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Cummins ISX / Signature / QSX15 engines of 15 liters, repair e-manual (in Russian)

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Publisher: © "Diez"
ISBN: 978-5-903883-15-8
Number of pages: 260
Format: file PDF

About the manual

Engine displacement: 15 l.

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service engine
  • Information on the design of the engine and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible
Publisher: Diez
Categories: Engines
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Diez"
ISBN: 978-5-903883-15-8
Number of pages: 260
Format: file PDF

About the manual

Engine displacement: 15 l.

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service engine
  • Information on the design of the engine and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible

Contents

Operation and maintenance

Cummins ISX engine

  • Engine identification
  • Engine data plate
  • Decal of the electronic engine control module ECM
  • Engine specification
  • Fuel system
  • Lubrication system
  • Cooling system
  • Exhaust system

Operation manual

  • Normal engine start
  • Fuel shut-off valve
  • Low temperature engine operation
  • Winter operating conditions
  • Operation in arctic conditions
  • Closing the radiator for the winter
  • Starting the engine at low temperatures using starting fluid
  • Means to facilitate starting and operation of the engine at low temperatures
  • Engine operation rules
  • Engine operating range
  • General information
  • Stopping the engine
  • Engine braking system
  • General information
  • Driving on a flat and dry road surface (engine braking)
  • Engine braking when driving downhill
  • Driving on a slippery road surface
  • Electronic fuel system
  • Engine protection system
  • Programmable parameters
  • Fuel system electrical controls
  • Idle speed control
  • Engine brake switch
  • Engine diagnostic switch
  • Cruise control switch
  • Diagnostic trouble codes
  • Checking for DTCs
  • Display of fault codes
  • Cruise control
  • Power take-off operation
  • Remote PTO operation
  • Low gear protection
  • Adjusting low idle speed
  • Idle speed cut-off function
  • Idling shutdown in power take-off mode
  • Idling shutdown blocking
  • Engine warm-up protection
  • Layered security
  • Checking the operation of diagnostic lamps

Climate system ICON TM

  • Maintaining engine temperature
  • Maintaining comfort in the cab
  • Forced engine shutdown
  • ICON TM system launch
  • Activating the mode of maintaining the temperature in the cab
  • Keeping the temperature in the cab
  • Shutting down the ICON TM system
  • ICON TM programmable modes
  • Cab thermostat operation
  • SET point
  • HEAT - Cab heating
  • COOL - Cab cooling
  • ICON TM system idle speed control
  • Notes on trouble codes
  • Correspondence table of degrees Fahrenheit and Celsius
  • Fahrenheit and Celsius conversion formulas

Daily maintenance

  • General information
  • Water separator
  • Drain
  • Lubricating oil level
  • Checkout
  • Coolant level
  • Checkout
  • Radiator fan
  • Checkout
  • Drive belts
  • Checkout
  • Air intake piping
  • Checkout
  • Air aftercooler air line
  • Checkout
  • Air receivers and tanks
  • Drain
  • Crankcase breather pipe
  • Checkout

Maintenance operations after 32,000 km (20,000 miles) or after 625 operating hours or 6 months of operation

  • General information
  • Lubricating oil and oil filters
  • Drain
  • Filling engine oil
  • Installation
  • Additional coolant additive (SCA)
  • Checkout

Maintenance operations after 80,000 km (50,000 miles) or 1,500 hours or 1 year of operation

  • General information
  • Coolant filter
  • General information
  • Withdrawal
  • Installation
  • Fuel filter (easily removable cartridge type)
  • Withdrawal
  • Installation
  • Automatic belt tensioner
  • Check for reuse
  • Air leaks in the air intake and exhaust system
  • Checkout
  • Any aftercooler air line or connecting hose
  • Mounting gasket for turbocharger connection and exhaust collector
  • Turbine housing seal surface
  • Compressor housing seal surface
  • Checking the degree of clogging of the air filter
  • Checkout
  • Engine wiring
  • Checkout

Maintenance operations after 200,000 km (125,000 miles) driven every 3,000 hours or 2 years of operation

  • General information
  • Engine hoses
  • Checkout
  • Means to facilitate starting the engine in the cold season
  • Checkout
  • Steam engine cleaning
  • Engine mounting bolts
  • Checkout
  • Crankcase breather pipe
  • Disassembly
  • Build
  • Torsional vibration damper
  • Checkout

Maintenance operations after 800,000 km (500,000 miles) every 10,000 hours or 5 years of operation

  • Belt driven fan hub
  • Inspection and maintenance
  • Carbon deposits in an air compressor
  • Inspection and maintenance
  • Air compressor release check
  • Adjustment of valve clearances, injectors, engine brake
  • Adjustment
  • Installation marks - A, B and C
  • Complete engine brake
  • Adjustment
  • Setting marks: "BRAKE SET"

Adjustment, repair and replacement

  • Pneumatic starter
  • General information
  • Battery cables and connections
  • Parallel and serial connections
  • Turbocharger
  • Withdrawal
  • Installation
  • Long-term preservation of the engine
  • General information

Functional diagrams of engine systems

  • Functional diagrams of engine systems - general information
  • Fuel system
  • Lubrication system
  • Cooling system
  • Air intake system

Maintenance specifications

  • Specifications
  • Installations for adjusting valve and nozzle clearances
  • Fuel system
  • Lubrication system
  • Cooling system
  • Air intake system
  • Exhaust system
  • Electrical equipment
  • Batteries (electrolyte density)
  • Technical characteristics of CUMMINS / LEETGUARD® / NELSON® filters
  • Recommendations and specifications for fuel
  • General information
  • Recommendations and specifications for engine oil
  • General information
  • Engine oils for new engine break-in
  • Oil change intervals
  • Application of non-proprietary oil additives
  • Oil filter (easily removable cartridge type)
  • Operating the engine in arctic conditions
  • Coolant recommendations and specifications
  • Ready-to-use coolant / antifreeze
  • Water quality
  • Sealing additives in the cooling system
  • Soluble oils for the cooling system
  • Fleetguard® nelson® dca4 replacement filters and liquid additives
  • ISX Series coolant filter options
  • Additional coolant additives (SCA)
  • Set CC-2602 To check the concentration of SCA additives
  • Checking the coolant
  • Frequency of inspections
  • Coolant replacement requirements
  • Values ​​of tightening torques of engine units and components
  • Bolt markings and tightening torques
  • Bolt markings and tightening torques - metric thread
  • USA bolt marking and tightening torques
  • Tensioning the drive belt

Warranty

  • Automotive engines L10 / M11 / ISM / N14 / ISX / SIG for the whole world
  • Scope
  • Warranty items
  • Basic engine warranty
  • Extended warranty for major components
  • Responsibility of CUMMINS corporation
  • During basic engine warranty
  • During extended major component warranty
  • Owner responsibility
  • During basic engine warranty
  • During extended major components warranty
  • Limitations

Additional service literature

Engine repair manual

Troubleshooting

  • Troubleshooting procedure and technique
  • General information
  • Troubleshooting tables
  • General information
  • The air pressure generated by the air compressor rises slowly
  • Increasing the duty cycle of the air compressor
  • Excessive noise from the air compressor
  • Air compressor sucks excess lubricating oil into the pneumatic system
  • The air compressor does not maintain the required air pressure (in continuous operation)
  • Air compressor does not stop pumping air
  • No or insufficient alternator battery charging
  • External coolant losses
  • Internal coolant losses
  • Coolant temperature too high - gradual overheating
  • Coolant temperature too high - gradual overheating (continued)
  • Coolant temperature too high - sudden overheating
  • Coolant temperature too low
  • Excessive crankcase gas breakthrough
  • Poor throttle response or slow engine response
  • Engine brake not working
  • Engine brake not working (continued)
  • Motor brake - low braking performance or response delay
  • Engine brake - braking one or more cylinders when the power switch is turned off
  • Engine slows down slowly
  • Engine starts with difficulty or does not start at all (smoky exhaust)
  • Engine starts with difficulty or does not start at all (continued)
  • Engine starts with difficulty or does not start at all (no smoky exhaust)
  • Increased engine noise
  • Increased engine noise - detonation
  • Reduced engine power output
  • Reduced engine power output (continued)
  • Engine runs unevenly at idle
  • Engine runs unevenly or intermittently
  • Engine stops suddenly or when decelerating
  • Abrupt changes in engine speed at high and low idle speeds
  • Sudden changes in engine speed under load or in operation
  • Engine starts but stalls quickly
  • Increased engine vibration
  • Engine crankshaft does not turn or turns slowly
  • The engine does not develop the rated speed (RPM)
  • The engine does not reach the rated speed (RPM) (continued)
  • The engine does not stop
  • Increased fuel consumption
  • Increased fuel consumption (continued)
  • Fuel in the coolant
  • Fuel in the lubricating oil
  • Intake manifold air temperature too high
  • Intake manifold air temperature too high (continued)
  • Increased consumption of lubricating oil
  • Contaminated lubricating oil
  • Increased lubricating oil pressure
  • Low lubricating oil pressure
  • Low lubricating oil pressure (continued)
  • Excessive oil sludge in the crankcase
  • Lubricating oil temperature too high
  • Presence of lubricating or transmission oil in the coolant
  • Reduced operating fuel pressure
  • Power take-off (PTO) or automatic speed control not working
  • Excessive black smoke from the muffler
  • Excessive black smoke from the muffler (continued)
  • Excessive white smoke from the muffler
  • Reduced boost pressure of the turbocharger
  • Engine oil or turbocharger fuel leaks

Removal and engine installation

  • General information
  • Withdrawal
  • Installation
  • Lifting lugs
  • Removal / installation
  • Cleaning / checking
  • Front engine mount
  • Removal / installation
  • Cleaning / checking

Cylinder block

  • Connecting rod bearings
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Main bearings
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Connecting rod
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Crankshaft
  • Checking the smoothness of rotation
  • Crankshaft pulley
  • Withdrawal
  • If available and fan or crankshaft driven PTO
  • Check for reuse
  • Installation
  • Front crankshaft oil seal
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Crankshaft rear oil seal
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installing cylinder block
  • Check for reuse
  • Leak test
  • Cylinder liner
  • Confusion
  • Cleaning
  • Check for reuse
  • Installation
  • Gear housing
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Piston
  • General information
  • Withdrawal
  • Disassembly
  • Cleaning
  • Check for reuse
  • Build
  • Installation
  • Piston cooling lubricator
  • Withdrawal
  • Installation
  • Piston rings
  • Check for reuse
  • Torsional vibration damper
  • Removal (car engine)
  • Removal (industrial engine and generator sets)
  • Fan or crankshaft driven PTO
  • Fan or PTO without crankshaft drive
  • Cleaning
  • Check for reuse
  • Installation
  • Measuring eccentricity
  • Runout measurement
  • Piston and connecting rod assembly
  • Withdrawal
  • Disassembly
  • Cleaning
  • Check for reuse
  • Build
  • Installation
  • Lower idler gear
  • Withdrawal
  • Adjustable idler gear
  • Withdrawal
  • Installation
  • Gear housing upper cover
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Lower gear housing cover
  • Withdrawal
  • Installation
  • Brackets
  • Automotive engine
  • Industrial engine and generator set
  • Support for auxiliary units
  • Removal, car engine
  • Removal, industrial engine and generator set
  • Installation, car engine
  • Installation, industrial engine and generator

Engine synchronization

  • Gears
  • Adjustment
  • Removing the camshaft gear
  • Removing the injector camshaft gear
  • Removing the adjustable idler gear
  • Removing the lower idler gear
  • Installing sync wedges
  • Installing the lower idler gear
  • Pre-installation of adjustable idler gear
  • Pre-installation of the injector camshaft gear
  • Pre-installation of the camshaft gear
  • Adjusting the clearance in the meshing of the gear teeth
  • Final installation of the adjustable idler gear
  • Final installation of the injector camshaft gear
  • Final installation of the camshaft gear
  • Cylinder block protection plate
  • Withdrawal
  • Installation

Cylinder head

  • Withdrawal
  • Cleaning
  • Check for reuse
  • Leak test
  • Installation
  • Cylinder head gasket
  • General information
  • Valve camshaft
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Injector camshaft
  • Camshaft bearings
  • Withdrawal
  • Check for reuse
  • Camshaft backlash

Rocker arms

  • Crankcase breather
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Valve cover
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Rocker arms and rocker shafts
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Adjustment of clearances in the valve and injector drive mechanism
  • General information
  • Adjustment

Fuel system

  • General information
  • Fuel system operation
  • Valve installation recommendations
  • Specifications
  • Fuel pump
  • Withdrawal
  • Functional diagram of the fuel system
  • Check for reuse
  • Checking the pressure generated by the pump
  • Checking for fuel leaks
  • Installation
  • Air exhaust (signature engine)
  • Fuel pump pressure pulsation damper
  • Withdrawal
  • Check for reuse
  • Build and install
  • Fuel cut-off valve
  • Withdrawal
  • Check for reuse
  • Build and install
  • Combined fuel module
  • Withdrawal
  • Check for reuse
  • Installation
  • Air in fuel
  • Fuel filter
  • Withdrawal
  • Installation
  • Measuring the resistance to fuel supply fuel lines and connections
  • Check for reuse
  • Injector
  • Withdrawal
  • Installation
  • Fuel pump filter
  • Withdrawal
  • Installation

Lubrication system

  • General information
  • Functional diagrams of the lubrication system
  • Cylinder block
  • Cylinder head
  • Turbocharger, oil filter and thermostat
  • Specifications
  • Oil cooler
  • Withdrawal
  • Disassembly / assembly
  • Cleaning
  • Installation
  • Dipstick
  • Calibrating the dipstick
  • Dipstick tube
  • Removal / installation
  • Oil filter
  • Withdrawal
  • Cleaning
  • Installation
  • Oil filter bypass valve
  • General information
  • Withdrawal
  • Cleaning / checking for reuse
  • Installation
  • Oil filter head
  • Withdrawal
  • Cleaning / checking for reuse
  • Installation
  • Engine oil leaks
  • Leak detection
  • Oil pan
  • Draining engine oil
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Oil pump
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Oil suction line
  • Withdrawal
  • Check for reuse
  • Installation
  • Filling the lubrication system with engine oil
  • Oil thermostat
  • Withdrawal
  • Check for reuse
  • Installation

Cooling system

  • Functional diagrams of the cooling system
  • Specifications
  • Coolant pump drive belt
  • Withdrawal
  • Check for reuse
  • Installation
  • Coolant temperature indicator
  • Checkout
  • Coolant filter
  • Withdrawal
  • Installation
  • Thermostat housing
  • Installation
  • Thermostat
  • Checkout
  • Thermostat seal
  • Draining the cooling system
  • System pressure test
  • Air or exhaust gases in the coolant
  • Air check
  • Air flow control valve (louver)
  • Air compressor cylinder head
  • Exhaust gas check
  • Fan hub
  • Withdrawal
  • Automotive engine
  • Industrial engine and generator set
  • Check for reuse
  • Installation
  • Fan shroud
  • Radiator
  • Checkout
  • Fan
  • Checkout
  • Radiator
  • Cleaning
  • Checkout
  • Radiator blinds
  • Coolant pump
  • Withdrawal
  • Automotive engine
  • Industrial engine and generator set
  • Cleaning
  • Installation
  • Coolant pump drive belt automatic tensioner
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Coolant inlet
  • Withdrawal
  • Installation
  • Fan support (if fitted)
  • Withdrawal
  • Installation
  • Valve pulley fan

Air intake system

  • Functional diagram of the air intake system
  • Air and exhaust leaks
  • Checkout
  • Charge air cooler
  • Cleaning
  • Check for reuse
  • Checking air ducts
  • Pressure test
  • Checking temperature difference
  • Differential pressure check
  • Air supply limitation
  • Turbocharger
  • Withdrawal
  • Check for reuse
  • Installation
  • Turbocharger actuator
  • Checkout
  • Intake manifold
  • Measuring the pressure in the intake manifold
  • Intake manifold pipe
  • Withdrawal
  • Installation
  • Intake manifold flap actuator
  • Withdrawal
  • Check for reuse
  • Installation

Exhaust system

  • Functional diagram of the exhaust system
  • Specifications
  • Exhaust manifold
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation
  • Exhaust back pressure
  • Measurement

Pneumatic system

  • Functional diagram of the pneumatic system
  • Compressor
  • Withdrawal
  • Check for reuse
  • Compressor deposits
  • Checkout
  • Removing / installing compressor cylinder head

Electrical equipment

  • Engine electrical equipment
  • Specifications
  • Generator
  • Checkout
  • Withdrawal
  • Installation
  • Alternator drive belt
  • Removal / installation
  • Battery
  • Checkout
  • Battery cables
  • Magnetic starter switch
  • Checkout
  • Voltage measurement
  • Starter solenoid
  • Voltage measurement
  • Starter
  • Removal / installation
  • Automatic alternator drive belt tensioner
  • Withdrawal
  • Cleaning
  • Check for reuse
  • Installation

Flywheel

  • Withdrawal
  • Cleaning
  • Check for reuse
  • Replacing the ring gear
  • Flywheel bore eccentricity measurement
  • Flywheel face runout measurement
  • Installation
  • Flywheel housing
  • Cleaning
  • Check for reuse
  • Installation

Engine brake

  • Engine brake wiring
  • Removal / installation
  • Engine brake solenoids
  • Removal / installation
  • Engine brake control valves
  • Removal / installation
  • Engine brake rocker adjusting screw
  • Adjusting the engine brake
  • Resistance test
  • Voltage test
  • Checking solenoids
  • Adjustment

Specifications

  • Cylinder block
  • Cylinder liner
  • Piston
  • Torsional vibration damper
  • Engine Synchronization
  • Tightening torques for threaded connections
  • Engine synchronization
  • Cylinder head
  • Tightening torques for threaded connections
  • Rocker arms
  • Tightening torques for threaded connections
  • Fuel system
  • Tightening torques for threaded connections
  • Lubrication system
  • Tightening torques for threaded connections
  • Cooling system
  • Tightening torques for threaded connections
  • Air intake system
  • Exhaust system
  • Tightening torques for threaded connections
  • Pneumatic system
  • Tightening torques for threaded connections
  • Electrical equipment
  • Flywheel
  • The maximum amount of runout of the face of the flywheel
  • Tightening torques for threaded connections
  • Engine brake
  • Tightening torques for threaded connections

Fault codes

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