Cummins engine Signature ISX QSX15 Service Workshop Shop Repair Manual - PDF Service Manual
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1 Cummins engine Signature ISX QSX15 Service Workshop Shop Repair Manual - PDF Service Manual DOWNLOAD HERE "Cummins engine Signature ISX QSX15 Service Workshop Shop Repair Manual - PDF Service Manual Signature ISX and QSX15 Service Manual 2000 > 2010 If your working on the Cummins engine: Signature ISX QSX15
2 then you have just found the workshop manual for you, massive manual covering everything you need to know in the service and repair of your engine. PLEASE NOTE: You need to be connected to the internet to use this manual. Sections in this manual: Section i - Introduction ( shopds) About the Manual ( shopds) How to Use the Manual ( ) Symbols ( ) Illustrations
3 ( tr) General Safety Instructions ( tr) General Repair Instructions ( ) General Cleaning Instructions ( ) Acronyms and Abbreviations Section E - Engine and System Identification ( tr) Engine Identification ( tr) Engine Diagrams Section F - Familiarization ( ) Complete Engine - Overview ( ) Cylinder Block - Overview
4 ( ) Cylinder Head - Overview ( ) Rocker Levers - Overview ( tr) Fuel System - Overview ( tr) Flow Diagram, Fuel System ( ) Injectors and Fuel Lines - Overview ( ) Lubricating Oil System - Overview ( tr) Flow Diagram, Lubricating Oil System ( ) Cooling System - Overview ( tr) Flow Diagram, Cooling System ( ) Air Intake System - Overview ( tr) Flow Diagram, Air Intake System ( ) Exhaust System - Overview
5 ( tr) Flow Diagram, Exhaust System ( ) Compressed Air System - Overview ( tr) Flow Diagram, Compressed Air System ( ) Electrical Equipment - Overview ( ) Engine Testing - Overview ( ) Vehicle Braking - Overview Section TS - Troubleshooting Symptoms (99-t tr) Troubleshooting Procedures and Techniques (99-t00-002) Troubleshooting Symptoms Charts ( t004-tr) Air Compressor Air Pressure Rises Slowly ( t005-tr) Air Compressor Cycles Frequently
6 ( t006-tr) Air Compressor Noise is Excessive ( t007-tr) Air Compressor Pumping Excess Lubricating Oil into the Air System ( t008-tr) Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) ( t009-tr) Air Compressor Will Not Pump Air ( t010-tr) Air Compressor Will Not Stop Pumping ( t011-tr) Aftertreatment Diesel Particulate Filter - Excessive Soot Loading ( t012-tr) Aftertreatment Diesel Particulate Filter - Excessive Ash Cleaning ( t013-tr) Alternator Not Charging or Insufficient Charging ( t020-tr) Coolant Loss - External
7 ( t021-tr) Coolant Loss - Internal ( t022-tr) Coolant Temperature Above Normal - Gradual Overheat ( t023-tr) Coolant Temperature Above Normal - Sudden Overheat ( t024-tr) Coolant Temperature Below Normal ( t025-tr) Coolant in the Lubricating Oil ( t027-tr) Crankcase Gases (Blowby) Excessive ( t028-tr) Crankcase Coalescing Filter - Frequent Replacement ( t036-tr) Engine Brake Does Not Operate ( t037-tr) Engine Brake - Low Retarding Power or Slow to Activate ( t038-tr) Engine Brake - One or More Cylinders Braking with Power Switch Off ( t041-tr) Engine Decelerates Slowly ( t047-tr) Engine Noise Excessive
8 ( t048-tr) Engine Noise Excessive - Combustion Knocks ( t049-tr) Engine Noise Excessive - Connecting Rod ( t050-tr) Engine Noise Excessive - Main Bearing ( t051-tr) Engine Noise Excessive - Piston ( t052-tr) Engine Noise Excessive - Turbocharger ( t064-tr) Engine Shuts Off Unexpectedly or Dies During Deceleration ( t068-tr) Engine Speed Surges in PTO or Cruise Control ( t072-tr) Engine Starts But Will Not Keep Running ( t077-tr) Engine Will Not Crank or Cranks Slowly (Air Starter) ( t078-tr) Engine Will Not Crank or Cranks Slowly (Electric Starter) ( t081-tr) Engine Will Not Shut Off ( t087-tr) Fuel Consumption Excessive
9 ( t091-tr) Fuel in Coolant ( t092-tr) Fuel in the Lubricating Oil ( t096-tr) Intake Manifold Air Temperature Above Specification ( t097-tr) Intake Manifold Pressure (Boost) is Below Normal ( t101-tr) Lubricating Oil in the Fuel ( t102-tr) Lubricating Oil Consumption Excessive ( t103-tr) Lubricating Oil Contaminated ( t tr) Lubricating Oil Filter Plugged ( t104-tr) Lubricating Oil Pressure High ( t105-tr) Lubricating Oil Pressure Low ( t106-tr) Lubricating Oil Sludge in the Crankcase Excessive ( t107-tr) Lubricating Oil Temperature Above Specification
10 ( t108-tr) Lubricating or Transmission Oil in the Coolant ( t122-tr) Turbocharger Leaks Engine Oil or Fuel ( t146-tr) Stationary Regeneration - Will Not Activate ( t147-tr) Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary Regeneration ( t149-tr) Stationary Regeneration - Will Not Complete (10-t00-004) Troubleshooting Overview Section TT - Troubleshooting Symptoms (New Format) (70-t ) Engine Performance Troubleshooting Tree - Signature and ISX CM870
11 (16-t a) Engine Performance Troubleshooting Tree - ISX with CM871 (10-feisx02) Fuel Economy Troubleshooting Tree (10-feisx07) Fuel Economy Troubleshooting Tree (105-t ) Vibration Excessive Section 0 - Complete Engine - Group 00 ( _00) Service Tools ( tr) Engine Removal ( tr) Engine Installation ( tr) Engine Storage - Long Term Section DS - Engine Disassembly Group 00
12 ( shopds) Cooling System ( shopds) Lubricating Oil System ( shopds) Engine Removal ( shopds) Lubricating Oil Filter (Spin-On) ( shopds) Coolant Filter ( shopds) Fuel Filter (Spin-On Type) ( shopds) Rocker Lever Cover ( shopds) Starting Motor ( shopds) Drive Belt, Cooling Fan ( shopds) Belt Tensioner, Automatic (Water Pump) ( shopds) Fan Hub, Belt Driven ( shopds) Fan Support
13 ( shopds) Drive Belt, Refrigerant Compressor ( shopds) Idler Pulley, Refrigerant Compressor ( shopds) Belt Tensioner, Refrigerant Compressor, Automatic ( shopds) Refrigerant Compressor ( shopds) Crankcase Breather (External) ( shopds) Lubricating Oil Fill Tube ( shopds) Lubricating Oil Dipstick Tube ( shopds) EGR Mixer ( shopds) Air Intake Connection ( shopds) ECM Cooling Plate, Fuel Cooled ( shopds) Aftertreatment Injector Lines ( shopds) Aftertreatment Fuel Shutoff Manifold
14 ( shopds) Integrated Fuel System Module (IFSM) ( shopds) Turbocharger Air Shutoff Valve Filter ( shopds) Turbocharger, Variable Geometry Control Valve Air Supply Line ( shopds) Turbocharger Control Shutoff Valve Filter Head ( shopds) Turbocharger, Variable Geometry Actuator Air Supply Line ( shopds) Aftertreatment Adapter Pipe ( shopds) Aftertreatment Fuel Injector ( shopds) Turbocharger, Variable Geometry Actuator ( shopds) Turbocharger Coolant Hoses ( shopds) Turbocharger ( shopds) Heat Shield ( shopds) EGR Cooler Coolant Lines
15 ( shopds) EGR Valve Coolant Lines ( shopds) EGR Valve ( shopds) EGR Valve Mounting Bracket ( shopds) Exhaust Gas Pressure Sensor Tube ( shopds) Exhaust Gas Pressure Sensor Adapter ( shopds) Exhaust Manifold, Dry ( shopds) EGR Connection Tubes ( shopds) EGR Cooler ( shopds) Lubricating Oil Cooler ( shopds) Engine Lifting Brackets ( shopds) Coolant Thermostat Housing ( shopds) Coolant Thermostat
16 ( shopds) Alternator ( shopds) Alternator/Refrigerant Compressor Mounting Bracket ( shopds) Refrigerant Compressor Mounting Bracket ( shopds) Water Inlet Connection ( shopds) Water Pump ( shopds) Rocker Lever Assembly ( shopds) Injector ( shopds) Vibration Damper, Viscous ( shopds) Gear Cover, Upper ( shopds) Crankshaft Seal, Front ( shopds) Gear Cover, Lower ( shopds) Air Compressor Coolant Lines
17 ( shopds) Air Compressor ( shopds) Engine Base Timing ( shopds) Overhead Camshaft, Valve ( shopds) Overhead Camshaft, Injector ( shopds) Cylinder Head ( shopds) Engine Support Bracket, Front ( shopds) Idler Gear, Lower Scissor ( shopds) Lubricating Oil Pan ( shopds) Lubricating Oil Suction Tube (Block-Mounted) ( shopds) Block Stiffner Plate ( shopds) Piston Cooling Nozzle ( shopds) Piston and Connecting Rod Assembly
18 ( shopds) Bearing, Connecting Rod ( shopds) Piston Rings ( shopds) Flywheel ( shopds) Crankshaft Seal, Rear ( shopds) Flywheel Housing ( shopds) Flywheel Housing, REPTO ( shopds) Gear Housing, Front ( shopds) Lubricating Oil Pump ( shopds) Crankshaft ( shopds) Bearings, Thrust ( shopds) Bearings, Main ( shopds) Cylinder Liner
19 Section AS - Engine Assembly - Group 00 ( shopas) Cylinder Liner ( shopas) Bearings, Main ( shopas) Bearing, Thrust ( shopas) Crankshaft ( shopas) Lubricating Oil Pump ( shopas) Gear Housing, Front ( shopas) Flywheel Housing ( shopas) Flywheel Housing, REPTO ( shopas) Crankshaft Seal, Rear ( shopas) Flywheel
20 ( shopas) Piston Rings ( shopas) Bearings, Connecting Rod ( shopas) Piston and Connecting Rod Assembly ( shopas) Piston Cooling Nozzle ( shopas) Block Stiffener Plate ( shopas) Lubricating Oil Suction Tube (Block-Mounted) ( shopas) Lubricating Oil Pan ( shopas) Idle Gear, Lower Scissor ( shopas) Engine Support Bracket, Front ( shopas) Cylinder Head ( shopas) Overhead Camshaft, Injector ( shopas) Overhead Camshaft, Valve
21 ( shopas) Engine Base Timing ( shopas) Air Compressor ( shopas) Air Compressor Coolant Lines ( shopas) Gear Cover, Lower ( shopas) Crankshaft Seal, Front ( shopas) Gear Cover, Upper ( shopas) Vibration Damper, Viscous ( shopas) Injector ( shopas) Rocker Lever Assembly ( shopas) Overhead Set ( shopas) Water Pump ( shopas) Water Inlet Connection
22 ( shopas) Refrigerant Compressor Mounting Bracket ( shopas) Alternator/Refrigerant Compressor Mounting Bracket ( shopas) Alternator ( shopas) Coolant Thermostat ( shopas) Coolant Thermostat Housing ( shopas) Engine Lifting Brackets ( shopas) Lubricating Oil Cooler ( shopas) EGR Cooler ( shopas) EGR Connection Tubes ( shopas) Exhaust Manifold, Dry ( shopas) Exhaust Gas Pressure Sensor Adapter ( shopas) EGR Valve Mounting Bracket
23 ( shopas) Exhaust Gas Pressure Sensor Tube ( shopas) EGR Valve ( shopas) EGR Valve Coolant Lines ( shopas) EGR Cooler Coolant Lines ( shopas) Heat Shield ( shopas) Turbocharger ( shopas) Turbocharger Coolant Hoses ( shopas) Turbocharger, Variable Geometry Actuator ( shopas) Aftertreatment Fuel Injector ( shopas) Aftertreatment Adapter Pipe ( shopas) Turbocharger, Variable Geometry Actuator Air Supply Line ( shopas) Turbocharger, Control Shutoff Valve Filter Head
24 ( shopas) Turbocharger, Variable Geometry Control Valve Air Supply Line ( shopas) Turbocharger Air Shutoff Valve Filter ( shopas) Integrated Fuel System Module (IFSM ) ( shopas) Aftertreatment Fuel Shutoff Manifold ( shopas) Aftertreatment Injector Lines ( shopas) ECM Cooling Plate, Fuel Cooled ( shopas) Air Intake Connection ( shopas) EGR Mixer ( shopas) Lubricating Oil Dipstick Tube ( shopas) Lubricating Oil Fill Tube ( shopas) Crankcase Breather (External) ( shopas) Refrigerant Compressor
25 ( shopas) Belt Tensioner, Refrigerant Compressor, Automatic ( shopas) Idler Pulley, Refrigerant Compressor ( shopas) Drive Belt, Refrigerant Compressor ( shopas) Fan Support ( shopas) Fan Hub, Belt Driven ( shopas) Belt Tensioner, Automatic (Water Pump) ( shopas) Drive Belt, Cooling Fan ( shopas) Starting Motor ( shopas) Rocker Lever Cover ( shopas) Fuel Filter (Spin-On Type) ( shopas) Coolant Filter ( shopas) Lubricating Oil Filter (Spin-On)
26 ( shopas) Engine Installation ( shopas) Lubricating Oil System ( shopas) Cooling System Section 1 - Cylinder Block - Group 01 ( _01) Service Tools ( tr) Bearings, Connecting Rod ( tr) Bearings, Main ( tr) Bearings, Thrust ( ) Connecting Rod ( tr) Crankshaft ( tr) Crankshaft Adapter
27 ( ) Crankshaft Gear, Front (Crankshaft Installed) ( ) Crankshaft Pulley ( tr) Crankshaft Seal, Front ( tr) Crankshaft Seal, Rear ( tr) Cylinder Block ( ) Cylinder Block and Liner Seats ( tr) Cylinder Liner ( tr) Gear Housing, Front ( ) Piston ( tr) Piston Cooling Nozzle ( tr) Piston Rings ( tr) Vibration Damper, Viscous
28 ( tr) Piston and Connecting Rod Assembly ( ) Crankshaft Tone Wheel ( tr) Idler Gear, Lower Scissor ( ) Idler Gear, Adjustable ( tr) Gear Cover, Upper ( tr) Gear Cover, Lower ( ) Bracket, Retaining Brace ( ) Bracket, Accessory ( tr) Engine Base Timing ( tr) Block Stiffener Plate Section 2 - Cylinder Head - Group 02
29 ( _02) Service Tools ( tr) Cylinder Head ( ) Valve Guide Seal, Cylinder Head ( tr) Overhead Camshaft, Valve ( tr) Overhead Camshaft, Injector ( ) Overhead Camshaft Bushings, Valve ( ) Overhead Camshaft Bushings, Injector ( ) Over Camshaft End Clearance, Valve ( ) Overhead Camshaft End Clearance, Injector ( ) Overhead Camshaft Gear, Valve ( ) Injector Camshaft Scissor Gear
30 Section 3 - Rocker Levers - Group 03 ( _03) Service Tools ( tr) Crankcase Breather (External) ( tr) Crankcase Breather (Internal) ( tr) Overhead Set ( tr) Rocker Lever Assembly ( tr) Rocker Lever Cover ( tr) Crankcase Breather Element Section 5 - Fuel System - Group 05 ( _05) Service Tools ( ) Fuel Consumption
31 ( ) Fuel Pump ( ) Fuel Pump Pulsation Damper ( ) Fuel Shutoff Valve ( ) Fuel Lift Pump ( ) Stall Speed Test ( tr) Integrated Fuel System Module (IFSM) ( ) Fuel Inlet Pre-Filter Section 6 - Injectors and Fuel Lines - Group 06 ( _06) Service Tools ( ) Air in Fuel ( tr) ECM Cooling Plate, Fuel Cooled
32 ( ) Fuel Drain Line Restriction ( tr) Fuel Filter (Spin-On Type) ( ) Fuel Inlet Restriction ( ) Fuel Supply Lines ( tr) Injector Section 7 - Lubricating Oil System - Group 07 ( _07) Service Tools ( tr) Lubricating Oil Cooler ( ) Lubricating Oil Cooler Element ( ) Lubricating Oil Dipstick ( tr) Lubricating Oil Dipstick Tube
33 ( tr) Lubricating Oil Filter (Spin-On) ( ) Lubricating Oil Filter Bypass Valve ( tr) Lubricating Oil Filter Head Adaptor ( ) Lubricating Oil High Pressure Relief Valve ( ) Lubricating Oil Leaks ( tr) Lubricating Oil Pan ( ) Lubricating Oil Pressure Gauge ( tr) Lubricating Oil Pump ( tr) Lubricating Oil Suction Tube (Block-Mounted) ( tr) Lubricating Oil System ( ) Lubricating Oil Thermostat ( tr) Lubricating Oil Fill Tube
34 ( ) Centinel System ( ) Lubricating Oil and Filter Analysis Section 8 - Cooling System - Group 08 ( _08) Service Tools ( tr) Drive Belt, Cooling Fan ( ) Drive Belt, Water Pump ( tr) Coolant Filter ( ) Coolant Filter Valve ( tr) Coolant Thermostat ( tr) Coolant Thermostat Housing ( ) Coolant Thermostat Seal
35 ( ) Coolant Vent Lines ( tr) Cooling System ( ) Cooling System - Air or Combustion Gas Test ( ) Fan Clutch, On-Off ( ) Fan Drive Idler Pulley Assembly ( tr) Fan Hub, Belt Driven ( ) Fan Shroud Assembly ( ) Fan, Cooling ( ) Radiator ( ) Radiator Hoses ( ) Radiator Pressure Cap ( ) Radiator Shutter Assembly
36 ( tr) Water Pump ( tr) Belt Tensioner, Automatic (Water Pump) ( tr) Water Inlet Connection ( tr) Fan Support ( ) Fan Pulley ( tr) Water Pump Cartridge Section 9 - Drive Units - Group 09 ( tr) Refrigerant Compressor ( tr) Drive Belt, Refrigerant Compressor ( tr) Belt Tensioner, Refrigerant Compressor, Automatic ( tr) Idler Pulley, Refrigerant Compressor
37 ( tr) Refrigerant Compressor Mounting Bracket ( tr) Alternator/Refrigerant Compressor Mounting Bracket Section 10 - Air Intake System - Group 10 ( _10) Service Tools ( tr) Air Leaks, Air Intake and Exhaust Systems ( ) Charge-Air Cooler ( ) Air Intake Restriction ( tr) Turbocharger ( tr) Turbocharger Coolant Hoses ( ) Turbocharger Wastegate Actuator ( tr) Turbocharger Wastegate Valve Body
38 ( ) Intake Manifold Pressure ( tr) Air Intake Connection ( ) Turbocharger Wastegate Controller ( tr) Turbocharger, Variable Geometry Actuator ( tr) Turbocharger Air Shutoff Valve Filter ( tr) Turbocharger Control Shutoff Valve Filter Head ( tr) Turbocharger, Variable Geometry Actuator Air Supply Line ( tr) Turbocharger, Variable Geometry Control Valve Air Supply Line ( ) Variable Geometry Turbocharger Actuator, Electric ( ) Variable Geometry Turbocharger Cross Shaft ( ) Variable Geometry Turbocharger Shroud Plate
39 Section 11 - Exhaust System - Group 11 ( _11-tr) Service Tools ( tr) Exhaust Manifold, Dry ( tr) Exhaust Restriction ( tr) EGR Cooler ( tr) EGR Mixer ( tr) EGR Valve ( ) EGR Cooler Connection ( tr) EGR Connection Tubes ( ) EGR Differential Pressure Sensor Tubes ( tr) Exhaust Gas Pressure Sensor Tube ( ) EGR Differential Pressure Sensor Adapter
40 ( tr) EGR Valve Coolant Lines ( tr) EGR Cooler Coolant Lines ( tr) Heat Shield ( tr) Exhaust Gas Pressure Sensor Adapter ( tr) Aftertreatment Diesel Particulate Filter ( tr) Aftertreatment Fuel Injector ( tr) Aftertreatment Adapter Pipe ( tr) EGR Valve Mounting Bracket ( tr) Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket ( tr) Aftertreatment Diesel Particulate Filter Differential Pressure Sensor
41 Tubes ( tr) Aftertreatment Inlet and Outlet ( tr) Aftertreatment Diesel Oxidation Catalyst ( tr) Aftertreatment System ( tr) Aftertreatment Injector Lines ( tr) Aftertreatment Fuel Shutoff Manifold ( tr) Aftertreatment Fuel Injector Flow ( ) Exhaust System Diagnostics ( tr) Aftertreatment Fuel Injector Coolant Test Section 12 - Compressed Air System - Group 12
42 ( tr) Air Compressor Carbon Buildup ( tr) Air Compressor Coolant Lines ( tr) Air Compressor Cylinder Head, Single Cylinder ( ) Air Compressor Unloader and Valve Assembly ( tr) Air Compressor ( ) Air Governor (Air Compressor Will Not Pump) ( ) Air Governor (Air Compressor Pumps Continuously) ( ) Air Leaks, Compressed Air System ( tr) Air Pressure Relief Valve Section 13 - Electrical Equipment - Group 13 ( _13) Service Tools
43 ( tr) Alternator ( ) Drive Belt, Alternator ( ) Alternator Pulley ( ) Batteries ( ) Battery Cables and Connections ( ) Starter Magnetic Switch ( ) Starter Switch ( ) Starter Solenoid ( tr) Starting Motor ( ) Belt Tensioner, Automatic (Alternator) ( ) Alternator Spacer ( ) Alternator Idler Pulley
44 ( ) Bracket, Idler Pulley and Alternator Belt Tensioner Section 14 - Engine Testing - Group 14 ( _14) Service Tools ( tr) Dynamometer Worksheet ( tr) Engine Testing (Chassis Dynamometer) ( tr) Engine Run-in (Chassis Dynamometer) ( ) Engine Run-in (Without Dynamometer) ( tr) Engine Testing (Engine Dynamometer) ( tr) Engine Run-in (Engine Dynamometer) ( ) Engine Testing (In Chassis) ( ) Engine Testing (Portable Dynamometer or Load Bank)
45 ( tr) Crankcase Blowby, Measure ( ) Aftertreatment Testing Section 16 - Mounting Adaptations - Group 16 ( _16) Service Tools ( tr) Engine Lifting Brackets ( tr) Engine Support Bracket, Front ( tr) Flywheel ( tr) Flywheel Housing ( tr) Flywheel Housing, REPTO ( ) Flywheel Ring Gear ( ) Engine Mounts
46 Section 20 - Vehicle Braking - Group 20 ( ) Engine Brake Assembly ( ) Engine Brake Solenoid Valve ( ) Engine Brake Wiring Harness ( ) Engine Brake Control Valve ( ) Engine Brake Piston Section L - Service Literature ( tr) Additional Service Literature ( ) Service Literature Ordering Location ( ) Cummins Customized Parts Catalog
47 Section V - Specifications ( tr) General Engine ( ) Fuel System ( ) Lubricating Oil System ( tr) Cooling System ( tr) Air Intake System ( tr) Exhaust System ( ) Electrical System ( ) Compressed Air System ( ) Engine Testing ( ) Drive Belt Tension
48 ( ) Fraction, Decimal, Millimeter Conversions ( ) Weights and Measures - Conversion Factors ( ) Capscrew Markings and Torque Values ( ) Newton-Meter to Foot-Pound Conversions ( ) Pipe Plug Torque Values ( ) Tap-Drill Chart - U.S. Customary and Metric User tags: cummins engine signature isx qsx15 servi " DOWNLOAD HERE
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