New Engine Inspection Checklist
| No. | Inspection Item | Specific Content |
| 1 | Customer Training | (1) Whether the service provider has explained engine maintenance and operation knowledge to the customer. |
| 2 | Assembly | (1) Check for interference between all components. (2) Verify that the assembly torque of all components meets the requirements. |
| 3 | Air Intake System | (1) Check if clamps, pipes, and brackets of the intake system are securely installed. (2) Verify correct installation of the air filter element. (3) Ensure the intake restriction indicator is securely installed and its hose clamp is tightened. (4) Check the reliability of intake air sealing. |
| 4 | Fuel System | (1) Check for fuel leaks. (2) Verify correct installation of the fuel filter and remove deposits from the pre-filter. |
| 5 | Cooling System | (1) Check that cooling system hoses and clamps are securely installed, inspect exhaust pipe installation, and check for engine coolant leaks. (2) Verify normal coolant level, check for leaks, and ensure the radiator cap is properly installed. (3) Check if belts are loose or damaged, and tighten the tensioner pulley. (4) Check the DCA4 concentration in the antifreeze. (5) Verify that the water filter valve is open. (6) Check the installation gap between the fan and fan shroud is correct. |
| 6 | Exhaust System | (1) Check the connection between the exhaust system and the chassis. |
| 7 | Lubrication System | (1) Verify correct installation of the oil dipstick and check if the drain plug is tightened. (2) Check if the oil level is normal. (3) Check for oil leaks. |
| 8 | Electrical System | (1) Inspect all engine wiring, sensors, and cables for damage, and check if O-rings on connectors are missing. (2) Verify reliable connection between the engine and equipment, and confirm that all gauges are working properly (including oil pressure gauge, water temperature gauge, air pressure gauge, and indicators for fault, shutdown, maintenance, and waiting-to-start). (3) Use INSITE software to check for active or inactive fault codes and clear them if present. (4) Check for corrosion on engine sensor harnesses and connector pins, and ensure connectors are securely connected. (5) Verify reliable connection of engine ground wire and ECM ground wire. |
| 9 | Others | (1) Check correct installation of all brackets and valves. (2) Check for abnormal engine noise. (3) Inspect and tighten the engine front and rear mounts. (4) Check if the steering hydraulic oil is clean and if the filter screen is clogged. (5) Check throttle acceleration and deceleration response. (6) Verify normal idle speed, high idle speed, and oil pressure. |
Cummins Engine Key Maintenance Schedule
| Maintenance Item | Technical Requirements | Maintenance Interval | Application Scope |
|---|---|---|---|
| Engine Oil Change | API CH-4 grade | 20,000 km / 4 months / 400 hours (whichever comes first) | All Cummins engine series |
| Engine Oil Filter Replacement | Cummins-approved brand | 20,000 km / 4 months / 400 hours (whichever comes first) | All Cummins engine series |
| Fuel Filter Replacement | Cummins-approved brand | 20,000 km / 4 months / 400 hours (whichever comes first) | All Cummins engine series |
| Coolant Replacement | Long-life OAT type | 24 months or 200,000 km (whichever comes first) | C/L/Z series engines |
| Coolant Replacement | Long-life OAT or IAT type | 24 months or 200,000 km (whichever comes first) | B/D series engines |
| Air Filter Maintenance | Cummins-approved brand | Clean every 5,000 km; replace every 30,000 km. Interval halved under severe conditions (high temperature, dusty, humid environments) | All Cummins engine series |
Cummins On-Highway Engine Mandatory Maintenance Schedule
| Maintenance Stage | Interval | Replacement Items | Inspection & Cleaning Items | Adjustment Items |
|---|---|---|---|---|
| Daily Check | Every day | — | – Lubricant oil level- Coolant level- Drive belts and fan- Drain water from fuel water separator- Check for leaks in air compressor bolts/nuts and brake system (if equipped)- Air intake pipe- Crankcase breather pipe- Air tanks and oil tanks (if equipped)- Check urea level (if equipped) | — |
| New Engine Initial Check | 1,500–2,500 km | (Refer to the New Engine Inspection Checklist) | (Refer to the New Engine Inspection Checklist) | — |
| First Maintenance | 10,000 km (4,000 km) / 2 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter | – Inspect air filter- Inspect intake system- Inspect intercooler- Inspect battery, cables and terminals | – Valve clearance- Engine brake clearance |
| Regular Maintenance 1 | 20,000 km (8,000 km) / 4 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter- Steering hydraulic oil | – Inspect air filter- Inspect intake system- Inspect intercooler- Inspect battery, cables and terminals | – Valve clearance- Engine brake clearance |
| Maintenance Stage | Interval | Replacement Items | Inspection & Cleaning Items | Adjustment Items |
|---|---|---|---|---|
| Regular Maintenance 2 | 40,000 km (16,000 km) / 8 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter- Steering hydraulic oil | – Inspect air filter- Inspect intake system- Inspect intercooler- Inspect battery, cables and terminals | – Valve clearance- Engine brake clearance |
| Regular Maintenance 3 | 60,000 km (24,000 km) / 12 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter- Steering hydraulic oil- Exhaust gas separator for aftertreatment (if equipped)- Exhaust treatment fluid tank filter (if equipped) | – Inspect air filter- Inspect intake system- Inspect intercooler- Clean aftertreatment system (if equipped)- Check radiator hoses- Inspect fan shaft and bolts- Inspect air compressor exhaust pipe- Inspect belt tensioner and belt tension- Inspect shock absorber- Engine steam cleaning- Inspect battery, cables and terminals | – Valve clearance- Engine brake clearance |
| Regular Maintenance 4 | 80,000 km (32,000 km) / 16 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter- Steering hydraulic oil | – Inspect air filter- Inspect intake system- Inspect intercooler- Clean aftertreatment system (if equipped)- Inspect fan shaft and bolts- Inspect belt tensioner and belt tension- Inspect battery, cables and terminals- Inspect and tighten cylinder head bolts | – Valve clearance- Engine brake clearance |
| Regular Maintenance 5 | 100,000 km (40,000 km) / 20 months (whichever comes first) | – Engine oil- Oil filter- Fuel filter- Steering hydraulic oil- Thermostat- Aftertreatment injection pump main filter (if equipped) | – Inspect air filter- Inspect intake system- Inspect intercooler- Inspect battery, cables and terminals- Inspect and tighten cylinder head bolts | – Valve clearance- Engine brake clearance |
Note: The above schedule applies to highway trucks, military vehicles, concrete mixers, sanitation trucks, highway buses (including city buses), and airport shuttle buses.Mileages in parentheses ( ) apply only to dump trucks, vehicles modified from dump truck chassis, and vehicles frequently operated on rough roads or off-road conditions.After completing the 100,000 km (40,000 km) maintenance items (whichever comes first between mileage and months), continue maintenance by repeating the cycles for the 20,000 km, 40,000 km, 60,000 km, and 100,000 km service intervals until the end of the warranty period.We recommend customers continue to follow this maintenance schedule even after the warranty expires.
