The use and precautions of Cummins diesel engine

1. The use and precautions of the engine

1.1. Fitting of new engine
The following rules must be observed when the initial mileage is 1500~2500 km or 30~50 hours ago:

A: Before starting the car, it should run at medium and low speed to avoid driving at high speed and under heavy load.
B: It is forbidden to run the engine idling or full load for more than 5 minutes.
C: Appropriate shift to prevent engine force.
D: Always observe the working state of oil temperature gauge, oil pressure gauge and water temperature gauge.
E: Check the oil and coolant levels frequently.
F: Trailers are not allowed, and the carrying weight is less than 70% of the rated carrying weight of the vehicle.

Remind
A: After running, there is no need to change the oil and oil filter.
B: During run-in, the engine does not need special run-in oil.
C: Combined driving mileage of 1500~2500 kilometers or 20~50 hours, with Dongfeng Cummins engine Co., LTD. “Quality Assurance Manual”, car purchase invoice and engine (or vehicle) qualification certificate to Dongfeng Cummins engine Co., LTD. Owned or commissioned service station for new machine inspection and maintenance, this inspection and maintenance is free

1.2. Start the engine
A. Check the coolant level and oil scale before the first start every day, and release water to the oil-water separator.
B. The starting time of the starter shall not exceed 30 seconds, and the continuous starting interval shall be 2 minutes.
C. After starting the engine, pay attention to the change of oil pressure within 15 seconds.
D. After starting for the first time every day, the machine should be warmed at medium and low speed for 5 minutes before starting. It must be done when the temperature is lower than 0℃.

1.3. Engine preheating and idling
A. When the engine is starting and preheating, the engine speed should be gradually increased. It is forbidden to run the engine with high throttle.
B. It is strictly prohibited to run the engine at idle speed for more than 10 minutes.

Warning: the engine idle time is long, will lead to the combustion chamber temperature drop, cause poor combustion, the formation of carbon blocking nozzle nozzle hole, and cause the piston ring and valve gluing.

1.4 Engine stop
Before the engine is stopped, it must run at idle speed for 3~5 minutes so that the lubricating oil and coolant can take the heat away from the combustion chamber, bearings and friction pairs, especially for the turbocharged and turbocharged and intercooled engines.

1.5 Matters needing attention in engine operation
A. Avoid running the engine continuously when the coolant is lower than 60℃ or higher than 100℃, and find the reason as soon as possible.
B. Do not run the engine when the oil pressure is too low.
C. The running time of the engine in full throttle open and maximum torque speed must not exceed 30 seconds.

Remind:
A. At normal water temperature, the minimum oil pressure shall not be lower than the following values:
Idle speed (750 to 800r/min)? 69kp
Full speed full load? 207kpa—- These two figures should be problematic, there are question marks

B, in any case, the engine speed shall not exceed the high idle speed (3600 RPM), down the steep slope, to prevent the engine overspeed, should be combined with the gearbox gear and engine or driving brake to control the speed and engine speed.

C. It is strictly prohibited to run the engine with fault.

Remind:
In the actual operation of the engine, there are corresponding early signs before the failure. Attention should be paid to the performance, sound and various parameters of the engine. If any abnormality is found, it should be stopped immediately for inspection or repair.

For the Cummins DONGFENG Engine, the following is some tips.

Dongfeng Cummins engine (20-200KW)
(1) Cummins engine normal starting requirements
a. Each operation of Cummins starter shall not exceed 30s, and the time interval for re-starting shall be 2min.
b. The pressure of lubricating oil should reach 70KPa within 15s after starting; otherwise, check the oil level immediately.
c. Load can only be added at idle speed for 3-5 minutes after starting; otherwise, the bearing bush will have instantaneous insufficient oil supply.
d. Idle speed can not exceed 10min, otherwise there will be combustion chamber carbon accumulation, Cummins engine supercharger oil leakage and other adverse phenomena.
e. Cummins engine water temperature should not be lower than 60℃, otherwise the fuel will enter the oil and destroy lubrication, can be used to accelerate the empty car to increase the water temperature.
f. Keep idle speed after starting in winter until the thermometer pointer turns or enters operation after 10min. While observing the water temperature gauge, pay attention to whether the oil pressure gauge meets the requirements. Always use a sprayer with a volume hole when using auxiliary starter fluid in winter.

(2) Cummins engine basic operation requirements
a. In Cummins engine operation to often observe the instrument: the water temperature should be between 74℃ and 91℃; Oil pressure at idle speed should be greater than 70KPa, in 1200r/min above should be in the range of 276-517kPa.
b. If Cummins engine overheats, it should be operated at reduced load. If it is still overheating after a period of load reduction, it should be stopped to check the fault.
c. The following changes of the engine should be paid close attention to during the operation of Cummins engine. If any of them suddenly changes, it is likely to be a sign of failure. Please check and repair it in time.
① engine fire or fire poor; ② vibration condition; ③ The engine has abnormal noise; (4) the working pressure and temperature of the engine change suddenly; ⑤ engine exhaust smoke is too large; ⑥ engine power is insufficient; ⑦ oil consumption becomes larger; ⑧ fuel consumption becomes larger; ⑨ Fuel, oil or water leakage.

(3) Operating range of Cummins engine
A. when the cummins engine is below the maximum torque speed, the full throttle operation should not exceed 30s. Otherwise, the overhaul life of the engine will be shortened and the engine may be seriously damaged. Cummins engines work best above the maximum torque speed point, so it is recommended to run Cummins engines in this range.
b. Under no circumstances or circumstances shall the Cummins engine operate above the maximum empty speed.

(4) Cummins engine operating in cold environment
Special oils, fuels and coolants should be used when running an engine in extremely cold conditions.

(5) Cummins engine stop
a. Cummins engine is required to idle for 3-5 minutes before stopping. Because the diesel engine idle 3-5 minutes before each stop, can let the oil take away the heat of the combustion chamber, bearings and oil seals, especially the supercharger. If the machine stops suddenly, the bearing and oil seal are likely to be killed.
b. The purpose of Cummins engine shutdown can be achieved by cutting off the current of the fuel pump solenoid valve.

Two, Cummins engine maintenance
Cummins ISLe series engines
Maintenance is the key to reduce the use cost. A diesel engine needs regular maintenance according to a maintenance schedule in order to maintain efficient operation. Preventive maintenance is the easiest and most economical maintenance. It allows the maintenance department to work at the right time. The maintenance cycle and content are slightly different for different series and models of engines. For details, please refer to the engine maintenance manual. Taking N and K series engines as examples, the maintenance cycle and content are briefly introduced.

(1) Grade A maintenance inspection (daily inspection)
Make engine work daily report and provide to maintenance department.
① Report content: 1) Whether the oil pressure is low; 2) Whether the power is insufficient; 3) Whether the temperature of cooling water or oil is abnormal; 4) Whether the engine sound is abnormal; 5) whether there is smoke; 6) Whether the coolant, fuel or oil is over consumption; 7) Whether coolant, fuel oil or oil leakage.
② Check the engine: 1) check the engine oil plane; 2) Check the engine coolant level.
③ Check the pump belt;
(4) Check the Marine gear box;
⑤ Check whether the engine is leaky, bruised, loose and so on.

(2) Grade A maintenance inspection (weekly inspection)
① Repeat the daily inspection every week.
② Check the air filter and intake resistance: clean or replace the air filter element.
③ Discharge the water of the air reservoir.
④ Discharge sediment from the fuel tank.

(3) Grade B maintenance inspection
Cycle: Chart method or 250h, 6 months or 16000km. In each grade B maintenance inspection, to complete all the grade A inspection items, plus the following items:
1) Change the engine oil:
(1) Start the engine to reach the working temperature, then stop the engine and release the oil;
(2) install playback oil screw plug;
(3) Check the oil gauge to make the oil level reach the “H” mark;
(4) Start the engine and check whether there is oil leakage;
⑤ Stop the machine for 15min and check the oil plane.

2) Replace the filter:
① full-flow oil filter;
② bypass type oil filter;
③ Fuel filter.

3) Check coolant: Check DCA concentration of engine coolant, replace core and add DCA4 additive when necessary
4) Check the oil level.
5) Clean or replace the crankcase ventilator and air compressor ventilator.
6) Check the zinc plug.

(4) Grade C maintenance inspection
Maintenance inspection cycle is 1500h, 1 year or driving mileage is 96000km.
At each grade C maintenance inspection, complete all Grade A and B inspection items, plus adjust the injector stroke and valve clearance.
(1) “cold adjustment” : the engine should be stopped for at least 4h at the ambient temperature to be adjusted, in order to achieve a stable temperature;
② “Heat adjustment” : the engine oil temperature is above 99℃ for at least 10 minutes, or after reaching the normal oil temperature, adjust the injector and valve immediately.
The adjustment of fuel injection stroke and valve clearance of Cummins engine must be done by specially trained personnel.
(5) Grade D maintenance inspection

Maintenance inspection cycle of 4500h, 2 years or driving mileage of 288000km.
At each grade D maintenance inspection, complete all Grade A, B and C inspection items, plus the following items:
① Clean and calibrate the fuel injector and fuel pump.
(2) Check, repair or replace the supercharger, shock absorber, air compressor.
Repair or replace the fan, water pump belt tensioning wheel assembly, water pump.

(6) Seasonal inspection
1) Spring:
① Steam clean the engine;
(2) tight mounting bolt;

Check the crankshaft axial clearance;
(4) Check the heat exchanger plug every year or as required.

2) Autumn:
(1) Clean and rinse the cooling system;
② Replace the hose to be replaced;
③ Clean the electrical connector and check the battery.