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

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