the engine, wait a few minutes for the oil to drain into the crankcase.

Remove the dipstick and wipe off the oil from the dipstick with a clean cloth.

Insert the dipstick all the way into the dipstick guide.

Remove the dipstick slowly and check that the oil level is within the specified range.

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If the oil level is below the minimum, top up with the recommended engine oil.

Note: the volume of oil added to the crankcase from the lower level mark to the upper level mark is 1 liter.

Caution: Filling with engine oil above the maximum level will negatively affect engine performance.

Start the engine, set the engine to idle, and then shut it off. Wait a while and check the oil level again to make sure the level is within the specified range.

Make sure that the oil has sufficient viscosity and check that the oil is free of coolant, fuel and contaminated oil.

Changing engine oil and filter

When changing the engine oil, it is recommended to replace the oil filter as well.

The oil change interval depends on its quality and operating conditions.

When using the recommended grade of oil (CES-20072, CES-20077, CES-20078), the oil and filter must be changed every 20,000 km.

When using oil with a class lower than the recommended one - every 10,000 km.

Park the vehicle on a level, level surface.

Warm up the engine to 60 ° C and turn it off.

Remove the oil filler cap and unscrew the oil pan drain plug.

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Drain the oil into a suitable container.

Attention: be careful as the oil is hot.

Remove the oil filter.

a) Remove any dirt around the oil filter.

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b) Unscrew the oil filter with a puller or wrench.

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c) Clean the oil filter mating surface.

Install the oil filter.

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a) Lightly lubricate the O-ring with oil.

b) Fill the filter with clean oil.

Caution: Lack of lubrication due to the delay caused by filling the filter with oil can damage the engine.

Note: Do not allow foreign particles to enter the filter.

When using oil from a canister sealed with metal or plastic foil, carefully peel off the foil. If it is pierced with a knife or sharp object, foreign particles may enter the canister.

c) Screw the filter onto the seat by hand until the gasket contacts the mating surface.

d) Using a puller, additionally tighten the filter 3/4 - 1 turn.

Install the drain plug with a new O-ring.

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Tightening torque 20 Nm

Fill with new engine oil.

Refueling capacity:

- in the oil pan about 10.5 l

- total capacity 13.1 l

Note: The amount of engine oil can vary significantly depending on the engine version.

Start the engine. Check for leaks.

Stop the engine, wait about 5 minutes and check the engine oil level with the dipstick,

Coolant

Make sure the coolant level on a cold engine in the expansion tank is between the "MAX" and "MIN" (or "ADD") marks on the surface of the reservoir.

If the coolant level is low, check for leaks and add coolant to the MAX (warm engine) or MIN (cold engine) mark.

Caution: Do not add cold coolant to a hot engine, this may damage the engine cast parts. Allow the engine to cool down to below 50˚C before refilling.

Remove the radiator cap.

Caution: To avoid burns, do not remove the radiator cap while the engine is hot, as fluid and vapor are pressurized.

Check for rust deposits around the radiator cap valves and the radiator filler neck.

Make sure the coolant is clear and free of oil. If the coolant is dirty, clean the coolant passages and replace the coolant.

Replace the radiator cap.

Replacing the coolant

Remove the radiator / expansion tank cap.

Drain the coolant.

a) Drain the coolant from the radiator by unscrewing the drain plug.

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b) Drain the coolant from the engine by unscrewing the drain plug of the coolant inlet pipe.

Note: Prepare a container with a capacity of more than 20 liters to collect the coolant.

c) Drain the coolant from the expansion tank.

Flush the cooling system if necessary. Fill the cooling system with liquid so that the system does not become airy. After filling, wait 2 - 3 minutes for air to escape, then add liquid to the upper level.

The following systems are designed for air extraction:

- The thermostat is equipped with a valve that allows air to be vented when the thermostat is closed.

- The air outlet is connected to the expansion tank.

This opening allows normal ventilation when filling the system at a rate of 19 liters per minute.

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To clean the cooling system, use a baking soda solution, Restore, or equivalent.

Restore, used to clean the cooling system of engines operating in severe conditions, removes corrosion products, silica gel and other deposits.

The effectiveness of Restore depends on processing time, temperature and concentration levels.

Thus, a large amount of scale or partial blockage of the system may require an increase in the concentration level of the detergent, the temperature and rinsing time, or the use of Restore Plus.

The level of concentration of Restore is considered safe, exceeding the recommended one by no more than 2 times.

Be sure to use Restore Plus only at the recommended concentration.

If there is a lot of limescale or heavy blockages in the system, it may be necessary to flush it several times.

a) Fill the cooling system with cleaning agent.

Attention: do not install the radiator cap. When performing this operation, the engine must be running without the radiator cap.

b) Warm up the engine and let it run for 5 minutes at a coolant temperature above 80 ° C.

c) Turn off the engine and drain the flushing fluid from the cooling system.

d) Fill the cooling system with clean water.

Attention: do not install the radiator cap.

Note: Before starting the engine, make sure that the manual air bleed valve in the coolant drain circuit of the EGR cooler is closed.

e) Start the engine and let it run for 5 minutes at a coolant temperature above 80 ° C.

f) Stop the engine and drain the coolant from the cooling system.

Note: If the drain water is still dirty, be sure to flush the system until it runs clean.

Fill with coolant.

Attention: it is strictly forbidden to use clean water as a cooling liquid. This can damage the engine from corrosion.

Use a mixture of equal parts water and antifreeze based on ethylene glycol or propylene glycol to fill the cooling system.

a) Fill with coolant in the amount specified in the vehicle operating instructions.

Filling capacity approx. 15 l

Recommended coolant:

- GAZ cars: "Cool Stream Premium", "Shell GlycosheU, Diluted", "ES Compteat".

- PAZ buses: "Cool Stream Standart 40", "Fleet Charge 50/50".

b) Install the filler cap.

c) Warm up the engine to 80 ° C and check that there are no coolant leaks.

d) Recheck the coolant level to ensure that the system is full of coolant or that the level has risen to the maximum level in the system expansion vessel (if present).

Removing water from the coarse fuel filter

Note: Drain the water from the fuel filter regularly without waiting for the indicator to light up.

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Stop the engine.

Unscrew the plug (5) located at the bottom of the water separator.

Drain water until fuel appears.

If more than 50 g of fuel will be drained, prime the fuel system using a manual fuel priming pump.

a) Unscrew the plug (6) 2 - 3 turns.

b) Bleed the fuel system with a manual fuel priming pump (2) until fuel appears without air bubbles.

c) Screw on the plug (6). Tightening torque 6 Nm

Fuel filter

Disconnect the connector from the water sensor.

Loosen and remove the fuel filter.

Make sure the O-ring is not stuck to the fuel filter head.

Remove the O-ring if necessary.

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Lubricate the O-ring with clean oil.

Install the fuel filter onto the filter cover.

Screw on the filter until it contacts the cover. Use a puller to tighten the filter 3/4 turn. Tightening torque 23 Nm

Note: Do not add fuel to the fuel filter beforehand.

Prime the low pressure fuel system using a hand pump (140 to 150 strokes for a dry filter).

Start the engine. If the engine does not start within 30 seconds, turn off the ignition.

Run the fuel priming pump again, repeating the above operations until the engine starts.

If the engine starts, it is possible that it will run erratically and noisy for the first few minutes, which is not a malfunction.