Page 518 - Foton Workshop Manual - Auman EST-M

EG - 2 Engine section – Engine (Cummins ISF3.8)

Precautions
1. Be sure to read this manual carefully before doing any maintenance work to avoid unnecessary damage
caused by improper operation.
2. During all maintenance operations, follow the procedure described in this manual to standardize the
operation to avoid technical mistakes, in order to achieve safe operation and ensure efficiency.
3. Before performing maintenance operations, fire extinguishers must be placed in the required locations for
immediate use, if required.
4. Before performing maintenance operations, the operator shall wear safety shoes, work gloves and goggles
to protect personal safety, if required.
5. Before performing maintenance operations, it is necessary to confirm that the vehicle has been properly
protected, such as protective covers for the seat, steering wheel, floor, etc., and protective covers for engine
room.
6. Before lifting the vehicle, it is necessary to check whether the lifting machine works well, the vehicle is
parked properly, and the lifting points of the lifting arms to the vehicle is aligned properly. In the process of
lifting or landing the vehicle, it is necessary to confirm that there is no people or irrelevant goods under the
vehicle.
7. After the pipelines and the junctions are disconnected, it is necessary to take the protective measures to
prevent the pollutions of the pipelines and the junctions from the outside and the foreign matters.
8. When maintaining the interior of the engine, it is necessary to follow the prescribed steps and handle the
fragile parts gently.
9. The bolts and nuts must be tightened in accordance with the specified torque, sequence, direction, angle and
other parameter specifications and the overexertion shall be avoided.
10. When overhauling the engine, such as overhauling the bent axle, piston and cylinder cover, it is necessary
to thoroughly clean and lubricate the parts before installation.
11. When repairing the engine or before installing the oil pan, the waste sealant must be cleaned up in order to
ensure the smooth sealing bonding surface. Install a new gasket and smear a proper amount of sealant.
12. The engine oil used must be with specified level and viscosity, otherwise, the abrasion of the engine will
be aggravated.
13. Prohibit the use of non-genuine engine parts, genuine original accessories shall be used, otherwise the
engine will be damaged or work abnormally.
14. When using a new engine, it must be run in accordance with the regulations. In the running period, sudden
acceleration or heavy load operation is not allowed.
15. When the engine is working or in high speed and high load, the immediate shutdown is not allowed, the
shutdown shall be carried out in low speed state after running in 3~5min, so that the engine can have heat
dissipation evenly.
16. The sealant is used in many parts of the engine for the full sealing, and it is necessary to pay special
attention to the smearing amount, smearing position and state of the gluing surface. Too less smearing amount
will cause leakage, and excessive smearing amount will cause overflow of sealant and blocking of water or oil
channel or narrowing channel. Therefore, the sealant shall be applied as required.
17. In some occasions, it is necessary to knock the parts lightly with a mallet, rubber mallet or similar tool to
break the sealant on the bonding surface or to gently infiltrate the bonding surface with a flat, smooth and thin
sealant scraper, but the mating face cannot be damaged.
18. Eliminate the sundries on the sealing surface with a sealant scraper or wire brush. It is necessary to
confirm that the sealing surface is smooth and there is no oil stain or foreign matter. Do not forget to remove
the sealant in the mounting holes and the threaded holes.
19. Apply the sealant evenly over the specified diameter and fully enclose the periphery of the mounting holes.
The unhardened sealant can be erased. Install in the confirmed location when the sealant is wet (within 15
min). Do not glue the sealant to the unwanted place in installation. After installation, it is necessary to wait
until the sealant is very hard (about 1h). Do not apply oil or wet the smearing part or start the engine during
this time.
20. Record the factory number and type of the engine and vehicle model, which is required to contact the
repair stations of Foton for repairing the engine. (The factory number of the engine is printed on the inclined
plane on the left side of the engine block)

EG-002