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